Danfoss IPS 8 User guide

User Guide

Intelligent Purging System (IPS 8)

Ammonia

230 V AC, 60 Hz

Info for UK customers only Danfoss Ltd. Oxford Road, UB9 4LH Denham, UK

Other IPS 8 User Guide languages

148R9653

ir.danfoss.com

User Guide | Intelligent Purging System (IPS 8) Ammonia

Contents	Legal notice...................................................................................................................................................................................................................	3
	Technical data..............................................................................................................................................................................................................	4
	Ordering...........................................................................................................................................................................................................................	4
	Introduction..................................................................................................................................................................................................................	5
	Features............................................................................................................................................................................................................................	5
	Working principle .....................................................................................................................................................................................................	6
	Working cycle...............................................................................................................................................................................................................	7
	Air traps............................................................................................................................................................................................................................	8
	Connection locations..............................................................................................................................................................................................	9
	Connection points.................................................................................................................................................................................................	11
	Installation...................................................................................................................................................................................................................	12
	Electrical wiring .......................................................................................................................................................................................................	14
	Light Indicators.........................................................................................................................................................................................................	16
	Quick Startup.............................................................................................................................................................................................................	17
	General display.........................................................................................................................................................................................................	17
	Configuring using the LCD...............................................................................................................................................................................	18
	Modbus RTU..............................................................................................................................................................................................................	20
	Maintenance/Service/Disposal......................................................................................................................................................................	27

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User Guide | Intelligent Purging System (IPS 8) Ammonia

Legal notice	This product information is a part of the documentation for the Danfoss scope of delivery and serves
	as product presentation and customer advisory service. It contains important information and
	technical data regarding the product.
	This product information should be supplemented with the information about the industrial safety
	and health related regulations at the site of installation of the product. The regulations vary from
	place to place as a result of the statutory regulations applicable at the site of installation and are
	therefore not considered in this product information.
	In addition to this product information and the accident prevention regulations applicable for the
	respective country and area where the product is used, the technical regulations for safe and
	professional work must also be observed.
	This product information has been written in good faith. However, Danfoss cannot be held responsible
	for any errors that this document may contain or for their consequences.
	Danfoss reserves the right to make technical changes during the course of further development of the
	equipment covered by this product information.
	Illustrations and drawings in this product information are simplified representations. As a result of
	the improvements and changes, it is possible that the illustrations do not exactly match the current
	development status. The technical data and dimensions are subject to change. No claims will be
	accepted on the basis of them.

Danfoss A/S

6430 Nordborg Denmark CVR nr.: 20 16 57 15

Telephone: [phone]

Fax:

[phone]

EU DECLARATION OF CONFORMITY

Danfoss A/S

Refrigeration & Air Conditioning Controls

declares under our sole responsibility that the

Product category: Intelligent Purger System (Air Purger)

Type designation(s): IPS 8

Covered by this declaration is in conformity with the following directive(s), standard(s) or other normative document(s), provided that the product is used in accordance with our instructions.

Machine Directive 2006/42/EC

EN 378-2:2016 Refrigerating systems and heat pumps - Safety and environmental requirements - Part 2: Design, construction, testing, marking and documentation

IEC 60204-1:2018 Safety requirements for electrical equipment for measurement, control and laboratory use - Part 1:

General requirements

Pressure Equipment Directive 2014/68/EU (PED)

EN 378-2:2016 Refrigerating systems and heat pumps - Safety and environmental requirements - Part 2: Design, construction, testing, marking and documentation

Ammonia side (R717): Category A4P3. Fluid group: 1. PS = 40 bar. TS: -40 C to 60 C

R452A side: Category 1. Fluid group: 2. PS = 28 bar. TS: -40 C to 60 C

Ambient temperature: -10 C to 43 C

Electromagnetic Compatibility Directive 2014/30/EU (EMC)

IEC 61000-6-2 Electromagnetic compatibility (EMC) - Part 6-2: Generic standards - Immunity standard for industrial environments (IEC77/488/CDV:2015)

EN 61000-6-4 Electromagnetic compatibiliy (EMC) - Part 6-4: Generic standards - Emission standard for industrial environments

Note: EMC test performed with cable length < 30m.

Date: YYYY.MM.DD	Issued by	Date: YYYY.MM.DD	Approved by
Place of issue:		Place of issue:
	Signature:		Signature:
	Name: Su Cheong Ho		Name: Behzad Parastar
	Title: Lead Design Engineer		Title: Product Manager

Danfoss only vouches for the correctness of the English version of this declaration. In the event of the declaration being translated into any other language, the translator concerned shall be liable for the correctness of the translation

ID No:

084R9456

Revision No: AA

Page 1 of 1

This doc. is managed by 500B0577

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User Guide | Intelligent Purging System (IPS 8) Ammonia

Technical data

Supply voltage	230V AC, 1ph, 60Hz
Current	5.7 A (max. 6.5 A)
Power consumption	max. 1.3 kW
Short-circuit current rating	Icc 10kA
Temperature range ambient	-10 °C to +43 °C (14 °F to 109 °F)
Temperature range transport/storage	-30 °C to +60 °C (-22 °F to 140 °F)
Enclosure	IP55
Weight	max. 100 kg (221 lbs)
Dimensions (LxWxH)	1051 x 441 x 703 mm (41.4 x 17.4 x 27.7 inches)
Purger refrigerant	R452A 900 gram (31.7 oz)
Max. operating pressure (PS) R452A	28 bar (406 psi)
System refrigerant	R717
Min. operating pressure R717	6.5 bar (94 psi)
Max. operating pressure R717	40 bar (580 psi)
Operating temperature R717	-40 °C to +60 °C (-40 °F to 140 °F)

Ordering
	Unit			Code number
	Danfoss Intelligent Purging System IPS 8 60Hz unit			084H5002
	Accessories/Spare parts	Accessory	Spare part	Code
	Flange blind blank incl Bolts, nuts and Gaskets*	x		084H5053
	SV3 Float Valve	x		027B2023
	ICF 15-4 solenoid, DIN Butt weld 15mm ½ inch	x		027L4543
	ICF 15-4 solenoid, ANSI Socket weld 15mm ½ inch	x		027L4538
	ICF 15-4 solenoid, ANSI Butt weld 15mm ½ inch	x		027L4602
	Welding Flange incl Bolts, nuts and Gaskets		x	084H5061
	Purger solenoid kit (Armature, tube, Sealing, Orifice, Filter insert)		x	084H5051
	Solenoid coil, 24V DC for AKV	x	x	018F6757
	PSU, 24V DC - optional for powering purge points	x	x	080Z0055
	Restrictor, purge line		x	084H5054
	Compressor Cranck case heater		x	084H5058
	Condenser coil assy incl screws		x	084H5059
	Fan motor for condenser Incl fan grid and screws		x	084H5060
	Extraction Fan		x	084H5056
	Air grid with filter (1 piece)		x	084H5057
	Pre-programmed MCX 15		x	084H5052
	Pressure transmitter evaporator, soldered (AKS 32R)		x	060G3552
	Compressor including Start relay box and Start and Run Capacitor		x	123B2156
	Compressor Hi-temp sensor		x	084N2003
	Expansion valve, R452A		x	068U3881
	Sight glass		x	014-0191
	Pressure transmitter - R717, Threaded, AKS2050		x	060G5750
	Thermostat for crankcase heater control		x	060L111166
	Temperature sensor - R717, AKS 21M		x	084N2003
	Pressure switch for Fan		x	Contact Danfoss
	Pressure safety switch		x	Contact Danfoss
	* For closing system flange during system pressure testing

Note:

All Spare part items are parts already built into the IPS 8 All accessories are not.

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User Guide | Intelligent Purging System (IPS 8) Ammonia

Introduction	The Danfoss Intelligent Purging System (IPS 8)
	is a stand-alone, self-contained purging unit
	designed to remove non-condensable gases
	(NC gases = air and other unwanted foreign
	gases) from industrial ammonia refrigeration
	systems.
	The IPS control can handle up to 8 purge points
	automatically.
	The ingress of NC gases into a refrigeration
	system is inevitable, regardless of the refrigerant,
	pressures, or temperatures. NC gases in the
	system will result in a decrease in system
	efficiency, both in terms of an increase in power
	consumption and reduced cooling capacity.
	Due to having a different density than ammonia,
	the ingressed air will accumulate in specific areas
	of the system, where it can be removed using the
	Danfoss IPS 8.
	The accumulation areas are identified in the
	Connection locations section, along with
	recommended connection principles.
	The purger unit is an electronically controlled,
	self-contained R452A refrigerant system that runs

independent of the main ammonia system and with only one flange connection to the ammonia plant.

The flanged opening allows the ammonia gas/ NC gas mix access to the purger’s heat exchanger, where it is split into ammonia condensate and NC gases. The ammonia condensate is returned by gravity to the main plant, while the NC gases are purged to the atmosphere through e.g. a water bath.

Through the flanged opening, the purger unit has access to the parameters from the ammonia plant required for full electronic control.

The unit runs automatically in 24-hour cycles, checking for the presence of NC gases and, if present, removes the NC gases.

To regain and retain the design capacity of the main ammonia system and prevent future air accumulation, it is highly recommended to install the Danfoss IPS 8.

Features	• State-of-the-art electronically controlled unit
	based on the Danfoss MCX controller platform
	• Reduced power consumption of the ammonia
	plant
	• Automatic purging response to NC gases in the
	refrigeration system
	• Continuous and smart monitoring of
	differential pressure between the system
	refrigerant and the purger’s refrigerant
	• Smart purging that minimizes refrigerant
	(ammonia) release to the environment
	• Self-contained unit operation, which functions
	independently from the main plant
	• An operation log for easy purging cycle data
	monitoring
	• Industry standard Modbus RTU
	communication for remote monitoring and
	system integration
	• Reduced purging unit power consumption
	compared to other units due to on-demand
	operation only

•Self-diagnostics for both unit and system operation to shut down in the event of malfunctions

•Cost-effective installation with few mechanical and electrical connections

•A fully brazed and leak-tested R452A cooling system, minimizing leakage risks

•A plug-and-play stand-alone design, which simplifies installation and commissioning while reducing potential errors

•No need for advanced settings

•A compact and easy-to-handle design

•Patent pending on IPS 8

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User Guide | Intelligent Purging System (IPS 8) Ammonia

Working principle	The Danfoss IPS 8 is factory-tested and ready to
	use in ammonia plants with a condenser pressure
	of more than 6,5 bar (94 psi). The purger is
	charged with 900 gram (31.7 oz) of R452A.
	Only 2 mechanical connections are needed for
	the purger (see fig. 1). The flow of ammonia/NC
	gases from the main plant is done through the
	flange for ammonia (see 13 in Fig. 1 below), while
	the NC gas purge is done through the blow-off
	pipe after the purge restrictor (18).
	Through the flange for ammonia (13), a mixture
	of ammonia gas and NC gases enters the heat
	exchanger (12) part of the purger.
	The ammonia gas/NC gas mix is cooled down
	below the condensing temperature of the
	ammonia by the R452A circuit. At this point,
	ammonia gas condenses and returns by gravity
	to the ammonia plant whereas the NC gases
	accumulate in the heat exchanger (12) for
	subsequent purging.

By condensing the ammonia gas, a new ammonia/NC gases mix is naturally pulled through. This new mix is separated through a continuous process.

As the NC gas concentration in the heat exchanger (12) increases, the R452A heat exchanger pressure and temperature will simultaneously decrease.

The controller continuously monitors the R452A heat exchanger pressure as well as ammonia pressure and temperature. When the R452A pressure reaches a predefined pressure difference when compared with the ammonia pressure (temperature) it prepares to purge the NC gases through the solenoid valve (16). The blow-off

is activated by the solenoid (16) and through appropriate piping/hosing, should be led into a water bath. This process is recommended to retain small amounts of ammonia (see Installation section).

		19	20
	7	6
	5
4		9
		8
3	2	10
	1a
1
		11
		3a	15
			16
		14	17
			18
		12
		13

Fig. 1 - Purger R452A lay-out

1	Compressor R452A	11	Expansion valve, R452A
1a	Compressor Cranck case heater	12	Heat exchanger Ammonia/R452A
2	Thermostat for crankcase heater control	13	Welding Flange
3	Discharge temp sensor R452A	14	Pressure transmitter R452A
3a	Suction temperature sensor R452A	15	Pressure transmitter R717
4	Pressure safety switch	16	Solenoid valve AKVA and coil
5	Condenser	17	NC temperature sensor R717
6	Extraction fan	18	Restrictor, purge line
7	Pressure switch for Fan	19	MCX 15 (Pre-programmed)
8	Receiver	20	PSU, 24V
9	Filter		900 gram (31.7 oz) R452A
10	Sight glass

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User Guide | Intelligent Purging System (IPS 8) Ammonia

Working cycle	The Danfoss IPS 8 operates in 24-hour cycles, of
	which 45 minutes are dedicated to an R452A pull
	down. At power on, the pull down is initiated
	immediately. If no NC gases are detected during
	the 45 minute pull down, the system will close
	the solenoid valve at purge point 1 and open the
	solenoid valve at point 2. After a cycle time of 24
	hours/N (Number of purge points), the
	compressor will pull down again condensing the
	ammonia. After 24 hours, all purge points have
	been vented one time.
	To identify NC gases, the controller utilizes upper
	and lower thresholds for R452A evaporating
	temperature. If, during pull down, the
	temperature continues decreasing and the lower
	threshold is passed, the controller considers

this to be a high concentration of NC gases and opens the purge solenoid valve. The purge valve will stay open until sufficient condensing

ammonia is present to lift the R452A evaporating temperature above the upper threshold.

The compressor will continue running and if the temperature again decreases below the lower threshold, a new purge will be performed. This process will be repeated until the R452A heat exchanger temperature stays above the lower threshold for >45 minutes following the previous closure of the purge valve.

<![if ! IE]> <![endif]>Power on	<![if ! IE]> <![endif]>Purger Pull down (PDT): 45 min	<![if ! IE]> <![endif]>Purger Pull down	<![if ! IE]> <![endif]>(PDT): 45 min	<![if ! IE]> <![endif]>Purger Pull down	<![if ! IE]> <![endif]>(PDT): 45 min
	Cycle (CST) *			Cycle (CST) *
					Time
Compressor
On
O
Purge valve
On
O

Fig. 2 - Power on & Cycle at no NC gases present: CST (compressor start time) and PDT (pull down time) are configurable * Cycle (CST) = 24 hours/N (number of purge points)

<![if ! IE]>

<![endif]>Evaporator Temp. (Tsat452)

Compressor

On

O

Purge valve

On

O

Upper Threshold (VClseT)

Non condensables has been purged - new cycle starts *

Lower Threshold (VClseT)

Time

Fig. 3 - Purging procedure - Low R452A evap. temperature detected during PDT: Thresholds are configurable

* If low evaporator temperature is detected (passing lower threshold), the purging procedure will be repeated immediately

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Air traps

Fig. 4 Liquid level. Bottom connected receiver

Fig. 5 Liquid level. Top connected receiver

For systems with low pressure liquid level control, the correct condenser/ receiver installation is as shown in Fig. 4 and Fig. 5.

The discharge gas from the compressor (1) is led to the condenser (2) where it is condensed. The receiver (3) holds the liquid until there is a demand for liquid from the LP side, e.g., until the expansion valve (4) opens. If the expansion valve is closed, the liquid condensed in the condenser will need to be stored in the receiver and the level will increase. To ensure a free flow to the receiver, the gas must be allowed to leave the receiver; this process is accomplished through the pressure equalizing line (a). The pressure

equalizing line makes the pressure in the receiver the same as in the compressor discharge line. The pressure in the condenser outlet is lower due to the pressure loss in the condenser. Since the condenser outlet pressure is lower than in the receiver, it is therefore necessary to mount the condenser higher than the receiver and allow for a higher liquid level in the piping between the condenser and the receiver (b).

The liquid column in the line (b) compensates for the pressure difference between the condenser outlet and the receiver.

Fig. 4 shows the liquid connection at the bottom of the receiver.

If the liquid from the condenser is connected to the top of the receiver (Fig. 5), a slightly different arrangement must be made.

The liquid line (b) from the condenser to the receiver will need to have a goose neck/liquid trap to ensure that the liquid column is actually established.

As air is heavier than ammonia gas, the air will collect in two locations in this type of installation: On top of the liquid in the receiver (x) and/or

on top of the liquid in the drop leg from the condenser (y).

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