Danfoss VZH052-065 Application guide

Application guidelines
Danfoss scroll compressors
VZH052-065
Single
R410A
http://cc.danfoss.com
Content
GENERAL INFORMATION ........................ 4
PRODUCT INFORMATION ....................... 5
How do IDVs work? ................................................... 5
Compressor model designation ..............6
Nomenclature ............................................................ 6
Dimensions ..............................................10
VZH052-065G/J/H ...................................................10
Electrical data, connections and wiring 13
Supply voltage ......................................................... 13
Phase sequence and reverse rotation
protection .................................................................. 15
IP rating ....................................................................... 16
Motor protection.....................................................16
Approval and certificates .......................17
Low voltage directive 2014/35/EU .................... 17
Internal free volume............................................... 17
SYSTEM DESIGN ..................................... 18
Drive installation .....................................18
Direct and indirect exposure of drive to water 18
Condensation ...........................................................18
Dust Exposure .......................................................... 18
Mechanical Mounting ........................................... 18
Ambient temperature ........................................... 19
EMC best practices ................................................. 20
EMC remediation ....................................................20
EMC remediation .................................................... 21
Mechanical dimension ......................................... 21
Unit Architecture .................................... 22
Design piping ......................................... 23
General requirements ...........................................23
Design compressor mounting .............. 24
General requirements ........................................... 24
Single requirements...............................................24
Manage oil in the circuit ........................ 25
Requirement ............................................................. 25
System evaluation ..................................................25
Test, criteria and solutions ................................... 25
Manage sound and vibration ................ 26
Compressor sound radiation ..............................26
Mechanical vibrations ........................................... 27
Gas pulsation ............................................................ 27
Requirement ............................................................. 28
System evaluation ..................................................28
Test, criteria and solutions ................................... 29
Manage off cycle migration ................... 30
Requirement ............................................................. 30
System evaluation .................................................30
Manage operating envelope ................. 32
Requirement ............................................................. 32
System evaluation .................................................. 33
Manage speed limit .................................37
Speed limit requirement ...................................... 37
Start/Stop/Ramp setting ...................................... 37
Control logic ........................................... 38
Safety control logic requirements .................... 38
Short cycle protection ......................................... 39
Defrost cycle logic .................................................. 39
Pump-down logic recommendations .............39
Oil management logic ..........................................40
Reduce moisture in the system ..............41
Requirements ........................................................... 41
Solutions.....................................................................41
INTEGRATION INTO SYSTEMS .............. 42
Assembly line procedure ....................... 42
Compressor storage ...............................................42
Compressor holding charge ............................... 42
Handling .................................................................... 42
Piping assembly.......................................................43
System pressure test and leak detection ....... 43
Vacuum evacuation and moisture removal . 44
Refrigerant charging .............................................. 44
Dielectric strength and insulation resistance
tests .............................................................................. 44
Commissioning ....................................... 45
Preliminary check.................................................... 45
Initial start-up ........................................................... 45
System monitoring .................................................45
Oil level checking and top-up ............................ 45
Troubleshooting ..................................... 46
Dismantal and disposal ......................... 49
ORDERING INFORMATION ................... 50
Ordering codes ........................................51
Accessories ...............................................52
3AB237586440343en-000601

General Information

PRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION GENERAL INFORMATION
Danfoss scroll compressors are designed and manufactured according to the state of the art and to valid European and US regulations. Particular emphasis has been placed on safety and reliability. Related instructions are highlighted with the following icons:
This icon indicates instructions to avoid safety risk.
R
This icon indicates instructions to avoid reliability risk.
The purpose of this guideline is to help customers qualify compressors in the unit. You are strongly advise to follow these instructions. For any deviation from the guidelines, please contact Danfoss Technical Support. In any case, Danfoss accepts no liability as a result of the improper integration of the compressor into the unit by the system manufacturer.
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Features

Intermediate discharge valves for better efficiency at low pressure-ratio

GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION PRODUCT INFORMATION

Optimized scrolls for better part load efficiency
EMC (Electro-Magnetic Compatibility) bracket provided allows for grounding termination of shielded wire-harness, which reduces EMC emissions between drive and compressor
New designed oil cup to minimize oil stirring loss under high liquid level
PVE 32 lubricant ensures better lubrication and efficiency
High speed oil circulation minimized by a oil return tube
New distributed IPM motor lead to higher power factor
Linear control oil pump

How do IDVs work?

Danfoss Intermediate Discharge Valves (IDVs) are located close to the discharge side of the compressor. They reduce excessive compression of refrigerant under part-load conditions while maintaining the same cooling capacity. The IDVs open when discharge pressure falls below the built-in optimization point. They adapt the effort of the motor to the varying load and pressure conditions in the system, thus reducing the effort of the motor and its electrical consumption and improving the system’s seasonal energy efficiency.
5AB237586440343en-000601

Compressor model designation

Nomenclature

Compressor nomenclature
BNAGC065ZHV
Variable speed
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION PRODUCT INFORMATION
PVE 32 (160 HV) lubricant,
R410A refrigerant
Swept volume
Design pressure ratio
C: IDV and part load
ef iciency optimizedf
Frequency converter nomenclature
Dedicated compressor
drive for VZH scroll
High overload
output power
P11K/P15K/P22K
Family
VZH scroll
Lubricant
in cm³/rev
Serie 303
in kW
Evolution index
Motor protection type N: no internal motor protection
(protection by drive)
Equipement version A: brazed connections, single version D: brazed connections, unified version
Oil sight glass Oil level switch
Single version Threaded None Unified version Threaded Threaded
Motor voltage code to CDS303 * G: 380-480V/3~/50 & 60Hz H: 525-600V/3~/50 & 60Hz J: 200-240V/3~/50 & 60Hz
* main supply voltage to frequency converter
H2E20T4P11K303CDS
RFI class
H2/H3/HX
Enclosure protection
IP rating E20/E55
Main supply voltage
T2: 200-240V/3 ph/50-60 Hz T4: 380-480V/3 ph/50-60 Hz T6: 525-600V/3ph/50-60 Hz
Note: High overload output power: output power @160% Torque
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Technical specifications
Compressor size
Frequency converter variants
Compressor and frequency converter combinations
To have the optimum compressor selection, select a compressor size which achieves the peak load system cooling capacity demand at its maximum speed.
Different frequency converter variants are available according to:
1. Mains supply voltage
2. IP class (CDS303 drives are available in IP20 or IP55 housings)
When the compressor size and mains voltage have been defined in the above selection criteria, the code number tables from the “Ordering information and packaging” section provides the appropriate frequency converter sizes and up to four corresponding code numbers for each compressor model.
Detailed performances can be found in datasheets and in selection programs.
3. RFI (Radio Frequency Interference) class H2/H3 or HX.
4. Printed Circuit Board (PCB) coated
Note this compressor is equipped with a six-pole electrical motor so the applied frequency from the inverter will be 50 Hz for 1000 rpm up to 330 Hz for 6600 rpm.
Please refer to the table below
min max
Compressor speed
Drive output frequency Hz 50 330
rps 16.7 110
rpm 1000 6600
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
PRODUCT INFORMATION
7AB237586440343en-000601
Technical specifications
Compressor specifications
Displacement
Compressor
model
VZH065 65.1 4.0 3.9 138 11.7 413 14.1 498 25.8 911 1.57 53 35 77 VZH052 52 .1 3.2 3.1 109 9.4 332 11.3 399 20.6 727 1.57 53 35 77
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
Swept volume
(cm³/re v) (cu.in/rev) (m³/h) (cu.ft/h) (m³/h) (cu.ft/h) (m³/h) (cu.ft/h) (m³/h) (cu.ft/h) (dm
1000 rpm 3000 rpm 3600 rpm 6600 rpm
Oil charge Net weight
3
) (oz) (kg) (lbs)
Frequency converter specifications
PRODUCT INFORMATION
T2: 200 - 240 V ±10% (3-phase)
Mains supply voltage
Supply frequency 50 / 60 Hz Output voltage 0 - 100 % of supply voltage Inputs 6 digital (0-24V), 2 analog (0/±10V or 4-20mA, scalable) Programmable outputs 2 digital (0-24V), 1 analog (0/4-20mA), 2 relay Protection functions Over-current protection, low / high current handling Compressor functions Motor protection, compressor ramp up/down control
T4: 380 - 480 V ±10% (3-phase) T6: 525 - 600V ±10% (3-phase)
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Technical specifications
OIL level sensor A TEKLAB LC-XN optical-electrical level sensor
is fixed on the inverter compressor. The oil level sensor prism is fixed on the compressor, the electrical part is ordered by accessory kit. The oil level sensor monitors the compressor oil level and sends oil level signal to an external relay or digital input of unit controller. A 5±2 seconds delay is recommended to mitigate oil level fluctuationand avoid false alarms.
- Lack of oil: Circuit between 2 and 3 will be opened internally, there will be no current flowing through load or coil of external relay, relay is open.
230VAC MODEL
L1 L2 L3
N
Sensor
External
Load / Relay
1
2
3
24VAC
0VAC
External
Load / Relay
- Enough oil: Circuit between 2 and 3 will be closed internally, there will be current flowing through load or coil of external relay, relay is close.
Note: For 24VDC, output voltage in case of lack of oil is >13V DC and not 0V
For customers who needs UL certificates, please order 24V AC/DC sensor.
24VAC MODEL
1
2
Sensor Sensor
3
24VDC
24VDC MODEL
0VDC
1
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
2
3
External
Load / Relay
PRODUCT INFORMATION
Oil level sensor is a special component which assembles on variable speed compressor. It is provided in oil level sensor accessory kit.
VZH052-065
9AB237586440343en-000601

Dimensions

ΦD
ΦD

VZH052-065G/J/H

GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
PRODUCT INFORMATION
H
H1
H2
H2
L1
L2
L1
H
H1
L2
Single version Unified version
Mounting GrommetTerminal box
29.5
EMC bracket to terminations of shielded wire
Recommended torque for mounting bolts: 11 Nm (±1 Nm)
Version Compressor model
Earth grounding
D H H1 H2 L1 L2
(mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch)
Single VZH052-065 183.5 7. 22 436 17.17 403 15 .87 261 10.28 190 .5 7. 5 190. 5 7. 5 8590007
Unified VZH052-065 183. 5 7. 22 436 17.17 403 15.87 261 10. 28 190.5 7. 5 190.5 7. 5 8590013
Ø11
Ø 41
Outline drawing number
10 AB237586440343en-000601
Dimensions
Connection Details
Suction connection Br aze d 7/8 " Discharge connection Brazed 3/4" Oil sight glass Threaded (1"1/8 – 18 UNF) Oil equalization connection ­Shrader Male 1/4" Flare incorporating a Schrader valve
1) VZH compressors single versions come equipped with a threaded oil sight glass with 1"1/8 – 18 UNEF connection. It can be used for a visual check of oil amount and condition.
Compressor models Brazed connection size
VZH052-065
Suction 7/8 " 1-1/4" 7/ 8"
Discharge 3/4" 1-1/4" 3/4" 120Z0 366
VZH compressors are all delivered with suction and discharge brazed connections only. They are copper-plated steel connections.
VZH052-065 single version
2) Schrader: The oil fill connection and gauge port is a 1/4" male flare connector incorporating a Schrader valve.
Rotolock adaptor set
(adaptor, gasket, sleeve, nut)
Rotolock Solder sleeve ODF Code Number Code Number
120Z0128
Rotolock adaptor
( adaptor only)
120Z0 367
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
PRODUCT INFORMATION
Rotolock adaptors are available, refer to the information above.
11AB237586440343en-000601
Dimensions
CDS303 Frequency converter
Frequency converter dimensions depend on supply voltage, IP rating and power. The table below gives an overview of the overall dimensions and different drive enclosures (B1 ­B4). Details for each drive enclosure are on the following pages.
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
W
IP20 IP55
Drive supply voltage
Compressor
voltage code
Drive power kW
PRODUCT INFORMATION
T2: 200-240/3/50-60 11 J VZH052-065 B4
11*
T4: 380-480/3/50-60
G
Compressor model
VZH052 B3
15 VZH065 B3
15
T6: 525-600/3/50-60
VZH052 B3
H
22 VZH065 B4
Variable speed compressor package VZH065 (voltage code G) + CDS303 (T4, 11kW) is qualified, to be used at drive supply voltage 380-440V (3 phase, 50/60Hz). Any further information please contact local Danfoss engineers.
Overall drive size
[H x W x L]
mm
(inch)
Drive enclosure
520x230x242
(20.47x9.06x9.53)
399 x165x249
(15.71x6 .5x9. 8)
399 x165x249
(15.71x6 .5x9. 8)
399 x165x249
(15.71x6 .5x9. 8)
520x230x242
(20.47x9.06x9.53)
Overall drive size
[H x W x L] mm
(inch)
incl. decoupling
plate
595x230x242
(23.43x9.06x9.53)
420x165x249
(16.54x6.5x9.8)
420x165x249
(16.54x6.5x9.8)
420x165x249
(16.54x6.5x9.8)
595x230x242
(23.43x9.06x9.53)
Clearance
above/
below
mm
(inch)
200
(8)
100
(4)
100
(4)
100
(4)
200
(8)
Overall drive size
[H x W x L] mm
(inch)
Drive enclosure
650x242x260
B2
(25.59x9.53x10.24)
480x242x260
B1
(18.90x9.53x10.24)
480x242x260
B1
(18.90x9.53x10.24)
480x242x260
B1
(18.90x9.53x10.24)
650x242x260
B2
(25.59x9.53x10.24)
Min 100/200 Clearance above for cooling
L
H
Min 100/200 Clearance above for cooling
Overall drive
size
[H x W x L]
mm
(inch)
incl.
decoupling
plate
-
-
-
-
-
Clearance
above/
below
mm
(inch)
200
(8)
100
(4)
100
(4)
100
(4)
200
(8)
Enclosure Height Width Depth Mounting hole
Frame IP Class A A
1)
a B b C d e f
(mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) (mm) (inch) kg lb
B1 IP55 480 18.9 - - 454 17.87 242 9.53 210 8.27 260 10.24 19 0.75 9 0.35 9 0.35 23 51 B2 IP55 650 25.59 - - 624 24.57 242 9.53 210 8.27 260 10.24 19 0.75 9 0.35 9 0.35 27 60 B3 IP20 399 15.71 420 16.54 380 14.96 165 6.5 140 5. 51 249 9.80 12 0.47 6.8 0.27 7.9 0. 31 12 26 B4 IP20 520 20.47 595 23.43 495 19.49 230 9.06 200 7. 87 242 9.53 - - 8.5 0.33 15 0.59 23 51
1)
A
Including decoupling plate.
The dimensions are only for the physical units, but when installing in an application it is necessary to add space for free air passage both above and below the units. The amount of space for free air passage is listed in “frequency converter dimensions - Clearance above/below (mm/inch)”.
12 AB237586440343en-000601
Max. Weight

Electrical data, connections and wiring

Supply voltage

Compressor electrical specifications
RLA (Rated Load Amp)
MOC (Max Operating Current)
Because VZH compressors are powered by a frequency converter, the mains frequency, 50 or 60 Hz, is no longer an issue. Only the mains voltage is to be taken into account. With 3 motor voltage codes, the most common mains voltages and frequencies are covered. Never connect the VZH compressor directly to the mains power supply in case of motor burnt.
Compressor rated
voltage (V)
400 VZH052-G 575 VZH052-H 22.6 26 400 VZH065-G 27. 2 31.2 575 VZH065-H 27. 2 31.2 208 VZH052-J 208 VZH065-J 55.3 63.6
RW: Winding resistance per winding, measured at motor terminals RLA: Rated load Amp
Model
RW(Ω) at 20°C line
Rated Load Amp value is the current value at maximum load, in the operating envelope, and at maximum speed and rated drive input voltage.
Max operating current is the maximum continuous current which is 115% of RLA. This
Voltage code Mains voltage range of drive
J 200-240V / 3ph / 50Hz & 60Hz (±10%)
G 380-480V / 3ph / 50Hz & 60Hz (±10%)
H 525-600V /3ph / 50Hz & 60Hz (±10%)
to line
0.177Ω±7 %
0.053Ω±7%
RLA (A)
22.6 26
44.2 50.7
Max Operating
Current (A)
RLA is the measured value at the compressor terminals (after the drive).
value is printed on compressor nameplate. MOC can be used to select cables and contactors.
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
PRODUCT INFORMATION
Wiring connections
Electrical power is connected to the compressor terminals by Ø 4.8mm (3/16") screws. The maximum tightening torque is 3Nm. Use a 1/4" ring terminal on the power leads.
Terminal cover mounting The terminal cover and gasket should be installed
prior to operation of the compressor. The terminal cover has two outside tabs, 180 degrees apart,
Terminal cover removal
push
EMC bracket to terminations of shielded wire
Earth grounding
that engage the terminal fence. When installing the cover, check that it is not pinching the lead wires.
push
push
13AB237586440343en-000601
Electrical data, connections and wiring
Fuses Danfoss recommends using the fuses listed
below to protect service personnel and property
For circuit breakers, Moeller types have been
tested and are recommended. in case of component break-down in the frequency converter.
Frequency
converter
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
3x200-240V CDS303-11k W 80A gG KTN-R80 JKS-80 JJN-80 5014006 -080 KLN-R80 NZMB1-A10 0 NZMB1- A100 3x380-480V CDS303-11k W 63A gG KTS-R40 JKS-40 JJS-40 5014006-040 KLS-R40 PKZM4-50 PKZM4-63 CDS3 03-15kW 63A gG KTS-R50 JKS-50 JJS-50 5014006-050 KLS-R50 PKZM4-50 PKZM4- 63 3x525-600V CDS3 03-15kW 63A gG KTS-R-45 JKS-45 JKJS-45 5014006-050 KLSR045 PKZM4-50 PKZM4-63 CDS303-22kW 63A gG KTS-R-60 JKS-60 JJS-60 5014006-063 KLSR060 NZM B1-A10 0 NZMB1-A10 0
EN50178 compliant fuses
Size Typ e Type RK1 Type J Typ e T Type RK1 Type RK1 Moeller type
Bussmann SIBA Little fuse IP20 IP55
UL Compliant fuses Recommended circuit breaker
Wire sizes Below table lists maximum wiring sizes for the motor compressor power supply cables.
PRODUCT INFORMATION
from network to drive
I
Power input
Circuit breaker
From network to frequency converter From frequency converter to compressor
Typ e mm² AWG Type mm² AWG
200 - 240 V
380 - 400 V
525 - 600 V
Note: The wire size in the guideline is the maximum wire size that connectors can accept but not the actual needed cable. The need­ed cable size should be specified by the OEM depending on the unit design, ambient temperature, the wire material, current, etc...
CDS303-11k W 10 8 VZH052-J 10 8 CDS303-11k W 16 6 VZH065-J 16 6
CDS303-11k W 4 12 VZH052-G 4 12 CDS3 03-15kW 4 12 VZH065-G 6 10 CDS3 03-15kW 4 12 VZH052-H 4 12 CDS303-22kW 4 12 VZH065-H 6 10
from drive to to compressor
14 AB237586440343en-000601
Electrical data, connections and wiring
Soft-start control

Phase sequence and reverse rotation protection

The CDS303 frequency converter generates by design a compressor soft start with an default initial ramp up of 7.5s to 50 rps.
Current inrush will not exceed the frequency converter maximum current.
The compressor will only operate properly in a single direction. If electrical connections are done correctly between the drive and the compressor terminals (compressor T1/T2/T3 and drive terminals U, V & W matching), the drive will provide correct phase supply to the compressor, and reverse rotation will be not possible:
• CDS terminal U (96) to VZH terminal T1
• CDS terminal V (97) to VZH terminal T2
• CDS terminal W (98) to VZH terminal T3
If compressor T1/T2/T3 and drive U, V & W terminals are not matching, the compressor
Basically seen from the mains, the inrush peak reach a level which is only a few percent more than the rated nominal current.
can operate in a reverse rotation. This results in excessive noise, no pressure differential between suction and discharge, and suction line warming rather than immediate cooling. The compressor can be rapidly damaged in these conditions. If reverse rotation symptoms occur, shut the compressor down and connect the phases to their proper terminals.
Mains connection to the CDS frequency converter order has no influence on the output phase sequence which is managed by the frequency converter.
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
PRODUCT INFORMATION
15AB237586440343en-000601
Electrical data, connections and wiring

The compressor terminal box IP rating according to IEC529 is IP22.IP rating

GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
Element Numerals or letters Meaning for the protection of equipment
Against ingress of solid foreign objects
First characteristic
numeral
Second
characteristic
numeral
0 1 2 3 4 5 6
0 1 2 3 4 5 6 7 8
(non protected) ≥ 50 mm diameter ≥ 12.6 mm diameter ≥ 2.5 mm diameter ≥ 1.0 mm diameter dust protected dust tight
Agains ingress of water with harmful effects
(non protected vertically dripping dripping (15° tilted) spaying splashing jetting powerful jetting temporary immersion continuous immersion

Motor protection

PRODUCT INFORMATION
Voltage imbalance
VZH scroll compressors are not equipped with an internal motor protector. Motor protection is provided by the variable speed drive. All parameters are factory preset in order to guaranty locked rotor or overload current protection.
The maximum allowable voltage imbalance between each phase is 3%. Voltage imbalance causes high amperage over one or several
When a warning situation is reached in the current control, the CDS frequency converter will automatically reduce the compressor speed in order to keep the motor current of the compressor below the maximum allowed.
phases, which in turn leads to overheating and possible drive damage.
16 AB237586440343en-000601
Approval and certificates
certificates
VZH compressors comply with the following approvals and certificates.Approvals and
CE
(European Directive) UL
(Underwriters Laboratories)
EMC Class A Group 1
2014/30/EU
CCC VZH code G
VZH code G & code J
All VZH models
VZH compressor and drive package

Low voltage directive 2014/35/EU

Internal free volume

Products VZH052-065
Declaration of conformity ref. Low voltage directive 2014/35/EU
Products Internal free volume at LP side without oil (lite/cu.inch)
VZH052 4. 7/287
VZH065 4.7/287
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
Contact Danfoss
PRODUCT INFORMATION
17AB237586440343en-000601
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