Spare parts & accessories ....................... 52
3AB218186428184en-001501
Page 4
General Information
PRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONGENERAL 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.
You are strongly advise to follow these
instructions. For any deviation from the
guidelines, please contact Danfoss Technical
Support.
4AB218186428184en-001501
Page 5
PRODUCT INFORMATION
Features
Discharge tube
Fixed scroll
Terminal cover
Danfoss H-series scroll compressors are
manufactured using the most advanced
machining, assembly, and process control
techniques. In design of both the compressor
and the factory, very high standards of reliability
and process control were first priority. The result
is a highly efficient product with the highest
reliability obtainable, and a low sound level.
The H-series compressors can be black or blue
depending on the production site.
Lifting lug
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
Check valve
Orbiting scroll
Slider block
Counterweight
Electric terminal
Lower bearing
Rotor
Stator
Eccentric shaft
Shell
Magnet
5AB218186428184en-001501
Page 6
Compressor model designation
Nomenclature
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
T: design optimized for 7.2/54.4°C
U: design optimized for 7.2/37.8°C
Danfoss H-series scroll compressor for R22/
R407C/R410A is available as single compressor
and can be assembled in tandem combinations.
The example below presents the compressor
TypeFeaturesMotorSize
HRHP6U1L
036
6
8
nomenclature which equals the technical
reference as shown on the compressor
nameplate. Code numbers for ordering are listed
section “Ordering information and packaging”.
HC M120T41034 950119 2 6010.223.4211 .7162.434.112.6647
Displacement at nominal speed: 2900 rpm at 50 Hz, 3500 rpm at 60 Hz
Net weight with oil charge
TR = Ton of Refrigeration Standard rating conditions: ARI standard Evaporating temperature: 7.2 °C
COP = Coefficient Of Performance Refrigerant: R22 Condensing temperature: 54.4 °C
EER = Energy Efficiency Ratio Superheat: 11.1 K Sub-cooling: 8.3 K
All performance test data after run-in 72hr
Subject to modification without prior notification
Data given for motor code 4 compressor, for full data details and capacity tables refer to Online Datasheet Generator: www.danfoss.com/odsg
Swept
volume
Displacement Oil charge
3
/revm3/hdm
3
64.413 .531.5739
Net
weight
kg
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
HCP109T49.131 450107 3509.463.3211.3148 .831.252.6647
HC P120T410.033 970115 96010.593.2111.0162.434.112.6647
Displacement at nominal speed: 2900 rpm at 50 Hz, 3500 rpm at 60 Hz
Net weight with oil charge
TR = Ton of Refrigeration Standard rating conditions: ARI standard Evaporating temperature: 7.2 °C
COP = Coefficient Of Performance Refrigerant: R407C Condensing temperature: 54.4 °C
EER = Energy Efficiency Ratio Superheat: 11.1 K Sub-cooling: 8.3 K
Swept
volume
Displacement Oil charge
3
/revm3/hdm
102. 821.581.5741
Net
weight
3
kg
All performance test data after run-in 72hr
Subject to modification without prior notification
Data given for motor code 4 compressor, for full data details and capacity tables refer to Online Datasheet Generator: www.danfoss.com/odsg
HC J121T41035 940122 62 011. 073.2511.0811 6.424.432.4649
Displacement at nominal speed: 2900 rpm at 50 Hz, 3500 rpm at 60 Hz
Net weight with oil charge
TR = Ton of Refrigeration Standard rating conditions: ARI standard Evaporating temperature: 7.2 °C
COP = Coefficient Of Performance Refrigerant: R410A Condensing temperature: 54.4 °C
EER = Energy Efficiency Ratio Superheat: 11.1 K Sub-cooling: 8.3 K
Swept
volume
Displacement Oil charge
3
/revm3/hdm
49.310.361.5741
Net
weight
3
kg
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
All performance test data after run-in 72hr
Subject to modification without prior notification
Data given for motor code 4 compressor, for full data details and capacity tables refer to Online Datasheet Generator: www.danfoss.com/odsg
The maximum allowable voltage imbalance is
2%. Voltage imbalance causes high amperage
over one or several phases, which in turn leads
|Vavg - V1-2 |+|Vavg - V1-3 |+|Vavg - V2-3 |
% voltage unbalance:
Vavg = Mean voltage of phases 1, 2 and 3
V1-2 = Voltage between phases 1 and 2
Danfoss Scroll Compressors H-series will only
compress gas while rotating counter-clockwise
(when viewed from the compressor top). Since
single-phase motors will start and run in only
one direction, reverse rotation is not a major
consideration. Three-phase motors, however,
will start and run in either direction, depending
on the phase angles of the supplied power. Care
must be taken during installation to ensure that
the compressor operates in the correct direction
(see “Phase sequence and reverse rotation
protection”).
to overheating and possible motor damage.
Voltage imbalance is given by the formula:
x 100
avg
2 xV
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3.
Electrical box cover must be fitted and cable
gland or similar protection component must
be used on electrical box’s knockouts before
energizing the compressor to against accidental
contact with electrical parts inside.
The drawings below show electrical terminal
labelling and should be used as a reference
when wiring the compressor. For three phase
applications, the terminals are labelled T1,
T2, and T3. For single-phase applications the
terminals are labelled C (common), S (start), and
R (run).
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
Terminal cover mounting
Terminal cover removal
Quick connect spade terminals
P terminal box type
The terminal cover and gasket should be
installed prior to operation of the compressor.
The terminal cover has two outside tabs, 180
degrees apart, that engage the terminal fence.
push
C
T₁
S
T₂
R
T₃
Ring connect screw terminals
C terminal box type
When installing the cover, check that it is not
pinching the lead wires. Both the inside of the
terminal cover and the gasket have labels for the
terminal pins: C (common), R (run), and S (start).
push
push
15AB218186428184en-001501
Page 16
Electrical data, connections and wiring
Three phase electrical
characteristics
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
19AB218186428184en-001501
Page 20
Electrical data, connections and wiring
IP rating
LRA (Locked Rotor Amp)
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
MCC (Maximum
Continuous Current)
Max Oper. A (Max
operating current)
The compressor terminal box IP rating according to IEC 529 is IP22 for all models. IP ratings is only
valid when correctly sized cable glands of the IP rating is applied.
• First numeral, level of protection against contact and foreign objects
2 protection against object size over 12.5 mm (fingers of similar)
• Second numeral, level of protection against water
2 protection against dripping water when tilted up to 15°
Locked Rotor Amp value is the higher average
current as measured on mechanically blocked
compressors tested under nominal voltage. The
LRA value can be used as a rough estimation for
The MCC is the current at which the motor
protection trips under maximum load and
low voltage conditions. This MCC value is the
maximum at which the compressor can be
The max. operating current is the current when
the compressors operate at maximum load
conditions and 10% below nominal voltage.
Max Oper. A can be used to select cables and
contactors. In normal operation, the compressor
the starting current. However, in most cases, the
real starting current will be lower.
operated in transient conditions and out of
the application envelope. Above this value,
the external electronic module will cut-out the
compressor to protect the motor.
current consumption is always less than the Max
Oper. A value. When using the Max Operating
Current to define cables and contactors, a
tolerance of +5% need to be taken into account.
Winding resistanceWinding resistance is the resistance between
indicated terminal pins at 25°C (resistance value
+/- 7%).
Winding resistance is generally low and it
requires adapted tools for precise measurement.
Use a digital ohm-meter, a ‘4 wires’ method and
measure under stabilised ambient temperature.
Winding resistance varies strongly with winding
temperature ; If the compressor is stabilised
at a different value than 25°C, the measured
resistance must be corrected with following
formula:
Motor protectionDanfoss Scroll Compressors H-Series are
equipped with an internal line break protector
mounted on the motor windings. The protector
is an automatic reset device, containing a snap
action bimetal switch.
Internal protectors respond to over-current and
overheating. They are designed to interrupt
Phase sequence and
reverse rotation
protection
The compressor will only operate properly in a
single direction. Use a phase meter to establish
the phase orders and connect line phases L1, L2
and L3 to terminals T1, T2 and T3, respectively.
For three-phase compressors, the motor will run
equally well in both directions. Reverse rotation
results in excessive noise; no pressure differential
between suction and discharge; and suction line
warming rather than immediate cooling.
A service technician should be present at initial
start-up to verify that supply power is properly
phased and that compressor and auxiliaries are
a + t
R
= R
tamb
a + t
t
25°C
t
amb
R
25°C
R
amb
25°C
: reference temperature = 25°C
: temperature during measurement (°C)
: winding resistance at 25°C
: winding resistance at t
amb
25°C
amb
coefficient a= 234.5
motor current under a variety of fault conditions,
such as lose phase, running overload, and locked
rotor.
If the internal overload protector trips out,
it must cool down to about 60°C to reset.
Depending on ambient temperature, this may
take up to several hours.
rotating in the correct direction.
Danfoss HR* and HL* series scroll compressor are
designed to operate for a maximum of 150 hours
in reverse, but as a reverse rotation situation can
go unnoticed for longer periods, phase monitors
are recommended.
For HC* series compressors, phase monitors are
required. The selected phase monitor should
lock out the compressor from operation in
reverse.
20AB218186428184en-001501
Page 21
Electrical data, connections and wiring
Electrical connections
PSC wiring
CSR wiring
Nominal capacitor value
and relays
Danfoss scroll compressors are designed to
operate without any assistance if running within
The start winding (C-S) of the motor remains in
circuit through a permanent (run) capacitor.
This permanent (run) capacitor is connected
between the start winding (C-S) and the run
winding (C-R).
If start assist is required, in case of operating
below the nominal voltage, a CSR starting device
is required.
During start-up, the start winding (C-S) is
energised through an electromagnetic potential
relay and a start capacitor.
GENERAL INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATIONPRODUCT INFORMATION
PVEPolyvinyl ether (PVE) is an innovative
refrigeration lubricant for HFC refrigerant
systems. PVE is as hygroscopic as existing
polyolester lubricants (POE), but PVE doesn’t
chemically react with water; no acids are formed
and compressor evacuation is easier.
Alkylbenzene oil
Alkylbenzene oil can be applied in systems
using HCFC refrigerants (R22). Compared to
a mineral oil it provides distinct advantages:
excellent miscibility, excellent thermal stability,
compatibility with mineral oils and constant
quality.
Oil type
Danfoss scroll compressors are charged with
oil at the factory with the oils indicated, in the
following table.
Compressor range Oil type
HRM / HLM / HCMAlkylbenzene
HRP / HLP / HCP PVE
HRH / HLHPVE
HLJ/HCJPVE
The compressor technology applied in Danfoss
H-series scroll compressors in combination with
PVE lubricant provides the best possible result in
terms of reliability and compressor lifetime.
The PVE lubricant is compatible with R22 which
makes the Danfoss H-series scroll compressors a
very versatile multi- refrigerant solution.
Danfoss Scroll H_M series compressors are
charged with Alkylbenzene oil and herewith
offer an economically interesting alternative to
the Danfoss H series in regions where R22 is still
the predominant refrigerant. Note however that
Danfoss H-series scroll compressors can not be
used with HFC refrigerants.
Effective week 31 of 2009, the HRP/HLP/
HCP & HRH/HLH series of compressors were
changed from POE oil to PVE oil. Compressors
produced prior to this week still had POE,
and may be in stock in the warehouses until
supply is exhausted. This change was made
to standardize to the better oil for reliability.
Replacement PVE 320HV is available for topping
up or replacing oil in the field (see accessory
section). As it is fully miscible with POE, Danfoss
recommends the 320HV regardless of original oil
charge in the compressor.
Residual moisture
Prior to shipment from the factory, every
compressor is dehydrated, evacuated, and
charged with dry nitrogen. Maximum residual
Run-in processOur H product ranges feature a compliance
technology which allows
. an exceptional slugging capability (radial
compliance)
. a very low starting torque (axial compliance)
moisture levels are 0.0082 oz. for models
capacities up to HRM/HRP047 and HRH040 and
0.0120 oz. for larger compressors.
When a compressor with compliance technology
is new, the performance is not immediately at
peak. A run-in period is needed to polish all
surfaces as well as to reduce friction and leakage.
The run-in period eliminates extra power input
23AB218186428184en-001501
Page 24
SYSTEM DESIGN
Design piping
General requirementsProper piping practices should be employed to:
1. Ensure adequate oil return, even under
minimum load conditions (refrigerant speed,
piping slope). For validation tests see section
“Manage oil in the circuit”.
g.1
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
0.5 % slope,
max. 4 m
max. 4 m
4 m/s or more
U-trap, as short as possible
8 to 12 m/s
0.5 % slope,
4 m/s or more
U-trap, as short as possible
U-trap
Evaporator
To condenser
2. Avoid condensed liquid refrigerant from
draining back to the compressor when stopped
(discharge piping upper loop). For validation
tests see section “Manage off cycle migration”.
General recommendations are described in the
figures below:
g. 2
Upper loop
Condenser
HP
U-trap
LP
3D exibility
3. Piping should be designed with adequate
three-dimensional flexibility to avoid excess
vibration. It should not be in contact with the
surrounding structure, unless a proper tubing
mount has been installed. For more information
on noise and vibration, see section on: “Manage
sound and vibration”.
24AB218186428184en-001501
Page 25
Design piping
Tandem requirementsDanfoss scroll compressor H series tandem use
static oil balancing principle to equalize oil level
between the compressors by gravity. This is
ensured by a precise suction and oil equalization
piping designs.
Danfoss scroll H series compressors in C8 version
can be mounted in tandem assemblies.
By default, H series tandems are not factory-built,
just provide tandem version compressors (feature
8).
The discharge line as no impact on oil balancing
and is shown with tees, to indicate that both left
and right side discharge header are possible
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Such manifolding applications require special
design considerations that go beyond the scope
of this document. Please contact Danfoss for
further information.
For each tandem configuration, specific outline
drawings are available as indicated in following
tables.
drawing must be respected (diameters, minimum
straight lengths)
(in)
Gas equalization
(in)
Kit tandem
Code No
Outline drawing
number
25AB218186428184en-001501
Page 26
Design compressor mounting
General requirements
Single requirements
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Tandem requirements
Parallel mounting feet
Compressors used in single applications must be
mounted with flexible grommets.
Compressors used in parallel application must be
mounted with rigid mounting spacers onto rails
H-series compressors come delivered with
flexible grommets, accessory Mounting kit
120Z5064.
The grommets must be compressed until contact
between the flat washer and the steel mounting
sleeve is established. The required bolt size for
the H-series compressors is M8*40mm. This bolt
must be tightened to a torque of 11 Nm.
For parallel mounting, the compressor must be
mounted with rigid mounting spacers (included
in the tandem kit 120Z0636) on the rails.
and the manifold assembly must be mounted
with flexible grommets onto frame.
During operation, the maximum inclination from
the vertical plane must not exceed 3 degrees.
1.7
29.5
41
5/16” - 18 UNC
Ø11
Ø 41
Recommended torque for mounting bolts:
11 Nm (±1 Nm)
self tapping
Rubber grommets and sleeves (delivered with
the compressor) must be installed below the rails.
26AB218186428184en-001501
Supplied with the compressor
Included in tandem
Not supplied
Page 27
Manage sound and vibration
Compressor sound
radiation
Typical sounds and vibrations in systems can be
broken down into the following three categories:
• Sound radiation (through air)
The following sections focus on the causes and
methods of mitigation for each of the above
sources.
• Mechanical vibrations (through parts and
structure)
• Gas pulsation (through refrigerant)
For sound radiating from the compressors,
the emission path is air and the sound waves
Sound levels are as follows:
• For compressors running alone:
are travelling directly from the machine in all
directions.
50 Hz60 Hz
Compressor model
HRM025-038665695120Z5083
HRM040-047675705120Z5083
HRM048-054685715120Z5 084
HRM058-06069572512 0Z5084
HLM068-0 81705735120Z 508 4
HCM094715745120Z5085
HCM109-120745785120Z5085
HRH029-032655685120Z5083
HRH034-040665695120Z5083
HRH041-05467570512 0Z5084
HLH0 61705735120Z 508 4
HLH068-HLJ083715745120Z 508 4
HC J091-106-121735765120Z5085
Attenuation given with acoustic hood only
Acoustic hood could be applied for both single and tandem version compressors.
Materials are UL approved and RoHS compliant
Sound power and attenuation are given at ARI conditions, measured in free space
H*P series same as H*M series. Compressor’s noise test is after compressor run-in 72hrs. Maximum sound is +5dBA
Sound power
dB(A)
Attenuation
dBA
Sound power
dB(A)
Attenuation
dBA
Acoustic hood
code number
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Note: During compressor shut down, a short
reverse rotation sound is generated. The duration
of this sound depends on the pressure difference
at shut down and should be less than 3 seconds.
This phenomenon has no impact on compressor
reliability.
Mitigations methods:
We can consider two means to reduce
compressors sound radiations:
1. Acoustic hoods are quick and easy to install
and do not increase the overall size of the
compressors to a great extent. Acoustic hoods
are available from Danfoss as accessories. Refer to
the table above for sound levels, attenuation and
code numbers.
2. Use of sound-insulation materials on the inside
of unit panels is also an effective means to reduce
radiation.
27AB218186428184en-001501
Page 28
Sound and vibration management
Mechanical vibrationsVibration isolation constitutes the primary
method for controlling structural vibration.
H-series scroll compressors are designed to
produce minimal vibration during operations.
The use of rubber isolators on the compressor
base plate or on the frame of a manifolded unit
is very effective in reducing vibration being
transmitted from the compressor(s) to the unit.
Rubber grommets are supplied with all H-series
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
scroll compressors.
Once the supplied rubber grommets have
been properly mounted, vibration transmitted
from the compressor base plate to the unit
Gas pulsationThe Danfoss Scroll Compressors H-series has
been designed and tested to ensure that gas
pulsation has been optimised for the most
commonly encountered air conditioning
pressure ratio. Manifolded compressors are
equivalents to lagged sources of gas pulsation.
Therefore pulse level can vary during time.
are held to a strict minimum. In addition, it is
extremely important that the frame supporting
the mounted compressor be of sufficient mass
and stiffness to help dampen any residual
vibration potentially transmitted to the frame.
The tubing should be designed so as to both
reduce the transmission of vibrations to other
structures and withstand vibration without
incurring any damage. Tubing should also be
designed for three-dimensional flexibility. For
more information on piping design, please see
the section entitled “Essential piping design
considerations”.
Mitigations methods:
If an unacceptable level is identified, a discharge
muffler with the appropriate resonant volume
and mass can be installed.
28AB218186428184en-001501
Page 29
Manage operating envelope
RequirementThe operating envelope for H-series scroll
R
compressors is given in the figures below and
guarantees reliable operations of the compressor
for steady-state and transient operation.
R22, R407C
70
Model variation T
65
60
55
50
45
40
35
Condensing temperature (°C)
30
25
20
-30-25-20-15-10-5051015
Evaporating temperature (°C)
Steady-state operation envelope is valid for a
suction superheat within 5K to 30K range.
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
SH 11K
R410A
Model variation T
70
65
60
55
50
45
40
35
Condensing temperature (°C)
30
25
20
-30-25-20-15-10-5051015
SH 5K
SH 11K
Evaporating temperature (°C)
HCJ121 & HCJ 120
condensing temperature boundary
29AB218186428184en-001501
Page 30
Manage operating envelope
Bracket
R22, R410A
Model variation U
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
70
65
60
55
50
45
40
35
Condensing temperature (°C)
30
25
20
-30-25-20-15-10-5051015
Working pressure range high side bar (g)10.9 - 27.710.5 - 29.115.8 - 44.5
Working pressure range low side bar (g)1.4 - 6.91.1 - 6.41.9 - 10.8
Maximum high pressure safety switch setting* bar (g)293045
Minimum low pressure safety switch setting bar (g)0.50.51.5
Recommended pump-down switch settings bar (g)
Minimum low pressure pump-down switch setting bar (g)1.51.32.3
Evaporating temperature (°C)
SH 11K
R22R407CR410A
1.5 bar below nominal evap. pressure with
minimum limitation as below
High and low pressure
protection
Maximum allowable pressure on high pressure side according to PED regulation.
*
LP and HP safety switches must never
R
be bypassed nor delayed and must stop all the
compressors.
The discharge gas thermostat accessory kit (code
7750009) includes all components required
for installation as shown on the right. DGT
installation must respect below requirements:
When caused low by LP safety switch, limit the
number of auto-restart to maximum 5 times
within 12 hours.
• The thermostat must be attached to the
discharge line within 150 mm from the
compressor discharge port and must be
HP safety switch must be manual reset
Depending on application operating envelope,
you must define HP and LP limits within
thermally insulated and tightly fixed on the pipe.
• The DGT should be set to open at a discharge
gas temperature of 135°C.
operating envelope and pressure setting table
above.
For H-series compressors, the external Discharge
Gas Temperature protection (DGT) is required
if the high and low pressure switch settings do
Discharge line
not protect the compressor against operations
beyond its specific application envelope.
Thermostat
Insulation
30AB218186428184en-001501
Page 31
Manage operating envelope
System evaluationHP and LP must be monitored to respect operating envelope limitations. We consider two types of
operating envelope management:
Basic:
• HP and LP switch
• MOP (Max Operating Pressure) ensured by expansion
device
• Condensing pressure control
• DGT external
Advanced:
• HP and LP sensor
• Operating envelope limits (permanent and transient)
integrated into control logic
• DGT external
See “Test, criteria and solutions”
DGT
Continuous
Running Area
LP switch setting
Condensing pressure control
HP switch setting
o
1 and 2
tests N
3
o
MOP + test N
Test, criteria and solutions
Tes t N °PurposeTest conditionPass criteriaSolutions
1
Check the
compressor
operation in
2
the “continuous
running area”.
Start test at minimum foreseeable
evaporating temperature (minimum
ambient temerature)
Perform a defrost test if reversible
unit
Confirmed compressor stable
working in the continuous running
area.
Work on compressor staging, fan
staging, water flow etc.
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
31AB218186428184en-001501
Page 32
Manage superheat
Requirement
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
System evaluation
During normal operation, refrigerant enters
the compressor as a superheated vapor. Liquid
flood back occurs when a part of the refrigerant
entering the compressor is still in liquid state.
In steady state conditions,
• Suction superheat must remain within 5K to 30K
• According to the floodback chart
Discharge temperature sensor must be placed
onto the discharge fitting and be insulated.
Oil temperature sensor must be placed on the
mid shell, closed to the lower shell, and be
insulated.
Use the tables below in relation with the system
charge and the application to quickly evaluate
the risk and potential tests to perform.
Liquid flood back can cause oil dilution and, in
extreme situations lead to liquid slugging that
can damage compression parts.
In transient conditions,
• According to the floodback chart
BELOW cHargELimitaBOVE cHargELim it
Non reversibleNo test or additional safeties requiredLiquid flood back test
-For Electronic expansion valve
(EXV) check measurement chain and
PID....
2. Add a suction accumulator*.
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Defrost test
Check liquid
floodback
during defrost
cycle
Defrost test must be carried out in
the most unfavorable condition (at
0°C evaporating temperature).
18
16
14
12
10
8
6
Sump Superheat, K
4
2
0
-25-20-15-10-5051015
Acceptable
Refer to flood back chart criteria
Floodback Requirement
Unacceptable
Saturated Suction Temp. °C
In reversible systems, the defrost
logic can be worked out to limit
liquid floodback effect. (for more
details see “Control Logic”).
*Suction accumulator offers protection by trapping the liquid refrigerant upstream from the compressor. The accumulator should be
sized at least 50 % of the total system charge. Suction accumulator dimensions can impact oil return (gas velocity, oil return hole size…),
therefore oil return has to be checked according to section “Manage oil in the circuit”.
33AB218186428184en-001501
Page 34
Manage off cycle migration
Requirement
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Evaluate the risk
R
Off -cycle refrigerant migration happens:
• when the compressor is located at the coldest
part of the installation, refrigerant vapor
condenses in the compressor.
• or directly in liquid-phase by gravity or pressure
difference.
• Compressor can tolerate occasional flooded
start, but it should remain exceptional situation
and unit design must prevent that this situation
happen at each start
• Right after start, liquid refrigerant must not flow
massively to compressor
Use the table below in relation with the system
charge (refer to charge limit table in section
“Manage superheat”) and the application to
BELOW cHargELimitaBOVE cHargELim it
Non splitNo test or additional safeties required
Since each installation is unique, no test can fully evaluate off-cycle migration, therefore
Split
the following safeties are required:
• Crankcase Heater *
• Liquid Line Solenoid Valve**+ pump-down cycle***
• (Internal Non-Return Valve integrated)
When the compressor restarts, the refrigerant
diluted in the oil, or stored in evaporator,
generates poor lubrication conditions and may
reduce bearings life time. In extreme situations,
this leads to liquid slugging that can damage
compression scrollset.
• The charge limit is a threshold beyond some
protective measures must be taken to limit risk of
liquid slugging and extreme dilution at start.
(refer to charge limit table in section “Manage
superheat”).
quickly define necessary safeties to implement
and test to perform:
• Crankcase Heater*
• Migration test
• External Non Return Valve
34AB218186428184en-001501
Page 35
Manage off cycle migration
Test, criteria and solutions
Tes t N °PurposeTest conditionPass criteriaSolutions
Migration test
Check that
there is no
migration of
refrigerant into
the compressor
(either liquid
or vapour
condensating)
Energize CCH*.
Stabilize the non-running system at
a pressure equivalent to 5°C .
Raise the system pressure
equivalent to 20°C. When saturated
condensing temperature reaches
20°C then start the unit.
When all compressors are idle:
• Check in liquid line sight glass that
there is no liquid refrigerant transfer
• Refer to flood back chart criteria
After compressors has started:
• Oil superheat must remain the
criteria refer to flood back chart.
Oil temperature sensor must be placed between
oil sight glass and compressor baseplate and be
insulated.
* Crank case heater (CCH)
The Crank case heaters are designed to protect
the compressor against off-cycle migration of
refrigerant.
Additional heater power or thermal insulation
might be needed in case of ambient temperature
below -5°C and a wind speed above 5m/second.
The heater must be energized whenever all the
compressors are off.
Crank case heater accessories are available from
Danfoss (see section “Accessories”).
Optimum
location area
1. Check bulb position, tightness of
expansion device,
2. add LLSV**
3. add pump down cycle***
4. Check Crank Case Heater
efficiency
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
It’s recommended that the heater be turned on
for a minimum of 8 hours prior to starting the
compressor.
**Liquid line solenoid valve (LLSV)
A LLSV is used to isolate the liquid charge
on the condenser side, thereby preventing
against charge transfer to the compressor
during off -cycles. The quantity of refrigerant
on the low-pressure side of the system can be
further reduced by using a pump-down cycle in
association with the LLSV.
***Pump-down cycle
By decreasing pressure in the sump, pump down:
• evacuates refrigerant from oil
• set the sump saturating pressure much
lower than ambiance temperature and due
to that, avoid refrigerant condensation in the
compressor.
On/off cycling (cycle rate
limit)
Provide separate electrical supply for the
heaters so that they remain energized even
when the machine is out of service (e.g. seasonal
shutdown).
Danfoss recommends a restart delay timer to
limit compressor cycling. The timer prevents
reverse compressor rotation, which may occur
during brief power interruptions.
The system must be designed in a way that
guarantees a minimum compressor running
time of 2 minutes so as to provide for sufficient
For more details on pump-down cycle see
section “Control Logic”.
motor cooling after start-up along with proper
oil return. Note that the oil return may vary since
it depends upon system design.
There must be no more than 12 starts per hour, a
number higher than 12 reduces the service life of
the motor-compressor unit. A three-minute (180sec) time out is recommended.
35AB218186428184en-001501
Page 36
Provide power supply and electrical protection
Wiring information
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Requirements:
• An additional external overload protection is
still advisable for either alarm or manual reset.
For overload setting, take the max current
you can face on the application and add
10%. Setting must always be lower than Max
Operating Current (see table “Three phase
electrical characteristics” from the section
“Electrical data, connections and wiring”)
The wiring diagrams below are examples for a safe and reliable compressor wiring:
Control device .................................................. TH
Optional short cycle timer (3 min) ......... 180 s
Control relay .................................................... KA
Liquid Line Solenoid valve .........................LLSV
Compressor contactor .................................. KM
Compressor motor ...........................................M
Discharge gas thermostat ......................... DGT
• HP safety switch and DGT must be wired in the
safety chain. Other safety devices such as LP can
be either hardware or software managed.
• Provide separate electrical supply for the
heaters so that they remain energized even
when the machine is out of service (e.g.
seasonal shutdown).
CONTROL CIRCUIT
F1F1
KA
KM
KAKA
PM
A1
KS
LP
KM
KA
A3
180 s
A2
TH
KS
LLSVKS
Wiring diagram with pump-down cycle
L1 L3L2
Q1
KS
T1
HPs
DGT
KM
T2
T3
M
36AB218186428184en-001501
Note:
For H-series compressor, phase monitors are mandatory. The selected phase monitor should lock out
the compressor from operation in reverse.
Page 37
Control logic
Safety control logic
requirements
HP switch
LP safety switch
Electronic module
(Motor protection, DGT)
Tripping conditionsRe-start conditions
ValueTimeValueTime
See Pressure settings table
from section “Manage
operating envelope”
Contact M1-M2 opened
Immediate, no delay.
No by- pass
Conditions back to normal.
Switch closed again
Manual reset
Maximum 5 auto reset during
a period of 12 hours, then
manual reset.
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Cycle rate limit
requirements
Oil management logic
recommendations
Danfoss requires a minimum compressor running
time of 2 minutes to ensure proper oil return and
sufficient motor cooling.
Additionally, compressor service life is based on a
maximum of 12 starts per hour.
In some cases, oil management can be enhanced
by control logic:
If oil return test failed, a function can be
integrated in control to run all compressors
simultaneously during one minute every hour in
order to boost oil return. Time and delay can be
fine-tuned by oil return test N°1 §Manage oil in
the circuit. During oil boost, pay special attention
to superheat management to avoid liquid flood
back and foaming.
Therefore, to guarantee these 2 requirements,
a three-minute (180- sec) time out is
recommended.
If after running long time in full load, oil
unbalance appears, then a function can be in
control to stop all compressors in manifold
during one minute every two hours in order to
balance oil between compressors. Time and delay
can be fine-tuned by Oil balancing test N°2 §
Manage oil in the circuit.
37AB218186428184en-001501
Page 38
Control logic
Defrost logic
recommendations
Compressor 1
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
Compressor 2
4WV
EXV
In reversible systems, the defrost logic can be
worked out to limit liquid flood back effect by:
1. Running full load during defrost to share liquid
refrigerant between all compressors.
The following defrost logic combines both
advantages:
ON
ON
Heating
100%
Defrost start. Stop all compressors
4 Way Valve (4WV) stays in heating
mode.
EXV opened to transfer liquid from
outdoor to indoor exchanger thanks
to pressure difference
When pressures are almost balanced*,
Start Cp1 and Cp 2 with 0.5 seconds
change 4WV to cooling mode.
delay between 2 successive starts
2. Transferring liquid refrigerant from one
exchanger to the other one thanks to pressures.
Defrost
4 Way Valve (4WV) stays in heating
Defrost end. Stop all compressors
mode.
EXV opened to transfer liquid from
indoor to outdoor exchanger thanks
to pressure difference
When pressures are almost balanced*,
Start Cp1 and Cp 2 with 0.5 seconds
change 4WV to heating mode.
delay between 2 successive starts
Pump-down logic
recommendations
* EXV Opening degree and time have to be set to keep a minimum pressure for 4 way valve moving.
In any case, defrost logics must respect requirements and tests described in sections “Manage
superheat” and “Manage operating envelope”.
Pump down is initiated prior to shutting
down the last compressor on the circuit by
de-energizing a liquid line solenoid valve
or closing electronic expansion valve. When
suction pressure reached the cut-out pressure,
compressor is stopped, and liquid solenoid valve
or electronic expansion valve remains closed.
Two types of pump-down exist:
• One shot pump down (preferred): when
last compressor of the circuit stops, suction
presssure is decreased 1.5 bar (R22,R407C),
2.5 bar (R410A) below nominal evaporating
pressure. Even if suction pressure increases
again, the compressor will not restart.
• Continuous pump-down: traditional pumpdow, Compressor restarts automatically when
suction pressure increases. A non-return valve in
the discharge line is recommended.
38AB218186428184en-001501
Page 39
Reduce moisture in the system
Requirements
Solutions
Excessive air and moisture
• can increase condensing pressure and cause
excessively high discharge temperatures.
• can create acid giving rise to copper platting.
H-series compressors are delivered with < 100
ppm moisture level.
At the time of commissioning, system moisture
content may be up to 100 ppm.
To achieve this requirement, a properly sized
and type of drier is required. Important selection
criteria’s include:
• driers water content capacity,
• system refrigeration capacity,
• system refrigerant charge.
• can destroy the lubricating properties of the oil.
All these phenomena can reduce service life
and cause mechanical and electrical compressor
failure.
During operation, the filter drier must reduce this
to a level between 20 and 50 ppm.
GENERAL INFORMATIONPRODUCT INFORMATIONINTEGRATION INTO SYSTEMORDERING INFORMATIONSYSTEM DESIGN
For new installations with H-series compressors
with polyolester oil, Danfoss recommends using
the Danfoss DML (100% molecular sieve) solid
core filter drier.
39AB218186428184en-001501
Page 40
INTEGRATION INTO SYSTEM
Assembly line procedure
Compressor storage
Compressor holding
charge
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNORDERING INFORMATIONINTEGRATION INTO SYSTEM
Handling
Store the compressor not exposed to rain,
corrosive or flammable atmosphere between
-35°C and 70°C when charged with nitrogen and
Each compressor is shipped with a nominal dry
nitrogen holding charge between 0.3 and 0.7 bar
and is sealed with elastomer plugs.
Respect the following sequence:
• Remove the nitrogen holding charge via the
suction Schrader valve to avoid an oil mist blow
out.
Each Danfoss H-series scroll compressor is
equipped with the lift ring on the top shell and
ring for the discharge port.
• Always use both these rings when lifting the
compressor.
• Use lifting equipment rated and certified for
the weight of the compressor or compressor
assembly.
• A spreader bar rated for the weight of the
compressor is highly recommended to ensure a
better load distribution.
• The use of lifting hooks closed with a clasp is
recommended.
between -35°C and 55°C when charged with
refrigerant.
• Remove the suction plug first and the discharge
plug afterwards to avoid discharge check valve
gets stuck in open position.
An opened compressor must not be exposed to
air for more than 20 minutes to avoid moisture is
captured by the PVE oil.
• For tandem and trio assemblies, use a spreader
bar and all compressor rings as shown in picture
below.
• Never use the lift rings on the compressor to lift
the full unit.
Maintain the compressor in an upright position
during all handling manoeuvres (maximum of
15° from vertical).
HEAVY
do not lift
manually
40AB218186428184en-001501
Page 41
Assembly line procedure
Piping assemblyGood practices for piping assembly is a pre-requisite to ensure compressor service life.
System cleanliness
Circuit contamination possible cause:Requirement:
Brazing and welding oxidesDuring brazing, flow nitrogen through the system
Filings and particles from the removal of burrs in
pipe-work
Moisture and air
Remove any particles and burrs generated by tube
cutting and hole drilling
Use only clean and dehydrated refrigeration grade
copper tubing
Opened compressor must not be exposed to air more
than 20 minutes to avoid moisture captured by POE oil.
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNORDERING INFORMATIONINTEGRATION INTO SYSTEM
Brazing procedure:
• Brazing operations must be performed by
qualified personnel.
• Make sure that no electrical wiring is connected
to the compressor.
• To prevent compressor shell and electrical box
overheating, use a heat shield and/or a heatabsorbent compound.
• Clean up connections with degreasing agent
• Flow nitrogen through the compressor.
• Use flux in paste or flux coated brazing rod.
Before eventual un-brazing of the
compressor or any system component, the
refrigerant charge must be removed.
• Use brazing rod with a minimum of 5% silver
content.
• It is recommended to use double-tipped torch
using acetylene to ensure a uniform heating of
connection.
• To enhance the resistance to rust, a varnish on
the connection is recommended.
heat shield
A
C
B
System pressure test and
leak detection
The compressor has been strength tested
and leak proof tested (<3g/year) at the factory.
For system tests:
• Pressurize the system on HP side first then LP
side.
• Do not exceed the following pressures:
• Always use an inert gas such as Nitrogen or
Helium.
Maximum compressor test pressures
Maximum compressor test pressure high side (HP)
Maximum compressor test pressure low side (LP)31.1 bar (g)
45 bar (g), Do keep the low side pressure not exceed
31.1 b ar(g)
41AB218186428184en-001501
Page 42
Assembly line procedure
Vacuum evacuation and
moisture removal
Refrigerant charging
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNORDERING INFORMATIONINTEGRATION INTO SYSTEM
Dielectric strength and
insulation resistance tests
Requirements:
• Never use the compressor to evacuate the
system.
• Connect a vacuum pump to both the LP and HP
sides.
• Evacuate the system to a pressure of 500 μm Hg
(0.67 mbar) absolute.
R
Initial charge:
• For the initial charge, the compressor must not
run.
• Charge refrigerant as close as possible to the
nominal system charge.
• This initial charging operation must be done in
liquid phase between the condenser outlet and
the filter drier.
The tests are performed on each compressor at
the factory between each phase and ground.
• Dielectric strength test is done with a high
potential voltage (hi-pot) of 2Un +1000V AC
at least, and leakage current must be less than
5 mA. Additional tests of this type are not
recommended as it may reduce motor lifetime.
Nevertheless, if such a test is necessary, it must
be performed at a lower voltage.
Recommendations:
• Energized heaters improve moisture removal.
• Alternate vacuum phases and break vacuum
with Nitrogen to improve moisture removal.
For more detailed information see “Vacuum
pump-down and dehydration procedure”
TI-026-0302.
If needed, a complement of charge can be done:
• In liquid phase while compressor is running by
slowly throttling liquid in.
• On the low pressure side, as far away as possible
from the compressor suction connection.
• Never bypass safety low pressure switch.
For more detailed information see
“Recommended refrigerant system charging
practice“ FRCC.EN.050.
• Insulation resistance is measured with a 500 V
DC megohm tester and must be higher than 1
megohm.
• The presence of refrigerant around the
motor windings will result in lower resistance
values to ground and higher leakage current
readings. Such readings do not indicate a faulty
compressor. To prevent this, the system can be
first operated briefly to distribute refrigerant.
Do not use a megohm meter nor apply
R
power to the compressor while it is under
vacuum as this may cause internal damage.
42AB218186428184en-001501
Page 43
Commissioning
Preliminary check
Check electrical power supply:
• Phase order: For H-series compressors, reverse
rotation is obvious if the compressor do not
build up pressure and sound level is abnormal
high. For more details refer to section “Motor
protection”.
• Voltage and voltage unbalance within tolerance:
For more details refer to section “Motor voltage”.
Initial start-up
System monitoring
Oil level checking and
top-up
• Crankcase heaters must be energized at least 8
hours in advance to remove refrigerant.
• A quicker start-up is possible by “jogging” the
compressor to evacuate refrigerant.
The system must be monitored after initial
startup for a minimum of 60 minutes to ensure
proper operating characteristics such as:
• Correct superheat and subcooling.
• Current draw of individual compressors within
acceptable values (max operating current).
• No abnormal vibrations and noise.
• Correct oil level.
In installations with good oil return and line
runs up to 50 ft, no additional oil is required.
If installation lines exceed 50 ft, additional oil
may be needed. 1 or 2% of the total system
refrigerant charge (in weight) can be used to
roughly define the required oil top-up quantity.
Start the compressor for 1 second, then wait for
1 to 2 minutes. After 3 or 4 jogs the compressor
can be started. This operation must be repeated
for each compressor individually.
If Oil Top-up is needed, it must be done while the
compressor is idle. Use the schrader connector
or any other accessible connector on the
compressor suction line. Always use new cans.
For more detailed information see “Lubricants
filling in instructions for Danfoss Commercial
Compressors” TI 2-025-0402.
Always use oil from new cans.
Top-up the oil while the compressor is idle. Use
any accessible connector on the compressor
suction line and a suitable pump.
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNORDERING INFORMATIONINTEGRATION INTO SYSTEM
43AB218186428184en-001501
Page 44
Dismantle and disposal
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNORDERING INFORMATIONINTEGRATION INTO SYSTEM
Danfoss recommends that compressors and compressor oil should be recycled by a
suitable company at its site.
44AB218186428184en-001501
Page 45
ORDERING INFORMATION
Ordering information and packaging
Packaging
Single pack
Industrial pack
Compressors are packed individually in a
cardboard box. They can be ordered in any
quantity. Minimum ordering quantity = 1. As far
as possible, Danfoss will ship the boxes on full
pallets of 9 compressors according below table.
• Each box also contains following accessories:
• 4 grommets
• 4 assemblies of self tapping US thread bolts,
washers and sleeves
• 4 additional sleeves
• 1 screw for earth connection
• Run capacitors are not provided
Compressors are not packed individually but are
shipped all together on one pallet. They can be
ordered in quantities of full pallets only, multiples
of 12 compressors, according below table.
Each industrial pack pallet contains following
accessories:
• 4 grommets per compressor
• 4 sleeves per compressor
• 1 screw for earth connection per compressor
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
Packaging details
Delivered regionPackagingNbrPallet typeComments
All
* Nbr : number of compressors/pallet
Single pack9Danfoss pallet
Industrial pack12Danfoss pallet
-
45AB218186428184en-001501
Page 46
Ordering information and packaging
Compressor code
numbers
Danfoss H-series scroll compressors can be
ordered in either industrial packs or in single
Please use the code numbers from below tables
for ordering.
packs.
R22 Single pack
GENERAL INFORMATIONPRODUCT INFORMATIONSYSTEM DESIGNINTEGRATION INTO SYSTEMORDERING INFORMATION
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