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Transcript of Application guidelines - Danfossfiles.danfoss.com/technicalinfo/dila/17/FRCC.PC.037.A3.02-DSH... ·...
Danfoss scroll compressors DSH 240-485
50 Hz - 60 Hz - R410A
Application guidelines
httpccdanfosscom
Content
GENERAL INFORMATION 4
PRODUCT INFORMATION 5
Features5Overview 5How do IDVs work 5
Compressor model designation 6Nomenclature 6
Technical specifications 750-60 Hz data 7
Dimensions 8Single compressors 8Tandem assemblies 9Trio assemblies 10Connection details 10
Electrical data connections and wiring 11Motor voltage 11Wiring connections 11IP rating 12Terminal box temperature 12Three phase electrical characteristics 12Motor protection 13
Approval and certification 15Approval and certificates 15Low voltage directive 15Machines directive 15Pressure equipment 15Internal free volume 15
SYSTEM DESIGN 16
Design piping 16General requirements 16Tandem and trio requirements 17Suction washer position 18Oil equalization design 19
Design compressor mounting 20General requirements 20Single requirements20Tandem and trio requirements 20
Manage oil in the circuit 21Requirement 21System Evaluation 21Test criteria and solutions 21
Manage sound and vibration 22Compressor sound radiation 22Mechanical vibrations 23Gas pulsation 23
Manage operating envelope 24Requirement 24System evaluation 25Test criteria and solutions 25
Manage superheat 26Requirement 26System evaluation 26Test criteria and solutions 27
Manage off cycle migration 28Requirement 28System evaluation 28Test criteria and solutions 29
Provide power supply and electrical protection 30
Wiring information 30Soft starters 32
Control logic 33Safety control logic requirements 33Cycle rate limit requirements 33Oil management logic recommendations 33Defrost logic recommendations 34Pump-down logic recommendations 34
INTEGRATION INTO SYSTEMS 35
Reduce moisture in the system 35Requirements 35Solutions 35
Assembly line procedure 36Compressor storage 36Compressor holding charge 36Handling 36
Assembly line procedure 37Piping assembly37System pressure test and leak detection 37Vacuum evacuation and moisture removal 38Refrigerant charging 38Dielectric strength and insulation resistance tests 38
Commissioning 39Preliminary check39Initial start-up 39System monitoring 39
Dismantal and disposal 40
ORDERING INFORMATION 41
Packaging 41
Ordering codes 42
Accessories 44
3FRCCPC037A302
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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 reliability risk
This icon indicates instructions to avoid safety risk
The purpose of this guideline is to help customers qualify compressors in the unitYou are strongly advised 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
R
4 FRCCPC037A302
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DSH 240-295-381-485 scroll compressor benefit from an improved design to achieve the highest efficiency and increased life time
Features
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 systemrsquos seasonal energy efficiency
How do IDVs work
Intermediate discharge valves (IDVs) increase seasonal efficiency
Internal Non Return Valve (INRV)prevents excessive leak rate from high pressure side
Heat shield lowers the heat transfer between discharge and suction gas and the acoustic level
Integrated discharge gas temperature protection (DGT)
Lead free polymer bearings improve behavior under poor lubrication conditionsPatented gas path flow with gas intake design induce higher resistance to liquid slugging
Organ pipe masters oil circulation in manifold configuration
Overview
5FRCCPC037A302
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Compressor model designation
Danfoss scroll compressor DSH for R410A is available as single compressor and can be assembled in tandem or trio combinations The example below presents the compressor
nomenclature which equals the technical reference as shown on the compressor nameplate Code numbers for ordering are listed in section ldquoOrdering codesrdquo
Nomenclature
Family lubricant amp refrigerantDSH Scroll POE lubricant for R410A Motor protection
A Electronic module 24V ACB Electronic module 110-240V
Suction and discharge connectionsA Brazed connections
Family lubricant
amp refrigerant
Nominalcapacity
Approvals Voltage Version Evolutionindex
Evolution indexA~Z
A4DSH A AB485
Motor voltage code3 200-230V3~60 Hz4 380-415V3~50 Hz - 460V3~60 Hz for DSH240 and DSH381 380-400V3~50 Hz - 460V3~60 Hz7 500V3~50 Hz - 575V3~60 Hz9 380V3~60 Hz
UL index
Nominal capacity in thousand Btuh at 60 Hz R410A ARI conditions
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Technical specifications
50-60 Hz data
Tandem and trios
ModelNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Swept
volumeDisplace-ment Oil charge Net weight
TR W Btuh kW WW BtuhW cm3rev m3h dm3 kg
50 Hz
DSH240 20 59500 203200 188 317 1082 22760 396 67 1080
DSH295 25 72200 246600 224 322 1099 27620 481 67 1110
DSH381 30 91100 310900 285 319 1089 34500 60 67 1590
DSH485 40 116400 397400 358 325 1109 44260 77 67 1750
60 Hz
DSH240 20 72400 247300 225 322 1099 22760 478 67 1080
DSH295 25 87600 299000 269 326 1113 27620 58 67 1110
DSH381 30 109500 373800 345 318 1085 34500 723 67 1590
DSH485 40 141800 484100 436 325 1109 44260 929 67 1750
Model CompositionNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Displacement
TR W Btuh kW WW BtuhW m3h
50 Hz
Tand
em
DSH482 2xDSH240 40 118000 402700 3759 315 1076 792
DSH535 DSH240+DSH295 45 130600 445700 4123 318 1085 877
DSH590 2xDSH295 50 143200 488700 4487 321 1094 962
DSH620 DSH240+DSH381 50 149300 509500 4732 317 1081 996
DSH675 DSH295+DSH381 55 161900 552500 5096 319 1089 1081
DSH760 2xDSH381 60 180600 616200 5705 318 1085 120
DSH725 DSH240+DSH485 60 174400 595100 5462 320 1093 1166
DSH780 DSH295+DSH485 65 187000 638100 5826 322 1099 1251
DSH865 DSH381+DSH485 70 205700 701900 6435 321 1095 137
DSH970 2xDSH485 80 230800 787600 7166 323 1104 154
Trio
DSH720 3xDSH240 60 174700 596200 5639 314 1073 1188
DSH885 3xDSH295 75 212000 723400 6730 320 1091 1443
DSH1140 3xDSH381 90 267300 912200 8558 317 1082 180
DSH1455 3xDSH485 120 341600 1165800 10748 323 1101 231
DSH1245 2xDSH381+DSH485 100 292100 996800 9288 319 1090 197
DSH1350 DSH381+2xDSH485 110 316800 1081300 10018 321 1095 214
60 Hz
Tand
em
DSH482 2xDSH240 40 143600 490100 4501 320 1094 956
DSH535 DSH240+DSH295 45 158600 541300 4936 323 1101 1058
DSH590 2xDSH295 50 173600 592600 5371 325 1108 116
DSH620 DSH240+DSH381 50 180300 615500 5696 318 1084 1201
DSH675 DSH295+DSH381 55 195400 666800 6131 320 1092 1303
DSH760 2xDSH381 60 217100 740900 6891 316 1080 1446
DSH725 DSH240+DSH485 60 212400 724800 6612 322 1099 1407
DSH780 DSH295+DSH485 65 227400 776100 7048 324 1105 1509
DSH865 DSH381+DSH485 70 249100 850200 7808 320 1093 1652
DSH970 2xDSH485 80 281100 959500 8724 324 1105 1858
Trio
DSH720 3xDSH240 60 212600 725400 6751 320 1091 1434
DSH885 3xDSH295 75 257100 877300 8057 324 1105 174
DSH1140 3xDSH381 90 321400 1096800 10337 316 1077 2169
DSH1455 3xDSH485 120 416200 1420400 13086 323 1102 2787
DSH1245 2xDSH381+DSH485 100 353000 1204700 11253 319 1087 2375
DSH1350 DSH381+2xDSH485 110 384600 1312500 12170 321 1094 2581
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 72 degC Superheat 111 KEER Energy Efficiency Ratio Refrigerant R410A Condensing temperature 544 degC Subcooling 83 KCOP Coefficient Of Performance
Subject to modification without prior notificationData given for motor code 4 compressor for full data details and capacity tables refer to Coolselectorreg2wwwcoolselectordanfosscom
7FRCCPC037A302
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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SYST
EM D
ESIG
N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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EM D
ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
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N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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EM D
ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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SYST
EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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RMAT
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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UCT
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SYST
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ESIG
NIN
TEG
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ON
INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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EM D
ESIG
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TEG
RATI
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INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
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ESIG
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
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TEG
RATI
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INTO
SYS
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
NIN
TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
NPR
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UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
Content
GENERAL INFORMATION 4
PRODUCT INFORMATION 5
Features5Overview 5How do IDVs work 5
Compressor model designation 6Nomenclature 6
Technical specifications 750-60 Hz data 7
Dimensions 8Single compressors 8Tandem assemblies 9Trio assemblies 10Connection details 10
Electrical data connections and wiring 11Motor voltage 11Wiring connections 11IP rating 12Terminal box temperature 12Three phase electrical characteristics 12Motor protection 13
Approval and certification 15Approval and certificates 15Low voltage directive 15Machines directive 15Pressure equipment 15Internal free volume 15
SYSTEM DESIGN 16
Design piping 16General requirements 16Tandem and trio requirements 17Suction washer position 18Oil equalization design 19
Design compressor mounting 20General requirements 20Single requirements20Tandem and trio requirements 20
Manage oil in the circuit 21Requirement 21System Evaluation 21Test criteria and solutions 21
Manage sound and vibration 22Compressor sound radiation 22Mechanical vibrations 23Gas pulsation 23
Manage operating envelope 24Requirement 24System evaluation 25Test criteria and solutions 25
Manage superheat 26Requirement 26System evaluation 26Test criteria and solutions 27
Manage off cycle migration 28Requirement 28System evaluation 28Test criteria and solutions 29
Provide power supply and electrical protection 30
Wiring information 30Soft starters 32
Control logic 33Safety control logic requirements 33Cycle rate limit requirements 33Oil management logic recommendations 33Defrost logic recommendations 34Pump-down logic recommendations 34
INTEGRATION INTO SYSTEMS 35
Reduce moisture in the system 35Requirements 35Solutions 35
Assembly line procedure 36Compressor storage 36Compressor holding charge 36Handling 36
Assembly line procedure 37Piping assembly37System pressure test and leak detection 37Vacuum evacuation and moisture removal 38Refrigerant charging 38Dielectric strength and insulation resistance tests 38
Commissioning 39Preliminary check39Initial start-up 39System monitoring 39
Dismantal and disposal 40
ORDERING INFORMATION 41
Packaging 41
Ordering codes 42
Accessories 44
3FRCCPC037A302
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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 reliability risk
This icon indicates instructions to avoid safety risk
The purpose of this guideline is to help customers qualify compressors in the unitYou are strongly advised 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
R
4 FRCCPC037A302
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DSH 240-295-381-485 scroll compressor benefit from an improved design to achieve the highest efficiency and increased life time
Features
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 systemrsquos seasonal energy efficiency
How do IDVs work
Intermediate discharge valves (IDVs) increase seasonal efficiency
Internal Non Return Valve (INRV)prevents excessive leak rate from high pressure side
Heat shield lowers the heat transfer between discharge and suction gas and the acoustic level
Integrated discharge gas temperature protection (DGT)
Lead free polymer bearings improve behavior under poor lubrication conditionsPatented gas path flow with gas intake design induce higher resistance to liquid slugging
Organ pipe masters oil circulation in manifold configuration
Overview
5FRCCPC037A302
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Compressor model designation
Danfoss scroll compressor DSH for R410A is available as single compressor and can be assembled in tandem or trio combinations The example below presents the compressor
nomenclature which equals the technical reference as shown on the compressor nameplate Code numbers for ordering are listed in section ldquoOrdering codesrdquo
Nomenclature
Family lubricant amp refrigerantDSH Scroll POE lubricant for R410A Motor protection
A Electronic module 24V ACB Electronic module 110-240V
Suction and discharge connectionsA Brazed connections
Family lubricant
amp refrigerant
Nominalcapacity
Approvals Voltage Version Evolutionindex
Evolution indexA~Z
A4DSH A AB485
Motor voltage code3 200-230V3~60 Hz4 380-415V3~50 Hz - 460V3~60 Hz for DSH240 and DSH381 380-400V3~50 Hz - 460V3~60 Hz7 500V3~50 Hz - 575V3~60 Hz9 380V3~60 Hz
UL index
Nominal capacity in thousand Btuh at 60 Hz R410A ARI conditions
6 FRCCPC037A302
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Technical specifications
50-60 Hz data
Tandem and trios
ModelNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Swept
volumeDisplace-ment Oil charge Net weight
TR W Btuh kW WW BtuhW cm3rev m3h dm3 kg
50 Hz
DSH240 20 59500 203200 188 317 1082 22760 396 67 1080
DSH295 25 72200 246600 224 322 1099 27620 481 67 1110
DSH381 30 91100 310900 285 319 1089 34500 60 67 1590
DSH485 40 116400 397400 358 325 1109 44260 77 67 1750
60 Hz
DSH240 20 72400 247300 225 322 1099 22760 478 67 1080
DSH295 25 87600 299000 269 326 1113 27620 58 67 1110
DSH381 30 109500 373800 345 318 1085 34500 723 67 1590
DSH485 40 141800 484100 436 325 1109 44260 929 67 1750
Model CompositionNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Displacement
TR W Btuh kW WW BtuhW m3h
50 Hz
Tand
em
DSH482 2xDSH240 40 118000 402700 3759 315 1076 792
DSH535 DSH240+DSH295 45 130600 445700 4123 318 1085 877
DSH590 2xDSH295 50 143200 488700 4487 321 1094 962
DSH620 DSH240+DSH381 50 149300 509500 4732 317 1081 996
DSH675 DSH295+DSH381 55 161900 552500 5096 319 1089 1081
DSH760 2xDSH381 60 180600 616200 5705 318 1085 120
DSH725 DSH240+DSH485 60 174400 595100 5462 320 1093 1166
DSH780 DSH295+DSH485 65 187000 638100 5826 322 1099 1251
DSH865 DSH381+DSH485 70 205700 701900 6435 321 1095 137
DSH970 2xDSH485 80 230800 787600 7166 323 1104 154
Trio
DSH720 3xDSH240 60 174700 596200 5639 314 1073 1188
DSH885 3xDSH295 75 212000 723400 6730 320 1091 1443
DSH1140 3xDSH381 90 267300 912200 8558 317 1082 180
DSH1455 3xDSH485 120 341600 1165800 10748 323 1101 231
DSH1245 2xDSH381+DSH485 100 292100 996800 9288 319 1090 197
DSH1350 DSH381+2xDSH485 110 316800 1081300 10018 321 1095 214
60 Hz
Tand
em
DSH482 2xDSH240 40 143600 490100 4501 320 1094 956
DSH535 DSH240+DSH295 45 158600 541300 4936 323 1101 1058
DSH590 2xDSH295 50 173600 592600 5371 325 1108 116
DSH620 DSH240+DSH381 50 180300 615500 5696 318 1084 1201
DSH675 DSH295+DSH381 55 195400 666800 6131 320 1092 1303
DSH760 2xDSH381 60 217100 740900 6891 316 1080 1446
DSH725 DSH240+DSH485 60 212400 724800 6612 322 1099 1407
DSH780 DSH295+DSH485 65 227400 776100 7048 324 1105 1509
DSH865 DSH381+DSH485 70 249100 850200 7808 320 1093 1652
DSH970 2xDSH485 80 281100 959500 8724 324 1105 1858
Trio
DSH720 3xDSH240 60 212600 725400 6751 320 1091 1434
DSH885 3xDSH295 75 257100 877300 8057 324 1105 174
DSH1140 3xDSH381 90 321400 1096800 10337 316 1077 2169
DSH1455 3xDSH485 120 416200 1420400 13086 323 1102 2787
DSH1245 2xDSH381+DSH485 100 353000 1204700 11253 319 1087 2375
DSH1350 DSH381+2xDSH485 110 384600 1312500 12170 321 1094 2581
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 72 degC Superheat 111 KEER Energy Efficiency Ratio Refrigerant R410A Condensing temperature 544 degC Subcooling 83 KCOP Coefficient Of Performance
Subject to modification without prior notificationData given for motor code 4 compressor for full data details and capacity tables refer to Coolselectorreg2wwwcoolselectordanfosscom
7FRCCPC037A302
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
8 FRCCPC037A302
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
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N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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SYST
EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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YSTE
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ATIO
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RMAT
ION
SYST
EM D
ESIG
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RMAT
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INTE
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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EM D
ESIG
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INTO
SYS
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ORD
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G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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INTO
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ATIO
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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SYST
EM D
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NIN
TEG
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ON
INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
PRO
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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 reliability risk
This icon indicates instructions to avoid safety risk
The purpose of this guideline is to help customers qualify compressors in the unitYou are strongly advised 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
R
4 FRCCPC037A302
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DSH 240-295-381-485 scroll compressor benefit from an improved design to achieve the highest efficiency and increased life time
Features
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 systemrsquos seasonal energy efficiency
How do IDVs work
Intermediate discharge valves (IDVs) increase seasonal efficiency
Internal Non Return Valve (INRV)prevents excessive leak rate from high pressure side
Heat shield lowers the heat transfer between discharge and suction gas and the acoustic level
Integrated discharge gas temperature protection (DGT)
Lead free polymer bearings improve behavior under poor lubrication conditionsPatented gas path flow with gas intake design induce higher resistance to liquid slugging
Organ pipe masters oil circulation in manifold configuration
Overview
5FRCCPC037A302
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Compressor model designation
Danfoss scroll compressor DSH for R410A is available as single compressor and can be assembled in tandem or trio combinations The example below presents the compressor
nomenclature which equals the technical reference as shown on the compressor nameplate Code numbers for ordering are listed in section ldquoOrdering codesrdquo
Nomenclature
Family lubricant amp refrigerantDSH Scroll POE lubricant for R410A Motor protection
A Electronic module 24V ACB Electronic module 110-240V
Suction and discharge connectionsA Brazed connections
Family lubricant
amp refrigerant
Nominalcapacity
Approvals Voltage Version Evolutionindex
Evolution indexA~Z
A4DSH A AB485
Motor voltage code3 200-230V3~60 Hz4 380-415V3~50 Hz - 460V3~60 Hz for DSH240 and DSH381 380-400V3~50 Hz - 460V3~60 Hz7 500V3~50 Hz - 575V3~60 Hz9 380V3~60 Hz
UL index
Nominal capacity in thousand Btuh at 60 Hz R410A ARI conditions
6 FRCCPC037A302
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Technical specifications
50-60 Hz data
Tandem and trios
ModelNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Swept
volumeDisplace-ment Oil charge Net weight
TR W Btuh kW WW BtuhW cm3rev m3h dm3 kg
50 Hz
DSH240 20 59500 203200 188 317 1082 22760 396 67 1080
DSH295 25 72200 246600 224 322 1099 27620 481 67 1110
DSH381 30 91100 310900 285 319 1089 34500 60 67 1590
DSH485 40 116400 397400 358 325 1109 44260 77 67 1750
60 Hz
DSH240 20 72400 247300 225 322 1099 22760 478 67 1080
DSH295 25 87600 299000 269 326 1113 27620 58 67 1110
DSH381 30 109500 373800 345 318 1085 34500 723 67 1590
DSH485 40 141800 484100 436 325 1109 44260 929 67 1750
Model CompositionNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Displacement
TR W Btuh kW WW BtuhW m3h
50 Hz
Tand
em
DSH482 2xDSH240 40 118000 402700 3759 315 1076 792
DSH535 DSH240+DSH295 45 130600 445700 4123 318 1085 877
DSH590 2xDSH295 50 143200 488700 4487 321 1094 962
DSH620 DSH240+DSH381 50 149300 509500 4732 317 1081 996
DSH675 DSH295+DSH381 55 161900 552500 5096 319 1089 1081
DSH760 2xDSH381 60 180600 616200 5705 318 1085 120
DSH725 DSH240+DSH485 60 174400 595100 5462 320 1093 1166
DSH780 DSH295+DSH485 65 187000 638100 5826 322 1099 1251
DSH865 DSH381+DSH485 70 205700 701900 6435 321 1095 137
DSH970 2xDSH485 80 230800 787600 7166 323 1104 154
Trio
DSH720 3xDSH240 60 174700 596200 5639 314 1073 1188
DSH885 3xDSH295 75 212000 723400 6730 320 1091 1443
DSH1140 3xDSH381 90 267300 912200 8558 317 1082 180
DSH1455 3xDSH485 120 341600 1165800 10748 323 1101 231
DSH1245 2xDSH381+DSH485 100 292100 996800 9288 319 1090 197
DSH1350 DSH381+2xDSH485 110 316800 1081300 10018 321 1095 214
60 Hz
Tand
em
DSH482 2xDSH240 40 143600 490100 4501 320 1094 956
DSH535 DSH240+DSH295 45 158600 541300 4936 323 1101 1058
DSH590 2xDSH295 50 173600 592600 5371 325 1108 116
DSH620 DSH240+DSH381 50 180300 615500 5696 318 1084 1201
DSH675 DSH295+DSH381 55 195400 666800 6131 320 1092 1303
DSH760 2xDSH381 60 217100 740900 6891 316 1080 1446
DSH725 DSH240+DSH485 60 212400 724800 6612 322 1099 1407
DSH780 DSH295+DSH485 65 227400 776100 7048 324 1105 1509
DSH865 DSH381+DSH485 70 249100 850200 7808 320 1093 1652
DSH970 2xDSH485 80 281100 959500 8724 324 1105 1858
Trio
DSH720 3xDSH240 60 212600 725400 6751 320 1091 1434
DSH885 3xDSH295 75 257100 877300 8057 324 1105 174
DSH1140 3xDSH381 90 321400 1096800 10337 316 1077 2169
DSH1455 3xDSH485 120 416200 1420400 13086 323 1102 2787
DSH1245 2xDSH381+DSH485 100 353000 1204700 11253 319 1087 2375
DSH1350 DSH381+2xDSH485 110 384600 1312500 12170 321 1094 2581
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 72 degC Superheat 111 KEER Energy Efficiency Ratio Refrigerant R410A Condensing temperature 544 degC Subcooling 83 KCOP Coefficient Of Performance
Subject to modification without prior notificationData given for motor code 4 compressor for full data details and capacity tables refer to Coolselectorreg2wwwcoolselectordanfosscom
7FRCCPC037A302
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
8 FRCCPC037A302
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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EM D
ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
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EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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EM D
ESIG
N
Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
NO
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M
Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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DSH 240-295-381-485 scroll compressor benefit from an improved design to achieve the highest efficiency and increased life time
Features
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 systemrsquos seasonal energy efficiency
How do IDVs work
Intermediate discharge valves (IDVs) increase seasonal efficiency
Internal Non Return Valve (INRV)prevents excessive leak rate from high pressure side
Heat shield lowers the heat transfer between discharge and suction gas and the acoustic level
Integrated discharge gas temperature protection (DGT)
Lead free polymer bearings improve behavior under poor lubrication conditionsPatented gas path flow with gas intake design induce higher resistance to liquid slugging
Organ pipe masters oil circulation in manifold configuration
Overview
5FRCCPC037A302
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Compressor model designation
Danfoss scroll compressor DSH for R410A is available as single compressor and can be assembled in tandem or trio combinations The example below presents the compressor
nomenclature which equals the technical reference as shown on the compressor nameplate Code numbers for ordering are listed in section ldquoOrdering codesrdquo
Nomenclature
Family lubricant amp refrigerantDSH Scroll POE lubricant for R410A Motor protection
A Electronic module 24V ACB Electronic module 110-240V
Suction and discharge connectionsA Brazed connections
Family lubricant
amp refrigerant
Nominalcapacity
Approvals Voltage Version Evolutionindex
Evolution indexA~Z
A4DSH A AB485
Motor voltage code3 200-230V3~60 Hz4 380-415V3~50 Hz - 460V3~60 Hz for DSH240 and DSH381 380-400V3~50 Hz - 460V3~60 Hz7 500V3~50 Hz - 575V3~60 Hz9 380V3~60 Hz
UL index
Nominal capacity in thousand Btuh at 60 Hz R410A ARI conditions
6 FRCCPC037A302
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Technical specifications
50-60 Hz data
Tandem and trios
ModelNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Swept
volumeDisplace-ment Oil charge Net weight
TR W Btuh kW WW BtuhW cm3rev m3h dm3 kg
50 Hz
DSH240 20 59500 203200 188 317 1082 22760 396 67 1080
DSH295 25 72200 246600 224 322 1099 27620 481 67 1110
DSH381 30 91100 310900 285 319 1089 34500 60 67 1590
DSH485 40 116400 397400 358 325 1109 44260 77 67 1750
60 Hz
DSH240 20 72400 247300 225 322 1099 22760 478 67 1080
DSH295 25 87600 299000 269 326 1113 27620 58 67 1110
DSH381 30 109500 373800 345 318 1085 34500 723 67 1590
DSH485 40 141800 484100 436 325 1109 44260 929 67 1750
Model CompositionNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Displacement
TR W Btuh kW WW BtuhW m3h
50 Hz
Tand
em
DSH482 2xDSH240 40 118000 402700 3759 315 1076 792
DSH535 DSH240+DSH295 45 130600 445700 4123 318 1085 877
DSH590 2xDSH295 50 143200 488700 4487 321 1094 962
DSH620 DSH240+DSH381 50 149300 509500 4732 317 1081 996
DSH675 DSH295+DSH381 55 161900 552500 5096 319 1089 1081
DSH760 2xDSH381 60 180600 616200 5705 318 1085 120
DSH725 DSH240+DSH485 60 174400 595100 5462 320 1093 1166
DSH780 DSH295+DSH485 65 187000 638100 5826 322 1099 1251
DSH865 DSH381+DSH485 70 205700 701900 6435 321 1095 137
DSH970 2xDSH485 80 230800 787600 7166 323 1104 154
Trio
DSH720 3xDSH240 60 174700 596200 5639 314 1073 1188
DSH885 3xDSH295 75 212000 723400 6730 320 1091 1443
DSH1140 3xDSH381 90 267300 912200 8558 317 1082 180
DSH1455 3xDSH485 120 341600 1165800 10748 323 1101 231
DSH1245 2xDSH381+DSH485 100 292100 996800 9288 319 1090 197
DSH1350 DSH381+2xDSH485 110 316800 1081300 10018 321 1095 214
60 Hz
Tand
em
DSH482 2xDSH240 40 143600 490100 4501 320 1094 956
DSH535 DSH240+DSH295 45 158600 541300 4936 323 1101 1058
DSH590 2xDSH295 50 173600 592600 5371 325 1108 116
DSH620 DSH240+DSH381 50 180300 615500 5696 318 1084 1201
DSH675 DSH295+DSH381 55 195400 666800 6131 320 1092 1303
DSH760 2xDSH381 60 217100 740900 6891 316 1080 1446
DSH725 DSH240+DSH485 60 212400 724800 6612 322 1099 1407
DSH780 DSH295+DSH485 65 227400 776100 7048 324 1105 1509
DSH865 DSH381+DSH485 70 249100 850200 7808 320 1093 1652
DSH970 2xDSH485 80 281100 959500 8724 324 1105 1858
Trio
DSH720 3xDSH240 60 212600 725400 6751 320 1091 1434
DSH885 3xDSH295 75 257100 877300 8057 324 1105 174
DSH1140 3xDSH381 90 321400 1096800 10337 316 1077 2169
DSH1455 3xDSH485 120 416200 1420400 13086 323 1102 2787
DSH1245 2xDSH381+DSH485 100 353000 1204700 11253 319 1087 2375
DSH1350 DSH381+2xDSH485 110 384600 1312500 12170 321 1094 2581
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 72 degC Superheat 111 KEER Energy Efficiency Ratio Refrigerant R410A Condensing temperature 544 degC Subcooling 83 KCOP Coefficient Of Performance
Subject to modification without prior notificationData given for motor code 4 compressor for full data details and capacity tables refer to Coolselectorreg2wwwcoolselectordanfosscom
7FRCCPC037A302
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
8 FRCCPC037A302
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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ERA
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ERA
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INFO
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ION
SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ATIO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Compressor model designation
Danfoss scroll compressor DSH for R410A is available as single compressor and can be assembled in tandem or trio combinations The example below presents the compressor
nomenclature which equals the technical reference as shown on the compressor nameplate Code numbers for ordering are listed in section ldquoOrdering codesrdquo
Nomenclature
Family lubricant amp refrigerantDSH Scroll POE lubricant for R410A Motor protection
A Electronic module 24V ACB Electronic module 110-240V
Suction and discharge connectionsA Brazed connections
Family lubricant
amp refrigerant
Nominalcapacity
Approvals Voltage Version Evolutionindex
Evolution indexA~Z
A4DSH A AB485
Motor voltage code3 200-230V3~60 Hz4 380-415V3~50 Hz - 460V3~60 Hz for DSH240 and DSH381 380-400V3~50 Hz - 460V3~60 Hz7 500V3~50 Hz - 575V3~60 Hz9 380V3~60 Hz
UL index
Nominal capacity in thousand Btuh at 60 Hz R410A ARI conditions
6 FRCCPC037A302
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Technical specifications
50-60 Hz data
Tandem and trios
ModelNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Swept
volumeDisplace-ment Oil charge Net weight
TR W Btuh kW WW BtuhW cm3rev m3h dm3 kg
50 Hz
DSH240 20 59500 203200 188 317 1082 22760 396 67 1080
DSH295 25 72200 246600 224 322 1099 27620 481 67 1110
DSH381 30 91100 310900 285 319 1089 34500 60 67 1590
DSH485 40 116400 397400 358 325 1109 44260 77 67 1750
60 Hz
DSH240 20 72400 247300 225 322 1099 22760 478 67 1080
DSH295 25 87600 299000 269 326 1113 27620 58 67 1110
DSH381 30 109500 373800 345 318 1085 34500 723 67 1590
DSH485 40 141800 484100 436 325 1109 44260 929 67 1750
Model CompositionNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Displacement
TR W Btuh kW WW BtuhW m3h
50 Hz
Tand
em
DSH482 2xDSH240 40 118000 402700 3759 315 1076 792
DSH535 DSH240+DSH295 45 130600 445700 4123 318 1085 877
DSH590 2xDSH295 50 143200 488700 4487 321 1094 962
DSH620 DSH240+DSH381 50 149300 509500 4732 317 1081 996
DSH675 DSH295+DSH381 55 161900 552500 5096 319 1089 1081
DSH760 2xDSH381 60 180600 616200 5705 318 1085 120
DSH725 DSH240+DSH485 60 174400 595100 5462 320 1093 1166
DSH780 DSH295+DSH485 65 187000 638100 5826 322 1099 1251
DSH865 DSH381+DSH485 70 205700 701900 6435 321 1095 137
DSH970 2xDSH485 80 230800 787600 7166 323 1104 154
Trio
DSH720 3xDSH240 60 174700 596200 5639 314 1073 1188
DSH885 3xDSH295 75 212000 723400 6730 320 1091 1443
DSH1140 3xDSH381 90 267300 912200 8558 317 1082 180
DSH1455 3xDSH485 120 341600 1165800 10748 323 1101 231
DSH1245 2xDSH381+DSH485 100 292100 996800 9288 319 1090 197
DSH1350 DSH381+2xDSH485 110 316800 1081300 10018 321 1095 214
60 Hz
Tand
em
DSH482 2xDSH240 40 143600 490100 4501 320 1094 956
DSH535 DSH240+DSH295 45 158600 541300 4936 323 1101 1058
DSH590 2xDSH295 50 173600 592600 5371 325 1108 116
DSH620 DSH240+DSH381 50 180300 615500 5696 318 1084 1201
DSH675 DSH295+DSH381 55 195400 666800 6131 320 1092 1303
DSH760 2xDSH381 60 217100 740900 6891 316 1080 1446
DSH725 DSH240+DSH485 60 212400 724800 6612 322 1099 1407
DSH780 DSH295+DSH485 65 227400 776100 7048 324 1105 1509
DSH865 DSH381+DSH485 70 249100 850200 7808 320 1093 1652
DSH970 2xDSH485 80 281100 959500 8724 324 1105 1858
Trio
DSH720 3xDSH240 60 212600 725400 6751 320 1091 1434
DSH885 3xDSH295 75 257100 877300 8057 324 1105 174
DSH1140 3xDSH381 90 321400 1096800 10337 316 1077 2169
DSH1455 3xDSH485 120 416200 1420400 13086 323 1102 2787
DSH1245 2xDSH381+DSH485 100 353000 1204700 11253 319 1087 2375
DSH1350 DSH381+2xDSH485 110 384600 1312500 12170 321 1094 2581
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 72 degC Superheat 111 KEER Energy Efficiency Ratio Refrigerant R410A Condensing temperature 544 degC Subcooling 83 KCOP Coefficient Of Performance
Subject to modification without prior notificationData given for motor code 4 compressor for full data details and capacity tables refer to Coolselectorreg2wwwcoolselectordanfosscom
7FRCCPC037A302
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
8 FRCCPC037A302
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
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ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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SYST
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ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
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+
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=
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43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Technical specifications
50-60 Hz data
Tandem and trios
ModelNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Swept
volumeDisplace-ment Oil charge Net weight
TR W Btuh kW WW BtuhW cm3rev m3h dm3 kg
50 Hz
DSH240 20 59500 203200 188 317 1082 22760 396 67 1080
DSH295 25 72200 246600 224 322 1099 27620 481 67 1110
DSH381 30 91100 310900 285 319 1089 34500 60 67 1590
DSH485 40 116400 397400 358 325 1109 44260 77 67 1750
60 Hz
DSH240 20 72400 247300 225 322 1099 22760 478 67 1080
DSH295 25 87600 299000 269 326 1113 27620 58 67 1110
DSH381 30 109500 373800 345 318 1085 34500 723 67 1590
DSH485 40 141800 484100 436 325 1109 44260 929 67 1750
Model CompositionNominal
tons 60 HzNominal cooling
capacityPowerinput COP EER Displacement
TR W Btuh kW WW BtuhW m3h
50 Hz
Tand
em
DSH482 2xDSH240 40 118000 402700 3759 315 1076 792
DSH535 DSH240+DSH295 45 130600 445700 4123 318 1085 877
DSH590 2xDSH295 50 143200 488700 4487 321 1094 962
DSH620 DSH240+DSH381 50 149300 509500 4732 317 1081 996
DSH675 DSH295+DSH381 55 161900 552500 5096 319 1089 1081
DSH760 2xDSH381 60 180600 616200 5705 318 1085 120
DSH725 DSH240+DSH485 60 174400 595100 5462 320 1093 1166
DSH780 DSH295+DSH485 65 187000 638100 5826 322 1099 1251
DSH865 DSH381+DSH485 70 205700 701900 6435 321 1095 137
DSH970 2xDSH485 80 230800 787600 7166 323 1104 154
Trio
DSH720 3xDSH240 60 174700 596200 5639 314 1073 1188
DSH885 3xDSH295 75 212000 723400 6730 320 1091 1443
DSH1140 3xDSH381 90 267300 912200 8558 317 1082 180
DSH1455 3xDSH485 120 341600 1165800 10748 323 1101 231
DSH1245 2xDSH381+DSH485 100 292100 996800 9288 319 1090 197
DSH1350 DSH381+2xDSH485 110 316800 1081300 10018 321 1095 214
60 Hz
Tand
em
DSH482 2xDSH240 40 143600 490100 4501 320 1094 956
DSH535 DSH240+DSH295 45 158600 541300 4936 323 1101 1058
DSH590 2xDSH295 50 173600 592600 5371 325 1108 116
DSH620 DSH240+DSH381 50 180300 615500 5696 318 1084 1201
DSH675 DSH295+DSH381 55 195400 666800 6131 320 1092 1303
DSH760 2xDSH381 60 217100 740900 6891 316 1080 1446
DSH725 DSH240+DSH485 60 212400 724800 6612 322 1099 1407
DSH780 DSH295+DSH485 65 227400 776100 7048 324 1105 1509
DSH865 DSH381+DSH485 70 249100 850200 7808 320 1093 1652
DSH970 2xDSH485 80 281100 959500 8724 324 1105 1858
Trio
DSH720 3xDSH240 60 212600 725400 6751 320 1091 1434
DSH885 3xDSH295 75 257100 877300 8057 324 1105 174
DSH1140 3xDSH381 90 321400 1096800 10337 316 1077 2169
DSH1455 3xDSH485 120 416200 1420400 13086 323 1102 2787
DSH1245 2xDSH381+DSH485 100 353000 1204700 11253 319 1087 2375
DSH1350 DSH381+2xDSH485 110 384600 1312500 12170 321 1094 2581
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 72 degC Superheat 111 KEER Energy Efficiency Ratio Refrigerant R410A Condensing temperature 544 degC Subcooling 83 KCOP Coefficient Of Performance
Subject to modification without prior notificationData given for motor code 4 compressor for full data details and capacity tables refer to Coolselectorreg2wwwcoolselectordanfosscom
7FRCCPC037A302
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
8 FRCCPC037A302
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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CT IN
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ATIO
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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ESIG
N
Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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ESIG
N
Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ATIO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ION
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EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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SYST
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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N
Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ESIG
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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N IN
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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SYST
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ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
NPR
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EM D
ESIG
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TEG
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INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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SYST
EM D
ESIG
NIN
TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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SYST
EM D
ESIG
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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Dimensions
Oslash D
Oslash D
L2 L2
L1L3 L3L1
HH2
H1
HH2
H1
Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number
DSH240 318 683 331 648 428 345 371
8556089DSH295 318 683 331 648 428 345 371
DSH381 333 755 331 697 428 477 345 371
8556091
8556059
DSH485 333 755 331 697 428446 345 371 8556133
8556160
compressor motor codes 4 7 9 compressor motor code 3
Single compressors
8 FRCCPC037A302
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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ATIO
N
Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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SYST
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
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EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ATIO
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ATIO
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Dimensions
Tandem model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH482 DSH240 + DSH240 1025 527 731
8556112
DSH535 DSH240 + DSH295 1025 527 731 8556112
DSH590 DSH295 + DSH295 1025 527 731 8556112
DSH620 DSH240 + DSH381 1025 527 803
8556115
DSH675 DSH295 + DSH381 1025 527 803 8556115
DSH725 DSH240 + DSH485 1025 546 803 8556134
DSH760 DSH381 + DSH381 1025 527 803 8556117
DSH780 DSH295 + DSH485 1025 546 803 8556141
DSH865 DSH381 + DSH485 1025 555 803
8556136
DSH970 DSH485 + DSH485 1025 555 803 8556137
compressor motor codes 4 7 9Tandems to be achieved by assembly of individual compressors
Tandem assemblies
H
L
D
H
L
D
H
L
D
9FRCCPC037A302
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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N
M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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INTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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NPR
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Trio assemblies
Connection details
Dimensions
H
L
D
H
L
D
Trio model Composition L(mm) D(mm) H(mm) Outline drawing number
DSH720 3 x DSH240 1467 543 731
8556118
DSH885 3 x DSH295 1467 543 731 8556118
DSH1143 3 x DSH381 1467 545594 803
8556120
DSH1455 3 x DSH485 1520 573590 802 8556138
DSH1245 2 x DSH381 + DSH485 1520 573594 802 8556172
DSH1350 DSH381 + 2 x DSH485 1520 573594 802 8556173
compressor motor codes 4 7 9 compressor motor code 3Trio to be acheived by assembly of individual compressors
DSH240-295-381 DSH485
Suction connection Brazed 1 58 Brazed 1 58
Discharge connection Brazed 1 18 Brazed 1 38
Oil sight glass Threaded (118 - 18 UNF)
Oil equalization connection Rotolock 2 14
Oil drain connection Female frac14 Flare incorporating a Schrader valve
Low pressure gauge port (Shrader) Male frac14 Flare incorporating a Schrader valve
10 FRCCPC037A302
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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EM D
ESIG
N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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SYST
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NO
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INFO
RMAT
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INTE
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N IN
TO S
YSTE
M
Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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SYST
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RMAT
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INTE
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N IN
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YSTE
M
Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ERA
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RMAT
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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RMAT
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RMAT
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N IN
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YSTE
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
ION
SYST
EM D
ESIG
NO
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INFO
RMAT
ION
INTE
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N IN
TO S
YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
NIN
TEG
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ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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NPR
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
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INTO
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G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
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IGN
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Electrical data connections and wiring
Danfoss scroll compressors DSH are available in five different motor voltages as listed below
Electrical power is connected to the compressor terminals by Oslash 48 mm (316) screws
The maximum tightening torque is 3 Nm Use a 14 ring terminal on the power leads
Motor voltage
Wiring connections
DSH240-295-381-485except code 3
DSH381 code 3
The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit
The 3 power supply knockouts accommodate the following diametersbull Oslash 508 mm (UL 112 conduit) amp Oslash 437 mm (UL
114 conduit) amp Oslash 345 mm (UL 1 conduit)bull Oslash 405 mm (ISO40) amp Oslash 322 mm (ISO32) amp
Oslash 255 mm (ISO25)bull Oslash 255 mm (ISO25)
The 4 others knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)
(x2)bull Oslash 207 mm (ISO20 or PG135) (x2)
The terminal box is provided withbull Oslash 505 mm (ISO 50 amp UL112 conduit) hole with possible Oslash 635 mm (ISO63 and UL 2conduit) knockout for power supplybull 2 x Oslash 225 mm (PG16 and UL frac12 conduit) knockouts for safety control circuit
Motor voltage code Code 3 Code 4 Code 7 Code 9
50 Hz Nominal voltage - 380-415 V - 3 ph
380-400 V - 3 ph 500 V - 3 ph -
Voltage range - 342-457 V 342-440 V 450-550 V 380 V
60 HzNominal voltage 200-230 V - 3 ph 460V - 3 ph 575 V - 3 ph 380-400 V - 3 ph
Voltage range 180-253 V187-253 V 414-506 V 517-632 V 340-418 V
DSH485-3 DSH240-4 and DSH381-4
Vavg = Mean voltage of phases 1 2 3
V1-2 = Voltage between phases 1 and 2
V1-3 = Voltage between phases 1 and 3
V2-3 = Voltage between phases 2 and 3
| Vavg - V1-2 | + | Vavg - V1-3 | + | Vavg - V2-3 |
2 x Vavg voltage imbalance = x 100
The maximum allowable voltage imbalance is 2 Voltage imbalance causes high amperage over one or several phases which in turn leads to
overheating and possible motor damage Voltage imbalance is given by the formula
Power supply
Power supply
Black
Sump heater
Cover holding screws (x3) Torque 22 Nm
Blue Brown
M1 M2Control circuit
Terminal box
Black Blue Brown
Faston 14 tabs
Power supply
Sump heater
Modulepower supply
M1-M2Control circuit
11FRCCPC037A302
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ATIO
N
M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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N
Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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N
Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
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N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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INFO
RMAT
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
GEN
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FORM
ATIO
NPR
OD
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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INFO
RMAT
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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PRO
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ATIO
N
M1-M2 control circuit
Power supply
Power supply
Power supply
Electrical data connections and wiring
The terminal box is provided with 2 triple knockouts for power supply 2 double knockouts and 3 simple knockouts for the safety control circuit
The 2 power supply knockouts accommodate the following diametersbull Oslash 635 mm (ISO63 and UL 2conduit) amp Oslash 542mm (PG42)amp 437 mm (UL 114 conduit)
The 5 other knockouts are as followsbull Oslash 225 mm (PG16) (UL 12) amp Oslash 165 mm (ISO16)bull Oslash 255 mm (ISO25) amp 20 mm (ISO20 or PG135)bull Oslash 225 mm (PG16) (UL 12)bull Oslash 255 mm (ISO25) (x2)
DSH485 code 3
The motor protection modules come preinstalled within the terminal box Phase sequence protection connections and thermistor connections are pre-wired and should not be removed The module must be connected to a power supply of the appropriate voltage The module terminals are 63-mm size Faston type
L N S1 S2 M1 M2
L1 L2 L3Black Blue Brown
Phase sequence input
Internal control contact
SafetycircuitThermistor
connectionModule power
IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are usedFirst numeral level of protection against contact and foreign objects
5 - Dust protectedSecond numeral level of protection against water
4 - Protection against water splashing
The temperature inside the terminal box must not exceed 70degC Consequently if the compressor is installed in an enclosure precautions must be taken to avoid that the temperature around the compressor and in the terminal box would rise too much A ventilation installation on the enclosure panels may be necessary If not the
electronic protection module may not operate properly Any compressor damage related to this will not be covered by Danfoss warranty In the same manner cables must be selected in a way that ensures the terminal box temperature does not exceed 70degC
Terminal box temperature
Three phase electrical characteristics Compressor model LRA MCC Max operating current Winding resistance
A A A Ω
Motor voltage code 3200-230 V 3ph 60 Hz
DSH240 485 105 103 016DSH295 560 128 112 013DSH381 717 170 155 009DSH485 1010 190 187 007
Motor voltage code 4 380-415 V 3ph 50 Hz
460 V 3ph 60Hz
DSH240 215 51 49 062DSH295 260 62 56 052DSH381 320 79 72 042DSH485 413 90 89 023
Motor voltage code 7500 V 3ph 50 Hz 575 V 3 ph 60 Hz
DSH240 175 41 38 094DSH295 210 45 44 082DSH381 235 60 55 056DSH485 327 71 71 036
Motor voltage code 9380 V 3ph 60 Hz
DSH240 260 60 58 042DSH295 310 72 69 036DSH381 360 90 85 024DSH485 491 111 106 016
Preliminary data380-400V 3 ph 50 Hz for DSH240 and DSH381
12 FRCCPC037A302
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N
Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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N
Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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N
Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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SYST
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N
Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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RMAT
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SYST
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N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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ESIG
N
Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
NO
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ATIO
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Motor protection Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box This device provides efficient and reliable protection against overheating and overloading as well as phase lossreversal
The motor protector comprises a control module and PTC sensors embedded in the motor winding
The motor temperature is being constantly measured by a PTC thermistor loop connected on S1-S2 If any thermistor exceeds its response temperature its resistance increases above the trip level (4500 Ω) and the output relay then trips ndash ie contacts M1-M2 are open After cooling to below the response temperature (resistance lt 2750 Ω) a 5-minute time delay is activated
After this delay has elapsed the relay is once again pulled in ndash ie contacts M1-M2 are closed The time delay may be cancelled by means of resetting the mains (L-N -disconnect) for approximately 5 sec
A redgreen twin LED is visible on the module (except on DSH485-3) A solid green LED denotes a fault free condition A blinking red LED indicates an identifiable fault condition
Electrical data connections and wiring
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 operated in transient conditions and out of
the application envelope Above this value the internal motor protection or external electronic module will cut-out the compressor to protect the motor
Locked Rotor Amp value is the highest average current measured on mechanically blocked compressors tested under nominal voltage The LRA value can be used as a rough estimation for
the starting current However in most cases the real starting current will be lower A soft starter can be applied to reduce starting current (see section ldquosoft starterldquo)
MCC (Maximum Continuous Current)
LRA (Locked Rotor Amp)
Winding resistance is the resistance between phases at 25degC (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 25degC the measured resistance must be corrected using the following formula
a + tamb
Rtamb = R25degC _______ a + t25degC
t25degC reference temperature = 25degCtamb temperature during measurement (degC)R25degC winding resistance at 25degCRamb winding resistance at tambCoefficient a = 2345
The max operating current is the current when the compressors operate at maximum load conditions and 10 below nominal voltage (max evaporating temperature and max condensing
temperature) Max Oper A can be used to select cables and contactors In normal operation the compressor current consumption is always less than the Max Oper A value
Winding resistance
Max operating Current
PTC overheat
Delay timer active (after PTC over temp)
Appr 1 second40ms 40ms460ms 460ms
Appr 1 second920ms80ms
13FRCCPC037A302
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Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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EM D
ESIG
N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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EM D
ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
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N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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EM D
ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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SYST
EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
INTE
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TIO
N IN
TO S
YSTE
MO
RDER
ING
INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ION
SYST
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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SYST
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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SYST
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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INTE
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
NPR
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UCT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
NPR
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RMAT
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SYST
EM D
ESIG
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TEG
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INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
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SYST
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ESIG
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INTO
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G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
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G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
NPR
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UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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STEM
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IGN
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CT IN
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N
Phase sequence and reverserotation protection
Use a phase meter to establish the phase orders and connect line phases L1 L2 and L3 to terminals T1 T2 and T3 respectively
Compressor models DSH 240 to 485 are delivered with an electronic module which provides protection against phase reversal and phase loss at start-up
The phase sequencing and phase loss monitoring functions are active during a 5-sec window 1 second after compressor start-up (power on L1-L2-L3)
Should one of these parameters be incorrect the relay would lock out (contact M1-M2 open) The red LED on the module will show the following blink code (except on DSH485-3)
The lockout may be cancelled by resetting the power mains (disconnect L-N) for approximately 5 seconds
For more detailed information see ldquo Instructions for electronic modulerdquo FRCCPI031
Compressorstart
Phase monitoring 0 1 s 6 s
Phase sequence module logic
In case of phase reverse error
In case of phase loss error
Appro 760 ms120 ms120 ms120 ms 400ms
Appr 1second500ms 500ms
Electrical data connections and wiring
14 FRCCPC037A302
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Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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SYST
EM D
ESIG
N
Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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ESIG
N
Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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ESIG
N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ATIO
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RMAT
ION
SYST
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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SYST
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ESIG
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INTE
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
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TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
NPR
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SYST
EM D
ESIG
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TEG
RATI
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INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
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SYST
EM D
ESIG
NIN
TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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SYST
EM D
ESIG
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TEG
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INTO
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ERA
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INFO
RMAT
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SYST
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NIN
TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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INFO
RMAT
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
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STEM
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IGN
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CT IN
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ATIO
N
Approval and certification
DSH scroll compressors comply with the following approvals and certificates
Certificates are listed on wwwcommercialcompressorsdanfosscomdocumentationcertificates
The DSH381 and DSH485 incorporate an internal relief valve set to open between the internal high and low pressure sides of the compressor when
the pressure differential between the discharge and suction pressures surpasses 424 to 49 bar
Pressure equipment
Machines directive200642EC
Low voltage directive
Approval and certificates
Internal free volume
directive 201468EU
Pressure internal relief valve (IPRV)
201435EU
CE 0062 or CE 0038 (European Directive) All DSH models
UL (Underwriters Laboratories) All 60Hz DSH models
Other approvals certificates Contact Danfoss
Products DSH240-295-381-485
Manufacturerrsquos declaration of incorporation Contact Danfoss
Products DSH240-295-381-485
Declaration of conformity Contact Danfoss
ProductsInternal free volume without oil (liter)
Low pressure side High pressure side Total
DSH240-295 285 25 310DSH381 303 4 343DSH485 282 38 32
Products DSH240-295 DSH381 DSH485
Refrigerant fluids Group 2 Group 2 Group 2PED Category II III IIEvaluation module D1 H D1MaximumMinimum temperature - Ts -35degC lt Ts lt 52degC -35degC lt Ts lt 51degC -35degC lt Ts lt 51degC
Maximum allowable pressure - Ps 311 bar(g) 302 bar(g) 302 bar(g)
Declaration of conformity Contact Danfoss
15FRCCPC037A302
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SYST
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N
Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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N
Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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SYST
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N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ESIG
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Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ATIO
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Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
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N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
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EM D
ESIG
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TEG
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INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
GEN
ERA
L IN
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ATIO
NPR
OD
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
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ATIO
NPR
OD
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
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INFO
RMAT
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INTE
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MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
General requirements Proper piping practices should be employed to
1 Ensure adequate oil return even under minimum load conditions (refrigerant speed piping slopeshellip) For validation tests see section ldquoManage oil in the circuitrdquo
2 Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop) For validation tests see section ldquoManage off cycle migrationrdquo
General recommendations are described in the figures below
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 ldquoSound and vibration managementrdquo
HP
4 ms or more
05 slope
To condenser
max 4 m
max 4 m
05 slope
U-trap as short as possible
4ms or more
U trap as short as possible
Evaporator
LP
8 to 12 ms
HP
LP
Condenser
3D exibility
Upper loop
16 FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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ATIO
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RMAT
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INTE
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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SYST
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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SYST
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TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ESIG
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TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
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INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
MO
RDER
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
Tandem and trio requirements
For each tandem and trio configuration specific outline drawings are available as indicated in the following tables
Suction and oil equalization piping drawings must be respected (diameters minimum straight lengthshellip)
DSH tandem and trio 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 design
The discharge line has no impact on oil balancing and is shown with tees to indicate that both left and right side discharge headers are possible
R
Tandem model Composition Suction Discharge Oil equalization Kit tandemCode No
Outline drawing number
DSH482 DSH240 + DSH240 218 158 138 7777041 8556112
DSH535 DSH240 + DSH295 218 158 138 7777037 8556112
DSH590 DSH295 + DSH295 218 158 138 7777041 8556112
DSH620 DSH240 + DSH381 218 158 138 7777048 8556115
DSH675 DSH295 + DSH381 218 158 138 7777037 8556115
DSH725 DSH240 + DSH485 218 158 158 120Z0569 8556134
DSH760 DSH381 + DSH381 218 158 138 7777041 8556117
DSH780 DSH295 + DSH485 258 158 158 120Z0551 8556141
DSH865 DSH381 + DSH485 258 158 158 120Z0550 8556136
DSH970 DSH485 + DSH485 258 158 158 120Z0578 8556137
Trio model Composition Suction Discharge Oil equalization Suction from Kit tandemCode No
Outline drawing number
DSH720 3xDSH240 258 158 158Left 120Z0673
8556118Right 7777039
DSH885 3xDSH295 258 158 158Left 120Z0673
8556118Right 7777039
DSH1143 3xDSH381 258 158 158Left 7777040
8556120Right 7777049
DSH1455 3xDSH485 318 218 158Left
7777040 8556138Right
DSH1245 2xDSH381 + DSH485 258 218 158
Left7777063 8556172
Right
DSH1350 DSH381 + 2xDSH485 318 218 158
Left7777063 8556173
Right
17FRCCPC037A302
GEN
ERA
L IN
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ATIO
NPR
OD
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INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
MO
RDER
ING
INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
GEN
ERA
L IN
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ATIO
NPR
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INFO
RMAT
ION
INTE
GRA
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N IN
TO S
YSTE
MO
RDER
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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ATIO
NPR
OD
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INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
MO
RDER
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
GEN
ERA
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ATIO
NPR
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INFO
RMAT
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INTE
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N IN
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MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
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INTE
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N IN
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YSTE
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
GEN
ERA
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ATIO
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RMAT
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INTE
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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ERA
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ATIO
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INTE
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
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Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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SYST
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ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ERA
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FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
NPR
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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INTE
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RMAT
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SYST
EM D
ESIG
N
Design piping
Right suction
Cp1 Cp2 Tandem model Suction from Kit code ndegto order
Washer reference Washer Oslash (mm) Washer in
suction of
DSH240 DSH240 DSH482Left
7777041 Not neededRight
DSH240 DSH295 DSH535Left
7777037 5311579P01 31 Cp1Right
DSH295 DSH295 DSH590Left
7777041 Not neededRight
DSH240 DSH381 DSH620Left
7777048 5311579P05 29 Cp1Right
DSH295 DSH381 DSH675Left
7777037 5311579P01 31 Cp1Right
DSH240 DSH485 DSH725Left
120Z0569 5311579P09 24 Cp1Right
DSH381 DSH381 DSH760Left
7777041 Not neededRight
DSH295 DSH485 DSH780Left
120Z0551 5311579P07 27 Cp1Right
DSH381 DSH485 DSH865Left
120Z0550 5311579P08 30 Cp1Right
DSH485 DSH485 DSH970Left
120Z0578 Not neededRight
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
Compressor 2(Cp2)
Compressor 1(Cp1)
Suction washer position
On tandem models
R Depending on manifold configuration it is essential to equalize the pressure of compressor sumps Hence a suction washer must be added
on certain compressors according to the table Suction washers are included in tandem or trio accessory kits as described in the illustrations
Included in tandem or trio accessory kitNot supplied
18 FRCCPC037A302
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INTE
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MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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SYST
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N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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RMAT
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SYST
EM D
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N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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RMAT
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SYST
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N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ATIO
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ION
SYST
EM D
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N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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SYST
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
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N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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SYST
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N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ATIO
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Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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TEG
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INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
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INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
MO
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ING
INFO
RMAT
ION
SYST
EM D
ESIG
N
Design piping
The oil level is balanced by a pipe of 138 or 158 To connect the equalization line on rotolock connections the adaptor sleeves
included in the tandem or trio accessory kit must be used
Supplied with the compressorIncluded in tandem or trio accessory kitNot supplied
Compressor 1(Cp1)
Compressor 2(Cp2)
Compressor 3(Cp3)
Right suction
Cp1 Cp2 Cp3 Trio model Suction from Kit code ndegto order
Washer reference
Washer Oslash (mm)
Washer in suction of
DSH240 DSH240 DSH240 DSH720Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH295 DSH295 DSH295 DSH885Left 120Z0673 5311579P08 30 Cp3
Right 7777039 5311579P03 345 Cp1 and Cp3
DSH381 DSH381 DSH381 DSH1140Left 7777040 5311579P02 33 Cp3
Right 7777049 Not needed
DSH485 DSH485 DSH485 DSH1455Left
7777040 5311579P02 33 Cp2 and Cp3Right
DSH381 DSH381 DSH485 DSH1245Left
7777063 5311579P05 29 Cp1Right
DSH381 DSH485 DSH485 DSH1350Left
7777063 5311579P05 29 Cp3Right
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
Oil equalization design
On trio models
19FRCCPC037A302
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ATIO
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INFO
RMAT
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INTE
GRA
TIO
N IN
TO S
YSTE
MO
RDER
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
GEN
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ATIO
NPR
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INFO
RMAT
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INTE
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N IN
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
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INTE
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N IN
TO S
YSTE
MO
RDER
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ERA
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ATIO
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INFO
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INTE
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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ATIO
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INTE
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INFO
RMAT
ION
SYST
EM D
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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ATIO
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RMAT
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SYST
EM D
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N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ERA
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ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ATIO
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ESIG
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Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
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ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ESIG
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ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
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EM D
ESIG
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TEG
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INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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EM D
ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ESIG
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ERA
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ATIO
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INFO
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TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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RATI
ON
INTO
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TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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N
Design compressor mounting
General requirements
Single requirements
Tandem and trio requirements
Parallel mounting feet
Compressors used in single applications must be mounted with flexible grommets During operation the maximum inclination from the vertical plan must not exceed 3 degrees
Compressors used in parallel applications must be mounted with rigid spacers onto rails and the manifold assembly must be mounted with flexible grommets onto the frame The height difference between the 2 compressors of the manifold should not exceed 5mm
To be used in single applications an additional accessory including flexible grommets is necessary accessory conversion kit 8156138
For parallel mounting the compressors must be mounted with hexagonal rigid spacers on the rails Rubber grommets and spacers must be
installed below the rails These parts are included in accessories
The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established The required bolt size for the DSH240-295-381-485 compressors is HM8-55 This bolt must be tightened to a torque of 21 Nm
Rubber grommets fromkit 8156138
HM 8 boltLock washer
Flat washer
Steel mounting sleeve
Rubber grommet
Nut
275 mm
Compressorbase plate
Tightening torque 44 NmHM10 x100
5mm ThicknessTightening torque 16 Nm
Tightening torque 55 Nm
Supplied in accessory kit 7777045Included in tandem or trio accessory kitNot supplied
For 60Hz applications it is recommended to replace hexagonal rigid spacers by triangular rigid spacers available in kit 120Z0495 (see
also section ldquoMechanical vibrationsrdquo) instead of hexagonal ones from kit 7777045
20 FRCCPC037A302
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SYST
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ESIG
N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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SYST
EM D
ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ION
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EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
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ION
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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ESIG
NIN
TEG
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ON
INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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RMAT
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ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ESIG
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
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TEG
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INTO
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ORD
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
NPR
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UCT
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
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Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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N
Manage oil in the circuit
RRequirement
System Evaluation
Test criteria and solutions
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
Single compressor Manifolded compressors
Non split Test Ndeg1 Test Ndeg1+2
Split Test Ndeg1+3 Test Ndeg1+2+3
Test Ndeg Purpose Test condition Pass criteria Solutions
1 Check proper oil return Minimum number of compressor
running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Top-up with oil generally 3 of the total system refrigerant charge (in weight) Above 3 look for potential oil trap in the system2 Integrate a function in control logic to run all compressors simultaneously in order to boost oil return (for more details see section ldquoControl Logicrdquo)3 Oil separator can be added
2 Check oil balancing
All compressors running for 6 hours at a condition corresponding to highest pressure ratio foreseeable on the system application
Oil level must be visible or full in the sight glass when the compressors are running and when all compressors of the circuit are stopped
1 Check that manifold piping is conform to Danfoss requirements2 Integrate a function in control logic to stop manifold periodically in order to balance oil (for more details see section ldquoControl Logicrdquo)
3 Oil return in split systems
Since each installation is unique test 1 and 2 can not fully validate the oil return Oil level must be checked and adjusted at commissioning
Oil level must be visible or full in the sight glass when the compressor is running and when all compressors of the circuit are stopped
1 Pay special attention to ldquoPiping designrdquo2 Oil separator is strongly recommended especially in case of part load
A
A
21FRCCPC037A302
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Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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ERA
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EM D
ESIG
N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ERA
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ATIO
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
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N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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EM D
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
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Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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ERA
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ERA
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ATIO
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EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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SYST
EM D
ESIG
N
Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ATIO
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EM D
ESIG
NO
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
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ION
SYST
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ESIG
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ATIO
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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Manage sound and vibration
Typical sounds and vibrations in systems can be broken down into the following three categoriesbull Sound radiation (through air)bull Mechanical vibrations (through parts and
structure)bull Gas pulsation (through refrigerant)
The following sections focus on the causes and methods of mitigation for each of the above sources
Compressor sound radiation
For sound radiating from the compressors the emission path is air and the sound waves
are travelling directly from the machine in all directions
bull For compressors running simultaneously
- the global sound level of ldquonrdquo identical compressors isLGLOBAL = Li + 10 Log10 nExample for the trio DSH720 = 3 x DSH240 (50Hz)LDSH240 = 82dB(A)LDSH720 = 82 + 10 Log10 3 = 868dB(A)
Example for the tandemDSH620 = DSH240+DSH381 (50Hz)LDSH240 = 82dB(A) LDSH381 = 83dB(A)LDSH620 =10 Log10(1001x82+1001x83) = 855dB(A)
Compressor model
50 HZ 60 HZAcoustic hoodcode number
Bottom insulation
code number Sound power
dB(A)Attenuation
dB(A) Sound power
dB(A)Attenuation
dB(A)
DSH240 82 6 86 4 120Z0022 120Z0353
DSH295 82 6 86 4 120Z0022 120Z0353
DSH381 87 6 89 4 120Z0022 120Z0353
DSH485 89 4 91 4 120Z0022 120Z0353
Sound power and attenuation are given at ARI conditions measured in free space For DSH381code 3 use acoustic hood reference 120Z0579No acoustic hood available for DSH485 code 3 Attenuation given with acoustic hood only Bottom insulation is provided in surface sump heater accessories for DSH-240-295-381-485 models Additional attenuation is 2 to 4 dBA Materials are UL approved and RoHS compliant
Model CompositionSound power dB(A)
50Hz 60Hz
Tandem
DSH482 2xDSH240 85 89DSH535 DSH240+DSH295 85 89DSH590 2xDSH295 85 89 DSH620 DSH240+DSH381 855 895DSH675 DSH295+DSH381 855 895DSH760 2xDSH381 86 90DSH725 DSH240+DSH485 898 922DSH780 DSH295+DSH485 898 922DSH865 DSH381+DSH485 90 925DSH970 2xDSH485 92 94
Trio
DSH720 3xDSH240 868 908DSH885 3xDSH295 868 908DSH1140 3xDSH381 878 918DSH1455 3xDSH485 938 958DSH1245 2xDSH381+DSH485 908 935DSH1350 DSH381+2xDSH485 925 948
LGLOBAL = 10 Log10(sum 1001Li)i=n
i=1
- the global sound level of ldquonrdquo different compressors with respectively Li sound level is
Sound levels are as followsbull For compressors running alone
22 FRCCPC037A302
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N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ION
SYST
EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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INTE
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
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SYST
EM D
ESIG
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ON
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ERIN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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SYST
EM D
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G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ORD
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G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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EM D
ESIG
NIN
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ON
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ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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ATIO
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N
Manage sound and vibration
Mitigations methodsWe 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 Acoustic hoods are available from Danfoss as accessories Refer to the tables above for sound levels attenuation and code numbers
2 Use of sound-insulation materials on the inside of unit panels is also an effective mean to reduce sound radiation
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
Mechanical vibrations
Gas pulsation
A compressor generates vibrations that propagate into the surrounding parts and structure The vibration level of a DSH compressor alone does not exceed 154 microm peak to peak However when system structure natural frequencies are close to running frequency vibrations are amplified due to resonance phenomenonA high vibration level is damageable for piping reliability and generates high sound levels
Mitigations methods1 To ensure minimum vibrations transmission to the structure strictly follow Danfoss mounting requirements (mounting feet rails etc) For
further information on mounting requirements please refer to section ldquoDesign compressor mountingrdquo
2 Ensure that there is no direct contact (without insulation) between vibrating components and structure
3 To avoid resonance phenomenon piping and frame must have natural frequencies as far as possible from running frequencies(50 or 60Hz) Solutions to change natural frequencies are to work on structure stiffness and mass (brackets metal sheet thickness or shapehellip)
DSH compressors have been designed and tested to ensure that gas pulsation is optimized 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
Mitigations methodsIf an unacceptable level is identified a discharge muffler with the appropriate resonant volume and mass can be installed
23FRCCPC037A302
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RMAT
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ESIG
N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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N
Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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ESIG
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Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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EM D
ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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YSTE
MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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SYST
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NO
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RMAT
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YSTE
M
Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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RMAT
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ESIG
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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RMAT
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ESIG
NO
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RMAT
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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INTE
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
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TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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SYST
EM D
ESIG
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INTO
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ORD
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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UCT
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
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Danfoss Optyma Condensing Units
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Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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N
Manage operating envelope
RRequirement The operating envelope for DSH compressors is given in the figures below and guarantees reliable operation of the compressor for steady-state and transient operation
Steady-state operation envelope is valid for a suction superheat within 5K to 30K range
DSH (except motor code 3) operating envelope is showed below
DSH motor code 3 operating envelope is as below
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
1
SH = 5 K
SH = 30 K
Area 1 Continuous running SH 5 to 30K
Area 1 Continuous running SH 5 to 30K
Cond
ensi
ng te
mpe
ratu
re (deg
C)
Evaporating temperature (degC)
-40
5
10
15
20
25
30
35
40
45
50
55
60
65
70
-35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
1
SH = 5 K
SH = 30 K
24 FRCCPC037A302
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Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ERA
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ATIO
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ION
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EM D
ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
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Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ERA
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ATIO
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
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RMAT
ION
SYST
EM D
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ATIO
NPR
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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RMAT
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SYST
EM D
ESIG
NIN
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INTO
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ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Manage operating envelope
Pressure settings R410A
Working range high side bar(g) 99-447Working range low side bar(g) 17-155Maximum high pressure safety switch setting bar(g) 45Minimum low pressure safety switch setting bar(g) 15
Minimum low pressure pump-down switch setting bar(g) 15 bar below nominal evap pressure with minimum of 17 bar(g)
Maximum allowable pressure on high pressure side according to PED regulation
R LP and HP safety switches must never be bypassed nor delayed and must stop all the compressors
LP switch auto restart must be limited to 5 times within 12 hours
HP safety switch must be reset manually
Depending on application operating envelope you must define HP and LP limits within operating envelope and pressure setting table above
System evaluation
Test criteria and solutions
DSH240 to 485 compressors include an integrated Discharge Gas Temperature protection (DGT) Excessive discharge temperature will
result in tripping of electronic module output relay This protection is effective within a suction superheat range from 5 to 30K
Basicbull HP and LP switchbull MOP (Max Operating Pressure) ensured by expansion
devicebull Condensing pressure controlbull (DGT integrated)
Advancedbull HP and LP sensorbull Operating envelope limits (permanent and transient)
integrated into control logicbull (DGT integrated)
See ldquoTest criteria and solutionsrdquo No additional test are required
HP switch setting
MO
P +
test
No 3
LP s
witc
h se
ttin
g
Condensing pressure control
DGT (integrated)
tests No 1 and 2
Test Ndeg Purpose Test condition Pass criteria Solutions
1
Check that Area 1 is reached
within maximum transient time
Start test at minimum foreseeable evaporating temperature (minimum
ambient temperature)Continuous running within area 1
At start-up or for any map exit respect max transient time according
to area number
Work on compressor stagingfan staging water flow etc
2 Perform a defrost test if reversible unit
3Perform a start-up test at maximum
foreseeable evaporating temperature (max ambient temperature or start
up with hot waterhellip)
Improve MOP function Work on compressor stagingfan
staging water flow etc
HP and LP must be monitored to respect operating envelope limitations We consider two types of operating envelope management
25FRCCPC037A302
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ESIG
N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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SYST
EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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INTE
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RDER
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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SYST
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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RMAT
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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ESIG
NIN
TEG
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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RMAT
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EM D
ESIG
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TEG
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INTO
SYS
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ESIG
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
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TEG
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INTO
SYS
TEM
ORD
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
NPR
OD
UCT
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
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Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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N
Manage superheat
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
Liquid flood back can cause oil dilution and in extreme situations lead to liquid slugging that can damage the compressor
Requirement
System evaluation
In any conditions the expansion device must ensure a suction superheat within 5K to 30K
Use the table in relation with the application to quickly evaluate the risk and potential tests to perform
Application Tests to perform
Non reversible Liquid flood back test
Reversible Liquid flood back test Defrost test
26 FRCCPC037A302
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Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
NPR
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INFO
RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
OD
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INFO
RMAT
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SYST
EM D
ESIG
NIN
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ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ATIO
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INFO
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SYST
EM D
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ORD
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G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ERA
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ATIO
NPR
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RMAT
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SYST
EM D
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NIN
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ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ERA
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ATIO
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RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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ATIO
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INTE
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Manage superheat
Oil temperature sensor must be placed between the oil sight glass and the compressor baseplate Some thermal paste shall be used to improve the conductivity The sensor must also be correctly thermally insulated from the ambiance
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Liquid flood back test
Steady-state
Liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load
Oil superheat shall be above the safe limit defined in the Dilution Chart (See graph below)
1 Check expansion valve selection and setting -For Thermostatic Expansion Valve (TXV) check bulb position-For Electronic Expansion Valve (EXV) check measurement chain and PID2 Add a suction accumulator
Transient
Tests must be carried out with most unfavorable conditions bull fan staging bull compressor start-up stagingbull etc
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
Defrost testCheck liquid floodback during defrost cycle
Defrost test must be carried out in the most unfavorable condition (at 0degC outdoor ambient temperature)
Oil superheat shall not be more than 30 sec below the safe limit defined in the Dilution Chart (see graph below)
In reversible systems the defrost logic can be worked out to limit liquid floodback effect (for more details see ldquoControl Logicrdquo)
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 etc) therefore oil return has to be checked according to section ldquoManage oil in the circuitrdquo
A
The Oil superheat is defined as (Oil temperature - Evaporating temperature)
20
175
125
75
25
15
10
5
0-30 -25 -20 -15 -10 -5 0 5 10 15 20
Unsafe Area
Safe Area
Evaporating Temperature (degC)
Dilution Chart
25
27FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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INTE
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RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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SYST
EM D
ESIG
N
Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ATIO
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ESIG
NO
RDER
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INFO
RMAT
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YSTE
M
Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
NPR
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INFO
RMAT
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EM D
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TEG
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SYS
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
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ION
SYST
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ESIG
NIN
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ORD
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ATIO
NPR
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RMAT
ION
SYST
EM D
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NIN
TEG
RATI
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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EM D
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ERIN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Manage off cycle migration
R
Requirement
System evaluation
Off -cycle refrigerant migration happens bull when the compressor is located at the coldest part of the installation refrigerant vapor condenses in the compressorbull or directly in liquid-phase by gravity or pressure difference
When the compressor starts running again the refrigerant diluted in the oil generates poor lubrication conditions In extreme situations this leads to liquid slugging that can damage the compressor
At start-up the amount of liquid refrigerant in the compressors must not exceed an acceptable level
Use the tables below in relation with the system charge and the application to quickly define
necessary safeties to implement and test to perform
Application BELOW cHargE Limit aBOVE cHargE Limit
Non split No test or additional safeties required(Internal Non-Return Valve integrated)
bull Surface Sump Heater bull Migration testbull (Internal Non-Return Valve integrated)
Split
Since each installation is unique no test can fully evaluate off-cycle migration therefore the following safeties are requiredbull Surface Sump Heater bull Liquid Line Solenoid Valve+ pump-down cyclebull (Internal Non-Return Valve integrated)
Charge limit is defined in table below
Models Composition Refrigerant charge limit (kg)
Single
DSH240 15DSH295 15DSH381 17DSH485 17
Tandem
DSH482 2xDSH240 21DSH535 DSH240+DSH295 21DSH590 2xDSH295 25DSH620 DSH240+DSH381 21DSH675 DSH295+DSH381 25DSH760 2xDSH381 29DSH725 DSH240+DSH485 21DSH780 DSH295+DSH485 25DSH865 DSH381+DSH485 29DSH970 2xDSH485 34
Trio
DSH720 3xDSH240 21DSH885 3xDSH295 25DSH1140 3xDSH381 29DSH1245 2xDSH381+DSH485 29DSH1350 DSH381+2xDSH485 29DSH1455 3xDSH485 34
28 FRCCPC037A302
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SYST
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N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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YSTE
MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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SYST
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NO
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RMAT
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YSTE
M
Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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RMAT
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ESIG
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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RMAT
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ESIG
NO
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RMAT
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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INTE
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
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TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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SYST
EM D
ESIG
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INTO
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ORD
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
ESIG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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UCT
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
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ATIO
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ESIG
N
Manage off cycle migration
Test criteria and solutions
Test Ndeg Purpose Test condition Pass criteria Solutions
Migration test
Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)
Energize SSHStabilize the non-running system at a pressure equivalent to 5degC Raise the system pressure equivalent to 20degC When saturated condensing temperature reaches 20degC then start the unit
Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated
When all compressors are idlebull Check in liquid line sight glass that there is no liquid refrigerant transferbull Oil superheat must be gt10K during off-cycle
After compressors have startedbull Oil superheat must remain gt10K
1 Check bulb position tightness of expansion device 2 add LLSV 3 add pump down cycle
Surface Sump heater (SSH) The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant Additional heater power or thermal insulation around compressor might be needed in case of ambient temperature below -5degC and a wind speed above 5msecond The heater must be turned on whenever all the compressors are offSurface sump heater accessories are available from Danfoss (see section ldquoAccessoriesrdquo)
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 cycleBy decreasing pressure in the sump pump down systembull evacuates refrigerant from oilbull sets the sump saturating pressure much lower than ambiance temperature and therefore avoids refrigerant condensation in the compressorPump-down must be set higher than 17 bar(g)For more details on pump-down cycle see section ldquoControl Logicrdquo
29FRCCPC037A302
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ATIO
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N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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RMAT
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SYST
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ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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SYST
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ESIG
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
NPR
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ESIG
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TEG
RATI
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INTO
SYS
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ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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ESIG
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ERIN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
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EM D
ESIG
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TEG
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ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
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ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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EM D
ESIG
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RATI
ON
INTO
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TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
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ATIO
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RMAT
ION
SYST
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ESIG
N
Provide power supply and electrical protection
Requirementsbull Protect the compressor from short circuit and
overcurrent by a thermal magnetic motor circuit breaker set to Max Operating Current or lower (see table in section ldquoThree phase electrical characteristicsrdquo)
bull Compressor models DSH240-295-381-485 are delivered with a pre-installed motor protection module inside the terminal box that must be powered on
bull HP safety switch and electronic module relay output (M1-M2) must be wired in the safety chain
bull Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (eg seasonal shutdown)
The wiring diagrams below are examples for a safe and reliable compressor wiring
Compressor model DSH240-295-381
Wiring information
MPM
S
SSH
CCSS
LPS
UNITCONTROLLER
KM
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
Legends
30 FRCCPC037A302
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ESIG
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Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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INTE
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MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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SYST
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ESIG
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ESIG
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N IN
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YSTE
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ESIG
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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ATIO
NPR
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RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
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INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ERA
L IN
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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ATIO
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INTE
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RMAT
ION
SYST
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ESIG
N
Compressor model DSH485 code 3
1
2
3
L1 L3 L2
7
8
9L1
L3L3
L2L2
S
L1
MPM MPM
LPS
UNITCONTROLLER
KM
KM
CCSS
SSH
Legends
Provide power supply and electrical protection
Compressor model DSH485 except code 3
SSH
CONTROLCIRCUIT
LPS
UNITCONTROLLER
SEPARATESUPPLY
KM
DGT
MPM
S
Fuses F1Compressor contactor KMHigh pressure safety switchHPSafety pressure switch LPS Discharge gas thermistor DGTCompressor motor MMotor Protection Module MPMThermistor chainSSurface sump heater SSH
31FRCCPC037A302
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YSTE
MO
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INFO
RMAT
ION
SYST
EM D
ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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ION
SYST
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ESIG
N
Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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RMAT
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SYST
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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SYST
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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SYST
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ESIG
NO
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RMAT
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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RMAT
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SYST
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
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SYST
EM D
ESIG
NO
RDER
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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RMAT
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EM D
ESIG
NO
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RMAT
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YSTE
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ERA
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ATIO
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RMAT
ION
SYST
EM D
ESIG
NO
RDER
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INFO
RMAT
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INTE
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N IN
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YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
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ESIG
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RATI
ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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SYST
EM D
ESIG
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TEG
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INTO
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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INTO
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
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ON
INTO
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TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ERA
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ATIO
NPR
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SYST
EM D
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NIN
TEG
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ON
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ORD
ERIN
G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
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SYST
EM D
ESIG
NIN
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ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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EM D
ESIG
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ON
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TEM
ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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ATIO
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INTE
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RMAT
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SYST
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ESIG
N
Soft starters Soft starters are designed to reduce the starting current of 3-phase AC motors Soft starter must be set so compressor start-up time is always less than 05 seconds to ensure proper lubrication of compressor parts
Ramp-down must be set to minimum to ensure proper discharge valve closingDanfoss MCI and MCD soft-start controller are available as accessories MCI and MCD can reduce the inrush current up to 40
Selection table
Compressor model Soft starter referenceAmbient max 40degC
Soft starter referenceAmbient max 55degC
DSH240 code 4 MCI50CM MCI50CMDSH295 code 4 MCI50CM MCI50CMDSH381 code 4 MCI50CM MCI50CMDSH485 code 4 MCD201-055 MCD201-055DSH485 code 3 MCD5-0195B-T5 MCD5-0195B-T5
Frequency Initial torque (U) Voltage Ramp-up (seconds) Ramp-down (seconds)
50 Hz 60 2 060 Hz 70 05 0
bull MCI50CM replaces the contactor KM All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modification
bull MCI50CM requires a by-pass contactor K1 This configuration is needed to withstand current
or temperature levels All settings such as initial torque ramp-up time (less than 05 sec) and ramp-down time are preset and do not require any modificationSee wiring diagram
bull For MCD201-055 the following settings have to be adjusted
bull For MCD5-0195B-T5 constant current mode has to be used with Current Limit Initial Current set at 400A
Q1
Provide power supply and electrical protection
R
32 FRCCPC037A302
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SYST
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ESIG
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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SYST
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ESIG
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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ESIG
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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ATIO
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ATIO
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RMAT
ION
SYST
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ESIG
NO
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RMAT
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N IN
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M
Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ATIO
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RMAT
ION
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ESIG
NO
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RMAT
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ATIO
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RMAT
ION
SYST
EM D
ESIG
NO
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INFO
RMAT
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N IN
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YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ATIO
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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NPR
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ESIG
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ON
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
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ATIO
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ATIO
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ATIO
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INFO
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SYST
EM D
ESIG
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ERIN
G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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Control logic
Safety control logic requirements
SafetiesTripping conditions Re-start conditions
Value Time Value Time
HP switchSee Pressure settings table
from section ldquoManage operating enveloperdquo Immediate no delay
No by-passConditions back to normal
Switch closed again
Manual reset
LP safety switchMaximum 5 auto reset during
a period of 12 hours then manual reset
Electronic module (Motor protection DGT) Contact M1-M2 opened
Maximum 5 auto reset during a period of 12 hours then
manual reset
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 must no exceed 12 starts per hour
In some cases oil management can be enhanced by control logicbull If oil return test failed a function can
be integrated in control logic to run all compressors simultaneously during 2 minutes every hour in order to boost oil return Time and delay can be fine-tuned by oil return test Ndeg1 in section ldquoManage oil in the circuitrdquo During oil boost pay special attention to superheat management to avoid liquid flood back
bull If after running long time in full load oil unbalance appears then a function can be in control logic to stop all manifold compressors during one minute every two hours in order to balance oil Time and delay can be fine-tuned by Oil balancing test Ndeg2 in section ldquoManage oil in the circuitrdquo
33FRCCPC037A302
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Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ESIG
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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RMAT
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YSTE
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ERA
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ATIO
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ION
SYST
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ESIG
NO
RDER
ING
INFO
RMAT
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INTE
GRA
TIO
N IN
TO S
YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
L IN
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ATIO
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ERA
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ATIO
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OD
UCT
INFO
RMAT
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SYST
EM D
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ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ERA
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ATIO
NPR
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INFO
RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ERA
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ATIO
NPR
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UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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INFO
RMAT
ION
SYST
EM D
ESIG
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TEG
RATI
ON
INTO
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TEM
ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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INTE
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ESIG
N
Control logic
Pump-down logic recommendations
Defrost logic recommendations
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 reaches the cut-out pressure compressor is stoppedTwo types of pump-down exist
bull One shot pump down (preferred) when last compressor of the circuit stops suction presssure is decreased 15 bar below nominal evaporating pressure with minimum of 17 bar(g) Even if suction pressure increases again the compressor will not restart
bull Continuous pump-down compressor restarts automatically when suction pressure increases DSH240 to 485 compressors integrate tight Internal Non Return Valve (INRV) therefore an external Non Return Valve (NRV) is not needed
In reversible systems the defrost logic can be worked out to limit liquid flood back effect by1 Running full load during defrost to share liquid refrigerant between all compressors
2 Transferring liquid refrigerant from one exchanger to the other one thanks to pressures
The following defrost logic combines both advantages
Defro
st sta
rt St
op all c
ompre
ssors
4 Way
Valve (
4WV) s
tays
in h
eatin
g mode
EXV o
pened
to tr
ansfe
r liq
uid fr
om
outdoor t
o indoor e
xchan
ger th
anks
to
press
ure d
iffer
ence
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to co
oling m
ode
When
pre
ssure
s are
alm
ost bala
nced
chan
ge 4W
V to h
eatin
g mode
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Star
t Cp1 a
nd Cp 2
with 0
5 sec
onds
delay b
etwee
n 2 su
cces
sive s
tarts
Defro
st en
d Sto
p all c
ompre
ssors
4 WV st
ays i
n coolin
g mode
EXV o
pened
to tr
ansfe
r liq
uid
from
indoor t
o outd
oor exc
hanger
than
ks to
pre
ssure
diff
eren
ce
Defro
st
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 ldquoManage superheatrdquo and ldquoManage operating enveloperdquo
Compressor 1
Compressor 2
4WV
EXV
ON
ON
Heating
100
34 FRCCPC037A302
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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ESIG
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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ESIG
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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ERA
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ATIO
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RMAT
ION
SYST
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ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
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N IN
TO S
YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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ERA
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ATIO
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ESIG
NIN
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RATI
ON
INTO
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ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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ESIG
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G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
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INFO
RMAT
ION
SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ATIO
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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SYST
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ORD
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G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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Reduce moisture in the system
Excessive air and moisture bull can increase condensing pressure and cause excessive high discharge temperaturesbull can create acid giving rise to copper plattingbull can destroy the lubricating properties of the oil
All these phenomena reduce compressor life time and cause mechanical and electrical compressor failure
Requirements
Solutions
DSH compressors are delivered with lt 100 ppm moisture level At the time of commissioning system moisture content may be up to 100 ppm
During operation the filter drier must reduce this to a level between 20 and 50 ppm
To achieve this requirement a properly sized and type of drier is required Important selection criteria includesbull driers water content capacitybull system refrigeration capacity bull system refrigerant charge
For new installations with DSH compressors with polyolester oil Danfoss recommends using the Danfoss DML (100 molecular sieve) solid core filter drier
R
35FRCCPC037A302
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
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38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ERA
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ATIO
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OD
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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Assembly line procedure
Compressor holding charge
Handling
Compressor storage
Each compressor is shipped with a nominal dry nitrogen holding charge between 03 and 07 bar and is sealed with elastomer plugs
Respect the following sequence to avoid discharge check valve gets stuck in open position
bull Remove the suction plug first bull Remove the discharge plug afterwards An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the oil
Each DSH compressor is equipped with two lift rings on the top shellbull Always use both these rings when lifting the
compressor bull Use lifting equipment rated and certified for
the weight of the compressor or compressor assembly
bull A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution
bull The use of lifting hooks closed with a clasp is recommended
bull For tandem and trio assemblies use a spreader bar and all compressor rings as shown in picture below
bull Never use the lift rings of the compressors to lift the full unit
Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15deg from vertical)
The compressor must not be exposed to rain nor corrosive or flammable atmosphere during storage Store the compressor between -35degC and 70degC when charged with nitrogen and between
-35degC and Ts max value (see section ldquoPressure equipment directiverdquo) when charged with R410A refrigerant
R
Spreader bars
Slings
Frame
Spreader bar
HEAVY
do not liftmanually
36 FRCCPC037A302
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Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
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Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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SYST
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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TEG
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INTO
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TEM
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Assembly line procedure
Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor life time (system cleanliness brazing procedure etc)
System cleanliness
Circuit contamination possible cause Requirement
Brazing and welding oxides During brazing flow nitrogen through the system
Particles and burrs Remove any particles and burrs generated by tube cutting and hole drilling
Moisture and airUse only clean and dehydrated refrigeration grade copper tubingOpened compressor must not be exposed to air more than 20 minutes to avoid moisture captured by oil
Brazing procedurebull Brazing operations must be performed by
qualified personnelbull Make sure that no electrical wiring is connected
to the compressorbull To prevent compressor shell and electrical box
overheating use a heat shield andor a heat-absorbent compound
bull Clean up connections with degreasing agentbull Flow nitrogen through the compressorbull Use flux in paste or flux coated brazing rod
bull Use brazing rod with a minimum of 5 silver content
bull It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection
bull For discharge connections brazing time should be less than 2 minutes to avoid NRVI damages if any
bull To enhance the resistance to rust a varnish on the connection is recommended
Before eventual un-brazing of the compressor or any system component the refrigerant charge must be removed
System pressure test and leak detection The compressor has been strength tested
and leak proof tested (lt3gyear) at the factory For system testsbull Do not exceed the following pressures indicated in table below
bull Pressurize the system on HP side first then LP side
bull Always use an inert gas such as nitrogen or helium
Maximum compressor test pressures DSH240-295 DSH381-485
Maximum compressor test pressure high side (HP) 45 bar (g) HP-LPlt37bar
Maximum compressor test pressure low side (LP)343 bar (g) LP-HPlt5barMaximum speed 48 bar second
333 bar (g)LP-HPlt5barMaximum speed 48 bar second
On DSH240-295-381-485 models with internal non return valve in discharge fitting or if an external non return valve is present on the discharge line maximum pressurizing speed must be respected to ensure pressure equalization between LP and HP side over scroll elements
heat shield
C B A
37FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Assembly line procedure
Vacuum evacuation and moisture removal
Refrigerant charging
Dielectric strength and insulation resistance tests
Requirements bull Never use the compressor to vacuum the
system bull Connect a vacuum pump to both the LP and HP
sides bull Evacuate the system to a pressure of 500 μm Hg
(067 mbar) absolute
Recommendationsbull Energized heaters improve moisture removalbull Alternate vacuum phases and break vacuum
with nitrogen to improve moisture removal
For more detailed information see ldquoVacuum pump-down and dehydration procedurerdquo reference TI-026-0302
Initial chargebull For the initial charge the compressor must not
runbull Charge refrigerant as close as possible to the
nominal system chargebull This initial charging operation must be done in
liquid phase between the condenser outlet and the filter drier
If needed a complement of charge can be done before evaporator in liquid phase while compressor is running by slowly throttling liquid in Never bypass safety low pressure switch
Several tests have been performed on each compressor at the factory between each phase and ground
bull 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 Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 20 megohm
Recommendationsbull Additional dielectric test is not recommended
as it may reduce motor lifetime Nevertheless if such a test is necessary it must be performed at a lower voltage
bull Insulation resistance test can be donebull 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 power to the compressor while it is under vacuum as this may cause internal damage
R
R
R
38 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NO
RDER
ING
INFO
RMAT
ION
INTE
GRA
TIO
N IN
TO S
YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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ERA
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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ERA
L IN
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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RMAT
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
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INTE
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Commissioning
Preliminary checkCheck electrical power supply
bull Phase order For DSH240 to 485 compressors equipped with an electronic module reverse rotation will be automatically detected For more details refer to section ldquoMotor protectionrdquo
bull Voltage and voltage unbalance within tolerance For more details refer to section ldquoMotor voltagerdquo
Initial start-up
System monitoring
bull Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant from oil
bull A quicker start-up is possible by ldquojoggingrdquo the compressor to evacuate refrigerant 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
The system must be monitored after initial startup for a minimum of 60 minutes to ensure proper operating characteristics such as bull Correct superheat and subcoolingbull Current draw of individual compressors within
acceptable values (depending on running conditions see wwwcoolselectordanfosscom)
bull No abnormal vibrations and noisebull Correct oil level
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 original Danfoss POE oil 160SZ from new cans For more detailed information see ldquoLubricants filling in instructions for Danfoss Commercial Compressorsrdquo reference TI 2-025-0402
39FRCCPC037A302
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RMAT
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EM D
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NO
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INFO
RMAT
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INTE
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N IN
TO S
YSTE
M
Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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EM D
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NIN
TEG
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ON
INTO
SYS
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ORD
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G IN
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ATIO
N
Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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RMAT
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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RMAT
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SYST
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ON
INTO
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
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ORD
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G IN
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ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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RMAT
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SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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Dismantal and disposal
Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site
40 FRCCPC037A302
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Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
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INTO
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TEM
ORD
ERIN
G IN
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ATIO
N
Packaging
Single pack
Industrial pack
Compressor model Length(mm)
Width(mm)
Height(mm)
Gross weight
(kg)
DSH240 760 600 900 122
DSH295 760 600 900 125
DSH381 760 600 900 172
DSH485 760 600 900 189
Compressor model Nbr Length (mm)
Width (mm)
Height (mm)
Gross weight
(kg)
Static stacking pallets
DSH240 6 1150 965 768 683 2
DSH295 6 1150 965 768 702 2
DSH381 4 1150 965 800 671 2
DSH485 4 1150 965 800 737 2
nbr number of compressors per pack
41FRCCPC037A302
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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INTO
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ATIO
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
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L IN
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NPR
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INFO
RMAT
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NIN
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ON
INTO
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G IN
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Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
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L IN
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NPR
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Ordering codes
Single pack
DSH compressors can be ordered in either industrial or single packs Please use the code numbers from below tables for ordering For use in single applications flexible grommets
are available as accessory kit 8156138 For use in manifold configuration rigid spacers are available as accessory kit 7777045 (120Z0495 for 60Hz applications)
Compressor code numbers
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1159 120H1119 120H1151 120H1135
Brazed Module 110-240V 120H1161 120H1121 120H1152 120H1137
DSH295Brazed Module 24V AC 120H1163 120H1123 120H1153 120H1139
Brazed Module 110-240V 120H1165 120H1125 120H1154 120H1141
DSH381Brazed Module 24V AC 120H1167 120H1127 120H1155 120H1143
Brazed Module 110-240 V 120H1169 120H1129 120H1156 120H1145
DSH485Brazed Module 24V AC 120H1105 120H1131 120H1157 120H1147
Brazed Module 110-240 V - 120H1133 120H1158 120H1149
Electronic motor protection module located in terminal boxMounting kit for single compressor applications Ref 8156138
Compressor model Connections Motor
protection
Code no3 4 7 9
200-230360 380-415350460360
575350575360 380-400360
DSH240Brazed Module 24V AC 120H1160 120H1120 - 120H1136
Brazed Module 110-240 V 120H1162 120H1122 - 120H1138
DSH295Brazed Module 24V AC 120H1164 120H1124 - 120H1140
Brazed Module 110-240 V 120H1166 120H1126 - 120H1142
DSH381Brazed Module 24V AC 120H1168 120H1128 - 120H1144
Brazed Module 110-240 V 120H1170 120H1130 - 120H1146
DSH485Brazed Module 24V AC 120H1104 120H1132 - 120H1148
Brazed Module 110-240 V - 120H1134 - 120H1150
Electronic motor protection module located in terminal boxMounting kit for manifold configurations (one kit per compressor)Ref 7777045 for 50 Hz applications Ref 120Z0495 for 60 Hz applications
Industrial pack
42 FRCCPC037A302
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INTO
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ATIO
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Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
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Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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INTO
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TEM
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ERIN
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Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
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OD
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RMAT
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SYST
EM D
ESIG
NIN
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ON
INTO
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TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
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FORM
ATIO
NPR
OD
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INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Ordering codes
Tandem code numbers
Trio code numbers
To build a tandem you must order the 2 compressors and the Tandem kit code below
To build a trio you must order 3 compressors and the trio kit code below
For example Tandem SH535- Compressor 1 DSH240 Code number 120H1122 (Motor code 4110-240 V electronic module Industrial pack)
- Compressor 2 DSH295 Code number 120H1126 (Motor code 4110-240 V electronic module Industrial pack)- Tandem kit DSH535 Code number 7777037- Two mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
For example Trio DSH1245- Compressors 1 and 2 DSH381 Code number 120H1130 (Motor code 4110-240 V electronic moduleIndustrial pack)
- Compressor 3 DSH485 Code number 120H1134 (Motor code 4110-240 V electronic module Industrial pack)- Trio kit DSH1245 Code number 7777063- Three mounting Kits 7777045 (or 120Z0495 if 60 Hz application)
Tandem model Cp1 Cp2 Suction from Kit code ndeg
DSH482 DSH240 DSH240Left
7777041Right
DSH535 DSH240 DSH295Left
7777037Right
DSH590 DSH295 DSH295Left
7777041Right
DSH620 DSH240 DSH381Left
7777048Right
DSH675 DSH295 DSH381Left
7777037Right
DSH725 DSH240 DSH485Left
120Z0569Right
DSH760 DSH381 DSH381Left
7777041Right
DSH780 DSH295 DSH485Left
120Z0551Right
DSH865 DSH381 DSH485Left
120Z0550Right
DSH970 DSH485 DSH485Left
120Z0578Right
Trio model Cp1 Cp2 Cp3 Suction from Kit code ndeg
DSH720 DSH240 DSH240 DSH240Left 120Z0673
Right 7777039
DSH885 DSH295 DSH295 DSH295Left 120Z0673
Right 7777039
DSH1140 DSH381 DSH381 DSH381Left 7777040
Right 7777049
DSH1455 DSH485 DSH485 DSH485Left
7777040Right
DSH1245 DSH381 DSH381 DSH485Left
7777063Right
DSH1350 DSH381 DSH485 DSH485Left
7777063Right
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
+
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
43FRCCPC037A302
GEN
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FORM
ATIO
NPR
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RMAT
ION
SYST
EM D
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NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
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ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
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NPR
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RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
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ATIO
NPR
OD
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INFO
RMAT
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SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Solder sleeve
Solder sleeve adapter set
Rotolock adapter
Gaskets
Code ndeg Description Application Packaging Pack size
7765028 Rotolock adaptor set (214 ~ 158) (134 ~ 118) DSH240-295-381 Multipack 6
120Z0504 Rotolock adaptor set (214 ~ 158) (134 ~ 138) DSH485 Multipack 6
Code ndeg Description Application Packaging Pack size
120Z0364 Adaptor (134 Rotolock - 118 ODS) Models with 118 ODF Multipack 10
120Z0431 Adaptor (134 Rotolock - 138 ODS) Models with 138 ODF Multipack 10
120Z0432 Adaptor (214 Rotolock - 158 ODS) Models with 158 ODF Multipack 10
Code ndeg Description Application Packaging Pack size
8153004 Solder sleeve P02 (134 Rotolock - 118 ODF) Models with 134 rotolock connection Multipack 10
8153006 Solder sleeve P03 (214 Rotolock - 158 ODF) Models with 214 rotolock connection Multipack 10
Code ndeg Description Application Packaging Pack size
8156132 Gasket 134 Models with 134 rotolock connection Multipack 10
7956003 Gasket 134 Models with 134 rotolock connection Industry pack 50
8156133 Gasket 214 Models with 214 rotolock connection Multipack 10
7956004 Gasket 214 Models with 214 rotolock connection Industry pack 50
Rotolock nut
Code ndeg Description Application Packaging Pack size
8153124 Rotolock nut 134 Models with 1-34 rotolock connection Multipack 10
8153126 Rotolock nut 214 Models with 2-14 rotolock connection Multipack 10
44 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Rotolock service valve set
3-phase soft start equipment
Motor protection modules
Code ndeg Description Application Packaging Pack size
037N0401 Electronic soft start kit MCI50CM DSH240-295-381 Single pack 1
175G5205 Electronic soft start kit MCD201-055-T6-CV1 DSH485 Single pack 1
175G5510 Electronic soft start kit MCD5-0195B-T5 DSH485 code 3 Single pack 1
except DSH485 code 3
Code ndeg Description Application Packaging Pack size
7703383 Valve set V03 (214 ~ 158) V02 (134 ~ 118) DSH240-295-381 Multipack 4
120Z0547 Valve set V03 (214 ~ 158) V10 (134 ~ 138) DSH485 Multipack 4
Code ndeg Description Application Packaging Pack size
120Z0584 Electronic motor protection module 24 V AC DSH240-295-381-485 Single pack 1
120Z0585 Electronic motor protection module 115240 V DSH240-295-381-485 Single pack 1
120Z0624 Electronic motor protection module 24V AC DSH485 code 3 Single pack 1
except DSH485 code 3
Terminal boxes covers and T-block connectors
Code No Description Application Packaging Pack Size
8173230 T block connector 60x75 mm DSH240-295-381 Multipack 10
8173331 T block connector 80x80 mm DSH240-295-381 code 3-485 Multipack 10
120Z0458 Terminal box 210 x 190 mm incl cover DSH240-295-381-485 Single pack 1
120Z0150 Terminal box cover DSH381 code 3 Single pack 1
120Z0604 Terminal box 210x340mm incl cover DSH485 code 3 Single pack 1
except code 3
45FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Accessories
Surface sump heaters
Code no Accessory description Application Packaging Pack size
120Z0360 56W 24V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0376 56W 230V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0377 56W 400V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0378 56W 460V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
120Z0379 56W 575V surface sump heater + bottom insulation CE amp UL DSH240-295-381-485 Multipack 6
Acoustic hoods
Code No Description Application Packaging Pack Size
120Z0022 Acoustic hood for scroll compressor DSH240-295-381-485 Single pack 1
120Z0579 Acoustic hood for scroll compressor DSH381 code 3 Single pack 1
120Z0353 Bottom insulation for scroll compressor DSH240-295-381-485 Single pack 1
except code 3
Mounting hardware
Code No Description Application Packaging Pack Size
8156138 Mounting kit for scroll compressors Grommets sleeves bolts washers DSH240 to 485 in single installation Single pack 1
7777045 Mounting kit for 1 scroll compressors including 4 hexagon rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
120Z0495 Mounting kit for 1 scroll compressor including 4 triangle rigid spacer 4 sleeves 4 bolts 4 washers DSH240 to 485 in parallel installation Single pack 1
46 FRCCPC037A302
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
GEN
ERA
L IN
FORM
ATIO
NPR
OD
UCT
INFO
RMAT
ION
SYST
EM D
ESIG
NIN
TEG
RATI
ON
INTO
SYS
TEM
ORD
ERIN
G IN
FORM
ATIO
N
Tandem kits including
Trio kits
Code No Description Application Packaging Pack Size
7777041 Suction washer grommets sleeve for oil connect DSH482590760 Single pack 1
7777037 Suction washer grommets sleeve for oil connect DSH535675 Single pack 1
7777048 Suction washer grommets sleeve for oil connect DSH620 Single pack 1
120Z0569 Suction washer grommets sleeve for oil connect DSH725 Single pack 1
120Z0550 Suction washer grommets sleeve for oil connect DSH865 Single pack 1
120Z0551 Suction washer grommets sleeve for oil connect DSH780 Single pack 1
120Z0578 Suction washer grommets sleeve for oil connect DSH970 Single pack 1
Code No Description Application Packaging Pack Size
7777039 Suction washer grommets sleeve for oil connect DSH720885 (right suction) Single pack 1
7777040 Suction washer grommets sleeve for oil connect DSH1140 (left suction) 1455 (left and right suction) Single pack 1
7777049 Suction washer grommets sleeve for oil connect DSH1140 (right suction) Single pack 1
7777063 Suction washer grommets sleeve for oil connect DSH12451350 Single pack 1
120Z0673 Suction washer grommets sleeve for oil connect DSH720885 (left suction) Single pack 1
Lubricant
Miscellaneous
Code No Description Packaging Pack Size
7754023 POE lubricant 1 litre can Single pack 1
120Z0571 POE lubricant 25 litre can Single pack 1
Code No Description Packaging Pack Size
8156019 Sight glass with gaskets (black amp white) Multipack 4
8156129 Gasket for oil sight glass 118 (white teflon) Multipack 10
7956005 Gasket for oil sight glass 118 (white teflon) Multipack 50
8154001 Danfoss Commercial Compressors blue spray paint Single pack 1
Accessories
47FRCCPC037A302
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors
Danfoss Commercial Compressors is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs
We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate from engineering and manufacturing facilities spanning across three continents
FRCCPC037A302 copy Danfoss | DCS (CC) | 201610
Our products can be found in a variety of applications such as rooftops chillers residential air conditioners heatpumps coldrooms supermarkets milk tank cooling and industrial cooling processes
httpccdanfosscom
Danfoss Inverter Scrolls
Danfoss Turbocor Compressors
Danfoss Scrolls
Danfoss Optyma Condensing Units
Danfoss Maneurop Reciprocating Compressors
Danfoss Commercial Compressors BP 331 01603 Treacutevoux Cedex France | +334 74 00 28 29
Danfoss Light Commercial RefrigerationCompressors