Application guidelines -...

Danfoss scroll compressors DSH 090-184

50 Hz - 60 Hz - R410A

Application guidelines

http://cc.danfoss.com

Content

GENERAL INFORMATION ........................ 4

PRODUCT INFORMATION ....................... 5

Features..................................................... 5Overview ......................................................................5How do IDVs work? ...................................................5

Compressor model designation ............. 6Nomenclature ............................................................6

Technical specifications ........................... 750-60 Hz data Single compressor .......................750-60 Hz data Tandem compressor ...................8

Dimensions ............................................... 9Single compressors ..................................................9Tandem assemblies ................................................10

Electrical data, connections and wiring 11Motor voltage ...........................................................11Wiring connections ................................................11IP rating .......................................................................12Three phase electrical characteristics .............12Motor protection.....................................................13

Approval and certificates ...................... 14Low voltage directive ............................................14Machines directive .................................................14Pressure equipment directive ............................14Internal free volume...............................................14

SYSTEM DESIGN ..................................... 15

Design piping ......................................... 15General requirements ...........................................15Tandem requirements ...........................................16Suction washer position .......................................17Oil equalization design .........................................18

Design compressor mounting .............. 19General requirements ...........................................19Single requirements...............................................19Tandem requirements ...........................................19Parallel mounting feet ..........................................19

Manage oil in the circuit ........................ 20Requirement ............................................................ 20Evaluate the risk ...................................................... 20Test, criteria and solutions .................................. 20

Manage sound and vibration ................ 21Compressor sound radiation ..............................21Mechanical vibrations .......................................... 22Gas pulsation ........................................................... 22

Manage operating envelope ................. 23Requirement ............................................................ 23Evaluate the risk ...................................................... 24Test, criteria and solutions .................................. 24

Manage superheat ................................. 25Requirement ............................................................ 25Evaluate the risk ...................................................... 25Test, criteria and solutions .................................. 26

Manage off cycle migration ................... 27Requirement ............................................................ 27Evaluate the risk ...................................................... 27Test, criteria and solutions .................................. 28

Provide power supply and electrical protection ............................................... 29

Wiring information ................................................ 29Soft starts .................................................................. 30

Control logic ........................................... 31Safety control logic requirements ....................31Cycle rate limit requirements .............................31Defrost logic recommendations .......................31Pump-down logic recommendations ............ 32

Reduce moisture in the system ............. 33Requirements .......................................................... 33Solutions ................................................................... 33

INTEGRATION INTO SYSTEMS .............. 34

Assembly line procedure ....................... 34Compressor storage .............................................. 34Compressor holding charge .............................. 34Handling ................................................................... 34Piping assembly...................................................... 35System pressure test and leak detection ...... 35Vacuum evacuation and moisture removal 36Refrigerant charging ............................................. 36Dielectric strength and insulation resistance tests ............................................................................. 36

Commissioning ....................................... 37Preliminary check....................................................37Initial start-up ...........................................................37System monitoring .................................................37

ORDERING INFORMATION ................... 38

Packaging ............................................... 38

Ordering codes ....................................... 39

Accessories .............................................. 41

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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 safety risk.

This icon indicates instructions to avoid reliability risk.

The purpose of this guideline is to help customers qualify compressors in the unit.You are strongly advise to follow these instructions. For any deviation from the guidelines, please contact Danfoss Technical Support. In any case, Danfoss accepts no liability as a result of the improper integration of the compressor into the unit by the system manufacturer.

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DSH 090-105-120-140-161-184 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 system’s seasonal energy efficiency.

How do IDVs work?

Intermediate discharge valves (IDVs) increase seasonal efficiency

Heat shield lowers the heat transfer between discharge and suction gas and the acoustic level

PTFE spring seal

R410A optimized and dedicated scroll profile

Lead free polymer bearings improve behavior under poor lubrication conditions

Patented motor cap

Lower bearing centring

Patented motor centring spacer

Overview

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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 “Ordering information”.

Nomenclature

Family, lubricant & refrigerantDSH: Scroll, POE lubricant, for R410A 60 Hz Motor protection

L: Internal overload protector

Suction and discharge connectionsA: Brazed connections

Family, lubricant

& refrigerant

Nominalcapacity

Approvals Voltage Version Evolutionindex

Evolution indexA~Z

A4DSH A AB184

Motor voltage code3: 200-230V/3~/60 Hz4: 380-415V/3~/50 Hz - 460V/3~/60 Hz7: 575V/3~/60 Hz9: 380-400V/3~/60 Hz

UL index

Nominal capacity in thousand Btu/h at 60 Hz, R410A, ARI conditions

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Technical specifications

50-60 Hz data Single compressor

ModelNominal

tons 60 HzNominal cooling

capacityPowerinput COP E.E.R. Swept

volumeDisplace-ment Oil charge Net weight

TR W Btu/h kW W/W Btu/h/W cm3/rev m3/h dm3 kg

50 Hz

DSH090 7.5 24600 84100 4.2 5.83 19.90 88.4 15.4 3.0 58.0

DSH105 9 29100 99300 5.0 5.80 19.80 103.5 18.0 3.3 64.0

DSH120 10 33100 112900 5.6 5.94 20.27 116.9 20.3 3.3 64.0

DSH140 12 37400 127700 6.4 5.84 19.93 133 23.1 3.3 67.0

DSH161 13 43000 146700 7.2 5.96 20.34 151.7 26.4 3.3 69.0

DSH184 15 48400 165000 8.2 5.88 20.07 170.3 29.6 3.6 71.5

60 Hz

DSH090 7.5 29800 101600 5.1 5.79 19.76 88.4 15.4 3.0 58.0

DSH105 9 35200 120000 6.1 5.75 19.62 103.5 18.0 3.3 64.0

DSH120 10 39900 136100 6.8 5.89 20.10 116.9 20.3 3.3 64.0

DSH140 12 45100 153800 7.8 5.76 19.66 133 23.1 3.3 67.0

DSH161 13 51700 176300 8.9 5.81 19.83 151.7 26.4 3.3 69.0

DSH184 15 58200 198700 10.0 5.80 19.80 170.3 29.6 3.6 71.5

Displacement at nominal speed: 2900 rpm at 50 Hz, 3500 rpm at 60 Hz Net weight with oil charge

TR: Ton of Refrigeration, Standard conditions Evaporating temperature: 4 °C Superheat: 10 KEER: Energy Efficiency Ratio Refrigerant: R410A Condensing temperature: 32 °C Subcooling: 0 KCOP: Coefficient Of Performance,

Subject to modification without prior notification.Data given for motor code 4 compressor with above condition, for full data details and capacity tables refer to Coolselector®2www.coolselector.danfoss.com

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Model CompositionNominal

tons 60 HzNominal cooling

capacityPowerinput COP E.E.R. Displacement

TR W Btu/h kW W/W Btu/h/W m3/h

50 Hz

DSH182 2xDSH090 15.0 48800 166600 8.4 5.78 19.73 30.8

DSH195 DSH090 + DSH105 16.5 53300 181700 9.2 5.76 19.67 33.4

DSH210 DSH090 + DSH120 17.5 57200 195200 9.8 5.84 19.94 35.7

DSH212 2xDSH105 18.0 57700 196800 10.0 5.75 19.62 36.0

DSH230 DSH090 + DSH140 19.5 61500 209900 10.6 5.79 19.74 38.5

DSH242 2xDSH120 20.0 65600 223800 11.1 5.89 20.10 40.6

DSH251 DSH090 + DSH161 20.5 67000 228700 11.4 5.86 20.00 41.8

DSH260 DSH140 + DSH120 22.0 69900 238500 12.0 5.84 19.91 43.4

DSH274 DSH090 + DSH184 22.5 72300 246800 12.4 5.81 19.83 45.0

DSH281 DSH161 + DSH120 23.0 75400 257300 12.8 5.90 20.13 46.7

DSH282 2xDSH140 24.0 74200 253200 12.8 5.79 19.75 46.2

DSH289 DSH105 + DSH184 24.0 76800 261900 13.2 5.80 19.78 47.6

DSH301 DSH161 + DSH140 25.0 79700 272000 13.6 5.85 19.97 49.5

DSH304 DSH120 + DSH184 25.0 80700 275400 13.8 5.85 19.97 49.9

DSH322 2xDSH161 26.0 85200 290800 14.4 5.91 20.16 52.8

DSH324 DSH140 + DSH184 27.0 85000 290100 14.6 5.81 19.82 52.7

DSH345 DSH161 + DSH184 28.0 90500 308900 15.4 5.87 20.01 56.0

DSH368 2xDSH184 30.0 95800 327000 16.4 5.83 19.88 59.2

60 Hz

DSH182 2xDSH090 15.0 59000 201300 10.3 5.74 19.58 30.8

DSH195 DSH090 + DSH105 16.5 64400 219600 11.3 5.71 19.50 33.4

DSH210 DSH090 + DSH120 17.5 69000 235500 11.9 5.79 19.77 35.7

DSH212 2xDSH105 18.0 69700 237900 12.2 5.70 19.43 36.0

DSH230 DSH090 + DSH140 19.5 74200 253100 13.0 5.72 19.51 38.5

DSH242 2xDSH120 20.0 79000 269700 13.5 5.84 19.91 40.6

DSH251 DSH090 + DSH161 20.5 80700 275400 14.0 5.75 19.62 41.8

DSH260 DSH140 + DSH120 22.0 84200 287200 14.6 5.77 19.68 43.4

DSH274 DSH090 + DSH184 22.5 87200 297600 15.2 5.75 19.60 45.0

DSH281 DSH161 + DSH120 23.0 90700 309600 15.7 5.79 19.76 46.7

DSH282 2xDSH140 24.0 89300 304800 15.7 5.71 19.47 46.2

DSH289 DSH105 + DSH184 24.0 92600 315900 16.2 5.73 19.55 47.6

DSH301 DSH161 + DSH140 25.0 95900 327100 16.7 5.73 19.56 49.5

DSH304 DSH120 + DSH184 25.0 97200 331800 16.8 5.78 19.74 49.9

DSH322 2xDSH161 26.0 102400 349500 17.8 5.76 19.64 52.8

DSH324 DSH140 + DSH184 27.0 102400 349400 17.9 5.73 19.56 52.7

DSH345 DSH161 + DSH184 28.0 108900 371700 18.9 5.75 19.63 56.0

DSH368 2xDSH184 30.0 115400 393900 20.1 5.75 19.62 59.2

Displacement at nominal speed: 2900 rpm at 50 Hz, 3500 rpm at 60 Hz Net weight with oil charge

TR: Ton of Refrigeration, Standard conditions Evaporating temperature: 4 °C Superheat: 10 KEER: Energy Efficiency Ratio Refrigerant: R410A Condensing temperature: 32 °C Subcooling: 0 KCOP: Coefficient Of Performance,

Subject to modification without prior notification.Data give for motor code 4 compressor with above condition, for full data details and capacity tables refer to Coolselector®2www.coolselector.danfoss.com

50-60 Hz data Tandem compressor

Technical specifications

(*Tandem configurations are going to be released, please contact Danfoss to check availability.)

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Dimensions

Compressor model D (mm) H (mm) H1(mm) H2(mm) L1(mm) L2(mm) L3(mm) Outline drawing number

DSH090 243 485 235 451 180 230 230 8560004

DSH105-120-140-161 243 542 278 509 180*201** 230 230 8560003 *

8560041 **

DSH184 243 558 299 524 201 230 230 8560023

* compressor motor codes 4, 7, 9** compressor motor code 3

Single compressors

Connection Details

Ø D

H1

4 x holesØ19.05

L3

L2

190.5

190.5L1

30°

30°

H2H

Ø D

H1

4 x holesØ19.05

L3

L2

190.5

190.5L1

30°

30°

H2H

DSH090 DSH105-120-140-161-184

Suction connection Brazed 1"1/8 Brazed 1"3/8

Discharge connection Brazed 7/8" Brazed 7/8"

Oil sight glass Threaded (1"1/8 – 18 UNF)

Oil equalization connection Rotolock 1"4/3

Low pressure gauge port (Shrader) Male ¼" Flare incorporating a Schrader valve

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L1 H1L1 H1

Dimensions

Tandem model Composition L (mm) D (mm) H (mm) L1 H1 Outline drawing number

DSH182 DSH090 + DSH090 722 488 507

240 min

150 min 8560092

DSH195 DSH090 + DSH105 738 488 565 150 min 8560101

DSH210 DSH090 + DSH120 738 488 565 150 min 8560101

DSH212 DSH105 + DSH105 738 488 565 240 min 8560093

DSH230 DSH090 + DSH140 738 488 565 150 min 8560101

DSH242 DSH120 + DSH120 738 488 565 240 min 8560093

DSH251 DSH090 + DSH161 738 488 565 150 min 8560101

DSH260 DSH140 + DSH120 738 488 565 150 min 8560103

DSH274 DSH090 + DSH184 738 494 580 150 min 8556185

DSH281 DSH161 + DSH120 738 488 565 150 min 8560103

DSH282 DSH140 + DSH140 738 488 565 240 min 8560093

DSH289 DSH105 + DSH184 738 488 580 150 min 8560102

DSH301 DSH161 + DSH140 738 488 565 150 min 8560103

DSH304 DSH120 + DSH184 738 488 580 150 min 8560102

DSH322 DSH161 + DSH161 738 488 565 240 min 8560093

DSH324 DSH140 + DSH184 738 488 580 150 min 8560102

DSH345 DSH161 + DSH184 738 494 580 240 min 8556186

DSH368 DSH184 + DSH184 745 494 580 240 min 8560094

Tandems to be achieved by assembly of individual compressors

Tandem assemblies

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Electrical data, connections and wiring

Danfoss scroll compressors DSH are available in four different motor voltages as listed below.

Electrical power is connected to the compressor terminals by Ø 4.8 mm (3/16") screws.

The maximum tightening torque is 3 Nm. Use a 1/4" ring terminal on the power leads.

Motor voltage

Wiring connections

DSH090-105-120-140-161*except DSH140-161 code3

DSH140-161 code3 & DSH184

The terminal box is provided with a Ø 25.5 mm (ISO25) and a Ø 29 mm (PG21) knockouts.

The terminal box is provided with a Ø 40.5 mm hold (ISO40) for power supply and a Ø 16.5 mm knockout (ISO16).

Motor voltage code Code 3 Code 4 Code 7 Code 9

50 Hz Nominal voltage - 380-415 V - 3 ph - -

Voltage range - 342-457 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 V 414-506 V 517-632 V 342-440 V

Vavg = Mean voltage of phases 1, 2, 3.

V1-2 = Voltage between phases 1 and 2.



| 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:

Terminal box

Ø 25.5 mm knockout

Power supply

Ø 29 mm knockout

Ø 40.5 mm hole

Ø 16.5 mm knockout Power supply

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IP rating The compressor terminal box according to IEC529 is IP54 for all models when correctly sized IP54 rated cable glands are used.First numeral, level of protection against contact and foreign objects

5 - Dust protectedSecond numeral, level of protection against water

4 - Protection against water splashing

Three phase electrical characteristics

Compressor modelLRA MCC Max. operating current Winding resistance

A A A Ω

Motor voltage code 3200-230 V / 3ph / 60 Hz

DSH090 203 43 38 0.39DSH105 267 51 45 0.27DSH120 267 61 48 0.27DSH140 304 64 56 0.24DSH161 315 69 64 0.22DSH184 351 75 71 0.22

Motor voltage code 4 380-415 V / 3ph / 50 Hz

460 V / 3ph / 60Hz

DSH090 98 22 19 1.47DSH105 142 25 22 1.05DSH120 142 29 24 1.05DSH140 147 30 28 0.92DSH161 158 35 31 0.83DSH184 197 38.6 36 0.83

Motor voltage code 7 575 V / 3 ph / 60 Hz


Motor voltage code 9380-400 V / 3ph / 60 Hz


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 higher average current as measured on mechanically blocked compressors tested under nominal voltage. The LRA value can be used as a rough estimation for

the 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 “soft start“).

MCC (Maximum Continuous Current)

LRA (Locked Rotor Amp)

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Motor protection Compressor models DSH 090 to 184 are provided with internal overload motor protection to prevent against excessive current and temperature caused by overloading, low refrigerant flow or phase loss. The cutout current is the MCC value listed in table “Three phase electrical characteristics”.

The protector is located in star point of motor and, should it be activated, will cut out all three phases. It will be reset automatically.

While not compulsory, an additional external overload is still advisable for either alarm or manual reset.

Then it must be set below MCC value (at max operating current):

• When the motor temperature is too high, then the internal protector will trip.

• When the current is too high the external overload protection will trip before the internal protection therefore offering possibility of manual reset.


Winding resistance is the resistance between phases at 25°C (resistance value +/- 7%).Winding resistance is generally low and it requires adapted tools for precise measurement. Use a digital ohm-meter, a “4 wires” method and measure under stabilised ambient temperature. Winding resistance varies strongly with winding temperature. If the compressor is stabilised at a different value than 25°C, the measured resistance must be corrected using the following formula:

a + tamb

Rtamb = R25°C _______ a + t25°C

t25°C : reference temperature = 25°Ctamb: temperature during measurement (°C)R25°C: winding resistance at 25°CRamb: winding resistance at tambCoefficient a = 234.5

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

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 090 to 184 incorporates an internal reverse vent valve which will react when the compressor is run in reverse and will allow refrigerant to circulate through a by-pass from the suction to the discharge. Although reverse rotation is not destructive for these models, it should be corrected as soon as possible. Repeated reverse rotation over 24

hours may have negative impact on the bearings. Reverse rotation will be obvious to the user as soon as power is turned on: the compressor will not build up pressure, the sound level will be abnormally high and power consumption will be minimal. If reverse rotation symptoms occur, shut the compressor down and connect the phases to their proper terminals. If reverse rotation is not halted, the compressor will cycle off-on the motor protection.

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Approval and certificates

DSH scroll compressors comply with the following approvals and certificates.

www.commercialcompressors.danfoss.com/documentation/certificates/

Pressure equipment directive

Machines directive2006/42/EC

Low voltage directive

Approval and certificates

Internal free volume

2014/68/EU

2014/35/EU

CE 0062 or CE 0038 or CE0871 (European Directive) All DSH models

UL (Underwriters Laboratories) All DSH models

Other approvals / certificates Contact Danfoss

Products DSH090-105-120-140-161-184

Manufacturer’s declaration of incorporation Contact Danfoss

Products DSH090-105-120-140-161-184

Declaration of conformity Contact Danfoss

ProductsInternal free volume without oil (litre)

Low pressure side High pressure side Total

DSH090 11.7 0.7 12.4DSH105 13.6 0.7 14.3DSH120 13.6 0.7 14.3DSH140 13.6 0.7 14.3DSH161 13.6 0.7 14.3DSH184 13.9 0.7 14.6

Products DSH090-105-120-140-161-184

Refrigerant fluids Group 2Category PED IIEvaluation module D1Service temperature-Ts -35°C < Ts < 55°CService pressure - Ps 33.3 bar(g)Declaration of conformity Contact Danfoss

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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 slopes…). For validation tests see section “Manage oil in the circuit”.

2. Avoid condensed liquid refrigerant from draining back to the compressor when stopped (discharge piping upper loop). For validation tests see section “Manage off cycle migration”.

General recommendations are described in the figures below:

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: “Sound and vibration management”.

HP

4 m/s or more

0.5% slope

To condenser

max. 4 m

max. 4 m

0.5% slope

U-trap, as short as possible

4m/s or more

U trap, as short as possible

Evaporator

LP

8 to 12 m/s

HP

LP

Condenser

3D flexibility

Upper loop

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Tandem requirements

Design piping

DSH tandem use static oil balancing principle to equalize oil level between the compressors by gravity. This is ensured by a precise suction and oil equalization piping design.

The discharge line has no impact on oil balancing and it shown with tees, to indicate that both left and right side discharge headers are possible.

For each tandem configuration, specific outline drawings are available as indicated in the following table.

Suction and oil equalization piping drawings must be respected (diameters, minimum straight lengths, …)

R

Tandem model Composition Suction Discharge Oil equalization Kit tandem Code No

Outline drawing number

DSH182 DSH090 + DSH090 1"3/8 1"3/8 1"1/8 120Z0634 8560092

DSH195 DSH090 + DSH105 1"5/8 1"3/8 1"1/8 120Z0644 8560101

DSH210 DSH090 + DSH120 1"5/8 1"3/8 1"1/8 120Z0645 8560101

DSH212 DSH105 + DSH105 1"5/8 1"3/8 1"1/8 120Z0634 8560093

DSH230 DSH090 + DSH140 1"5/8 1"3/8 1"1/8 120Z0644 8560101

DSH242 DSH120 + DSH120 1"5/8 1"3/8 1"1/8 120Z0634 8560093

DSH251 DSH090 + DSH161 1"5/8 1"3/8 1"1/8 120Z0645 8560101

DSH260 DSH140 + DSH120 1"5/8 1"3/8 1"1/8 120Z0646 8560103

DSH274 DSH090 + DSH184 1"5/8 1"3/8 1"1/8 120Z0660 8556185

DSH281 DSH161 + DSH120 1"5/8 1"3/8 1"1/8 120Z0646 8560103

DSH282 DSH140 + DSH140 1"5/8 1"3/8 1"1/8 120Z0634 8560093

DSH289 DSH105 + DSH184 1"5/8 1"3/8 1"1/8 120Z0659 8560102

DSH301 DSH161 + DSH140 1"5/8 1"3/8 1"1/8 120Z0646 8560103

DSH304 DSH120 + DSH184 1"5/8 1"3/8 1"1/8 120Z0659 8560102

DSH322 DSH161 + DSH161 1"5/8 1"3/8 1"1/8 120Z0634 8560093

DSH324 DSH140 + DSH184 1"5/8 1"3/8 1"1/8 120Z0659 8560102

DSH345 DSH161 + DSH184 1"5/8 1"3/8 1"1/8 120Z0645 8556186

DSH368 DSH184 + DSH184 1"5/8 1"3/8 1"1/8 120Z0634 8560094

Tandem to be achieved by assembly of individual compressors

16 FRCC.PC.045.A3.02

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Suction washer position 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 accessory kits as described in the illustrations.

R

Included in tandem kitNot supplied

Design piping

Compressor1(Cp1)

Compressor1(Cp1)

Right suction Left suction

Compressor2(Cp2)

Compressor2(Cp2)

Cp1 Cp2 Tandem Model Suction From Kit Code No To Order Washer Reference Washer Φ (mm) Washer In Suction

Of

DSH090 + DSH090 DSH182Left

120Z0634 Not neededRight


120Z06445312497P02 Φ24 Cp1

Right 5312639P04 Φ24.5 Cp2


120Z06455312497P05 Φ26 Cp2

Right 5312497P05 Φ26 Cp2


120Z06445312639P05 Φ23 Cp1

Right 5312497P02 Φ24 Cp1






120Z06455312639P01 Φ20 Cp1

Right 5312639P06 Φ22 Cp1


120Z06465312497P04 Φ27 Cp2

Right 5312497P05 Φ26 Cp2


120Z06605312497P07 Φ19 Cp1

Right 5312497P07 Φ19 Cp1


120Z06465312497P01 Φ25 Cp2

Right 5312497P01 Φ25 Cp2




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Design piping

Included in tandem kitSupplied with the compressor

The organ pipe needs to be installed in the direction indicated by the label attached on pipe surface, which will ensure best oil balance.

R

Oil equalization design The oil level is balanced by a pipe of 1"1/8 oil equalization line.

In order ensure best oil balance, the organ pipe need to be mounted inside the compressor at oil equalization port as indicated on below picture. The organ pipe adaptor and teflon gasket are included in the tandem kit.

Tightening torque 100Nm

Cp1 Cp2 Tandem Model Suction From Kit Code No To Order Washer Reference Washer Φ (mm) Washer In Suction

Of


120Z06595312639P02 Φ22 Cp1

Right 5312639P03 Φ23.5 Cp1


120Z06465312497P05 Φ26 Cp2

Right 5312497P05 Φ26 Cp2


120Z06595312639P04 Φ24.5 Cp1

Right 5312639P04 Φ24.5 Cp1




120Z06595312639P04 Φ24.5 Cp1

Right 5312497P01 Φ25 Cp1


120Z06455312497P05 Φ26 Cp1

Right 5312497P05 Φ26 Cp1




18 FRCC.PC.045.A3.02

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Design compressor mounting

General requirements

Single requirements

Tandem requirements

Parallel mounting feet

Compressors used in single applications must be mounted with flexible grommets.

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.

During operation, the maximum inclination from the vertical plane must not exceed 3 degrees.

Compressors DSH090-105-120-140-161-184 come delivered with rubber grommets and metal sleeve liners that serve to isolated the compressor from the base frame.

For parallel mounting, the compressors must be mounted with rigid mounting spacers on rails. Rubber grommets and spacers must be installed below the rails.

The rigid mounting spacers are included in tandem accessory kits. The rubber grommets are supplied with compressor.

For more details about parallel mounting feet, please see parallel unit outline drawing.

The grommets must be compressed until contact between the flat washer and the steel mounting sleeve is established. The required bolt size for the DSH090-105-120-140-161-184 compressors is HM8-40. This bolt must be tightened to a torque of 15 Nm.

15 mm

HM 8 bolt

Lock washer

Flat washer

Steel mountingsleeve

Rubber grommet

Nut

Tightening torque 15 Nm

Included in tandem kitNot supplied

Supplied with the compressor

Not supplied Φ8x75mm

Tightening torque15Nm

4mm thickness

Tightening torque15Nm

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Test N° Purpose Test condition Pass criteria Solutions

1 Check proper oil return

Minimum load: minimum number of compressors running 6 hours.

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 system.2. Integrate a function in control to run all compressors simultaneously in order to boost oil return (for more details see section “Control Logic”)3. Oil separator can be added

2 Check oil balancing

Maximum load: maximum number of compressors running 6 hours

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 requirements.2. Integrate a function in control to stop manifold periodically in order to balance oil (for more details see section “Control Logic”)

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.


1. Pay special attention to “Piping design”2. Oil separator is strongly recommended, espacially in case of part load.

A

Manage oil in the circuit

RRequirement

Evaluate the risk

Test, criteria and solutions


Single compressor Manifold compressors

Non split Test N°1 Test N°1+2

Split Test N°1+2 Test N°1+2+3

A

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Manage sound and vibration

Typical sounds and vibrations in systems can be broken down into the following three categories:• Sound radiation (through air)• Mechanical vibrations (through parts and

structure)

• 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.

Sound levels are as follows:• For compressors running alone:

Compressor model50 Hz 60 Hz

Acoustic hoodcode numberSound power

dB(A)Attenuation

dBA Sound power

dB(A)Attenuation

dBA

DSH090 73 6 76 6 120Z0034

DSH105 75 6 78 6 102Z0035

DSH120 75 6 78 6 120Z0035

DSH140 * 76 6 79 6 120Z0035

DSH161 * 76 6 79 6 120Z0035

DSH184 78 6 81 6 120Z0135

Sound power and attenuation are given at ARI conditions, measured in free space* For DSH140 code 3 and DSH161 code 3 use acoustic hood reference 120Z0135 Attenuation given with acoustic hood only

Tandem model CompositionSound power dB(A)

50Hz 60Hz

DSH182 DSH090 + DSH090 76.0 79.0

DSH195 DSH090 + DSH105 77.1 80.1

DSH210 DSH090 + DSH120 77.1 80.1

DSH212 DSH105 + DSH105 78.0 81.0

DSH230 DSH090 + DSH140 77.8 80.8

DSH242 DSH120 + DSH120 78.0 81.0

DSH251 DSH090 + DSH161 77.8 80.8

DSH260 DSH140 + DSH120 78.5 81.5

DSH274 DSH090 + DSH184 79.2 82.2

DSH281 DSH161 + DSH120 78.5 81.5

DSH282 DSH140 + DSH140 79.0 82.0

DSH289 DSH105 + DSH184 79.8 82.8

DSH301 DSH161 + DSH140 79.0 82.0

DSH304 DSH120 + DSH184 79.8 82.8

DSH322 DSH161 + DSH161 79.0 82.0

DSH324 DSH140 + DSH184 80.1 83.1

DSH345 DSH161 + DSH184 80.1 83.1

DSH368 DSH184 + DSH184 81.0 84.0

Note: During compressor shut down, a short reverse rotation sound is generated. The duration of this sound depends on the pressure difference at shut down and should be less than 3 seconds. This phenomenon has no impact on compressor reliability.

Mitigations methods:We can consider two means to reduce compressors sound radiations:

1. Acoustic hoods are quick and easy to install and do not increase the overall size of the compressors. Acoustic hoods are available from Danfoss as accessories. Refer to the table above for sound levels, attenuation and code numbers.2. Use of sound-insulation materials on the inside of unit panels is also an effective means to reduce radiation.

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Manage sound and vibration

Mechanical vibrations

Gas pulsation

A compressor generates some vibrations that propagate into the surrounding parts and structure. The vibration level of a DSH090 to DSH184 compressor alone does not exceed 120 µm peak to peak. However, when system structure natural frequencies are close to running frequency, vibrations are amplified due to resonance phenomenon.

A high vibration level is damageable for piping reliability and generates high sound levels.

Mitigations methods:1. Danfoss DSH scroll compressors are designed to produce minimal vibration during operations.To ensure minimum vibrations transmission

to the structure, strictly follow mounting requirements (mounting feet, rails etc..). For further information on mounting requirements, please refer to “Design compressor mounting”.

2. Ensure that there is no direct contact (without insulation) between vibrating components and structure.

3. To avoid resonance phenomenon, pipings 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 shape…)

The Danfoss scroll compressor DSH has 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 methods:If an unacceptable level is identified, a discharge muffler with the appropriate resonant volume and mass can be installed.

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Manage operating envelope

RRequirement The operating envelope for DSH scroll compressors is given in the figures below and guarantees reliable operations of the compressor for steady-state and transient operation.

Steady-state operation envelope is valid for a suction superheat within 5K to 30K range.

DSH090 – 184 operating envelope is showed below:

Pressure settings R410A

Working range high side bar(g) 9.9-44.5Working range low side bar(g) 1.7-15.5Maximum high pressure safety switch setting* bar(g) 45Minimum low pressure safety switch setting bar(g) 1.5

Minimum low pressure pump-down switch setting** bar(g) 1.5 bar below nominal evap. pressure with minimum of 1.7 bar(g)

*Maximum allowable pressure on high pressure side according to PED regulation.

Cond

ensi

ng te

mpe

ratu

re (°

C)

Evaporating temperature (°C)

-40 0

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

S.H. = 5 K

S.H. = 30 K

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Manage operating envelope

R Low-pressure (LP) and high-pressure (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 manual reset

Depending on application operating envelope, you must define HP and LP limits within operating envelope and pressure setting table above.

For DSH090-105-120-140-161-184 compressors, the external Discharge Gas Temperature protection (DGT) is required if the high and low pressure switch settings do not protect the compressor against operations beyond its specific application envelope.

The discharge gas thermostat accessory kit (code 7750009) includes all components required for installation as shown on the right. DGT installation must respect below requirements:

• The thermostat must be attached to the discharge line within 150 mm from the compressor discharge port and must be thermally insulated and tightly fixed on the pipe.

• The DGT should be set to open at a discharge gas temperature of 135°C.

Evaluate the risk We consider two types of operating envelope management:

Basic:• HP and LP switch• MOP (Max Operating Pressure) ensured by expansion

device• Condensing pressure control• DGT external

Advanced:• HP and LP sensor• Operating envelope limits integrated into control

logic• DGT external

See “Test, criteria and solutions” No additional test are required

HP switch setting

MO

P +

test

No 3

LP s

witc

h se

ttin

g

Condensing pressure control

DGT

tests No 1 and 2

Discharge line

Insulation

Bracket

Thermostat



1

Check to ensure compressor can operate within safety envelop.

Start test at minimum foreseeable evaporating temperature (minimum

ambient temerature...)

Confirm compressor stabilized working in safety envelope.

Improve MOP function. Work on compressor staging,fan

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 water…)

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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 compression parts.

Requirement

Evaluate the risk

In steady state conditions, • Suction superheat must remain within 5K to 30K• Discharge superheat must be higher than 15K• Oil superheat must be higher than safety operation line, see “dilution chart”.

In transient conditions,• Discharge superheat must be higher than 5K• Oil superheat must be higher than safety

operation line, see “dilution chart”.

Use the tables below in relation with the system charge and the application to quickly evaluate the risk and potential tests to perform.

Discharge temperature sensor must be placed onto the discharge fitting and be insulated.

Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated.

Tests to perform

Non reversible Liquid flood back test

Reversible Liquid flood back test Defrost test

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Manage superheat



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 stay in safety area, see “dilution chart”.Steady-state discharge superheat>15K

1. Check expansion valve selection and setting.2. Add a suction accumulator*.

Transient

Tests must be carried out with most unfavorable conditions :• fan staging, • compressor staging• …

Oil superheat stay in safety area, see “dilution chart”.Transient discharge superheat >5K

1. Check expansion valve selection and setting. -For Thermostatic expansion valve (TXV) check bulb position...-For Electronic expansion valve (EXV) check measurement chain and PID....2. Add a suction accumulator*.

Defrost testCheck liquid floodback during defrost cycle

Defrost test must be carried out in the most unfavorable condition (at 0°C evaporating temperature).

Oil superheat stay in safety area, see “dilution chart”.Transient discharge superheat >5K

In reversible systems, the defrost logic can be worked out to limit liquid floodback effect. (for more details see “Control Logic”).

*Suction accumulator offers protection by trapping the liquid refrigerant upstream from the compressor. The accumulator should be sized at least 50 % of the total system charge. Suction accumulator dimensions can impact oil return (gas velocity, oil return hole size…), therefore oil return has to be checked according to section “Manage oil in the circuit”.

A

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Manage off cycle migration

R

Requirement

Evaluate the risk

Off -cycle refrigerant migration happens: • when the compressor is located at the coldest part of the installation, refrigerant vapor condenses in the compressor.• or directly in liquid-phase by gravity.

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 compression parts.

Amount of liquid refrigerant in the compressors must not overpass the charge limit at start-up.

Use the table below in relation with the system charge (refer to charge limit table in below) and the application to quickly define necessary

safeties to implement and test to perform:

BELOW charge limit ABOVE charge limit

Non split No test or additional safeties required• Surface Sump Heater *• Migration test• External Non-Return Valve

Split

Since each installation is unique, no test can fully evaluate off-cycle migration, therefore the following safeties are required:• Surface Sump Heater *• Liquid Line Solenoid Valve**+ pump-down cycle***• External Non-Return Valve

Models Composition Refrigerant charge limit (kg)

Single

DSH090 5.9DSH105 7.9DSH120 7.9DSH140 7.9DSH161 7.9DSH184 7.9

Tandem

DSH182 DSH090 + DSH090 8.0DSH195 DSH090 + DSH105 8.5DSH210 DSH090 + DSH120 8.5DSH212 DSH105 + DSH105 10.5DSH230 DSH090 + DSH140 8.5DSH242 DSH120 + DSH120 10.5DSH251 DSH090 + DSH161 8.5DSH260 DSH140 + DSH120 10.5DSH274 DSH090 + DSH184 8.5DSH281 DSH161 + DSH120 10.5DSH282 DSH140 + DSH140 10.5DSH289 DSH105 + DSH184 10.5DSH301 DSH161 + DSH140 10.5DSH304 DSH120 + DSH184 10.5DSH322 DSH161 + DSH161 10.5DSH324 DSH140 + DSH184 10.5DSH345 DSH161 + DSH184 10.5DSH368 DSH184 + DSH184 10.5

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Migration test

Check that there is no migration of refrigerant into the compressor (either liquid or vapour condensating)

Energize SSH*.Stabilize unit ambient temperature at 5°C then increase ambient up to 20°C in a few minutes. When saturated condensing temperature reaches 20°C then start the unit and monitor oil sump temperature.Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated.

When all compressors are idle:• Check in liquid line sight glass that there is no liquid refrigerant transfer• Oil superheat must be >10K during off-cycle

After compressors has started:• Oil superheat must stay in safety area, see “dilution chart”

1. Check bulb position, tightness of expansion device, 2. add LLSV** 3. add pump down cycle***

*Surface Sump heater The surface sump heaters are designed to protect the compressor against off-cycle migration of refrigerant. Additional heater power or thermal insulation might be needed in case of ambient temperature below -5°C and a wind speed above 5m/second. The heater must be turned on whenever all the compressors are off.Surface sump heater accessories are available from Danfoss (see section “Accessories”).

**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:• evacuates refrigerant from oil• set the sump saturating pressure much lower than ambiance temperature and due to that, avoid refrigerant condensation in the compressor.Pump-down must be set higher than 1.7 bar(g).

For more details on pump-down cycle see section “Control Logic”.

Oil temperature sensor must be placed between oil sight glass and compressor baseplate and be insulated.

Manage off cycle migration

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Provide power supply and electrical protection

Requirements:• An additional external overload protection is

still advisable for either alarm or manual reset. For overload setting, take the max current you can face on the application and add 10%. Setting must always be lower than Max Operating Current (see table “Three phase electrical characteristics” from the section “Electrical data, connections and wiring”)

• HP safety switch and DGT must be wired in the safety chain. Other safety devices such as LP can be either hardware or software managed.

• Provide separate electrical supply for the heaters so that they remain energized even when the machine is out of service (e.g. seasonal shutdown).

The wiring diagrams below are examples for a safe and reliable compressor wiring:

Compressor model DSH 090 - 105 - 120 - 140 - 161 - 184

Wiring information

Fuses .............................................................................................................F1Compressor contactor ............................................................................ KMControl relay ..............................................................................................KASafety lock out relay ..................................................................................KSOptional short cycle timer (3 min) ...................................................180 sHigh pressure safety switch....................................................................HPControl device ............................................................................................TH

Liquid Line Solenoid valve .................................................................. LLSVDischarge gas thermostat ...................................................................DGTFused disconnect ......................................................................................Q1Compressor motor .................................................................................... MMotor Protection Module .................................................................. MPMThermistor chain..........................................................................................SSafety pressure switch ........................................................................... LPS

Legends

MDGT

HP

LPS

180 s

THLP

CONTROL CIRCUIT

F1F1

KM

KM

KM

KA KA

A1

A2

A3

KA

KA

KS

KS

KS

L1 L3 L2

Q1

T1

T3

T2

LLSV KS

Wiring diagram with pump-down cycle

KM

L1 L3 L2

Q1

CONTROL CIRCUIT

F1F1

KM KA

KA KS

KS

KS

HP

DGT

TH

180 s

85 52 019 - A

T1 T2

M

T3

KA KA

A1

A2

A3

Wiring diagram without pump-down cycle

LPS

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Soft starts 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 0.5 seconds to ensure proper lubrication of compressor parts.

Ramp-down must be set to minimum to ensure proper discharge valve closing.Danfoss 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 start referenceAmbient max. 40°C

Soft start referenceAmbient max. 55°C

DSH090 code 4 MCI15C MCI15CDSH105-120 code 4 MCI25C MCI25C

DSH140-161-184 code 4 MCI25C MCI25C*

• MCI15C, MCI25C replaces the contactor KM . All settings such as initial torque, ramp-up time (less than 0.5 sec) and ramp-down time are preset and do not require any modification.

See wiring diagram:

• MCI25M* 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 0.5 sec) and ramp-down time are preset and do not require any modification.

See wiring diagram:

Q1

Provide power supply and electrical protection

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Control logic

Safety control logic requirements

Tripping conditions Re-start conditions

Value Time Value Time

HP switchSee Pressure settings table

from section “Manage operating envelope”

Immediate, no delay.No by- pass

Conditions back to normal.Switch closed again

Manual reset

LP safety switchMaximum 5 auto reset during

a period of 12 hours, then manual reset.

Cycle rate limit requirements

Defrost logic recommendations

Danfoss requires a minimum compressor running time of 2 minutes to ensure proper oil return and sufficient motor cooling.Additionally, compressor service life is based on a maximum of 12 starts per hour.

Therefore, to guarantee these 2 requirements, a three-minute (180- sec) time out is recommended.

In reversible systems, the defrost logic can be worked out to limit liquid flood back effect by:1. Running full load during defrost to share liquid refrigerant between all compressors.

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 p

ress

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 fr

om

indoor t

o outd

oor exc

hanger

than

ks

to p

ress

ure d

iffer

ence

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 “Manage superheat” and “Manage operating envelope”.

Compressor 1

Compressor 2

4WV

EXV

ON

ON

Heating

100%

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Control logic

Pump-down 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 reached the cut-out pressure, compressor is stopped, and liquid solenoid valve or electronic expansion valve remains closed.Two types of pump-down exist:

• One shot pump down (preferred): when last compressor of the circuit stops, suction presssure is decreased 1.5 bar below nominal evaporating pressure. Even if suction pressure increases again, the compressor will not restart.

• Continuous pump-down: traditional pump-dow, Compressor restarts automatically when suction pressure increases up to 4 cycles maximum. A non-return valve in the discharge line is recommended.

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Reduce moisture in the system

Excessive air and moisture • can increase condensing pressure and cause

excessively high discharge temperatures.• can create acid giving rise to copper platting.• can destroy the lubricating properties of the oil.

All these phenomena can reduce service life and cause mechanical and electrical compressor failure.

Requirements

Solutions

DSH compressors are delivered with < 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’s include:• driers water content capacity,• system refrigeration capacity, • 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.

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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 0.3 and 0.7 bar and is sealed with elastomer plugs.

Respect the following sequence:• Remove the nitrogen holding charge via the suction Schrader valve to avoid an oil mist blow out.

• Remove the suction plug first and the discharge plug afterwards to avoid discharge check valve gets stuck in open position.An opened compressor must not be exposed to air for more than 20 minutes to avoid moisture is captured by the POE oil.

Each Danfoss DSH scroll compressor is equipped with two lift rings on the top shell.• Always use both these rings when lifting the

compressor. • Use lifting equipment rated and certified for

the weight of the compressor or compressor assembly.

• A spreader bar rated for the weight of the compressor is highly recommended to ensure a better load distribution.

• The use of lifting hooks closed with a clasp is recommended.

• For tandem and trio assemblies, use a spreader bar and all compressor rings as shown in picture below.

• Never use the lift rings on the compressor to lift the full unit.

Maintain the compressor in an upright position during all handling manoeuvres (maximum of 15° from vertical).

Store the compressor not exposed to rain, corrosive or flammable atmosphere between -35°C and 70°C when charged with nitrogen and

between -35°C and 55°C when charged with R410A refrigerant.

Spreader bar

HEAVY

do not liftmanually

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Piping assembly Good practices for piping assembly is a pre-requisite to ensure compressor service life (system cleanliness, brazing procedure...)

System cleanliness

Circuit contamination possible cause: Requirement:

Brazing and welding oxides During brazing, flow nitrogen through the system

Filings and particles from the removal of burrs in pipe-work

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 POE oil.

Brazing procedure:• Brazing operations must be performed by

qualified personnel.• Make sure that no electrical wiring is connected

to the compressor.• To prevent compressor shell and electrical box

overheating, use a heat shield and/or a heat-absorbent compound.

• Clean up connections with degreasing agent• Flow nitrogen through the compressor.• Use flux in paste or flux coated brazing rod.

• Use brazing rod with a minimum of 5% silver content.

• It is recommended to use double-tipped torch using acetylene to ensure a uniform heating of connection.

• For discharge connections brazing time should be less than 2 minutes to avoid compressor internal non-return valve (NRVI) damages if any.

• 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 (<3g/year) at the factory. For system tests:• Always use an inert gas such as Nitrogen or

Helium.

• Pressurize the system on HP side first then LP side.

• Do not exceed the following pressures:

Maximum compressor test pressures

Maximum compressor test pressure high side (HP) 48.7 bar (g) HP-LP<37bar

Maximum compressor test pressure low side (LP)33.3 bar (g)LP-HP<5barMaximum speed 4,8 bar/ second*

* On DSH 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

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Vacuum evacuation and moisture removal

Refrigerant charging

Dielectric strength and insulation resistance tests

Requirements: • Never use the compressor to evacuate the

system. • Connect a vacuum pump to both the LP and HP

sides. • Evacuate the system to a pressure of 500 μm Hg

(0.67 mbar) absolute.

Recommendations:• Energized heaters improve moisture removal.• Alternate vacuum phases and break vacuum.

with Nitrogen to improve moisture removal.

For more detailed information see “Vacuum pump-down and dehydration procedure” TI-026-0302.

Initial charge:• For the initial charge, the compressor must not

run.• Charge refrigerant as close as possible to the

nominal system charge.• This initial charging operation must be done in

liquid phase between the condenser outlet and the filter drier.

If needed, a complement of charge can be done:• In liquid phase while compressor is running by

slowly throttling liquid in. • On the low pressure side, as far away as possible

from the compressor suction connection.• Never bypass safety low pressure switch.

For more detailed information see “Recommended refrigerant system charging practice“ FRCC.EN.050.

The tests are performed on each compressor at the factory between each phase and ground.

• Dielectric strength test is done with a high potential voltage (hi-pot) of 2Un +1000V AC at least, and leakage current must be less than 5 mA. Additional tests of this type are not recommended as it may reduce motor lifetime. Nevertheless, if such a test is necessary, it must be performed at a lower voltage.

• Insulation resistance is measured with a 500 V DC megohm tester and must be higher than 1 megohm.

• The presence of refrigerant around the motor windings will result in lower resistance values to ground and higher leakage current readings. Such readings do not indicate a faulty compressor. To prevent this, the system can be first operated briefly to distribute refrigerant.

Do not use a megohm meter nor apply power to the compressor while it is under vacuum as this may cause internal damage.

R

R

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Commissioning

Preliminary checkCheck electrical power supply:

• Phase order: Reverse rotation is obvious if the compressor do not build up pressure and sound level is abnormal high. For DSH090-184 compressors equipped with internal reverse vent valve which can protect compressor

without damage within duration below 24h. For more details refer to section “Phase sequence and reverse rotation protection”.

• Voltage and voltage unbalance within tolerance: For more details refer to section “Motor voltage”.

Initial start-up

System monitoring

• Surface sump heaters must be energized at least 6 hours in advance to remove refrigerant.

• A quicker start-up is possible by “jogging” 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: • Correct superheat and subcooling.• Current draw of individual compressors within

acceptable values (max operating current).• No abnormal vibrations and noise.• 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 “Lubricants filling in instructions for Danfoss Commercial Compressors” TI 2-025-0402.

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Packaging

Single pack

Industrial pack

Compressor model Length(mm)

Width(mm)

Height(mm)

Gross weight

(kg)

DSH090 565 470 718 69

DSH105 565 470 718 76

DSH120 565 470 718 76

DSH140 565 470 718 79

DSH161 565 470 718 81

DSH184 565 470 718 84

Compressor model Nbr* Length (mm)

Width (mm)

Height (mm)

Gross weight

(kg)

Static stacking pallets

DSH090 8 1150 950 680 494 2

DSH105 8 1150 950 750 544 2

DSH120 8 1150 950 750 544 2

DSH140 8 1150 950 750 566 2

DSH161 8 1150 950 750 582 2

DSH184 8 1150 950 750 606 2

* nbr: number of compressors per pack

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Ordering codes

Single pack

Danfoss scroll compressors DSH can be ordered in either industrial packs or in single packs. Please

use the code numbers from below tables for ordering.

Compressor code numbers

Compressor model Connections Mounting

feetMotor

protection

Code no.3 4 7 9

200-230/3/60 380-415/3/50460/3/60 575/3/60 380-400/3/60

DSH090 Brazed Flexible Internal 120H1180 120H1182 120H1184 120H1186






Compressor model Connections Mounting

feetMotor

protection

Code no.3 4 7 9

200-230/3/60 380-415/3/50460/3/60 575/3/60 380-400/3/60







Industrial pack

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Ordering codes

Tandem Model Cp1 Cp2 Suction From Kit Code No To Order

DSH182 DSH090+DSH090Left

120Z0634Right


120Z0644Right


120Z0645Right


120Z0634Right


120Z0644Right


120Z0634Right


120Z0645Right


120Z0646Right


120Z0660Right


120Z0646Right


120Z0634Right


120Z0659Right


120Z0646Right


120Z0659Right


120Z0634Right


120Z0659Right


120Z0645Right


120Z0634Right

Tandem code number To build a complete tandem, you must order the 2 compressors and the Tandem kit code below:

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Accessories

Solder sleeve

Solder sleeve adapter set

Rotolock adapter

Gaskets

Code n° Description Application Packaging Pack size

120Z0125 Rotolock adaptor set (1"3/4 ~ 1"1/8) , (1"1/4 ~ 7/8") DSH090 Multipack 8

120Z0405 Rotolock adaptor set (1"3/4 ~ 1"3/8) , (1"1/4 ~ 7/8") DSH105 to 184 Multipack 8


120Z0367 Adaptor (1"1/4 Rotolock - 7/8" ODS) Models with 7/8" ODF Multipack 10

120Z0364 Adaptor (1"3/4 Rotolock - 1"1/8 ODS) Models with 1"1/8 ODF Multipack 10

120Z0431 Adaptor (1"3/4 Rotolock - 1"3/8 ODS) Models with 1"3/8 ODF Multipack 10


8156131 Gasket, 1"1/4 Models with 1"1/4 rotolock connection Multipack 10

7956002 Gasket, 1"1/4 Models with 1"1/4 rotolock connection Industry pack 50

8156132 Gasket, 1"3/4 Models with 1"3/4 rotolock connection Multipack 10

7956003 Gasket, 1"3/4 Models with 1"3/4 rotolock connection Industry pack 50


8153004 Solder sleeve P02 (1"3/4 Rotolock - 1"1/8 ODF) Models with 1"3/4 rotolock connection Multipack 10

8153008 Solder sleeve P04 (1"1/4 Rotolock - 3/4" ODF) Models with 1"1/4 rotolock connection Multipack 10

8153012 Rotolock connector P05 (1"1/4 Rotolock - 7/8" ODF) Models with 1"1/4 rotolock connection Multipack 10

8153013 Solder sleeve P07 (1"3/4 Rotolock - 7/8" ODF) Models with 1"3/4 rotolock connection Multipack 10

8153003 Solder sleeve P10 (1"3/4 Rotolock - 1"3/8 ODF) Models with 1"3/4 rotolock connection Multipack 10

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Rotolock nut

Accessories

Rotolock service valve set

3-phase soft start equipment


8153123 Rotolock nut,1"1/4 Models with 1-1/4" rotolock connection Multipack 10

8153124 Rotolock nut,1"3/4 Models with 1-3/4" rotolock connection Multipack 10


7703008 Valve set, V02 (1"3/4 ~ 1"1/8), V05 (1"1/4 ~ 7/8") DSH090 Multipack 6

7703392 Valve set, V10 (1"3/4 ~1"3/8), V05 (1"1/4 ~ 7/8") DSH105 to 184 Multipack 6

* diameter restriction

Type Code n° Description Application Packaging Pack size

MCI 15 C 7705006 Electronic soft start kit, MCI 15 C DSH090 Single pack 1

MCI 25 C 7705007 Electronic soft start kit, MCI 25 C DSH105 to 184 Single pack 1

Surface sump heaters

Code no. Accessory description Application Packaging Pack size

120Z0388 80W 24V surface sump heater CE and UL

DSH090 to 184

Multipack 8

120Z0389 80W 230V surface sump heater CE and UL Multipack 8




Discharge temperature protection

Type Code No Description Application Packaging Pack Size

7750009 Discharge thermostat kit DSH090 to 184 Multipack 10

7973008 Discharge thermostat kit DSH090 to 184 Industry pack 50

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Accessories

Acoustic hoods

Lubricant

Miscellaneous

Code No Description Packaging Pack Size

7754023 POE lubricant, 1 litre can Single pack 1

Code No Description Packaging Pack Size

8156019 Sight glass with gaskets (black & white) Multipack 4

8156129 Gasket for oil sight glass, 1"1/8 (white teflon) Multipack 10

8154001 Danfoss Commercial Compressors blue spray paint Single pack 1

Mounting hardware


120Z0066Mounting kit for scroll compressors. Grommets, sleeves, bolts, washers

DSH090 to 184 Single pack 1


120Z0034 Acoustic hood for scroll compressor DSH090 Single pack 1

120Z0035 Acoustic hood for scroll compressor DSH105 to 161 (except DSH161-140 code3) Single pack 1

120Z0135 Acoustic hood for scroll compressor DSH184 - DSH140 code3 - DSH161 code3 Single pack 1

Terminal boxes, covers and T-block connectors


120Z0413 Terminal box cover DSH184 - DSH140 code3 - DSH161 code3 Single pack 1

8156135 Service kit for terminal box 96 x 115 mm, including 1 cover, 1 clamp

DSH090 to 161 (except DSH140 code3 and DSH161 code3) Multipack 10

8173230 T block connector 52 x 57 mm DSH090 to 161 (except DSH140 code3 and DSH161 code3) Multipack 10

8173021 T block connector 60 x 75 mm DSH184 - DSH140 code3 - DSH161 code3 Multipack 10

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Accessories

Tandem kits including

Code No Description Application Packaging Pack Size

120Z0634 Organ pipe assembly, rigid spacer, gasket DSH182-212-242-282-322-368 Single 1

120Z0644 Organ pipe assembly, rigid spacer, gasket DSH195-230 Single 1

120Z0645 Organ pipe assembly, rigid spacer, gasket DSH210-251-345 Single 1

120z0646 Organ pipe assembly, rigid spacer, gasket DSH260-281-301 Single 1

120Z0659 Organ pipe assembly, rigid spacer, gasket DSH289-304-324 Single 1

120Z0660 Organ pipe assembly, rigid spacer, gasket DSH274 Single 1

44 FRCC.PC.045.A3.02

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.

FRCC.PC.045.A3.02 © Danfoss | DCS (CC) | 2016.08

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.

http://cc.danfoss.com

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