Application guidelines - Danfossfiles.danfoss.com/technicalinfo/dila/17/FRCC.PC.037.A3.02-DSH... ·...

48
Danfoss scroll compressors DSH 240-485 50 Hz - 60 Hz - R410A Application guidelines http://cc.danfoss.com

Transcript of Application guidelines - Danfossfiles.danfoss.com/technicalinfo/dila/17/FRCC.PC.037.A3.02-DSH... ·...

Page 1: 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

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

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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

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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

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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

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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

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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

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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

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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

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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

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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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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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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

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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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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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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

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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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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

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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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SYST

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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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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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NO

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N IN

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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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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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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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OD

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INFO

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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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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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ON

INTO

SYS

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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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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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ON

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G IN

FORM

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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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ON

INTO

SYS

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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

Page 2: 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

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

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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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RMAT

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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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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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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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INFO

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

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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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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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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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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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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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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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YSTE

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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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NO

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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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ION

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NO

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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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INFO

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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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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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NIN

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ON

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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

Page 3: 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

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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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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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

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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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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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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

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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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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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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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

Page 4: 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

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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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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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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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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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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

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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

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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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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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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

Page 5: 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

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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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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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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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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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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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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

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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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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

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

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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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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

Page 6: 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

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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

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H

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H

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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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PRO

DU

CT IN

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ATIO

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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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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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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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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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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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

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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

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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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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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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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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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N IN

TO S

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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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

NIN

TEG

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ON

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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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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NIN

TEG

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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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ON

INTO

SYS

TEM

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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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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

Page 7: 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

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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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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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INFO

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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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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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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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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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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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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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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

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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

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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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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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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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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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INFO

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ESIG

NIN

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ON

INTO

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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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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

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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

Page 8: 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

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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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ATIO

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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ATIO

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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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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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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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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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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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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INFO

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

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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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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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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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

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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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

Page 9: 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

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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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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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SYST

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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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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

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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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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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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

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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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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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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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SYST

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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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SYST

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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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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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ATIO

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NO

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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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ATIO

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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

OD

UCT

INFO

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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

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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ON

INTO

SYS

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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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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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ON

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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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NPR

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ON

INTO

SYS

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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

Page 10: 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

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PRO

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CT IN

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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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ATIO

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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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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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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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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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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INFO

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ION

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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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ION

SYST

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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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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

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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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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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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

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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

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

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

Page 11: 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

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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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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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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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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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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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SYST

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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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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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INFO

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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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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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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INFO

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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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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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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

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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

Page 12: 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

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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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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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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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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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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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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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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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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

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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

RDER

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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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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

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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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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

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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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ESIG

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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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SYS

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ERIN

G IN

FORM

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

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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

Page 13: 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

GEN

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PRO

DU

CT IN

FORM

ATIO

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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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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SYST

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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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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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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

GEN

ERA

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FORM

ATIO

NPR

OD

UCT

INFO

RMAT

ION

INTE

GRA

TIO

N IN

TO S

YSTE

MO

RDER

ING

INFO

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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ION

SYST

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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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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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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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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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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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N IN

TO S

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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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

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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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ON

INTO

SYS

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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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TEG

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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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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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INTO

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G IN

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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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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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INTO

SYS

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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

Page 14: 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

GEN

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CT IN

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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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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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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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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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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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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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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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INFO

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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ATIO

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SYST

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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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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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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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TO S

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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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

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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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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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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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NIN

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ON

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SYS

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G IN

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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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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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NIN

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ON

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SYS

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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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NIN

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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

Page 15: 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

GEN

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SYST

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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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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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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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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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ION

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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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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

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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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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

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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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SYST

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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

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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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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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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ING

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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

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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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

Page 16: 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

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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

+

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+

+

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=

=

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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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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ION

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N IN

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INFO

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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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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

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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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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

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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

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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

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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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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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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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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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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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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

Page 17: 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

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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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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

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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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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

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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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RMAT

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SYST

EM D

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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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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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NO

RDER

ING

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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

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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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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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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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

Page 18: 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

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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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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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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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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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TO S

YSTE

MO

RDER

ING

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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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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MO

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INFO

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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ATIO

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ION

SYST

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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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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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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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N IN

TO S

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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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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ON

INTO

SYS

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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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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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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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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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ON

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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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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

Page 19: 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

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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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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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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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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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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ION

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YSTE

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ING

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

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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INTE

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N IN

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YSTE

MO

RDER

ING

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

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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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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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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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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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TO S

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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INTE

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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

NIN

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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ON

INTO

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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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TEG

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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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INTO

SYS

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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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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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OD

UCT

INFO

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ION

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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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NIN

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ON

INTO

SYS

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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

Page 20: 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

GEN

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INFO

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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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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

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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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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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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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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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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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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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SYST

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NO

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INFO

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INTE

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TIO

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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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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ESIG

NO

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N IN

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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

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ATIO

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INFO

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ION

SYST

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NO

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INFO

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INTE

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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

OD

UCT

INFO

RMAT

ION

SYST

EM D

ESIG

NO

RDER

ING

INFO

RMAT

ION

INTE

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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

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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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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

ION

SYST

EM D

ESIG

NIN

TEG

RATI

ON

INTO

SYS

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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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ON

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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

Page 21: 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

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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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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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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

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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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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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SYST

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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

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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

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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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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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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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

Page 22: 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

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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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ION

SYST

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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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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

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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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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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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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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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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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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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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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TEG

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ON

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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ERIN

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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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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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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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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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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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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

Page 23: 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

GEN

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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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SYST

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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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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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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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ATIO

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INTE

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INFO

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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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

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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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ION

SYST

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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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ATIO

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ESIG

NO

RDER

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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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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

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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

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NIN

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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

Page 24: 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

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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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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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NPR

OD

UCT

INFO

RMAT

ION

INTE

GRA

TIO

N IN

TO S

YSTE

MO

RDER

ING

INFO

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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ATIO

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OD

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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

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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INTE

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N IN

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YSTE

MO

RDER

ING

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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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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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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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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ING

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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

NIN

TEG

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ON

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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ON

INTO

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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

NPR

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ESIG

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TEG

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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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NIN

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ON

INTO

SYS

TEM

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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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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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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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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

Page 25: 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

GEN

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INFO

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ION

SYST

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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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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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ION

SYST

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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

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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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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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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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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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ATIO

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INFO

RMAT

ION

SYST

EM D

ESIG

NO

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INFO

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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

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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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NPR

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SYST

EM D

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NIN

TEG

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INTO

SYS

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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

NPR

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RMAT

ION

SYST

EM D

ESIG

NIN

TEG

RATI

ON

INTO

SYS

TEM

ORD

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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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NPR

OD

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SYST

EM D

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NIN

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ON

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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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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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RMAT

ION

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EM D

ESIG

NIN

TEG

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ON

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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

Page 26: 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

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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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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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SYST

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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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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

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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SYST

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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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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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NO

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INFO

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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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ATIO

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NO

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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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INFO

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ION

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NO

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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

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

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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NIN

TEG

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ON

INTO

SYS

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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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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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ON

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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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ON

INTO

SYS

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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

Page 27: 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

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INFO

RMAT

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SYST

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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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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

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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

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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TO S

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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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

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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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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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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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ON

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SYS

TEM

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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

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OD

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NIN

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ON

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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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ON

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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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ON

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SYS

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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

Page 28: 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

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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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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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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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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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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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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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ESIG

NIN

TEG

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ON

INTO

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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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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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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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ATIO

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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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SYST

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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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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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ON

INTO

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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

Page 29: 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

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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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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

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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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SYST

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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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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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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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NO

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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

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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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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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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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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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ATIO

NPR

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INFO

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ION

SYST

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ESIG

NIN

TEG

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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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SYST

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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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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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NIN

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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

Page 30: 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

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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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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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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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ERA

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ATIO

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ION

SYST

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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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ERA

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ATIO

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INFO

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ION

SYST

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ESIG

NO

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INFO

RMAT

ION

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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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NO

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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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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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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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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

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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INFO

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SYST

EM D

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NIN

TEG

RATI

ON

INTO

SYS

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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

NPR

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ION

SYST

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ESIG

NIN

TEG

RATI

ON

INTO

SYS

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ORD

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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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NPR

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SYST

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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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SYS

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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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NIN

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ON

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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

Page 31: 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

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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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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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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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ERA

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INFO

RMAT

ION

SYST

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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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ERA

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ATIO

NPR

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UCT

INFO

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ION

SYST

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ESIG

NO

RDER

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INFO

RMAT

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INTE

GRA

TIO

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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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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NO

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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

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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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INTO

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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

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

OD

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INFO

RMAT

ION

SYST

EM D

ESIG

NIN

TEG

RATI

ON

INTO

SYS

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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

NPR

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NIN

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ON

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SYS

TEM

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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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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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ON

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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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ON

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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

Page 32: 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

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INFO

RMAT

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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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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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ERA

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MO

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INFO

RMAT

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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ERA

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ATIO

NPR

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UCT

INFO

RMAT

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

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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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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INTO

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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

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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INFO

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ION

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EM D

ESIG

NIN

TEG

RATI

ON

INTO

SYS

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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

NPR

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UCT

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NIN

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ON

INTO

SYS

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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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OD

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RMAT

ION

SYST

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NIN

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ON

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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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ON

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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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NIN

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ON

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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

Page 33: 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

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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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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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RMAT

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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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ATIO

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UCT

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ION

SYST

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RMAT

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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

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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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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

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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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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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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

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NIN

TEG

RATI

ON

INTO

SYS

TEM

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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

NPR

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RMAT

ION

SYST

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NIN

TEG

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ON

INTO

SYS

TEM

ORD

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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

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RMAT

ION

SYST

EM D

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NIN

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RATI

ON

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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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NIN

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ON

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SYS

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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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NPR

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RMAT

ION

SYST

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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

Page 34: 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

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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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ATIO

NPR

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UCT

INFO

RMAT

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SYST

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INFO

RMAT

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INTE

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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

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ERA

L IN

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ATIO

NPR

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UCT

INFO

RMAT

ION

SYST

EM D

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NO

RDER

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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

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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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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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NIN

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SYS

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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

NPR

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RMAT

ION

SYST

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NIN

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ON

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SYS

TEM

ORD

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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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OD

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SYST

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NIN

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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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SYS

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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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FORM

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

Page 35: 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

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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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ERA

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ATIO

NPR

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UCT

INFO

RMAT

ION

SYST

EM D

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NO

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RMAT

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INTE

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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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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

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

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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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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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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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

Page 36: 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

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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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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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NPR

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RMAT

ION

SYST

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ESIG

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RATI

ON

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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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NPR

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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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G IN

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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

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NIN

TEG

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ON

INTO

SYS

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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

Page 37: 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

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NO

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RMAT

ION

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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

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NO

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INFO

RMAT

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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

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FORM

ATIO

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OD

UCT

INFO

RMAT

ION

SYST

EM D

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NO

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INFO

RMAT

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INTE

GRA

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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

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INFO

RMAT

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EM D

ESIG

NIN

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

GEN

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

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

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

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

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

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

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

Page 38: 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

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

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ERA

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FORM

ATIO

NPR

OD

UCT

INFO

RMAT

ION

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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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

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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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

Page 39: 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

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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

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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

Page 40: 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

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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

+

+

+

+

+

+

+

+

+

+

+

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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

Page 41: 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

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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

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

+

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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

Page 42: 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

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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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=

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

Page 43: 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

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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

Page 44: 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

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INTO

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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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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

GEN

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L IN

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ATIO

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ESIG

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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

Page 45: 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

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

Page 46: 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

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

Page 47: 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

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