Maneurop® Reciprocating Compressors MT/MTZ: Application Guidelines
Maneurop® Reciprocating Compressors MT/MTZ: Application Guidelines
Maneurop® reciprocating
compressors MT/MTZ
50 - 60 Hz
Group 2: R22, R417A, R407A/C/F, R134a, R404A / R507, R448A / R449A, R452A, R513A
Group 1: R454C
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Application Guidelines Content
AB196386425654en-011401 3
Application Guidelines General Information
4 AB196386425654en-011401
Application Guidelines Maneurop® reciprocating compressors
Maneurop® reciprocating compressors from MT and MTZ compressors have a large internal
Danfoss Commercial Compressors are specially free volume that protects against the risk of
designed for applications with a wide range of liquid hammering when liquid refrigerant enters
operating conditions. All components are of high the compressor.
quality and precision in order to assure a long
product life. MT and MTZ compressors are fully suction-
gas cooled. This means that no additional
Maneurop® MT and MTZ series compressors compressor cooling is required and allows
are of the hermetic reciprocating type and are the compressors to be insulated with acoustic
designed for medium and high evaporating jackets, to obtain lower sound levels, without the
temperature applications. risk of compressor overheating.
The positive benefits of internal motor MT and MTZ compressors are available in 16
protection, high efficiency circular valve design different models with displacement ranging from
and high torque motors provide for a quality 30 to 271 cm3/rev. Seven different motor voltage
installation. ranges are available for single and three phase
power supplies at 50 and 60 Hz. All compressors
MT & MTZ have the same mechanical and motor are available in VE version (oil equalisation + oil
design. sight glass).
AB196386425654en-011401 5
Application Guidelines Compressor model designation
Code numbers
(for ordering)
Packaging type
Compressor type I : single pack
M : industrial pack
(see ordering section)
Polyolester oil
Oil equalisation port
and threaded sight glass
Available code numbers are listed section “Ordering information and packaging”
Compressor reference
(indicated on the com-
pressor nameplate) D
Compressor
type
Oil equalisation port
and sight glass
Polyolester oil
Generation index
6 AB196386425654en-011401
Application Guidelines Specifications
Technical specifications
Displacement Oil Net Available motor voltage codes
Compressor Cyl. charge weight
model m3/h at number
Code cm /rev
3
dm3 kg 1 3 4 5 6 7 9
2900 rpm
MT/MTZ018 JA 30.23 5.26 1 0.95 21 ● ● ● ● - - -
MT/MTZ022 JC 38.12 6.63 1 0.95 21 ● ● ● ● ● - ●
MT/MTZ028 JE 48.06 8.36 1 0.95 23 ● ● ● ● ● - ○
MT/MTZ032 JF 53.86 9.37 1 0.95 24 ● ● ● ● ● ○ ●
MT/MTZ036 JG 60.47 10.52 1 0.95 24 ● ● ● ● ● ○ ○
MT/MTZ040 JH 67.89 11.81 1 0.95 24 ● ● ● - ● - -
MT/MTZ044 HJ 76.22 13.26 2 1.8 35 ○ ● ● - ○ ○ ●
MT/MTZ050 HK 85.64 14.90 2 1.8 35 ● ● ● - ● ○ ●
MT/MTZ056 HL 96.13 16.73 2 1.8 37 ● ● ● - ● ● ●
MT/MTZ064 HM 107.71 18.74 2 1.8 37 ● ● ● - ● - ●
MT/MTZ072 HN 120.94 21.04 2 1.8 40 - ● ● - ○ - ●
MT/MTZ080 HP 135.78 23.63 2 1.8 40 - ● ● - ● - ●
MT/MTZ100 HS 171.26 29.80 4 3.9 60 - ● ● - ● ● ●
MT/MTZ125 HU 215.44 37.49 4 3.9 64 - ● ● - ● ● ●
MT/MTZ144 HV 241.87 42.09 4 3.9 67 - ● ● - ● ● ●
MT/MTZ160 HW 271.55 47.25 4 3.9 67 - ● ● - ● ● ●
● Available in MT and MTZ ○ Available in MTZ only
Approvals and certificates Maneurop® MT/MTZ compressors comply with Other certificates/approvals please contact
the following approvals and certificates. Danfoss
UL
All 60 Hz models
(Underwriters Laboratories)
CCC
All models code 4 and 5 under CCC scope.
(China Compulsory Product Certification)
Pressure equipment di- Products MT/MTZ 018 to 040 MT/MTZ 018 to 040** MT/MTZ 044 to 160
rective 2014/68/EU Refrigerating fluids* Group 2 Group 1 Group 2
Category PED I II II
Evaluation module no scope D1 D1
Maximum/minimum allowable 50°C > Ts > -35°C 50°C > Ts > -35°C 50°C > Ts > -35°C
temperature - TS
MT maximum allowable pressure - PS 18.4 bar(g) 18.4 bar(g) 18.4 bar(g)
MTZ maximum allowable pressure - PS 22.6 bar(g) 22.6 bar(g) 22.6 bar(g)
* According to the PED classification Group1 contains hazardous fluids e.g. flammable, while Group 2 all other fluids
** Only motor code 4 and 5
Low voltage directive Products MT/MTZ 018 to 040 MT/MTZ 044 to 160
2014/35/EU
Manufacturer's declaration contact Danfoss contact Danfoss
AB196386425654en-011401 7
Application Guidelines Specifications
R404A Refrigeration
50 Hz, EN12900 ratings 50 Hz, ARI ratings 60 Hz, ARI ratings
To = -10°C, Tc = 45°C, SC = 0K, SH = 10K To = -6.7°C, Tc = 48.9°C, SC = 0K, SH = 11.1K To = -6.7°C, Tc = 48.9°C, SC = 0K, SH = 11.1K
Compressor
model Cooling Power Current Cooling Power Current Cooling Power Current
C.O.P. E.E.R. E.E.R.
capacity input input capacity input input capacity input input
W/W Btu.h/W Btu.h/W
W kW A W kW A W kW A
MTZ018-4* 1910 1.21 2.73 1.58 2070 1.31 2.86 5.39 2630 1.76 2.86 5.10
MTZ022-4* 2630 1.48 3.06 1.77 2830 1.62 3.24 5.96 3600 2.05 3.27 5.99
MTZ028-4* 3430 1.96 4.04 1.75 3690 2.14 4.30 5.88 4680 2.68 4.23 5.96
MTZ032-4* 3980 2.16 4.25 1.84 4260 2.37 4.56 6.13 5110 2.98 4.56 5.85
MTZ036-4* 4670 2.58 4.95 1.81 4990 2.83 5.33 6.02 5900 3.33 5.09 6.05
MTZ040-4* 5330 2.95 5.87 1.81 5680 3.24 6.29 5.98 6740 3.76 5.88 6.12
MTZ044-4* 5370 2.78 5.35 1.93 5780 3.02 5.67 6.53 7110 3.85 5.85 6.30
MTZ050-4* 6260 3.22 5.95 1.94 6700 3.50 6.33 6.53 8360 4.42 6.53 6.46
MTZ056-4* 6710 3.51 6.83 1.91 7250 3.85 7.25 6.43 9490 4.98 7.52 6.50
MTZ064-4* 7980 4.20 7.82 1.90 8590 4.60 8.35 6.37 10540 5.67 8.31 6.34
MTZ072-4* 8920 4.69 8.95 1.90 9570 5.11 9.50 6.39 11960 6.53 9.73 6.25
MTZ080-4* 10470 5.61 10.20 1.87 11180 6.14 10.94 6.21 13610 7.81 11.35 5.95
MTZ100-4* 12280 6.76 12.21 1.82 13170 7.35 12.94 6.12 15480 8.72 12.79 6.06
MTZ125-4* 15710 8.44 14.69 1.86 16800 9.22 15.82 6.22 19970 11.37 16.41 5.99
MTZ144-4* 18490 9.78 16.77 1.89 19690 10.66 17.99 6.30 23540 12.99 18.47 6.18
MTZ160-4* 20310 11.08 18.80 1.83 21660 12.09 20.22 6.11 25570 14.73 20.77 5.92
* 50 Hz, EN12900 data for indicated models are Asercom certified R404A data are also valid for refrigerant R507
8 AB196386425654en-011401
Application Guidelines Specifications
AB196386425654en-011401 9
Application Guidelines Specifications
R407F Refrigeration
50 Hz, EN12900 ratings 50 Hz, ARI ratings 60 Hz, ARI ratings
To = -10°C, Tc = 45°C, SC = 0K, SH = 10K To = -6.7°C, Tc = 48.9°C, SC = 0K, SH = 11.1K To = -6.7°C, Tc = 48.9°C, SC = 0K, SH = 11.1K
Compressor
model Cooling Power Current Cooling Power Current Cooling Power Current
C.O.P. E.E.R. E.E.R.
capacity input input capacity input input capacity input input
W/W Btu.h/W Btu.h/W
W kW A W kW A W kW A
MTZ018-4 1850 1.08 2.53 1.71 2080 1.19 2.66 5.97 2500 1.43 2.77 5.97
MTZ022-4 2540 1.33 2.83 1.91 2840 1.48 3.01 6.55 3410 1.77 3.14 6.58
MTZ028-4 3320 1.76 3.74 1.89 3710 1.96 4.00 6.46 4450 2.35 4.17 6.46
MTZ032-4 3860 1.94 3.93 1.99 4280 2.16 4.24 6.76 5130 2.59 4.42 6.76
MTZ036-4 4520 2.32 4.58 1.95 5010 2.58 4.95 6.63 6010 3.10 5.17 6.62
MTZ040-4 5170 2.65 5.43 1.95 5700 2.96 5.85 6.57 6840 3.55 6.10 6.58
MTZ044-4 5200 2.49 4.95 2.09 5810 2.76 5.28 7.18 6970 3.31 5.50 7.19
MTZ050-4 6060 2.90 5.50 2.09 6730 3.20 5.88 7.18 8080 3.85 6.13 7.16
MTZ056-4 6500 3.16 6.31 2.06 7270 3.51 6.74 7.07 8730 4.21 7.03 7.08
MTZ064-4 7730 3.78 7.23 2.05 8620 4.19 7.76 7.02 10340 5.03 8.09 7.02
MTZ072-4 8640 4.21 8.27 2.05 9610 4.66 8.84 7.04 11530 5.60 9.22 7.03
MTZ080-4 10140 5.04 9.43 2.01 11230 5.60 10.18 6.84 13470 6.72 10.61 6.84
MTZ100-4 11900 6.07 11.28 1.96 13220 6.71 12.04 6.72 15870 8.05 12.55 6.73
MTZ125-4 15220 7.58 13.58 2.01 16870 8.41 14.72 6.85 20240 10.09 15.35 6.85
MTZ144-4 17910 8.78 15.50 2.04 19770 9.72 16.73 6.94 23730 11.66 17.45 6.95
MTZ160-4 19670 9.95 17.38 1.98 21740 11.03 18.81 6.73 26090 13.24 19.62 6.73
To: Evaporating temperature at dew point (saturated suction temperature)
Tc: Condensing temperature at dew point (saturated discharge temperature)
SC: Subcooling
SH: Superheat
10 AB196386425654en-011401
Application Guidelines Specifications
R452A Refrigeration
50 Hz, EN12900 ratings 50 Hz, ARI ratings 60 Hz, ARI ratings
To = -10°C, Tc = 45°C, SC = 0K, SH = 10K To = -6.7°C, Tc = 48.9°C, SC = 0K, SH = 11.1K To = -6.7°C, Tc = 48.9°C, SC = 0K, SH = 11.1K
Compressor
model Cooling Power Current Cooling Power Current Cooling Power Current
C.O.P. E.E.R. E.E.R.
capacity input input capacity input input capacity input input
W/W Btu.h/W Btu.h/W
W kW A W kW A W kW A
MTZ018-4 2000 1.15 2.65 1.74 2150 1.25 2.77 5.87 2580 1.49 2.88 5.91
MTZ022-4 2810 1.51 2.98 1.86 3010 1.65 3.15 6.23 3610 1.98 3.29 6.22
MTZ028-4 3250 1.86 4.00 1.75 3480 2.03 4.23 5.85 4170 2.44 4.41 5.83
MTZ032-4 3790 2.06 3.83 1.84 4060 2.27 4.13 6.10 4870 2.73 4.31 6.09
MTZ036-4 4300 2.48 4.84 1.74 4610 2.72 5.17 5.78 5530 3.26 5.39 5.79
MTZ040-4 5090 2.89 6.11 1.76 5470 3.18 6.52 5.87 6560 3.81 6.80 5.88
MTZ044-4 5370 2.73 5.24 1.96 5780 2.98 5.55 6.62 6940 3.58 5.79 6.62
MTZ050-4 6110 3.16 5.74 1.93 6630 3.47 6.07 6.52 7960 4.16 6.33 6.53
MTZ056-4 6790 3.48 6.93 1.95 7370 3.82 7.33 6.58 8850 4.58 7.64 6.59
MTZ064-4 7840 3.98 7.48 1.97 8450 4.36 8.00 6.61 10140 5.24 8.34 6.60
MTZ072-4 9020 4.61 9.34 1.96 9730 5.06 9.98 6.56 11670 6.07 10.41 6.56
MTZ080-4 9680 5.26 10.04 1.84 10390 5.75 10.72 6.17 12470 6.90 11.18 6.17
MTZ100-4 12310 6.37 11.68 1.93 13270 6.97 12.42 6.50 15930 8.37 12.96 6.50
MTZ125-4 16070 8.19 14.09 1.96 17330 8.96 14.98 6.60 20790 10.75 15.62 6.60
MTZ144-4 17830 9.58 16.44 1.86 18950 10.46 17.77 6.18 22740 12.55 18.54 6.18
MTZ160-4 19880 10.80 18.20 1.84 21130 11.80 19.68 6.11 25360 14.16 20.52 6.11
To: Evaporating temperature at dew point (saturated suction temperature)
Tc: Condensing temperature at dew point (saturated discharge temperature)
SC: Subcooling
SH: Superheat
AB196386425654en-011401 11
Application Guidelines Specifications
12 AB196386425654en-011401
Application Guidelines Operating envelopes
R The operating envelopes for MT and MTZ compressors are given in the figures below and
guarantees reliable operations of the compressor for steady-state operation.
MT - R22 - R417A
60
S.H. = 11.1 K
55
S.H. = 30 K
50
45
40
35
30
-30 -25 -20 -15 -10 -5 0 5 10 15 20
Evaporating temperature (°C)
MTZ - R134a
75
70
65
Condensing temperature (°C)
60
55
50 MTZ R134a
45 SH 10K
40 RGT 20°C
35
30
-30 -25 -20 -15 -10 -5 0 5 10 15 20
Evaporating temperature (°C)
AB196386425654en-011401 13
Application Guidelines Operating envelopes
SH 10K
RGT 20°C
SH 10K
RGT 20°C
MTZ – R448A/R449A
70
65
60
55 SH 10K
50
45 RGT 20°C
40
35
30
25
20
15
10
5
0
-35 -30 -25 -20 -15 -10 -5 0 5 10 15
SH10K RGT20
14 AB196386425654en-011401
Application Guidelines Operating envelopes
MTZ – R452A
70
65
60
SH 10K
55
50
45 RGT 20°C
40
35
30
25
20
15
10
5
0
-35 -30 -25 -20 -15 -10 -5 0 5 10 15
SH10K RGT20
MTZ – R454C
70
65
60
55 SH 10K
50
RGT 20°C
45
40
35
30
25
20
15
10
5
0
-35 -30 -25 -20 -15 -10 -5 0 5 10 15
SH10K RGT20°C
AB196386425654en-011401 15
Application Guidelines
MTZ – R513A
80
75
70
65
60
SH 10K
55
50
45 RGT 20°C
40
35
30
25
20
15
10
5
0
-30 -25 -20 -15 -10 -5 0 5 10 15 20 25
SH10K RGT20°C
Discharge temperature R Even when the motor windings are discharge line as indicated below at no more
protection protected against overheating by the internal than 150 mm from the discharge connection.
motor protection, the compressor discharge
gas temperature could exceed the maximum
Thermostat
allowed value of 135°C when the compressor
is operated outside its application envelope.
The most effective protection against too
high discharge gas temperature is to mount Discharge line
16 AB196386425654en-011401
Application Guidelines Operating envelopes
Zeotropic refrigerant Refrigerant mixtures can be either zeotropic or In a zeotropic mixture (like R407C) on the other
mixtures azeotropic. hand the composition of vapour and liquid
changes during the phase transition. When the
An azeotropic mixture (like R502 or R507) effect of this phase transition is very small, the
behaves like a pure refrigerant. During a phase mixture is often called a near-azeotropic mixture.
transition (from vapour to liquid or from liquid R404A is such a near-azeotropic mixture.
to vapour) thecomposition of vapour and liquid
stays the same. The composition change causes phase shift and
temperature glide.
Phase shift In system components where both vapour and special attention. Zeotropic refrigerants must
liquid phase are present (evaporator, condenser, always be charged in liquid phase. Flooded
liquid receiver), the liquid phase and vapour evaporators should not be applied in systems
phase do not have the same composition. In with zeotropic refrigerants. This also applies to
fact both phases form two different refrigerants. near-azeotropic mixtures.
Therefore zeotropic refrigerants need some
Temperature glide During the evaporating process and the Points C and D are mean point values. These
condensing process at constant pressure, are temperatures which correspond more or
the refrigerant temperature will decrease less with the average temperature during the
in the condenser and rise in the evaporator. evaporating and condensing process. For the
Therefore when speaking about evaporating refrigerants with glide of around 6K, mean point
and condensing temperatures, it is important to temperatures are typically about 2°C to 3°C lower
indicate whether this is a dew point temperature than dew point temperatures. According to
or a mean point value. In the figure below, the Asercom recommendations, Danfoss Commercial
dotted lines are lines of constant temperature. Compressors uses dew point temperatures for
selection tables and application envelopes etc.
They do not correspond to the lines of constant
pressure. To obtain exact capacity data at mean point
temperatures, the mean point temperatures
Points A and B are dew point values. These are must be converted to dew point temperatures
temperatures on the saturated vapour line. with help of refrigerant data tables from the
refrigerant manufacturer.
AB196386425654en-011401 17
Application Guidelines Outline drawings
1 cylinder
Ø 224
Bump on
single phase
Suction rotolock
1” (1)
1”1/4 (2)
LP gauge
port 1/4”
(schrader)
333 (1)
356 (2)
263
Discharge rotolock
3/8” oil equalisation 1”
98
68 68
25
82
Mounting hole for PTC crankcase heater
35° 33°
Code
Threaded oil Model
Suction: 142 (1) / 147 (2) 1 3 4 5 6 7 9
Discharge: 142 (1) (2) sight glass MT/MTZ018 (1) (1) (1) (1) - - -
MT/MTZ022 (2) (1) (1) (1) (1) - (1)
39 MT/MTZ028 (2) (1) (1) (1) (1) - (1)
MT/MTZ032 (2) (2) (2) (2) (2) (2) (2)
68 MT/MTZ036 (2) (2) (2) (2) (2) (2) (2)
MT/MTZ040 (2) (2) (2) - (2) - -
141
123
17
159
17°
Terminal box
Silent bloc
Ø 21 mm
Earth M4-12
23
15
Knock-out Ø 21 mm
Ø 31.75
18 AB196386425654en-011401
Application Guidelines Outline drawings
2 cylinders
Ø 288
Suction rotolock
1"3/4
Schrader 1/4"
413
Discharge rotolock
1"1/4
252
Oil equalisation 265
3/8"
74
125
8°
96
188 (1) / 196 (2)
Terminal box for model (1) Terminal box for model (2)
Silent bloc
Screw
Spade connectors 10-32 UNF x 9.5
Bolt HM8-40
1/4" AMP-AWE
Ø 21 mm Knock-out
Earth M4-12 Ø 25.5 mm
23 Earth M4-12
15
Knock-out Ø 21 mm
Knock-out Ø 29 mm
Ø 31.75
IP rating: 55 (with cable gland) IP rating: 54 (with cable gland)
MT/MTZ 044 - 050 - 056 - 064 - 072 1"3/4 1"1/4 7/8" 3/4" V07 V04
AB196386425654en-011401 19
Application Guidelines Outline drawings
4 cylinders
Ø 352 210
Suction rotolock
1"3/4
Discharge rotolock
1"1/4
117
Oil equalisation Threaded oil
3/8" sight glass
209
233
155
125
99 95
98
232
246
15°
205
155°
All dimensions in mm
15°
246
Terminal box
Silent bloc
Screw
10-32 UNF x 9.5
Knock-out
Ø 25.5 mm
Earth M4-12
Knock-out Ø 29 mm
20 AB196386425654en-011401
Application Guidelines Electrical connections and wiring
Trickle circuit The trickle circuit provides the facility of heating By using PSC or CSR starting systems,
the compressor crankcase by feeding a small compressor models MT / MTZ 018 - 022 can
current to the auxiliary winding and the run be operated without crankcase heaters as the
capacitor (See the drawings in section “Electrical heater function is provided by the trickle circuit.
connections and wiring”).
R For the larger single phase compressor
models MT / MTZ 028 - 064, the use of the PTC
crankcase heater is recommended.
PSC wiring PSC wiring may be used for refrigerant circuits ensured before start-up because of the low
with capillary tubes or expansion valves with starting torque characteristics of this system.
bleed ports. Pressure equalisation must be
CSR wiring CSR wiring provides additional motor torque Some applications with high differential pressure
at start-up, by the use of a start capacitor in can require a very high starting torque. For such
combination with the run capacitor. This system cases the CSR starting kit can be converted to
can be used for refrigerant circuits with capillary a very high starting torque kit by an additional
tubes or expansion valves. The start capacitor is start capcitor of 100 μF parallel to the start
only connected during the starting operation, a capacitor of the CSR kit. This configuration
potential relay is used to disconnect it after the can also be used to reduce erratic starting
start sequence. at unfavourable conditions such as very low
ambient temperature or weak voltage.
AB196386425654en-011401 21
Application Guidelines Electrical connections and wiring
220 kΩ - 1 W C
IOL
A µF S R
C µF
Thermostat
IOL Motor protector
A & C Run capacitors
C Common
S Start winding (auxiliary)
R Run winding (main)
5
220 kΩ - 1 W C
IOL
A µF S R
1
C µF
C
5
Thermostat
IOL
CµF
Run capacitor 2
IOL Motor protector
A+C Run capacitors
AµF
Run capacitor S R
B Start capacitor 1
C Common
S Start winding (auxiliary)
R Run winding (main) BµF
Capacitors A and C can be replaced by
Start capacitor 15 kΩ -1 w
a single capacitor of size A + C
B capacitor delivered in two parts for
MT(Z)56 & 64-1
22 AB196386425654en-011401
Application Guidelines Electrical connections and wiring
Winding resistance Winding resistance is the resistance between Winding resistance is generally low and it
indicated terminal pins at 20°C (resistance value requires adapted tools for precise measurement.
+/- 7%).
Motor protection and The 3-phase compressors are protected by Note: once the overload protector has tripped it
suggested wiring dia- an internal motor protector, connected to may take up to 3 hours to reset and restart the
grams the neutral point of the star connected stator compressor.
windings, the protector cuts out all 3-phases For all 3-phase compressors, a PTC crankcase
simultaneously. heater is required.
relay F1 F1
KM
KA KS
KM KA KA
A1
T1 T2
Control device ................................................. TH KS
A3
180 s
Optional short cycle timer (3 min) ...... 180 s HP
A2 T3
Control relay ..................................................... KA
Liquid Solenoid valve ............................... LLSV
TH
Compressor contactor ................................. KM LP
AB196386425654en-011401 23
Application Guidelines Electrical connections and wiring
Q1
F1 F1
KM
KA KS
KA KA
A1
T1 T2
A3
HP
180 s
A2 T3
Soft starters Starting current of Maneurop® 3-phase For details of the CI-tronicTM MCI soft starters,
compressors can be reduced by using a soft please refer to literature DKACT.PD.C50.
starter. Version available: CI-tronicTM soft starters
type MCI (recommended). The starting current The number of starts should be limited to 6 per
can be reduced by up to 50% depending on the hour. HP/LP pressure equalisation is required
compressor model and the type of soft starter. before starting.
Also mechanical stresses that occur at starting
are reduced which increases the life of the Soft starters cannot be used with Refrigerant
internal components. Group 1 e.g. R454C.
IP rating The compressor terminal boxes IP rating The IP ratings are only valid when correctly sized
according to CEI 529 are shown on the outline cable glands of the same IP rating are applied.
drawings section.
IP 5 5
1st numeral, level of protection against contact and foreign objects
5 complete protection against contact and against harmful dust deposits
24 AB196386425654en-011401
Application Guidelines Refrigerants and lubricants
General information When choosing a refrigerant, different aspects Additional points could influence the final
must be taken into consideration: choice:
• Legislation (now and in the future) • Environmental considerations
• Safety • Standardisation of refrigerants and lubricants
• Application envelope in relation to expected • Refrigerant cost
running conditions • Refrigerant availability
• Compressor capacity and efficiency
• Compressor manufacturer recommendations The table below gives an overview of the
& guidelines different refrigerant - lubricant - compressor
Only Danfoss lubricant are allowed for combinations for Maneurop® MT & MTZ
Maneurop® MT & MTZ compressors. compressors.
Lubricant Compressor
Refrigerant Type Danfoss lubricant Application
type type
R407A/C/F HFC Polyolester MTZ Polyolester oil 175PZ Medium / High temperature
R134a HFC Polyolester MTZ Polyolester oil 175PZ Medium / High temperature
Alternative R22 retrofit Polyolester MT/MTZ Polyolester oil 175PZ Medium / High temperature
with HFC refrigerants
Capacity and other data for HFC blends as replacements in existing installations, see
refrigerants are not published in this document. technical news FRCC.EN.049. and FRCC.EN.085.
Maneurop® compressors however are suitable for for more information on retrofit.
use with these refrigerants and can still be used
R22 R22 is an HCFC refrigerant and is still in use today. The Maneurop® MT compressor is supplied with
It has a low ODP (Ozone Depletion Potential) an initial mineral oil charge.
and therefore it will be phased out in the future.
Check local legislation. Always use mineral oil
160P with R22.
Alternatives R22, HFC A wide variety of HFC blends exist. There were - R427A, ... Retrofit technical news have been
retrofit developed as temporary HCFC and HFC high issued to advice about use of these refrigerants.
GWP alternatives. Some examples are R422A/D
R407C Refrigerant R407C is an HFC refrigerant with information about zeotropic refrigerants; refer to
similar thermodynamic properties to those of section "zeotropic refrigerant mixtures". R407C
R22. must be charged in the liquid phase.
R407C has zero ozone depletion potential Always use the Maneurop® MTZ compressors
(ODP=0). Many installers and OEMs consider with Danfoss 160PZ or 175PZ polyolester oil,
R407C to be the standard alternative for which is supplied with the MTZ compressor for
R22. R407C is a zeotropic mixture and has a R407C applications.
temperature glide of about 6 K. For more specific
AB196386425654en-011401 25
Application Guidelines Refrigerants and lubricants
R134a Refrigerant R134a is an HFC refrigerant with high condensing temperatures, R134a is the
thermodynamic properties comparable to ideal choice. R134a is a pure refrigerant and has
those of the CFC refrigerant R12. R134a has zero temperature glide. For R134a applications
zero ozone depletion potential (ODP = 0) and is always use the Maneurop® MTZ compressor with
commonly accepted as the best R12 alternative. Danfoss 175PZ polyolester oil which is supplied
For applications with high evaporating and with the MTZ compressor.
R404A Refrigerant R404A is an HFC refrigerant with other aspects this small glide can be neglected.
thermodynamic properties comparable to Because of the small glide, R404A is often called
those of the CFC refrigerant R502. R404A has a near-azeotropic mixture. For more information
zero ozone depletion potential (ODP = 0) and refer to section «zeotropic refrigerant mixtures».
is commonly accepted as one of the best R502 For low evaporating temperature applications
alternatives. R404A is especially suitable for down to -45°C, Maneurop® NTZ compressors
low evaporating temperature applications but should be used. Refer to the NTZ selection and
it can also be applied to medium evaporating application guidelines. For medium temperature
temperature applications. R404A is a mixture and R404A applications, always use the Maneurop®
has a very small temperature glide, and therefore MTZ compressor with 175PZ polyolester oil
must be charged in its liquid phase, but for most which is supplied with the MTZ compressor.
R507 Refrigerant R507 is an HFC refrigerant with mixture with no temperature glide. For low
thermodynamic properties comparable to evaporating temperature applications down to
those of the CFC refrigerant R502 and virtually -45°C, Maneurop® NTZ compressor should be
equal to those of R404A. R507 has no ozone used. Refer to the NTZ selection and application
depletion potential (ODP = 0) and is commonly guidelines. For medium temperature R507
accepted as one of the best R502 alternatives. applications, always use the Maneurop® MTZ
As with R404A, R507 is particularly suitable for compressor and Maneurop® 175PZ polyolester oil
low evaporating temperature applications but which is supplied with the MTZ compressor.
it can also be used for medium evaporating
temperature applications. R507 is an azeotropic
R407A Refrigerant R407A is an HFC with similar in liquid phase, R407A GWP is stated at 2107
thermodynamic properties to those of R404A, [CO2=1,0]. Always use the Maneurop MTZ
R407A is a zeotropic refrigerant and has a compressors with danfoss 175PZ polyolester oil,
temperature glide of about 6,6K. For more which is supplied with the MTZ compressors for
specific information about zeotropic refrigerant, R407A applications.
refer to section “zeotropic refrigerants mixtures”
and read FRCC.EN.085. R407A must be charged
R407F Refrigerant R407F is an HFC with similar in liquid phase, R407F GWP is stated at 1825
thermodynamic properties to those of R404A, [CO2=1,0]. R407F is mainly suitable for high &
R407F is a zeotropic refrigerant and has a medium temperature application- Always use
temperature glide of about 6,4K. For more the Maneurop MTZ compressors with danfoss
specific information about zeotropic refrigerant, 175PZ polyolester oil, which is supplied with the
refer to section “zeotropic refrigerants mixtures” MTZ compressors for R407F applications..
and read FRCC.EN.085. R407F must be charged
R448A/R449A R448A/R449A is an HFO/HFC Blend, with R448A/R449A must be charged in liquid phase,
similar thermodynamic properties to those R448A GWP is stated at 1387/1397 [CO2=1,0].
of R404A or R22. R448A/R449A is a Zeotropic Always use the Maneurop MTZ compressors with
refrigerant and has a temperature glide of about Danfoss 175PZ polyolester oil, which is supplied
6,1/6,3K. For more specific information about with the MTZ compressors for R448A/R449A
zeotropic refrigerant, refer to section “zeotropic applications.
refrigerants mixtures” and read FRCC.EN.085.
26 AB196386425654en-011401
Application Guidelines Refrigerants and lubricants
R452A R452A is an HFO/HFC Blend, with similar in liquid phase, R452A GWP is stated at 1945
thermodynamic properties to those of R404A [CO2=1,0]. Always use the Maneurop® MTZ
or R22. R452A is a Zeotropic refrigerant and compressors with Danfoss 175PZ polyolester oil,
has a temperature glide of about 4K. For more which is supplied with the MTZ compressors for
specific information about zeotropic refrigerant, R452A applications.
refer to section “zeotropic refrigerants mixtures”
and read FRCC.EN.085. R452A must be charged
R454C R454C is an HFO Blend, with similar and directives about the use of refrigerant of
thermodynamic properties to R404A. R454C is the A2L safety group (EN378, EN60335). Outside
a Zeotropic refrigerant and has a temperature Europe refer to the local regulation.
glide of about 6K and therefore must be
charged in liquid phase. R With R454C, liquid migration to the
compressor have to be avoid:
For R454C GWP is stated below 150 limit. - Maintain adequate superheat setting of
Always use the Maneurop MTZ compressors minimum 8-10K
with Danfoss 175PZ polyolester oil, which is - Use solenoid valve on the liquid line and pump
supplied with the MTZ compressors for R454C down is recommended.
applications. - Use a crankase heater to avoid dissolution of
the lubricant.
R454C is classified A2L with low flammability
properties. Please refer to European regulation
R513A R513A is an HFO/HFC Blend, with similar R With R513A, liquid migration to the
thermodynamic properties to the R134a. R513A is compressor have to be avoid:
a Azeotrope refrigerant with a negligible glide. - Maintain adequate superheat setting of
minimum 8-10K
R513A has zero ozone depletion potential - Use solenoid valve on the liquid line and pump
(ODP=0) and a Global Warming Potential (AR5) down is recommended.
at 573 [CO2=1] . Always use the Maneurop® MTZ - Use a crankase heater to avoid dissolution of
compressors with Danfoss 175PZ polyolester oil, the lubricant.
which is supplied with the MTZ compressors for
R513A applications.
Hydrocarbons Hydrocarbons such as propane, isobutane Maneurop® MT or MTZ compressors in any way,
etc. are extremely flammable. Danfoss does even with a reduced refrigerant charge.
not authorise the use of hydrocarbons with
AB196386425654en-011401 27
Application Guidelines System design recommendations
Piping design Oil in a refrigeration circuit is required to system, the amount of oil returning to the
lubricate moving parts in the compressor. During compressor is lower than the amount of oil
normal system operation small oil quantities leaving the compressor, the compressor will
will continuously leave the compressor, with the become starved of oil and the condenser,
discharge gas. With good system piping design evaporator and/or refrigerant lines will become
this oil will return to the compressor. As long filled with oil. In such situations, additional oil
as the amount of oil circulating through the charge will only correct the compressor oil level
system is small it will contribute to good system for a limited period of time and increase the
operation and improved heat transfer efficiency. amount of surplus oil in the rest of the system.
However, too large amounts of oil in the system
will have a negative effect on condenser and Only correct piping design can ensure a good oil
evaporator efficiency. If, in a poorly designed balance in the system.
Suction lines Horizontal suction line sections shall have a Gas velocities higher than 12 m/s will not
slope of 0.5% in the direction of refrigerant flow contribute to significantly better oil return.
(5 mm per meter). The cross-section of horizontal However they will cause higher noise levels
suction lines shall be such that the resulting and result in higher suction line pressure drops
gas velocity is at least 4 m/s. In vertical risers, a which will have a negative effect on the system
gas velocity of 8 to 12 m/s is required to ensure capacity.
proper oil return. A U-trap is required at the
foot of each vertical riser. If the riser is higher
than 4 m, additional U-traps are required for
each additional 4 meters. The length of each
U-trap must be as short as possible to avoid the
accumulation of excessive quantities of oil (see
figure below).
Note that the suction rotolock valves, which The pipe sizes selected for specific systems may
can be ordered from Danfoss as accessories, are differ from these recommended sizes.
designed for average pipe sizes, selected for
systems running at nominal conditions. It is recommended that the suction lines are
insulated to limit suction gas superheat.
28 AB196386425654en-011401
Application Guidelines System design recommendations
Oil charge and oil separator In most installations the initial compressor oil installations with the risk of slow oil return such
charge will be sufficient. In installations with line as in multiple evaporator or multiple condenser
runs exceeding 20 m, or with many oil traps or an installations, an oil separator is recommended.
oil separator, additional oil may be required. In
Filter driers For new installations with MTZ compressors filter driers containing activated alumina are
Danfoss recommends using the Danfoss DML recommended.
100%-molecular sieve, solid core filter drier.
Molecular sieve filter driers with loose beads The drier is to be oversized rather than
from third party suppliers shall be avoided. undersized. When selecting a drier, always
take into account its capacity (water content
For servicing of existing installations where acid capacity), the system refrigerating capacity and
formation is present the Danfoss DCL solid core the system refrigerant charge.
Operating limits
High pressure A high pressure safety switch is required to stop R The HP switch must either be in a lockout
the compressor, should the discharge pressure circuit, or be a manual reset device to prevent
exceed the values shown in the table below. The compressor cycling around the high pressure
high pressure switch can be set to lower values limit. When a discharge valve is used, the HP
depending on the application and ambient switch must be connected to the service valve
conditions. gauge port, which cannot be isolated.
Low pressure R A low pressure safety switch is recommended to avoid compressor operation at too lower
suction pressures.
MT MTZ
R22 R417A R407A R407C R407F R134a R404A / R507 R452A R449A R448A R454C R513A
160P 175PZ 175PZ 175PZ 175PZ 175PZ 175PZ
bar (g)
Working pressure range 10.9 - 27.7 9.32 - 25.5 11.6 - 25.8 12.5 - 29.4 12.1 - 24 7.87 - 22.6 13.2 - 27.7 12.5-27.3 11.7-25.9 11.7-26.0 5.2 - 22.3 8.37-23.36
high side
Working pressure range 1.01 - 6.89 0.54 - 5.66 0.53 - 5.94 1.43 - 6.55 0.99 - 6.25 0.06 - 4.72 1.04 - 7.2 0.84-6.69 0.6-6.07 0.6-6.08 0.4 - 5.2 0.21-5.12
low side
*Relief valve opening 30 30 30 30 30 30 30 30 30 30 30 30
pressure difference
*Relief valve closing 8 8 8 8 8 8 8 8 8 8 8 8
pressure difference
* Relief valve fitted on 2 and 4 cyl.
Low ambient temperature At low ambient temperatures, the condensing valve in the discharge line is required and
operation temperature and condensing pressure in air special care should be taken when designing the
cooled condensers will decrease. discharge line.)
• Reduce air flow to condensers.
This low pressure may be insufficient to supply
enough liquid refrigerant to the evaporator. As a Other problems can also occur when the
result the evaporator temperature will strongly compressor is operating at low ambient
decrease with the risk of frosting. At compressor temperature. During shut down periods, liquid
start-up, the compressor can pull a deep vacuum refrigerant can migrate to a cold compressor.
and it can be switched off by the low pressure
protection. Depending on the low pressure For such conditions a belt-type crankcase heater
switch setting and delay timer short cycling can is strongly recommended.
occur. To avoid these problems, several solutions
are possible, based on reducing condenser Note that with 100% suction gas cooled motors,
capacity: Maneurop® compressors can be externally
• Indoor location of condensers insulated.
• Liquid flooding of condensers (note: this
solution requires extra refrigerant charge, which Refer to section "Liquid refrigerant control &
can introduce other problems. A non-return charge limits" for more details.
AB196386425654en-011401 29
Application Guidelines System design recommendations
Cycle rate limit R There may be no more than 12 starts per The system must be designed in such a way
hour (6 when a soft start accessory is used). A to guarantee a minimum compressor running
higher number reduces the service life of the time in order to provide proper oil return and
motor-compressor unit. If necessary, use an anti- sufficient motor cooling after starting.
short-cycle timer in the control circuit. Note that the oil return rate varies as a function
A time-out of six minutes is recommended. of the system design.
Liquid refrigerant control Refrigeration compressors are basically designed oil from the sump. Good system design can
and charge limit as gas compressors. Depending on the limit the amount of liquid refrigerant in the
compressor design and operating conditions, compressor, which will have a positive effect on
most compressors can also handle a limited the compressor service life.
amount of liquid refrigerant. Maneurop® MT
and MTZ compressors have a large internal Liquid refrigerant can enter a compressor in
volume and can therefore handle relatively large different ways, with different effects on the
amounts of liquid refrigerant without major compressor.
problems. However even when a compressor
can handle liquid refrigerant, this will not be R With R513A and R454C, liquid migration to
favourable to its service life. Liquid refrigerant the compressor must be avoided by maintaining
can dilute the oil, wash oil out of bearings and adequate superheat setting of min. 8-10K.
result in high oil carry over, resulting in loss of
Off-cycle migration During system standstill and after pressure At lower pressures the oil holds less refrigerant,
equalisation, refrigerant will condense in the and as a result part of the refrigerant will
coldest part of the system. The compressor can violently evaporate from the oil, causing the oil
easily be the coldest spot, for example when it to foam. This process is often called “boiling”.
is placed outside in low ambient temperatures.
After a while, the full system refrigerant charge The negative effects from migration on the
can condense in the compressor crankcase. A compressor are:
large amount will dissolve in the compressor • oil dilution by liquid refrigerant
oil until the oil is completely saturated with • oil foam, transported by refrigerant gas and
refrigerant. If other system components are discharged into the system, causing loss of oil
located at a higher level, this process can be and in extreme situations risk for oil slugging
even faster because gravity will assist the liquid • in extreme situations with high system
refrigerant to flow back to the compressor. When refrigerant charge, liquid slugging could occur
the compressor is started, the pressure in the (liquid entering the compressor cylinders).
crankcase decreases rapidly.
Liquid floodback during During normal and stable system operation, refrigerant due to different reasons:
operation refrigerant will leave the evaporator in a • wrong dimensioning, wrong setting or
superheated condition and enter the compressor malfunction of expansion device
as a superheated vapour. • evaporator fan failure or blocked air filters.
Normal superheat values at compressor suction In these situations, liquid refrigerant will
are 5 to 30 K. However the refrigerant leaving continuously enter the compressor.
the evaporator can contain an amount of liquid
30 AB196386425654en-011401
Application Guidelines System design recommendations
The negative effects from continuous liquid • in extreme situations with high system
floodback are: refrigerant charge and large amounts of
• permanent oil dilution floodback, liquid slugging could occur.
Liquid floodback at change In heat pumps, change over from cooling to The negative effects are:
over cycles in reversible heat heating cycles, defrost and low load short cycles • oil dilution
pumps may lead to liquid refrigerant floodback or • in extreme situations with high system
saturated refrigerant return conditions. refrigerant charge and large amounts of
floodback, liquid slugging could appear.
Liquid floodback and zeo- Liquid floodback in systems working with a This new refrigerant composition may result in
tropic refrigerants zeotropic refrigerant such as R407C introduces different compressor operating pressures and
additional negative effects. e.g. R407C, R454C. temperatures.
A part of the refrigerant leaves the evaporator
in liquid phase and this liquid has a different
composition than the vapour.
Crankcase heater R A crankcase heater protects against the Belt crankcase heaters are not self-regulating.
off-cycle migration of refrigerant and proves Control must be applied to energise the belt
effective if oil temperature is maintained 10 heater once the compressor has been stopped
K above the saturated LP temperature of the and then to de-energise it while the compressor
refrigerant. Tests must thereby be conducted is running. The belt heater must be energised 12
to ensure that the appro-priate oil temperature hours before restarting the compressor following
is maintained under all ambient conditions. A an extended down period.
PTC crankcase heater is recommended on all
stand-alone compressors and split systems. PTC If the crankcase heater is not able to maintain the
crankcase heaters are self-regulating. oil temperature at 10 K above the saturated LP
temperature of the refrigerant during off cycles
Under extreme conditions such as very low or if repetitive floodback is present a the Liquid
ambient temperature a belt type crankcase Line Solenoid Valve (LLSV) + pump-down cycle
heater could be used in addition to the PTC is required, eventually in conjunction with a
heater, although this is not a preferred solution suction accumulator.
for 1 and 2 cylinder compressors. The belt
crankcase heater must be positioned on the R Crankcase heater or PTC crankcase heater
compressor shell as close as possible to the oil always has to be use when refrigerant R454C or
sump to ensure good heat transfer to the oil. R513A is used.
Liquid line solenoid valve & In refrigeration applications, the Liquid Line A pump-down cycle design is required when
pump-down Solenoid Valve (LLSV) is highly recommended. evaporators are fitted with electric defrost
During the off-cycle, the LLSV isolates the liquid heaters.
charge in the condenser side, thus preventing
against refrigerant transfer or excessive Liquid line solenoid valve and pump down have
migration of refrigerant into the compressor. to be use with refrigierant R513A.
Furthermore, when using a LLSV in conjunction
with a pump-down cycle, the quantity of
refrigerant in the low-pressure side of the system
will be reduced.
Suction accumulator A suction accumulator offers considerable The suction accumulator must be selected in
protection against refrigerant floodback at accordance with the accumulator manufacturer
start-up, during operation or after the defrost recommendations. As a general rule, Danfoss
operation. This device also helps to protect recommends to size the accumulator for at least
against off-cycle migration by means of 50% of the total system charge. Tests however
providing additional internal free volume to the must be conducted to determine the optimal
low pressure side of the system. size.
AB196386425654en-011401 31
Application Guidelines Sound and vibration management
Sound Running compressors cause sound and vibration. Because Maneurop® compressors are 100%
Both phenomena are closely related. suction gas cooled, and require no body cooling,
they can be insulated. Values for the sound
Sound produced by a compressor is transmitted reduction achieved with acoustic hoods are
in every direction by the ambient air, the shown also in the table on the right. For inside
mounting feet, the pipework and the refrigerant mounted compressors, sound insulation of the
in the pipework. plantroom is an alternative to sound insulation of
the compressor.
The easiest way to reduce the sound transmitted
through ambient air is to fit a Danfoss acoustic Sound transmitted by mounting feet, pipework
hood accessory. and refrigerant should be treated the same way
as for vibration. Please refer to the next section.
* Provisional Data
Sound power level for MTZ
As first approach, use these figures with -3 dB(A) reduction on the R404A sound power for MT models applied with R22.
** Acoustic hood accessory can reduce noise level by 6 to 10 dBA (depending on the operating conditions and models).
Vibration The mounting grommets delivered with the Care must be taken to avoid tubing having
compressor should always be used. They reduce resonant frequencies close to those of the
the vibration transmitted by the compressor compressor frequency.
mounting feet to the base frame.
Vibration is also transmitted by the refrigerant
The base on which the compressor is mounted gas. Maneurop® compressors have built in
should be sufficiently rigid and of adequate mass mufflers to reduce this vibration.
to ensure the full effectiveness of the mounting
grommets. To further reduce vibration an extra muffler can
be installed.
The compressor should never be directly
mounted to the base frame without the Note: Maneurop® MT & MTZ compressors have
grommets, otherwise high vibration transmission been designed and qualified for stationary
would occur and the compressor service life equipment used in A/C and Refrigeration
reduced. Suction and discharge lines must applications.
have adequate flexibility in 3 planes. Eventually
vibration absorbers may be required. Danfoss doesn’t warrant these compressors
for use in mobile applications, such as trucks,
railways, subways, etc...
32 AB196386425654en-011401
Application Guidelines Installation and service
System cleanliness System contamination is one of the main factors material. Clean all parts before brazing and
affecting equipment reliability and compressor always purge nitrogen or CO2 through the
service life. pipes during brazing to prevent oxidation. If
flux is used, take every precaution to prevent
Therefore it is important to ensure system leakage into the piping. Do not drill holes (e.g.
cleanliness when manufacturing a refrigeration for schräder valves) in parts of the installation
system. During the manufacturing process, that are already completed, when filings and
system contamination can be caused by: burrs can not be removed. Carefully follow the
• Brazing and welding oxides instructions below regarding brazing, mounting,
• Filings and particles from removing burrs from leak detection, pressure test and moisture
pipe-work removal. All installation and service work shall
• Brazing flux only be done by qualified personnel respecting
• Moisture and air. all procedures and using tools (charging systems,
tubes, vacuum pump, etc.) dedicated for the
Only use clean and dehydrated refrigeration refrigerant that will be used.
grade copper tubes and silver alloy brazing
Compressor handling,
mounting and connection
to the system
Compressor handling Maneurop® MT and MTZ compressors are lug should never be used to lift the complete
provided with a lifting lug. This lug should installation.
always be used to lift the compressor. Once the Keep the compressor in an upright position
compressor is installed, the compressor lifting during handling.
Compressor mounting Mount the compressor on a horizontal plane These grommets largely attenuate the
with a maximum slope of 3 degrees. All compressor vibration transmitted to the base
compressors are supplied with three or four frame. The compressor must always be mounted
rubber mounting grommets, each complete with with these grommets. Refer to the table below
metal sleeves and nuts and bolts. Refer to the for torque values.
section “Outline drawings”.
Compressor connection to New compressors have a protective nitrogen valves to the pipework before the compressor
the system holding charge. is mounted. When all brazing is finished and
when the total system is ready, the compressor
R The suction and discharge caps should caps can be removed and the compressor can
only be removed just before connecting the be connected to the system with a minimum
compressor to the installation to avoid air and exposure to ambient air.
moisture entering the compressor.
If this procedure is not possible, the sleeves
Whenever possible the compressor must be the or valves may be brazed to the pipes when
last component to be integrated in the system. It mounted on the compressor.
is advisable to braze the solder sleeves or service
AB196386425654en-011401 33
Application Guidelines Installation and service
In this situation nitrogen or CO2 must be purged Note: When the compressor is built into a ”pack”
through the compressor via the schrader valve to or “rack” configuration which is not installed
prevent air and moisture ingress. Purging must immediately on its final location, a vacuum pull-
start when the caps are removed and proceeded down and moisture removal must be performed
during the brazing process. to this pack (rack) as if it were a complete system
When rotolock valves are used on the (see below). The pack must be charged with
compressor, they shall be closed immediately nitrogen or CO2 and open tubes must be blocked
after mounting, thus keeping the compressor with caps or plugs.
isolated from atmosphere or from a not yet
dehydrated system.
System pressure test It is recommended that an inert gas such as 1-2-4 cylinder
nitrogen be used for pressure testing. Dry air compressors
may also be used but care should be taken Maximum compressor test 25 bar(g)
pressure, low side
since it can form an inflammable mixture with
Maximum compressor test
the compressor oil. When performing a system 30 bar(g)
pressure, high side
pressure test, the maximum allowed pressure
for the different components should not be Do not exceed 30 bar pressure difference
exceeded. between high pressure side and low pressure
side of the compressor because this will open the
For MT/MTZ compressors the maximum test internal compressor relief valve.
pressures are shown in the table beside.
Leak detection Whenever possible (if valves are present) the or HCFC refrigerants for leak detection of HFC
compressor must be kept isolated from the systems.
system. Perform a leak detection using the final
refrigerant. Pressurise with nitrogen or another Note 1: Leak detection with refrigerant may
neutral gas and use a leak detector for the not be allowed in some countries. Check local
applied refrigerant. Any spectrometric detection regulations.
system using helium can also be applied.
Note 2: Leak detecting additives shall not be
Eventual leaks shall be repaired respecting used as they may affect the lubricant properties.
the instructions written above. It is not
recommended to use other gasses such as Warranty may be voided if leak detecting
oxygen, dry air or acetylene as these gasses can additives have been used.
form an inflammable mixture. Never use CFC
Vacuum pull-down mois- Moisture obstructs the proper functioning of the lubricating properties of the oil. Air and moisture
ture removal compressor and the refrigeration system. also increase the risk of acid formation, giving
rise to copper platting. All these phenomena
Air and moisture reduce service life and increase can cause mechanical and electrical compressor
condensing pressure, and cause excessively high failure.
discharge temperatures, which can destroy the
34 AB196386425654en-011401
Application Guidelines Installation and service
To eliminate these factors, a vacuum pull- A new leak detection must be performed and
down according to the following procedure is the vacuum pull-down procedure should be
recommended: restarted from step 1. When the pressure slowly
Whenever possible (if valves are present) increases, this indicates the presence of moisture.
the compressor must be kept isolated from the In this case step 2 and 3 should be repeated.
system. Connect the compressor to the system by
After the leak detection, the system must be opening the valves. Repeat step 2 and 3.
pulled-down under a vacuum of 500 microns Break the vacuum with nitrogen or the final
(0.67 mbar). A two stage vacuum pump shall be refrigerant.
used with a capacity appropriate to the system Repeat step 2 and 3 on the total system.
volume. It is recommended to use connection At commissioning, system moisture content may
lines with a large diameter and to connect these be up to 100 ppm. During operation the filter
to the service valves and not to the schrader drier must reduce this to a level < 20 ppm.
connection to avoid too high pressure losses.
When the vacuum level of 500 micron is Do not use a megohmmeter or apply power
reached, the system must be isolated from the to the compressor while it is under vacuum, as
vacuum pump. Wait 30 minutes during which this may cause motor winding damage.
the system pressure should not rise. When the
pressure rapidly increases, the system is not leak R Never run the compressor under vacuum
tight. as it may cause compressor motor burn-out.
Start-up Before initial start-up or after a prolonged shut power for single phase compressors with trickle
down period, energise the crankcase heater circuit.
(if fitted) 12 hours prior to start-up, or turn on
Refrigerant charging R Zeotropic and «near-azeotropic» The refrigerant charge quantity must be suitable
refrigerant mixtures such as R404A, R407A/C/F, for both winter and summer operation. Refer
R448A, R449A and R454C must always be also to section “Protection against flooded starts
charged in the liquid phase. For the initial and liquid floodback” for information about
charge, the compressor must not run and service refrigerant charge limits.
valves must be closed. Charge refrigerant as
close as possible to the nominal system charge R when a liquid line solenoid valve is used,
before starting the compressor. Then slowly the vacuum in the low pressure side must be
add refrigerant in the liquid phase, on the low broken before applying power to the system.
pressure side as far away as possible from the
running compressor.
Oil charge and oil level The oil charge must be checked before contained in accessories such as oil separators
commissioning (1/4 to 3/4 of the oil sight glass). or oil traps). If this amount has already been
Check the oil level again after a minimum of 2 added and the oil level in the compressor keeps
hours operation at nominal conditions. In most decreasing, the oil return in the installation is
installations the initial compressor oil charge insufficient. Refer also to section "Piping design".
will be sufficient. In installations with line runs
exceeding 20 m or with many oil traps or an In installations where slow oil return is likely such
oil separator, additional oil may be required. as in multiple evaporator or multiple condenser
Normally the quantity of oil added should be installations, an oil separator is recommended.
no more than 2% of the total refrigerant charge Refer to the table section “Refrigerant and
(this percentage does not take into account oil lubricants” to select the correct oil.
Suction gas superheat The optimum suction gas superheat is 10K. A The maximum allowable superheat is about 30
lower superheat value will contribute to better K. Higher values can be accepted but in these
system performance (higher mass flow and cases, tests have to be performed to check that
more efficient use of evaporator surface). Low the maximum discharge temperature of 130°C
superheat values however increase the risk of will not be exceeded. Note that high superheat
unwanted liquid floodback to the compressor. values decrease the compressor application
envelope and system performance.
For very low superheat values an electronically
controlled expansion valve is recommended.
AB196386425654en-011401 35
Application Guidelines Ordering information and packaging
Packaging
36 AB196386425654en-011401
Application Guidelines Ordering information and packaging
AB196386425654en-011401 37
Application Guidelines Ordering information and packaging
VI = Single compressor, threaded oil sight glass, 3/8" oil equalisation connection
38 AB196386425654en-011401
Application Guidelines Ordering information and packaging
AB196386425654en-011401 39
Application Guidelines Ordering information and packaging
VI = Single compressor, threaded oil sight glass, 3/8" oil equalisation connection
* Qualifed with R454C.
40 AB196386425654en-011401
Application Guidelines Updates
• Page 4: and then in the whole document-The safety and reliability risk icons are added
• Page 7: Pressure equipment directive - Refrigerant Group 1 is added
• Page 12: Nominal performance data for R454C is added
• Page 15: Operating envelope for R454C is added
• Page 24: Soft starter with flammable refrigeration - recommendation
• Page 25: Refrigerants and lubricants - R454C with POE oil is added
• Page 27: Refrigerants and lubricants - R454C is added
• Page 29: Pressures for R454C are added
• Page 31: Crankcase heater recommendation updated
• Page 32: Sound data for R454C is added
• Page 33: Accessories - Mounting kits code numbers are updated
AB196386425654en-011401 41
Danfoss Cooling
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.
Danfoss Scrolls
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.
www.danfoss.com