Residential and light commercial scroll compressors Hz - R407C - R22 - R410A. Selection & Application guidelines MAKING MODERN LIVING POSSIBLE

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1 MAKING MODERN LIVING POSSIBLE Residential and light commercial scroll compressors Hz - R407C - R22 - R410A REFRIGERATION & AIR CONDITIONING DIVISION Selection & Application guidelines

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3 Co n t e n t s Sc r o l l c o m p r e s s i o n p r i n c i p l e... 5 Scroll compressor components... 5 The scroll compression process... 6 Performance... 6 Co m p r e s s o r m o d e l designation... 7 Nomenclature... 7 Label... 7 Te c h n i c a l specifications Hz data * Hz data *... 9 Di m e n s i o n s HRM / HRP / HRH / HRM / HRP / HRH HRM / HLM / HRP / HLP / HRH / HLH / HLJ HCM/HCP El e c t r i c a l d a t a, c o n n e c t i o n s a n d wiring Motor voltage...14 Wiring connections...14 IP rating...15 LRA (Locked Rotor Amp)...15 MCC (Maximum Continuous Current)...15 Winding resistance...15 Electrical connections...15 Nominal capacitor value and relays...16 Internal motor protection...16 Phase sequence and reverse rotation protection...16 Voltage imbalance...16 Ap p r o v a l s a n d certifications Approvals and certificates...17 Pressure equipment directive 97/23/EC...17 Low voltage directive73/23/ec, 93/68/EC...17 Internal free volume...17 Op e r a t i n g c o n d i t i o n s Refrigerant and lubricants...18 Motor supply...19 Compressor ambient temperature...19 Application envelope...19 R22, R407C and R410A Model variation T...19 R22 and R410A Model variation U...20 Maximum discharge gas temperature...20 High and low pressure protection...21 On/off cycling (cycle rate limit)...21 Sy s t e m d e s i g n r e c o m m e n d a t i o n s General...22 Essential piping design considerations...22 Refrigerant charge limit...23 Crankcase heater...25 Reversible heat pump systems...26 Loss of charge protection...26 Tandem...26 Oil level checking and top-up...26 Minimum sump superheat...26 High pressure ratio...26 Phase sequence and reverse rotation protection...26 Internal motor protection...27 Preventing liquid flood back...27 Testing for excessive liquid flood back...27 Split unit cooling mode...27 Water utilizing systems...27 FRCC.PC.012.A3.22 3

4 Co n t e n t s So u n d a n d vibration m a n a g e m e n t Starting sound level...28 Running sound level...28 Stopping sound level...28 Sound generation in a refrigeration system / air conditioning system...28 Compressor sound radiation...28 Mechanical vibrations...29 Gas pulsation...29 In s t a l l a t i o n System cleanliness...30 Compressor handling and storage...30 Compressor mounting...30 Compressor holding charge...30 Tube brazing procedure...30 Brazing material...30 Vacuum evacuation and moisture removal...31 Liquid line filter driers...32 Refrigerant charging...32 Insulation resistance and dielectric strength...32 Compressor replacement after motor burn out...32 Or d e r i n g i n f o r m a t i o n a n d p a c k a g i n g Packaging...33 Packaging details...33 R22 Single pack...34 R22 Industrial pack...35 R407C Single pack...36 R407C Industrial pack...37 R410A Single pack...38 R410A Industrial pack...39 Sp a r e p a r t s & a c c e s s o r i e s Run capacitors for PSC wiring...40 Start capacitors and starting relay for CSR wiring...40 Rotolock adaptor set...40 Rotolock adaptor...40 Crankcase heater...41 Discharge temperature protection...41 Lubricant...41 Mounting hardware FRCC.PC.012.A3.22

5 ApplicAtion guidelines scroll compression principle Scroll compressor components The motor stator is rigidly attached to the shell. The rotor is shrink-fit onto the eccentric shaft. The shaft is supported by two bearings, one in the crankcase and the second below the motor. Lifting lug Discharge tube Check valve Fixed scroll Orbiting scroll Terminal cover Slider block Counterweight Electric terminal Rotor Stator Eccentric shaft Lower bearing Shell Magnet FRCC.PC.012.A3.22 5

6 Scroll compressor principle The scroll compression process The entire scroll compression process is illustrated below. The centre of the orbiting scroll traces a circular path around the centre of the fixed scroll. This movement creates compression pockets between the two scroll elements. Low pressure suction gas is trapped within each crescent-shaped pocket as it forms; continuous motion of the orbiting scroll serves to seal the pocket, which decreases in volume as the pocket moves towards the centre of the scroll set, with corresponding increase in gas pressure. Maximum compression is achieved, as the pocket reaches the discharge port at the centre. Scroll compression is a continuous process: when one pocket of gas is being compressed during the second orbit, another gas quantity enters a new pocket formed at the periphery, and simultaneously, another is being discharged. SUCTION COMPRESSION DISCHARGE Danfoss scroll compressors are manufactured using the most advanced machining, assembly, and process control techniques. In design of both the compressor and the factory, very high standards of reliability and process control were first priority. The result is a highly efficient product with the highest reliability obtainable, and a low sound level. Performance The Performer H referenced in this guide is a fully compliant scroll and actually improves with run time in it's early commissioning. A seventy-two hour run-in is recommended to meet performance expectations. 6 FRCC.PC.012.A3.22

7 Compressor model designation Nomenclature Type HRH Application: H: high temperature / air conditioning Family: C: light commercial scroll R: residential scroll (new platform) L: light commercial scroll (new platform) Size 036 Motor U1L Features P6 Other features Oil sight glass 6 None 7 Threaded 8 None Oil equalization None None Brazed Oil drain None None None LP gauge port None None None Gas equalization port None None Brazed Refrigerant & lubricant: M: R22, alkylbenzene lubricant P: R407C, PVE lubricant H: R410A, PVE lubricant J: R410A, PVE lubricant Tubing and electrical connections P: brazed connections, spade terminals C: brazed connections, screw terminals Motor protection L: internal motor protection Nominal capacity: In thousand Btu/h at 60 Hz, ARI conditions Model variation T: design optimized for 45/130 F U: design optimized for 45/100 F Motor voltage code 1: V/1~/60 Hz 2: V/3~/50Hz & V/3~/60 Hz 4: V/3~/50 Hz & 460V/3~/60 Hz 5: V/1~/50 Hz 7: 500V/3~/50 Hz & 575V/ 3~/60 Hz 9: 380V/3~/60 Hz Label Serial number S K Manufacturing location Production week Production year Incremental number FRCC.PC.012.A3.22 7

8 Technical specifications 60-Hz data * R22 R407C R410A Nominal Swept Nominal cooling capacity Power input A max. Efficiency Model Cap. 60 Hz volume Displacement Oil charge Net weight TR W Btu/h kw A COP W/W EER Btu/h/W cu.in/rev cu.ft/h oz lbs HRM032U HRM034T HRM034U HRM038T HRM038U HRM040T HRM040U HRM042T HRM042U HRM045U HRM047U HRM048U HRM051T HRM051U HRM054U HRM058U HRM060T HRM060U HLM068T HLM072T HLM075T HLM078T ? HLM081T HCM094T HCM109T HCM120T HRP051T HRP060T HLP081T HRH029U HRH031U HRH032U HRH034U HRH036U HRH038U HRH040U HRH041U HRH044U HRH049U HRH051U HRH054U HRH056U HLH061T HLH068T HLJ072T HLJ075T HLJ083T HCJ090T HCJ105T HCJ120T TR = Ton of Refrigeration *: ARI standard rating conditions, Evaporating temperature : 45 F COP = Coefficient Of Performance 460V / 3ph / 60Hz Condensing temperature: 130 F EER = Energy Efficiency Ratio Superheat: 20 F Sub-cooling: 15 F Subject to modification without prior notification For full data details and capacity tables refer to Online Datasheet Generator : 8 FRCC.PC.012.A3.22

9 Technical specifications 50-Hz data * Nominal Cap Swept Nominal cooling capacity Power input A max. Efficiency Model 60 Hz volume Displacement Oil charge Net weight TR W Btu/h kw A COP W/W EER Btu/h/W cu.in/rev cu.ft/h oz lbs HRM032U HRM034T HRM034U HRM038T HRM038U HRM040T HRM040U HRM042T HRM042U HRM045U HRM047U HRM048U HRM051T HRM051U HRM054U HRM058U HRM060T HRM060U HLM068T HLM072T HLM075T HLM078T ? HLM081T HCM094T HCM109T HCM120T HRP034T HRP038T HRP040T HRP042T HRP045T HRP047T HRP048T HRP051T HRP054T HRP058T HRP060T HLP068T HLP072T HLP075T HLP081T HCP094T HCP109T HCP120T HRH029U HRH031U HRH032U HRH034U HRH036U HRH038U HRH040U HRH041U HRH044U HRH049U HRH051U HRH054U HRH056U HLH061T HLH068T HLJ072T HLJ075T HLJ083T HCJ090T HCJ105T HCJ120T TR = Ton of Refrigeration *: ARI standard rating conditions, Evaporating temperature : 45 F COP = Coefficient Of Performance 400V / 3ph / 50Hz Condensing temperature: 13 F EER = Energy Efficiency Ratio Superheat: 20 F Sub-cooling: 15 F Subject to modification without prior notification - For full data details and capacity tables refer to Online Datasheet Generator : R22 R407C R410A FRCC.PC.012.A3.22 9

10 Di m e n s i o n s HRM / HRP / HRH / HRM / HRP / HRH x Ø (1) (2) Discharge line Suction line (1) (2) (1) (2) (1) 7.76 (2) 8.67 (1) 9.09 (2) P6 (1) HRM / HRP / HRH (2) HRM / HRP / HRH All dimensions in inch Terminal box Mounting grommet Quick connect spade terminals P terminal box type 5/16-18 UNC self tapping Ø Ø Recommended torque for mounting bolts: 8 ft.lbs (±1ft.lbs) Refer to page 41 for overview of shipped mounting accessories 10 FRCC.PC.012.A3.22

11 Di m e n s i o n s HRM / HLM / HRP / HLP / HRH / HLH / HLJ x Ø x Ø (1) 4.76 (2) (1) 4.76 (2) Discharge line (1) (2) Suction line Discharge line (1) (2) Suction line P C6 (1) HRM / HLM / HRP / HLP / HRH / HLH / HLJ (2) HLM / HLP All dimensions in inch (1) HRM / HLM / HRP / HLP / HRH / HLH / HLJ (2) HLM / HLP All dimensions in inch Terminal boxes C T₁ Mounting grommet S T₂ Quick connect spade terminals P terminal box type R T₃ Ring connect screw terminals C terminal box type 5/16-18 UNC self tapping Ø Ø Recommended torque for mounting bolts: 8 ft.lbs (±1ft.lbs) Refer to page 41 for overview of shipped mounting accessories FRCC.PC.012.A

12 d i m e n s i o n s HCM/HCP x Ø Discharge line Suction line (1) (2) (1) (2) (1) HCM/HCP 094 (2) HCM/HCP All dimensions in inch C6 Terminal box C T₁ Mounting grommet S T₂ R T₃ Ring connect screw terminals C terminal box type 5/16-18 UNC self tapping Ø Ø Recommended torque for mounting bolts: 8 ft.lbs (±1ft.lbs) Refer to page 41 for overview of shipped mounting accessories 12 FRCC.PC.012.A3.22

13 d i m e n s i o n s HCJ x Ø Discharge line Suction line HCJ All dimensions in inch Terminal boxes C T₁ Mounting grommet S T₂ R T₃ Ring connect screw terminals C terminal box type 5/16-18 UNC self tapping Ø Ø Recommended torque for mounting bolts: 8 ft.lbs (±1ft.lbs) Refer to page 41 for overview of shipped mounting accessories FRCC.PC.012.A

14 Electrical data, connections and wiring Motor voltage Scroll compressors are available in 6 different motor voltages. Nominal voltage 50 Hz Voltage range 50 Hz Nominal voltage 60 Hz Voltage range 60 Hz Motor voltage code 1 Motor voltage code 2 Motor voltage code 4 Motor voltage code 5 Motor voltage code 7 Motor voltage code V-3-50 Hz V-3-50 Hz V-1-50 Hz 500V-3-50 Hz V-1-60 Hz V-3-60 Hz 460V-3-60 Hz - 575V-3-60 Hz 380V-3-60 Hz Prior to energizing, verify that leads and terminal connectors are in proper working condition. Warning: For safety reasons, make voltage measurements at the unit contactor, not at compressor terminals. Always keep the terminal cover in place when the compressor is energized. Wiring connections Performer H scroll compressors will only compress gas while rotating counter-clockwise (when viewed from the compressor top). Since singlephase motors will start and run in only one direction, reverse rotation is not a major consideration. Three-phase motors, however, will start and run in either direction, depending on the phase angles of the supplied power. Care must be taken during installation to ensure that the compressor operates in the correct direction (see Phase sequence and reverse rotation protection page 16). The drawings below show electrical terminal labelling and should be used as a reference when wiring the compressor. For three phase applications, the terminals are labelled T1, T2, and T3. For single-phase applications the terminals are labelled C (common), S (start), and R (run). C T₁ S T₂ R T₃ Quick connect spade terminals P terminal box type Ring connect screw terminals C terminal box type Terminal cover mounting Terminal cover removal The terminal cover and gasket should be installed prior to operation of the compressor. The terminal cover has two outside tabs, 180 degrees apart, that engage the terminal fence. When installing push the cover, check that it is not pinching the lead wires. Both the inside of the terminal cover and the gasket have labels for the terminal pins: C (common), R (run), and S (start). push push 14 FRCC.PC.012.A3.22

15 Electrical data, connections and wiring IP rating The compressor terminal box IP rating according to CEI 529 is IP22 for all models. IP ratings is only valid when correctly sized cable glands of the IP rating is applied. First numeral, level of protection against contact and foreign objects 2 protection against object size over 1/2 inch (fingers of similar) Second numeral, level of protection against water 2 protection against dripping water when tilted up to 15 LRA (Locked Rotor Amp) MCC (Maximum Continuous Current) Winding resistance Electrical connections PSC wiring LRA is the higher average current as measured on a mechanically blocked compressor tested under nominal voltage. LRA is printed on the nameplate. The MCC is the current at which the internal motor protection trips under maximum load and low voltage conditions. Winding resistance is the resistance between indicated terminal pins at 77 F (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 stabilized ambient temperature. Winding resistance varies strongly with winding temperature; If the compressor is stabilized at a different value than 77 F, the measured resistance must be corrected with following formula: Danfoss scroll compressors are designed to operate without any assistance if running within the The start winding (C-S) of the motor remains in circuit through a permanent (run) capacitor. 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. Many countries have defined limits for the starting current in domestic use. A soft starter can be applied to reduce starting current. 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 overload will switch off to protect the motor. a + t amb R tamb = R 77 F a + t 77 F t 77 F : reference temperature = 77 F t amb : temperature during measurement ( F) R 77 F : winding resistance at 77 F R amb : winding resistance at t amb coefficient a= 390 defined nominal voltage. PSC wiring is sufficient (see below). C S This permanent (run) capacitor is connected between the start winding (C-S) and the run winding (C-R). Line R Run Capacitor CSR wiring If start assist is required, in case of operating below the nominal voltage, a CSR starting device is required. During start-up, the start winding (C-S) is energised through an electromagnetic potential relay and a start capacitor. A permanent (run) capacitor is wired between the start winding (C-S) and the run winding (C-R). Line C S R 2 Run Capacitor 5 Potential Relay 1 Start Capacitor FRCC.PC.012.A

16 Electrical data, connections and wiring Nominal capacitor value and relays 60 Hz, motor voltage code 1 50 Hz, motor voltage code 5 R22 R407C R410A R22 R407C R410A Models PSC wiring Run capacitor CSR wiring Start capacitor Relay HRM μf μf 3ARR3*3M* HRM μf μf 3ARR3*3L* HRM μf μf 3ARR3*3L* HRM μf μf 3ARR3*3L* HRM μf μf 3ARR3*3L* HRM058T1-060T1 55 μf μf 3ARR3*25S* HRM058U1-060U1, HLM μf μf 3ARR3*3L* HRP μf μf 3ARR3*3L* HLP μf μf 3ARR3*3L* HRH μf μf 3ARR3*3M* HRH μf μf 3ARR3*3L* HRH μf μf 3ARR3*3AL* HRH μf μf 3ARR3*3L* HRH μf μf 3ARR3*3L* HRH , HLH068, HLJ μf μf 3ARR3*3L* HRM μf μf 3ARR3*3AL* HRM μf μf 3ARR3*3AL* HRM μf μf 3ARR3*24AP* HRM μf μf 3ARR3*24AP* HRM μf μf 3ARR3*25AS* HLM μf μf 3ARR3*25AS* HRP μf μf 3ARR3*3AL* HRP μf μf 3ARR3*3AL* HRP μf μf 3ARR3*24AP* HRP μf μf 3ARR3*24AP* HRP μf μf 3ARR3*25AS* HLP μf μf 3ARR3*25AS* HRH μf μf 3ARR3*3AL* HRH μf μf 3ARR3*3AL* HRH μf μf 3ARR3*25AS* HLH068, HLJ μf μf 3ARR3*25AS* Internal motor protection Phase sequence and reverse rotation protection Voltage imbalance Performer H scroll compressors are equipped with an internal line break protector mounted on the motor windings. The protector is an automatic reset device, containing a snap action bimetal switch. The compressor will only operate properly in a single direction. Use a phase meter to establish the phase orders and connect line phases L1, L2 and L3 to terminals T1, T2 and T3, respectively. For three-phase compressors, the motor will run equally well in both directions. Reverse rotation results in excessive noise; no pressure differential between suction and discharge; and suction line warming rather than immediate cooling. A service technician should be present at initial start-up to verify that supply power is properly phased and that compressor and auxiliaries are rotating in the correct direction. For three-phase applications the voltage measured at the compressor terminals for each phase Internal protectors respond to over-current and overheating. They are designed to interrupt motor current under a variety of fault conditions, such as failure to start, running overload, and fan failure. If the internal overload protector trips out, it must cool down to about 140 F to reset. Depending on ambient temperature, this may take up to several hours. Performer H through Hxx075 scroll compressors are designed to operate for a maximum of 150 hours in reverse, but as a reverse rotation situation can go unnoticed for longer periods, phase monitors are recommended. For compressors Hxx078 and larger, phase monitors are required. The selected phase monitor should lock out the compressor from operation in reverse. At brief power interruptions, reverse rotation can occur with single phase compressors. In this case the internal protector will stop the compressor. It will have to cool down and will restart safely afterwards. should be within ± 2% of the average for all phases. 16 FRCC.PC.012.A3.22

17 Approvals and certifications Approvals and certificates Performer H-series compressors comply with the following approvals and certificates. Certificates are listed on the product datasheets: CE 0062 or CE 0038 (European Directive) UL (Underwriters Laboratories) Other approvals / certificates All models All 60 Hz models Contact Danfoss Pressure equipment directive 97/23/EC Products Refrigerating fluids Group 2 Category PED I Evaluation module no scope Low voltage directive 73/23/EC, 93/68/EC Products Manufacturer's declaration of incorporation ref. EC Machines Directives 98/392/CE Contact Danfoss Internal free volume HRM/P HRH HRM/P HRH040 Products Internal free volume at LP side without oil (in. 3 ) HRM/P , HLM/P HRH , HLH/J HCM/P HCJ FRCC.PC.012.A

18 Operating conditions The Performer H scroll compressor application range is influenced by several parameters which need to be monitored for a safe and reliable operation. These parameters and the main recommendations for good practice and safety devices are explained hereunder. Refrigerant and lubricants Motor supply Compressor ambient temperature Application envelope (evaporating temperature, condensing temperature, return gas temperature) Refrigerant and lubricants General information PVE When choosing a refrigerant, different aspects must be taken into consideration: Legislation (now and in the future) Safety Application envelope in relation to expected running conditions Compressor capacity and efficiency Compressor manufacturer recommendations & guidelines Polyvinyl ether (PVE) is an innovative refrigeration lubricant for HFC refrigerant systems. PVE is as hygroscopic as existing polyolester lubricants (POE), but PVE doesn t chemically react with water; no acids are formed and compressor evacuation is easier. Additional points could influence the final choice: Environmental considerations Standardization of refrigerants and lubricants Refrigerant cost Refrigerant availability The compressor technology applied in Performer H scroll compressors in combination with PVE lubricant provides the best possible result in terms of reliability and compressor lifetime. The PVE lubricant is compatible with R22 which makes the Performer H scroll compressors a very versatile multi- refrigerant solution. Alkylbenzene oil Alkylbenzene oil can be applied in systems using HCFC refrigerants (R22). Compared to a mineral oil it provides distinct advantages: excellent miscibility, excellent thermal stability, compatibility with mineral oils and constant quality. Performer H_M series compressors are charged with Alkylbenzene oil and herewith offer an economically interesting alternative to the Performer H series in regions where R22 is still the predominant refrigerant. Note however that Performer H scroll compressors can not be used with HFC refrigerants. Oil type Danfoss scroll compressors are charged with oil at the factory with the oils indicated, in the following table. Compressor range HRM / HLM / HCM HRP / HLP / HCP HRH / HLH HLJ/HCJ Oil type Alkylbenzene PVE PVE PVE Effective week 31 of 2009, the HRP/HLP/HCP & HRH/HLH series of compressors were changed from POE oil to PVE oil. Compressors produced prior to this week still had POE, and may be in stock in the warehouses until supply is exhausted. This change was made to standardize to the better oil for reliability. Replacement PVE 320HV is available for topping up or replacing oil in the field (see accessory section). As it is fully miscible with POE, Danfoss recommends the 320HV regardless of original oil charge in the compressor. Residual moisture Prior to shipment from the factory, every compressor is dehydrated, evacuated, and charged with dry nitrogen. Maximum residual moisture levels are oz. for models capacities up to HRM/HRP047 and HRH040 and oz. for larger compressors. 18 FRCC.PC.012.A3.22

19 Operating conditions Motor supply Performer H scroll compressors can be operated at nominal voltages as indicated on page 14. Under-voltage and over-voltage operation is allowed within the indicated voltage ranges. In case of risk of under-voltage operation, special attention must be paid to current draw and start assist for single-phase compressors may be required. Compressor ambient temperature Performer H scroll compressors can be applied from -30 F to 120 F ambient temperature. The compressors are designed as 100 % suction gas cooled without need for additional fan cooling. Ambient temperature has very little effect on the compressor performance. High ambient temperature In case of enclosed fitting and high ambient temperature it s recommend to check the temperature of power wires and conformity to their insulation specification. In case of safe tripping by the internal compressor overload protection the compressor must cool down to about 140 F before the overload will reset. A high ambient temperature can strongly delay this cool-down process. Low ambient temperature Although the compressor itself can withstand low ambient temperature, the system may require specific design features to ensure safe and reliable operation. See section Specific application recommendations. Application envelope R22, R407C and R410A Model variation T (optimized for 45/130 F) The operating envelopes for Danfoss scroll compressors are given in the figures below, where the condensing and evaporating temperatures represent the range for steady-state operation. Under transient conditions, such as start-up and defrost for heat pump applications, the compressor may operate outside this envelope for short periods. The figures below show the operating envelopes for HR / HL / HC compressors with refrigerants R22, R407C and R410A with model variation related to T or U design optimization. The operating limits serve to define the envelope within which reliable operations of the compressor are guaranteed: Maximum discharge gas temperature: +275 F A suction superheat below 9 F is not recommended due to the risk of liquid flood back Maximum superheat of 54 F Minimum and maximum evaporating and condensing temperatures as per the operating envelopes. Condensing temperature ( F) SH: 20 F SH: 54 F Evaporating temperature ( F) FRCC.PC.012.A

20 Operating conditions R22 and R410A Model variation U (optimized for 45/100 F) Condensing temperature ( F) SH: 20 F SH: 54 F Evaporating temperature ( F) Maximum discharge gas temperature The discharge temperature depends mainly on the combination of evaporating temperature, condensing temperature and suction gas superheat. Discharge gas temperature should be controlled with an isolated thermocouple or thermostat attached to the discharge line 6 in. from the compressor shell. Maximum discharge gas temperature must not exceed 275 F when the compressor is running within the approved operating envelope. Discharge gas temperature protection (DGT) DGT protection is required if the high and low pressure switch settings do not protect the compressor against operations beyond its specific application envelope. Please refer to the examples below, which illustrate where DGT protection is required (n 1) and where it is not (n 2). 160 The compressor must not be allowed to cycle on the discharge gas thermostat. Continuous operations beyond the compressor s operating range will cause serious damage to the compressor! A DGT accessory is available from Danfoss: refer to page Condensing temperature ( F) LP1 LP2 Example 1 Example 2 HP1 HP Example 1 (R410A, SH = 20 F) LP switch setting: LP1 = 60 psig (0 C) HP switch setting: HP1 = 550 psig (140 F) The LP and HP switches don't protect sufficiently from operation outside the envelope. A DGT protection is required to avoid operation in the hatched area. Evaporating temperature ( F) Example 2 (R410A, SH = 20 F) LP switch setting: LP2 = 75 psig (10 F) HP switch setting: HP2 = 430 psig (120 F) The LP and HP switches protect from operation outside the envelope. No DGT protection required. 20 FRCC.PC.012.A3.22

21 Operating conditions The discharge gas temperature must not exceed 275 F. Thermostat The discharge gas thermostat accessory kit includes all components required for installation, as shown below. The thermostat must be attached to the discharge line within 6 in. from the compressor discharge port. Discharge line Bracket Insulation Discharge thermostat kit code number: High and low pressure protection R22 R407C R410A Working pressure range high side psig Working pressure range low side psig Maximum high pressure safety switch setting psig Minimum low pressure safety switch setting psig Minimum low pressure pump-down switch setting psig LP safety switch shall never be bypassed. Recommended pump-down switch settings: 22 psi (R22, R407C) and 36 psi (R410A) below nominal evaporating pressure. Depends on the models, check on the nameplate High pressure Low pressure On/off cycling (cycle rate limit) A high-pressure (HP) safety switch is recommended to shut down the compressor should the discharge pressure exceed the values shown in the table below. The high-pressure switch can be set to lower values depending on the application and ambient conditions. The HP switch must either be placed in a lockout circuit or consist of a manual reset device to prevent cycling around the highpressure limit. If a discharge valve is used, the HP switch must be connected to the service valve gauge port, which must not be isolated. A low pressure (LP) safety switch is recommended. Deep vacuum operations of a scroll compressor can cause internal electrical arcing and scroll instability. Danfoss scroll compressors exhibit high volumetric efficiency and may draw very low vacuum levels, which could induce such a problem. The minimum low-pressure safety switch (loss of charge safety switch) setting is given in Danfoss recommends a restart delay timer to limit compressor cycling. The timer prevents reverse compressor rotation, which may occur during brief power interruptions. The system must be designed in a way that guarantees a minimum compressor running time of 2 minutes so as to provide for sufficient motor cooling after start-up along with proper oil return. Note: because power consumption of scroll compressors is almost directly proportional to discharge pressure, the high-pressure control can be used to indirectly limit the maximum current draw. A high-pressure control used in this manner however can never replace an external overload protector. Danfoss HCM/HCP scroll compressors are not equipped with an internal pressure relief valve; therefore a high pressure switch is required, set no higher than the limits given in the table above. the following table. For systems without pumpdown, the LP safety switch must either be a manual lockout device or an automatic switch wired into an electrical lockout circuit. The LP switch tolerance must not allow for vacuum operations of the compressor. LP switch settings for pumpdown cycles with automatic reset are also listed in the table above. Note that the oil return may vary since it depends upon system design. There must be no more than 12 starts per hour, a number higher than 12 reduces the service life of the motor-compressor unit. A three-minute (180- sec) time out is recommended. FRCC.PC.012.A

22 System design recommendations General Successful application of scroll compressors is dependent on careful selection of the compressor for the application. If the compressor is not correct for the system, it will operate beyond the limits given in this manual. Poor performance, reduced reliability, or both may result. Essential piping design considerations Proper piping practices should be employed to ensure adequate oil return, even under minimum load conditions with special consideration given to the size and slope of the tubing coming from the evaporator. Tubing returns from the evaporator should be designed so as not to trap oil and to prevent oil and refrigerant migration back to the compressor during off-cycles. If the evaporator lies above the compressor, as is often the case in split or remote condenser systems, the addition of a pump-down cycle is strongly recommended. If a pump-down cycle were to be omitted, the suction line must have a loop at the evaporator outlet to prevent refrigerant from draining into the compressor during offcycles. If the evaporator were situated below the compressor, the suction riser must be trapped so as to prevent liquid refrigerant from collecting at the thermal bulb location (see fig. 1). When the condenser is mounted at a higher position than the compressor, a suitably sized «U»- shaped trap close to the compressor is necessary to prevent oil leaving the compressor from draining back to the discharge side of the compressor during off cycle. The upper loop also helps avoid condensed liquid refrigerant from draining back to the compressor when stopped (see fig. 2). The maximum elevation difference between the indoor and outdoor section cannot exceed 26 feet. System manufacturers should specify precautions for any applications that exceed these limits to ensure compressor reliability. Piping should be designed with adequate threedimensional flexibility. It should not be in contact with the surrounding structure, unless a proper tubing mount has been installed. This protection proves necessary to avoid excess vibration, which can ultimately result in connection or tube failure due to fatigue or wear from abrasion. Aside from tubing and connection damage, excess vibration may be transmitted to the surrounding structure and generate an unacceptable noise level within that structure as well (for more information on noise and vibration, see the section on: "Sound and vibration management" p.28). fig.1 To condenser fig. 2 Upper loop 0.5 % slope, 13 ft/s or more U-trap Condenser max. 13 ft HP max. 13 ft 26 to 40 ft/s U-trap, as short as possible 0.5 % slope, 13 ft/s or more Evaporator U-trap LP 3D flexibility U-trap, as short as possible 22 FRCC.PC.012.A3.22

23 System design recommendations Refrigerant charge limit Scroll compressors can tolerate liquid refrigerant up to a certain extend without major problems. However, excessive liquid refrigerant in the compressor is always unfavorable for service life. Besides, the installation cooling capacity may be reduced because of the evaporation taking place in the compressor and/or the suction line instead of the evaporator. System design must be such that the amount of liquid refrigerant in the compressor is limited. In this respect, follow the guidelines given in the section: Essential piping design recommendations in priority. Use the tables below to quickly evaluate the required compressor protection in relation with the system charge and the application. More detailed information can be found in the paragraphs hereafter. Please contact Danfoss for any deviation from these guidelines. Notes: for reversible heat pump systems and other specific applications, please refer to section "Specific application recommendations". Compressor models HRM HRP HRH HRM / HLM HRP / HLP HRH / HLH HLJ HCM HCP HCJ Refrigerant charge limit (lbs) Depending on test results, crankcase heaters, Liquid Line Solenoid Valve, pump down or suction accumulator must be applied see below. BELOW charge limit ABOVE charge limit Packaged units No test or additional safeties required REQ REQ Off cycle migration test Liquid flood back test REQ Off cycle migration test System with remote heat exchanger REC Off cycle migration test REQ Liquid flood back test REC Recommended REQ Required No test or additional safeties required Note: for special conditions such as low ambient temperature, low load operation or brazed plate heat exchangers please refer to corresponding sections FRCC.PC.012.A

24 System design recommendations Split unit heating mode Repeat the test, but with the system in heating mode and the outdoor temperature at 0 F (-17.8 C) dry bulb. If the sump superheat is not in the ACCEPTABLE ZONE shown in the Flood back Requirement graph on the next page, a suction accumulator is required. Heat pumps INDOOR COIL Expansion device NON- BLEED NON- BLEED OUTDOOR COIL Expansion device NON- BLEED BLEED SYSTEM CHARGE <8 lbs (1) <12 lbs (2) <16 lbs (3) >8 lbs (1) >12 lbs (2) >16 lbs (3) TEST REQUIRED NO YES ACCEPTABLE SUMP SUPERHEAT TEMPERATURE NO YES ACCUMULATOR REQUIRED NO YES NO YES INDOOR COIL Expansion device BLEED BLEED OUTDOOR COIL Expansion device NON- BLEED BLEED SYSTEM CHARGE <8 lbs (1) <12 lbs (2) <16 lbs (3) <8 lbs (1) <12 lbs (2) <16 lbs (3) <8 lbs (1) <12 lbs (2) <16 lbs (3) <8 lbs (1) <12 lbs (2) <16 lbs (3) ` TEST REQUIRED YES YES ACCEPTABLE SUMP SUPERHEAT TEMPERATURE NO YES NO YES ACCUMULATOR REQUIRED YES NO YES YES NO YES (1) HRM HRP HRH (2) HRM / HLM HRP / HLP HRH / HLH HLJ (3) HCM HCP HCJ FRCC.PC.012.A3.22

25 System design recommendations Air-conditioning INDOOR COIL Expansion device NON- BLEED BLEED TYPE OUTDOOR COIL Expansion device SYSTEM CHARGE <8 lbs (1) <12 lbs (2) <16 lbs (3) <8 lbs (1) <12 lbs (2) <16 lbs (3) TEST REQUIRED NO YES ACCEPTABLE SUMP SUPERHEAT TEMPERATURE NO YES ACCUMULATOR REQUIRED NO YES NO YES (1) HRM HRP HRH (2) HRM / HLM HRP / HLP HRH / HLH HLJ (3) HCM HCP HCJ Floodback requirement Sump superheat, F Acceptable Unacceptable Saturated suction temp. F Crankcase heater Crankcase heaters provide extra compressor protection, and should be considered for all applications. For HCM/HCP and HCJ , to prevent excessive refrigerant migration during off cycles, a crankcase heater is required. For initial installation of precharged systems and for any extended power interruptions, the crankcase heater should be energized for 24 hours prior to compressor startup. FRCC.PC.012.A

26 System design recommendations Reversible heat pump systems Loss of charge protection Tandem Transients are likely to occur in reversible heat pump systems, i.e. a changeover cycle from cooling to heating, defrost or low-load short cycles. These transient modes of operation may lead to liquid refrigerant carryover (or flood back) or excessively wet refrigerant return conditions. As such, reversible cycle applications require specific precautions for ensuring a long compressor life and satisfactory operating characteristics. Regardless of the refrigerant charge in the system, specific tests for repetitive flood back are required Danfoss HCM/HCP scroll compressors do not include a thermal valve protection; therefore, all applications require loss of charge protection : For Air Conditioning, a low pressure switch in the low pressure side of the system is required. Danfoss scroll compressors in C8 version can be mounted in tandem assemblies. Such manifolding applications require special design considerations that go beyond the scope of this document. Please contact Danfoss for further information. to confirm whether or not a suction accumulator needs to be installed. A crankcase heater and discharge gas thermostat are required for reversible heat pump applications. These considerations cover the most important issues in the realm of common applications. Each application design however should be thoroughly tested to ensure acceptable operating characteristics. For Heat pump applications a discharge line thermostat set no higher than 275 F is required. The thermostat must be a manual lockout type device (or electrical lockout circuit) and be located within 5.90 in. of the compressor discharge connection. The discharge line thermostat must be insulated to insure proper sensing and operation. Oil level checking and top-up Minimum sump superheat High pressure ratio Phase sequence and reverse rotation protection In installations with good oil return and line runs up to 50 ft, no additional oil is required. If installation lines exceed 50 ft, additional oil may be needed. 1 or 2% of the total system refrigerant charge (in weight) can be used to roughly define the required oil top-up quantity. Use a phase meter to establish the phase orders and connect line phases L1, L2 and L3 to terminals T1, T2 and T3, respectively. The compressor will only operate properly in a single direction, and the motor is wound so that if the connections are correct, the rotation will also be correct. This is particularly important with three-phase compressors since the motor will run equally well in both Always use oil from new cans. Top-up the oil while the compressor is idle. Use any accessible connector on the compressor suction line and a suitable pump. The minimum sump temperature is in the range from 10 F to 30 F above saturated suction temperature. Refer to the flood back test criteria on pages 24 and 25. Scroll compressors are machines with fixed volume ratio, and operate more efficiently near the design pressure ratio. In the extreme, do not exceed a 7.5:1 pressure ratio (absolute discharge pressure to absolute suction pressure) for extended periods. The Danfoss scroll compressor is equipped with an internal pressure relief valve for protection against blocked condenser and fan failure conditions. directions. Reverse rotation results in excessive noise; no pressure differential between suction and discharge; and suction line warming rather than immediate cooling. A service technician should be present at initial start-up to verify that supply power is properly phased and that compressor and blowers are rotating in the correct direction. Danfoss Scroll compressors are designed 26 FRCC.PC.012.A3.22

27 System design recommendations Internal motor protection Preventing liquid flood back Testing for excessive liquid flood back Split unit cooling mode Water utilizing systems to operate for a maximum of 150 cycles (hours) in reverse, but as a reverse rotation situation can go unnoticed for longer periods, phase monitors are recommended. Danfoss scroll compressors are equipped with internal line break protectors mounted on their motor windings. The protectors are automatic reset devices, each containing a snap action bimetal switch. Internal protectors respond to over-current and to high temperature. They are designed to interrupt motor current under a variety of fault conditions, Danfoss recommends the use of a thermostatic expansion valve for all air conditioning and heat pump applications. A TXV has two key benefits: it provides modulating control of the system under varying load conditions, and it protects the compressors from flood back during adverse running conditions. Set up a system with the smallest rated indoor section for the tested outdoor section. Charge the system with 120% of the system nameplate charge using 25 ft. (7.62 m) of interconnecting tubing. Ensure that both indoor and outdoor sections have full airflow. Apply voltage to the compressor. Operate the system at 115 F (46.1 C) dry bulb outdoor and 67 F (19.4 C) dry bulb and Apart from residual moisture in the system after commissioning, water could also enter the refrigeration circuit during operation. Water in the system shall always be avoided. Not only because it can shortly lead to electrical failure, sludge in sump and corrosion but in particular because it can cause serious safety risks. Common causes for water leaks are corrosion and freezing. For compressors HLM078, HLP081, HLJ083 and larger, phase monitors are required for all applications. Danfoss recommends phase protection for residential compressors. The selected phase sensing device should lock out the compressor from operation in reverse. such as failure to start, running overload, and fan failure. In single-phase compressors, internal protectors guard against external miswiring, such as reversing electrical connections to the Run (R) and Start (S) terminals. In three-phase compressors the internal protectors provide protection during secondary single-phase conditions (loss of phase). Excessive liquid refrigerant flood back during steady state operation is a major system design consideration for all types of compressors. Oil dilution that occurs with excessive flood back can have a significant adverse effect on bearing reliability. Suction accumulators may be required in some applications to prevent flood back. When the use of fixed orifice devices is specified in the system design, and when a TXV is applied at the limit of its control range, the following tests should be conducted to determine if a suction accumulator is needed. Refer to the flowcharts on pages 24 and 25 to determine when to apply the excessive liquid flood back test. 57 F (13.9 C) wet bulb indoor for a minimum of one hour. Unless the sump superheat is in the area designated Acceptable Zone in the chart on page 25, a suction accumulator is required. (Sump superheat is found by subtracting saturated suction temperature from compressor base temperature.) Corrosion: Materials in the system shall be compliant with water and protected against corrosion. Freezing: When water freezes into ice its volume expands which can damage heat exchanger walls and cause leaks. During off periods water inside heat exchangers could start freezing when ambient temperature is lower than 32 F. During on periods ice banking could occur when the circuit is running continuously at too low load. Both situations should be avoided by connecting a pressure and thermostat switch in the safety line. FRCC.PC.012.A

28 Sound and vibration management Starting sound level Running sound level Danfoss scroll compressors are designed with optimized discharge ports and wrap geometry During start-up transients it is natural for the compressor sound level to be slightly higher than during normal running. Danfoss scroll compressors exhibit very little increased start-up transient sound. If a 3-phase model is miswired, the compressor will run in reverse. Reverse compressor rotation is characterized by an objectionable sound. To correct reverse rotation, disconnect power and switch any two of the three power leads at the unit contactor. Never switch leads at the compressor terminals. to reduce the sound level when a compressor is running. Model Sound power (dba) Without jacket 60 Hz 50 Hz Sound power (dba) With jacket Sound power (dba) Without jacket Sound power (dba) With jacket HRM HRM HRM HRM HLM HCM HCM HRH HRH HRH HLH HLH068 - HLJ HCJ HCJ H*P series same as H*M Stopping sound level Sound generation in a refrigeration system / air conditioning system Compressor sound radiation Danfoss scrolls have very low shutdown sound due to minimal volume of discharge volume to push scrolls in reverse at shutdown. Due to this Typical sound and vibration in refrigeration and air conditioning systems encountered by design and service engineers may be broken down into the following three source categories. Sound radiation: This generally takes an airborne path. For sound radiating from the compressor, the emission path is airborne and the sound waves are travelling directly from the machine in all directions. The Danfoss scroll compressor is designed to be quiet and the frequency of the sound generated is pushed into the higher ranges, which not only are easier to reduce but also do not generate the penetrating power of lower-frequency sound. small re expansion there is no internal break mechanism required to prevent reverse spin of the scroll set. Mechanical vibrations: These generally extend along the parts of the unit and structure. Gas pulsation: This tends to travel through the cooling medium, i.e. the refrigerant. The following sections will focus on the causes and methods of mitigation for each of the above sources. Use of sound-insulation materials on the inside of unit panels is an effective means of substantially reducing the sound being transmitted to the outside. Ensure that no components capable of transmitting sound/vibration within the unit come into direct contact with any non-insulated parts on the walls of the unit. Because of the Danfoss s unique design of a fullsuction gas & oil cooled motor, compressor body insulation across its entire operating range is possible. 28 FRCC.PC.012.A3.22

29 Sound and vibration management Mechanical vibrations Vibration isolation constitutes the primary method for controlling structural vibration. Danfoss scroll compressors are designed to produce minimal vibration during operations. The use of rubber isolators on the compressor base plate or on the frame of a manifolded unit is very effective in reducing vibration being transmitted from the compressor(s) to the unit. Rubber grommets are supplied with all Danfoss compressors. Once the supplied rubber grommets have been properly mounted, vibration transmitted from the compressor base plate to the unit are held to a strict minimum. In addition, it is extremely important that the frame supporting the mounted compressor be of sufficient mass and stiffness to help dampen any residual vibration potentially transmitted to the frame. The tubing should be designed so as to both reduce the transmission of vibrations to other structures and withstand vibration without incurring any damage. Tubing should also be designed for three-dimensional flexibility. For more information on piping design, please see the section entitled "Essential piping design considerations" page 22. Gas pulsation The Performer H scroll compressor has been designed and tested to ensure that gas pulsation has been optimized for the most commonly encountered air conditioning pressure ratio. On heat pump installations and other installations where the pressure ratio lies beyond the typical range, testing should be conducted under all expected conditions and operating configurations to ensure that minimum gas pulsation is present. If an unacceptable level is identified, a discharge muffler with the appropriate resonant volume and mass should be installed. This information can be obtained from the component manufacturer. FRCC.PC.012.A

30 In s t a l l a t i o n Each Danfoss scroll compressor is shipped with printed Instructions for installation. These Instructions can also be downloaded from our web site or directly from: System cleanliness The refrigerant compression system, regardless of the type of compressor used, will only provide high efficiency and good reliability, along with a long operating life, if the system contains solely the refrigerant and oil it was designed for. Any other substances within the system will not improve performance and, in most cases, will be highly detrimental to system operations. The presence of non-condensable substances and system contaminants, such as metal shavings, solder and flux, have a negative impact on compressor service life. Many of these contaminants are small enough to pass through a mesh screen and can cause considerable damage within a bearing assembly. The use of highly hygroscopic POE and PVE oils in R407C and R410A compressors requires that the oil be exposed to the atmosphere just as little as possible. System contamination is one of main factors affecting equipment reliability and compressor service life. It is important therefore to take system cleanliness into account when assembling a refrigeration system. During the manufacturing process, circuit contamination may be caused by: Brazing and welding oxides, Filings and particles from the removal of burrs in pipe-work, Brazing flux, Moisture and air. Consequently, when building equipment and assemblies, the following precautions must be taken: never drill holes into the pipe-work after installation. Compressor handling and storage Compressor mounting Compressors are provided with a lifting lug. This lug should always be used to lift the compressor. Once the compressor is installed, the lifting lug should never be used to lift the complete installation. The compressor must be handled with caution in the vertical position, with a maximum inclination of 15 from vertical. Store the compressor between -30 F and 120 F, not exposed to rain or corrosive atmosphere. Maximum inclination from the vertical plane, while operating must not exceed 7 degrees. All compressors are delivered with 4 rubber grommets and metal sleeves. Compressors must always be mounted with these grommets. Compressor holding charge Each compressor is shipped with a nominal dry nitrogen holding charge between 6 psi and 10 psi, and is sealed with elastomer plugs. The plugs should be removed with care to avoid oil loss when the holding charge is released. Remove the suction plug first and the discharge plug afterwards. The plugs shall be removed only just before connecting the compressor to the installation in order to avoid moisture entering the compressor. When the plugs are removed, it is essential to keep the compressor in an upright position to avoid oil spillage. Tube brazing procedure Do not bend the compressor discharge or suction lines or force system piping into the compressor connections, because this will increase stresses that are a potential cause of failure. Recommended brazing procedures and material, are described on following page. Brazing material For copper suction and discharge fittings, use copper-phosphorus brazing material. Sil-Fos and other silver brazing materials are also acceptable. If flux is required for the brazing operation, use coated rod or flux core wire. To avoid system contamination, do not brush flux on. 30 FRCC.PC.012.A3.22

31 In s t a l l a t i o n Compressor connection When brazing the compressor fittings, do not overheat the compressor shell, which could severely damage certain internal components due to excessive heating. Use of a heat shield and/ or a heat-absorbent compound is highly recommended. For brazing the suction and discharge connections, the following procedure is advised: Make sure that no electrical wiring is connected to the compressor. Protect the terminal box and compressor painted surfaces from torch heat damage (see diagram). Use only clean refrigeration-grade copper tubing and clean all connections. Purge nitrogen or CO 2 through the compressor in order to prevent against oxidation and flammable conditions. The compressor should not be exposed to the open air for extended periods. Use of a double-tipped torch is recommended. Apply heat evenly to Area A until the brazing temperature is reached. Move the torch to Area B and apply heat evenly until the brazing temperature has been reached there as well, and then begin adding the brazing material. Move the torch evenly around the joint, in applying only enough brazing material to flow the full circumference of the joint. Move the torch to area C only long enough to draw the brazing material into the joint, but not into the compressor. Remove all remaining flux once the joint has been soldered with a wire brush or a wet cloth. Remaining flux would cause corrosion of the tubing. Ensure that no flux is allowed to enter into the tubing or compressor. Flux is acidic and can cause Heat shield C B A substantial damage to the internal parts of the system and compressor. The POE and PVE oils used in compressors are highly hygroscopic and will rapidly absorb moisture from the air. The compressor must therefore not be left open to the atmosphere for a long period of time. The compressor fitting plugs shall be removed just before brazing the compressor. Before eventual unbrazing the compressor or any system component, the refrigerant charge must be removed from both the high and low pressure sides. Failure to do so may result in serious personal injury. Pressure gauges must be used to ensure all pressures are at atmospheric level. For more detailed information on the appropriate materials required for brazing or soldering, please contact the product manufacturer or distributor. For specific applications not covered herein, please contact Danfoss Commercial Compressors for further information. Vacuum evacuation and moisture removal Moisture obstructs the proper functioning of both the compressor and the refrigeration system. Air and moisture reduce service life and increase condensing pressure, which causes abnormally high discharge temperatures that are then capable of degrading the lubricating properties of the oil. The risk of acid formation is also increased by air and moisture, and this condition can also lead to copper plating. All these phenomena may cause both mechanical and electrical compressor failures. The typical method for avoiding such problems is a vacuum pump-down executed with a vacuum pump, thus creating a minimum vacuum of 0.02 in Hg (500 µm Hg). Please refer to Bulletin "Vacuum pump down and dehydration procedure". Be sure to follow all government regulations regarding refrigerant reclamation and storage. FRCC.PC.012.A

32 In s t a l l a t i o n Liquid line filter driers A properly sized filter drier is required for all Danfoss scroll applications. Danfoss recommends DCL (solid core) driers for HCFC refrigerants with mineral oil, and DML (100% molecular seives) driers for HFC refrigerants R407C and R410A with POE or PVE oil. For servicing of existing installations where acid formation is present the Danfoss DCL solid core filter driers containing activated alumina are recommended. The drier is to be oversized rather than under sized. When selecting a drier, always take into account its capacity (water content capacity), the system refrigeration capacity and the system refrigerant charge. Refrigerant charging It is recommended that system charging be done using the weighed charge method, adding refrigerant to the high side of the system. Charging the high and low sides of a system with gas simultaneously at a controlled rate is also an acceptable method. Do not exceed the recommended unit charge, and never charge liquid to the low side. Insulation resistance and dielectric strength Insulation resistance must be greater than 1 megohm when measured with a 500 volt direct current megohm tester. Each compressor motor is tested at the factory with a high potential voltage (hi-pot) that exceeds the UL requirement both in potential and in duration. Leakage current is less than 0.5 ma. Danfoss scroll compressors are configured with the pump assembly at the top of the shell, and the motor below. As a result, the motor can be partially immersed in refrigerant and oil. 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, and should not be cause for concern. In testing insulation resistance, Danfoss recommends that the system be first operated briefly to distribute refrigerant throughout the system. Following this brief operation, retest the compressor for insulation resistance or current leakage. Compressor replacement after motor burn out If there has been a motor burnout follow the evacuation procedure described on previous page. Remove and replace the liquid line filter drier and install a Danfoss type DAS burnout drier of appropriate capacity. Refer to the DAS drier instructions and technical information on correct use and monitoring of the burnout drier and the liquid line and suction line filter driers. 32 FRCC.PC.012.A3.22

33 Ordering information and packaging Packaging Single pack Compressors are packed individually in a cardboard box. They can be ordered in any quantity. Minimum ordering quantity = 1. As far as possible, Danfoss will ship the boxes on full pallets of 8 or 16 compressors according below table. Each box also contains following accessories: 4 grommets 4 assemblies of self tapping US thread bolts, washers and sleeves 4 additional sleeves 1 screw for earth connection Depending on model and shipping type a run capacitor may be included (see table). Industrial pack Compressors are not packed individually but are shipped all together on one pallet. They can be ordered in quantities of full pallets only, multiples of 12 or 16 compressors, according below table. Each industrial pack pallet contains following accessories: 4 grommets per compressor 4 sleeves per compressor Packaging details According to delivery region, packaging dimensions and compressor quantities are different. See below for details. Delivered region Packaging Nbr Pallet type Comments Americas Asia Pacific Middle East Single pack 16 US pallet Industrial pack 16 US pallet Optimized for overseas container loading Single pack 8 Danfoss pallet Europe Industrial pack 12 Danfoss pallet * Nbr : number of compressors/pallet - FRCC.PC.012.A

34 Ordering information and packaging R22 Single pack Compressors Model Variation Connections Features Code no HRM032 U P 6 120U U U0996 T P 6 120U0956 HRM034 U P 6 120U U U U2232 T P 6 120U U U2087 HRM038 U P 6 120U U U U U1056 T P 6 120U U U2092 HRM040 U P 6 120U U U U U1061 T P 6 120U U U2462 HRM042 U P 6 120U U U U U1066 T P 6 120U U U2107 HRM045 U P 6 120U U U U U1071 HRM047 U P 6 120U U U U U1076 T P 6 120U U U2097 HRM048 U C 8 120U1671 U P 6 120U U U1791 HRM051 T P 6 120U U U2382 U P 6 120U U U U U1801 U C 6 120U1516 HRM054 U P 6 120U U U U U1811 T P 6 120U2292 T C 6 120U1526 HRM058 T P 6 120U U2112 U C 6 120U1536 U P 6 120U U U U U1821 T P 6 120U U U2082 T C 6 120U2242 HRM060 U C 6 120U U2077 U C 8 120U1741 U P 6 120U U U U U1831 HLM068 T C 6 120U U U U2392 T P 6 120U U1616 T C 6 120U U U U1856 HLM072 T C 8 120U U2067 T P 6 120U U1626 HLM075 T C 6 120U U U1836 T P 6 120U U1636 HLM078 T C 6 120U U1771 T C 6 120U U U U2102 HLM081 T C 8 120U2009 T P 6 120U U1646 T C 6 120U U U U0746 HCM094 T C 7 120U0586 T C 8 120U U U U0756 T C 6 120U U0366 HCM109 T C 7 120U0371 T C 8 120U1924 T C 6 120U U0391 HCM120 T C 7 120U U0396 T C 8 120U U FRCC.PC.012.A3.22

35 Ordering information and packaging R22 Industrial pack Compressors Model Variation Connections Features Code no HRM032 U P 6 120U U U0993 T P 6 120U0953 HRM034 T P 6 120U U U2084 U P 6 120U U U U2229 HRM038 T P 6 120U U U2089 U P 6 120U U U U U1053 HRM040 T P 6 120U U U2459 U P 6 120U U U U U1058 HRM042 T P 6 120U U U2104 U P 6 120U U U U U1063 HRM045 U P 6 120U U U U U1068 HRM047 T P 6 120U U U2094 U P 6 120U U U U U1073 HRM048 U C 8 120U1668 U P 6 120U U U1788 HRM051 T P 6 120U U U2379 U P 6 120U U U U U1798 T P 6 120U2289 HRM054 U C 6 120U1513 U P 6 120U U U U U1808 T C 6 120U1523 T P 6 120U U2109 HRM058 U C 6 120U1533 U C 8 120U1716 U P 6 120U U U U U1818 T C 6 120U2239 T P 6 120U U U2079 HRM060 U C 6 120U U2074 U C 8 120U1738 U P 6 120U U U U U1828 HLM068 T C 6 120U U U U2389 T P 6 120U U1613 T C 6 120U U U U1853 HLM072 T C 8 120U U2064 T P 6 120U U1623 HLM075 T C 6 120U U U1833 T P 6 120U U1633 HLM078 T C 6 120U U1768 T C 6 120U U U U2099 HLM081 T C 8 120U2006 T P 6 120U U1643 T C 6 120U U U U0743 HCM094 T C 7 120U0583 T C 8 120U U U U0753 T C 6 120U U0363 HCM109 T C 7 120U0368 T C 8 120U1921 T C 6 120U U0388 HCM120 T C 7 120U U0393 T C 8 120U U2204 FRCC.PC.012.A

36 Ordering information and packaging R407C Single pack Code no. Compressors Model Variation Connections Features HRP034 T P 6 120U U2019 HRP038 T P 6 120U U U0961 HRP040 T P 6 120U U U1929 HRP042 T P 6 120U U U2157 HRP045 T P 6 120U U U0976 HRP047 T P 6 120U U U0986 HRP048 T C 8 120U1661 HRP048 T P 6 120U1656 HRP051 T P 6 120U U U U U1796 HRP054 T P 6 120U U U1806 T C 8 120U2004 HRP058 T C 8 120U1706 T P 6 120U U U1816 HRP060 T C 8 120U1731 T P 6 120U U U U1826 HLP068 T C 6 120U2014 T P 6 120U U1621 T C 6 120U1756 HLP072 T C 8 120U2072 T P 6 120U U1631 HLP075 T C 6 120U U1841 T P 6 120U U1641 HLP078 T C 6 120U U2454 T C 6 120U U U1851 HLP081 T C 8 120U1786 T P 6 120U U1651 T C 6 120U U0601 HCP094 T C 7 120U U0606 T C 8 120U U0611 T C 6 120U0376 HCP109 T C 7 120U0381 T C 8 120U0386 T C 6 120U U0401 HCP120 T C 7 120U U0406 T C 8 120U U FRCC.PC.012.A3.22

37 Ordering information and packaging R407C Industrial pack Code no. Compressors Model Variation Connections Features HRP034 T P 6 120U U2016 HRP038 T P 6 120U U U0958 HRP040 T P 6 120U U U1926 HRP042 T P 6 120U U U2154 HRP045 T P 6 120U U U0973 HRP047 T P 6 120U U U0983 HRP048 T C 8 120U1658 HRP048 T P 6 120U1653 HRP051 T P 6 120U U U U U1793 HRP054 T P 6 120U U U1803 T C 8 120U2001 HRP058 T C 8 120U1703 T P 6 120U U U1813 HRP060 T C 8 120U1728 T P 6 120U U U U1823 HLP068 T C 6 120U2011 T P 6 120U U1618 T C 6 120U1753 HLP072 T C 8 120U2074 T P 6 120U U1628 HLP075 T C 6 120U U1838 T P 6 120U U1638 HLP078 T C 6 120U U2451 T C 6 120U U U1848 HLP081 T C 8 120U1783 T P 6 120U U1648 T C 6 120U U0598 HCP094 T C 7 120U U0603 T C 8 120U U0608 T C 6 120U0373 HCP109 T C 7 120U0378 T C 8 120U0383 T C 6 120U U0398 HCP120 T C 7 120U U0403 T C 8 120U U0408 FRCC.PC.012.A

38 Ordering information and packaging R410A Single pack Compressors Model Variation Connections Features Code no HRH029 U P 6 120U U U2287 HRH031 U P 6 120U U U U U1216 HRH032 U P 6 120U U U U U1221 HRH034 U P 6 120U U U U U U2654 HRH036 U P 6 120U U U U U1231 HRH038 U P 6 120U U U U U U2658 HRH039 U P 6 120U2466 HRH040 U P 6 120U U U U U1241 U P 6 120U U U U1406 HRH041 U C 6 120U2412 U C 8 120U U U2402 HRH044 U P 6 120U U U U1411 HRH047 U P 6 120U2362 HRH048 U P 6 120U2582 HRH049 U P 6 120U U U U1416 U C 8 120U U U2478 HRH050 U P 6 120U2470 HRH051 U P 6 120U U U U U1421 HRH054 U P 6 120U U U U U1426 HRH056 U C 6 120U U2237 U P 6 120U U U U U1431 T C 6 120U U U U2450 HLH061 T P 6 120U U2047 T C 8 120U U U2490 T C 6 120U U U1436 HLH068 T P 6 120U U1341 T C 8 120U U U2422 T C 6 120U U U2037 HLJ072 T P 6 120U U1346 T C 8 120U U U2498 HLJ075 T C 6 120U U U2262 T C 8 120U U U2437 T C 6 120U U U U2387 HLJ083 T P 6 120U U1351 T C 8 120U U U2502 T C 6 120U U U2312 HCJ090 T C 7 120U U U2510 T C 8 120U U U2514 T C 6 120U U U2332 HCJ105 T C 7 120U U U2518 T C 8 120U U U2522 T C 6 120U U U2352 HCJ120 T C 7 120U U U2526 T C 8 120U U U FRCC.PC.012.A3.22

39 Ordering information and packaging R410A Industrial pack Compressors Model Variation Connections Features Code no HRH029 U P 6 120U U U2284 HRH031 U P 6 120U U U U U1213 HRH032 U P 6 120U U U U U1218 HRH034 U P 6 120U U U U U U2651 HRH036 U P 6 120U U U U U1228 HRH038 U P 6 120U U U U U U2655 HRH039 U P 6 120U2463 HRH040 U P 6 120U U U U U1238 U P 6 120U U U U1403 HRH041 U C 6 120U2409 U C 8 120U U U2399 HRH044 U P 6 120U U U U1408 HRH047 U P 6 120U2359 HRH048 U P 6 120U2579 HRH049 U P 6 120U U U U1413 U C 8 120U U U2475 HRH050 U P 6 120U2467 HRH051 U P 6 120U U U U U1418 HRH054 U P 6 120U U U U U1423 HRH056 U C 6 120U U2234 HRH056 U P 6 120U U U U U1428 T P 6 120U U2044 HLH061 T C 6 120U U U U2447 T C 8 120U U U2487 T C 6 120U U U1433 HLH068 T C 8 120U U U2419 T P 6 120U U1338 T C 6 120U U U2034 HLJ072 T C 8 120U U U2495 T P 6 120U U1343 HLJ075 T C 6 120U U U U1443 T C 8 120U U U2434 T C 6 120U U U U2384 HLJ083 T C 8 120U U U2499 T P 6 120U U1348 T C 6 120U U U2309 HCJ090 T C 7 120U U U2507 T C 8 120U U U2511 T C 6 120U U U2329 HCJ105 T C 7 120U U U2515 T C 8 120U U U2519 T C 6 120U U U2349 HCJ120 T C 7 120U U U2523 T C 8 120U U U2527 FRCC.PC.012.A

40 Spare parts & accessories Run capacitors for PSC wiring Type Code n Description Application Packaging 70 µf 120Z0051 PSC wiring Run Capacitor 70 µf, motor voltage code V / 1 / 50Hz Start capacitors and starting relay for CSR wiring HRM HRP HRH Pack size Multipack µf 120Z0050 PSC wiring Run Capacitor 60 µf, HRM HRP HRH Multipack µf PSC wiring Run Capacitor 55 µf, motor voltage code V / 1 / 50Hz HRM / HLM HRP / HLP HRH / HLH068 / HLJ Multipack 10 Type Code n Description Application Packaging µf 120Z0399 CSR wiring Start Capacitor µf, motor voltage code V / 1 / 50Hz Rotolock adaptor set HRM/P HRH Pack size Multipack µf 120Z0040 CSR wiring Start Capacitor µf, motor voltage code V / 1 / 50Hz HRM/P Multipack µf CSR wiring Start Capacitor µf, motor voltage code V / 1 / 50Hz RVA9CKL 120Z0393 CSR wiring Starting Relay, motor voltage code V / 1 / 50Hz HRM/P HLM/P HRH HLH068 HLJ HRM/P HRH Multipack 10 Multipack 10 RVA3EKL 120Z0394 CSR wiring Starting Relay, motor voltage code V / 1 / 50Hz HRM/P Multipack 10 RVA4GKL 120Z0395 CSR wiring Starting Relay, motor voltage code V / 1 / 50Hz HRM/P HLM/P HRH HLH068 HLJ Multipack 10 Type Code n Description Application Packaging Pack size Rotolock adaptor 120Z0126 Rotolock adaptor set (1-1/4" ~ 3/4"), (1" ~ 1/2") 120Z0127 Rotolock adaptor set (1-1/4" ~ 7/8"), (1" ~ 1/2") HRP/HRM HRH group 1 HRP/HRM HRH group 2 Multipack 6 Multipack 6 120Z0128 Rotolock adaptor set (1-1/4" ~ 7/8"), (1-1/4" ~ 3/4") HRM/HRP group 3 Multipack 6 120Z0129 Rotolock adaptor set (1-3/4" ~ 1-1/8"), (1-1/4" ~ 7/8") HCM/P HCJ group 4 Multipack 6 Type Code n Description Application (see above group) Packaging 120Z0366 Rotolock adaptor (1-1/4" ~ 3/4") Group 1 suction Multipack Z0367 Rotolock adaptor (1-1/4" ~ 7/8") Group 2 & 3 suction Multipack Z0364 Rotolock adaptor (1-3/4" ~ 1-1/8") Group 4 suction Multipack Z0365 Rotolock adaptor (1" ~ 1/2") Group 1 & 2 discharge Multipack Z0366 Rotolock adaptor (1-1/4" ~ 3/4") Group 3 discharge Multipack Z0367 Rotolock adaptor (1-1/4" ~ 7/8") Group 4 discharge Multipack 10 Pack size 40 FRCC.PC.012.A3.22

41 Spare parts & accessories Crankcase heater Type Code No Description Application Packaging Pack Size 120Z0055 Belt type crankcase heater, 40 W, 230 V, CE mark HRM Multipack 6 120Z0056 Belt type crankcase heater, 40 W, 400 V, CE mark HRP HRH Multipack 6 120Z0057 Belt type crankcase heater, 50 W, 230 V, CE mark HRM / HLM068- Multipack 6 120Z0058 Belt type crankcase heater, 50 W, 400 V, CE mark HRP / HLP HRH Multipack / HLH / HLJ072 / HLJ Z0059 Belt type crankcase heater, 65 W, 230 V, CE mark, UL Multipack 6 120Z5011 Belt type crankcase heater, 70 W, 230 V, UL, CE mark HLM / HCM HLP081 Multipack 6 120Z0060 Belt type crankcase heater, 65 W, 400 V, CE mark, UL / HCP HLJ083 - HCJ 090- Multipack 6 120Z5012 Belt type crankcase heater, 70 W, 460 V, UL, CE mark Multipack 6 120Z5013 Belt type crankcase heater, 70 W, 575 V, UL, CE mark Multipack 6 Discharge temperature protection Type Code No Description Application Packaging Discharge thermostat kit All models Multipack Discharge thermostat kit All models Industry pack 50 Pack Size Lubricant Type Code No Description Application Packaging 120Z5034 PVE (0.95 liter can) HRH, HLH, HLJ, HCJ, HRP, HLP & HCP Multipack 1 Pack Size Mounting hardware Type Code No Description Application Packaging 120Z5017 Mounting grommet All models Single pack 1 120Z5014 Mounting sleeve All models Single pack 1 120Z5031 Mounting kit, including 1 bolt, 1 sleeve, 1 washer All models Single pack 1 120Z5005 Mounting kit for 1 scroll compressor including 4 grommets, 4 sleeves, 4 bolts, 4 washers All models Single pack 1 Pack Size FRCC.PC.012.A

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44 The Danfoss product range for the refrigeration and air conditioning industry Danfoss Refrigeration & Air Conditioning is a worldwide manufacturer with a leading position in industrial, commercial and supermarket refrigeration as well as air conditioning and climate solutions. We focus on our core business of making quality products, components and systems that enhance performance and reduce total life cycle costs the key to major savings. Controls for Commercial Refrigeration Controls for Industrial Refrigeration Electronic Controls & Sensors Industrial Automation Household Compressors Commercial Compressors Sub-Assemblies Thermostats Brazed plate heat exchanger We are offering a single source for one of the widest ranges of innovative refrigeration and air conditioning components and systems in the world. And, we back technical solutions with business solution to help your company reduce costs, streamline processes and achieve your business goals. Danfoss A/S Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved. FRCC.PC.012.A November 2009 Produced by Danfoss CC - DSS - 11/09