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Contents

1 - Introduction
2 - Transportation, storage
3 - Safety measures prior to assembly
4 - Assembly  
5 - Leak detection 
6 - Vacuum dehydration procedure
7 - Electrical connections
8 - Filling the system
9 - Verification before commissioning

10 - Start up
11 - Troubleshooting
12 - Maintenance
13 - Replacement
14 - User advisory 

1 - Introduction

These instructions pertain to Bluestar condensing
units used for refrigeration purposes. They are
intended to provide necessary information
regarding safety features and proper handling of
this product.

Note that this is a general document for the entire
range of condensing units; certain details therefore
may not be applicable to the particular model you
purchased. Please keep your manual and all
relevant information handy for future reference.

• Equipment description: condensing units are
available under different configurations. They
incorporate a compressor and a fan-cooled
condenser mounted on a base frame. In addition,
they may include a liquid receiver, a pressure
switch, a connecting box and service valves.

• Approved list of refrigerants:

- The MGM, HGM, MCMC and MGMC product

line (fitted with  Maneurop

®

MT compressors)

can be used with R22, R12 and R502.

- The MGZ, HGZ, MCZC and MGZC product

line (fitted with Maneurop

®

MTZ compressors)

can be used with R404A, R507A, R134a and
R407C.

- The LGZ, LCHC and LGHC product line (fitted

with Maneurop

®

LTZ or NTZ compressors) can

be used with R404A and R507A.

• Note that Maneurop

®

compressors are filled

with lubricant before leaving the factory:

- The MT series with mineral oil (ref. 160P),
- The MTZ series with polyolester oil (ref. 160PZ),
- The LTZ and NTZ series with polyolester oil

(ref. 160Z).

These lubricants must not be mixed with one another.

• Condensing units must only be used for their
designed purpose(s) and within their scope of
application (refer to Fig. 1).

Condensing units are delivered under nitrogen

gas pressure (between 1 and 2 bar) and hence
cannot be connected as is; please refer to the
"

Assembly

" section for further details.

Condensing units are not certified for mobile

and explosion-proof applications. Any use of

flammable refrigerant (e.g. hydrocarbons) or air is
also strictly forbidden.

• Under all circumstances, the EN378 (or other
applicable local regulation) requirement must be
fulfilled.

When pressure tests are required on the system,

they are to be performed by qualified personnel, in
paying close attention to potential pressure-rela-

ted hazards and heeding the pressure limits dis-
played on the compressor nameplate or in the
application guidelines.

Modifications or alterations to the compressor

or receiver (such as brazing on the shell) not
expressly approved by the party responsible for
ensuring compliance could invalidate the user's
authorization to operate the equipment.

2 - Transportation, storage

• The condensing unit must be handled in the
vertical position (maximum offset from the
vertical: 15°). Should the unit be handled in an
upside-down position, its performance may no
longer be insured.

• Beware that all condensing unit handling must
be carried out with extreme caution to avoid any
shocks. Appropriate and safe lifting equipment
is to be used during handling and unpacking.
Be careful with the condenser’s front surface
(note that the condenser side is indicated on
the packaging).

• Any damage noticed on either the packaging
or the product itself upon reception should be
indicated on a Customer Claim addressed to the
shipping company. The same recommendation
applies to all instances when transport instructions
have not been fully respected.

• Please review the safety instructions printed on
the cardboard packaging before storage.

• Verify that the condensing unit is never stored in
an ambient temperature of below -35°C (-31°F) or
above 50°C (122°F).

• Ensure that the condensing unit and its
packaging are not exposed to rain and/or a
corrosive, flammable atmosphere.

3 - Safety measures prior to assembly

• All installation and servicing is to be performed
by qualified personnel in compliance with all
pertinent practices and safety procedures.

• The condensing unit must be located in a
well-ventilated area; air flow through unit shall not
be restricted in any way (refer to Fig.2). Make
sure that the ambient temperature never exceeds
50°C (122°F) during the off-cycle.

• For outdoor installations, provide a shelter or
use a Danfoss condensing unit housing.

• Make certain that the condensing unit can be
mounted onto a horizontal plane with a maximum
slope of 3°.

• Check that the condensing unit model 
corresponds to system specifications (capacity,
use of refrigerant, etc.).

• Verify that the power supply corresponds to
compressor and fan motor characteristics (refer
to the condensing unit nameplate for precision).

• Ensure that the refrigerant charging equipment,
vacuum pumps, etc. for HFC refrigerant systems
have been specifically reserved for these refrigerants
and never used with other CFC, HCFC refrigerants.

• Use only clean and dehydrated refrigeration-
grade copper tubes as well as silver alloy brazing
material.

• Verify that all system components are
appropriate (use of refrigerant, etc.), clean and
dehydrated before being connected to the
completed assembly.

Perform a check on the suction lines: horizontal
sections are to be sloped downwards towards
the compressor. Suction gas velocity must be
high enough to provide for an adequate oil
return.This velocity must be within 8 to 12 m/s in
vertical risers. In horizontal pipes, this velocity
can decrease to 4 m/s. The use of U-trap and
double-suction risers may be required on vertical
sections, but not in excess of 4 m unless a second
U-trap system has been fitted (refer to Fig. 3).
Suction line piping must be insulated in order to
minimize the effects of superheating.

• The piping connected to the compressor must be
configured on the basis of a flexible 3-axis design
to dampen vibrations and designed in such a way
as to prevent free liquid refrigerant migration and
drainage back to the compressor sump.

When installing a liquid receiver or any other

pressure-containing component on the condensing
unit, be sure that these components comply with
the European P.E.D.

Make sure the installation is equipped with

high-pressure safety components (e.g. pressure
switch, pressure relief valve) to prevent against
the bursting of pressure-containing components.

• Note that all local and regional regulations and
safety standards, such as EN378, must be taken
into account when designing, connecting and
running the system.

4 - Assembly

The condensing unit’s time of exposure to

the atmosphere during installation shall be held
to a minimum. The condensing unit is fitted with
suction and liquid copper stubs equipped with
shut-off valves to enable connection to the circuit
without ingress of air or moisture in the unit.

Opening the shut-off valves before connection will
cause moisture contamination of the compressor
lubricant.

• Rubber grommets can be installed under the
condensing unit base frame, as shown in Fig 4,
to prevent vibration interference from other
operating equipment or machinery and to reduce
vibration transmission to the supporting structure.

Before opening the compressor connection

fittings, it is mandatory to connect a 1/4” service
hose to the Schrader fitting on the compressor
shell in order to gradually release the nitrogen
holding charge.

• Ensure that no material enters into the system
while cutting the tubing. Moreover, never drill
holes in the pipe work after installation.

• Avoid flare-type connections and exercise great
care while brazing (use only state-of-the-art
practices); apply a nitrogen gas flow to prevent
oxidation inside the tubing, especially when HFC
refrigerants are being used. All brazing material is
to contain a minimum of 5% silver.

• When brazing, protect the valves and all other
unit components from torch heat damage (painted
surfaces, gaskets, connecting box).

• Note that it is not necessary to remove compressor
shut-off valves for connection to the system,
hence no need to replace associated gaskets.

• Be sure to connect the required safety and control
devices onto compressor shut-off valves or fittings.

• In case of oil return through the Schrader fitting
on the compressor shell, make sure the internal
valve is removed.

Instructions

4

8510198 P03-A     © Danfoss Commercial Compressors 03/05

Summary of Contents for Bluestar MGM016

Page 1: ...MTZ65 MCZC121 MTZ73 MCZC136 MTZ81 900 900 759 MCZC171 MTZ100 MGZC215 MTZ125 MGZC242 MTZ144 1350 820 759 MGZC271 MTZ160 50 Hz Comp W D H ressor LCHC048 NTZ048 500 620 451 LCHC068 NTZ068 LCHC096 NTZ096...

Page 2: ...2 8510198 P03 A Danfoss Commercial Compressors 03 05 Fig 4 Fig 3 Fig 5 1 x coil height Min clearance 2 x unit length Fig 2 Fig 6...

Page 3: ...61 060 1263 060 1283 LP man LP auto LP auto LP man HP man HP man HP auto HP auto LP aut reset LP man reset HP AC1 16 A DC 11 LR 112A AC3 16 A 400 V 12 W AC1110 A 220 V When used acc to UL regulations...

Page 4: ...condensing unit must be located in a well ventilated area air flow through unit shall not be restricted in any way refer to Fig 2 Make sure that the ambient temperature never exceeds 50 C 122 F during...

Page 5: ...5 and 6 for typical wiring connections and examine the specific wiring diagram located in the electrical box cover For further details refer to the condensing unit guidelines Note that Maneurop compr...

Page 6: ...s proper voltage balance between phases Change the filter dryer when necessary Check that all electrical connections are still adequately fastened Make sure the condensing unit is clean and in good wo...

Page 7: ...MTZ81 900 900 759 MCZC171 MTZ100 MGZC215 MTZ125 MGZC242 MTZ144 1350 820 759 MGZC271 MTZ160 50 Hz Comp L P H resseur LCHC048 NTZ048 500 620 451 LCHC068 NTZ068 LCHC096 NTZ096 630 650 605 LCHC108 NTZ108...

Page 8: ...8 8510198 P03 A Danfoss Commercial Compressors 03 05 8 12 m s capacit minimun 8 12 m s capacit maximun Fig 4 Fig 3 Fig 5 1 x hauteur de batterie Espace minimum 2 x longueur Fig 2 Fig 6...

Page 9: ...declenchement Differentiel Differentiel fixe Point de renclenchement Test manuel Point de declenchement Couple de serrage 20 Nm Fil de cuivre uniquement Point de renclenchement Reset manuel Reglage d...

Page 10: ...e au transporteur Les m mes recommandations s appliquent aux cas de non respect des instructions de transport Veuillez lire soigneusement les consignes de s curit imprim es sur l emballage carton ava...

Page 11: ...s bobinages du moteur Ne pas utiliser d additifs pour la d tection des fuites Ne pas utiliser de CFC HCFC comme fluide traceur de d tection des fuites dans le cas d installations pr vues pour HFC 6 Ti...

Page 12: ...limites d application du compresseur doivent tre respect es En outre des valeurs lev es de surchauffe conduisent des hautes temp ratures de refoulement et font diminuer la capacit du compresseur La t...

Page 13: ...ous r f rer au chapitre Mesures de s curit avant montage Pour de plus amples renseignements sur les proc dures de remplacement se reporter aux chapitres pr c dent Note En cas de panne moteur du compre...

Page 14: ...MTZ125 MGZC242 MTZ144 1350 820 759 MGZC271 MTZ160 50 Hz Verdi L B H chter LCHC048 NTZ048 500 620 451 LCHC068 NTZ068 LCHC096 NTZ096 630 650 605 LCHC108 NTZ108 LCHC136 NTZ136 755 700 656 LCHC215 NTZ215...

Page 15: ...L fter f r Optyma Verfl ssigungss tze Zwei L fter f r Bluestar Verfl ssigungss tze Ein oder zwei L fter f r Optyma Verfl ssigungss tze Zwei L fter f r Bluestar Verfl ssigungss tze Abb 4 Abb 3 Abb 5 1...

Page 16: ...konformem Einsatz 1 bar Pe 30in Hg KP 15 15A 17W 17B KP17W B 060 539366 060 539466 ND auto ND auto HD man HD auto Einschalten ND HD ND HD Differenz Feste Differenz Ausschalten Manueller Test Einschal...

Page 17: ...sigungssatzes mit u erster Sorgfalt erfolgen sollen um St e und damit u erliche aber auch innere Besch digungen zu vermeiden F r die Handhabung und beim Auspacken sind geeignete und sichere Hebewerkze...

Page 18: ...Durchf hrung des Lecktests getrost geschlossen gehalten bleiben jeder Verfl ssigungssatz wird bereits im Werk 100 auf etwaige Leckagen getestet Beim Auftreten einer Leckage sollte diese beseitigt und...

Page 19: ...Verfl s sigungssatz Ein Niederdruckschalter wird empfohlen um Betrieb unter Vakuum vorzubeugen Eine Mindesteinstellung von 1 2 bar absolut ist als Faustwert angesehen werden Es ist daf r zu sorgen das...

Page 20: ...falls zu ermitteln und deren Behebung zu veranlassen Wird diese Analyse und Reparatur nicht vorgenommen k nnen sich Ausf lle wiederholen Bitte beachten dass sich bei der Diagnose zum Austausch des Ver...

Page 21: ...Z100 MGZC215 MTZ125 MGZC242 MTZ144 1350 820 759 MGZC271 MTZ160 50 Hz Spr arka S D W LCHC048 NTZ048 500 620 451 LCHC068 NTZ068 LCHC096 NTZ096 630 650 605 LCHC108 NTZ108 LCHC136 NTZ136 755 700 656 LCHC2...

Page 22: ...ss Commercial Compressors 03 05 22 Tlumik wibracji 8 do 12 m s przy minimalnej wydajnosci 8 do 12 m s przy maksymalnej wydajnosci Fig 4 Fig 3 Fig 5 1 x wysoko wymiennika Minimalny odst p 2 x szeroko a...

Page 23: ...5 15A 17W 17B KP 17B 060 539366 060 539466 LP auto LP auto HP man HP auto Ci nienie za czania R nica Sta a r nica Ci nienie wy czania Sprawdzian manualny Ci nienie za czania Tightening torque 20 lb in...

Page 24: ...wania czy te produktu zauwa one przy dostawie powinny by niezw ocznie zg oszone przewoz nikowi Te same zalecenia odnosz si do przypadku gdy wykryte zostan uchybienia podczas transportu produktu do u y...

Page 25: ...ponowi zgodnie z procedur tj pkt 1 i 2 5 pod czy spr ark do uk adu poprzez otwarcie zawor w odcinaj cych spr arki 6 powt rzy kroki 1 i 2 przy otwartych zaworach odcinaj cych na spr arce 7 wype ni inst...

Page 26: ...minimum 12 godzin poprzedzaj ce rozruch i lub podczas d u szych okres w postoju 10 Uruchomienie Zabrania si za czania spr arki je eli nie jest ona nape niona czynnikiem ch odniczym Nie nale y boczniko...

Page 27: ...ych w punkcie 3 rodki bezpiecze stwa podj te przed monta em urz dzenia Wprzypadkukonieczno ciwymianyelement w uk adu nale y stosowa si do szczeg owych zalece podanych we wcze niejszych punktach Uwaga...

Page 28: ...rks of Danfoss A S All rights reserved Danfoss Commercial Compressors BP 331 F 01603 Tr voux France T l 04 74 00 28 29 33 4 74 00 28 29 Fax 04 74 00 52 44 33 4 74 00 52 44 http cc danfoss com Gdynia t...

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