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
