Danfoss Maneurop MT R 22 User Manual Download

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www.danfoss.us.com

Application guidelines

Danfoss scroll compressors

SM - SY - SZ

R22 - R407C - R137a - R404A - R507A - 50 - 60 Hz

MAKING MODERN LIVING POSSIBLE

Summary of Contents for Maneurop MT R 22

Page 1: ...www danfoss us com Application guidelines Danfoss scroll compressors SM SY SZ R22 R407C R137a R404A R507A 50 60 Hz MAKING MODERN LIVING POSSIBLE ...

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Page 3: ...atures 28 Discharge temperature protection 30 High and low pressure protection 30 Cycle rate limit 31 System design recommendations 32 General 32 Essential piping design considerations 32 Refrigerant charge limit 33 Off cycle migration 33 Liquid flood back 35 Specific application recommendations 36 Low ambient application 36 Low load operations 37 Brazed plate heat exchangers 37 Electronic expansi...

Page 4: ...ng scroll in grey traces a circular path around the centre of the fixed scroll in black This movement creates symmetrical compression pockets between the two scroll elements Low pressure suction gas is trapped within each crescent shaped pocket as it gets formed continuous motion of the orbiting scroll serves to seal the pocket which decreases in volume as the pocket moves towards the centre of th...

Page 5: ... cap design Part protection and assembly reduces internal leaks and increases life durability Improved part isolation reduces greatly acoustic levels Gas intake design induces higher resistance to liquid slugging Heat shield that lowers the heat transfer between discharge and suction gas and the acoustic level R22 optimized scroll profile Improved lower bearing centering Patented motor centering s...

Page 6: ...240 300 SZ Scroll POE lubricant R407C R134a and R404A R507A for SZ084 to SZ185 Voltage Version Evolution index C A 4 7 SZ SY A R CA 185 300 Single compressors Single compressors brazed Internal overload protector A S 112 124 147 230 V 24 V AC 24 V AC 230 V C brazed Motor protection type V brazed S 084 090 100 110 120 148 161 Applies to S R rotolock X P brazed brazed rotolock CB CA Y rotolock C bra...

Page 7: ...22 500 27 33 3 46 11 8 32 42 3263 285 28 348 R407C SINGLE SZ084 7 19 300 65 900 6 13 3 15 10 8 6 99 703 112 08 141 SZ090 7 5 20 400 69 600 6 45 3 16 10 8 7 35 741 112 08 143 SZ100 8 21 600 73 700 6 84 3 15 10 8 7 76 782 112 08 143 SZ110 9 24 600 84 000 7 76 3 17 10 8 8 80 886 112 08 161 SZ120 10 28 600 97 600 8 99 3 17 10 8 10 17 1024 112 08 161 SZ147 12 34 900 119 100 9 92 3 52 12 0 11 81 1190 11...

Page 8: ... 194 SM175 14 51 100 174 400 15 3 3 34 11 4 14 22 1728 210 220 SM SY185 15 55 300 188 700 16 3 3 39 11 6 15 25 1853 210 220 SY240 20 74 100 252 900 22 1 3 35 11 4 21 22 2579 272 331 SY300 25 94 500 322 500 27 5 3 43 11 7 26 70 3245 272 346 SY380 30 115 300 393 500 33 4 3 46 11 8 32 42 3939 285 348 R407C SINGLE SZ084 7 22 500 76 800 7 1 3 19 10 9 6 99 849 110 141 SZ090 7 5 24 400 83 300 7 6 3 2 10 ...

Page 9: ... B 13 02 3 95 A 20 B 21 97 A 9 92 B 11 35 A 5 59 B 7 02 3 91 11 18 11 18 8 66 8 66 A 6 42 B 7 05 7 29 A 6 17 B 6 38 A SM SZ 084 090 100 B SM SZ 110 120 45 30 6 41 3 89 4 holes Ø 0 76 HM 8 bolt Lock washer Flat washer Steel mounting sleeve Rubber grommet Nut 1 10 inch Compressor base plate 9 FRCC PC 003 A5 22 Application guidelines ...

Page 10: ... 20 04 A SM112 B SM124 147 3 98 Ø 9 57 10 94 4 holes Ø 0 75 60 7 09 6 06 9 06 7 5 6 81 30 9 06 Ø 8 82 Ø 9 57 4 holes Ø 0 75 6 18 6 06 9 06 7 5 7 87 6 06 6 81 9 06 7 5 30 30 60 3 98 20 04 21 26 10 94 HM 8 bolt Lock washer Flat washer Steel mounting sleeve Rubber grommet Nut 1 10 inch Compressor base plate Application guidelines 10 FRCC PC 003 A5 22 ...

Page 11: ...oles Ø 0 76 6 8 8 66 8 66 11 18 14 08 8 23 11 18 SM 148 161 code 3 SM 148 161 code 4 30 23 27 7 09 14 79 4 54 10 65 Ø10 47 3 92 17 33 7 36 13 03 3 89 HM 8 bolt Lock washer Flat washer Steel mounting sleeve Rubber grommet Nut 1 10 inch Compressor base plate 11 FRCC PC 003 A5 22 Application guidelines ...

Page 12: ... 34 7 09 4 33 Ø 10 08 Ø 10 47 Brazed version Rotolock version Ø 12 45 7 67 6 74 13 60 4 holes Ø 0 76 11 14 60 12 7 76 7 09 16 91 9 39 7 36 7 32 30 HM 8 bolt Lock washer Flat washer Steel mounting sleeve Rubber grommet Nut 1 10 inch Compressor base plate Application guidelines 12 FRCC PC 003 A5 22 ...

Page 13: ...15 83 C 16 54 5 5 Ø13 54 Discharge A B 1 1 8 C 1 3 8 Ø13 11 A 27 2 2 B 67 63 2 C 28 58 A 24 33 B 24 76 C 25 71 A 18 88 1 2 B 19 31 1 2 C 20 26 1 2 Suction A B 1 5 8 C 2 1 8 8 50 7 7 3 43 3 86 6 29 90 187 Discharge 1 1 8 Suction A 1 1 2 B 1 5 8 15 91 A SY SZ240 B SY SZ300 15 90 8 19 90 30 35 4 holes Ø0 98 15 43 15 43 12 7 95 7 32 17 87 11 58 7 62 8 23 5 5 Ø13 54 Ø13 11 A 27 2 2 B 67 63 2 A 24 33 B ...

Page 14: ...e equipped with a sight glass 1 1 8 18 UNF which may be used to determine the amount and condition of the oil contained within the sump Model SM SZ084 090 100 110 120 148 161 SM SZ 175 SM SZ SY185 SM 112 124 SM SZ 147 SY SZ 240 300 SY SZ 380 Version V K R S W Y C J P U X AL MA MB AA AB AA AB Suction and discharge connection brazed rotolock brazed brazed rotolock brazed brazed Oil sight glass threa...

Page 15: ...Ø 1 hole The 3 other knockouts are as follows Ø 0 81 Ø 7 8 for a 1 2 conduit Ø 0 65 SM SZ 084 090 100 110 112 120 124 147 148 161 Except for motor voltage code 3 SM SZ 148 161 code 3 175 185 SY185 R C version The terminal box is provided with a Ø 1 59 hole for power supply and a Ø 0 65 knockout SM SZ 147 code 3 Motor voltage code 3 Motor voltage code 4 Motor voltage code 7 Motor voltage code 9 Nom...

Page 16: ...y sized IP54 rated cable glands are used First numeral level of protection against contact and foreign objects 5 Dust protected Second numeral level of protection against water 4 Protection against water splashing IP rating SY SZ 240 300 380 The terminal box is provided with 2 triple knockouts and 1 single knockout for power supply and 4 double knockouts for the safety control circuit The 3 power ...

Page 17: ...237 50 48 0 26 SM SZ124 267 51 45 0 27 SM SZ147 304 57 52 0 24 SM SZ148 255 64 57 0 29 SM SZ161 255 64 61 0 29 SM SZ175 380 75 70 0 19 SM SZ185 380 75 73 0 19 SY SZ240 460 109 100 0 14 SY SZ300 560 130 130 0 12 Motor voltage code 4 380 400V 3 ph 50 Hz 460V 3 ph 60 Hz SM SZ084 86 17 17 1 74 SM SZ090 98 18 5 17 1 48 SM SZ100 98 19 18 1 48 SM SZ110 130 22 20 1 05 SM SZ112 142 25 21 1 05 SM SZ120 130 ...

Page 18: ...ion is always less than the Max Oper A value The MCC is the current at which the motor protection trips under maximum load and low voltage conditions This MCC value is the maximum at which the compressor can be operated in transient conditions and out of the application envelope Above this value the internal motor protection or external electronic module will cut out the compressor to protect the ...

Page 19: ...the system to build pressure But it remains mandatory for compressor protection to apply an LP safety switch The LP safety switch must never be bypassed Pressure settings for the LP and HP safety switch and pump down are indicated section Operating conditions When ever possible ie PLC control it is recommended to limit the possibilities of compressor auto restart to less than 3 to 5 times during a...

Page 20: ...hM Compressor motor M Motor Protection Module MPM Thermistor chain S Safety pressure switch LPS CONTROL CIRCUIT F1 F1 KA KA KA HP LPS T1 T2 T3 KM DGT KS KS 1 2 M ThM KS KS KA KM KM LLSV 180s TH F2 Q1 L1 L3 L2 A1 A2 A3 Wiring diagram with pump down cycle LP CONTROL CIRCUIT F1 F1 KA KA KA HP T1 T2 T3 KM DGT KS KS 1 2 TH KS LPS KA KM 180s F2 Q1 L1 L3 L2 M ThM A1 A2 A3 Wiring diagram without pump down...

Page 21: ...ngle throw thermostat located in the motor windings In the event of motor overheating caused by low refrigerant flow or improper motor rotation the thermostat will open Because the thermostat is an automatic reset device it must be wired within a lockout safety circuit with a manual reset to restart the unit For over current and phase loss protection an external overload protector must be used The...

Page 22: ...essor A phase sequence detector is strongly recommended Compressor models SM SZ 084 to 185 except SM112 124 147 incorporate an internal reverse vent valve which will react in the presence of reverse rotation and will allow refrigerant to circulate through a by pass from the suction to the discharge Although reverse rotation is not destructive even over long periods of time up to several days it sh...

Page 23: ...maximum allowable voltage unbalance is 2 Voltage unbalance causes high amperage over one or several phases which in turn leads to overheating and possible motor damage Voltage unbalance is given by the formula Vavg Mean voltage of phases 1 2 3 V1 2 Voltage between phases 1 2 V1 3 Voltage between phases 1 3 V2 3 Voltage between phases 2 3 Vavg V1 2 Vavg V1 3 Vavg V2 3 2 x Vavg voltage unbalance x 1...

Page 24: ... of incorporation ref Machines Directive 2006 42 EC Contact Danfoss Products SM SZ084 to SY SZ380 Declaration of conformity ref Low voltage Directive 2006 95 EC Contact Danfoss Products Internal free volume without oil in3 SM SZ084 090 100 860 SM SZ 110 120 897 SM 112 124 SM SZ 147 872 SM SZ 148 161 1196 SM SZ 175 185 and SY185 2014 SY SZ 240 300 2307 SY SZ 380 2392 Products SM084 to 185 SZ084 to ...

Page 25: ...properties comparable to R404A R507 has no ozone depletion potential ODP 0 As with R404A R507 is particularly suitable for low evaporating temperature applications but it can also be used for medium evaporating temperature applications R507 is an azeotropic mixture with no temperature glide Mineral oil can be applied in system using HCFC s refrigerant because it has a good miscibility with HCFC an...

Page 26: ...inimum and maximum evaporating and condensing temperatures as per the operating envelopes SM SY SZ compressors can be applied from 31 F to 145 4 F for SM SZ084 to 185 and 127 4 F for SY SZ 240 to 380 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 In case of e...

Page 27: ... Evaporating temperature F S H 54 F SUPERHEAT S H 20 F 80 90 100 110 120 130 140 150 160 0 10 20 30 40 50 60 Condensing temperature F S H 20 F Evaporating temperature F S H 54 F SUPERHEAT 80 90 100 110 120 130 140 150 10 0 10 20 30 40 50 60 Evaporating temperature F S H 20 F S H 54 F SUPERHEAT Condensing temperature F 27 FRCC PC 003 A5 22 Application guidelines ...

Page 28: ...with the constant pressure lines For a given cycle the MEAN point temperatures are typically about 35 6 to 37 4 F lower than DEW point temperatures In these Selection and Application Guidelines Danfoss Commercial Compressors displays temperatures as DEW point values The performance tables for R407C are also based on DEW point values 80 90 100 110 120 130 140 150 160 10 0 10 20 30 40 50 60 Condensi...

Page 29: ...xample for SZ 084 to 185 80 90 100 110 120 130 140 150 160 10 0 10 20 30 40 50 60 70 S H 54 F SUPERHEAT S H 20 F Condensing temperature F Evaporating temperature F Dew temperature conditions 80 90 100 110 120 130 140 150 160 10 0 10 20 30 40 50 60 Condensing temperature F Evaporating temperature F Mean temperature conditions S H 20 F S H 54 F SUPERHEAT pressure log enthalpy Dew Dew Mean Mean 29 FR...

Page 30: ...pressor s operating range will cause serious damage to the compressor Discharge temperature protection A high pressure HP safety switch is required to shut down the compressor should the discharge pressure exceed the values shown in the table next page 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 lo...

Page 31: ...nected as shown in the wiring diagram section Suggested wiring diagrams logic A three minute 180 sec time out is recommended Please contact Danfoss Technical Support for any deviation from this guidelines Note that these two different low pressure switches also require different settings The low pressure pump down switch setting must always be within the operating envelope for example 13 psi for R...

Page 32: ...ator outlet to prevent refrigerant from draining into the compressor during off cycles If the evaporator were situated below the compressor the suction riser must be trapped so as to prevent liquid refrigerant from collecting at the outlet of the evaporator while the system is idle which would mislead the expansion valve s sensor thermal bulb at start up When the condenser is mounted at a higher p...

Page 33: ...occasional flooded starts as long as the total system charge does not exceed the maximum compressor refrigerant charge A suitable test to evaluate the risk of off cycle migration is the following Stabilize the non running system at 41 F ambient temperature Raise the ambient temperature to 68 F and keep it for 10 minutes Start the compressor and monitor sump temperature sight glass indication and s...

Page 34: ...harge transfer or excessive migration to the compressor during off cycles The quantity of refrigerant on the low pressure side of the system can be further reduced by using a pump down cycle in association with the LLSV A pump down cycle represents one of the most effective ways to protect against the off cycle migration of liquid refrigerant Once the controls has been satisfied a solenoid valve c...

Page 35: ...lead to lack of lubrication and high rate of oil leaving the compressor Liquid flood back test Repetitive liquid flood back testing must be carried out under expansion valve threshold operating conditions a high pressure ratio and minimum evaporator load along with the measurement of suction superheat oil sump temperature and discharge gas temperature During operations liquid flood back may be det...

Page 36: ...mum load and low ambient conditions as well The following considerations should be taken into account to ensure proper system operating characteristics Expansion device The expansion device should be sized to ensure proper control of the refrigerant flow into the evaporator An oversized valve may result in erratic control This consideration is especially important in manifolded units where low loa...

Page 37: ... remove superheat and condense the incoming discharge gas more quickly Reversible heat pump systems 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 floodback or excessively wet refrigerant return conditions As such reversible ...

Page 38: ... place excess strain on both the bearings and motor To prevent such occurrences it is important that a 1 meter minimum discharge line length be allowed between the compressor discharge port and the reversing valve or any other restriction This gives sufficient free volume for the discharge gas to collect and to reduce the pressure peak during the time it takes for the valve to change position At t...

Page 39: ...omes mandatory Suction line accumulator 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 corro...

Page 40: ...l 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 Sound generation in a refrigeration or air conditioning system Model 50 Hz 60 Hz Acoustic hood code number Bottom insulation code n R22 R407C R22 R407C Sound power dB A Attenuation dB A Sound power dB A Attenuation dB A Sound power dB A Attenuatio...

Page 41: ...imal 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 un...

Page 42: ...ed to rain corrosive or flammable atmosphere between 31 F and 122 F when charged with refrigerant and between 31 F and 158 F when charged with nitrogen When the compressor is mounted as part of an installation never use the lift rings on the compressor to lift the installation The risk is run that the lugs could separate from the compressor or that the compressor could separate from the base frame...

Page 43: ...eration 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 precautions listed in the following paragraphs must be taken Tubing Only use clean and dehydrated refrigeration grade copper tubing Tube cu...

Page 44: ... 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...

Page 45: ...fter assembly SM SY SZ compressors are delivered with 100 ppm moisture level The required moisture level in the circuit after vacuum dehydration must be 100 ppm for systems with an SM SY SZ Never use the compressor to evacuate the system Connect a vacuum pump to both the LP HP sides Evacuate the system to a pressure of 0 02 inHg 300 μm Hg absolute Do not use a megohm meter nor apply power to the c...

Page 46: ...d a complement of charge can be done in liquid phase slowly throttling liquid in on the low pressure side as far away as possible from the compressor suction connection while compressor is running The refrigerant charge quantity must be suitable for both summer and winter operations Vacuum or charge from one side can seal the scrolls and result in a non starting compressor When servicing always en...

Page 47: ...or 2 of the total system refrigerant charge in weight can be used to roughly define the required oil top up quantity but in any case the oil charge has to be adjusted based on the oil level in the compressor sight glass When the compressor is running under stabilized conditions the oil level must be visible in the sight glass The presence of foam filling in the sight glass indicates large concentr...

Page 48: ... 12 6 22 8 143 8 45 3 37 4 29 3 1197 2 SM SZ147 15 0 12 6 22 8 150 8 45 3 37 4 29 3 1248 2 SM SZ148 161 18 5 14 6 26 4 194 6 44 9 37 4 31 1 1204 3 SM SZ175 185 SY185 18 5 15 7 27 5 234 6 44 9 37 4 34 5 1429 2 SY SZ240 20 1 18 3 30 7 344 4 44 9 37 4 35 6 1400 2 SY SZ300 20 1 18 3 30 7 355 4 44 9 37 4 36 0 1400 2 SY SZ380 20 1 18 3 31 7 362 4 44 9 37 4 37 0 1426 2 Nbr number of compressors per palle...

Page 49: ...5 4CAI SM185 7CAI SM185 9CAI Brazed Module 24 V AC SM185 3PCI SM185 4PCI SM185 7PCI Brazed Module 230 V AC SM185 4XCI SM185 9XCI Rotolock Thermostat SM185 3RI SM185 4RI SM185 7RI SM185 9RI Rotolock Module 24 V AC SM185 3SCI SM185 4SCI SM185 7SCI Rotolock Module 230 V AC SM185 4YCI SM185 9YCI SY185 Brazed Thermostat SY185 4CAI Rotolock Thermostat SY185 4RI SY240 Brazed Module 24V AC SY240A4CAI Braz...

Page 50: ...5 4SCI SZ175 7SCI SZ185 Brazed Thermostat SZ185 3CAI SZ185 4CAI SZ185 7CAI SZ185 9CAI Brazed Module 24 V AC SZ185 3PCI SZ185 4PCI SZ185 7PCI Brazed Module 230 V SZ185 4XCI SZ185 9XCI Rotolock Thermostat SZ185 3RI SZ185 4RI SZ185 7RI SZ185 9RI Rotolock Module 24 V AC SZ185 3SCI SZ185 4SCI SZ185 7SCI Rotolock Module 230 V SZ185 4YCI SZ185 9YCI SZ240 Brazed Module 24 V AC SZ240A4CAI Brazed Module 115...

Page 51: ...connection Industry pack 50 G08 8156133 Gasket 2 1 4 Models with 2 1 4 rotolock connection Multipack 10 G08 7956004 Gasket 2 1 4 Models with 2 1 4 rotolock connection Industry pack 50 8156013 Gasket set 1 1 4 1 3 4 2 1 4 OSG gaskets black white All Rotolock models Multipack 10 Type Code n Description Application Packaging Pack size P02 8153004 Solder sleeve P02 1 3 4 Rotolock 1 1 8 ODF Models with...

Page 52: ...ultipack 6 120Z0380 48W 230V surface sump heater bottom insulation CE UL Multipack 6 120Z0381 48W 400V surface sump heater bottom insulation CE UL Multipack 6 120Z0382 48W 460V surface sump heater bottom insulation CE Multipack 6 120Z0383 48W 575V surface sump heater bottom insulation CE Multipack 6 120Z0360 56W 24V surface sump heater bottom insulation CE UL SM SZ 175 SM SY SZ 185 Multipack 6 120...

Page 53: ...ic hood for scroll compressor SM112 124 147 SM112 124 147 except SM147 code 3 SZ147 Single pack 1 120Z0135 Acoustic hood for scroll compressor SM147 3 SM SZ147 code 3 Single pack 1 120Z0356 Bottom insulation SM SZ084 090 100 110 120 148 161 Single pack 1 120Z0353 Bottom insulation SM SZ175 SM SY SZ185 Single pack 1 120Z0355 Bottom insulation SY SZ240 to SY SZ380 Single pack 1 Type Code No Descript...

Page 54: ...M084 090 100 110 112 120 124 147 148 161 except SM148 3 161 3 SZ084 090 100 110 120 148 161 except SZ148 3 161 3 Multipack 10 8173230 T block connector 2 x 2 2 inch SM SZ084 110 120 148 except 3 161 except 3 SM112 124 147 except 3 SZ147 Multipack 10 8173021 T block connector 2 4 x 3 inch SM SZ147 3 148 3 161 3 175 185 SY240 300 380 except SY240 3 300 3 SZ175 185 240 300 380 except SZ240 3 300 3 Mu...

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Page 56: ... quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business and positioned us as distinct variable speed technology specialists Today we operate fr...

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