8510223 P01-A © Danfoss Commercial Compressors March 2006
Instructions
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 - Troublesooting
12 - Maintenance
13 - Replacement
14 - User advisory
1 - Introduction
These Instructions pertain to Maneurop® Variable
Speed hermetic compressors used for A/C and
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 Variable Speed hermetic compressors;
certain details therefore may not be applicable to
the particular model you have purchased. Please
keep your manual and all relevant information
handy for future reference.
• Equipment description: This compressor is de-
livered with all assembly equipment (rubber
gr washers), an electrical box
(cover + spring), connecting sleeves and gaskets,
and Instructions.
• Approved list of refrigerants:
- The VTZ series can be used with R404A, R507A,
R407C and R134a.
• Compressors are filled with lubricant before
leaving the factory:
- The VTZ series with Polyolester oil (ref. 160PZ),
This lubricant must not be mixed with one another.
• Maneurop® Variable Speed compressors must
only be used for their designed purpose(s) and
within their scope of application (Please refer to
the Application Guidelines).
Maneurop® compressors 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.
Compressors 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
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-related hazards and heeding the
pressure limits displayed on the compressor
nameplate or in the application guidelines.
Modifications or alterations to the compres-
sor (such as brazing on the shell) not expressly
approved by the party responsible for ensuring
compliance could invalidate the user’s authoriza-
tion to operate the equipment.
2 - Transportation, storage
• The compressor must be handled in the vertical po-
sition (maximum offset from the vertical: 15°).Should
the compressor be handled in an upside-down posi-
tion, its performance may no longer be insured.
• Beware that all compressor handling must be
carried out with extreme caution to avoid any
shocks. Dedicated packing handles are to be used
for all required manipulation of the compressor;
otherwise appropriate and safe lifting equipment
is to be used during handling and unpacking.
• 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 compressor is never stored in an
ambient temperature of below -35°C (-31°F) or
above 50°C (122°F).
• Ensure that the compressor 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 compressor must be located in a ventilated
area to ensure that the ambient temperature
never exceeds 50°C (122°F) during the off-cycle.
• Make certain that the compressor can be moun-
ted onto a horizontal plane with a maximum
slope of 3°.
• The compressor can only be supplied by a
frequency converter. Make sure that the drive
is the dedicated one for the compressor (power
size and voltage: input & output). Compressor/
frequency converter/refrigerant models selection
are listed on parameter 1.13 of the frequency
converter.
• Ensure that refrigerant-charging equipment, va-
cuum 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 Figs. 2, 3 and 5). Suction line
piping must be insulated in order to minimize
the effects of superheating.
• Perform a check on the discharge lines: Piping to
the condenser must be designed so as to prevent
liquid return to the compressor and adequat
refrigerant gas velocity. The use of non-return
valves may prove necessary, depending on the
position of the compressor with respect to the
condenser. A suitably-sized U-trap may also be
necessary if the condenser has been placed
above the compressor (refer to Fig. 1).
• The piping connected to the compressor must
be configured on the basis of a flexible 3-axis de-
sign to dampen vibrations and designed in such
a way as to prevent free liquid refrigerant migra-
tion and drainage back to the compressor sump
and discharge cylinder heads (refer to fig. 1).
• 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 EN 378, must be taken
into account when designing, connecting and
running the system
4 - Assembly
The compressor’s time of exposure to the
atmosphere during installation shall be held to
a minimum (less than 1/2 hour). The compressor
connection must be fast in order to avoid moisture
contamination of the lubricant.
• The grommets must be installed under the
compressor feet, as shown in Fig. 4. Rubber
grommets are to undergo compression until
contact is made between the flat washer and the
steel mounting sleeve.
Before opening the compressor connection
fittings, it is mandatory to connect a 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.
• Should additional components need to be
connected onto the compressor sight glass or oil
equalization ports, it is recommended that such an
operation be carried out prior to final assembly, to
allow for compressor inclination and movement.
• 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. All brazing material is
to contain a minimum of 5% silver. If flux additive is
used, don’t put the copper tube into the receiver of
flux, but put flux around the tube (i.e. with a pencil).
this will prevent pure flux getting inside the tube.
• When brazing, protect the terminal box and
painted surfaces of the compressor from torch
heat damage.
• Remove the Teflon gaskets when brazing Rotolock
connectors with the solder sleeve and be aware
that original suction and discharge gaskets must
be replaced.
• When installing Rotolock fittings, always use
two wrenches when tightening any fittings to
insure that the torque is effectively cancelled on
the adjacent tubing and fittings. Do not exceed
the maximum tightening torque for Rotolock
connections to the compressor :
1" rotolock 80 Nm
1"1/4 rotolock 90 Nm
1"3/4 rotolock 110 Nm.
• Be sure to connect the required safety and
control devices onto compressor shut-off valves
or fittings. In case of oil return through the Schra-
der fitting on the compressor shell, make sure the
internal valve is removed.
5 – Leak detection
Never use oxygen or dry air in order to avoid
the risk of fire or explosion.
• Perform a leak detection test on the complete
system by means of: a dry nitrogen pressure test,
a mixture of nitrogen and the refrigerant to be
used in the system, a helium leak test and/or a
