Danfoss LRZ254HSVCHA Rotary Compressors Instructions

Danfoss LRZ254HSVCHA Rotary Compressors

Product Information

Nameplates:

• Model number
• Serial number
• Approvals
• Refrigerant
• Supply voltage, Starting Current
• Housing service pressure
• Factory charged lubricant

Fixed speed C-R-S identification:
The compressor must only be used for its designed purpose(s) and within the scope of the applicable local safety regulations. Under all circumstances, the compressor is delivered under EN378 (or other nitrogen gas pressure between 0.3 and 0.7 bar) and hence cannot be connected to further details. Available from cc.danfoss.com

Single-phase winding diagram:
RUNNING CAPACITOR, START RUNNING CAPACITOR CAPACITOR POWER SOURCE S SUB COIL PSC R MAIN COIL INTERNAL PROTECTOR c START RELAY POWER SOURCE S SUB COIL CSR R MAIN COIL INTERNAL PROTECTOR c

Three-phase winding diagram:
POWER SOURCE INVERTER S(W) W U COMPRESSOR C(U) R(V) V THERMOSTAT

Variable speed winding diagram:
POWER SOURCE INVERTER S(W) W U COMPRESSOR C(U) R(V) V THERMOSTAT

Operating limits:
Refrigerant R404A/R290

Model: LRZ254HSVCHA, LRZ254HDV2EA, LRZ307HBV2EA, LRZ356HSVCLA, LRZ254HDS2EA, LRZ488WTVCMA, LRZ488HTCCMA, LRZ488HBC2EA,LRZ550HTUBMA, LRN122DDV1DC, LRN145DDV1DC, LRN160DDV1DC
Refrigerant R404A: MRZ096DSVFFC, MRZ193LSVCJA, MRZ127DDV1AB, MRZ160LDX2EA, MRZ211LDX2EA
Refrigerant R290: MRN084DDV1AB, MRN102DDV1AB, MRN135WSVFBC, MRN160WSVDBC, MRN307HSVBHD, MRN470WTVCMA

Condensing temperature:

Variable speed LBP:

Model: VRZ254HTRBMA, VRZ356HTRBMA, VRZ420HTRBMA

Variable speed LBP:

Model: VRZ254HTRBMA, VRZ356HTRBMA, VRZ420HTRBMA

Product Usage Instructions

• The compressor must only be used for its designed purpose(s) and within the scope of the applicable local safety regulations.
• The compressor is delivered under EN378 (or other nitrogen gas pressure between 0.3 and 0.7 bar) and cannot be connected further.
• Refer to the specific model number and serial number on the name plates for detailed information about the compressor.
• Check the approvals mentioned on the nameplates to ensure compliance with safety regulations.
• Note the refrigerant type mentioned on the nameplates to ensure correct usage.
• Refer to the supply voltage and starting current information on the nameplates to ensure proper electrical connection.
• Check the housing service pressure mentioned on the name plates for safe handling and operation of the compressor.
• The compressor comes factory-charged with lubricant. Do not remove or add lubricant without proper guidance.
• Refer to the provided winding diagrams for single-phase, three-phase, and variable-speed configurations for proper electrical connections.
• Follow the operating limits mentioned for the specific refrigerant used to ensure optimal performance and reliability.
• Refer to the specific model and application information to match the compressor with the intended cooling system.
• For variable speed compressors, refer to the speed ranges for different zones to adjust the compressor’s performance as needed.

Name plates

1. Model number
2. Serial number
3. Approvals
4. Refrigerant
5. Supply voltage, Starting current 6: Housing service pressure
6. Factory charged lubricant

Fixed speed C-R-S identification

• The compressor must only be used for its designed purpose(s) and within its scope of application (refer to «operating limits»). Consult Application guidelines and datasheet available from cc.danfoss.com
• Under all circumstances, the EN378 (or other applicable local safety regulations) requirements must be fulfilled.
• The compressor is delivered under nitrogen gas pressure (between 0.3 and 0.7 bar) and hence cannot be connected as is; refer to the «assembly» section for further details.
• The compressor must be handled with caution in the vertical position (maximum offset from the vertical: 15°)

Instructions

Single phase winding diagram

Three phase winding diagram

Fixed speed C-R-S identification

Variable speed winding diagram

Operating limits

R404A

| LRZ254HSVCHA| MBP / LBP
LRZ254HDV2EA| MBP / LBP
LRZ307HBV2EA| MBP / LBP
LRZ356HSVCLA| MBP / LBP
LRZ254HDS2EA| MBP / LBP
LRZ488WTVCMA| MBP / LBP
LRZ488HTCCMA| MBP / LBP
LRZ488HBC2EA| MBP / LBP
LRZ550HTUBMA| MBP / LBP

R290

| LRN122DDV1DC| MBP / LBP
LRN145DDV1DC| MBP / LBP
LRN160DDV1DC| MBP / LBP

R404A

| MRZ096DSVFFC| MBP
MRZ193LSVCJA| MBP
MRZ127DDV1AB| MBP
MRZ160LDX2EA| MBP
MRZ211LDX2EA| MBP
Refrigerant| Model| Application
---|---|---

R290

| MRN084DDV1AB| MBP
MRN102DDV1AB| MBP
MRN135WSVFBC| MBP
MRN160WSVDBC| MBP
MRN307HSVBHD| MBP
MRN470WTVCMA| MBP

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max

R404A

| VRV150DBQ1CE| 2400| 5400| 2400| 5400| 1800| 5400| MBP / LBP
VRZ163DTQAKE| 2100| 7200| 2100| 5400| 1000| 7200| MBP / LBP
VRZ752ETTENA| 2100| 6600| 2100| 5400| 900| 6600| MBP / LBP

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max

R290

| VRN163DTQAKE| 2100| 7200| 2100| 5400| 1000| 7200| MBP / LBP
VRN356HTRBMA| 2000| 7200| 2000| 5400| 900| 7200| MBP / LBP

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max

R404A

| VRZ254HTRBMA| 2000| 7200| 2000| 5400| 900| 7200| MBP / LBP
VRZ356HTRBMA| 2000| 7200| 2000| 5400| 900| 7200| MBP / LBP
VRZ420HTRBMA| 2000| 7200| 2000| 5400| 900| 7200| MBP / LBP

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max
R290| VRN150DBQ1CE| 1800| 5400| 2400| 5400| 1800| 7200| MBP / LBP

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max
R290| VRN420HTRBMA| 900| 7200| 2000| 5400| 900| 7200| MBP / LBP

Refrigerant

|

Model

| Speed range (rpm)|

Appli- cation

---|---|---|---
Zone A| Zone B| Zone C| Zone D
Min| Max| Min| Max| Min| Max| Min| Max
R290| VRN550HTWBMA| 900| 6000| 2000| 5400| 2000| 6000| 900| 6000| MBP / LBP

Refrigerant| Model| Min speed (rpm)| Max speed (rpm)| Application
---|---|---|---|---

R404A

| VRZ110DTMADE| 1000| 6600| MBP
VRV420HBR2PA| 1800| 5400| MBP
Refrigerant| Model| Min speed (rpm)| Max speed (rpm)| Application
---|---|---|---|---

R290

| *VRN110DTM*| 1000| 6600| MBP
VRN226DTP| 900| 7200| MBP

Refrigerant| Model| Min speed (rpm)| Max speed (rpm)| Application
---|---|---|---|---

R404A

| VRZ250HBR2EA| 1800| 4800| MBP / LBP
VRZ356HBR2EA| 1800| 4800| MBP / LBP

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max

R290

| VRN226WTPAGE| 2400| 5400| 2400| 7200| 900| 7200| Heat pump
VRN307WTRBQA| 2000| 5400| 2000| 7200| 900| 7200| Heat pump
VRN418WTRBQA| 2000| 5400| 2000| 7200| 900| 7200| Heat pump
VRN548WTRBRA| 2000| 5400| 2000| 6600| 900| 6600| Heat pump

Refrigerant

|

Model

| Speed range (rpm)|

Application

---|---|---|---
Zone A| Zone B| Zone C
Min| Max| Min| Max| Min| Max
R290| VRN150WSQASE| 2100| 5000| 2100| 7200| 1000| 7200| Heat pump

PS TS Information

Fixed speed

R290

| 125| 125| 25.0| 31.3| LRN122DD~LRN160DD/MRN084DD/MRN102DD/MRN307HS/ MRN135WS/MRN160WS
125| 125| 25.0| 34.0| MRN470WT

R404A

| ****

125

| ****

125

| ****

8.2

| ****

34.1

| LRZ254HD/LRZ254HS/LRZ307HB/LRZ356HS/LRZ488HB/ LRZ488HT/LRZ488WT/LRZ550HT/MRZ096DS/MRZ127DD/ MRZ160LD/MRZ193LS/MRZ211LD

Variable speed

R290

| 125| 125| 25.0| 31.3| VRN110DT/VRN150DB/VRN163DT~VRN226DT/VRN150WS/ VRN226WT~VRN548WT
125| 125| 25.0| 43.0| VRN356HT~VRN550HT/VRN752WT
R404A| 125| 125| 8.2| 34.1| VRV150DB/VRV420HB/VRZ110DT~VRZ163DT/VRZ250HB/ VRZ254HT~VRZ420HT/VRZ356HB/VRZ752ET

Installation and servicing of the compressor by qualified personnel only. Follow these instructions and sound refrigeration engineering practices relating to installation, commissioning, maintenance, and service.

Introduction

These instructions pertain to the Danfoss rotary compressors used for stationary refrigeration and climatization systems. They provide necessary information regarding the safety and proper usage of this product.

Handling and storage

• The compressor should be carried carefully to avoid drop, drag, and impact and should not apply partial force on projection parts such as pipes, hermetic terminals, foot during carrying and processing.
• Don’t expose the compressor and the packaging to rain or corrosive atmosphere.

Safety measures before assembly

• Never use the compressor in an ATEX zone.
• Verify that the power supply corresponds to the compressor motor characteristics (see nameplate).
• Use the refrigerant of the specified brand. When the refrigerant not specified, it will possibly cause trouble of the performance and reliability of the compressor by the impurities in the refrigerant.
• Use clean and dehydrated refrigeration-grade copper tubes and silver alloy brazing material.
• Use clean and dehydrated system components.
• The piping connected to the compressor must be flexible in 3 dimensions to dampen vibrations.

Assembly

• Vertical compressors shall be installed and run with the rotational axis within 5° at all directions from vertical.
• A horizontal compressor without any additional vibration weakness must not be applied for transportation equipment directly, and the compressor should be perpendicular to the direction of motion. No matter at which condition, the dis-charge tube must be above the oil level.
• Rubber grommets are designed soft to provide noise isolation and to lessen vibration energy transmission. The stud bolt should be designed to provide sufficient clearance for noise and vibration isolation and to prevent the compressor from coming off its mount.
• The compressor should not be left open in the atmosphere for more than 5 minutes.
• The pipe and hermetic pens attached to the compressor should not be bent.
• The hermetic terminals of the compressor should not be inserted slantingly and not be applied twisting force after inserting to avoid reducing of terminal fixed force.
• Dust of compressor hermetic terminals
• Compressor hermetic terminals should be mounted with specified cover in the right way to prevent dust from entering and should be used in the direction in which dust is hard to enter in.
• Lead wire of compressor hermetic terminals
• In measuring the temperature of hermetic terminals, lead wire should be resisted to the temperature and be clamped so as not in touch with the surface of the compressor and pipe.
• Impurities in the refrigerating system

The weight of residue on the inside surface of the heat exchanger and tube should be less than 0.01g/m2. But metallic dust should not be permitted in the system. This value means the weight of foreign residue collected by filer paper after washing inside the surface of the heat exchanger tubes.
Prevent the impurities from entering the enclosed unit system. When the impurities enter the enclosed system, it will damage the moving mechanism parts and result in capillary de-positing.
Eliminate all system contaminants such as trichlo-rethylene, alkalies, soaps, oil, acids & washing fluid used at machining heat exchangers and tubes.

• Purge parts with dry nitrogen or dry air to remove remains in parts (dust, detergent, etc.) be-fore assembly of the system.
• Time fur purging: over one second for pipe; over three seconds for heat exchanger.
• Purging pressure: 0.9±0.1MpaG.
• Dew point of dry air: Below –20 °C.
• Dry nitrogen should be charged in the compressor before the assembly of the system.
• Welding should be finished within one minute after the charge of nitrogen.
• Dry nitrogen needs to be charged again and welded if over one minute.
• Always purge the compressor with dry nitrogen during the assembly of the system.
• To avoid water and impurity in the refrigeration system and make sure no leakage of refrigerant during the operating course. It’s required to direct the erector and maintenance man of the air-conditioner.
• The compressor should not be splashed with water intentionally. Prevent moisture from entering the enclosed unit system. When moisture enters the unit of the refrigerant R290, the refrigerant oil and the organic compound material presented in the hermetic motor will possibly decompose on the affecting of water. It will result in capillary depositing and the reduction of insulation resistance.
• It is necessary to install a dryer to dehumidify the residual moisture mixed in the refrigerant in the cycling system.
• The specially defined molecular-sieve dryer is advised.
• There should be adequate clearance between the lower surface of the bolt flange and the upper surface of rubber grommets.

Support structure 1: Use reducing bolts

• A: The clearance between the top of the rubber foot and the gasket is 1-2mm.

• B: The radial clearance between the inner diameter of the rubber foot and the outer diameter of the bushing is 0.5-1mm.
  Support structure 2: Use ordinary bolt + steel sleeve

• A: The clearance between the top of the rubber foot and the gasket is 1-2mm. That is, the height between the rubber foot and the bushing is 1-2mm.

• B: The radial clearance between the inner diameter of the rubber foot and the outer diameter of the bushing is 0.5-1mm.

• A: The clearance between the top of the rubber foot and the gasket is 1-2mm. That is, the height between the rubber foot and the bushing is 1-2mm.

• B: The radial clearance between the inner diameter of the rubber foot and the outer diameter of the bushing is 0.5-1mm.

1. In designing and routing tubing that connects from the compressor to the other parts of the system, the following should be considered.
2. Moving tubes to the moving parts; minimum clearance 12.7mm (1/2”)
3. Moving tubes to non-moving parts; minimum clearance 9.5mm ((3/8”)
4. Moving tubes never touch to lead wire.
5. The tube thickness as follows

Leak detection.

• Never pressurize the circuit with oxygen or dry air. This could cause fire or explosion.

• Do not use leak detection dye.

• Perform a leak detection test on the complete system.
  The leakage test pressure should be less than R404A: 3.20 MPa.
  R290: 2.343MPa.

• When a leak is discovered, repair the leak, and repeat the leak detection.

Vaccum dehydration

• The compressor should not be operated to form a vacuum and to absorb air.
• Never use the compressor to evacuate the system.
• Do not use a megohmmeter nor apply power to the compressor while it is under vacuum as this may cause internal damage.
  The degree of vacuum in the refrigerating system should be less than 20Pa (150×103mmHg) at room temperature just before charging the refrigerant. The quantity of water should be less than 0.15ml.

Electrical connections

• The compressor only can run in one direction according to the lead routing wiring diagram. Never reversion otherwise the compressor will be in trouble.

• For variable speed, the specified inverter is linked up with compressor terminals. The applied voltage of this inverter should be voltage specified in this “compressor specification”. Alternating voltage should never be applied on terminals (for exam-ple: commercial alternating voltage of 1ph 100V, 200V, 3ph 200V). This is because that if alternating current the direct current motor will demagnetize.

• For variable speed, the compressor should be operated in the range of rated voltage±10%, under standard conditions and overload condition of rated frequency (applied voltage to inverter).

• It must be satisfied with the temperature and pressure requirement in this instruction and the overload condition should not be continuous.

• But the standard condition and overload condition mentioned here refer to the condition specified in GB/T 7725.(The standard condition refers to the rating cooling condition and the overload condition refers to the maximum operating condition.)

• For fixed speed compressor, the voltage applied to the hermetic terminal should be equal to the rated voltage +/-10%.In the case of three phases, the phase imbalance should be within 3% among the compressor terminals.

• The phase imbalance should be calculated according to the following formula.
  the phase imbalance= (V)max – (V)mean/(V) mean×100%
  (V)max: Maximum voltage among the three terminals.
  (V)mean Average voltage among the three terminals.

• The main electric circuit should be equipped with fuse or breaker.

• All electrical components must be selected as per local standards and compressor requirements.

Filling the system

• Keep the compressor switched off.
• Refrigerant should be charged from the end of the condenser of refrigerating systems. Never charge refrigerant to the compressor directly. The refrigerant should always be charged in liquid state. When the refrigerant is charged in gas state, the percent component will possibly be changed. Do not recharge with the remaining refrigerant in the system when leakage happens. Because the percent component of the refrigerant in the unit system had possibly been changed.
• Refrigerant R-290 99.9% in purity should be used for the apparatus. 99.95% is recommended, if possible.

Verification before commissioning

• The trouble of cross valve, electromagnetic valve, defroster, refrigerant controller, fan motor used in the refrigerating system may cause compression accidents. So, their reliability should be ensured completely. Moreover, the way of designing, manufacturing, and applying of refrigeration cycle with fewer leaks should be adopted.
• The units of the refrigerating system should be connected to the earth.
• The operating temperatures and pressures of a compressor should be within the range shown in the operation limit.
• The compressor can be used when ambient temperature is higher than -10 °C. Confirm the start-up of the compressor if the temperature of the compressor surface is below -10 °C. Heat up the compressor to reach a temperature higher than -10 °C with a heater if the ambient temperature is below -10 °C.
• Set a thermostat on the case cover of the compressor to provide a complementary reaction in case of refrigerant leakage. The thermostat can stop the operation of the compressor when the compressor in abnormal temperature. The lead wires of the thermostat are enveloped with a tube, as same as that of the terminals, to avoid direct contact with the compressor and pipe.
• When using the R290 models, the manufacturing process of the refrigerating system must comply with the regulations related to flammable refrigerants, since R290 is a flammable refrigerant.
• When using the R290 models, an explosion-proof unit should be used in the system.

Start-up

• Never start the compressor when no refrigerant is charged.
• Do not provide any power to the compressor unless suction and discharge service valves are open, if installed.
• Energize the compressor. It must start promptly. If the compressor does not start, check wiring conformity and voltage on terminals.

Check with the running compressor

• In all allowable rotational speed ranges, the difference of pressure should be more than 0. 39MPa{4kgf/cm²}. But if there is no problem of noise when assembled in air conditioner, it can also be below this value.

• Discharge pipe temperature is measured at a distance 300mm from the surface of a compressor and should be less than 110°C for vertical type and 100°C for the horizontal type. The tip of the thermocouple is fixed by soldering when measuring discharge pipe temperature, furthermore, the soldering point is covered with urethane foam to prevent the effect of wind.

• The oil should be returned continuously to the compressor and the structure of the refrigerating system should not make oil stay in the system. When the oil cannot return to the compressor properly, oil separator should be installed.

• The start-stop frequency should be less than 6 times per hour. Operating time from start to stop should be more than 3 minutes.Stopping time should be more than 3 minutes. Suction and discharge pressure should balance completely before restarting.

• The rate of compressor rotational speed (acceleration) should be less than 133min-1/s, but if the variable range is below 120min-1, rate can also be less than 600min-1 when the rotational speed is reduced to avoid the temporary over-current.

• The compressor should be operated for more than 20 seconds within 15 minutes after charging refrigerant into the system so proper lubrication results.

• There should not exist noise of the liquid refrigerant compression, and current and vibrancy increase. The system can append the assistant stank or reduce the amount of refrigerant to prevent liquid refrigerant compression. A refrigerant system forbids liquid refrigerant from flowing back compressor in any case. In normal condition the overheat gas refrigerant should flow back compressor.

• The motor winding temperature should be less than 149 °C and the hermetic terminal body temperature should be less than 177 °C in process of manufacturing.

• The max vibration level of the pipes, which connect from the compressor to other parts of the refrigerate- or systems, should be less than 0.8mm (1/32”) when the compressor is operating at the allowable rotational speed range and volt-age range of rated ±10%. Displacement more than 0.8mm (1/32”) will require changing tube length and/or routing.
  Temperatures within systems during stable com-pressor operation should not be less than -35 °C to prevent wax precipitation from the oil.

• For variable speed compressor, adjust the start-up current of the compressor to get enough torsion by inverter. Confirm and measure the start-up current if change the parts and design.

• The current peak among motor terminals (including instantaneous current peak) should be below the demagnetizing current to prevent magnet in the motor from demagnetization.

• The refrigerant migration to the compressor shell should be avoided during the system shutdown periods, it’s suggested that the electric heating belt should be used around the shell bottom when necessary.

• Oil sump superheat (Oil sump temperature mi-nus Condensing temperature) It is necessary to have an oil superheat higher than 6K for R404A application and an oil superheat higher than 10K for R290 application.

• Discharge superheat (Discharge temperature

Maintenance

• Internal pressure and surface temperature are dangerous and may cause permanent injury. Maintenance operators and installers require appropriate skills and tools. Tubing temperature may exceed 100°C / 212°F and can cause severe burns.Ensure that periodic service inspections to ensure system reliability and as required by local regulations are performed. To prevent system-related compressor problems, following periodic maintenance is recommended:
• Verify that safety devices are operational and properly set.
• Ensure that the system is leak-tight.
• Check the compressor current draw.
• Confirm that the system is operating in a way consistent with previous maintenance records and ambient conditions.
• Check that all electrical connections are still adequately fastened.
• Keep the compressor clean and verify the absence of rust and oxidation on the compressor shell, tubes, and electrical connections.
• Acid/moisture content in the system and oil should be checked regularly.

Warranty

• Always transmit the model number and serial number with any claim filed regarding this product. The product warranty may be void in the following cases:
• Absence of nameplate
• External modifications; in particular, drilling, welding, broken feet, and shock marks.
• Compressor opened or returned unsealed.
• Rust, water, or leak detection dye inside the compressor.
• Use of a refrigerant or lubricant not approved by Danfoss.
• Any deviation from recommended instructions pertaining to installation, application, or maintenance.
• Use in mobile applications.
• Use in the explosive atmospheric environment.
• No model number or serial number was transmitted with the warranty claim.

Disposal

Danfoss recommends that compressors and compressor oil should be recycled by a suitable company at its site.

Danfoss AIS Climate Solutions  danfoss.com +45 7488 2222
Any information, including, but not limited to information on the selection of the product, its application or use, product design, and weight. dimensions, capacity or any other technical data in product manuals, catalog descriptions, advertisements, etc., and whether made available in writing, orally, electronica•y, online or via download, shall be considered informative and is only binding if and to the extent, explicit reference is made in a quotation or order confirmation. Danfoss Cannot accept any responsibility for possible errors in catalogs, brochures, Videos, and Other material, Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without changes to the form, fit or function Of the product. All trademarks in this material are property of Danfoss AIS or Danfoss group companies. Danfoss and the Danfoss logo are trademarks of Danfoss A’S. All rights reserved.

References

• Read more on our commercial compressors | Danfoss | Danfoss

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