Danfoss DSF090 User manual

Instructions
Danfoss scroll compressors
DSF 090-200
© Danfoss | DCS (CC) | 2020.07 8510294P01C - AN323020831102en-000101 | 1
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
regulation) 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°)
Installation and servicing of the compressor by qualified personnel only. Follow these instructions and sound refrigeration engineering
practice relating to installation, commissioning, maintenance and service.
1 – Introduction
These instructions pertain to the Danfoss scroll compressors DSF scroll compressors used for air-condi-
tioning systems. They provide necessary information regarding safety and proper usage of this pro-
duct.
3 - Operating map
2- Nameplate
A: Model number
B: Serial number
C: Refrigerant
D: Supply voltage, Starting current & Maximum
operating current
E: Housing service pressure
F: Factory charged lubricant
A
D
E
F
B
C
0
-35 -30 -25 -20 -15 -10 -5 10 15 20 25
30
0 5
10
20
30
40
50
60
70
5
15
25
35
45
55
65
Condensing temperature (°C)
Evaporating temperature (°C)
DSF 130
DSF155/175/200
DSF090/100/115
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DSF Operating map (SH 5K)

Instructions
2 | AN323020831102en-000101 - 8510294P01C © Danfoss | DCS (CC) | 2020.07
M
DGT
HP
UNIT
CONTROLLER
SS CC
F1 F1
KM
CB
Ph
L1
L1
L3
L3
L2
T1
T3
T2
KM
SSH
LPS
Ph
DSF 090-200
DSF 090-175 DSF200
These Danfoss scroll compressors are protected against overheating and
overloading by an internal safety motor protector. However, an external
manual reset overload protector is recommended for protecting the circuit
against over-current.
4 - Electrical connections details
Legend:
Fuses ........................................................................................... F1
Compressor contactor......................................................... KM
High pressure safety switch.................................................HP
Safety pressure switch .........................................................LPS
Discharge gas temperature protection......................... DGT
Compressor motor...................................................................M
Surface sump heater ........................................................... SSH
Thermal magnetic motor circuit breaker ...................... CB
Phase sequence relay.............................................................Ph
5 – Handling and storage
• Handle the compressor with care. Use the
dedicated handles in the packaging. Use the
compressor lifting lug and use appropriate
and safe lifting equipment.
• Store and transport the compressor in an
upright position.
• Store the compressor between Ts min and Ts
max values for LP side indicated on compres-
sor nameplate.
• Don’t expose the compressor and the packa-
ging to rain or corrosive atmosphere.
6 – Safety measures before assembly
Never use the compressor in a flammable at-
mosphere.
• Check before assembly that the compressor
does not show any obvious signs of deteriora-
tion that could have occurred during inappro-
priate transportation, handling or storage.
• The compressor ambient temperature may
not exceed Ts max value for LP side indicated
on compressor nameplate during off-cycle.
• Mount the compressor on a horizontal flat
surface with less than 3° slope.
• Verify that the power supply corresponds to
the compressor motor characteristics (see
nameplate).
• When installing DSF, use equipment specifi-
cally reserved for HFC refrigerants which was
never used for CFC or HCFC refrigerants.
• 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.
7 – Assembly
• The compressor must be mounted on rails or
chassis according to Danfoss recommenda-
tions described in related product guidelines
(type of spacer, tightening torques).
• Slowly release the nitrogen holding charge
through the schrader port.
• Remove the gaskets when brazing rotolock
connectors.
• Always use new gaskets for assembly.
• Connect the compressor to the system as
soon as possible to avoid oil contamination
from ambient moisture.
• Avoid material entering into the system while
cutting tubes. Never drill holes where burrs
cannot be removed.
• Braze with great care using state-of-the-art
technique and vent piping with nitrogen gas
flow.
• Connect the required safety and control de-
vices. When the schrader port is used for this,
remove the internal valve.
• Do not exceed the maximum tightening
torque for rotolock connections:
Rotolock connections Tightening torque
1” rotolock 80 Nm
1 1/4 “ rotolock 90 Nm
1 3/4” rotolock 110 Nm
2 1/4” rotolock 130 Nm.
8 – Leak detection
Never pressurize the circuit with oxygen or
dry air. This could cause fire or explosion.
• DSF090 to 200: Pressurize the system on HP
side first and then on LP side. Never let the
pressure on LP side exceed the pressure on
HP side with more than 5 bar. Such pressure
difference could cause internal compressor
damage.
• Do not use dye for leak detection.
• Perform a leak detection test on the complete
system.
• The test pressure must not exceed 1.1 x PS
value for LP side and PS value for HP side indi-
cated on compressor nameplate.
• When a leak is discovered, repair the leak and
repeat the leak detection.
9 – Vacuum dehydration
• Never use the compressor to evacuate the
system.
• Connect a vacuum pump to both the LP & HP
sides.
• Pull down the system under a vacuum of 500
µm Hg (0.67 mbar) absolute.
• Do not use a megohmmeter nor apply power
to the compressor while it is under vacuum as
this may cause internal damage.
10 – Electrical connections
• Switch off and isolate the main power supply.
See overleaf for wiring details.
• All electrical components must be selected as
per local standards and compressor require-
ments.
• Refer to section 4 for electrical connections
details.
• The Danfoss scroll compressors only works
correctly in one rotation direction. Line
phases L1, L2, L3 must absolutely be connec-
ted to compressor terminals T1, T2, T3 to
avoid reverse rotation.
• Use ø 4.8 mm (3/16”) screws and ¼” ring ter-
minals for the power connection. Fasten with
3 Nm torque.
• The compressor must be connected to earth
with the 5 mm earth terminal screw.
11 – Filling the system
• Keep the compressor switched off.
• Fill the refrigerant in liquid phase into the
condenser or liquid receiver. The charge must
be as close as possible to the nominal system
charge to avoid low pressure operation and
excessive superheat. Never let the pressure

Instructions
8510294P01C - AN323020831102en-000101 | 3
© Danfoss | DCS (CC) | 2020.07
on LP side exceed the pressure on HP side
with more than 5 bar. Such pressure difference
could cause internal compressor damage.
• Keep the refrigerant charge below the indi-
cated charge limits if possible. Above this limit;
protect the compressor against liquid flood-
back with a pump-down cycle or suction line
accumulator.
• Never leave the filling cylinder connected to
the circuit.
Compressor models Refrigerant charge
limit (kg)
DSF 115-130-155-175-200 10
DSF 090-100 8
12 – Verification before commissioning
Use safety devices such as safety pressure swit-
ch and mechanical relief valve in compliance with
both generally and locally applicable regulations
and safety standards. Ensure that they are opera-
tional and properly set.
Check that the settings of high-pressure swit-
ches and relief valves don’t exceed the maximum
service pressure of any system component.
• A low-pressure switch is recommended to
avoid vacuum operation. Minimum setting for
DSF: 1.5 bar g.
• Verify that all electrical connections are proper-
ly fastened and in compliance with local regu-
lations.
• When a crankcase heater is required, it must be
energized at least 12 hours before initial start-
up and start-up after prolonged shutdown for
belt type crankcase heaters (6 hours for surface
sump heaters).
13 – Start-up
Never operate the compressor without the
electrical box cover fitted.
• Never start the compressor when no refrige-
rant is charged.
• All service valves must be in the open position.
• Balance the HP/LP pressure.
• Energize the compressor. It must start promp-
tly. If the compressor does not start, check wi-
ring conformity and voltage on terminals.
• Eventual reverse rotation can be detected by
following phenomena; the compressor doesn’t
build up pressure, it has abnormally high sound
level and abnormally low power consumption.
In such case, shut down the compressor imme-
diately and connect the phases to their proper
terminals. Danfoss DSF scroll compressors are
protected against reverse rotation either by an
internal reverse rotation protection. They will
shut off automatically.
• If the internal overload protector trips out, it
must cool down to 60°C to reset. Depending
on ambient temperature, this may take up to
several hours.
14 – Check with running compressor
• Check current draw and voltage.
• Check suction superheat to reduce risk of slug-
ging.
• Observe the oil level in the sight glass for about
60 minutes to ensure proper oil return to the
compressor.
• Respect the operating limits.
• Check all tubes for abnormal vibration. Move-
ments in excess of 1.5 mm require corrective
measures such as tube brackets.
• When needed, additional refrigerant in liquid
phase may be added in the low-pressure side
as far as possible from the compressor. The
compressor must be operating during this pro-
cess.
• Do not overcharge the system.
• Never release refrigerant to atmosphere.
• For reversible systems, ensure that the 4-way
valve does not reverse when the compressor
is stopped due to heating or cooling demand
(stop on thermostat)
• Before leaving the installation site, carry out
a general installation inspection regarding
cleanliness, noise and leak detection.
• Record type and amount of refrigerant charge
as well as operating conditions as a reference
for future inspections.
15 – Maintenance
Internal pressure and surface temperature
are dangerous and may cause permanent inju-
ry.Maintenance operators and installers require
appropriate skills and tools. Tubing temperature
may exceed 100°C 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 ab-
sence of rust and oxidation on the compressor
shell, tubes and electrical connections.
16 - Warranty
Always transmit the model number and serial nu-
mber with any claim filed regarding this product.
The product warranty may be void in 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 main-
tenance.
• Use in mobile applications.
• Use in explosive atmospheric environment.
• No model number or serial number trans-
mitted with the warranty claim.
The compressor is not designed to withstand
natural disasters such as earthquakes, cyclones,
floods…. or extreme events such as fires, terrorist
attacks, military bombardments, or explosions of
any kind.
Danfoss Commercial Compressor is not liable
for any malfunction of its product resulting from
such events
17 – Disposal
Danfoss recommends that compressors
and compressor oil should be recycled
by a suitable company at its site.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
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