Danfoss DSG Series User manual

8510312P01AA - AN403622134116en-000102 | 1
© Danfoss | Climate Solutions | 2022.07
Instructions
Danfoss scroll compressors
DSG
The compressor must only be used for its
designed purpose(s) and within its scope of
application (refer to «operating limits»).
Consult Application guidelines available from
cc.danfoss.com
Under all circumstances, the
EN378 (or other applicable local
safety regulation) requirements
must be fullled.
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
oset from the vertical : 15°)
Installation and servicing of the compressor by
qualied personnel only. Follow these instructions and
sound refrigeration engineering practice relating to
installation, commissioning, maintenance and service.
A: Model number
B: Serial number
C: Refrigerant
D: Supply voltage, Starting current & Maximum operating current
E: Housing service pressure
F: Factory charged lubricant
1 – Introduction
These instructions pertain to the Danfoss scroll compressors DSG scroll com-
pressors used for air-conditioning systems. They provide necessary informa-
tion regarding safety and proper usage of this product.
DSG Large Operating map
3 - Operating map
2- Nameplate
MADE IN FRANCE
Model no : DSG480A4ABA
Compressor
Serial no : ZK1198782797 380 - 415V 3 ~ 50 Hz
460 V 3 ~ 60 Hz
LR 391,0A MAX OPER. 81,0 A
Thermally protected system
P. E.D.
Marking LP side HP side
PS 9.5 bar 17.6 bar
TS max 52.0 °C 150 °C
TS min -35.0 °C -35.0 °C
Volume 31.6 L 6.2 L
Lubricant: P. O.E. 160SZ
L
2022
Refrigerant: R1234ze R515B
876543210
PROTECTED BY DOMESTIC AND FOREIGN PATENTS
0094
1
5
6
7
2
4
089
A
D
E
F
B
C
Condensing temperature (°C)
Evaporating temperature (°C)
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
-40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
SH = 10K (18°F)
SH = 5K (9°F)
Condensing temperature (°F)
41
50
59
68
77
86
95
104
113
122
131
140
149
158
167
Danfoss
OE-000006
Evaporating temperature (°F)
-40 -31 -22 -13 -4 5 14 23 32 41 50 59 68 77 86 95

Instructions
2 | AN403622134116en-000102 - 8510312P01AA © Danfoss | Climate Solutions | 2022.07
These Danfoss scroll compressor motors are protected by an external
module protecting against phase loss/reversal, overheating and high
current draw.
DSG240 to DSG380
MPM
S
CCH
CCSS
LPS
UNIT
CONTROLLER
KM
DGT
CB
4 - Electrical connections details
DSG480
Legend:
Fuses .........................................................................................F1
Compressor contactor........................................................ KM
High pressure safety switch................................................ HP
Discharge gas thermistor
(embedded in compressors)............................................ DGT
Crankcase heater............................................................... CCH
Compressor motor .................................................................M
Motor Protection Module ...............................................MPM
Thermistor chain...................................................................... S
Safety pressure switch........................................................LPS
Thermal magnetic motor circuit breaker ....................... CB
CCH
CONTROL
CIRCUIT
LPS
UNIT
CONTROLLER
SEPARATE
SUPPLY
KM
DGT
MPM
S
CB
These Danfoss scroll compressor motors are protected by an external
module protecting against phase loss/reversal, overheating and high
current draw.

Instructions
8510312P01AA - AN403622134116en-000102 | 3
© Danfoss | Climate Solutions | 2022.07
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 compressor
nameplate.
• Don’t expose the compressor and the
packaging to rain or corrosive atmosphere.
6 – Safety measures before assembly
Never use the compressor in a ammable
atmosphere.
• Check before assembly that the compressor
does not show any obvious signs of
deterioration that could have occurred during
inappropriate transportation, handling or
storage.
• The compressor ambient temperature may not
exceed Ts max value for LP side indicated on
compressor nameplate during o-cycle.
• Mount the compressor on a horizontal at
surface with less than 3° slope.
• Verify that the power supply corresponds to
the compressor motor characteristics (see
nameplate).
• 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
exible in 3 dimensions to dampen vibrations.
7 – Assembly
• The compressor must be mounted on rails or
chassisaccordingto Danfoss recommendations
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
ow.
• Connect the required safety and control
devices. When the schrader port is used for
this, remove the internal valve.
8 – Leak detection
Never pressurize the circuit with oxygen or dry
air. This could cause re or explosion.
• Pressurize the system on HP side rst 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 dierence 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 HP side indicated 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 o and isolate the main power supply.
See overleaf for wiring details.
• All electrical components must be selected
as per local standards and compressor
requirements.
• 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 connected
to compressor terminals T1, T2, T3 to avoid
reverse rotation.
• Electrical power is connected to the
compressor terminals by M5 studs and nuts
. Use appropriate ring terminals, fasten with
3Nm torque.
• The compressor must be connected to earth
with the 5 mm earth terminal screw. The
maximum torque is 4Nm.
11 – Filling the system
• Keep the compressor switched o.
• 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
on LP side exceed the pressure on HP side
with more than 5 bar. Such pressure dierence
could cause internal compressor damage.
• Keep the refrigerant charge below the
indicated charge limits if possible. Above this
limit; protect the compressor against liquid
ood-back with a pump-down cycle or suction
line accumulator.
• Never leave the lling cylinder connected to
the circuit.
Compressor models Refrigerant charge
limit (kg)
DSG240, DSG295 15
DSG380, DSG480 17
12 – Verification before commissioning
Use safety devices such as safety pressure
switch and mechanical relief valve in compliance
with both generally and locally applicable
regulations and safety standards. Ensure that
they are operational and properly set.
Check that the settings of high-pressure
switches 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
-0.22 bar g.
• Verify that all electrical connections are
properly fastened and in compliance with local
regulations.
• 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.
13 – Start-up
Never operate the compressor without the
electrical box cover tted.
• Never start the compressor when no refrigerant
is charged.
• All service valves must be in the open position.
• Balance the HP/LP pressure.
• Energizethecompressor.It must start promptly.
If the compressor does not start, check wiring
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
immediately and connect the phases to
their proper terminals. DSG compressors are
protected against reverse rotation by the
external electronic protection module. They
will shut o automatically.
• If the internal pressure relief valve is opened
the compressor sump will be warm and
the compressor will trip out on the motor
protector.
14 – Check with running compressor
• Check current draw and voltage.
• Check suction superheat to reduce risk of
slugging.
• 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.
Movements 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
process.
• 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 injury.
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

© Danfoss | Climate Solutions | 2022.07

4 | AN403622134116en-000102 - 8510312P01AA
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.
• Conrm 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.
16 - Warranty
Always transmit the model number and serial
number with any claim led regarding this
product.
The product warranty may be void in following
cases:
• Absence of nameplate.
• External modications; 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 explosive atmospheric environment.
• No model number or serial number transmitted
with the warranty claim.
The compressor is not designed to withstand
natural disasters such as earthquakes, cyclones,
oods…. or extreme events such as res, 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.