INSTRUCTIONS
VSH COMPRESSORS
A
B
C
D
E
F
G
Oil injection control assembly
3 2 1
Oil injection
control valve
A: Model number
B: Serial number
C: Refrigerant
D: Supply voltage & Locked rotor current
70
65
60
55
50
45
(°C)
C
T
40
35
30
25
20
15
-30 -25 -20 -15 -10 -5 0 5 10 15 20
4
SH=6K
50 - 90 Hz
5 6
E: Housing service pressure
F: Factory charged lubricant
G: Compressor frequency & Max Must trip cur-
rent
R410A
50 - 90 Hz
30 - 90 Hz
T0 (°C)
Put the clip-on coil (1) with the gasket (2) over
the valve body (3) on the compressor
Oil injection control dismantling
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 http://cc.danfoss.com
1
Attach the connector (4) to the coil using the
delivered accessories (5) and (6).
Remove the clip-on coil by using a screw
driver.
Under all circumstances,
the EN378 (or other applicable
local safety regulation)
requirements must be
fulfilled.
FRCC.EI.005.A3.02 © Danfoss Commercial Compressors 09/10
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.
220V
2 A max
Wire the connector as indicated.
The compressor must be
handled with caution in the
vertical position (maximum
offset from the vertical : 15°)
RELAY
2
CDS302
Instructions
Basic connections
- Depending on the frequency converter
version, the physical position of individual
connectors may differ from below diagram.
- Always make sure that the compressor terminals T1, T2, T3 are connected to the frequency
converter terminals 96, 97, 98 respectively.
- The compressor motor cable must be shielded
L1 91 L1 W 98 T3
L2 92 L2 V 97 T2
L3 93 L3 U 96 T1
95 PE PE 99
39 39 Ana out COM
42 42 Ana out +
50 50 Ana in +10 V NC 03
53 53 Ana in 0 ± 10 V NO 02
54 54 Ana in 0 ± 10 V COM 01
55 55 Ana in COM
12 12 +24V COM 04
13 13 +24V
18 18 Dig in
19 19 Dig in
27 27 Dig in/out
29 29 Dig in/out
32 32 Dig in N- RS485 69 69
33 33 Dig in P+ RS485 68 68
20 20 Dig in COM COM RS485 61 61
37 37 Dig in
and the armoured part must be connected to
ground on both cable ends; at the side of the
compressor and at the side of the frequency
converter.
- Use an EMC cable gland for cable installation and
perfect grounding; The metallic terminal box of
the compressor has a paint-free surface around
1
RELAY
NC 06
NO 05
the connection hole for better conductivity.
- A low pressure safety switch is mandatory
to avoid compressor vacuum operation.
- At start-up, verfiy that the compressor rotates
in the right direction and pumps.
Legends:
Ana: Analogue
Dig: Digital
in: Input
out: Output
COM: Common
NC: Normally-closed
NO: Normally-open
230 V
～
2 A max
91, 92, 93: 3 Phase mains input X X
Open loop Process loop
95: Earth X X
39, 42 Analogue output - 50: Analogue input - 53: PLC+ (0 to 10 V) X 54: Sensor - - X
55: PLC- X 12: HP/LP switch X X
12: External On/Off (NO) X X
13: Factory bridged to 37 X X
13: Sensor + - X
18: External On/Off (NO) X X
19: Digital input - 27: HP/LP switch (NC) / safety devices X X
29: Digital input/output - 32, 33 Digital input - 20: Digital input Common - 37: Factory bridged to 13 X X
98: To compressor terminal T3 X X
97: To compressor terminal T2 X X
96: To compressor terminal T1 X X
99: To compressor earth connection X X
02, 01: Relay 1 to oil solenoid valve X X
06, 05, 04: Relay 2 - 69, 68: RS485 Bus - 61: RS485 Bus Common - -
- Optional connection X : Mandatory connection
The CDS302 frequency converter is factory preset with parameters for the open loop control
principle. The process loop control principle
can be selected by changing parameters in the
«Quick menu».
Open loop:
0 - 10 V control
Frequency converter in slave mode
Process loop:
4 - 20 mA control
Frequency converter under own PID controller
2
FRCC.EI.005.A3.02 © Danfoss Commercial Compressors 09/10
Instructions
1 - Introduction
These instructions pertain to the VSH Variable
Speed scroll compressors used for A/C systems.
They provide necessary information regarding
safety and proper usage of this product.
2 – 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 -35°C and 55°C.
• Don’t expose the compressor and the packaging to rain or corrosive atmosphere.
3 – Safety measures before assembly
Never use the compressor in a flammable
atmosphere.
• The compressor ambient temperature may
not exceed 50°C during off-cycle.
• Mount the compressor on a horizontal flat
surface with less than 3° slope.
• The compressor can only be supplied by a
frequency converter. Make sure that the frequency
converter is the dedicated one for the compressor
(power size and voltage: input & output).
Parameter 1.13 of the frequency converter lists the
possible combinations of compressors, frequency
converters and refrigerants.
• When installing a VSH, use equipment specifically reserved for HFC refrigerants which was
never used for CFC 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.
• Make sure the installation is equipped with highpressure safety components (e.g. pressure switch,
pressure relief valve) to prevent against the bursting of pressure-containing components.
4 - Assembly
• Slowly release the nitrogen holding charge
through the schrader port.
• 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 devices. When the schrader port is used for this,
remove the internal valve.
5 – Leak detection
Never pressurize the circuit with oxygen or
dry air. This could cause fire or explosion.
• Do not use dye for leak detection.
• Perform a leak detection test on the complete
system.
• The low side test pressure must not exceed 30 bar.
• When a leak is discovered, repair the leak and
repeat the leak detection.
6 – Vacuum dehydration
• 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 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.
7 – Electrical connections
• Switch off and isolate the main power supply.
See previous page for wiring details.
• The compressor is protected against excess
current by the frequency converter. Follow local
regulations regarding power line protection.
The compressor must be connected to ground.
• All electrical components must be selected as per
local standards and compressor requirements.
• Please refer to drawings for typical wiring connections and examine the specific wiring diagram
located in the frequency converter package. For
further details, refer to the application guidelines.
• Follow very closely the installation instruction
for the frequency converter:
- Mounting: The base frame of the frequency
converter must be very well fixed to the
support to ensure a very good continuity
between the ground potential of all electrical
panels and electrical boxes of the system.
- Wiring: All control wires have to be of a screee-
ned design. The cable for electrical motor supply has to be of a shielded design as well. Correct earthing of the shield cover has to be done
using the method shown on drawings, every
time this one has to be earthed on each end
of the cables. Distinct cable trays must be used
for control and motor supply.
• The frequency converter ensures direct motor
protection and the factory set parameters are
such to protect the motor over all current malfunctions. An external overload is not necessary.
• Set the frequency converter parameters in
accordance with Danfoss recommendations
for the CDS302 frequency converter and VSH
variable speed compressor.
8 – Filling the system
• Keep the compressor switched off.
• Fill the refrigerant in liquid phase into the
outlet side of 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.
Compressor Refrigerant charge limit (kg)
VSH088 5.9
VSH117 7.9
VSH170 13.5
Above this limit; protect the compressor against
liquid flood-back with a pump-down cycle not
lower than 2.3 bar (g) or a suction line accumulator.
• Never leave the filling cylinder connected to
the circuit to avoid overfilling.
9 – 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 swit-
ches and relief valves don’t exceed the maximum
service pressure of any system component.
• A low-pressure switch is mandatory to avoid vacuum operation. Minimum setting 1.5 bar (g).
• Verify that all electrical connections are properly
fastened and in compliance with local regulations.
• A crankcase heater is not required. This
function is integrated in the CDS302 which
provides a calibrated DC current during off
cycles to heat the electrical motor. The CDS302
must be energized at least 12 hours before initial start-up and after prolonged shutdown.
• After comissioning it is strongly recommended to
keep the frequency converter always energized.
FRCC.EI.005.A3.02 © Danfoss Commercial Compressors 09/10 3
10 – Start-up
• All service valves must be in the open position.
• Balance the HP/LP pressure.
• Energize the compressor. It must start promptly.
• If the compressor doesn’t start, verify that the
compressor is hooked up to the frequency
converter; check the power lead connections.
If these verifications reveal no abnormality,
check the motor windings with an ohmmeter.
• Check the frequency converter control panel: If any alarm is displayed check the wiring
and in particular the polarity of the control
cables. If an alarm is shown, refer to the frequency converter application manual. Verify
in particular the combination of compressor,
frequency converter and refrigerant.
• Check current draw and voltage levels on the
mains. The values for the compressor electrical motor can be directly displayed on the
frequency converter control panel.
• The optimum compressor suction superheat
is around 6K. The maximum allowed superheat is 30K.
11 – Check with running compressor
• Check current draw and voltage.
• Check suction superheat to reduce risk of
slugging.
• Observe the oil level at start and during operation to confirm that the oil level remains visible.
Excess foaming in oil sight glass indicates refrigerant on the sump.
• Monitor the oil sight glass for 1 hour after system equilibrium to ensure proper oil return to
the compressor. This oil check has to be done
over the speed range to guarantee:
- a good oil return at low speed with mini-
mum gas velocity.
- a good oil management at high speed
with maximum oil carry over.
• 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 the 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 the atmosphere.
• 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.
• Compressor failure to build up pressure: Check
all bypass valves in the system to ensure that
none of these has been opened. Also check that
all solenoid valves are in their proper position.
• Abnormal running noise: Ensure the absence of
any liquid flood-back to the compressor by means
of measuring the return gas superheat and compressor sump temperature. The sump should be
at least 6K above the saturated suction temperature under steady-state operating conditions.
• The high-pressure switch trips out: Check
condenser operations (condenser cleanliness,
fan operation, water flow and water pressure
valve, water filter, etc.). If all these are OK, the
problem may be due to either refrigerant
overcharging or the presence of a non-condensable (e.g. air, moisture) in the circuit.
• The low-pressure switch trips out: Check evaporator operations (coil cleanliness, fan operations,
water flow, water filter, etc.), liquid refrigerant
flow and pressure drops (solenoid valve, filter
dryer, expansion valve, etc.), refrigerant charge.
• Low refrigerant charge: The correct refrigerant
charge is given by the liquid sight glass indication,
the condenser delta T in relation to the refrigerant pressure tables (pressure-temperature), the
superheat and the sub-cooling, etc. (if additional
Instructions
charge is deemed necessary, refer to section 8).
• Compressor short cycling: The number of cycles shall never exceed 12 starts per hour.
13 - Warranty
Always transmit the model number and serial number with any claim filed regarding this product.
12 - Maintenance
Internal pressure and surface temperature
are dangerous and may cause permanent injury.
Maintenance operators and installers require
appropriate skills and tools. Tubing and compresssor upper shell 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 absence of rust and oxidation on the compressor shell, tubes and electrical connections.
• Check the internal temperature of the frequency converter on its display and the cooling air flow.
• Faults are logged in the frequency converter
memory and can be displayed. This can help
to evaluate and improve parameters of the
frequency converter or of the system itself.
Use the fault memory of the frequency converter to recover the fault descriptions before initializing the system and even before shutting off
the power.
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
maintenance.
• Use in mobile applications.
• Use in explosive atmospheric environment.
• No model number or serial number transmitted with the warranty claim.
14 – Disposal
Danfoss recommends that compressors, frequen-
cy converters and compressor oil should
be recycled by a suitable company.
Danfoss Commercial Compressors http://cc.danfoss.com
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.
FRCC.EI.005.A3.02 - Sept. 2010 Copyright Danfoss Commercial Compressors - 09/10
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