Danfoss PRACTICAL Installation guide

Brand: Danfoss

Model: PRACTICAL

Type: Installation guide

PRACTICAL INSTALLATION TIPS FOR BLACK STAR

CONDENSING UNITS

TIPS FOR

THE INSTALLER

CZ.80.B1.02

Produced by Danfoss G1 advertising agency 02.08 LN.bpv.AO

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.

General considerations when installing Blackstar condensing units . . . . . . . . . . . . . . . . 3

Careful ﬁtting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Blackstar tube connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Impurities and contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Copper tubing and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Silver solder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Protective gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Evacuation and charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Exceeding the max. permissible operating charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Inspection and setting of safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Technical regulations and stipulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Blackstar –air-cooled condensing units for R 134a and R 404A / R 507 . . . . . . . . . . . . . . . . 11

Electrical equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Compressor protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Shut-off valves (N2 and T2 models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Weather-resistant enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Leakage testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Evacuation and charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Max. permissible refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Exceeding the max. permissible charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressor Shell heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

»Pumpdown cycle« . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Max. permissible temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Solder Adaptor (FSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

50 Hz • R22 • R134a •

R290 • R404A

This section provides general appli-

cation information on Black Star

condensing units. Subsequent sections

will describe speciﬁc details of Black

Star condensing units.

Careful ﬁtting

Industrial refrigeration and air-

condition systems are increasingly

based on hermetic compressors.

Such refrigeration systems make high

demands on design and installation

quality.

General instruction can be found in

»Practical tips« in the folder »Tips for

the installer«, where the most impor-

tant facts and additional information

are repeated.

Installation

Black Star condensing units must be

installed in well-ventilated surround-

ings to ensure that there is sufﬁcient

air ﬂow, through the condenser, to

adequately cool the compressor.

In addition, it must be ensured that

discharge air is kept away from the

air intake. When the fan motor is con-

nected, air is drawn towards the

compressor over the condenser. The

condenser must be cleaned regularly

to ensure that the condensing unit

functions optimally.

General considerations when installing

Black Star condensing units

1 × Min. compartment length:

condenser 2 × condenser depth

height

Compressor

Condenser

Max. 1,5 m

Evaporator

Max. 1,5 m

Max. 5 m

Compressor

Condenser

Evaporator

Max. 30 m

Blackstar tube connections

Tubing runs must be as short and

compact as possible. Low-lying tube

sections where oil can collect (oil

pockets) should be avoided.

1. If the Blackstar condensing unit is

installed at the same height as the

evaporator.

The suction line should be ﬁtted with a

slight downward incline towards the

compressor.

The maximum permissible distance

between the condensing unit and the

evaporator is 30 m.

To ensure return oil ﬂow, the following

suction line dimensions are

recommended:

TL ∅8 mm FR ∅ 10 mm

SC ∅10 mm SC Twin ∅ 16 mm

The following tube dimensions are

recommended for liquid-carrying

lines:

TL ∅6 mm FR ∅6 mm

SC ∅8 mm SC Twin ∅ 10 mm

2. If the Blackstar condensing unit is

installed above the evaporator.

The vertical distance between the

condensing unit and the refrigeration

unit must not exceed 5 m. The length

of tubing between the condensing unit

and the evaporator must not exceed

30 m. Suction lines must incorporate

oil traps taking the form of double bends

at the bottom and top of the line.

The bends must be u-formed at the

bottom of the vertical tube section and

p-formed at the top. The maximum per-

missible distance between bends is

1-1.5 m.

General considerations when installing

Blackstar condensing units

Compressor

Condenser

Max. 1,5 m

Evaporator

Max. 1,5 m

Max.. 5 m

To ensure return oil ﬂow, the following

suction line dimensions are

recommended:

TL ∅8 mm SC 12/15 ∅10 mm

FR ∅10 mm SC Twin ∅6 mm

All others SC ∅12 mm

The following tube dimensions are

recommended for liquid-carrying

lines:

TL ∅6 mm FR ∅6 mm

SC ∅8 mm SC Twin ∅10 mm

3. If the Blackstar condensing unit is

installed below the evaporator.

The vertical distance between the

condensing unit and the evaporator

must not exceed 5 m. The length of

tubing between the condensing unit

and the evaporator must not exceed

30 m. Suction lines must incorporate

oil traps taking the form of double

bends at the bottom and top of the

line. The bends must be u-formed at

the bottom of the vertical tube section

and p-formed at the top. The maximum

permissible distance between bends is

1-1.5 m.

To ensure return oil ﬂow, the following

suction line dimensions are

recommended:

TL ∅8 mm FR ∅10 mm

SC ∅12 mm SC Twin ∅16 mm

The following tube dimensions are

recommended for liquid-carrying

lines:

TL ∅6 mm FR ∅6 mm

SC ∅8 mm SC Twin ∅10 mm

General considerations when installing

Blackstar condensing units

Silver solder

The most suitable solder is the so-

called silver solder, which is an alloy

of 55% silver, copper, zinc and tin.

The melting point of silver solder is

between 655°C and 755°C.

The coated silver solder contains the

ﬂux necessary to solder the connec-

tion. After soldering, excess ﬂux

should be removed using emery cloth

or a brush to avoid »hidden» leaks.

Silver solder is suitable for soldering

different materials, steel / copper for

example.

Protective gas

On exposure to air, oxidation products

(oxide scale) are immediately formed

at such high soldering temperatures.

The system must therefore be protect-

ed by a ﬂow of gas during soldering.

Direct a light ﬂow of dry inert gas

through the tube. Do not start solder-

ing until all air in the component has

been replaced by gas.

Start the process with a strong ﬂow of

protective gas, and reduce the ﬂow to

a minimum when starting soldering.

This light ﬂow of protective gas must

be maintained throughout the entire

soldering process. Supply oxygen and

gas during soldering. Use a soft ﬂame

and if possible a fork burner.

Do not apply the solder until the melt-

ing temperature has been reached.

Soldering

Impurities and contaminants

Impurities and contaminants are the

most common factors reducing the

reliability and operating life of refri-

geration plants.

During installation the following

impurities can enter the system:

●

Oxide scale from soldering

(oxidation)

●

Flux from soldering

●

Moisture and foreign gases

Copper tubing and components

Only clean and dry copper tubes

should be used for refrigeration plants.

All components must comply with

DIN 8964.

Further information is available in the

quick reference »Blackstar condensing

units, CB.32.Bx.2« if quick adjustment

of the refrigeration controls is necessary.

A well-arranged table in the brochure

shows which refrigeration controls are

required, allowing quick and easy

choice of necessary equipment.

General considerations when installing

Blackstar condensing units

Exceeding the max. permissible

operating charge

If the refrigerant charge is more than

the permissible operating charge,

precautions must be taken. Heating

the compressor shell is a simple and

fast way of preventing refrigerant mi-

gration during standstill phases.

Crankcase heater can be ordered at

Danfoss. Code.no.: 192H2096.

A »pumpdown cycle« is another

possibility. A solenoid valve controlled

by a thermostat must be installed in

the liquid line. When the solenoid

valve closes, the compressor sucks

on the low-pressure side until the

low-pressure switch cuts out at the

compressor pressure setting.

During a pumpdown cycle, the low-

pressure switch cut-in setting must be

set lower than the refrigerant satura-

tion pressure for the lowest condens-

ing unit and compressor ambient tem-

perature.

SC with shell heating

Evaporator

Sight glass

Filter drier

Expansion valveSolenoid valve

Thermostat

Evacuation and charging

Vacuum pump

The vacuum pump should be able

to remove system pressure to about

0.67 mbar and, preferably, be two-

stage. Moisture, atmospheric air and

protective gas should also be removed.

As far as possible, evacuation of the

condensing unit should be two-sided,

i.e. from suction and pressure sides.

Use the connections on the condensing

unit suction and shut-off valves.

Further details are given in the follow-

ing sections and/or in the section

»Practical tips« in the folder »Tips for

the installer«.

Charging

Charging the system involves the use

of a level or charging cylinder and/or a

balance. Provided a charging valve is

used, the refrigerant can be supplied

(as liquid) through the liquid line.

Otherwise, the refrigerant must be

charged into the system in gas form

through the shut-off valve, with the

compressor running (the vacuum

must be broken ﬁrst).

Remember that refrigerants R 404A,

R 507 and R 407C are blends.

Refrigerant producers recommend

that R 507 be charged in liquid or gas

form, while R 404A and R 407C must be

charged in liquid form.

It is further recommended that R 404A,

R 507 and R 407C be charged as

described, i.e. using a charging valve.

If the required quantity is not known,

charging must be performed until air

bubbles can no longer be seen in the

sight glass. Here, to ensure normal

operating temperature, the liquid and

suction gas temperatures must be

constantly monitored.

Evacuation and charging

This folder deals exclusively with

condensing units for operation with

expansion valves. These units are

marked T2, which means that the unit

is ﬁtted with a receiver and two shut-

off valves. Condensing units available

for capillary tube operation, marked

NO or N2, are not dealt with here.

Blackstar condensing units for the

UK market incorporate a fusible plug

according to BS1608.

Electrical equipment

The condensing units are ﬁtted, ready

for wiring up. A terminal box at the

front of the unit contains a board to

which the leads from the refrigeration

system can be connected.

Blackstar – condensing units

for R 134a and R 404A / R 507

Terminal box

Inspection and setting

of safety equipment

The setting and inspection of safety

equipment must be performed me-

chanically and electrically on the

equipment itself – while it is installed

and running. Functions must be

checked with measuring equipment.

Technical regulations and

Standards

The latest regulations and Standards

must followed, e.g.

●

Basic technical safety regulations for

building up, equipping, setting up

and operating refrigeration plant –

DIN 8975 or BS1608

●

EN 60335

●

PED

●

EN 378

Fan

The fan runs in self-lubricating

bearings and has a large oil reservoir

to ensure maintenance-free operation

for many years. All fan motors have a

built-in winding protector or are

impedance protected.

Marking:

TW = Thermally protected

ZP = Impedance protected

Shut-off valves (N2 and T2 models)

Blackstar condensing units are

equipped with shut-off valves on

suction and pressure sides. Turning

the spindle clockwise shuts off ﬂow to

the soldered connection while ﬂow

between the pressure gauge and ﬂared

connection is established. Turning the

spindle fully counterclockwise shuts

off the pressure gauge connection and

establishes ﬂow between the soldered

connection and the ﬂared connection.

With the spindle in its mid position,

there is ﬂow through all three connec-

tions.

Weather-resistant enclosure

Blackstar condensing units for

installation in the open air must be

protected by an overhead cover or

have a weather-resistant housing.

Blackstar »Outdoor Units« are avail-

able. These are ﬁtted with condensing

units in a weather-resistant housing

and the compressor is heated during

standstill phases.

Cabinets alone:

Single: Code no. 118U4620

TWIN: Code no. 118U4621

Fan motor and blade

Blackstar – condensing units

for R 134a and R 404A / R 507

It is recommended that the two parallel-

connected compressors in TWIN

condensing units be started via a time

relay (Danfoss code number:

117 N 0001).

This gives the condensing unit the

best starting conditions and ensures

minimum load on the mains supply.

Compressors are ﬁtted with an HST

starting system consisting of a start

relay and a start capacitor. The capa-

citor is designed for short-duty cycles

(1.7% ED).

This means in practice that the com-

pressor can be subjected to 10 starts

an hour with a cut-in time of 6 seconds

for each start.

Compressor protection

The fully hermetic compressors have

a built-in winding protector. When this

is activated, the result can be

compressor motor cut-out for up to 45

minutes, until accumulated heat in the

motor has been dissipated. By taking

resistance measurements it is possible

to establish whether the winding pro-

tector has been activated or a winding

has broken.

Zeitverzögerungsrelay

Blackstar – condensing units

for R 134a and R 404A / R 507

Max. permissible refrigerant charge

Blackstar condensing unit

Blackstar – condensing units

for R 134a and R 404A / R 507

Leakage testing

Before it leaves the factory, each

Blackstar condensing unit is leak-

tested with helium and is charged with

a protective gas. It must therefore be

evacuated together with the rest of the

system. The refrigerant circuit must

also be examined for leaks with a mix-

ture of nitrogen and refrigerant.

While the test is being conducted, the

suction and liquid shut-off valves in

the condensing unit must remain

closed. If a coloured leak detection

agent is used, the warranty becomes

invalid.

Evacuation and charging

For evacuation, both external hoses

must be connected to an installation

set and the condensing unit evacuated

with shut-off valves 1 and 2 open –

spindles in mid position.

After evacuation, valves 4 and 5 must

be connected to the installation set.

Only then must the vacuum pump be

switched off.

The refrigerant bottle must now be

connected to the installation set mid

connector 3, and the charging connec-

tor brieﬂy vented.

The corresponding valve 4 on the

installation set can now be opened and

the system charged – via the pressure

gauge connection on the suction

shut-off valve – with the maximum

permissible quantity of refrigerant,

and with the compressor running.

Warning:

The compressor should only be cut in

after the vacuum has been broken.

Allowing the compressor to run with

vacuum inside the shell produces the

risk of ﬂashover in the motor winding.

Blackstar – condensing units

for R 134a and R 404A / R 507

Max. Volume

R404A/R507 permissible Group of [cm

]

refrigerant condenser

Condensing Unit "T2" charge [g] Condenser Receiver

TL4CL, TL4DL, FR6CL 600 2 426 800

FR6DL, FR8,5CL 850 3 509

SC12CL 4 666

SC15CL, SC18CL, SC21CL,

5 928

1100

SC10DL, SC12DL 1300

SC15DL

6 1056

SC10/10CL

SC10/10DL, SC12/12CL,

1650

SC15/15CL, SC15/15DL, 2200 7 1807

SC18/18CL, SC21/21CL

Max. Volume

R134a permissible Group of [cm

]

refrigerant condenser

Condensing Unit "T2" charge [g] Condenser Receiver

TL3F, TL3G, TL4G, TL5G, NL7F,

1 217 800

NL7FT, NL9F, NL9FT 400

NL10FT, NL11F

2 426 800

FR6G, FR7.5G, FR8.5G, FR10G

900

FR11G

3 509

SC12FT, SC12G, SC18F, SC21F

1100

SC15FT, SC15G

1300

4 666

SC18FT, SC18G, SC21G 5 928

SC12/12G 6 1056

1650

SC15/15G, SC18/18G, SC21/21G 2200 7 1807

Exceeding the max. permissible

charge

If the refrigerant charge is greater than

the maximum permissible charge,

relevant precautions must be taken. In

this connection, the speciﬁcations giv-

en on page 17 must be complied with.

Compressor Shell heating

Shell heating should be ﬁtted directly

above the weld. If TWIN compressors

are used, both shells should be ﬁtted

with heaters. Electrical connection

can be made as shown in the diagrams

below.

With the main switch active, the

thermostat changeover switch (e.g.

KP 61) controls switching, i.e. com-

pressor OFF – heating ON – and vice

versa. After prolonged refrigeration

plant standstills, shell heating should

be started approx. 2-3 hours before the

system is to be taken into use.

If Blackstar condensing units are

installed outdoors, shell heating is

generally recommended.

Blackstar – condensing units

for R 134a and R 404A / R 507

Thermostat KP 61

Heat-

ing*

)

Fan

Pressure switch KP 17

Connection possibilities for KP 17W (not connected to terminal box)

Connection requires extra cables

‘) Shell heating only when required

(see installation instructions)

Thermostat KP 61

Heating

Fan

Pressure switch

KP 17W

Connection possibilities for KP 17W (not connected to terminal box)

Connection requires extra cables

‘) Shell heating only when required

(see installation instructions)

Pressure switch KP 5

Heating*

)

Thermostat

KP 61

SC 15/15 DLX T2

SC 18/18 CLX T2 und

SC 21/21 GX T2

Connection

to relay

terminals

4 and 5

All TWIN units, except

SC 15/15 DLX T2, SC 18/18 CLX T2

and SC 21/21 GX T2, to be

connected to relay terminals

10 and 14

Blackstar condensing unit

Model denomination: Version:

PL = Compressor type N0 = For capillary tube – without stop valves

TL = Compressor type N2 = For capillary tube – with 2 stop valves

FR = Compressor type T2 = For expansion valve – with receiver and

NL = Compressor type 2 stop valves

SC = Compressor type T2 (UL) = Liquid valve with fusible plug integrated

4=Displacement in cm

T0 = For expansion valve – with receiver. On request

(not valid for PL)

CL = R404A, LBP Colour Code:

G=R134a, HBP / LBP R134a = Blue stripe

GH = R134a, HBP R404A = Lilac stripe

FT = R134a, LBP Background:

X=High starting torque (HST) Yellow = 220-240 V

Green = 115 V

Blackstar – condensing units

for R 134a and R 404A / R 507

To fulﬁl EN 378 it has to be used FSA

(Flare Solder Adapter) instead of ﬂare

connections.

The sealing ring has to be replaced in

case of service.

Adapter (FSA)

Blackstar – condensing units

for R 134a and R 404A / R 507

»Pumpdown cycle«

A pumpdown cycle is an additional

means of preventing refrigerant

migration during »off« phases.

See remarks on pumpdown on page 10.

Max. permissible temperature

Evaporator superheating (registered

by the expansion valve sensor)

between 3 and 12 K. Maximum super-

heating of suction gas at the compres-

sor: 45°C. Unacceptably high suction

gas superheating results automatically

in a rapid increase in discharge gas

temperature. This must not exceed

135°C for SC compressors and 130°C

for TL, NL and FR compressors. Dis-

charge tube temperature should be

measured 50 mm from the compressor

discharge connector. The measuring

point should be insulated.

Blackstar – condensing units

for R 134a and R 404A / R 507

Evaporator

Sight glass

Filter drier

Expansion valveSolenoid valve

Thermostat

Danfoss PRACTICAL Installation guide

Danfoss PRACTICAL Installation guide

Danfoss PRACTICAL Installation guide

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