Danfoss iCO2 Installation guide

Optyma™ iCO2

Condensing Units OP-MPAM005COP04G

Name plate

A

B

C

D

This unit contains frequency converter and EMI filter with capacitors. Discon-

nect the AC mains and wait for at least 4 min to de-Energize all Electrical parts

E

before opening the door for performing any service or repair work. Failure to

F

wait the specified time after power has been removed could result in death

G

or serious injury

H

Installation and servicing of the condensing units by qualified personnel

I

only. Follow these instructions and sound refrigeration engineering practice

J

relating to installation, commissioning, maintenance, and service.

K

The condensing unit must only be used for its designed purpose(s) and within

L

its scope of application.

M

Under all circumstances, the EN378 (or other applicable local safety regula-

tion) requirements must be fulfilled.

* For exact values please refer name plate in unit

A: Model

The condensing unit is delivered under nitrogen gas pressure (1 bar) and

B: Code number

hence it cannot be connected as it is; refer to the «installation» section for

C: Application, IP protection level

further details.

D: Refrigerant (R744=CO2)

E: Maximum working pressure

The condensing unit must be handled with caution in the vertical position

F: Middle working pressure

(maximum offset from the vertical: 15°)

G: Minimum working pressure

H: Supply voltage

Compressor of condensing unit cannot be connected directly to the network

I: Locked Rotor Ampere, Maximum Current Consumption

in any case, only via original drive from Danfoss.

J: Oil type

K: CDU serial number

L: European Article Number

M: Condensing unit Label PN (Factory)

Q	W
Y		Z
R
	X				Picture 3 : Electronic controller display
					Active alarm
Picture 1 : Minimum mounting distances					No function
Q: Air in	R: Air out				Display shows temperature value for suction
	W	X	Y	Z
Unit					pressure.	Push	middle	button	to	switch	to
	[mm] [mm] [mm] [mm]				Evaporating temp. setpoint.
Housing	250	760	581	581

1- Introduction			• Suction accumulator
These instructions pertain to Optyma™ iCO2		The condensing unit includes following:	• Oil separator integrated to the compressor
condensing units OP-MPAM005COP04G		• Microchannel heat exchanger	• Ball valves with Shrader for unit inlet and
used for refrigeration systems. They provide		• Variable speed scroll compressor	outlet
necessary information regarding safety and		• Receiver	• Sight glass on liquid line
proper usage of this product.		• Pressure relief valve	• Filter drier
© Danfoss | Climate Solutions | 2021.12			AN399635986435en-000101 | 1

Instructions

•High pressure switch

•Electronic controller

•high and medium pressure valves

•Compressor drive with EMC filter

•Main circuit breaker (Main switch with overload protection)

•DC Fan

•Robust weatherproof housing

2 - Handling and storage

•It is recommended not to open the packaging before the unit is at the final place for installation.

•Handle the unit with care. The packaging allows for the use of a forklift or pallet jack. Use appropriate and safe lifting equipment.

•Store and transport the unit in an upright position.

•Store the unit between -35°C and 50°C.

•Don’t expose the packaging to rain or corrosive atmosphere.

•After unpacking, check that the unit is complete and undamaged.

3 - Installation precautions

Never place the unit in a flammable atmosphere.

Place the unit in such a way that it is not blocking or hindering walking areas, doors, windows or similar.

•Ensure adequate space around the unit for air circulation and to open doors. Refer to picture 1 for minimal values of distance to walls.

•Avoid installing the unit in locations which are daily exposed to direct sunshine for longer periods.

•Avoid installing the unit in aggressive and dusty environments.

•Ensure a foundation with horizontal surface (less than 3° slope), strong and stable enough to carry the entire unit weight and to eliminate vibrations and interference.

•The unit ambient temperature may not exceed 46°C during off-cycle.

•Ensure that the power supply corresponds to the unit characteristics (see nameplate).

•Use clean and dehydrated refrigerationgrade copper tubes.

•Use clean and dehydrated system components.

•The suction piping connected to the compressor must be flexible in 3 dimensions to dampen vibrations. Furthermore, piping must be done in such a way that oil return for the compressor is

ensured and the risk of liquid slug over in compressor is eliminated.

•Evaporator, suction, and liquid line must be rated for PS 80 barg.

•Liquid line and receiver are protected by a pressure relieve valve connected to the receiver. Pressure limit set at 80 barg.

•Suction line must be protected by a pressure relief valve set at 80 barg.

•All section of system that can be close by isolation valve must be protected by a PRV or a check valve to allow flow in the direction of a PRV.

•Pressure relieve valve must be place where no risk for people or goods

•Piping must be supported and clamped.

•The machine room if any and cold room must be equipped with a CO2 detector according to EN378.

4 - Installation

•The installation in which the condensing unit is installed must comply to European community Pressure directive (PED) and European standard EN 378.

•The condensing unit itself is a partly completed machine, which is not in the scope the PED directive.

•It is recommended to install the unit on rubber grommets or vibration dampers (not supplied).

•Slowly release the nitrogen holding charge through the Shrader port.

•Connect the unit to the system as soon as possible to avoid oil contamination from ambient moisture.

•Avoid material entering 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.

•Liquid line and return line must be thermally insulated. A badly insulated liquid line can generate flash gas during operation and receiver over pressure during standstill. Receiver overpressure can eventually result in the release of refrigerant through the receiver PRV.

•Apply liquid and return line insulation after leak test .

5 - Leak and pressure test

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

Do not use dye for leak detection.

•Pressure tests:

-Close condensing unit shutoff valve. We don’t want receiver relief valve to discharge during pressure test.

-make sure evaporator expansion valve is open.

-pressure test liquid and return line at 1,1 x PS = 88 bar with nitrogen.

•Leak test:

-Perform a leak detection test on the complete system at pressure P = 0,25 x PS = 20 bar.

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

•After completion of test, vent nitrogen to atmosphere and open condensing unit service valve.

6 - Electrical connections

•Switch off and isolate the main power supply.

•Ensure that power supply cannot be switched on during electrical connection.

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

•Refer to wiring diagram for electrical connections details.

•Ensure that the power supply corresponds to the unit characteristics and that the it is stable (nominal voltage ±10% and nominal frequency ±2,5 Hz).

•Dimension the power supply cables according to unit data for voltage and current, ambient temperature and cable grouping.

•Protect the power supply against overload, mechanical stress, and damage, and ensure correct earthing.

•Make the power supply according to local standards and legal requirements.

•The unit is equipped with an electronic controller.

•The unit is equipped with a main switch with overload protection.

•The unit is equipped with high pressure switch, which directly cut the power supply to the compressor in case of activation. PS = 140 bar.

7 - Setting the electronic controller

•The unit is equipped with an electronic controller which is factory programmed with parameters for use with the actual unit. Refer to application guideline for details.

•Energize the unit.

•The electronic controller display shows the temperature value for the suction

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Instructions

pressure.

•A short push on middle button show evaporating temperature setpoint r23. Factory setting of r23 = -10°C.

•Controller main switch parameter r12 should be set to 0 = stop (factory setting ).

•To change controller parameter,

-Push the upper button for a couple of seconds. The first parameter code r05 appears.

-Push the upper or lower button to find parameter.

-Push the middle button until the value for this parameter is shown.

-Push the upper or lower button to select the new value.

-Push the middle button to confirm the selected value.

-Select next parameter with upper or lower button or simply wait 20s to return to main display.

•If necessary, change parameter r23 to desired suction pressure (°C/°F).

•Change parameter c75 for pump down (OFF) and c76 for restart (ON) value according to your needs.

8 - Vacuum dehydration

•Before vacuuming the system, you need to open fully high pressure and bypass valve. Unit must be connected to power supply and controller main switch r12 must be set to value 2 = Vacuum mode.

•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.

9 - Oil addition

•Make calculation of oil charge addition with the excel sheet “Danfoss calculation of additional oil charge”

•If additional oil needed, you have additional oil can inside the unit charge through the suction service valve.

•If further oil is require you can get it from Danfoss article code : 118U4144 (250ml)

•The condensing unit is supply with Idemitsu PAG ND8 oil. Be sure to use same oil type

10 - Filling the system

•Use only R744 refrigerant grade 4.5 (99,995%).

•Make calculation of refrigerant charge

with the excel sheet before charging.

•Use a scale to measure the refrigerant charge you put in the system.

•Condensing unit main switch r12 must be

set to value 2 = Vacuum mode.

•Start fill the refrigerant in vapor phase into the liquid line. Ensure a slow charging of the system to 7-10 bar. This charging in vapor phase is required to avoid dry ice formation inside the circuit. Dry ice could prevent the charging of the circuit.

•When pressure in circuit reach 7-10 bar, fill the refrigerant in liquid phase into liquid line till you reach the charge given by the excel sheet.

•You may need to finish the charge in vapor phase on suction line when unit is running.

11 - Start-up

•All service valves must be in the open position.

•Check that the fan can rotate freely.

•After filling the system, condensing unit main switch r12 is set to 2 = Vacuum mode. To start the unit, first set r12 to value 0 = Stop. And then set r12 to value 1 = Automatic. Unit will make a reset of motorized valve and start.

•If the compressor does not start, check wiring conformity and voltage on terminals.

12 - Check with running unit

•Check the fan rotation direction. Air must flow from the condenser towards the fan.

•Check current draw and voltage.

•Check suction superheat to reduce risk of slugging. The optimum unit return gas superheat is around 6K. The maximum allowed superheat is 30K.

•Respect the operating limits.

•Check all tubes for abnormal vibration. Movements more than 1.5 mm require corrective measures such as tube brackets or balance weight.

•For charge adjustment please refer to next section

•in case of problem see Trouble shooting section

13 - Charge adjustment

•The remaining charge is done when installation has reached stable condition during operation.

•Do not overcharge the system.

•Overfilling the system may risk in pressure increase and release of refrigerant through the receiver relief valve.

•Liquid line sight glass should be 3/4 filled with liquid. A sight glass with 100% liquid could be an indication of overcharge.

• Tuning of refrigerant charge should be done by looking at the evaporator superheat, evaporator expansion valve opening and suction pressure value.

•Low charge will give low evaporating pressure, high superheat, largely open evaporator expansion valve

•Correction for overcharged unit: Release refrigerant via the access port of the suction side. Connect a service pipe equipped with a shutoff valve to the Shrader port. Open the valve very slowly.

•Correction in case of refrigerant shortage: Charge additional refrigerant through the low pressure Shrader port in vapor phase. Open the cylinder valve very slowly.

•Do not fill with liquid on suction line. It risks damaging the compressor.

•Do not fill on liquid line when system is running. Depending on running conditions, pressure of liquid line can reach high values. higher than cylinder pressure.

•Simulate high ambient by covering the gascooler and check system run correctly.

•Make a pump down to control the correct charge: with too low charge, system may have difficulty to recover after a pump down.

•Never leave the filling cylinder connected to the circuit.

•Record type and amount of refrigerant charge as well as operating conditions as a reference for future inspections.

•Before leaving the installation site, carry out a general installation inspection regarding cleanliness, noise, and leak detection.

14 - Trouble shooting

•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 should be at least 6K above the saturated suction temperature under steady-state operating conditions.

•The high-pressure switch trips: Check condenser operation (condenser cleanliness, fan operation). If all these are OK, the problem may be due to either refrigerant overcharging or the presence

© Danfoss | Climate Solutions | 2021.12

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