Danfoss OP-HJZ, OP-HJM, OP-HGM, OP-HNU, OP-HRU User guide

Manual

Installation and maintenance
condensing unit manual

OP-HJZ / HJM / HGM / HNU / HRU / HGZ / LJZ / LGZ

http://cc.danfoss.com

Manual

Contents

English version ....................................................................................................................4

Spanish version .................................................................................................................14

2 BC21808642813501-000201

Model

Serial Number

Compressor:

Fan Motor:

Design Pressure:

Oil Type: Mineral

Housing for Outdoor use:

Danfoss Code

A

B

C

D

E

F

H

I

J
K

L

G

OP-HJZ018D32Q

0012345AU0116

114N3209

R22, R404A, R507A,

R134a, R448A, R449A, R452A, R513A

Manual

Label

Installation & Maintenance

Picture 1 : Minimum
mounting distances

A: Model and bar code

B: Unit code and bar code

C: Serial number and bar code

D: Compressor voltage & Locked rotor amps & Rated

load amps

E: Fan voltage & Full load amps

F: Min. circuit Ampacity

G: Max. Fuse size

H: Design pressure

I: Refrigerant

J: Oil type

K: Outdoor housing

L: Wiring diagram

AIR FLOW

IMPORTANT

L

[mm]

300 650 550 550

1-Installation and mainteneance of the
condensing unit must be carried out by qualified
personnel only. Follow these instructions and best
practices on refrigeration engineering during
installation, commissioning, maintenance and
servicing tasks.
2-The condensing unit must only be used for
its designed purposes and within its scope of
application.

M

[mm]

N

[mm]

O

[mm]

3 - Under all circumstances, EN 378 (or any other
applicable local safety regulation) requirements
must be fulfilled.
4 - The condensing unit is delivered under
nitrogen gas pressure (1 bar) and hence it cannot
be connected as it is; refer to the “Installation”
section for further details.
5 - The condensing unit must be handled with
caution in a vertical position (maximum offset
from the vertical: 15°).

3BC21808642813501-000201

Manual

Installation & Maintenance

Introduction

Handling and storage

Installation precautions

These instructions pertain to OPTYMA™
condensing units (R22, R404A, R507A, R134a,
R448A, R449A, R452A, R513A) used for

• 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
the use of a forklift or pallet jack for handling. Use
appropriate and safe lifting equipment.

• Store and transport the unit in an upright
position.

Do not braze if the condensing unit is under

pressure.

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/or

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.

refrigeration systems. They provide necessary
information regarding safety and proper usage of
this product.

• 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.

• The unit ambient temperature may not exceed
50 °C during off-cycle.

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

• When installing units for HFC refrigerants,
use equipment specifically 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 suction piping connected to the compressor
must be flexible in 3 dimensions to dampen
vibrations. Furthermore piping has to 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.

Installation

Leak detection

Vacuum dehydration

• The unit must be securely installed on a stable
and rigid support, and fix from the beginning.

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

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

• Connect the unit 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.

Never pressurize the circuit with oxygen or dry

air. This could cause fire or explosions.

• Do not use dye for leak detection.

• Perform a leak detection test on the complete

system.

• Never use the compressor to evacuate the

system.

• Connect a vacuum pump to both the LP and HP

sides.

• Braze with great care using state-of-the-art
techniques and vent piping with nitrogen gas
flow.

• Connect the required safety and control devices.
Remove the internal valve when using the
Schraeder port for this.

• It is recommended to insulate the suction pipe
up to the compressor inlet with 19 mm thick
insulation.

• The maximum test pressure is 32 bar.

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

• Pull down the system under a vacuum of 500 µm

Hg (0.67 mbar) absolute.

• Do not use an ohmmeter nor apply power to the

compressor while it is under vacuum as this may
cause internal damage.

4 BC21808642813501-000201

Manual

Installation & Maintenance

Electrical connections

Filling the system

• Switch off the system and isolate the main power
supply.

• Ensure that power supply cannot be switched on
during installation.

• 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 power supply
is stable (nominal voltage ±10 % and nominal
frequency ±2.5 Hz).

• Dimension the power supply cables according to
unit data for voltage and current.

• Protect the power supply and ensure correct
earthing.

• Wear protective stuff like goggles and protective
gloves.

• Never start the compressor under vacuum. Keep
the compressor switched off.

• Before charging the refrigerant, verify that the oil
level is between “¼” and “¾” on the compressor
oil sight glass. If additional oil is required, please
refer to the compressor’s label for type of oil.

• Use only the refrigerant for which the unit is
designed for.

• Fill the refrigerant in liquid phase into the
condenser or liquid receiver. Ensure a slow

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

• The unit includes high and low-pressure switches
which, when activated, cut the power supply
to the compressor. Parameters for high and
low-pressure cut-outs are to be adjusted by
the installer, depending on the compressor
model, refrigerant and application. For units
with a 3-phase scroll compressor, correct phase
sequence for compressor rotation direction shall
be observed.

• Determine the phase sequence by using a phase
meter to establish the phase order of line phases
L1, L2 and L3.

• Connect line phases L1, L2 and L3 to main switch
terminals T1, T2 and T3, respectively.

charging of the system to 4-5 bar for R22, R404A,
R507A, R448A, R449A or R452A, and approx. 2
bar for R134a or R513A.

• Do not put liquid refrigerant through the suction
line.

• It is not allow to mix additives with the oil and/or
refrigerant

• The remaining charge is done until the
installation has reached a level of stable nominal
condition during operation.

• Never leave the filling cylinder connected to the
circuit.

Verification before
commissioning

Start-up

Use safety devices (such as safety pressure
switches and mechanical relief valves) in
compliance with both generally and locally
applicable regulations and safety standards. Make
sure that the devices 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.

• Never start the unit when no refrigerant is

charged.

• All service valves must be in the open position.

• Check compliance between unit and power

supply.

• Check that the crankcase heater is working.

• Check that the fan can rotate freely.

• Check that the protection sheet has been

removed from the backside of condenser.

• Balance the HP/LP pressure.

• Energize the unit. It must start promptly. If

the compressor does not start, check wiring
conformity, voltage on terminals and sequence
phase.

• 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 shut-down or belt
type crankcase heaters.

• Eventual reverse rotation of a 3-phase
compressor can be detected by the following
phenomena: unit doesn’t start, the compressor
doesn’t build up pressure, it has abnormally
high sound level and abnormally low power
consumption. In such case, shut down the unit
immediately and connect the phases to their
proper terminals.

• If the rotation direction is correct, the low­pressure gauge shall show a declining pressure
and the high-pressure gauge shall show an
increasing pressure.

5BC21808642813501-000201

Manual

Installation & Maintenance

Checks with running unit

Maintenance

• 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.

• When a sight glass is provided, observe the oil
level at start and during operation to confirm
that the oil level remains visible.

• 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

Always switch off the unit at main switch before

removing the fan panel.

Internal pressures and surface temperatures are

dangerous and may cause permanent injury.

Maintenance operators and installers require
appropriate skills and tools. Tubing temperature
may exceed 100 °C and therefore cause severe
burns.

Ensure that periodic service inspections to
ensure system reliability and as required by local
regulations are performed.
To prevent system related 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 unit clean and verify the absence of

rust and oxidation on the unit components,
tubes and electrical connections.

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.

The condenser must be checked at least once
a year for clogging and be cleaned if deemed
necessary. Access to the internal side of the
condenser takes place through the fan panel.
Microchannel coils tend to accumulate dirt on
the surface rather than inside, which makes them
easier to clean than fin-&-tube coils.

• Switch off the unit at main switch before
removing any panel from the condensing unit.

• Remove surface dirt, leaves, fibers, etc. with a
vacuum cleaner, equipped with a brush or other
soft attachment. Alternatively, blow compressed
air through the coil from the inside out, and
brush with a soft bristle. Do not use a wire
brush. Do not impact or scrape the coil with the
vacuum tube or air nozzle.

If the refrigerant system has been opened, the
system has to be flushed with dry air or nitrogen
to remove moisture and a new filter drier has to
be installed. If evacuation of refrigerant has to
be done, it shall be done in such a way that no
refrigerant can escape to the environment.

Maintenance

Disposal

6 BC21808642813501-000201

Always transmit the model number and serial
number 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.

Danfoss recommends that condensing
units and oil should be recycled by a
suitable company at its site.

• 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.

Drawing 1A, version D32 (Reciprocating Compressor, 1 fan, Weiguang)

Drawing 1B, version D40 (reciprocating compressor, 1 fan, Weiguang)

Suction Line

Manual

Installation & Maintenance

Drawing 1A, version D32 (reciprocating compressor, 1 fan)

Front View Left View

Suction Line

Liquid line

Air ow

Suction Line

Power inlet

Liquid Line

Top View

X

Fixation

X

X

Suction Line Liquid Line

X

X

[mm]Y [mm]

Height H

[mm]

Depth D

[mm]

OP-HJ … 018D-022D 16 126 463 310 1000
OP-HJ … 028D-036D
OP-HJ … 040D- 050D 688

14 174

538

420 1150

Drawing 1B, version D40 (reciprocating compressor, 1 fan)

Front View Left View

Length L

[mm]

Iso View

Suction Line

X

Y

Liquid line

L

Air ow

H

D

Liquid line

Top View

X

X

Fixation

OP-HJ … 018D-022D
OP-LJ … 048D-068D
OP-HJ … 028D-036D

OP-LJ … 108D-136D

X

X

X

[mm]Y [mm]

Height H

[mm]

Depth D

[mm]

16 126 463 310 1000

538

14 174

688

420 1150OP-HJ … 040D- 050D

Length L

[mm]

Suction Line

Liquid Line

Iso View

X

Y

H

L

D

7BC21808642813501-000201

Drawing 2A, version D32 (reciprocating compressor, 2 fan, Weiguang)

Suction Line

Drawing 2B, version D40 (reciprocating compressor, 2 fan, Weiguang)

Manual

Installation & Maintenance

Drawing 2A, version D32 (reciprocating compressor, 2 fan)

Front View

Suction Line

Liquid Line

Top View Iso View

Y Y

Left View

Suction Line

Air ow

Suction Line

H

Suction Line

Fixation

OP-HG … 064D-100D

OP-HG … 125D-160D 971

X1

[mm]

25 20 500

Liquid Line

X2

[mm]Y [mm]

Height H

[mm]

715

Drawing 2B, version D40 (reciprocating compressor, 2 fans)

Front View

Top View Iso View

Depth D

[mm]

800 120 0

Liquid Line

Suction Line

Length L

[mm]

Left View

L

Air ow

D

Liquid Line

Y

Fixation

X1

[mm]

X2

[mm]Y [mm]

OP-HG … 064D-100D

25 20 500

OP-LG … 215D-271D 715

8 BC21808642813501-000201

Height H

[mm]

715

Y

Depth D

[mm]

800 120 0OP-HG … 125D-160D 971

Liquid Line

Suction Line

Length L

[mm]

H

L

D

Liquid Line