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

Manual

Installation & Maintenance

Label

	A	Model
					OP-HJZ018D32Q
	B		Danfoss Code
					114N3209
	C	Serial Number
					0012345AU0116
	D					Design Pressure:
		Compressor:					R22, R404A, R507A,
	E
		Fan Motor:				R134a, R448A, R449A, R452A, R513A
						Oil Type: Mineral
	F					Housing for Outdoor use:
	G
	A: Model and bar code					G: Max. Fuse size
	B: Unit code and bar code					H: Design pressure
	C: Serial number and bar code					I: Refrigerant
	D: Compressor voltage & Locked rotor amps & Rated					J: Oil type
	load amps					K: Outdoor housing
	E: Fan voltage & Full load amps					L: Wiring diagram
	F: Min. circuit Ampacity

H

I

J

K

L

Picture 1 : Minimum mounting distances

AIR FLOW

L	M	N	O
[mm]	[mm]	[mm]	[mm]
300	650	550	550

IMPORTANT	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.

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°).

BC21808642813501-000201 3

Manual	Installation & Maintenance
Introduction	These instructions pertain to OPTYMA™	refrigeration systems. They provide necessary
	condensing units (R22, R404A, R507A, R134a,	information regarding safety and proper usage of
	R448A, R449A, R452A, R513A) used for	this product.

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
	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.

•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.

Installation precautions	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.

•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	• 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.

•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.

Leak detection	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.

•The maximum test pressure is 32 bar.

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

Vacuum dehydration	• Never use the compressor to evacuate the
	system.
	• Connect a vacuum pump to both the LP and HP
	sides.

•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	• 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.

•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.

Filling the system	• 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

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

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.

•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.

Start-up	• 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.

•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.

BC21808642813501-000201 5

Manual	Installation & Maintenance
Checks with running unit	• Check the fan rotation direction. Air must flow	liquid phase may be added in the low-pressure
	from the condenser towards the fan.	side as far as possible from the compressor.
	• Check current draw and voltage.	The compressor must be operating during this
	• Check suction superheat to reduce risk of	process.
	slugging.	• Do not overcharge the system.
	• When a sight glass is provided, observe the oil	• Never release refrigerant to the atmosphere.
	level at start and during operation to confirm	• Before leaving the installation site, carry out
	that the oil level remains visible.	a general installation inspection regarding
	• Respect the operating limits.	cleanliness, noise and leak detection.
	• Check all tubes for abnormal vibration.	• Record type and amount of refrigerant charge,
	Movements in excess of 1.5 mm require	as well as operating conditions as a reference for
	corrective measures, such as tube brackets.	future inspections.
	• When needed, additional refrigerant in the

Maintenance	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.

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	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.

•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.

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

6 BC21808642813501-000201

Manual	Installation & Maintenance

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

Front View	Left View
	Air ow
Suction Line	Suction Line

Power inlet

Liquid Line

Liquid line

Top View

Iso View

Suction Line

X

X

X

X

X	Suction Line	Liquid Line

Y H Liquid line

	Fixation	X	Y	Height H	Depth D	Length L	L
		[mm]	[mm]	[mm]	[mm]	[mm]
							D
	OP-HJ … 018D-022D	16	126	463	310	1000
	OP-HJ … 028D-036D	14	174	538	420	1150
	OP-HJ … 040D-050D			688
	Drawing 1B, version D40 (reciprocating compressor, 1 fan)
	Front View						Left View
							Air ow

Suction Line

Suction Line

Liquid line Liquid Line

Iso View

Top View

X

X

X

X Y

H

X

	Fixation	X	Y	Height H	Depth D	Length L
		[mm]	[mm]	[mm]	[mm]	[mm]
	OP-HJ … 018D-022D	16	126	463	310	1000
	OP-LJ … 048D-068D
	OP-HJ … 028D-036D			538
	OP-HJ … 040D-050D 14		174	688	420	1150
	OP-LJ … 108D-136D

L

D

BC21808642813501-000201 7

Manual	Installation & Maintenance

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

Front View	Left View	Air ow
	Suction Line

Suction Line

Liquid Line

Top View

Y Y

Suction Line

Liquid Line

Iso View

Suction Line

H

L

	Fixation	X1	X2	Y	Height H	Depth D	Length L
		[mm]	[mm]	[mm]	[mm]	[mm]	[mm]
	OP-HG … 064D-100D	25	20	500	715	800	1200
	OP-HG … 125D-160D				971

D

Liquid Line

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

Front View	Left View	Air ow

Liquid Line

Suction Line

Top View

Iso View

Y Y

	Liquid Line	H
	Suction Line

L

	Fixation	X1	X2	Y	Height H	Depth D	Length L
		[mm]	[mm]	[mm]	[mm]	[mm]	[mm]
	OP-HG … 064D-100D				715
	OP-HG … 125D-160D	25	20	500	971	800	1200
	OP-LG … 215D-271D				715

D

Liquid Line

Suction Line

8 BC21808642813501-000201