Danfoss OP-HPMD031-043-054, OP-HPMD063-068 User Manual
Instructions
Optyma™ Pack
OP-HPMD
L
MADE IN INDIA
A
OP-HPMD031AWW00G
Code no.:
B
Application
C
Refrigerant
D
M.W.P. HP
E
LP (1) 7 bar
Voltage 230V3N~/50Hz
F
LRA 40 12MCC
Serial No.
G
Barcode Serial No:
A: Model
B: Code number
C: Application, Protection
D: Refrigerant
E: Housing Service Pressure
F: Supply voltage, Locked Rotor Ampere,
Maximum Current Consumption
G: Serial Number and bar code
Picture 2
114X9101
HBP
(1) R22
(1) 25 bar
123456CG0514
IP54
(2)
(2)
118UXXXX
H: Cable entry ports
I: Suction port
J: Liquid port
K: Coil guard
Mounting bolts
Picture 3
N
M
Picture 1 : Minimum mounting distances
L
[mm]
250 650 550 550
Installation and servicing of the
condensing units by qualified
personnel only. Follow these
instructions and sound refrigeration
engineering practice relating to installation,
commissioning, maintenance and service.
The condensing unit must only be used for
its designed purpose(s) and within its scope of
application.
Under all circumstances, the applicable
local safety regulation) requirements must be
fulfilled.
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.
The condensing unit must be handled with caution in the vertical position (maximum offset
from the vertical : 15°)
M
[mm]
N
[mm]
O
O
[mm]
1 – Introduction
These instructions pertain to Optyma
condensing units OP-HPMD (R22) used for refrigeration systems. They provide necessary information regarding safety and proper usage of
this product.
The condensing unit includes following:
version W00
• Reciprocating compressor
• Fin-Tube heat exchanger
• Cartridge pressure switches
• Discharge gas thermostat (DGT)
• Service valves suction/ liquid
• Weather proof 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 com-
TM
Pack
© Danfoss | DCS (CC) | 2018.11
plete and undamaged.
3 – Installation precautions
Do not braze as long 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 picture1
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
50°C during off-cycle.
• Ensure that the power supply corresponds to
the unit characteristics (see nameplate).
• 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.
4 – Installation
• The installation in which the condensing unit is installed must comply to EEC Pressure directive (PED)
no. 2014/68/EU. The condensing unit itself is not a
”unit” in the scope this directive. Under all circumstances local safety regulations must be fulfilled.
• The unit must be securely installed on a stable
and rigid support, and fixed from the beginning. See picture 2.
• It is recommended to install the unit on rub-
ber grommets or vibration dampers . Rubber
pads with mounting bolts are supplied.
• Slowly release the nitrogen holding charge
through the schrader 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.
AN294425350971en-000101 | 1
Instructions
• 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.
• It is recommended to insulate the suction pipe
up to the compressor inlet with 19 mm thick
insulation.
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 maximum test pressure is 28 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.
• 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.
7 – Electrical connections
• Switch off and isolate the main power supply.
• Ensure that power supply can not 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).
• For safe working under compressor specification, unit is equipped with discharge gas thermostat (DGT), which directly cut the power
supply to the compressor in case of activation
(Activates at 130 ±5 °C and deactivates at 105
±10 °C discharge gas temperature. Make sure
that discharge gas thermostat is properly
connected as per wiring diagram (Refer DGT in
WD1 and WD2)
• 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 is equipped with high and low pressure
switches, which directly cut the power supply to
the compressor in case of activation.
• Determine the phase sequence by using a
phase meter in order to establish the phase orders of line phases L1, L2 and L3.
• Connect line phases L1, L2 and L3 to main switch terminals T1, T2 and T3 respectively.
8 – 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 compressors 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.
• Do not put liquid refrigerant through suction line.
• It is not allowed 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.
9 – Verification before commissioning
Use safety devices in compliance with both
generally and locally applicable regulations and
safety standards.
• 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 startup and start-up after prolonged shut-down period.
10 – Start-up
• Never start the unit when no refrigerant is
charged.
• All service valves must be in the open position.
See picture 3.
• 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 re-
moved from the backside of condenser.
• Balance the High Pressure / Low Pressure.
• Energize the unit. It must start promptly. If
the compressor does not start, check wiring
conformity, voltage on terminals and sequence
phase.
11 – 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 slug-
ging.
• 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. Move-
ments in excess of 1.5 mm require corrective
measures such as tube brackets.
• When needed, additional refrigerant in liquid
phase may be added in the low-pressure side as
far away as possible from the compressor. The
compressor must be operating during this process.
• Do not overcharge the system.
• Never release refrigerant to 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.
12 – Maintenance
Always switch off the unit at main switch before remove fan panel.
Internal pressure and surface temperature
are dangerous and may cause permanent injury.
Maintenance operators and installers require
appropriate skills and tools. Tubing 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 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.
• Switch off the unit at main switch before remove any panel from the condensing unit.
• Remove surface dirt, leaves, fibres, 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.
13 - Warranty
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.
• Working above specified envelope mentioned
(Maximum Ambient temperature 45 °C)
• No model number or serial number transmitted with the warranty claim.
14 – Disposal
Danfoss recommends that condensing units and
oil should be recycled by a suitable company at
its site.
2 | AN294425350971en-000101
© Danfoss | DCS (CC) | 2018.11
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