Danfoss OP-HRSM1000NC211Q, OP-HRSM1000NC211R Installation guide

Instructions

Optyma™ G & D HBP DSH140

OP-HRSM1000NC211Q / OP-HRSM1000NC211R

Designation system

OP-HRSM 1000 NCXXX Q

1 2 3 4 5 6 7

1 Application

H = HBP/Universal

2 Design

R = Air cooled condenser, Twin fan, Scroll compressor

3 Refrigerant

S = R410A

4 Condenser

M = Microchannel condenser size 100°F Max Ambient

5 Unit SIze (Nominal HP)

HP rating in hundredths of HP, i.e.: 0033=1/3 HP, 1000 = 10HP

6 Version

NCXX = Customer speciﬁc unit with unique identiﬁcation Number

7 Voltage code

R = Compressor 460V/3ph/60Hz, Fan(s) 460V/1ph/60Hz Q = Compressor 208-230V/3ph/60Hz, Fan(s) 230V/1ph/60Hz

1 – Introduction

These instructions pertain to Optyma G&D HBP DSH140 condensing units (R410A) used for refrigeration systems. They provide necessary information regarding safety and proper usage of this product. The condensing unit includes following:

• Scroll compressor

• Microchannel heat exchanger

• Fix low Pressure cartridge

• Fix high pressures cartridge

• Fix Fan control pressures cartridge

• Service valves Suction/ liquid

• Crankcase heater for compressor

• Receiver with stop valve

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.

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

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

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

3 – Installation precautions

Do not braze as long the condensing unit

is under pressure.

Never place the unit in a ﬂammable

atmosphere.

IPlace 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).

• 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.

Warnings

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

within its scope of application.

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

regulation) requirements must be fulﬁlled.

The condensing unit is delivered under nitro- gen 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 cau- tion in the vertical position (maximum oﬀset from the vertical: 15°)

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 unit must be securely installed on a stable and rigid support and ﬁxed 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 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.

• 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 19mm 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.

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Instructions

• 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.

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 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 is equipped with high- and lowpressure switches, which directly cut the power supply to the compressor in case of activation.

• 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 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.

• 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 such as safety pressure switch and mechanical relief valve in compliance with both generally and locally applicable regulations and safety standards. Ensure that they 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 period.

10 – 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 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 low

pressure indication on the low pressure gauge shall show a declining pressure and the high pressure indication on the high pressure gauge shall show an increasing pressure.

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

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 liquid phase may be added in the lowpressure 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. 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

remove 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,

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