Danfoss OP-LPHE, OP-MPZE Installation guide

Instructions

Optyma™ High Ambient 52 Pack

OP-LPHE/MPZE

A B C

D E

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

1 – Introduction

These instructions pertain to Optyma™ High Ambient 52 Pack condensing units OP-LPHE/ MPZE (R404A, R134a) used for refrigeration systems. They provide necessary information regarding safety and proper usage of this product. The condensing unit includes following:

• Reciprocating compressor

• Microchannel heat exchanger

• Dual pressure switches

• Service valves suction/liquid

• Weather proof housing

• Filter drier

• Receiver with stop valve

• Sight glass

• Solenoid valve

• Oil separator (LBP only)

• Discharge thermostat (LBP Only)

2 – Handling and storage

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

• Handle the unit with care. The packaging allows for the use of a forklift or pallet jack. Use

H: Cable entry ports I: Suction port J: Liquid port K: Microchannel heat exchanger

Picture 3

Mounting bolts

appropriate and safe lifting equipment.

• Store and transport the unit in an upright position.

• Store the unit between -35°C and 60°C.

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

• 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 ammable 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.

Picture 1 : Minimum mounting distances

[mm]

250 650 550 550

Installation and servicing of the

condensing units by qualied 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 EN378 (or other applicable local safety regulation) requirements must be fullled.

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 oset from the vertical : 15°)

• The unit ambient temperature may not exceed 52°C during o-cycle.

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

• When installing units for HFC refrigerants, use equipment specically 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 exible 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.

• For all units factory setting of fan speed controller to be 15 ±1 bar.

• For refrigerant R134a, adjust the factory pressure setting of XGE-2C (code no: 061H3144) from 15 ±1 bar to recommended setting 8 bar by rotating the screw by 9 turns in counter clockwise direction.

[mm]

1 | © Danfoss | DCS (CC)| 2017.12

FRCC.PI.056.A2.02

Instructions

4 – Installation

• The installation in which the condensing unit is installed must comply to EU 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 fullled.

• The unit must be securely installed on a stable and rigid support, and xed 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.

• Braze with great care using state-of-the-art technique and vent piping with nitrogen gas ow.

• Connect the required safety and control devices. When the schrader port is used for this, remove the internal valve.

• CU function and reliability is ensured/veried for super heat 10K (SH 10K) condition so, 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 re or explosion.

• 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.

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 o 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).

• 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.

8 – Filling the system

• Wear protective stu like goggles and protective gloves.

• Never start the compressor under vacuum. Keep the compressor switched o.

• 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 R404A.

• 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 lling 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 char-

ged.

• 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.

• 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 ow

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 conrm 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 o 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.

This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance 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.

• Conrm 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 n-&-tube coils.

• Switch o the unit at main switch before re-

move any panel from the condensing unit.

• Remove surface dirt, leaves, bres, 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 ushed with dry air or nitrogen to remove moisture and a new lter 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 led regarding this product. The product warranty may be void in following cases:

• Absence of nameplate.

• External modications; 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 transmit-

ted with the warranty claim.

14 – Disposal

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

FRCC.PI.056.A2.02

Instructions

OP-MPZE030 - 048, OP-LPHE048 - 068

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APP UNIT DESCRIPTION CHASSIS POWER SUPPLYCOMP

LBP LBP LBP LBP

LBP MBP MBP MBP MBP MBP

114X7140LBP 114X7150 114X7153 114X7120 114X7141 114X7151 114X7146 114X7156 114X7117 114X7123 114X7157

OP-LPHE048NTW07Q OP-LPHE048NTW07N OP-LPHE048NTW07V OP-LPHE068NTW07V OP-LPHE068NTW07Q OP-LPHE068NTW07N OP-MPZE030MTW07N OP-MPZE030MTW07Q OP-MPZE048MTW07V OP-MPZE048MTW07N OP-MPZE048MTW07Q

H2 H2 H2 H2 H2 H2 H2 H2 H2 H2 H2

230V/3/~60Hz 230V/1N/~60Hz 380V/3N/~60Hz 380V/3N/~60Hz

230V/3/~60Hz 230V/1N/~60Hz 230V/1N/~60Hz

230V/3/~60Hz 380V/3N/~60Hz 230V/1N/~60Hz

230V/3/~60Hz

NTZ048 NTZ048 NTZ048 NTZ068 NTZ068 NTZ068 MTZ018 MTZ018 MTZ028 MTZ028 MTZ028

OP-MPZE060 - 068 - 086, OP-LPHE108-136

APP UNIT DESCRIPTION CHASSIS POWER SUPPLYCOMP

LBP LBP LBP

LBP MBP MBP MBP MBP MBP MBP MBP MBP

114X7142LBP 114X7154 114X7152 114X7121 114X7143 114X7126 114X7158 114X7147 114X7148 114X7159 114X7118 114X7149 114X7160

OP-LPHE108NTW07Q OP-LPHE108NTW07V OP-LPHE108NTW07N OP-LPHE136NTW07V OP-LPHE136NTW07Q OP-MPZE060MTW07V OP-MPZE060MTW07Q OP-MPZE060MTW07N OP-MPZE068MTW07N OP-MPZE068MTW07Q OP-MPZE086MTW07V OP-MPZE086MTW07N OP-MPZE086MTW07Q

H3 H3 H3 H3 H3 H3 H3 H3 H3 H3 H3 H3 H3

230V/3/~60Hz 380V/3N/~60Hz 230V/1N/~60Hz 380V/3N/~60Hz

230V/3/~60Hz 380V/3N/~60Hz

230V/3/~60Hz 230V/1N/~60Hz 230V/1N/~60Hz

230V/3/~60Hz 380V/3N/~60Hz 230V/1N/~60Hz

230V/3/~60Hz

NTZ108 NTZ108 NTZ108 NTZ136

NTZ136

MTZ036 MTZ036 MTZ036 MTZ040 MTZ040 MTZ050 MTZ050 MTZ050

FRCC.PI.056.A2.02

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