Danfoss OP-LPQM, OP-MPXM Installation guide


Optyma™ Plus
OP-LPQM, OP-MPXM
Name plate
A
OP-MPXM034MLP00G
114X4261
B
Application MBP
D
Refrigerant (1) R404A R507 R448A/R449A R407A/R407F/R452A
E
M.W.P. HP (1) 28 bar M.W.P. LP (1) 7 bar
F
Voltage 230 V ~ 1N ~ 50Hz
LRA 60 A MCC 19 A
OIL INSIDE POE 46
G
Serial No. 123456CG2816
EAN No.
xxxxxxxxxxxxxx
A: Model B: Code number C: Application, Protection D: Refrigerant E: Housing Service Pressure (Maximum
working pressure)
F: Supply voltage, Locked Rotor Ampere,
Maximum Current Consumption
G: Serial Number and bar code
MADE IN INDIA
IP 54 (2) R134a R513A (2) 23 bar (2) 5 bar
Danfoss A/S, 6430 Nordborg, Denmark
Picture 1 : Minimum mounting distances
Q: Air in R: Air out
118UXXXXXX
(Code n° 114X34-- or 114X44--)
Unit
Housing 4
Q
W
ZY
R
X
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 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 cau-
W
[mm]X [mm]Y [mm]Z [mm]
250 900 700 700
tion in the vertical position (maximum offset from the vertical : 15°)
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.
Picture 2 : Stacked mounting
V
T
U
U
V
T: Mounting brackets for stacked mounting (not supplied) U: M8 bolts for stacked mounting (supplied) V: Mounting bolts (not supplied)
Picture 3 : Electronic controller display
Compressor running
Crankcase heater on
Fan running
Temperature value for suction pressure. Push lower button to switch to tempera­ture value for condensing pressure
Picture 4 : Normal wiring Picture 5 : Temporary wiring
118A2221B - AN363632996019en-ZA0102 | 1© Danfoss | Climate Solutions | 2021.10
Instructions
Designation system for the Optyma™ Plus range
OP - MPXM 034 ML P06 G
1 2 3 4 5 6 7 8
1 Application
M = MBP L = LBP
2 Package
Condensing unit family: P = Optyma™ Plus
3 Refrigerant
Q = R452A, R404A/R507 X = R404A/R507, R134a, R407A, R407F, R448A, R513A
R449A,R452A
4 Condenser
M = Microchannel heat condenser
5 Swept volume
Displacement in cm
3:
Example 034 = 34 cm
3
6 Compressor platform
ML = Fixed speed scroll MLZ LL = Fixed speed scroll LLZ
7 Version
P06: Optyma™ Plus with PRV
8 Voltage code
E = 400V/3-phase/50Hz compressor & 230V/1-phase fan
Version control
Optyma™ Plus (P06) IP level IP54 Compressor technology Scroll/ Reciprocating Control box (pre-wired E-panel) yes Microchannel condenser yes Fan speed controller* yes Main switch (circuit breaker) yes Supply monitoring relay ­Filter drier (flare connections) yes Sight glass yes Crankcase heater yes HP/LP adjustable pressostat Electronic Fail safe mini-pressostat Mechanical Access door(s) yes Acoustic insulation yes Condensing unit electronic controller yes Network connectivity yes Stack mounting yes Discharge gas thermostat yes HP/LP Alarm yes Pressure relief valve yes
* Inbuilt function within Condensing unit electronic controller
1 – Introduction
These instructions pertain to Optyma
Plus condensing units OP-LPOM, & OP-MPXM used for refrigeration systems. They provide necessary information regarding safety and proper usage of this product.
The condensing unit includes following:
• Microchannel heat exchanger
• Reciprocating or scroll compressor
• Receiver with stop valve
• Ball valves
• Sight glass
• High & low pressure switches
• Replaceable filter drier
• Electronic controller
• Main circuit breaker (Main switch with overload protection)
• Fan and compressor capacitors
• Compressor contactor
• Robust 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 complete and undamaged.
3 – Installation precautions
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
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.
4 – Installation
• The installation in which the condensing unit is installed must comply to pressure Equipment Directive (PED) 2014/68/EU. The condensing unit itself is not a ”unit” in the scope this directive.
• It is recommended to install the unit on rubber grommets or vibration dampers (not supplied).
• It is possible to stack units on top of each other.
Unit
Housing 4
(Code no. 114X34-- or 114X44--)
Maximum
stacking
2
• When stacking, the topmost unit must be
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Instructions
secured to the wall, as shown in picture 2.
• 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 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 31 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).
• 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 an electronic controller. Refer to Manual 118U3808 for details.
• The unit is equipped with a main switch with
overload protection. The overload protection is factory preset but it is recommended to check the value before taking the unit in operation. The value for the overload protection can be found in the wiring diagram in the front door of the unit.
• The unit is equipped with high and low pressure switches, which directly cut the power supply to the compressor in case of activation. Parameters for high and low pressure cut outs are preset in the controller, adapted to the compressor installed in the unit.
• P05 models are also equipped with phase sequence relay to protect the unit against phase loss/sequence/ asymmetry and under-/ over-voltage.
For units with a 3-phase scroll compressor (OP­MPXMxxxxxxxxE), 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 – Safety
Fusible Plug is not installed in unit, it is replaced with adapter blanking plug. Unit has liquid receiver with an Adapter Plug with 3/8” NPT connection. installer/end user can select various options as mentioned in EN378-2 : 2016 Article § 6.2.2.3
• Optyma Plus fitted with atmospheric pressure
relief valve. Don’t connect any tube at end of the pressure relief valve.
• Once the pressure relief valve opens, don’t use
dry air or oxygen to evacuate the refrigerants.
• Optyma Plus (P06 version only) factory fitted
with pressure relief valve at 33 bar setting.
• Once pressure relief valve opens, Danfoss
recommended to replace new pressure relief valve.
• The unit/installation into which the condensing unit is mounted/integrated, must be in accordance with the PED.
• Beware of extremely hot and cold components.
• Beware of moving components. Power supply should be disconnected while servicing.
9 – Filling the system
• Never start the compressor under vacuum. Keep the compressor switched off.
• 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/ R448A/R449A/R407A/R407F/R452A and approx. 2 bar for R134a and R513A.
• 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.
10 – Setting the electronic controller
• The unit is equipped with an electronic controller which is factory programmed with parameters for use with the actual unit. Refer to Manual 118U3808 for details.
• By default, the electronic controller display shows the temperature value for the suction pressure in °C. To show the temperature value for the condensing pressure, push the lower button (picture 3).
The electronic controller is factory preset for R404A or R449A or R452A or R134a depending on the model of compressor mounted and application (Refer Annexx in Optyma Controller installation manual). If another refrigerant is used, the refrigerant setting must be changed. Parameter r12 must be set to 0 before (software main switch= off).
• Push the upper button for a couple of seconds. The column with parameter codes appears.
• Push the upper or lower button to find parameter code o30.
• Push the middle button until the value for this parameter is shown.
• Push the upper or lower button to select the new value: 2 = R22, 3 = R134a, 36 = R513A, 17 = R507, 19 = R404A, 20 = R407C , 21 = R407A, 37 = R407F, 40 = R448A, 41 = R449A, 42 = R452A.
• Push the middle button to confirm the selected value.
• Push the upper or lower button to find parame­ter code r84.
• Push the middle button until the value for this parameter is shown as 125
• Push the upper button to select the new value:
130.
11 – 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 inside the
condensing unit are properly fastened as they could have worked loose during transportation.
• When a crankcase heater is required, the unit
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Instructions
must be energized at least 12 hours before initial start-up and start-up after prolonged shutdown for belt type crankcase heaters.
• The unit is equipped with a main switch with overload protection. Overload protection is preset from factory, but it is recommended to check the value before taking the unit in operation. The overload protection value can be found in the wiring diagram in the unit front door.
• Check if discharge temperature sensor is firm and has proper contact with discharge pipe.
12 – Start-up
• Never start the unit when no refrigerant is charged.
• All service valves must be in the open position.
• Rotalock valve on the receiver must be turned 1 round to close direction to get the right condensing pressure for the pressure transmitter
• 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 and voltage on terminals.
• Eventual reverse rotation of a 3-phase compressor can be detected by following phenomena; the compressor doesn’t build up pressure, it has abnormally high sound level and abnormally low power consumption. P05 models are equipped with a phase-reversal relay and compressor doesn’t start, the compressor doesn’t build up pressure, in case of wrong phase sequences. 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 controller (or low pressure gauge) shall show a declining pressure and the high pressure indication (or high pressure gauge) shall show an increasing pressure.
13 – 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 low-pressure side as far as possible from the compressor. The compressor must be operating during this process.
• Do not overcharge the system.
• Follow the local regulations for restoring the refrigerant from unit.
• 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.
14 – Emergency running without controller
In case of controller failure, the condensing unit can still be operated when the controller standard wiring (picture 4) is modified into a temporary wiring (picture 5) as described below.
This modification may be done by authorized electricians only. Country legislations have to be followed.
Disconnect the condensing unit from power supply (turn hardware main switch off)
• Contact of Room Thermostat must be possible
to switch 250VAC.
• Remove wire 22 (safety input DI3) and wire 24
(room thermostat DI1) and put them together with an insulated 250 Vac 10mm² terminal bridge.
• Remove wire 25 (room thermostat DI1) and
wire 11 (compressor supply) and put them together with an insulated 250VAC 10mm² terminal bridge.
• Remove wire 6 and connect it with terminal
bridge for wire 11 and 25. A fan pressure switch or fan speed controller can be connected in series to wire 6.
• Remove wire 14 (crankcase heater) and connect
it to the compressor contactor terminal 22.
• Remove wire 12 (supply crankcase heater),
extend this wire by using an 250 Vac 10mm² terminal bridge and 1,0mm² brown cable and connect it to compressor contactor terminal 21
• Remove the large terminal block from the
controller terminals 10 to 19.
• Connect the condensing unit to power supply
(turn hardware main switch on).
15 – Maintenance
Always switch off the unit at main switch before opening the fan door (s).
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 door. 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 opening the fan door.
• 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.
• Before closing the fan door, turn the fan blade in a safe position, to avoid that the door hits the fan.
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.
16 – Declaration of incorporation
Pressure Equipment Directive 2014/68/EU
EN 378-2:2016 - Refrigerating systems and Heat Pumps - Safety and environmental requirements­Parts 2: Design, construction, testing, marking and documentation. Low Voltage Directive 2014/35/EU EN 60335-1:2012 + A11:2014- Household and similar electrical appliances-Safety-Part 1: General requirements-for all above mentioned condensing units Eco-design DIRECTIVE 2009/125/ EC, establishing a framework for the setting of Eco-design requirements for energy­related products. REGULATION (EU) 2015/1095, implementing Eco­design Directive 2009/125/EC with regard to Eco­design requirements for professional refrigerated storage cabinets, blast cabinets, condensing units and process Chiller.
• Condensing unit measurements are made
according to standard “EN 13771-2:2017”
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Instructions
– Compressor and condensing units for refrigeration-performance testing and test methods- part 2: Condensing units.
17 - 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.
• No model and serial number transmitted with the warranty claim.
18 – Disposal
Danfoss recommends that condensing units and oil should be recycled by a suitable company at its site.
© Danfoss | Climate Solutions | 2021.10
118A2221B - AN363632996019en-ZA0102 | 5
Instructions
OP-LPQM215-271 & OP-MPXM125-162
C
English Legend
A Ø12 Hole for Mounting B Sight Glass C Controller Display
E
B
A
D Air in E Air out F Suction Port G Liquid Port
H
D
F
G
H4
H Nameplate
Electrical Cables
Note: all dimension are in mm
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Instructions
3
P06 Models: OP-LPQM215-271 & OP-MPXM125-162
T1
R2
1
B4
B2
1 Compressor 2 Electric Expansion Valve 3 Micro Channel Heat Exchanger with axial fan 4 Refrigerant receiver with rotalock valve 5 Filter Drier 6 Sight Glass 7 Liquid Ball Valve
T3
R3
P2
T4
R1
78
8 Suction Ball Valve B1 Condensing Pressure Transducer (P1) B2 Suction Pressure Transducer (P2) B3
High Pressure cartridge Switch (auto-reset)(PSH)
B4
Low Pressure cartridge Switch (auto-reset) (PSL)
D1
Pressure relief valve (PRV)
R1 Ambient Temperature sensor (T4)
B3
B1
R1
P1
PRV
4
R2 Discharge Temperature Sensor (T2) R3 Suction Temperature Sensor (T3) S1 Pressure Relief Valve R8 Discharge Temperature Sensor (T1)
Insulation
5
6
© Danfoss | Climate Solutions | 2021.10
118A2221B - AN363632996019en-ZA0102 | 7

Code E: OP-LPQM215-271 & OP-MPXM125-162
English Legend A1 : Optyma A2 : EMI Filter A3 : Liquid Injection Controller B1,B5 : Condensing Pressure Transducer B2 : Suction Pressure Transducer B3 : High Pressure Switch (OFF = 31bar(g),
B4 : Low Pressure Switch (OFF = -0,3bar(g),
C1 : Start Capacitor (Compressor)
Plus Controller
ON = 24bar(g))
ON = 0,5bar(g))
C2 : Run Capacitor (Compressor) C3 : Run Capacitor (Fan 1) C4 : Run Capacitor (Fan 2) F1 : Fuse (Control Circuit) F2,F3 : Motor protector K1 : Contactor K2 : Start Relay M1 : Compressor M2 : Fan Motor 1 M3 : Fan Motor 2 M4 : Electronic Expansion Valve
Q1 : Main Switch R1 : Ambient Temp. Sensor R2,R8 : Discharge Temp. Sensor R3 : Suction Temp. Sensor R4,R5 : Auxiliary Temp. Sensor (optional) R6 : Crankcase Heater R7 : NTC Resistor S1 : Room Thermostat (optional) S2 : Door Limit Switch X1 : Terminal
WD1
Supply : Supply Fan : Fan Alarm : Alarm Comp. : Compressor CCH : Crankcase Heater Aux : Auxiliary
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© Danfoss | Climate Solutions | 2021.10
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