Danfoss Optyma Plus INVERTER Application guide

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Application guidelines

2018

Optyma

Optyma™ Plus INVERTER

Stepless capacity modulation from 30 to 100 rps in a simple plug and play package

cc.danfoss.com

EcoDesign

by Danfoss

Application Guidelines

Content

Important information/Safety ................4

1.1 Symbols are shown left of the text ............. 4

Product description .................................5

2.1 Optyma™ Plus INVERTER condensing unit ... 5

2.2 Exploded view Optyma

2.3 Condensing unit nomenclature system ... 7

2.4 Label ...................................................................... 7

2.5 Approvals and certiﬁcates ............................ 8

2.6 Technical speciﬁcations .................................. 8

2.7 Spare part codes ............................................... 8

2.8 Cooling capacities, sound data, power

consumption .............................................................9

2.9 Layout .................................................................. 13

™

Plus INVERTER ..... 6

Application range...................................14

3.1 Main applications ............................................ 14

3.2 Condensing unit selection ..........................14

3.3 Application envelopes ................................. 15

3.4 Ambient conditions ....................................... 16

3.5 Limits for voltage supply ............................. 16

Installation .............................................. 17

4.1 Location & ﬁxings ............................................ 17

4.2 Electrical connection .................................... 18

4.2.1 Power supply protection ..............................18

4.2.2 Protection and features ................................18

4.3 Wiring diagrams .............................................. 19

4.3.1 Emergency running without controller 20

4.4 Electrical protection standard (protection

class) ...........................................................................23

4.5 EMC compliance .............................................. 23

4.5.1 Warning when touching unit

when OFF .................................................................23

4.6 Phase sequence .............................................. 24

4.7 Brazed connections........................................24

4.8 High pressure transmitter connection....25

System design recommendations .......26

5.1 Piping design ..................................................26

5.2 Evacuation ......................................................... 27

5.3 Refrigerant charge ..........................................28

5.4 Oil level ...............................................................29

5.5 Check before start .......................................... 29

5.6 Startup of the unit .......................................... 30

5.7 Check after start .............................................. 30

Condensing unit controller ...................31

6.1 Advantages ........................................................31

6.2 Controller’s regulation logic ....................... 31

6.3 Functions ........................................................... 31

6.4 Regulation reference for condensing

temperature ............................................................. 31

6.5 Fan operation ................................................... 31

6.6 Compressor control ....................................... 31

6.7 Maximum discharge gas temperature ....32

6.8 High pressure monitoring ........................... 32

6.9 Low pressure monitoring .............................32

6.10 Pump down limit ...........................................32

6.11 Data communication ................................... 32

6.12 Controller settings ........................................ 33

Service and maintenance ......................36

7.1 General recommendations .........................36

7.2 Condenser .........................................................36

7.3 Service and safety advice .............................36

7.4 Access ports ...................................................... 37

Transportation, handling and storage 38

8.1 Unpacking ..........................................................38

8.2 Transportation and handling ..................... 38

8.3 Disposal Instruction ....................................... 38

Warranty .................................................39

9.1 Warranty conditions ....................................... 39

9.2 Unauthorized changes ..................................39

Data collected during start up ..............40

3AB241186442766en-000801

WARNING

CAUTION

NOTICE

Application Guidelines

Important information/Safety

1.1 Symbols are shown left of the text

There are 3 symbols, used for diﬀerent degrees of danger:

Warning! Risk of serious injury or death to person!

Caution! Danger which can lead to serious damages!

Notice! Risk of damage to equipment!

This guideline is intended to enable users to ensure the safe installation, starting, operation and maintenance of Optyma condensing units. This guideline is not intended to replace the system expertise available from system manufacturers.

In addition to this instruction application instructions of compressor drive, controller and other internal components must be taken into consideration as well.

™

Plus INVERTER

4 AB241186442766en-000801

Application Guidelines

Product description

2.1 Op t y m a™ Plus INVERTER condensing unit

Optyma™ Plus INVERTER combines our market leading expertise in condensing unit design with the unique beneﬁts of stepless inverter scroll technology. The result is 20-30% higher energy eﬃciency in a ﬂexible plug-and-play package, for medium and high temperature refrigeration applications in the range of 2kW to 9kW.

Standard equipment features:

• Variable speed compressor (scroll) with acoustic housing and crankcase heater

• Compressor drive (with EMI ﬁlter)

• MCHX condenser

• Condenser fan motor

• Oil separator with oil heater

• Receiver with stop valve

• Ball valves

• Sight glass

• HP and LP switches

• Filter drier

™

• Optyma

• Circuit Breaker MCB, compressor contactor with overload relay

• Robust weather proof housing

Plus controller

5AB241186442766en-000801

ITEM NAME DESCRIPTION QTY

023U8007

009G7053

009G7054

118A0614

118A0639C

118A0615

HUSKY_118U3455_LEG

061F8492

014F0174

134N4263

MLZ026_HOOD

DIGITAL_DISPLY_2

118A0679

023Z8045

118U3202

061F7283

021F0075

118U3259

118U3243

118U3256

118U3258

118U3887

118U3255

118U3261

118U3241-02

118U3264

MANIFOLD_A6E500AJ0302

118A0632001

118A05930001

118U3431001

118U34320002

118A06310001

PRESSURE_TRANSDUCER

VZH028_035_044_INVERTER_SCROLL_

Application Guidelines

Product description

2.2 Exploded view Optyma

™

Plus INVERTER

Legend: 1: FSA Adaptor 2: Liquid line valve (with schrader) 3: Suction line valve + Extra service

connection 4: EMI ﬁlter (drive) 5: Oil return pipe 6: Oil separator 7: Receiver 8: High pressure switch 9: Sight glass 10: Compressor drive 11: Acoustic hood

6 AB241186442766en-000801

12: Optyma

™

Plus controller

13: EMI ﬁlter (controller) 14: Refrigerant ﬁlter 15: Fan guard 16: Low pressure switch 17: Microchannel heat exchanger 18: Right side door 19: E-box cover 20: Front door, right side 21: Unit frame 22: Fan bracket 23: Separation panel

24: Back panel 25: Base plate 26: Top panel 27: Fan assembly 28: Discharge pipe 29: Condenser outlet pipe 30: Receiver outlet pipe 31 Oil separator outlet pipe 32: Suction line 33: Rotalock valve 34: Compressor

2018

Application Guidelines

2.3 Condensing unit nomenclature system

Product description

OP - M P L M 028 VVL P01 E

1 2 3 4 5 6 7 8

1 Application M = MBP

2 Design P = Packaged units

3 Refrigerant

4 Condenser type

5 Displacement 028 = 28 cm

6 Compressor platform VVL = variable speed scroll VLZ compressor

7 Version P01

8 Electrical code E = Compressor 400 V/3 phase/50 Hz, fan 230 V/1 phase/ 50 Hz

L = R404A, R407A, R407F P= R404A, R407A, R407F, R448A, R449A

M = Standard with micro channel heat exchanger Tambient max 43 deg C

/rev

2.4 Label

MADE IN INDIA

A B C D

OP-MPPM044VVLP01E

Code Number.: 114X4334 Application MBP IP 54 Refrigerant (1) R448A/R449A/R407F

R407A/R404A (2)

M.W.P HP (1) 28 bar (2) LP (1) 7 bar (2)

Voltage 380V-400V~3N~50Hz LRA Inverter Driven MCC 12.1 A

A: Model B: Code number C: Application D: Refrigerant E: Housing Service Pressure F: Supply voltage, M§aximum Current Consumption G: Serial Number and bar code H: Protection

Serial No. 123456CG1015

Serial-no.: XXXXXXCGWWYY XXXXXX = ascending number CG = manufacturing plant WW = week of production YY = year of production

For more information related to EcoDesign compliance, please refer to Coolselector® coolselector.danfoss.com or contact Danfoss

EcoDesign

7AB241186442766en-000801

NOTICE

Application Guidelines

Product description

2.5 Approvals and certiﬁcates

2.6 Technical speciﬁcations

Unit

Typ e

OP-MPLM028 OP-MPPM028

OP-MPLM035 OP-MPPM035

OP-MPLM044 OP-MPPM044

Unit

OP-MPLM028 OP-MPPM028

OP-MPLM035 OP-MPPM035

OP-MPLM044 OP-MPPM044

G7 5200 1.62 1x50 0 6.2 481 14 06 965 3/4" 5/8" 150 124

G7 5200 1.62 1x50 0 6.2 481 14 06 965 3/4" 5/8" 151 125

All models OP-MPLM, OP-MPPM

Other Contact Danfoss

[dm3]

Condenser

fan

Fan blade

Ø [mm]

Max cont. power

consumption [kW]

Receiver Dimensions Weight [kg]

Volume [L]

(without

valve)

Depth

[mm]

Width

[mm]

MCC Fan

[A]

230 V/1 phase

Height

[mm]

Suction line Liquid line Gross Net

Fan power

output

[W]

Condenser coil

Air ﬂow

MCC compressor

40 0V/3ph ase

Internal volume

/h]

[A]

8.1 3.98 0.96 1x130 1x220

9.8 4.94 0.96 1x13 0 1x220

12. 0 6.33 0.96 1x13 0 1x220

Fan power

consumption

[W]

2.7 Spare part codes

Unit Compressor Condenser

OP-M PLM028 OP-M PPM028

OP-MPLM035 OP-MPPM035

OP-MPLM044 OP-MPPM044

Unit Controller* Main switch

OP-M PLM028 OP-M PPM028

OP-MPLM035 OP-MPPM035

OP-MPLM044 OP-MPPM044

120 G0162 118 U349 4 118 U382 9 118 U3 476 023Z5 04591 014F0174 009 G7053 009G7054 118U 40 21 118 U4 025 084N0003 084N2007 118 U3 48 5

120 G0159 11 8U34 94 118 U38 29 118 U3 476 023Z504591 014F0174 009G7053 0 09G7054 118U 40 21 118 U4 025 084N0003 084N2007 118 U3485

120 G0156 11 8U34 94 118 U382 9 118 U3 476 023Z504591 014F0174 009G7053 009G7054 118 U4 021 11 8U4 025 084N0003 084N2007 118U 34 85

118 U3465

Unit Top panel Fan Panel Back panel Front panel Access panel Left side panel

OP-MPLM028 OP-MPPM028

OP-MPLM035 OP-MPPM035

OP-MPLM044 OP-MPPM044

118 U38 52 118 U38 54

118 U513 1 118 U513 2 118 U5133 118 U513 4 118 U51 35 118 U51 65

Fan

assembly

Compressor

contact

118 U38 47 118 U38 58 120Z5 040 118U3718 118U 3720 120Z 5043 118U3973 118U3972 118U3974

Receiver Filter

Door

handle

Crankcase

heater

Sight glass

High

pressure

switch

Liquid

line

valve

Low

pressure

switch

Suction

line

valve

Acoustic

hood

High

pressure

transmitter

Compres-

sor drive

CDS803

Low

pressure

transmitter

EMI

ﬁlter

(Drive)

* For service replacement of controller in Optyma™ Plus INVERTER only new version of controller can be used: code number on the controller is 084B8080.

For service purpose original components (spare parts) recommended by Danfoss should be used.

Suction

and

ambient

temperature

EMI ﬁlter

(Controller)

Discharge

temperature

sensor

Compressor

oil

120Z5 034 120Z0 648

120Z5 034

120Z0 648

separator

118U3981

118U3982

Fan gr ill

Oil

8 AB241186442766en-000801

2018

Application Guidelines

Product description

2.8 Cooling capacities, sound data, power consumption

Optyma™ Plus INVERTER, R407A

Cooling capacity Q [kW] P [kW] EcoDesign (2)

Model number

OP-M PPM028V VLP01E 114X4302 VLZ028TGA

OP-M PPM035V VLP01E 114X4316 VLZ035TGA

OP-M PPM044V VLP01E 114X4334 VLZ044TGA

[1] Nominal conditions, Evaporating temperature -10°C. Ambient air temperature +32°C. Superheat 10K. [2] Rated conditions, Evaporating temperature -10°C. Ambient air temperature +32°C. Return Gas Temperature 20°C

Code

number

Compressor

Te [°C]

Tamb [° C]

speed, rps

Compressor

-15 C -10 C -5 C 0 C 5 C -10 °C

27 1435 1797 2227 2732 3320 32 1345 1686 2092 2570 3128 899 1.88

38 - 1557 1934 2380 2902 43 - - - - 27 2382 2994 37 11 4543 5499 32 2243 2829 3515 4310 5224 1333 2.12

38 - 2622 3267 4 015 4876 43 - 2442 3050 3757 4571 27 3499 4412 5470 6686 8069 32 3306 4177 5183 6339 7654 2005 2.08

38 - 3879 4821 5901 7131 43 - 3618 4503 5519 6676 27 4549 574 0 7106 8660 10413 32 4313 5438 6726 8192 9847 2830 1.92 5539 2834 1.95 3.49

100

38 - 5067 6261 7621 9158 43 - 4747 5864 7135 8575 27 1806 2259 2796 3426 4157 32 1692 2119 2626 3223 3916 1057 2.00

38 - 1956 2427 2983 3632 43 - - - - 27 2988 3751 4643 5674 6854 32 2812 3542 4393 5378 6504 1599 2.22

38 - 3279 4079 5003 6061 43 - 3051 3803 4674 5674 27 4374 5503 6805 8291 9973 32 4128 5203 6439 7849 9443 2445 2.13

38 - 4824 5977 7292 8779 43 - 4492 5573 6806 8201 27 5666 7124 8782 10652 12744 32 5367 6741 8302 1006 4 12035 3488 1.93 6876 3494 1.97 3.63

100

38 - 6270 7715 9345 11172 43 - 5864 7212 8734 10442 27 2303 2877 3556 4350 5268 32 2159 2699 3339 4091 4962 1278 2 .11

38 - 2491 3085 3785 4600 43 - - - - 27 3796 4757 5876 7163 8629 32 3569 4487 5553 6779 8175 1974 2.27

38 - 4148 5146 6294 7602 43 - 3852 4790 5870 7101 27 5527 6933 8542 10363 124 05 32 5208 6543 8067 9790 11720 3073 2.13

38 - 6052 7468 9069 10862 43 - 5620 6944 8440 10117 27 712 5 8914 10926 13170 156 49 32 6738 8 421 10311 12419 14750 4434 1.90 8612 4446 1.94 3.71

100

38 - 7813 9557 11502 13656 43 - 7288

8911 10721 12728

COP

Q [kW] P [kW] COPASEPR

(1)

SEPR, Seasonal Energy Performance Ratio

level dB(A)

Sound power

Sound pressure

72.8 41.8

73.4 42.4

74.0 43.0

75.3 44.3

71.7 40.7

72.3 41.3

72.9 41.9

74. 6 43.6

72.6 41.6

73.1 43.1

73.7 43.7

74.4 43.4

Q [W], Cooling Capacity

P [W], Power Input

level 10 m dB(A)

For more information related to EcoDesign compliance, please refer to Coolselector® coolselector.danfoss.com or contact Danfoss

EcoDesign

9AB241186442766en-000801

2018

Application Guidelines

Product description

Optyma™ Plus INVERTER, R407F

Cooling capacity Q [kW] P [kW] EcoDesign (2)

Model number

OP-M PPM028V VLP01E 114X4302 VLZ028TGA

OP-M PPM035V VLP01E 114X4316 VLZ035TGA

OP-M PPM044V VLP01E 114X4334 VLZ044TGA

Code

number

Compressor

Te [°C]

Tamb [° C]

speed, rps

Compressor

-15 C -10 C -5 C 0 C 5 C -10 °C

27 1534 1915 2363 2888 3496 32 1447 1808 2234 2733 3313 945 1.91

38 - 1679 2078 2547 3092 43 - - - - 27 2598 3258 4022 4900 5902 32 2450 3083 3815 4655 5613 1410 2.19

38 - 2862 3555 4349 5254 43 - 2669 3328 4083 4943 27 3826 4792 5901 7163 8590 32 3612 4539 5600 6806 8169 2121 2.14

38 - 4220 5223 6362 7647 43 - 3942 4895 5977 7197 27 4950 6174 7573 9158 10939 32 4689 5857 7191 8703 10400 2977 1.97 5905 2979 1.98 3.58

100

38 - 5470 6724 8145 9742 43 - 5141 6327 7671 9182 27 1931 2408 2969 3623 4380 32 1820 2272 2805 3428 4149 1115 2.04

38 - 2110 2609 3193 3871 43 - - - - 27 3258 4080 5029 6116 7351 32 3069 3858 4766 5804 6984 1698 2.27

38 - 3577 4435 5416 6529 43 - 3330 4147 5078 6135 27 4776 5970 7334 8878 10 612 32 4503 5648 6951 8425 10079 2594 2.18

38 - 5242 6472 7860 9 417 43 - 4888 6055 7372 8847 27 6156 7655 9358 11274 134 09 32 5825 7254 8876 10699 12731 3679 1.97 7326 3682 1.99 3.71

100

38 - 6764 8286 9996 11902 43 - 6347 7783 9397 11198 27 2464 3068 3778 4603 5555 32 2322 2895 3568 4354 5260 1353 2.14

38 - 2686 3316 4052 4903 43 - - - - 27 4135 5170 6359 7714 9244 32 3891 4882 6019 7311 8771 2105 2.32

38 - 4519 5591 6809 818 4 43 - 4200 5218 6374 7677 27 6024 7510 9195 110 89 1319 6 32 5670 7092 8700 10503 1250 9 3271 2.17

38 - 6567 8080 9774 116 58 43 - 6107 7540 9143 10924 27 7723 9567 11641 13951 16 496 32 7298 9052 1102 3 13215 15631 4694 1.93 9164 4701 1.95 3.78

100

38 - 8421 10265 12315 14574 43 - 7884

9618 115 48 13675

COP

Q [kW] P [kW] COPASEPR

(1)

SEPR, Seasonal Energy Performance Ratio

level dB(A)

Sound power

Sound pressure

71.7 40.7

72.3 41.3

72.9 41.9

74. 2 43.2

71.2 40.2

71.9 40.9

72.5 41.5

73.55 42.5

72 41

72.6 41.6

73.2 42.2

74 43

Q [W], Cooling Capacity

P [W], Power Input

level 10 m dB(A)

For more information related to EcoDesign compliance, please refer to Coolselector®

coolselector.danfoss.com or contact Danfoss

10 AB241186442766en-000801

EcoDesign

2018

Application Guidelines

Product description

Optyma™ Plus INVERTER, R404A

Cooling capacity Q [kW] P [kW] EcoDesign (2)

Model number

OP-M PPM028V VLP01E 114X4302 VLZ028TGA

OP-M PPM035V VLP01E 114X4316 VLZ035TGA

OP-M PPM044V VLP01E 114X4334 VLZ044TGA

Code

number

Compressor

Te [°C]

Tamb [° C]

speed, rps

Compressor

-15 C -10 C -5 C 0 C 5 C -10 °C

27 1597 199 0 2446 2972 3573 32 148 4 185 4 2284 2780 3349 10 02 1.85

38 - - - - 43 - - - - 27 2700 3340 4080 4929 5894 32 2505 310 6 3802 4601 5510 1537 2.02

38 2266 2820 3168 419 8 5039 43 2060 2574 3168 3853 4636 27 3994 4916 5976 7181 8542 32 3707 4574 5569 6701 7981 2349 1.95

38 3354 4151 4633 6110 7290 43 3048 3785 4633 5600 6698 27 5202 6381 7724 9241 10939 32 4832 5939 7198 8620 10214 3317 1.79 6250 3328 1. 88 3.47

100

38 4368 5384 5965 7845 9310 43 3962 4899 5965 7171 8528 27 2027 2 517 3085 3739 4485 32 1878 2339 2875 3491 419 6 1159 2.02

38 - - - - 43 - - - - 27 3402 4193 5108 6153 7338 32 3158 3899 4755 5735 6846 179 4 2 .17

38 2854 3533 3937 5215 6236 43 2590 3215 3937 4766 57 11 27 4962 6087 7381 8853 10511 32 4610 5659 6866 8240 9790 2813 2.01

38 4169 5126 5672 74 81 8899 43 3784 4662 5672 6826 8133 27 6354 7768 9389 11226 13287 32 5901 7218 8727 10438 1236 0 4070 1.77 7614 4088 1.86 3.77

100

38 5331 6529 7183 9460 11214 43 4828 5926 7183 8614 10227 27 2620 3236 3949 4767 5698 32 2426 3008 3681 4453 5334 1391 2.16

38 - - - - 43 - - - - 27 4322 5303 6426 7700 913 4 32 4012 4932 5987 7183 8532 2288 2.16

38 3623 4 470 4964 6541 7784 43 3284 4067 4964 5985 7139 27 6267 7656 9231 10997 12960 32 5812 7111 8583 10234 12 070 3618 1.97

38 5243 6432 7078 9289 10972 43 4744 5839 7078 8472 10027 27 8008 9755 11715 13888 16273 32 740 6 9033 10856 12879 15102 5190 1.74 9560 5220 1.83 3.76

100

38 6648 8128 8852 11626 13651 43 5980 7335

8852 10539 1239 9

COP

Q [kW] P [kW] COPASEPR

(1)

SEPR, Seasonal Energy Performance Ratio

level dB(A)

Sound power

Sound pressure

71.2 40.2

71.9 40.9

72.5 41.5

73.7 42.7

73.1 4 2.1

73.8 42.8

74. 4 43.4

75.4 44.4

73.1 4 2.1

73.9 42.9

74. 5 43. 5

75.5 44.5

Q [W], Cooling Capacity

P [W], Power Input

level 10 m dB(A)

For more information related to EcoDesign compliance, please refer to Coolselector® coolselector.danfoss.com or contact Danfoss

EcoDesign

11AB241186442766en-000801

2018

Application Guidelines

Product description

Optyma™ Plus INVERTER, R448A/R449A

Cooling capacity Q [kW] P [kW] EcoDesign (2)

Model number

OP-M PPM028V VLP01E 114X4302 VLZ028TGA

OP-M PPM035V VLP01E 114X4316 VLZ035TGA

OP-M PPM044V VLP01E 114X4334 VLZ044TGA

Code

number

Compressor

Te [°C]

Tamb [° C]

speed, rps

Compressor

-15 C -10 C -5 C 0 C 5 C -10 °C

27 1465 1839 2276 2783 3365 32 1375 1732 2149 2633 3190 939 1.84

38 - - - - 43 - - - - 27 2494 3107 3816 4629 5553 32 2346 2930 3605 4379 5259 1415 2.07

38 - 2706 3338 4064 4891 43 - 2510 3106 3790 4571 27 3656 4527 5536 6695 8 013 32 3443 4270 5226 6324 7573 2159 1.98

38 - 3949 4842 5866 7032 43 - 3670 4509 5472 6569 27 4686 57 74 7041 8502 10171 32 4421 5451 6648 8028 9605 3054 1.78 5548 3058 1. 81 3.38

100

38 - 5056 6170 7454 8922 43 - 4713 5761 6967 8346 27 1836 2301 2845 3476 4201 32 1722 216 6 2684 3284 3974 1081 2.00

38 - - - - 43 - - - - 27 3091 3846 4713 5699 6 812 32 2896 3616 4442 5381 6441 174 8 2.07

38 - 3327 4102 4983 5977 43 - 3076 3806 4637 5577 27 4505 5569 6792 8183 9752 32 4227 5238 6396 7713 9200 2718 1.93

38 - 4827 5907 7136 8523 43 - 4472 5487 6 641 7945 27 5773 7090 8615 10361 12338 32 5439 6683 8119 9765 11631 3839 1.74 6814 3837 1.78 3.29

100

38 - 6185 7518 9045 10779 43 - 5757 7006 8436 10061 27 2364 2954 3637 4 422 5317 32 2213 2776 3429 4180 5037 1316 2.11

38 - - - - 43 - - - - 27 3894 4834 5915 7145 8532 32 3650 4544 5570 6739 8058 2051 2.22

38 - 4185 514 4 6238 7473 43 - 3876 4779 5808 6973 27 5674 7003 8510 10203 12087 32 5308 6572 8003 9609 11397 3243 2.03

38 - 6034 7371 8873 10544 43 - 5566 6825 8237 9810 27 7289 8959 10828 1289 9 15173 32 6786 8375 10149 12112 14265 4739 1.77 8558 4753 1.8 3.73

100

38 - 7634 9291 11123 13130 43 - 6982

8539 10260 12145

COP

Q [kW] P [kW] COPASEPR

(1)

SEPR, Seasonal Energy Performance Ratio

level dB(A)

Sound power

Sound pressure

71.2 40.2

71.9 4 0.9

72.5 41. 5

73.7 42.7

73.1 4 2.1

73.8 42.8

74. 4 43.4

75.4 44.4

73.1 4 2.1

73.9 42.9

74. 5 43. 5

75.5 44.5

Q [W], Cooling Capacity

P [W], Power Input

level 10 m dB(A)

For more information related to EcoDesign compliance, please refer to Coolselector®

coolselector.danfoss.com or contact Danfoss

12 AB241186442766en-000801

EcoDesign

Application Guidelines

Product description

2.9 Layout

OP-MPLM028-035-044, OP-MPPM028-035-044

13AB241186442766en-000801

NOTICE

Application Guidelines

Application range

3.1 Main applications

3.2 Condensing unit

selection

Optyma™ Plus INVERTER is a perfect cooling solution for typical MBP applications like food retail, petrol forecourt sites, cold rooms ,and display cases. All units are fully wired and factory tested. They have one cabinet sizes and are equipped with one fan.

Inverter technology oﬀers more ﬂexibility in condensing unit selection than ﬁxed-speed units. Selection of the right inverter condensing unit size can be made by next method: Select a condensing unit size which achieves the peak load system cooling capacity demand at its maximum speed.

It is compulsory to secure that

condensing unit capacity at minimum speed (30 rps) will not be higher than necessary cooling capacity for the smallest evaporator!

In case minimum (at 30 rps) condensing unit capacity is higher than capacity of smallest evaporator it can cause work of condensing unit outside its application envelope and as consequence reduce lifetime.

Example1 (evaporating temperature -10 °C, ambient temperature 32 °C, R404A): Evaporator1= 3 kW Evaporator2= 3 kW Evaporator3= 3 kW Total Q = 9 kW (maximum cooling capacity) Minimum cooling capacity = minimum evaporator capacity = minimum evaporating capacity = 3kW According to the capacities at evaporating -10 °C, ambient 32 °C and refrigerant R404A condensing unit OP-MPPM044 (maximum capacity 9 kW) achieves the peak load system cooling capacity (9,3 kW) demand at its maximum speed and at the same time condensing unit capacity at minimum speed (minimum capacity 3 kW) is not higher than necessary cooling capacity for the smallest evaporator (3 kW).

Optyma units are released for R448A/R449A, R407A/F and R404A.

Evaporator1= 1 kW Evaporator2= 2,1 kW Evaporator3= 2,5 kW Evaporator4=1,5 kW Total Q = 7,1 kW (maximum cooling capacity) Minimum cooling capacity = minimum evaporator capacity = Evaporator1 = 1 kW.

According to the capacities at evaporating -10 °C, ambient 32 °C and refrigerant R404A condensing unit OP-MPPM035 (maximum capacity 7,2 kW) achieves the peak load system cooling capacity (7,1 kW) demand at its maximum speed but at the same time condensing unit capacity at minimum speed (minimum capacity 2,3 kW) is higher than necessary cooling capacity for the smallest evaporator (1 kW).

In this case it is recommended to connect few evaporators together (regulated by one thermostat) to achieve smallest required capacity higher than minimum capacity of condensing unit: by managing Evaporator1 and Evaporator4 via one thermostat minimum required capacity will be 2,5 kW (Evaporator2) which is higher than minimum capacity of condensing unit at low speed (2,3 kW).

INVERTER is equipped with a IPM (Interior Permanent Magnet) motor. The compressor cannot operate without frequency converter. It will be destroyed immediately if connected directly to public network. The applied frequency from the inverter will be 60 Hz for 30 rps (1800 rpm) up to 200 Hz for 100 rps (6000 rpm).

Please refer to the table below

™

Plus INVERTER outdoor condensing

Compressor of Optyma™ Plus

14 AB241186442766en-000801

Example2 (evaporating temperature -10 °C, ambient temperature 32 °C, R404A):

Compressor speed Min Max

rps 30 100

rpm 1800 6000

Drive output frequency Hz 60 200

Ambient temperature (°C)

Operating Map (R407F/A)

-20 -10 0 10 20-25 -15 -5 5 15

Evaporating temperature (°C)

30 rps-100 rps

SH10K

50 rps-100 rps

°C

(Te -10°C, Tamb 43°C)

Ambient temperature (°C)

Operating Map (R404A)

-20 -10 0 10 20-25 -15 -5 5 15

Evaporating temperature (°C)

30 rps-100 rps

SH10K

50 rps-100 rps

°C

(Te -15°C, Tamb 43°C)

Ambient temperature (°C)

Operating Map (R448A/R449A)

-20 -10 0 10 20-25 -15 -5 5 15

Evaporating temperature (°C)

30 rps-100 rps

SH 10K

50 rps-100 rps

°C

(Te -10°C, Tamb 43°C)

Application Guidelines

Application range

3.3 Application envelopes

The operating envelopes of Optyma™ Plus INVERTER are given in the ﬁgures below, where the ambient and evaporating temperatures represent the range for steady state operation. The ﬁgures below show the operating envelopes

for condensing units with refrigerants R448A/ R449A, R407A/F and R404A. The operating limits serve to deﬁne the envelopes within which reliable operation of the condensing units are guaranteed.

15AB241186442766en-000801

Application Guidelines

Application range

Red line on the application envelope indicates maximum safe ambient temperature for low load (30-50 rps) and high ambient conditions (above 32 °C for R448A/R449A, 32 °C for R404A and above 40 °C for R407A/F.

In case low unit capacity required (30-50 rps) at high ambient temperatures controller will increase compressor speed up to minimum safe

Minimum and maximum evaporating and condensing temperatures as per the operating

Other operating limits: Recommendation

Discharge gas temperature

Evaporator outlet superheat above 6K (to avoid liquid ﬂood back)

Suction gas superheat at compressor inlet within the limits shown on the application envelope

Special attention to suction line insulation will have to be secured in order to:

• Avoid too high superheat during high ambient conditions that can create too high discharge gas temperature.

speed at high temperature. This minimum safe speed at high temperature is factory preset to 50 rps (controller parameter c47: Start speed of the compressor). It is not recommended to decrease setting of parameter c47 below 50 rps as this can lead to work of compressor at low speed during high ambient conditions which can reduce lifetime of the unit.

envelopes – compressor should work inside application envelope.

125

°C maximum

• Avoid too low superheat during low ambient conditions that can create condensation of refrigerant in suction line.

3.4 Ambient conditions

3.5 Limits for voltage supply

Optyma™ Plus INVERTER units can be used with ambient temperature from -15°C to 43°C. For altitudes above 2000 m, contact Danfoss. The other working conditions should be within the limits of application envelope.

To assure that the unit can start during cold conditions the parameter “c94 LpMinOnTime” can be used. If this parameter is set to a value that is higher than 0 and the ambient temperature (Tamb) is below 5°C, the internal transmitter “LP switch c75” and “pump down limit c33” will be overridden for the number of seconds deﬁned in “c94 LpMinOnTime”. And the value for Min on time for the compressor will be set to the largest of the values of “c94 MinLpOnTime” and “c01 Min. on time”.

Voltage limits: Min: 360 V Max 440 V Phase asymmetry: ±3% Frequency limits: 50Hz ±1%

The CDS803 drive forces the compressor to 50rps (see Optyma Controller parameter c47) for 30s always at compressor start, to ensure proper oil return at low load and short runtimes. The start delay time can be modiﬁed via drive parameter 1-71, if a proper oil return is always ensured without or by modifying this start delay function.

In order to change 1-71, a separate LCP panel needs used to change the settings on the drive, the LCP panel has the ordering code 120Z0581.

When changing 1-71, a value not lower as 10 seconds should get applied.

16 AB241186442766en-000801

CAUTION

NOTICE

Application Guidelines

Installation

4.1 Location & ﬁxings

Optyma™ Plus INVERTER unit

has to be installed by competent authorized

The unit is to be placed in such a way that it is not blocking or expose an obstacle for walking areas, doors, windows etc. The foundation where the unit is to be placed upon has to be strong enough to carry the entire weight, see unit data. Ensure adequate space around the unit for air circulation. Avoid installing the unit in locations which are exposed to direct sunshine daily for long periods. Unit has to be placed on a horizontal surface - less than 3° slope, which has to be strong and stable enough to eliminate vibrations and interference. It is recommended to install the unit on rubber grommets or vibration dampers (not part of the Danfoss supply). Installation of unit shall not be done in aggressive and dusty environments.

Furthermore the installation of the unit shall not be done in facilities containing ﬂammable gasses or in installation containing ﬂammable gasses.

Special attention should be paid if unit needs to be installed close to the sea as this can reduce unit lifetime due to corrosion of metal parts.

personnel and the installation shall comply to applicable local laws and rules.

Where multiple units are to be installed in the same location, please consider each individual case carefully. Air by-pass around each condenser and between the units should be avoided at all times.

Optyma

™

Plus INVERTER condensing units can also be used for wall mounting on suitable brackets. Wall mounting brackets are not supplied by Danfoss.

Another factor to consider in ﬁnding a good installation site is the direction of the prevailing wind. For example if the air leaving the condenser faces the prevailing wind, the air ﬂow through the condenser can be impeded, causing high condensing temperatures, improper functioning of the unit and ultimately resulting in reducing the life of the unit. A baﬄe is a remedy for this situation.

Picture 1: Minimum mounting distances

Q: Air in R: Air out

Unit

Housing 3 250 760 580 580

[mm]X [mm]Y [mm]Z [mm]

17AB241186442766en-000801

WARNING

Application Guidelines

Installation

4.2 Electrical connection

Ensure that power supply

cannot be switched on during installation.

Below table lists recommended wiring sizes for the condensing unit power supply cables. These wiring sizes are valid for a cable length up to 30 m.

Model Cable size, mm2 (from network to unit main switch)

OP-MPLM028 OP-MPPM028

OP-MPLM035 OP-MPPM035

OP-MPLM044 OP-MPPM044

Note: 1.The wire size here is the guideline. In each speciﬁc case required cable size should be speciﬁed by the installer depending on the system design, ambient temperature, the wire material, current, etc.

In order to ensure a safe and problem free operation of the unit it is recommended to:

- Ensure that the power supply corresponds to the unit and that the power supply is stable (see nominal values on unit label and power supply

found in the wiring diagram. Wiring diagram can be found in front door of unit. Unit is equipped with high and low pressure switches, which directly cuts the power supply of the compressor contactor in case of activation.

Unit is equipped with an electronic controller and compressor drive.

The controller and compressor drive are preprogrammed with parameters ready for use with the actual unit.

limits in paragraph 3.5).

As standard the parameters for operation with

- Make the power supply according to present norm and legal requirements. Ensure that the unit is properly connected to ground.

refrigerant R449A set. If another refrigerant is to be used refrigerant parameter (o30) needs to be changed (refer to description in Controller

application manual). Parameters for high and The unit is equipped with a main switch with overload protection. Overload protection is preset from factory. Value for overload protection can be

low pressure cut outs are preset in the controller

adapted to the compressor and refrigerant

installed in the unit.

4.2.1 Power supply

protection

4.2.2 Protection and

features

You should use only original circuit breaker, min. short circuit breaking capacity needs to

- Electronic thermal compressor protection against

overload.

- Temperature monitoring of the heat sink ensures

that the frequency converter trips in case of overtemperature.

- The frequency converter is protected against

short-circuits between compressor terminals U, V, W.

- When a compressor phase is missing, the

frequency converter trips and issues an alarm.

- When a mains phase is missing, the frequency

converter trips or issues a warning (depending on the load).

be 100kA. Please refer to spare part section for

selection of components for service replacement.

- Monitoring of the intermediate circuit voltage ensures that the frequency converter trips, when the intermediate circuit voltage is too low or too high.

- The frequency converter is protected against ground faults on compressor terminals U, V, W.

- Occurring alarms will be shown in the controller display and by the red LED in front of the frequency converter.

- The root cause of an individual alarm can be shown with an optional LCP (local control panel, code 120Z0581) or the MCT10 setup software.

18 AB241186442766en-000801

Application Guidelines

Installation

4.3 Wiring diagrams

OP-MPLM028-035-044, OP-MPPM028-035-044

A1 : EMC/RFI Filter (Compressor) A2 : Frequency Converter A3 : EMI Filter (Controls) A4 : Optyma™ Plus Controller B1 : Condensing Pressure Transducer B2 : Suction Pressure Transducer B3 : High Pressure Switch B4 : Low Pressure Switch C1 : Run Capacitor (Fan) F1 : Fuse (Control Circuit) K1 : Contactor M1 : Compressor M2 : Fan Motor Q1 : Main Switch R1 : Ambient Temp. Sensor R2 : Discharge Temp. Sensor R3 : Suction Temp. Sensor R4,R5 : Auxiliary Temp. Sensor (optional) R6 : Crankcase Heater R7 : Oil Separator Heater S1 : Room Thermostat (optional) X1 : Terminal

Supply : Supply Fan : Fan Alarm : Alarm Comp. : Compressor CCH : Crankcase Heater Aux : Auxiliary

19AB241186442766en-000801

Application Guidelines

Installation

4.3.1 Emergency running without controller

In case of controller failure, the condensing unit can still be operated when the controller standard wiring (WD1) is modiﬁed into a temporary wiring (WD2) 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 6 (fan supply) and put them together. A fan pressure switch (e.g. KP5) or a fan speed controller (e.g. XGE) can be connected in series to wire 6.

• Remove wire 10 (drive start) and wire 24 (room thermostat) and put them together.

• Remove wire 11 (drive start) and wire 25 (room thermostat) and put them together.

• Remove wire 53 and 55 from drive terminals and connect the attached 10kOhm potentiometer (R8) as below:

wire 1 to drive terminal 55 wire 2 to drive terminal 53 wire 3 to drive terminal 50

• Turn the knob of the potentiometer to middle position, which corresponds approximately compressor speed 50rps.

• Remove wire 14 (crankcase and oil separator heaters) and connect it to the compressor contactor terminal 22.

• Remove wire 12 (supply crankcase and oil separator heaters), 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).

• Adjust the potentiometer to get the desired

speed.

• Replace the controller as soon as possible.

20 AB241186442766en-000801

Application Guidelines

Installation

OP-MPLM028-035-044, OP-MPPM028-035-044- Emergency Wiring

A1 : EMC/RFI Filter (Compressor) A2 : Frequency Converter A3 : EMI Filter (Controls) A4 : Optyma™ Plus Controller B1 : Condensing Pressure Transducer B2 : Suction Pressure Transducer B3 : High Pressure Switch B4 : Low Pressure Switch B5* : Fan Speed Controller / Pressure Switch C1 : Run Capacitor (Fan) F1 : Fuse (Control Circuit) K1 : Contactor M1 : Compressor M2 : Fan Motor Q1 : Main Switch R1 : Ambient Temp. Sensor R2 : Discharge Temp. Sensor R3 : Suction Temp. Sensor R4,R5 : Auxiliary Temp. Sensor (optional) R6 : Crankcase Heater R7 : Oil Separator Heater R8 : Compressor Speed S1 : Room Thermostat (optional) X1 : Terminal

Potentiometer

Supply : Supply Fan : Fan Alarm : Alarm Comp. : Compressor CCH : Crankcase Heater Aux : Auxiliary

21AB241186442766en-000801

Application Guidelines

Picture1. Normal wiring

Installation

Picture2. Emergency wiring

22 AB241186442766en-000801

WARNING

CAUTION

Application Guidelines

Installation

4.4 Electrical protection standard (protection class)

4.5 EMC compliance

4.5.1 Warning when

touching unit when OFF

- Scroll compressors: IP22

- Fan: IP54

- Controller: IP20

- Drive: IP20

- Complete unit: IP54

All necessary actions are taken to secure EMC compliance of complete condensing unit!

DC-link capacitors that can remain charged even when the frequency converter is not powered. To avoid electrical hazards, disconnect AC mains and wait 15 min for the capacitors to fully discharge before performing any service or repair work. Failure to wait the speciﬁed time after power has been removed before doing service or repair could result in death or serious injury.

The digital inputs are not a safety switch. They do not disconnect the frequency converter from the mains.

Do not remove mains connections, compressor connections or other power connections while the frequency converter is connected to power.

The ground leakage current from the frequency converter exceeds 3.5 mA. According to IEC 618005-1 a reinforced Protective Earth connection

Frequency converters contain

Leakage Current

Power connections under

voltage and can cause danger by electrical shock.

Optyma™ Plus INVERTER units are fully wired and factory tested. Electrical connection compromises only power supply.

must be ensured with a min. 10 mm2 Cu or an additional PE wire – with the same cable crosssection as the mains wiring - must be terminated separately.

Residual Current Device

This product can cause a DC current in the protective conductor. Where a residual current device (RCD) is used for extra protection, only an RCD of Type B (time delayed) shall be used on the supply side of this product.

Recommended Brand & Model Number :

Make RCCB Model Number

Doepke DFS 4B SK, Type B

ABB F 804 B, Type B ABL RA4403, Type B

Protective earthing of the frequency converter and the use of RCDs must always follow national and local regulations.

23AB241186442766en-000801

NOTICE

Application Guidelines

Installation

4.6 Phase sequence

4.7 Brazed connections

Optyma™ Plus INVERTER units are equipped with variable speed scroll compressors for which proper phase sequence is compulsory in order to secure rotation in right direction and therefore compression.

Refrigerant connections, brazing and ﬂange connections has to be done by a qualiﬁed installer according to EN378.

The unit is supplied with an positive protective pressure of Nitrogen (1 bar). The use of substances containing chlorine, mineral oil or other chemicals is not allowed.

Piping has to be designed to avoid vibrations, either through ﬂexibility or piping brackets. 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.

Only use clean and dehydrated refrigeration grade copper tubing. Tube-cutting must be carried out so as not to deform the tubing roundness and to ensure that no foreign debris remains within the tubing. Only refrigerant grade ﬁttings should be used and these must be of both a design and size to allow for a minimum pressure drop through the completed assembly. Follow the brazing instructions bellow. Never drill holes into parts of the pipe-work where ﬁlings and particles cannot be removed. Even during installation, if the system is left for any reasonable period of time (say 1 hour), pipes should be re-capped to prevent moisture and contaminant from entering the system.

Liquid/suction tubes are extended from the condensing unit housing, therefore we recommend to isolate the housing by using a heat shield and/or a heat-absorbent compound (e.g. wet cloth) on the copper tubing. Use a doubletipped torch.

heat shield

The phase sequence has to be secured between the drive and compressor. (The phase sequence between network and unit drive is of no inﬂuence on the compressor rotation direction).

For brazing the suction and liquid line connections, the following procedure is advised:

• Make sure that no electrical wiring is connected to the compressor.

• Use brazing material with a minimum of 5% silver content.

• Fit the copper tube into the unit tube.

• Apply heat evenly to area A until the brazing temperature is reached. Move the torch to area B and apply heat evenly until the brazing temperature has been reached there as well, and then begin adding the brazing material. Move the torch evenly around the joint, in applying only enough brazing material to ﬂow the full circumference of the joint.

• Move the torch to area C only long enough to draw the brazing material into the joint.

• Remove all remaining ﬂux “once the joint has been soldered” with a wire brush or a wet cloth.

Remaining ﬂux would cause corrosion of the tubing. Ensure that no ﬂux is allowed to enter into the tubing. Flux is acidic and can cause substantial damage to the internal parts of the system and compressor.

The polyolester oil used in VLZ compressors is highly hygroscopic and will rapidly absorb moisture from the air. Condensing unit must therefore not be left open to the atmosphere for a long period of time. Unit ﬁtting plugs shall be removed just before brazing. Condensing unit should always be the last component brazed into the system. Before eventual unbrazing of the compressor or any system component, the refrigerant charge must be removed from both the high- and low-pressure sides. Failure to do so may result in serious personal injury. Pressure gauges must be used to ensure all pressures are at atmospheric level. For more detailed information on the appropriate materials required for brazing or soldering, please contact the product manufacturer or distributor. For speciﬁc applications not covered herein, please contact Danfoss for further information.

24 AB241186442766en-000801

It is compulsory to braze with a protective atmosphere of nitrogen inside the piping. Nitrogen displaces the air and prevents the formation of copper oxides in the system.

NOTICE

WARNING

Application Guidelines

Installation

4.8 High pressure transmitter connection

(Copper oxide could block capillary tubes, thermal expansion valves and generate damage of compressor).

Furthermore it is recommended to insulate the suction pipe up to the compressor inlet.

Do not open the receiver Rotalock valve entirely, it must be turned 1 round (360°) to the closed direction to provide system pressure to the transmitter!

(Insulation should be at least 19 mm thick and is not a part of Danfoss supply). Use only dry pipes and components in order to avoid moisture in the system.

Maximum test pressure is 28 bar.

1. Valve In (from receiver).

2. Valve Out (to evaporator).

3. Service port (for safety devices).

4. Service port (for transmitter or service only).

Fig A: Fully closed Condition

Port 2 and 3 is fully open

port 4 is fully closed

Transmitter failure: Valve shall be opened entirely to disconnect transmitter port from

the others.

Rotolock spindle should be rotated by 5.5 turns/rotation in anticlockwise(from valve

fully closed position) to open the valve.

Fig B: Fully Opened Condition

Port 3 and 4 is fully open

port 2 is fully closed

Fig C: Partially Opened

Condition

Port 2, 3, 4 is fully opened.

25AB241186442766en-000801

NOTICE

Application Guidelines

System design recommendations

5.1 Piping design

Connection sizes! Unsuitable refrigerant ﬂow rate!

Do not assume that the liquid/

suction connection sizes on the unit are in fact the correct sizes to run your interconnecting refrigeration pipes!

The pipes should be sized to ensure optimum performance and good oil return. The sizing must also take into account the full capacity range through which this particular unit will need to operate.

Tube size Distance between 2 clamp supports

12 mm (1/2") 1 m

16 mm (5/8") 1,5 m

19 mm (3/4") 1,8 m

22 mm (7/8") 2 m

The suction line should:

• secure gentle slope towards the unit (recommended slope minimum 0,5/100).

• have P traps, double risers and reduced pipe diameters where long vertical risers cannot be avoided.

Pipe runs should be kept as short as possible, using the minimum number of directional changes. Use large radius bends and avoid trapping of oil and refrigerant. This is particularly important for the suction line. All pipes should be adequately supported to prevent sagging which can create oil traps. The recommended pipe clamp support distance is shown in Table below:

The suction gas velocity must be suﬃcient to ensure a good oil return, within 8 to 12 m/s in vertical risers. In horizontal pipes this velocity can decrease down to 4 m/s. The use of U-trap and double suction risers is often required. These suction risers must always be ﬁtted with a U-trap at the bottom and a P-trap at the top and never be higher than 4 m unless a second U-trap system is ﬁtted.

26 AB241186442766en-000801

8 to 12 m/s at minimum speed

If the evaporator lies above the CU, a pump-down cycle is strongly recommended. If a pump-down cycle were to be omitted, the suction line must have a loop at the evaporator outlet to prevent refrigerant from draining into the compressor during oﬀ-cycles. If the evaporator are situated below the CU, the suction riser must be trapped so as to prevent liquid refrigerant from collecting at the outlet of the evaporator while the system is idle, which would mislead the expansion valve’s sensor (thermal bulb) at start-up.

Maximum safety length of pipes between CU and last evaporator is 20 m.

If pipes length is more than 20 m special adjustment of complete system is needed (oil and refrigerant charge adjustments).

NOTICE

CAUTION

Application Guidelines

System design recommendations

5.2 Evacuation

Diameter of separate suction lines from evaporators to condensing unit manifold should be with appropriate size according evaporator capacity (securing recommended speed for proper oil return). Common manifold tube should be as close as possible to condensing unit.

Moisture obstructs the proper functioning of both the compressor and the refrigeration system. Air and moisture reduce service life and increase condensation pressure, which causes abnormally high discharge temperatures that are then capable of degrading the lubricating properties of the oil. The risk of acid formation is also increased by air and moisture, and this condition can also lead to copper plating. All these phenomena may cause both mechanical and electrical compressor failures. The typical method for avoiding such problems is a vacuum pump-down executed with a vacuum pump, thus creating a minimum vacuum of 500 microns (0.67 mbar).

The evacuation procedure is based upon achieving an actual system Vacuum standard and is NOT TIME DEPENDENT!

Evacuate the installation down to 0,67 mbar to ensure quality vacuum. It is recommended to evacuate on both high and low pressure side to achieve fast and uniform vacuum in the entire refrigeration system.

The installer is responsible for the installation of the unit and complete refrigeration system design according particular conditions of each application as this is not scope of current Guideline.

When the vacuum level has been reached, the system must be isolated from the pump. A vacuum of 0.67mbar has to be reached and maintained for 4 hours. This pressure is to be measured in the refrigeration system, and not at the vacuum pump gauge.

If pressure increases rapidly, the system is not airtight. Locate and repair leaks. Restart the vacuum procedure. If pressure increases slowly, the system contains moisture inside. Break the vacuum with nitrogen gas and restart the vacuum process again.

Do not use a megohmmeter nor apply power to the compressor while it is under vacuum as this may cause internal damage.

Leak detection must be carried out using a mixture of nitrogen and refrigerant or nitrogen and helium. Never use other gasses such as oxygen, dry air or acetylene as these may form an inﬂammable mixture. Pressurize the system on HP side ﬁrst then LP side.

27AB241186442766en-000801

Application Guidelines

System design recommendations

5.3 Refrigerant charge

For the initial charge condensing must not run and eventual service valves must be closed. Charge refrigerant as close as possible to the nominal system charge before starting the compressor. As maximum safe refrigerant charge for compressor is 3,6 kg initial charge can be considered close to 4 kg (will depend on tube sizes, lengths of each individual system). This initial

charging operation must be done in liquid phase as far away as possible from the compressor.

Never start the compressor under vacuum, ensure a progressive charge of the system to 4– 5 bar.

For the initial refrigerant charge service port on liquid line ball valve can be used. This port is equipped with Schrader valve.

For the adjustment of refrigerant charge port on the suction line can be used (located between oil return port and suction ball valve port). This port is also equipped with Schrader valve.

Refrigerant charge should secure stable work at minimum and maximum heat load within the limits of condensing unit application envelope!

The remaining charge is done until the installation has reached a level of stable nominal condition during operation.

Next steps can be followed for proper charging or the system:

- keep system working under the max load conditions (all evaporators working, maximum air/liquid ﬂow via evaporator(s)).

- slowly throttling liquid in on the low pressure side as far away as possible from the compressor suction connection by default via the port on suction line as described before.

- keep under the control evaporating pressure, condensing pressure, suction superheat.

- charge system until reaching suction superheat 6-12 K at desired evaporating temperature.

Suction superheat as well as suction, condensing pressures (temperatures) can be read from controller display.

To avoid system overcharging (which can cause higher energy consumption, high pressure alarms) maximum refrigerant charge can be calculated as follows:

Mmax = (Vrec + VliqL) * 0.9, Where Mmax = approximate maximum refrigerant charge, kg Vrec = receiver volume, L, for Optyma

™

Plus INVERTER 6,2 L VliqL = internal volume of liquid line, L (speciﬁc for each system)

0.9 – correlation coeﬃcient due to refrigerant density.

Liquid line – Dimension Liquid line - Volume

OD [inch]

3/8 9.5 7.9 0.05 0.5

1/2 12. 7 11.1 0.10 1.0

5/8 15.9 14.1 0.16 1.6

3/4 19.1 17.3 0.23 2.3

7/8 22.2 19.9 0.31 3.1

OD [mm] ID [mm]

VliqL

[L /1m]

VliqL

[L/10m]

28 AB241186442766en-000801

NOTICE

CAUTION

Application Guidelines

System design recommendations

5.4 Oil level

During all of the charge procedure keep the oil heaters ON and keep an eye on the oil sight glass, so that it doesn’t change color, density or appearance and it doesn’t start foaming. Refrigerant charge quantity must be suitable for maximum load conditions as well as for minimum load conditions for both summer and winter operations.

It means that refrigerant charge should be enough to feed all evaporators during the peak load conditions and condenser should not be ﬂooded by liquid refrigerant during minimum load conditions.

Receiver and liquid lines should be able to contain remaining refrigerant during low load conditions.

Optyma™ Plus INVERTER condensing units are supplied with POE oil, the oil separator is precharged with 0,3l oil. In case of adding oils always use original Danfoss POE oil from new cans.

After commissioning, the oil level should be checked and topped up if necessary.

When the compressor is running under stabilized conditions, the oil level must be visible in the sight glass. The presence of foam ﬁlling in the sight glass indicates large concentration of refrigerant in the oil and / or presence of liquid returning to the compressor. The oil level can also be checked a few minutes after the compressor stops, the level must be between ¼ and ¾ of sight glass. When the compressor is oﬀ, the level in the sight glass can be inﬂuenced by the presence of refrigerant in the oil.

Only refrigerant for which the unit is designed for has to be charged, see unit data.

In case of refrigerant blend charging has to be done in liquid form in order to avoid chemical changes of the refrigerant.

Don’t judge the refrigerant charge by the liquid sight glass as 100% correct way. It may mislead you!

When Optyma™ Plus INVERTER unit has to be scraped, refrigerant has to be disposed for destruction. Local laws and rules have to be followed for disposal of refrigerant.

In installations with good oil return and line runs up to 20 m, no additional oil is required. If installation lines exceed 20 m, additional oil may be needed. Oil charge has to be adjusted based on the oil level in the compressor sight glass.

Top-up the oil while the compressor is idle. Use the schrader connector or any other accessible connector on the compressor suction line and a suitable pump.

The oil ﬁlls connection and gauge port is a 1/4” male ﬂare connector incorporating a Schrader valve.

Oil changing is not normally necessary for package units.

5.5 Check before start

1. Compliance between unit and power supply.

2. Check that valves are opened. Remark: Do not open receiver valve entirely to get correct pressure to the discharge pressure transmitter. Turn valve spindle one round (360°) in close direction.

3. Check that crankcase and oil separator heaters are working.

4. Check that fan can rotate freely.

5. Check for possible faults in the installation.

6. Check main switch overload protection setting.

29AB241186442766en-000801

Application Guidelines

System design recommendations

5.6 Startup of the unit

After below steps are completed:

1) System is completely installed.

2) All electrical connections are done.

3) System is charged.

Next steps are needed to start the unit:

The controller of the condensing unit is set for R449A. If this factory setting of refrigerant as well as other factory settings of parameters ﬁts for the requirement of your application, no controller parameter must be changed.

• For a refrigerant change go into the parameter menu (press upper button 5 seconds).

• Select parameter “r12” (software main switch) with a short press on lower button.

• Activate parameter “r12” with middle button and change the value to 0 (zero).

• Conﬁrm the value with a short press on the middle button (the 3 LED’s start ﬂashing).

• Go to the parameter “o30” (Refrigerant).

• Change the value of parameter “o30” to 21 if R407A, 37 if R407F will be used.

• Conﬁrm the value with a short press on the middle button. Press short the upper (or lower) button to go to the next Parameter of the Parameter menu, e.g. Parameter r23 for suction pressure setpoint or r82

for Min Condensing Pressure. Scroll fast through the Parameters with a long press on these buttons.

• Press short the middle button to show the value of the selected Parameter.

• Press afterwards the upper (or lower) button to change the value of the selected parameter. A long press on these buttons will change the value fast

• Select parameter “r12” again.

• Change the value to 1 (one).

• Conﬁrm the value with a short press on the middle button (the 3 LED-signs stop ﬂashing and the condensing unit will start if required).

• After 20 seconds the display returns to the evaporation temperature in °C, the new refrigerant and all relevant parameters are changed.

It is compulsory to energize crankcase and oil separator heaters at least 1 hour before initial start-up and start-up after prolonged shutdown to remove refrigerant in liquid phase from the compressor.

Condensing unit is factory preset for quick installation and start up. Compressor drive is fully managed by condensing unit controller and therefore all parameters settings should be done only via condensing unit controller.

5.7 Check after start

After a couple of hours of stable operation following has to be checked via service parameters U :

1. Unit current consumption.

2. Rotation of fan (suction through condenser).

3. Check for leakages in refrigerant system.

4. Check superheat.

5. Check oil level.

6. Check for abnormal noises.

7. Check for abnormal vibrations.

8. Suction and discharge pressures.

30 AB241186442766en-000801

Application Guidelines

Condensing unit controller

6.1 Advantages

6.2 Controller’s regulation logic

6.3 Functions

In order to provide the highest level of compressor protection, energy eﬃciency and adaptation to

• Condensing pressure control in relation to outside temperature.

• Fan speed regulation.

• On/oﬀ and variable speed regulation of the compressor.

• Crankcase heating element control.

• Day/night controller operation.

The controller receives a signal for demanded cooling, and it then starts the compressor. If compressor is controlled by variable speed, the suction pressure (converted to temperature) will be controlled according to the set evaporating temperature.

Condenser pressure regulation is performed following a signal from the ambient temperature

• Control of condensing temperature.

• Control of fan speed.

• On/oﬀ control or speed regulation of the compressor.

• Control of heating element in crankcase.

• Liquid injection into economizer port.

variable conditions condensing unit is equipped with speciﬁc controller.

• Built-in clock function with power reserve .

• Built-in Modbus data communication.

• Monitoring discharge temperature td.

• Oil return management control at variable speed operation.

sensor and the set reference corresponding to diﬀerence between condensing and ambient temperatures. The controller will then control the fan, which allows the condensing temperature to be maintained at the desired value. The controller can also control the heating element in the crankcase so that oil is kept separate from the refrigerant.

• Raising the condenser pressure regulation reference during night operation.

• Both internal and external start/stop cooling.

• Safety cut-out activated via signal from

automatic safety control.

6.4 Regulation reference for condensing temperature

6.5 Fan operation

6.6 Compressor control

The controller controls the condensing temperature in relation to the ambient temperature. This diﬀerence is preset in the

The controller will control the fan so that the condensing temperature is maintained at the desired value above the ambient temperature.

The compressor is controlled by a signal at the DI1 input. The compressor will start once the input is connected. Three restrictions have been implemented to avoid frequent start/stops:

- minimum ON time.

- minimum OFF time.

- time elapsed between two starts. These three restrictions have the highest priority during regulation, and the other functions will wait until they are complete before regulation can continue. When the compressor is ‘locked’

controller. It can also, via another parameter, get increased at night.

by a restriction, this can be seen in a status notiﬁcation. DI3 input is used as a safety stop for the compressor, an insuﬃcient input signal will immediately stop the compressor. The compressor is speed-controlled with a voltage signal at the AO2 output. If the compressor has been running for a long period at low speed, the speed is increased for a short moment for the purpose of oil return.

31AB241186442766en-000801

Application Guidelines

Condensing unit controller

6.7 Maximum discharge gas temperature

6.8 High pressure

monitoring

6.9 Low pressure

monitoring

6.10 Pump down limit

The temperature is recorded by sensor Td. If variable speed control is chosen for the compressor, this control will initially reduce the compressor capacity if the Td temperature approaches the set maximum value. If higher temperature is detected than the set max. temperature, the fan’s speed will be set to 100%. If this does not cause the temperature to drop, and if the temperature remains high after the

During regulation, the internal high pressure monitoring function is able to detect an over the limit condensing pressure so that the regulation can continue. However, if the C73 setting is exceeded, the compressor will be stopped.

During regulation, the internal low pressure monitoring function will cut out the compressor upon detecting a suction pressure that falls below the lower limit, but only once the minimum ON

The compressor will be stopped if a suction pressure that falls below the set value is registered, but only once the minimum ON time is exceeded.

set delay time, the compressor will be stopped. The compressor will only be re-started once the temperature is 10 K lower than the set value. The above mentioned re-start restrictions must also be complete before the compressor can start once again. If the delay time is set to ‘0’, the function will not stop the compressor. The Td sensor can be deactivated (o63).

If, on the other hand, the signal comes from the interrupted safety circuit connected to DI3, the compressor will immediately be stopped and the fan will be set to 100%. When the signal is once again ‘OK’ at the DI3 input, the regulation will resume.

time is exceeded. An alarm will be issued. This function will be time delayed, if the compressor starts at low ambient temperature.

6.11 Data communication

The controller is delivered with built-in MODBUS data communication and can be connected to an ADAP KOOL® network. If a diﬀerent form of data communication is requested, a LON RS-485 module can be inserted in the controller. The connection will then be made on terminal RS

485.

Important: All connections to the data communication must comply with the requirements for data communication cables.

All condensing units are delivered with controllers which are factory pre-set. See below table with factory setting of controllers integrated into condensing units and controllers supplied separately for service replacement (when controller is supplied as spare part for service replacement its factory settings are slightly diﬀerent and should be adjusted according to controller unit speciﬁc settings in paragraph 6.12 and application speciﬁc requirements).

32 AB241186442766en-000801

Application Guidelines

Condensing unit controller

6.12 Controller settings

NOTE! In case of controller replacement beware that unit controller settings are diﬀerent from default controller factory settings!

Function Code Min.value Max.value

Normal operation

Set point Tc (regulation reference follows the number of degrees above the outside temperature Tamb)

Regulation Select SI or US display. 0=SI (bar and °C). 1=US (Psig and °F) r05 0/ °C 1/ F 0/ °C Internal Main Switch. Manual and service = - 1, Stop regulation = 0, Start regulation =1 r12 -1 1 0 1 Oﬀset during night operation. During night operation the reference is raised by this

value Set point for suction pressure Ts r23 -25 °C 10°C -7°C Readout of reference for Tc r29 - - Thermostat cut-in value for an external heating element (069=2 and o40=1) r71 -30.0°C 0.0°C -25°C Min. condensing temperature (lowest permitted Tc reference) r82 0°C 40°C 30°C Max. condensing temperature (highest permitted Tc reference) r83 20°C 50°C 40°C Max. discharge gas temperature Td r84 50°C 140°C 12 5°C 125°C Alarms Alarm time delay on signal on the DI2 input A28 0 min. 240 min. 30 min. Alarm for insuﬃcient cooling in condenser. Set temperature diﬀerence. A70 3.0 K 20.0 K 10.0 K Delay time for A70 alarm A71 5 min. 240 min. 30 min. Compressor Min. ON-time c01 1 s 240 s 5 s Min. OFF-time c02 3 s 240 s 12 0 s Min. time between compressor starts c07 0 min. 30 min. 5 min. Pump down limit at which the compressor is stopped (setting 0.0 = function

dis-activated) Min. compressor speed c46 30 rps 70 rps 30 rps Start speed for compressor and min. speed for high condensing temperatures c47 30 rps 70 rps 50 rps Max. compressor speed c48 50 rps 100 rps 10 0 rps Max. compressor speed during night operation (% value of c48) c69 50% 100% 70% Deﬁnition of compressor control:

0: No compressor - Condensing unit OFF 1: Fixed speed - Input DI1 used to start / stop of ﬁxed speed compressor 2: Variable speed - Input DI1 used for start / stop of variable speed-controlled compressor with a 0-10 V signal on AO2

Time delay for high Td. The compressor will stop when time expires c72 0 min. 20 min. 1 min. Max. pressure. Compressor stops if a higher pressure is recorded c73 7.0 bar 31.0 bar 23.0 bar 25.8 Diﬀerence for max. pressure (c73) c74 1.0 bar 10.0 bar 3.0 bar Min. suction pressure Ps. Compressor stops if a lower pressure is recorded c75 -0.3 bar 6.0 bar 1.4 bar 2 Diﬀerence for min. suction pressure and pump down c76 0.1 bar 5.0 bar 0.7 bar Ampliﬁcation factor Kp for compressors PI regulation c82 3.0 30.0 20.0 Integration time Tn for compressors PI regulation c83 30 s 360 s 60 s Liquid Injection Oﬀset c88 0.1 K 20.0 K 5.0 K Liquid Injection hysteresis c89 3.0 K 30.0 K 15.0 K Compressor stop delay after Liquid injection c90 0 s 10 s 3 s Desired compressor speed if the signal from the pressure transmitter Ps fails c93 25 Hz 70 Hz 60 Hz Min On time during Low Ambient LP c94 0 s 120 s 0 s Measured Tc for which the Comp min speed is raised to StartSpeed c95 10.0 °C 70.0°C 50.0°C Control parameters Ampliﬁcation factor Kp for PI regulation n04 1.0 20.0 7. 0 Integration time Tn for PI regulation n05 20 12 0 40 Kp max for PI regulation when the measurement is far from reference n95 5.0 50.0 20.0

--- 2.0 K 20.0 K 8.0 K

r13 0 K 10 K 2 K

C33 0.0 bar 6.0 bar 0.0 bar 2.3

c71 0 2 1 2

Default

controller

settings

Unit

controller

settings

33AB241186442766en-000801

Application Guidelines

Condensing unit controller

Function Code Min.value Max.value

Fan

Readout of fan speed in % F07 - - Permitted change in fan speed (to a lower value) % per second F14 1.0% 5.0% 5.0% Jog speed (speed as a % when the fan is started) F15 10% 100% 40% Jog speed at low temperature F16 0% 40% 10% Deﬁnition of fan control: 0=Oﬀ; 1=Internal control. 2=External speed control F17 0 2 1 Minimum fan speed. Decreased need will stop the fan F18 0% 40% 10% Maximum fan speed F19 40% 100% 100% Manual control of the fan’s speed. (Only when r12 is set to -1) F20 0% 100% 0% Phase compensation (should only be changed by specially trained personnel.) F21 0 50 20

Real time clock

Time at which they switch to day operation t17 0 hrs 23 hrs 0 Time at which they switch to night operation t18 0 hrs 23 hrs 0 Clock - Setting of hours t07 0 hrs 23 hrs 0 Clock - Setting of minute t08 0 min. 59 min. 0 Clock - Setting of date t45 1 day 31 day 1 Clock - Setting of month t46 1 mon. 12 mon. 1 Clock - Setting of year t47 0 year 99 year 0 Miscellaneous Network address o03 0 240 0 On/Oﬀ switch (Service Pin message)

IMPORTANT! o61 must be set prior to o04 (used at LON 485 only)

Access code (access to all settings) o05 0 100 0 Readout of controllers software version o08 Select signal for display view. 1=Suction pressure in degrees, Ts 2=Condensing

pressure in degrees, Ts Pressure transmitter working range Ps - min. value o20 -1 bar 5 bar -1 Pressure transmitter working range Ps- max. value o21 6 bar 200 bar 12 Refrigerant setting:

13=User deﬁned. 19=R404A. 20=R407C 21=R407A. 37=R407F. 40=R448A. 41=R4 49A

Input signal on DI2. Function: 0=not used, 1=External safety function. Regulate when closed, 2=external main switch, 3=Night operation when closed, 4=alarm function when closed, 5=alarm function when open, 6=on/oﬀ Status for monitoring 7=Alarm from speed regulation

Pressure transmitter working range Pc– min. value o47 -1 bar 5 bar 0 bar Pressure transmitter working range Pc – max. value o48 6 bar 200 bar 32 bar Setting of condensing unit type (is factory set when the controller is mounted

and cannot be subsequently changed) The sensor input S3 is to be used to measure the discharge gas temperature

(1=yes) Replace the controllers factory settings with the present settings o67 Oﬀ (0) On (1) Oﬀ (0) Deﬁnes the use of the Taux sensor: 0=not used; 1=measuring of oil

temperature; 2=other optional use Period time for heating element in crankcase (ON + OFF period) P45 30 s 255 s 240 s Diﬀerence for heating elements 100% ON point P46 -20 K -5 K -10 K Diﬀerence for heating elements 100% OFF point P47 5 K 20 K 10 K Read-out of operating time for condenser unit. (Value must be multiplied by

1,000). The value can be adjusted

Read-out of compressor operating time. (Value must be multiplied by 1,000). The value can be adjusted

o04 0/Oﬀ 1/O n 0/Oﬀ

o17 1 2 1

* o30 0 42 0 41

o37 0 7 0

0 3 1

* o61 0 69 0 55 or 56 or 57*

o63 0 1 1

o69 0 3 0

P48 - - 0 h

P49 - - 0 h

Default

controller

settings

Unit controller

settings

34 AB241186442766en-000801

NOTICE

Application Guidelines

Condensing unit controller

Function Code Min.value Max.value

Read-out of operating time of heating element in crankcase. (Value must be multiplied by 1,000). The value can be adjusted

Read-out of number of HP alarms. The value can be adjusted P51 - - 0

Read-out of number of LP alarms. The value can be adjusted P52 - - 0

Read-out of number of Td alarms. The value can be adjusted P53 - - 0

Oil return management. Compressor speed for the counter starting point

Oil return management. Limit value for counter P78 5 min. 720 min. 20 min. Oil return management. Boost-speed P79 40 Rps 100 Rps 50 Rps

Oil return management. Boost-time P80 10 s 600 s 60 s

Service

Readout pressure on Pc u01 bar

Readout temperature Taux u03 °C

Status on DI1 input. 1=on=closed u10

Status on night operation (on or oﬀ) 1=on=night operation u13

Readout superheat u21 K

Readout temperature at S6 sensor u36 °C

Status on DI2 input. 1=on=closed u37

Readout the compressor capacity in % u52 %

Status on relay to compressor. 1=on=closed ** u58

Status on relay to fan. 1=on=closed ** u59

Status on relay to alarm. 1=on=closed ** u62

Status on relay “Aux”. 1=on=closed ** u63

Status on relay to heating element in crank case. 1=on=closed ** u71

Status on high voltage input DI3. 1=on=230 V u87

Readout condensing pressure in temperature U22 °C

Readout pressure Ps U23 bar

Readout suction pressure in temperature U24 °C

Readout ambient temperature Tamb U25 °C

Readout discharge temperature Td U26 °C

Readout suction gas temperature Ts U27 °C

Readout the voltage on the output AO1 U44 V

Readout the voltage on the output AO2 U56 V

P50 - - 0 h

P77 25 rps 70 rps 40 rps

Default

controller

settings

Unit controller

settings

Following controller parameters are modiﬁed from factory setting by condensing unit production. All Other parameters in «unit controller setting» are same as "Default controller setting"

- r12: 1 (main switch = ON).

- c71: 2 (compressor type = variable speed

compressor).

- c73: 25.8 (max. condensing pressure =

25.8bar(g)).

- c75: 2.0 (min. suction pressure = 2.0 bar(g)).

- o30: 41 (refrigerant: 19=R404A, 21=R407A,

37=R407F, 40=R448A, 41=R449A).

- o61: 55, 56 or 57 (compressor size: 55=VLZ028, 56=VLZ035, 57=VLZ044).

Following parameter should be modiﬁed by installer if controller is used as pump down device.

- c33: 2.3 (pump down limit, should be min.

0.3bar higher than c75 to avoid

unwanted alarms). Modiﬁcation of controller parameters shall be done by qualiﬁed persons only.

In case of any problems with controller it is possible to connect unit bypassing it: see details in chapter 4.3.1 of this guideline.

35AB241186442766en-000801

WARNING

CAUTION

WARNING

Application Guidelines

Service and maintenance

7.1 General recommendations

7.2 Condenser

Even if main switch of condensing unit is in position OFF power still available at income terminals of main switch.

In case of any service related to electrical components inside condensing unit it is recommended to disconnect condensing unit from the power by switch located before condensing unit.

It is recommend to check the unit for leakages minimum once a year and in accordance with national requirements.

Condenser should at least once a year be checked for clogging and be cleaned if deemed necessary. Access to internal side of condenser takes place through fan door. Remember to switch oﬀ the unit at main switch before opening the fan door.

In comparison to ﬁn and tube heat exchangers, microchannel coils tend to accumulate more of the dirt on the surface and of the less dirt inside which can make them easier to clean. Step 1: Remove surface debris Remove surface dirt, leaves, ﬁbres, etc. with a vacuum cleaner (preferably with a brush or other soft attachment rather than a metal tube), compressed air blown from the inside out, and/ or a soft bristle (not wire!) brush. Do not impact or scrape the coil with the vacuum tube, air nozzle, etc.

Furthermore following should be checked:

1. Electrical and refrigerant connections for damages, corrosion etc.

2. The mounting devices (bolts, nuts, etc) of the unit.

3. Vibrations: if it is on the same level as after installation or any signs of abnormal vibration.

4. Operation conditions.

5. Airﬂow across the condenser.

6. Oil level.

7. Tightness of electrical connections.

8. Operation of the crankcase and oil separator heaters.

Compressor must always be warmer than any other component in the circuit, even if the circuit is switched oﬀ for seasonal stop.

Step 2: Rinse Do not use any chemicals (including those advertised as coil cleaners) to wash microchannel heat exchangers. They can cause corrosion. Rinse only with water. Hose the MCHE oﬀ gently, preferably from the inside out and top to bottom, running the water through every ﬁn passage until it comes out clean. Microchannels ﬁns are stronger than traditional tube & ﬁn coil ﬁns but still need to be handled with care. Do not bang the hose into the coil. Step 3: Optional blow dry Microchannel heat exchangers, because of their ﬁn geometry, tend to retain water more than traditional ﬁn & tube coils. It may be beneﬁcial to blow or vacuum out the rinse water from your unit to speed drying and prevent pooling.

7.3 Service and safety advice

36 AB241186442766en-000801

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 dryer 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. Beware of hot and cold components in the refrigeration system. The components in the refrigeration system are pressurized; as a consequence special attention has to be paid during operation on these components.

Do not operate condensing unit without refrigerant charge or without being connected to the system.

Safety goggles, gloves, protective clothing, safety boots, hard hats or another safety equipment should be worn when necessary. Never install a system in the ﬁeld and leave it unattended when it has no charge, a holding charge, or with the service valves closed without electrically locking out the system. Do not touch the compressor until it has cooled down. Ensure that other materials in the area of the compressor do not get in touch with it.

Before Starting Repair Work

- Disconnect from mains

- Wait as stated before for discharge of the DC-link. (Refer section 4.5.1 Warning when touching unit when OFF)

- Remove compressor cable.

Application Guidelines

7.4 Access ports

Charging port (suction line) adjustment of refrigerant charge

Service and maintenance

Charging port (liquid line) initial charge (=4kg)

37AB241186442766en-000801

Application Guidelines

Transportation, handling and storage

8.1 Unpacking

8.2 Transportation and handling

8.3 Disposal Instruction

When unit reaches your warehouse, inspect the packing for any visible damage and make sure it is in good condition. In the event you detect any damage, please contact your forwarder

Move the condensing unit only with appropriate mechanical or handling equipment according to weight. 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

Equipment containing electrical components must not be disposed of together with domestic waste. It must be separately collected with electrical and

immediately: send a registered letter to the shipping company claiming the suﬀered damage, a copy of which should be sent responsible contact in Danfoss.

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.

electronic waste according to local and currently valid legislation.

38 AB241186442766en-000801

NOTICE

Application Guidelines

Warranty

9.1 Warranty conditions

9.2 Unauthorized changes

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.

Warranty can also be rejected in case of unauthorized modiﬁcations of the condensing unit:

- Modiﬁcation of electrical box.

- Modiﬁcation of internal piping system of the condensing unit.

• Use in mobile applications.

• Use in explosive atmospheric environment.

• No model number or serial number transmitted with the warranty claim.

Charging of refrigerant or oil not speciﬁed by Danfoss as suitable for the unit will lead to annulment of warranty from Danfoss A/S side (if the refrigerant or oil are not approved in writing by Danfoss). Annulment of warranty from Danfoss side will also take place if the unit is altered without written approval from Danfoss.

Warranty is governed by the Danfoss general terms of warranty.

- Direct changes of drive parameter setting

(all parameter changes should be limited to controller setting changes. No changes allowed on the drive itself).

- Replacement of drive, compressor, fan or other

components on the condensing unit by similar components which are not Danfoss original components or approved by Danfoss.

39AB241186442766en-000801

Application Guidelines

Identiﬁcation

Country

Installation reference (shop name)

City of installation

Installer Company

Unit Co de/ Type

Serial N° of unit

Installation Date

Commission Date

Installation

Refrigerant

Number of evaporators connected to the variable speed condensing unit

Expected maximum Ambient temperature °C

Expected minimum Ambient temperature °C

Evaporators

Evaporator N° 1 2 3 4

Type of application (cold room, cabinet, process cooling, etc.)

Distance to the unit [m]

Vertical position of the unit (+ if above or - if below)

Evaporator Cooling capacity [kW]

Evaporating pressure [bar] / temperature [°C]

Superheat at evaporator outlet [K]

Type of expansion valve used : Thermostatic (TEV) - electronic (EEX)

Compressor

Suction gas temperature [°C] or pressure [bar] at compressor inlet

Frequency observed at stabilised condition

Oil level in oilsightglass after start-up (1/4 - 1/2 - 3/4)

Oil topup [L]

Refrigerant charge [kg]

Electrics & controls

Has the installation a stable power supply

Voltage (between L1/L2/L3) U1: U2: U3:

What's the type of grid (IT, TT, TN)

If system-manager used (AK-SM, AK-SC….), type

Data collected during start up

Kind request to provide after start-up completed copy of this page to your wholesaler of purchase, as part of warranty modalities.

40 AB241186442766en-000801

Danfoss Commercial Compressors

Danfoss Inverter Scrolls

is a worldwide manufacturer of compressors and condensing units for refrigeration and HVAC applications. With a wide range of high quality and innovative products we help your company to find the best possible energy efficient solution that respects the environment and reduces total life cycle costs.

We have 40 years of experience within the development of hermetic compressors which has brought us amongst the global leaders in our business, and positioned us as distinct variable speed technology specialists. Today we operate from engineering and manufacturing facilities spanning across three continents.

Danfoss Turbocor Compressors

Danfoss Scrolls

Danfoss Optyma Condensing Units

Danfoss Maneurop Reciprocating Compressors

Danfoss Light Commercial Refrigeration

Compressors

Our products can be found in a variety of applications such as rooftops, chillers, residential air conditioners, heatpumps, coldrooms, supermarkets, milk tank cooling and industrial cooling processes.

AB241186442766en-000801

Danfoss Optyma Plus INVERTER Application guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Important information/Safety

Product description

2.4 Label

2.7 Spare part codes

2.9 Layout

Application range

3.3 Application envelopes

3.4 Ambient conditions

Installation

4.2 Electrical connection

4.3 Wiring diagrams

4.5 EMC compliance

4.6 Phase sequence

4.7 Brazed connections

System design recommendations

5.2 Evacuation

5.3 Refrigerant charge

5.4 Oil level

5.5 Check before start

5.6 Startup of the unit

5.7 Check after start

Condensing unit controller

6.10 Pump down limit

6.11 Data communication

6.12 Controller settings

Service and maintenance

7.4 Access ports

Transportation, handling and storage

Warranty

Data collected during start up