Danfoss Optyma OP-FPZP Instructions Manual page 3

Instructions
1 – Introduction
These instructions pertain to Optyma™ INVERTER
condensing units OP-FPZP (R507A, R404A) used
for refrigeration systems. They provide necessary
information regarding safety and proper usage of
this product.
The condensing unit includes following:
• Reciprocating compressor
• Microchannel heat exchanger
• Adjustable low- and High-Pressure switch
• Frequency INVERTER for Danfoss compressor
• Rotolock Valve Suction / Discharge
• Service valves Suction/ liquid
• Oil Separator
• EC Fan motor
• Weather proof housing
• Filter drier
• Cranckcase heater for compressor
• Receiver with stop valve
• Sight glass
• Fully pre-wired electrical panel (Contactor)
2 – Handling and storage
• It is recommended not to open the packaging before
the unit is at the nal place for installation.
• Handle the unit with care. The packaging allows for
the use of a forklift or pallet jack. Use 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
Do not braze as long the condensing
unit is under pressure.
Never place the unit in a
atmosphere
Place the unit in such a way that it is not
blocking or hindering walking areas, doors,
windows or similar.
• Ensure adequate space around the unit for air
circulation and to open doors. Refer to picture1 for
minimal values of distance to walls.
• Avoid installing the unit in 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 o -cycle.
• Ensure that the power supply corresponds to the
unit characteristics (see nameplate).
• When installing units for HFC refrigerants, use
equipment speci cally reserved for HFC refrigerants
which was never used for CFC or HCFC refrigerants.
• Use clean and dehydrated refrigeration-grade
copper tubes and silver alloy brazing material.
• Use clean and dehydrated system components.
• The suction piping connected to the condensing
unit must be exible in 3 dimensions to dampen
vibrations. Furthermore piping has to be done
in such a way that oil return for the compressor
is ensured and the risk of liquid slug over in
compressor is eliminated.
4 – Installation
• The unit must be securely installed on a stable and
rigid support, and xed from the beginning. See
picture 2.
• It is recommended to install the unit on rubber
grommets or vibration dampers (not supplied).
• Slowly release the nitrogen holding charge through
© Danfoss | Climate Solutions | 2023.11
the schrader port.
• Connect the unit to the system as soon as possible
to avoid oil contamination from ambient moisture.
• Avoid material entering into the system while
cutting tubes. Never drill holes where burrs cannot
be removed.
• Braze with great care using state-of-the-art technique
and vent piping with nitrogen gas ow.
• Connect the required safety and control devices.
When the schrader port is used for this, remove the
internal valve.
• It is recommended to insulate the suction pipe up
to the compressor inlet minimum of 19 mm thick
insulation.
5 – Leak detection
Never pressurize the circuit with
oxygen or dry air. This could cause re
or explosion.
• Do not use dye for leak detection.
• Perform a leak detection test on the complete
system.
• The maximum test pressure is 32 bar.
• When a leak is discovered, repair the leak and
repeat the leak detection.
6 – Vacuum dehydration
• Never use the compressor to evacuate the system.
• Connect a vacuum pump to both the LP & HP sides.
• Pull down the system under a minimum vacuum
value of 500 m Hg (0.67 mbar) absolute.
• Do not use a megohmmeter nor apply power to the
compressor while it is under vacuum as this may
cause internal damage.
7 – Electrical connections
• Switch o and isolate the main power supply.
ammable
• Ensure that power supply can not be switched on
during installation.
• All electrical components must be selected as per
local standards and unit requirements.
• Refer to wiring diagram for electrical connections
details.
• Ensure that the power supply corresponds to the
unit characteristics and that the power supply
is stable (nominal voltage ±10% and nominal
frequency ±2,5 Hz).
• Dimension the power supply cables according to
unit data for voltage and current.
• Protect the power supply and ensure correct
earthing.
• Make the power supply according to local standards
and legal requirements.
• The unit is equipped with high and low pressure
switches, which directly cut the power supply to the
compressor in case of activation. Parameters for high
and low pressure cut outs should be set by installer
considering compressor model, refrigerant and
application.
8 – Filling the system
• Wear protective stu like goggles and protective
gloves.
• Never start the compressor under vacuum. Keep
the compressor switched o .
• Before charging the refrigerant, verify that the oil
level is between ¼ and ¾ on the compressor oil sight
glass. If additional oil is required please refer to the
compressors label for type of oil.
• Use only the refrigerant for which the unit is
designed for.
• Fill the refrigerant in liquid phase into the
condenser or liquid receiver. Ensure a total System
Charge must not exceed 9,0 kg due pump down
capacity of the system.
• The system is designed to guarantee 40 meters
line distance for a maximum sum of evaporator
volume of 16.5 liters at evaporating temperature =
5°C. Maximum sum of evaporator internal volume
should not exceed 25 liters.
• Do not put liquid refrigerant through suction line.
• It is not allowed to mix additives with the oil and/or
refrigerant
• The remaining charge is done until the installation
has reached a level of stable nominal condition
during operation.
• Never leave the lling cylinder connected to the
circuit.
9 – Verification before commissioning
Use safety devices such as safety
pressure switch and mechanical relief
valve in compliance with both generally
and locally applicable regulations and
safety standards. Ensure that they are
operational and properly set.
Check that the settings of high-pressure
switches and relief valves don't exceed
the maximum service pressure of any
system component.
• Verify that all electrical connections are properly fastened
and in compliance with local regulations.
• The condensing unit must be energized at least
12 hours before initial start-up and start-up after
prolonged shut-down period.
10 – Start-up
• Never start the unit when no refrigerant is charged.
• All service valves must be in the open position.See
picture 3.
• Check compliance between unit and power supply.
• Check that the crankcase heater is working and was
initiated 12 hours before.
• Check that the fan can rotate freely.
• Check that the cardboard protection sheet has
been removed from the backside of condenser.
• Respect the operating limits, high pressure can not
be higher than 7 bar at a temperature of 5ºC and
low pressure can not be lower than of 2 bar at a
temperature of -30ºC
• Turn on the unit by connecting the cables coming
from the electrical panel (customer) to the available
connectors, turn the main switch from the OFF (0)
position to the ON (1) position. Its operation should
start immediately. If not, follow the steps below:
11 – Check with running unit
• Check the fan rotation direction. Air must ow from
the condenser towards the fan.
• Check current draw and voltage.
• Check suction superheat to reduce risk of slugging.
• When a sight glass is provided observe the oil level
at start and during operation to con rm that the oil
level remains visible.
• Respect the operational limits demonstrated in the
envelopes of the condensing unit in Range (T. Evap:
-30ºC to 5 ° C T. AMB: 10 ° C to 43 ° C)
• 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 away as
possible from the compressor. The compressor must
be operating during this process.
• Do not overcharge the system.
• Never release refrigerant to atmosphere.
• Before leaving the installation site, carry out
a general installation inspection
cleanliness, noise and leak detection.
• Record type and amount of refrigerant charge
as well as operating conditions as a reference for
future inspections.
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