Danfoss Optyma Integral Series Instructions Manual page 6

Instructions
Contents
1 - Introduction
2 - Transportation, storage
3 - Safety measures prior to assembly
4 - Assembly
5 - Leak detection
6 - Vacuum dehydration procedure
7 - Electrical connections
8 - Filling the system
9 - Verification before commissioning
10 - Start up
11 - Troubleshooting
12 - Maintenance
13 - Replacement
14 - User advisory
15 - Declaration of incorporation
16 - Disposal
1 - Introduction
These instructions pertain to Optyma™ Blue
condensing units used for refrigeration purposes.
They are intended to provide necessary informa-
tion regarding safety features and proper handling
of this product.
Condensing units are delivered un-
der nitrogen gas pressure (between
1 and 2 bar) and hence cannot be
connected as it is; please refer to
the «Assembly» section for further
details.
Condensing units are not certified
for mobile and explosion-proof ap-
plications. Any use of flammable re-
frigerant (e.g. hydrocarbons) or air is
also strictly forbidden
Under all circumstances, the EN 378-
2:2016 (or other applicable local regula-
tion) requirement must be fulfilled.
When pressure tests are required
on the system, they are to be per-
formed by qualified personnel, in
paying close attention to potential
pressure-related hazards and hee-
ding the pressure limits displayed
on the compressor nameplate or in
the application guidelines.
Modifications or alterations to the
compressor or receiver (such as
brazing on the shell) not expressly
approved by the party responsible
for ensuring compliance could in-
validate the user's authorization to
operate the equipment.
Note that this is a general document for the en-
tire range of condensing units; certain details
therefore may not be applicable to the particular
model you purchased. Please keep your manual
and all relevant information handy for future re-
ference.
• Equipment description: condensing units are
available under different configurations. They
incorporate a compressor and a fan-cooled
condenser mounted on a base frame. In addi-
tion, they may include a liquid receiver, a pres-
sure switch, Filter drier, Sight Glass, Contactor,
Overload Relay a connecting box and service
valves.
• Approved list of refrigerants:
- The MCRN and MGRN product line (fitted
with Maneurop® MTZ compressors) can be
used with R404A, R507, R134a/R513A, R407C,
R407A, R452A, R448A, R449A.
6 | AN368656896297en-AU0102-118U5272
- The LCQN and LGQN product line (fitted with
Maneurop® NTZ compressors) can be used
with R404A, R452A and R507A.
• Note that Maneurop® compressors are filled
with lubricant before leaving the factory:
- The MTZ series with polyolester oil (ref. 175PZ),
- The NTZ series with polyolester oil (ref. 175Z).
These lubricants must not be mixed with one another.
• Condensing units must only be used for their
designed purpose(s) and within their scope of
application (refer to Fig. 1a,1b).
2 - Transportation, storage
• The condensing unit must be handled in the
vertical position (maximum offset from the
vertical: 15°). Should the unit be handled in an
upside-down position, its performance may
no longer be insured.
• Beware that all condensing unit handling
must be carried out with extreme caution to
avoid any shocks. Appropriate and safe lifting
equipment is to be used during handling and
unpacking. Be careful with the condenser's
front surface (note that the condenser side is
indicated on the packaging).
• Any damage noticed on either the packaging
or the product itself upon reception should be
indicated on a Customer Claim addressed to
the shipping company. The same recommen-
dation applies to all instances when transport
instructions have not been fully respected.
• Please review the safety instructions printed
on the cardboard packaging before storage.
• Verify that the condensing unit is never stored
in an ambient temperature of below -35°C
(-31°F) or above 50°C (122°F).
• Ensure that the condensing unit and its pac-
kaging are not exposed to rain and/or a corro-
sive, flammable atmosphere.
3 - Safety measures prior to assembly
When installing a liquid receiver or
any other pressure-containing com-
ponent on the condensing unit, be
sure that these components comply
with the PED 2014/68/EU.
Make sure this new installation is
equipped with high-pressure safety
components (e.g. pressure switch,
pressure relief valve) to prevent against
the bursting of pressure-containing
components.
• All installation and servicing is to be performed
by qualified personnel in compliance with all
pertinent practices and safety procedures.
• The condensing unit must be located in a
well-ventilated area; air flow through unit shall
not be restricted in any way (refer to Fig.2).
Make sure that the ambient temperature ne-
ver exceeds 50°C (122°F) during the off-cycle.
• For outdoor installations, provide a shelter or
use a Danfoss condensing unit housing.
• Make certain that the condensing unit can be
mounted onto a horizontal plane with a maxi-
mum slope of 3°.
• Check that the condensing unit model corres-
ponds to system specifications (capacity, use
of refrigerant, etc.).
• Verify that the power supply corresponds to
compressor and fan motor characteristics (re-
fer to the condensing unit nameplate for pre-
cision).
• Ensure that the refrigerant charging equip-
ment, vacuum pumps, etc. for HFC refrigerant
systems have been specifically reserved for
these refrigerants and never used with other
CFC, HCFC refrigerants.
• Use only clean and dehydrated refrigera-
tiongrade copper tubes as well as silver alloy
brazing material.
• Verify that all system components are ap-
propriate (use of refrigerant, etc.), clean and
dehydrated before being connected to the
completed assembly. Perform a check on the
suction lines: horizontal sections are to be
sloped downwards towards the compressor.
Suction gas velocity must be high enough to
provide for an adequate oil return.This velocity
must be within 8 to 12 m/s in vertical risers. In
horizontal pipes, this velocity can decrease to
4 m/s. The use of U-trap and double-suction
risers may be required on vertical sections, but
not in excess of 4 m unless a second U-trap sys-
tem has been fitted (refer to Fig. 3). Suction line
piping must be insulated in order to minimize
the effects of high superheating.
• The piping connected to the compressor must
be configured on the basis of a flexible 3-axis
design to dampen vibrations and designed in
such a way as to prevent free liquid refrigerant
migration and drainage back to the compres-
sor sump.
• Note that all local and regional regulations
and safety standards, such as EN 378-2:2016,
must be taken into account when designing,
connecting and running the system.
4 - Assembly
The condensing unit's time of expo-
sure to the atmosphere during ins-
tallation shall be held to a minimum.
The condensing unit is fitted with
suction and liquid copper stubs
equipped with Rotolock Valves to
enable connection to the circuit
without ingress of air or moisture in
the unit.
Opening the Rotolock Valves be-
fore connection will cause moisture
contamination of the compressor
lubricant.
Before opening the compressor
connection fittings, it is mandatory
to connect a 1/4" service hose to the
Schrader fitting on the compressor
shell in order to gradually release
the nitrogen holding charge.
• Silent block must be installed under the
condensing unit base frame, as shown in Fig
4, to prevent vibration interference from other
operating equipment or machinery and to re-
duce vibration transmission to the supporting
structure.
• Ensure that no material enters into the system
while cutting the tubing. Moreover, never drill
holes in the pipe work after installation.
• Avoid flare-type connections and exercise
great care while brazing (use only state-of-
the-art practices); apply a nitrogen gas flow to
prevent oxidation inside the tubing, especially
when HFC refrigerants are being used. All bra-
zing material is to contain a minimum of 5%
silver.
• When brazing, protect the valves and all other
unit components from torch heat damage
(painted surfaces, gaskets, connecting box).
Danfoss | Climate Solutions (CU) | 2022.07