Danfoss OP-HJM064D20Q Optyma Condensing Unit Instructions

: June 12, 2024
: Danfoss

OP-HJM064D20Q Optyma Condensing Unit

Instructions

Condensing Unit
Optyma™

A: Model
B: Code number
C: Serial number and bar code
D: Compressor data
E: Fan Motor information
F: Maximum applied current
G: Test conditions
H: Refrigerant Fluid
I: Lubricating oil
J: Electrical diagram

Figure 1: Minimum mounting distances

Recommended dimensions

Condensing units must only be
installed and serviced by qualified
personnel. Follow these instructions
and best refrigeration practices for assembly,
commissioning, maintenance, and servicing

Each condensing unit includes the following
components, depending on the version ordered

|

D20

|

D39

|

D49

---|---|---|---

Hermetic reciprocating compressor

|

X

|

X

|

X

Liquid receiver

|

X

|

X

|

X

Filter drier

|

X

|

X

|

X

Sight glass

|

X

|

X

|

X

Low pressure switch – Danfoss KP1

|

X

|

X

|

X

High pressure switch

– Cartridge design

|

X

|

X

|

X

Oil separator

|

X

Suction accumulator

|

X

Crankcase heater

|

X

|

X

|

X

Rotolock valve for suction

and discharge

|

X

|

X

|

X

Terminals and electrical connectors

|

X

|

Electrical distribution box

with circuit breaker, contactor, and phase failure relay

|

X

|

X

Important:

The condensing unit must only be used for its intended purpose(s) and within its scope of application.
In any case, the requirements of EN378 (or other applicable local safety standards) apply.
The condensing unit is delivered under nitrogen gas pressure (1 bar) and as such cannot be connected as is. See section “Assembly” for more information.
The condensing unit must be handled carefully in upright position (maximum offset from vertical: 15°).
Caution! During operation, the unit piping, oil separator, and condenser become hot, which can cause burns upon contact with skin.
Only authorized personnel are permitted to access the electrical distribution box on condensing units.

1 – Introduction

These instructions refer to Optyma™ condensing
units used in refrigeration systems for applications
with refrigerants R448A, R449A, R452A, R513A,
R22, R134a, R404A, and R507. Furthermore, these
instructions provide necessary information on
safety and the correct use of this product.

2 – Handling and storage

We recommend not opening the packaging
until bringing it to the intended installation
location.
Handle the unit with care. The packaging is
suitable for use with forklifts and loading skids.
Use safe, suitable lifting equipment.
Store and transport the unit in an upright
position.
Store the unit at a temperature between -35°C
and 50°C.
Do not expose the packaging to rain or a
corrosive atmosphere.
After unpacking, check that all unit components
are present and undamaged.

3 – Safety measures before assembly

Do not weld condensing unit while it is
pressurized.
Never install the unit in combustible
atmospheres.
When installing the unit, make sure that
it is not blocking or obstructing aisles, doors,
windows, and the like.

Ensure that there is sufficient space around the
unit for proper air circulation and for opening
the doors. See Figure 1 for the minimum
distance values to walls.
Avoid installing the unit in areas exposed to
direct sunlight over long periods.
Avoid installing the unit in extreme
environments or in areas with excessive dust.
Make sure to install the unit on a horizontal
surface (incline of less than 3°) that is firm and
stable enough to support the full weight of the
unit and to eliminate vibration and interference.
The ambient temperature at the location where
the unit is installed must not exceed 50°C when
the unit is switched off or at rest.
Make sure that the power supply matches the
electrical specifications of the unit (see label).
When installing units for use with HFC
refrigerants, use equipment exclusive to them
that has never been used for CFC or HCFC
refrigerants.
Use clean, moisture-free copper pipes specific
for cooling and silver alloy brazing material.
Use clean, moisture-free system components.
The pipes connected to the compressor must
be flexible in three dimensions to cushion
vibration. In addition, they must be arranged
so as to ensure that oil is routed back properly
to the compressor as well as to eliminate the
risk of liquid hammering in the compressor.

4 – Assembly

The unit must be installed and secured on a
firm, stable base.
The unit must be installed on rubber wedges
or vibration dampers (not supplied).
Gradually release the nitrogen from the
compressor through the Schrader valve on
the compressor.
Connect the unit to the system as soon as
possible to avoid contamination of the oil
charge due to ambient humidity.
When cutting piping, make sure that no residue
material is able to get into the system. Never
drill holes in locations that cannot be deburred.
Weld with extreme care, following proper
practices for chilling and circulation with
flowing nitrogen gas.
Connect the necessary safety and control
devices. If the Schrader valve is used for these
purposes, remove its core if the device does not
have a baffle pin.
We recommend thermally insulating the
suction line up to the compressor inlet.

5 – Leak detection

Never pressurize the circuit with oxygen or dry
air. This can cause a fire or explosion.
• Do not use dye for leak detection.
• Perform a leak test on the entire system.
• The maximum test pressure should not exceed
32 bar (464 psi).
• Repair any leaks, then repeat the leak test on
the entire circuit.

6 – Dehumidification via vacuum

Never use the compressor to generate vaccum
for the system.
Connect a vacuum pump to both the LP and
HP sides.
Generate a stable vacuum of 500 μm Hg
(0.67 mbar).
Do not use a megohmmeter or start the
compressor while it is under vacuum as this
may cause internal damage.

7 – Electrical connections

Disconnect and isolate the main power supply
before connecting any devices.
Secure the power outlet to prevent accidental
connection during installation.
All electrical components must be selected in
accordance with compressor requirements as
well as with local rules and regulations.
Refer to the wiring diagram for more
information on electrical connections.
Make sure that the power supply matches the
unit’s specifications and that the power supply
is stable (nominal voltage ±10% and nominal
frequency ±2.5 Hz).
Dimension supply cables according to the
unit’s current and voltage specifications.
Ensure that power is being supplied and that
the unit is properly grounded.
Install the power outlet in accordance with
local rules and regulations.
The unit is equipped with high and low pressure
switches that immediately cut power to the
compressor when triggered. The high and
low pressure cut-out values are preset on the
pressure switches, according to the compressor
installed in the unit.

8 – Refrigerant charge in system

Use personal protective equipment (PPE),
such as safety goggles and gloves.
Never start the compressor while it is under
vacuum. Keep the compressor switched off.
Before charging the system with refrigerant,
verify that the oil level is between ¼ and ¾
using the compressor oil sight glass. If more oil
is needed, refer to the compressor label for the
correct oil type.
Use only the refrigerant for which the unit is
designed.
Fill refrigerant in liquid state through the
condenser or liquid reservoir. Make sure to
slowly charge the system to between 4 and
5 bar for R404A/R507A/R448A/R449A/R452A/
R513A or R22, and to approx. 2 bar for R134a.
Do not charge refrigerant liquid through the
suction line.
Do not mix oil or coolant with additives.
The remaining charge must be supplied until
the system has reached a level where nominal
conditions are stable during operation.
Never leave the charging cylinder connected to
the circuit.

9 – Checking before commissioning

If necessary, use safety devices, such as
pressure switches or pressure relief valves, in
accordance with local legislation and safety
regulations. Make sure to select proper, well regulated
safety devices that function normally.
Make sure that the settings of the high pressure
switches and pressure relief valves do
not exceed the maximum operating pressure
of any system component.

Make sure that all electrical connections are
tight and compliant with local codes.
The crankcase heater must be turned on at
least 12 hours before initial commissioning and
after long periods of downtime.

10 – Commissioning

Never start the unit unless the refrigerant liquid
has been charged.
All service valves must be in the open position.
Make sure that the unit’s voltage and frequency
match those of the power supply.
Check that the crankcase heater is working
properly.
Check that the fan can rotate freely.
Equalize the high and low pressure sides.
Turn on the unit. It should start immediately.
If not, check the wiring, connections, and
terminals.

11 – General function checks for compressor

Check the rotation direction of the fan. Air must
be able to flow from the condenser to the fan.
Check the power consumption and voltage.
Check for suction overheating to reduce the
risk of water hammering.
Note the oil level at start-up and during
operation, making sure that the oil level gauge
remains visible.
Do not exceed operating limits.
Check for abnormal vibration. Vibrations
greater than 1.5 mm in amplitude require
corrective measures, such as pipe clamps.
Where necessary, a complementary charge
of refrigerant can be added on the low pressure
side, as far away as possible from the
compressor suction, which must be operating
throughout the entire process.
Do not overcharge the system with refrigerant.
Never release refrigerant into the atmosphere.
Before leaving, conduct a general inspection
of the installation site, making sure it is clean
and that there are no noise or leaks.
Note down the type and amount of refrigerant
charge as well as operating conditions to serve
as reference for future inspections.

12 – Maintenance

Always switch off the unit using the main
switch before handling the fan.
Both the internal pressure and the surface
temperature are hazardous and can cause
permanent injury. Maintenance technicians and
installers must have the necessary skills and
tools. The temperature of the pipes can exceed
100°C, which may cause severe burns.
To ensure system reliability, make sure that
periodic maintenance inspections are performed
in accordance with local regulations.
The following periodic maintenance is
recommended to avoid system-related problems:

Check that safety devices are adjusted correctly
and working properly.
Ensure that the system is leak-tight.
Check the electrical current to the compressor.
Confirm that the system functions in a manner
consistent with the maintenance records and
preceding conditions.
Check that all electrical connections are tight.
Keep the unit clean and check for rust on
components, pipes, and electrical connections.

The condenser should be checked for soiling
at least once a year and cleaned whenever
necessary. The microchannel condenser tends
to collect dirt on the surface and not inside,
making it easier to clean compared to finned
tube condensers.

Turn off the unit using the main circuit breaker
before removing any parts of the condensing
unit.
Remove dirt, leaves, fibers, etc.
from the surface using a vacuum cleaner
equipped with a brush or similar accessory.
Alternatively, you can use compressed air to
blow out the condenser, from inside to outside,
then use a soft brush to brush off the condenser.
Do not use a wire brush. Do not rub or scratch
the condenser with the suction hose or nozzle.

If the system has been opened, add nitrogen
to remove moisture, then install a new filter
drier. If it is necessary to put the system under
vacuum, this must be done in such a way that
no refrigerant escapes into the environment.

13 – Warranty

When making a warranty claim, always state
the model and serial number of the product. The
product warranty may be voided in the following
cases:

Missing label bearing the product’s serial
number and model.
External modifications, e.g., drilling, welding,
broken anchors, and impact marks.
Compressor unit opened or returned with seal
broken.
Oxidation, water, leak detection dye, or other
foreign material inside the compressor.
Use of a refrigerant or lubricating oil not
approved by Danfoss.
Failure to follow recommendations for
installation, maintenance, and operation of
the unit.
Use in mobile applications.
Use in hazardous areas (explosive atmospheres).
There is no model or serial number on the
warranty claim.
Check the local warranty policy for additional
conditions.

14 – Disposal of waste

Danfoss recommends having the
compressor oil, as well as the parts and
components of the condensing unit,
recycled by specialized recycling
companies at their own facilities.

Instructions

15 – Diagramas GA

diagram

Version

version

Instructions

Version (2 Fans)

airflow

Version (2 Fans)

fan

16 – Wiring Diagram

Electrical code G – 230V / 1F / 50Hz

electro code

Electrical code E – 400V / 3F / 50Hz

code

Electrical code N – 230 V / 1F / 60 Hz

electro

Electrical code Q – 230 V / 3F / 60 Hz

electro guide

Electrical code V – 380 V / 3F / 60 Hz

guide electro

Acronyms

|

Legend / Leyenda / Legenda

---|---
English
(#)| (#)| Identification ring
K| K| Contactor
CB| DJ| Circuit breaker
PFR| SFF| Phase failure relay
PE| PE| Electrical protection
PS| CH|

Power switch (ON/OFF)

CP| CP| Compressor
CH| RC| Crankcase heater
HP| PH|

High pressure switch

LP| PL| Low pressure switch
RC| CR| Run capacitor
SC| CS| Start capacitor
RL| RL| Start relay
FC| CV| Fan capacitor
F1-F2| V-V1-V2| Fan motor

Components not available for D20 version.

Acronyms

| Cable ID
---|---
English
BK| PT| Black
WH| BC| White
BR| MR| Brown
RD| VR| Red
GR| VD| Green
BU| AZ| Blue

Danfoss A/S
Climate Solutions + danfoss.us « +1 888 326 3677 – heating.cs.na@danfoss.com

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