Danfoss OP-FPZP Optyma condensing Inverter Instruction Manual

OP-FPZP Optyma condensing
Inverter Instruction Manual

OP-FPZP Optyma condensing Inverter

Instructions

Optyma™  INVERTER OP-FPZP

A: Model
B :Code number
C: Serial Number and bar code
D : Supply voltage, Locked Rotor Ampere
E : Housing Service Pressure
F: Refrigerant
G :Oil

Picture 1 : Minimum mounting distances

Installation and servicing of the condensing units by qualified personnel only. Follow these instructions and sound refrigeration engineering practice relating to installation, commissioning, maintenance and service.
The condensing unit must only be used for its designed purpose(s) and within its scope of application.
Under all circumstances, the EN378 (or other applicable local safety regulation) requirements must be fulfilled.
The condensing unit is delivered under nitrogen gas pressure (1 bar) and hence it cannot be connected as it is; refer to the «installation» section for further details.
The condensing unit must be handled with caution in the vertical position (maximum offset from the vertical : 15°)

Danfoss Optyma™ INVERTER can work with more than one cold room, once these conditions are met:

• If the chambers have different operating setpoints (different evaporation temperatures, such as, for example, a cooling chamber and a freezing chamber), it is mandatory to use a KVP valve according to the diagram below. In case of any doubts please refer to KVP application guide available in Danfoss Product Store.
• The maximum value of the sum of the volumes of the evaporators operating with the same INVERTER condensing unit must not exceed 25 liters, to obtain the maximum cooling capacity mentioned in the catalogue.
• Total refrigerant charge must not exceed 9.0 kg due to system pump down. The unit was designed to guarantee 40 meters of line for a total evaporator volume of 16.5 liters when operating at a maximum evaporation temperature of 5°C.
• To obtain the maximum performance of the unit in relation to energy consumption, it is recommended to use electronic expansion valves in the refrigeration system.

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)

Handling and storage

• It is recommended not to open the packaging before the unit is at the final place for installation.
• Handle the unit with care. The packaging allows for the use of a forklift or pallet jack. Use appropriate and safe lifting equipment.
• Store and transport the unit in an upright position.
• Store the unit between -35°C and 50°C.
• Don’t expose the packaging to rain or corrosive atmosphere.
• After unpacking, check that the unit is complete and undamaged.

Installation precautions

| Do not braze as long the condensing unit is under pressure.
---|---
Never place the unit in a flammable atmosphere
Place the unit in such a way that it is not blocking or hindering walking areas, doors, windows or similar.

• Ensure adequate space around the unit for air circulation and to open doors. Refer to 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 off-cycle.
• Ensure that the power supply corresponds to the unit characteristics (see nameplate).
• When installing units for HFC refrigerants, use equipment specifically reserved for HFC refrigerants which was never used for CFC or HCFC refrigerants.
• Use clean and dehydrated refrigeration-grade copper tubes and silver alloy brazing material.
• Use clean and dehydrated system components.
•  The suction piping connected to the condensing unit must be flexible in 3 dimensions to dampen vibrations. Furthermore piping has to be done in such a way that oil return for the compressor is ensured and the risk of liquid slug over in compressor is eliminated.

Installation

• The unit must be securely installed on a stable and rigid support, and fixed 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 the schrader port.
• Connect the unit to the system as soon as possible to avoid oil contamination from ambient moisture.
• Avoid material entering into the system while cutting tubes. Never drill holes where burrs cannot be removed.
• Braze with great care using state-of-the-art technique and vent piping with nitrogen gas flow.
• Connect the required safety and control devices. When the schrader port is used for this, remove the internal valve.
• It is recommended to insulate the suction pipe up to the compressor inlet minimum of 19 mm thick insulation.

Leak detection

Never pressurize the circuit with oxygen or dry air. This could cause fire or explosion.

• Do not use dye for leak detection.
• Perform a leak detection test on the complete system.
• The maximum test pressure is 32 bar.
• When a leak is discovered, repair the leak and repeat the leak detection.

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 μm Hg (0.67 mbar) absolute.
• Do not use a megohmmeter nor apply power to the compressor while it is under vacuum as this may cause internal damage.

Electrical connections

• Switch off and isolate the main power supply.
• Ensure that power supply can not be switched on during installation.
• All electrical components must be selected as per local standards and unit requirements.
• Refer to wiring diagram for electrical connections details.
• Ensure that the power supply corresponds to the unit characteristics and that the power supply is stable (nominal voltage ±10% and nominal frequency ±2,5 Hz).
• Dimension the power supply cables according to unit data for voltage and current.
• Protect the power supply and ensure correct earthing.
• Make the power supply according to local standards and legal requirements.
• The unit is equipped with 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.

Filling the system

• Wear protective stuff like goggles and protective gloves.
• Never start the compressor under vacuum. Keep the compressor switched off.
• 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 filling cylinder connected to the circuit.

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.

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:

Check with running unit

• Check the fan rotation direction. Air must flow from the condenser towards the fan.
• Check current draw and voltage.
• Check suction superheat to reduce risk of slugging.
• When a sight glass is provided observe the oil level at start and during operation to confirm that the oil level remains visible.
• Respect the 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 regarding cleanliness, noise and leak detection.
• Record type and amount of refrigerant charge as well as operating conditions as a reference for future inspections.

Maintenance

Always switch off the unit at main switch before remove fan panel.
Internal pressure and surface temperature are dangerous and may cause permanent injury.
Maintenance operators and installers require appropriate skills and tools.
Tubing temperature may exceed 100°C and can cause severe burns.
Ensure that periodic service inspections to ensure system reliability and as required by local regulations are performed.

To prevent system related problems, following Periodic maintenance is recommended:

• Verify that safety devices are operational and
  properly set.

• Ensure that the system is leak tight.

• Check the compressor current draw.

• Confirm that the system is operating in a way consistent with previous maintenance records and ambient conditions.

• Check that all electrical connections are still adequately fastened.

• Keep the unit clean and verify the absence of rust and oxidation on the unit components, tubes and electrical connections. Check the level and color of the oil to see if it is clean and sufficient to turn on the compressor, indicated level 3/4 of the total capacity.

The condenser must be checked at least once a year for clogging and be cleaned if deemed necessary. Access to the internal side of the condenser takes place through the fan panel. Microchannel coils tend to accumulate dirt on the surface rather than inside,  which makes them easier to clean than fin-&-tube coils.

• Switch off the unit at main switch before remove any panel from the condensing unit.
• Remove surface dirt, leaves, fibres, etc. with a vacuum cleaner, equipped with a brush or other soft attachment. Alternatively, blow compressed air through the coil from the inside out, and brush with a soft bristle. Do not use a wire brush. Do not impact or scrape the coil with the vacuum tube or air nozzle. Do not use high pressure washer.

If the refrigerant system has been opened, the system has to be flushed with dry air or nitrogen to remove moisture and a new filter drier has to be installed. If evacuation of refrigerant must be done, it shall be done in such a way that no refrigerant can escape to the environment.

Warranty

Always transmit the model number and serial number with any claim filed regarding this product.
The product warranty may be void in following cases:

• Absence of nameplate.
• External modifications; in particular, drilling, welding, broken feet and shock marks.
• Compressor opened or returned without seal of warranty or seal violated.
• Rust, water or leak detection dye inside the compressor or any other fluid different of recommended.
• Use of a refrigerant or lubricant not approved by Danfoss.
• Any deviation from recommended instructions pertaining to installation, application or maintenance.
• Use in mobile applications.
• Use in explosive atmospheric environment.
• No model number or serial number transmitted with the warranty claim.

Delivery

When the condensing unit is hoisted with ropes for delivery, take care to maintain the center of gravity. It could drop off if the stability is lost.

• Determine the delivery route and deliver unit to the installation place without removing packing. When hoisting the unit, use a pair of ropes and cushioning material to protect sections chafed by ropes.

Centre of Gravity

Weight (kg)| 170
X (mm)| 606
Y (mm)| 267
Z (mm)| 891

Centre of Gravity

Weight (kg)| 150
X (mm)| 585
Y (mm)| 215
Z (mm)| 740

Disposal

Danfoss recommends that condensing units and oil should be recycled by a suitable company at its site.

Frequency by-pass

If it is necessary to change the inverter, parameterize 4 frequency ranges in order to avoid resonance in the piping system in the specified range, according to the procedure below:

1. Access Main Meu of your INVERTER display available on the electrical box (image 1 and image 2). Then select Limits / Warnings (image 3).

2. Using the arrow – select 4-6 Speed Bypass and click “OK” button – display will appear as image below (image 1). You have the possibility to skip 04 independent frequency path [0], [1], [2] and [3].

3. Click “OK” to define the first frequency range on the first available path [0]. With the arrow adjust frequency from: 30 Hz; Press button “Back” and then press the arrow to scroll down the cursor and you will be able to adjust frequency to: 33 Hz.

4. Make the same procedure to:
   [1]: from 36Hz (2160rpm) to 39Hz (2340rpm).
   [2]: from 51Hz (3060rpm) to 55Hz (3300rpm).
   [3]: from 75Hz (4500rpm) to 77Hz (4620rpm).

Crankcase resistance connection.
When machine is energized, the Carter Resistor is on 100% of the time, to ensure that the oil is always at the correct temperature. However, before the first start, we must leave it running for 12 hours, so that the oil reaches the necessary viscosity so that there are no problems when starting.
To do this, simply energize the machine and turn the On/Off switch on the Panel door. Once this is done, the crankcase heater will be on, and after 12 hours, you will be able to start-up your condensing unit Optyma™ INVERTER.
Initial setting
Parameters Required for Start Up (It will be necessary to remove the front panel, where the switch is located.)
For condensing unit Optyma™ INVERTER work correctly, some parameters must be configured, namely:
Suction Temperature Setpoint
Condensation Temperature Setpoint or Condensing Floating Delta
Refrigerant Fluid
For them to be configured, you must follow the instructions below:
Suction Temperature Setpoint – On the initial screen, press the enter key once, the menu screen will appear, then use the arrows to select the Temperature Setpoint option, and press enter again. On the next screen there will be the option to select the setpoint. To do this, simply press enter, use the arrows to select the desired value, and press enter to save this configuration.
IMPORTANT: The T. Suc parameter must always be lower than the desired chamber temperature, the difference between the chamber temperature and the suction temperature is the delta T of the evaporator, use this value.
Condensation Temperature Setpoint or Condensing Floating Delta – On the initial screen, press the enter key once, the menu screen will appear, then use the arrows to select the Condensation Setpoint option, and press enter again. On the next screen there will be the option to select the setpoint. To do this, simply press enter, use the arrows to select the desired value, and press enter to save this configuration.
After completing the initial configurations, to enable the system to function, simply go to the Start/Stop Menu and select the Turn on condensing unit option. This way, the system will start as soon as it is within the defined operating parameters.
Refrigerant Fluid – To select the refrigerant fluid, the following steps must be followed:
Press the Enter key, go to the Parameters menu, access the ‘Config. Essential’ and select the type of refrigerant fluid (R404A or R507A)
Installation Settings
Case 1 – Start/Stop condensing unit based on Thermostat/Temperature Controller.
To use the condensing unit Optyma™ INVERTER with thermostats or temperature controllers (activation via digital output), the “DON Hab Digital ON-OFF?”
parameter must be enabled. This parameter is in the Parameters menu, General Submenu.
With this change made, the system will turn on or off not only by the security system and suction temperature setpoint, but also by the internal temperature of the Chamber.
IMPORTANT: The digital inputs of the condensing unit Optyma™ INVERTER MCX Controller are all VOLTAGE FREE (Dry Contact). If voltage is sent to the controller’s digital inputs, it may be damaged, preventing the Condenser Unit from functioning, and will not be covered by the Danfoss warranty.
Case 2 – EEV (Electronic Expansion Valve) Non-Danfoss.
To use the condensing unit Optyma™ INVERTER with thermostats or temperature controllers (activation via digital output), the “DON Hab Digital ON-OFF?”
parameter must be enabled. This parameter is in the Parameters menu, General Submenu.
With this change made, the system will turn on or off not only by the security system and suction temperature setpoint, but also by the internal temperature of the Chamber.
IMPORTANT: The digital inputs of the condensing unit Optyma™ INVERTER MCX Controller are all VOLTAGE FREE (Dry Contact). If voltage is sent to the controller’s digital inputs, it may be damaged, preventing the Condenser Unit from functioning, and will not be covered by the Danfoss warranty.
Case 3 – AKV Electronic Expansion Valve with AK-CC55 Controller
To use the condensing unit Optyma™ INVERTER together with our AK-CC55 Controller, simply follow the instructions in the User Manual that comes with the controller, and choose the type of application that fits your system.
This controller can be used to turn the condensing unit on and off, depending on the internal temperature of the chamber, in this case, a digital output from the AK-CC55 controller must be used as On/Off control of the condensing unit Optyma™ INVERTER, and the parameter must be enabled “DON Hab Digital ON- OFF?” at MCX. This parameter is in the Parameters menu, General Submenu.
With this change made, the system will turn on or off not only by the security system and suction temperature setpoint, but also by the internal temperature of the Chamber.
IMPORTANT: The digital inputs of the condensing unit Optyma™ INVERTER MCX Controller are all VOLTAGE FREE (Dry Contact). Case

Annex – A

Alarms, Tests and Features

Emergency
mode at a specified %|
Suction Pressure Failure| Value above or below the operating range| Condenser goes into Emergency
mode at a specified %|
Discharge Pressure Failure| Value above the operating range| Compressor Stop|
Suction Temperature Failure| Value above or below the operating range| Information on the Display|
Ambient Temperature Failure| Value above or below the operating range| Condenser goes into Emergency
mode at a specified %|
Suction Pressure Failure| Value below the operating range| Information on the Display|
Superheat Temperature Failure| Value below the operating range| Information on the Display|
Value above the operating range| Information on the Display|
Lack of Refrigerant| High superheat for more than 2 hours and Suction Pressure greater than 10 times| Information on the Display|
High Discharge  Temperature
Failure| Value above «X»°C (Default 120°C)| Compressor stop by MCX.
Compressor will turn on again
when the value is < 90°C|

Annex – B
GA & PID Drawings
OP – FPZP086

OP – FPZP086

Line Color Table

Red Line – High Pressure Line
Blue Line – Liquid Line
Green Line – Suction Line
Black Line – Oil Line

Annex – C
Wiring Diagram
Code Q: 230V / 3F / 50-60Hz

Code V: 380V / 3F / 50-60Hz

Legend|
---|---
A1| MCX08M2 Controller
CP| Compressor
CR| Run capacitor
CS| Start capacitor
CV| Fan capacitor
F1, F2, F3, F4| Fuses
FT1| Power Supply 24V
IF| Frequence Inverter
PAB| High & Low Pressure Switch
PD| Discharge Pressure Transducer
PH| Pressure switch – HBP
PL| Pressure switch – LBP
PS| Suction Pressure Transducer
Q1| Circuit Breaker
RC| Crankcase Heater
RL| Relay
TA| Ambient Temperature Sensor
TC| Compressor Temperature Sensor
TD| Discharge Temperature Sensor
TS| Suction Temperature Sensor
V, V1, V2| Fan Motor
Cable ID|
BK| Black
BL| Blue
BR| Brown
GR| Green
RD| Red
WH| White
YW| Yellow

Danfoss do Brasil Ind. e Com. Ltda. Climate Solutions • danfoss.com.br • +55 0800 87 87 847 • sac.brasil@danfoss.com
© Danfoss I Climate Solutions 2023.11 AN46964107948001-010101

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