Danfoss OP-LSVM Optyma Slim Pack Instructions

Danfoss OP-LSVM Optyma Slim Pack

Instructions
Optyma™ Slim Pack
OP-LSVM, MSTM and MSSM

Optyma™ Slim Pack electrical box ingress protection level is IP54 to avoid quick A2L refrigerant migration. Sealing needs to be maintained and any damage on sealing needs to be repaired appropriately.

E-Box door must always be closed during operation and after service/periodic maintenance.
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 and according to instruction.
Under all circumstances, the EN378 (or other applicable local safety regulation) requirements must be fulfilled.
The condensing unit is delivered under nitrogen gas pressure (2 bar(gauge)) 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°)
Condensing units can be used with mildly flammable refrigerants, necessary care to be taken during installation and servicing.
In case of A2L refrigerants, all components on the refrigeration circuit must be A2L certified. Example: Evaporator.

Relevant Standards and Directive

• EN 378 -2: Refrigerating Systems And Heat Pumps-Safety And Environmental Requirements.
• EN 60335-1: Household And Similar Electrical Appliances – Safety –Part 1: General Requirements
• Low Voltage Directive n° 2014 / 35 / UE
• Machinary Directive n° 2006 / 42 / CE
• EC Pressure directive (PED) no. 2014/68/EU
• RoHS Directive 2011-65-EU
• WEEE Directive 2012-19-EU (Other local applicable standards)

Introduction

• These instructions pertain to OptymaTM Slim Pack condensing units OP-LSVM, MSTM and MSSM (R448A, R449A, R452A, R407A, R407F, R507, R404A, R134a, R513A, R1234yf, R454C & R455A) used for refrigeration systems. They provide necessary information regarding safety and proper usage of this product.
• The condensing unit includes following:
  • Scroll/reciprocating compressor
  • Microchannel heat exchanger
  • Dual pressure switches
  • Service valves suction/ liquid with schrader Valve
  • Weather proof housing
  • Filter drier (Flare connections)
  • Cranckcase heater for compressor
  • Receiver with stop valve
  • Sight glass (Flare connections)
  • IP54 fully pre-wired electrical panel (including compressors contactor, overload relay)

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 as the
---|---
condensing unit is under pressure.
It’s not allowed to operate the unit in
flammable atmosphere.
Place the unit in such a way that it
is not blocking or hindering walking
areas, doors, windows or similar.
A2L refrigerants are heavier than air.
Unit has to be installed above floor
level to have a good compressor
compartment ventilation.

• Ensure adequate space around and below the unit for proper air circulation and to open doors. Refer to Annex – A, Picture 1 for minimum distance to walls and ground.
• Avoid installing the unit in locations which are daily exposed to direct sunshine for longer periods.
• 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 shall not exceed 50°C during off-cycle.
• Ensure that the power supply corresponds to the unit characteristics (See nameplate in unit).
• When installing units for R454C, R455A & R1234yf refrigerants, use equipment specifically reserved for mildly flammable refrigerant 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 compressor 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

• Installation/servicing of Optyma™ Slim Pack condensing units must be carried out by qualified personnel with respect to applicable local/international regulation.
• The installation in which the condensing unit is installed must comply to EC Pressure directive (PED) no. 2014/68/EU. The condensing unit itself is not a ”unit” in the scope of this directive.
• The unit must be securely installed on a stable and rigid support, and fixed from the beginning. See Annex-A, 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. Refer image Annex-A, Picture 3.
• 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 with 19 mm thick insulation.
• Make sure there is no refrigerant or damage inside unit and crack in pipes.
• Make sure that all components inside electrical box are protected against overload and not source of ignition from its respective manufacturer for approved refrigerants.
• Field wiring must be routed through IP65 cable glands and cable entry plate only. For any additional wire routing drilling or piercing electrical panel sides strictly prohibited.
• For field wiring, only required hole to be pierced. No pierced hole should be left without cable in it. If undesired/unwanted piercing happens entire gland plate should be replaced.
• Partition panel has dedicated openings for pre ventilation, do not seal/obstruct/close the openings in any manner.
• In the event of uncertain leakages, To avoid refrigerant concentration in compressor compartment, compressor has a on-time delay of 30 seconds (factory setting) do not reduce the setting below 30 seconds.

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 25 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.
• Vacuum pump must be certified to use in A2L refrigerant environment or ATEX certified.
• Pull down the system under a vacuum 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

• Verify that all electrical connections inside the condensing unit are properly fastened as they could have worked loose during transportation.
• 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 per EN60335-1, EN60204 or local applicable standard and unit requirement.
• Refer to wiring diagram for electrical connections details.
• All electrical components must be qualified to use A2L refrigerants and not source of ignition.
• All electrical connection should comply with IEC 60335-2 and EN 60335-1.
• 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).
• The power supply cables must be according to unit data for voltage, current and ambient condition. Refer Nameplate for voltage and current information.
• Protect the power supply and ensure correct earthing.
• Optyma™ Slim pack condensing unit starting frequency need to be limited for reciprocating compressors
  • Without starting capacitor 5 starts per hour maximum.
  • With starting capacitor 10 starts per hour maximum.
• 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 and provides 230V AC alarm signals (max. 50VA) in case of activation. Parameters for high and low pressure cut outs should be set by installer considering compressor model, refrigerant and application.
• Determine the phase sequence by using a phase meter in order to establish the phase orders of line phases L1, L2 and L3.
• Connect line phases L1, L2 and L3 to main switch terminals T1, T2 and T3 respectively.
• Timer should have minimum setting of 30 sec for pre ventilation. Rotate clockwise and set arrow to 30s marking or above (refer below image)

Safety

Electrical box door should be in closed condition before connecting to power supply.
Units has receive with 3/8» NPT adapter plug. User can select various options as mentioned in EN378-2:2016 Article § 6.2.2.3

• The unit/installation into which the condensing unit is mounted/integrated, must be in accordance with the PED.
• As per EU F-gas regulation, R1234yf, R454C & R455A are considered as mildly flammable refrigerant. Optyma™ Slim Pack units are qualified with R1234yf, R454C & R455A. All precaution and safety measure to be taken care before and after installation.
• All Optyma™ Slim pack condensing units are supplied with adjustable dual pressure switch (KP-17WB) with maximum 0.5A current rating.
• In order to avoid electric arc between hermetic connector pins, compressor must not start or electrical tests such dielectric strength must not be performed while the refrigerating system under vacuum.
• All components should be compatible to use with specified refrigerants according to Optyma™ Slim Pack condensing units codes .Refer Annex A.
• Optyma™ Slim Pack condensing units have pre ventilation via condenser fan prior to compressor starting (30 seconds). Never disconnect or modify timer settings.
• Beware of hot and extremely cold components.
• Beware of moving components. Power supply should be disconnected while servicing.

Filling the system

• Before filling the refrigerant into the Optyma™ Slim Pack condensing unit wear appropriate PPEs.
• Never start the compressor under vacuum. Keep the compressor switched off.
• 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.
• For glide refrigerants such as R454C, R455A, R448A, R449A, R452A use liquid valve in the refrigerant cylinder to charge.
• Fill the refrigerant in liquid phase into the condenser or liquid receiver. Ensure a slow charging of the system to 4 – 5 bar for R448A, R449A, R452A, R407A, R407F, R507, R404A, R454C & R455A or R452A and approx. 2 bar for R134a, R513A. R1234yf.
• 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 International and local 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 international and local regulations.
• When a crankcase heater is required, it must be energized at least 12 hours before initial start-up and start-up after prolonged shut-down period.
• Crankcase heater must be firmly fixed with compressor shell. ensure that it does not fall down and energizes in air.
• Electrical panel door must be firmly closed using the knob in door panel.
• All interconnecting tubes with (liquid and suction) Optyma™ Slim pack condensing unit must be sized properly depending upon the evaporator location.
• Pressure drop in the liquid line pipes must be evaluated as per evaporator location and distance (refer coolselector2).
• Optyma™ Slim Pack condensing units suction/discharge pressure must be within the operating envelope, never operate condensing unit suction pressure below absolute pressure (vacuum).

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.
• Check that the fan can rotate freely.
• Check that the protection sheet has been removed from the backside of condenser.
• Balance the HP/LP pressure.
• Energize the unit. Condenser fan must start promptly and after 30 seconds of time delay the compressor starts (pre ventilation).
• If the rotation direction is correct the low pressure indication on the low pressure gauge shall show a declining pressure and the high pressure indication on the high pressure gauge shall show an increasing pressure.
• Ensure you have read the installation guideline that is delivered with the condensing unit
• Only use the correct refrigerant(s) as detailed on the data plate
• Check compressor oil level
• Check all service valves are open
• Check all mechanical connections are tight
• Check all electrical overload settings are correct (See Annex D – Wiring Drawing).

Check with running unit

• Check the fan rotation direction. Air must flow from the condenser towards the fan.
• Check current drawn and voltage.
• Check suction superheat to reduce risk of liquid slugging.
• For glide refrigerants use temperature difference between saturated dew point at suction pressure and Suction line temperature on the tube.
• When a compressor sight glass is provided observe the oil level at start and during operation to confirm that the oil level remains visible.
• Respect the operating limits.
• Optyma™ Slim Pack condensing units are designed to operate up to 43°C. During normal operation or peak operation saturated dew point condensing temperature not to exceed corresponding to 63 °C for R448A, R449A, R452A, R454C, R455A. Saturated dew point condensing temperature not to exceed corresponding to 65 °C for R134a, R513A & R1234yf.
• Check all interconnecting tubes are free from abnormal vibrations. If any excess vibrations require corrective measures such as supporting brackets, clamps.
• When needed, additional refrigerant in liquid phase may be added in the low-pressure side as slow and far away as possible from the compressor. The compressor must be operating during this process.
• Do not overcharge the system.
• Follow the local regulations for restoring the refrigerant from unit.
• Never release refrigerant to free 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.
• Check refrigerant charge and running currents of motors to ensure correct operation
• Check compressor suction superheat to reduce risk of liquid slugging
• Allow the system to run for 3 – 4 hours. Check compressor oil level and top up with the correct oil type as identified on the data plate of the unit and compressor
• Recheck the compressor oil level again after 24 hours operation
• Carry out final leak test and ensure all covers are fitted and all screws fastened
• Complete refrigerant labelling to comply with local standard
• Ensure maintenance is carried out in accordance with the installation instructions

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
PPEs, skills, tools to carryout the
maintenance     activity.     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.
  • Micro channel heat exchanger surface adequately cleaned to avoid clogging.
  • Timer setting are set at 30 seconds during normal running condition.
  • Optyma™ Slim Pack condensing units are factory fitted with flare type filter drier. While changing the filter drier ensure that proper model designation and direction of flow.
  • Ensure to conduct the leakage check after replacement.
• 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 removing any panel from the condensing unit.
• All electrical equipments, PPEs, tool must be compatiable and approved to use with A2L refrigerants like R454C, R455A & R1234yf.
• Remove surface dirt, leaves, fibres, etc. with a vacuum cleaner, equipped with a soft 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.
• 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 has to be done, it shall be done in such a way that no refrigerant can escape to the environment.

Service panel removal procedure for W05 Version.

• Step 1: Make sure that power supply has been disconnected.
• Step 2: Remove all top panel screws and then remove Top panel.
• Step 3: Remove all side panel screws.
• Step 4: Remove side panel parallel to main switch. Step 5: Electrical panel box should be in closed condition. Ensure there is no refrigerant penetration inside Electrical panel before connecting to power supply.

Declaration of incorporation

• Pressure Equipment Directive 2014/68/EU EN 378-2:2016 – Refrigerating systems and Heat Pumps – Safety and environmental requirements-Parts 2: Design, construction, testing, marking and documentation
• Low Voltage Directive 2014/35/EU EN 60335-1:2012 + A11:2014- Household and similar electrical appliances-Safety-Part 1: General requirements-for all above mentioned condensing units
• Eco-design DIRECTIVE 2009/125/ EC, establishing a framework for the setting of Eco-design requirements for energy-related products. REGULATION (EU) 2015/1095, implementing Eco-design Directive 2009/125/EC with regard to Eco-design requirements for professional refrigerated storage cabinets, blast cabinets, condensing units and process Chiller.
• Condensing unit measurements are produced according to standard “EN 13771-2:2017”. Compressor and condensing units for refrigeration-performance testing and test methods- part 2: Condensing units. Eco design declaration; refer Danfoss
• Coolselector®2 with code number (114X….) to find the declaration.
• IEC 60335-2-40 applicable clauses Annex JJ and Annex NN

Warranty

• Always transmit the model number and serial number with any claim filed regarding this product.
• The product warranty may be invalied 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.
  • Use in mobile applications.
  • Use in explosive atmospheric environment.
  • No model number or serial number transmitted with the warranty claim.

Disposal

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

Dual Pressure switch – Factory settings

Refrigerants| High pressure settings (bar (g))| Low pressure settings (bar (g))
---|---|---
ON| OFF| ON| OFF
R404A/R507/R407A/R407F/R448A/R449A/R452A,R454C,  R455A| 23| 27| 2| 1
R134a/R513A| 13| 17| 2| 1

Dual Pressure switch – Refrigerant setting

Refrigerants| High pressure settings (bar (g))| Low pressure settings (bar (g))
---|---|---
ON| OFF| ON| OFF
R134a, R513A, R1234yf| 14| 17| 2| 1
R404A/R507, R452A| 24| 27| 2| 1
R454C| 19| 23| 2| 1
R455A| 21| 25| 2| 1
R448A/R449A| 22| 26| 2| 1

Annex – A Technical data

* For exact values please refer name plate in unit

• A: Model
• B: Code number
• C: Application, Protection
• D: Refrigerant
• E: Housing Service Pressure (Maximum working pressure)
• F: Supply voltage, Locked Rotor Ampere, Maximum Continuous Current
• G: Serial Number and bar code

Designation system for the Optyma™ Slim Pack range

1| Application
M = MBP L = LBP
---|---
2| Package
Condensing unit family: S = Slim Pack
3| Refrigerant
T = R404A/R507, R455A, R454C, R448A/R449A, R452A S = R134a, R513A, R1234yf V =R454C, R455A, R452A, R404A/R507
4| Condenser
M = Microchannel heat condenser
5| Swept volume
Displacement in cm3: Example 034 = 34 cm3
6| Compressor platform
(Such as DP/DX/DS = Fixed speed Reciprocating compressor)
7| Version
W05: Optyma™ Slim Pack standard version (see Version table)
8| Voltage code
G = 230V/1-phase compressor & fan
E = 400V/3-phase compressor & 230V/1-phase fan

Version control

* Compatible with A2L refrigerant

Technical data

Application| Codes| Condensing unit Model| Electrical Code| Refrigerant| Compressor| Chassis/ Housing| Receiver (L)| Liquid Valve| Suction Valve| Unit Dimensions (mm)
---|---|---|---|---|---|---|---|---|---|---
Inch| Inch| L| W| H
LBP| 114X7263| OP-LSVM014DPW05G| G| V| DPT14LA| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7242| OP-LSVM016DPW05G| G| V| DPT16LA| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7227| OP-LSVM026DSW05G| G| V| DST26NA| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7228| OP-LSVM034DSW05G| G| V| DST34LA| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
MBP| 114X7226| OP-MSTM008DYW05G| G| T| DLY80RAb| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7229| OP-MSTM009DYW05G| G| T| DLY90RAb| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7230| OP-MSTM012DPW05G| G| T| DPT12RA| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7231| OP-MSTM014DPW05G| G| T| DPT14RA| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7232| OP-MSTM018DXW05G| G| T| DX18TBa| B1| 1.3| 1/2″| 1/2″| 364| 910| 530
114X7238| OP-MSSM012SCW05G| G| S| SC12G| B1| 1.3| 1/2″| 1/2″| 364| 910| 530
114X7239| OP-MSSM015SCW05G| G| S| SC15G| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7240| OP-MSSM018SCW05G| G| S| SC18G| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7241| OP-MSSM021SCW05G| G| S| SC21G| B1| 1.3| 3/8″| 3/8″| 364| 910| 530
114X7233| OP-MSTM022DSW05G| G| T| DS22TB| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7234| OP-MSTM026DSW05G| G| T| DS26TB| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7235| OP-MSTM026DSW05E| E| T| DS26T3| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7237| OP-MSTM034DSW05G| G| T| DS34TB| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7236| OP-MSTM034DSW05E| E| T| DS34T3| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7248| OP-MSSM026CSW05G| G| S| CS26TB| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690
114X7249| OP-MSSM030CSW05G| G| S| CS30TB| B2| 3.4| 1/2″| 1/2″| 464| 1079| 690

Annex – B, KP switch settings

Annex – C, GA & PID Drawings

OP-LSVM, MSTM and MSSM

OP-LSVM, MSTM and MSSM

English Legend

• A Isolator Switch (W09 only)
• B Suction Valve
• C Liquid Valve
• D Air in
• E Air out
• F Door safety Lable
• G Name Plate
• Electrical Cables
• Note: all dimension are in mm

W05 Models: OP-LSVM, MSTM and MSSM

• B1 Liquid receiver
• B2 Filter drier (Flare)
• B3 Sight glass (Flare)
• D1 FSA connection (Flare)

Annex – D, Wiring Diagram

WD1 Code G (W05): OP-MSTM022,026,034 & OP-LSVM026,034 & OP-MSSM,026,030 Code E (W05): OP-MSTM026,034

Code G (W05): OP-MSSM021,OP-MSTM008,009,012,014,018,OP-LSVM016,014,OP- MSSM012,015,018

• BK black
• BU blue
• BN brown
• GY grey
• RD red
• WH white

Danfoss A/S
6430 Nordborg
Denmark

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without sub sequential changes being necessary in specification already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
© Danfoss | DCS (CC) | 2021.03

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