Danfoss Optyma iCO2 Instructions Manual Download Page 63

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Instructions

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Inspection item

Inspection at installation(1) Inspection at installation(2) Inspection at installation(3)

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Does abnormal vibration, noise occur?

Does oil spread around or inside?

Are there traces of running rusty water around or inside?

Is the drain pan discharge outlet clogged?

Is rust observed on the surface of compressor?

Is rust observed on the surface of vessels?

Are insulation materials deteriorated, broken?

• Piping (Aeroflex)

• Compressor (felt, Aeroflex)

• Accumulator (Aeroflex)

• Receiver (Aeroflex)

Is the heat exchanger damaged?

Is the heat exchanger corroded?

Does oil spreads on the heat exchanger?

Is piping in the machine corroded?

Is piping in the machine rubbed?

Does oil spread at pipe joints on the compressor?

Are compressor terminals deteriorating?

Is the compressor casing rusty, corroded?

Does oil spread at expansion valve joints?

Are service ports capped?

Does oil spread at service ports?

Does oil spread at brazed sections?

Is it frosting?

Is the indicator hardware corroded?

Are resin bands tightened properly?

Are resin bands cracked?

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Does abnormal noise or vibration (chatter) occur on the compressor or fan

motor?

Does flash-gas generate at the liquid outlet?

Isn’t refrigerant overcharged?

(Does the high pressure error (7 segment display, E40) or liquid back from

the medium pressure receiver (7 segment display, E43) occur?)

Is the oil level maintained above the lower limit during operation?

(Check with 7 segment display, C32: Level switch.)

Does oil spread around or inside?

Is the movement control pressure suitable to the purpose of low pressure

devices (load side)?

Is the cooling capacity of low pressure devices (load side) correct?

(Turn off the thermostat.)

Is it normal the frequency of compressor start/stop? (10 times/h)

Is the suction gas superheating degree correct?

(7 segment display, C49: Suction superheating degree 1,

[Judgment guide]

1. It is not frosting at the compressor side from its suction inlet.

2. 5 deg ≤ TsSH ≤ 40 deg

Is the discharge gas temperature correct?

(7 segment display C08: Discharge pipe temperature (CM1),

[Judgment guide] Td 125°C or under

Is the waste heat short-circuited?

(7 segment display C02: Outdoor air temperature (Tho-A))

Regular inspection check sheet

Installation ID
Installation Date
Remarks

This table shows points of regular inspection to use safely the refrigerating equipment which uses highly

pressurized CO2 refrigerant. Inspect the machine regularly and, if any anomaly is discovered, repair it immediately,

particularly when corrosion generates widely over the surface of compressor, or vessels, and deteriorates their

strength. Inspect the Optyma iCO

at installation after regular intervals. Record the inspection results on the

regular inspection check sheet.

Summary of Contents for Optyma iCO2

Page 1: ...12 6 Vacuum dehydration 13 7 Electrical connections 21 8 Filling the system 23 9 Setting the electronic controller 24 10 Procedure and caution for commissioning 35 11 Operation 38 12 Check with runni...

Page 2: ...g to ground fault Tighten wire terminals securely to specified torque If they are not tightened securely it could cause fire or electric shock owing to overheat on the terminal Usespecifiedcablesforwi...

Page 3: ...bitedtomixanymaterialotherthanR744duringinstallation repair or relocation If other refrigerant or other combustible materials like air oxygen propane or alcohol are mixed it could cause explosion fire...

Page 4: ...ely Since earth leakage or over current is suspected it could cause electric shock fire or rupture CAUTION Consideration for children Children shall not play with the appliance Refrain from placing so...

Page 5: ...sor Care must be taken particularly when charging or discharging oil during maintenance service or test run Others CAUTION When washing the gas cooler take care not to splash water directly over elect...

Page 6: ...capacity of condensing unit is increased The speed control by inverter features that it allows to change the capacity Since the inverter is in the advancing phase if an advancing capacitor is install...

Page 7: ...lve with schrader port for field service operation Confirm that the strength and levelness of foundation can prevent vibration and noise Fix the unit securely so that it will not be toppled by earthqu...

Page 8: ...s the enlargement of pipe diameter Typical instillation 5 m or less 22 m or less Evaporator Suction pipe Liquid pipe Suction pipe Liquid pipe Position the liquid solenoid valve closer to the expansion...

Page 9: ...generates electromagnetic radiation Caution Be sure to secure installation spaces It could cause failures on the compressor or electric equipment owing to short circuit in air flow Device to be connec...

Page 10: ...ber cushion must be able to support the entire bottom area of fixing leg See following figure X Y Z NOTE a Install the cushion rubber such that it will support the entire bottom area of the fixing leg...

Page 11: ...pipe Liquid pipe OP UPAC015COP04E 19 05 Brazing 12 7 Brazing Pipe wall thickness shows that of C1220T 1 2H Center line R Dimension Start evacuation from the low pressure side to prevent the reverse p...

Page 12: ...e drops Raise then the pressure to the design pressure and record the ambient temperature and the pressure Apply a foam liquid over the surface If no foam generates it passes the test It passes the te...

Page 13: ...the service port When the unit is not energized remove coils from the hot gas bypass solenoid valve and oil return solenoid valve and open the solenoid valve forcibly using a special magnet When the...

Page 14: ...ach pipe Where no branching pipe is used take the length of pipe to the farthest low pressure device as the pipe length Where it is used take the sum of the length of pipe to the pipe joint of farthes...

Page 15: ...11 x 10 11 x 10 7 x 10 5 x 3 5 x 1 11 x 10 7 x 10 5 x 1 5 x 1 1 140 cc 3 Additional condensing unit oil quantity Additional condensing unit oil is calculated to be 1 140 cc from 2 Round up the oil qua...

Page 16: ...ture at storage should be no higher than 40 C and avoid places where it is exposed to direct sunlight or temperatures change widely 4 The oil become colorless and transparent 5 Since the unit inside b...

Page 17: ...he oil pod Oil service port 6 3 Replenishment of condensing unit oil after operation 6 4 Refrigerant charge After vacuuming and charging the condensing unit oil charge the refrigerant as follows Use a...

Page 18: ...larger than the maximum refrigerant charge quantity Get the maximum refrigerant charge quantity from the 12 7 equivalent pipe length using the Fig 20 and calculate the 12 7 equivalent pipe length of F...

Page 19: ...itional charge quantity kg m 0 025 0 054 0 098 0 155 0 225 15 5 10 20 25 30 0 20 40 60 80 100 23 6m 17 9kg 15 7kg Maximum refrigerant charge quantity kg 12 7 equivalent pipe length m 6 Refrigerant cha...

Page 20: ...ng High pressure gas charge at a place where it can be seen by people When the charging place can be approached from more than one place show the board at respective places 5 Even when the charge pres...

Page 21: ...e c Ground the unit Do not connect the ground wire to a gas pipe lighting rod or telephone grounding wire If improperly grounded an electric shock or malfunction may result d The installation of an im...

Page 22: ...short circuited External output CNH Blue Operation output 12 VDC output 10 mA CNY White Error output CN NZ1 CNZ2 Red Black Set with 7 segment Molex Provide 5557 2R 5556T at site 0 Operation output 1...

Page 23: ...fixing band Fix the signal cable with care to protect the connection to the terminal board from external force Give an adequate allowance to the signal cable before fixing Interface board Tightening t...

Page 24: ...peration frequency when the high pressure HP is too higher Overcurrent protective control Reduces the operation frequency when the current value is too higher Discharge temperature overheat prevention...

Page 25: ...r of 0 1 2 9 0 It displays in the order of P00 P01 P02 P09 P00 6 Adjust at the code to change hold down SW7 Data write delete for 3 seconds continuously 7 Data at the data display section flickers at...

Page 26: ...L 30 150 1 C C12 Tho P1 power transistor temp CM1 L 20 120 1 C C14 Tho SC subcooling coil temp L 40 100 1 C C15 Tho R liquid feed pipe temp L 40 100 1 C C16 Tho S suction pipe temp L 40 100 1 C C18 CT...

Page 27: ...ooling coil temp sensor 1 saturation pressure 0 8 5 0 1 bar C49 Suction superheat degree 1 0 50 0 1deg C51 Subcooling coil superheat degree 0 50 0 1deg C52 Under dome superheat degree 1 0 50 0 1deg C5...

Page 28: ...t CNZ1 function assignment 2 Default 0 20 1 P06 External output CNZ2 function assignment 4 Default 0 20 1 P07 External input CNS2 function assignment 1 Default 0 20 1 Demand input 2 Quiet mode input 3...

Page 29: ...coil sensor broken wire Tho SC 7 time E37 7 Liquid feed pipe temp sensor broken wire Tho R E38 Continuous Once E38 Outdoor temp sensor broken wire Tho A E39 Continuous Once E39 1 Td sensor 1 broken w...

Page 30: ...ue that corresponds to the cooling capacity is set so as to control the inverter output frequency such that the low pressure LP being detected by the low pressure sensor will become the set low pressu...

Page 31: ...tion Medium pressure receiver inlet electronic expansion valve ordinary control operation Detected Low pressure valve 5 8 bar for 2 seconds Medium pressure value compressor start pressure setting Gas...

Page 32: ...nt of inverter becomes higher than the value preset as shown below the frequency output is restricted by the control PCB of condensing unit Restriction of frequency output Forcible frequency reduction...

Page 33: ...er on or 3 hours from second or more times of oil return and total oil loss exceeds the specified value the following control is performed It operates with the compressor frequency fixed at the freque...

Page 34: ...ntrol Initial speed 40 rps 105 sec 0 rps 3 min Stop aperture full open Initial aperture Ordinary control 45 sec 120 sec Stop aperture full open 45 sec OFF ON Stop Operation OFF ON OFF ON OFF ON OFF ON...

Page 35: ...CNS2 at the bottom of controller is turned OFF Remove the cartons and the bracket before operation 5 Anti vibration shipping washers are not used on the compressor Since this product does not use ant...

Page 36: ...operate properly To prevent the reverse phase operation the unit is equipped with the reverse phase prevention relay which checks whether the phase of power supply is positive or reverse and if it is...

Page 37: ...Pressure equivalent to evaporation temp Low pressure setting OFF value Low pressure setting ON value Error pressure Fruit vegetables 2 15 C 5 10 C 10 C 25 5 bar 13 3 bar 30 5 bar 5 8 bar Meat fishes...

Page 38: ...ad unit 5 Should the operation of total 180 minutes be counted up without detecting by the oil level sensor any oil shortage detection of oil shortage for 30 seconds continuously 7 segment display cha...

Page 39: ...r abnormal vibration Movements in excess of 1 5 mm require corrective measures such as tube brackets Whenneeded additionalrefrigerantinliquidphasemaybeaddedinthelow pressuresideasfaraspossiblefromthec...

Page 40: ...rankcase heater Insulation resistance 1 20 000 h Fuse Appearance 1 8 y PCB Control inverter Appearance 1 8 y High pressure breaker pressure sensors Contact resistance capillary rubbing 1 8 y Terminal...

Page 41: ...reset it can be reset externally Make sure however to check the error code and remove the cause of error before resetting If SW6 7 is turned to ON the warning oPE 11 is not displayed When total opera...

Page 42: ...eplace E37 4 Injection inlet temp sensor error Injection inlet temp sensor blown wire short circuit are detected Defective injection inlet temp sensor connector disconnection or short circuit Replace...

Page 43: ...er dome temp sensor blown wire short circuit are detected Under dome temp sensor connector disconnection or short circuit Replace E56 1 Power transistor temp sensor error Power transistor temp sensor...

Page 44: ...ailure was caused by weak foundation or fragile support frame 5 Accident resulted from modification incidental work or relocation at site or overriding protective devices provided on our product 6 Acc...

Page 45: ...th and the environment For more information about collection and recycling please contact your local authority Penalties may be applicable for incorrect disposal of this waste in accordance with natio...

Page 46: ...nect the connector to the control PCB of CO2 refrigerating machine Default functions of external inputs are as shown at right Inputs use non voltage contacts Functions can be changed from the default...

Page 47: ...NY White CNZ1 Red CNZ2 Black Red Red Red Black Black Black Black External output Operation output CNH Connector color Blue Error output CNY Connector color White 7 segment setting output CNZ1 Connecto...

Page 48: ...s More than 800 mm is nice to have to inspect or replace parts of the condensing unit Take care not to interfere with the service space during piping work Where the necessary space is not available in...

Page 49: ...04 Condensing unit IP level IP24 Refrigerant R744 CO2 Compressor technology 2 stage Scroll Rotary Control box pre wired E panel Yes Fin and Tube condenser Yes Fan speed controller Yes Main switch circ...

Page 50: ...eight kg 340 Stated as the rated output of compressor motor Rated speed at freezing or refrigeration whichever is larger is taken OP UPAC015COP04E Rated speed 104 rps Annex B PID and GA 28 X 14 1350 1...

Page 51: ...itch Oil separator Oil level sensor Low pressure sensor Middle pressure receiver Middle pressure sensor Oil pod Accumulator Subcooling coil temperature sensor Middle pressure receiver inlet temperatur...

Page 52: ...erature te 10 35 C Application MBP LBP Suction super heat 10 10 K Sub cooling 0 0 K Annual electricity consumption Q 30535 43818 kWh a Seasonal Energy Performance Ratio SEPR 3 95 1 74 32 C Rated cooli...

Page 53: ...Pressure sensor 16 Service Valve 17 Shut off Valve 18 Pressure Relief valve 19 Capillary 20 Sight glass 21 Under dome temperature sensor 22 Injection inlet temperature sensor 23 Discharge pipe temper...

Page 54: ...ER User interface MMILDS 12VDC Power Module controller Noise filter PCB Circuit breaker for cabling Inverter PCB Compressor terminal See enlarged view Earth leakage breaker Power source Power PCB PWB5...

Page 55: ...tal operation time reset SW3 8 Spare SW4 1 4 Model selection SW4 5 8 Spare SW5 1 3 For target middle pressure adjustment SW5 4 5 Spare SW5 6 8 Pressure check operation mode SW6 1 3 Spare SW6 4 Presenc...

Page 56: ...uct is absolutely incompatible mark Change of standards mark More thorough strict observation than conventional 1 Airtight test pressure R744 Medium low pressure side Max 80 Bar 24 hr 1 Evacuate for 2...

Page 57: ...ironmentally friendly refrigerant with the ozone depleting coefficient at 0 and a smaller global warming potential Refrigerant R410A is comparable with this in terms of the ozone depleting coefficient...

Page 58: ...led level Check with level gauge Yes No Is the Condensing unit installed on a suitable base Check foundation strength Is the Condensing unit installed near any oil and or hazardous gases Eg Sulphide g...

Page 59: ...L2 L3 L3 L1 L1 N L2 N L3 N V Fill in the voltage 3 09 Is the power supply balanced less than 2 3 10 Is below dip switch setting of control board or interface board samw as below SW4 6 of control board...

Page 60: ...ce between the farthest load unit and the condensing unit is 100m or less Follow the Maximun refrigerant charge quantity at the same time shown in 5 Leak detection and 6 Vacuum dehydration 6 02 Pipe s...

Page 61: ...of condensing unit oil 7 06 How much the refrigerant amount did you charge g The operation starts at 90 of the calucated amount of the refrigeration Follow the refrigerant amount shown in the install...

Page 62: ...rn control of the module controller SH Guard ALC_r20 2 0K SH Start ALC_r21 4 0K Oil ALC setpoint LBP_r22 2 0K Oil ALC setpoint MBP_r26 0 0K Oil ALC setpoint HBP_r27 3 0K EEV force low OD after oil rec...

Page 63: ...frigerant overcharged Does the high pressure error 7 segment display E40 or liquid back from the medium pressure receiver 7 segment display E43 occur Is the oil level maintained above the lower limit...

Page 64: ...e C00 Compressor operation frequency rps 40 104 C02 Outdoor air temp C 20 50 C03 Gas cooler inlet temp C 135 C04 Gas cooler outlet temp C 60 C08 Discharge pipe temp C 135 C10 Under dome temp C 85 C12...

Page 65: ...ormation Cooler 2 Liquid feeding solenoid valve ON 1 OFF 0 Cooler 2 defrost status 3 u60 ON 1 OFF 0 Cooler 2 fan Operating 3 u59 ON 1 OFF 0 Cooler 3 Roomtemperature SV 3 r00 C 45 30 Cooler 3 Roomtempe...

Page 66: ...oler7 Roomtemperature SV 3 r00 C 45 30 Cooler7 Roomtemperature PV 3 u36 C 45 30 Cooler7 superheat SV 3 u22 deg 5 Cooler7superheat PV 3 u21 deg 5 Cooler7 expansion valve opening duty 3 u23 0 100 Cooler...

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Page 68: ...68 AN405821998738en 000102 118A5495A Danfoss Climate Solutions 2023 02 LCA012A024...

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Summary of Contents for Optyma iCO2

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Danfoss Optyma iCO2, Instructions Manual, Page: 63 / 68

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