Instructions
118A2177C - AN37261897352601-010301 | 5
© Danfoss | Climate Solutions | 2022.02
11 – Verification before commissioning
Use safety devices such as safety
pressure switch and mechanical
relief valve (not supplied) 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 inside the
condensing unit are properly fastened as they
could have worked loose during transportation.
• When a crankcase heater is required, the unit
must be energized at least 12 hours before initial
start-up and start-up after prolonged shutdown
for belt type crankcase heaters.
•
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™ Plus condensing unit must be
sized properly depending upon the evaporator
location.
• Pressure drop in the suction and liquid line pipes
must be evaluated as per evaporator location
and distance (refer coolselector2).
•
Optyma™ Plus condensing units suction /
discharge pressure must be within the operating
envelope, never operate condensing unit suction
pressure below absolute pressure (vacuum).
• The unit is equipped with a main switch with
overload protection and short circuit protection.
Overload protection is preset from factory, but it
is recommended to check the value before taking
the unit in operation. The overload protection
value can be found in the wiring diagram in the
unit front door.
• Check if discharge temperature sensor is firm
and has proper contact with discharge pipe.
•
Ensure that 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 that all service valves are open
• Ensure the high pressure transmitter is open to
the system
• Check all mechanical connections are tight
• Check all electrical overload settings are correct
12 – Start-up
•
Never start the unit when no refrigerant is
charged.
• All service valves must be in the open position.
• Rotalock valve on the receiver must be turned
1 round to close direction to get the right
condensing pressure for the pressure transmitter
•
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).
•
Eventual reverse rotation of a 3-phase
compressor can be detected by following
phenomena; the compressor doesn’t build up
pressure, it has abnormally high sound level
and abnormally low power consumption. In
such case, shut down the unit immediately and
connect the phases to their proper terminals.
• If the rotation direction is correct the low pressure
indication on the controller (or low pressure
gauge) shall show a declining pressure and
the high pressure indication (or high pressure
gauge) shall show an increasing pressure (only
during startup).
13 – 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
slugging.
•
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™ Plus condensing units are designed to
operate upto 43 degree Celsius. During normal
operation or peak operation saturated dew
point condensing temperature not to exceed
corresponding to 63 deg Celsius for R404A/
R507, R448A, R449A, R452A, R454C, R455A.
Saturated dew point condensing temperature
not to exceed corresponding to 65 deg Celsius
for R134a, R513A & R1234yf.
•
Check all tubes for abnormal vibration.
Movements in excess of 0.15 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 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 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 suction & discharge pressure and
temperature.
• 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 are fastened.
• Complete refrigerant labelling to comply with
local standard
• Scroll Compressors are allowed to Operate at
maximum of 12 Start/Stop cycles per hour.
•
Reciprocating Compressors are allowed to
Operate at maximum of 10 Start/Stop cycles per
hour.
• Ensure maintenance is carried out in accordance
with the installation instructions.
14 – Emergency running without controller
In case of controller failure, the condensing unit
can still be operated when the controller standard
wiring is modified into a temporary wiring as
described below.
This modification may be done by
authorized electricians only. Country
legislations have to be followed.
Disconnect the condensing unit from
power supply (turn hardware main
switch off)
The controller must be exchanged as
soon as possible to avoid any lifetime
reduction.
• Contact of room thermostat at 24 - 25(i.e. DI1)
must be possible to switch 250VAC.
• Remove wire 22 (safety input DI3) and wire 24
(room thermostat DI1) and put them together
with an insulated 250 Vac 10mm² terminal
bridge.
• Remove wire 25 (room thermostat DI1) and wire
11 (compressor supply) and put them together
with an insulated 250VAC 10mm² terminal
bridge.
• Remove wire 6 and connect it with terminal
bridge for wire 11 and 25. A fan pressure switch
or fan speed controller can be connected in
series to wire 6.
• Remove wire 14 (crankcase heater) and connect
it to the compressor contactor terminal 22.
•
Remove wire 12 (supply crankcase heater),
extend this wire by using an 250 Vac 10mm²
terminal bridge and 1,0mm² brown cable and
connect it to compressor contactor terminal 21.
•
Remove the large terminal block from the
controller terminals 10 to 19.
• Connect the condensing unit to power supply
(turn hardware main switch on).
• For 114X33YY and 114X43YY unit with EC Fan
motor, Open the fan motor terminal box and
connect the 0-10V fan speed input to the 10V
supply terminal
15 – Maintenance
Always switch off the power supply to
the condensing unit by turning off the
main switch before opening the 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 are performed to the
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 drawn.
• 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
