Danfoss OPTYMA Instruction Manual

REFRIGERATION &
AIR CONDITIONING DIVISION
OPTYMATM Control
Three-phase
MAKING MODERN LIVING POSSIBLE
Operation and Maintenance Guide

©Danfoss A/S (RA Marketing/MWA), Nov. 08 RS8FE102, 080R9278 3
OPTYMATM Control three-phase Operation and Maintenance Guide
General.....................................................................................................................................................................................................4
Description .....................................................................................................................................................................................4
Functions and main characteristics .......................................................................................................................................4
Applications ...................................................................................................................................................................................4
Technical characteristics of OPTYMATM Control three-phase .......................................................................................5
Connection diagrams .................................................................................................................................................................6
Overall dimensions ............................................................................................................................................................................6
Identification data..............................................................................................................................................................................7
Transport and storage......................................................................................................................................................................7
Installation.............................................................................................................................................................................................7
Standard assembly kit ................................................................................................................................................................7
Mechanical assembly..................................................................................................................................................................7
Installing the unit .........................................................................................................................................................................8
Electrical wiring.......................................................................................................................................................................... 11
Front panel connection........................................................................................................................................................... 12
Checks before use..................................................................................................................................................................... 13
Calibrating the compressor motor circuit breaker........................................................................................................ 14
Closing the control ................................................................................................................................................................... 15
Control panel ..................................................................................................................................................................................... 16
Front keypad ............................................................................................................................................................................... 16
LED display .................................................................................................................................................................................. 17
General.......................................................................................................................................................................................... 17
Symbols used.............................................................................................................................................................................. 17
Setting and displaying the setpoints................................................................................................................................. 17
Level 1 - Programming (User Level).................................................................................................................................... 18
List of Level 1 variables (User Level) ................................................................................................................................... 18
Level 2 - Programming (Installer Level)............................................................................................................................. 19
List of Level 2 variables (Installer Level) ............................................................................................................................ 19
Switching on the OPTYMATM Control three-phase........................................................................................................ 20
Compressor activation/deactivation conditions ........................................................................................................... 20
Manual defrosting..................................................................................................................................................................... 20
Pump-down function .............................................................................................................................................................. 21
Password function .................................................................................................................................................................... 21
Alarm/AUX RELAY SWITCHING.................................................................................................................................................. 22
Alarm codes ........................................................................................................................................................................................ 24
Trouble shooting ............................................................................................................................................................................. 25
General safety instructions......................................................................................................................................................... 26
Maintenance ............................................................................................................................................................................... 26
Parts list................................................................................................................................................................................................ 27
Ordering............................................................................................................................................................................................... 28
Table of contents Page

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OPTYMATM Control three-phase Operation and Maintenance Guide
Description
The OPTYMATM Control three-phase is a controller for
refrigeration systems with a three-phase compressor
or for controlling the three-phase evaporating unit
only, for complete cold room management. Front
access to the magnetothermic protection and motor
circuit breaker for the compressor and an innovative
design combine to make it the ideal choice for
effective refrigeration control.
Applications
- Complete management of three-phase refrige-
rating systems up to 7.5 HP static or ventilated,
with off-cycle or electrical defrosting.
Functions and main characteristics
- LED icons to signal plant status.
- Electronic control with wide LED display and easy
to use buttons.
- Display and adjustment of cold room temperature
accurate to 0.1 °C.
- Display of evaporator temperature from para-
meter.
- System control activation/deactivation.
- Alarm signalling: probe errors, minimum and
maximum temperature alarm, compressor protec-
tion (man-in-cold-room alarm in preset models).
- Evaporator fan control.
- Automatic and manual defrost control (static,
heating element).
- Direct or pump-down control of motor compressor
unit (selectable by terminal block connection in
preset models).
- Room light activation, via panel key or door
switch
- Auxiliary relay with activation configurable by
parameter.
- Parameter access with password (4 different
selectable restriction levels).
- General magnetothermic circuit breaker accessible
from the front panel, which cuts the general power
supply.
- Adjustable motor circuit breaker for compressor
protection accessible from the front panel (in
preset models).
General

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OPTYMATM Control three-phase Operation and Maintenance Guide
Technical characteristics of OPTYMATM Control three-phase
Technical characteristics OPTYMATM Control (4 HP) OPTYMATM Control (7.5 HP)
Housing dimensions 400 x 300 x 135 mm 400 x 300 x 135 mm
Weight 9 kg 10 kg
Protection rating IP 65 IP 65
Power supply (3F+N+T) 400Vac ±10% 50/60Hz 400Vac ±10% 50/60Hz
Load type 3-phase 3-phase
Operating temperature - 5 to + 40 °C - 5 to + 40 °C
Storage temperature -25 to +55 °C -25 to +55 °C
Relative ambient humidity from 30% to 95% RH
w/out condensate
from 30% to 95% RH
w/out condensate
Altitude < 1000 m < 1000 m
Main switch / general protection
Interruption power
4-pole magnetothermic 16A “D”
Icn=6kA / Ics=8kA / Icu=15kA
4-pole magnetothermic 25A “D”
Icn=6kA / Ics=8kA / Icu=15kA
Compressor protection Adjustable motor circuit breaker Adjustable motor circuit breaker
Defrosting electrical electrical
Status indicators LED + display LED + display
Alarm signals LED + buzzer LED + buzzer
Inputs
Ambient probe EKS 221: code no. 084N3210 EKS 221: code no. 084N3210
Evaporator probe EKS 221: code no. 084N3210 EKS 221: code no. 084N3210
Door switch present present
High/low pressure switch present present
Kriwan® connection present present
Compressor functioning mode selection pump-down / thermostat pump-down / thermostat
Digital inputs (requirements to contacts) Gold plating Gold plating
Outputs
Compressor See motor circuit breaker
thermal range
See motor circuit breaker
thermal range
Condenser fans output 1 800W (1 phase) 800W
total
(1 phase)
Condenser fans output 2 (separated) (1 phase)
Evaporator fans 500W (1 phase) 2000W (1phase / 3 phases)
Defrosting heaters 6000W (AC1) eq. resistive load 9000W (AC1) eq. resistive load
Room light 800W (AC1) resistive load 800W (AC1) resistive load
Solenoid valve present present
Compressor oil heater present present
Alarm relay 100W 100W

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OPTYMATM Control three-phase Operation and Maintenance Guide
Overall dimensions
Dimensions in mm.
Connection diagrams

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OPTYMATM Control three-phase Operation and Maintenance Guide
The OPTYMATM Control three-phase unit is supplied with:
Standard assembly kit
Installation
• 4 rubber washers, to be tted between the
fixing screws and the housing back panel
• 1 operation and maintenance guide
• 1 wiring instruction.
• 1 drilling layout.
• 2 sensors
• Each control is designed to be wall-mounted;
please select an appropriate fixing method
depending on the weight.
• Install the device in places where the protection
rating is observed.
• To eect the correct electrical connection and
maintain the protection rating, use appropriate
cable glands and plugs to ensure a good seal.
Mechanical assembly
• Install the device at an appropriate height for
ease of use and maintenance. The installer must
not be put at risk when working on the panel.
The device must be located at a height of between
0.6 and 1.7 m from the ground.
• Install the device away from re and heat sources
and protect from the weather if necessary.
A label bearing the following information is affixed to
the side of the product described in this manual
• Name of manufacturer
• Product type and code number
• Product name
• Power supply
• Compressor range
• Serial number (10 digits)
• Date (Day/Month/Year)
Identification data
Each control is carefully packaged to ensure that
it arrives undamaged under normal transport
conditions. Prior to transportation, please ensure
that:
• No objects or loose parts are inside the control.
• The door is correctly closed and locked.
• If the original packaging is not used, the
product is suciently packaged to allow safe
transportation
Transport and storage
The storage room must be of a suitable temperature
and low humidity; avoid contact between the
electrical control and aggressive contaminants that
could impair functioning and electrical safety.
Example:
Installation to be done by authorised person only!

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OPTYMATM Control three-phase Operation and Maintenance Guide
1.
Lift the transparent cover protecting the general
magnetothermic circuit breaker.
Installing the unit
2.
Remove the screw cover on the right-hand side.
3.
Undo the 4 fixing screws on the front of the cover.

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OPTYMATM Control three-phase Operation and Maintenance Guide
4.
Close the transparent protection cover.
Installing the unit
(continued)
5.
Open the front of the housing, lift it and slide the two
hinges out as far as they will go.
6.
Bend the hinges and rotate the front panel by 180°
downward to gain access to the inside of the panel;
then disconnect the electronic card connector.

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OPTYMATM Control three-phase Operation and Maintenance Guide
7.
Squeeze both sides of each hinge together to remove
them from their seats and then completely remove
the front panel.
Installing the unit
(continued)
8.
Using a screwdriver, tap out the tabs in the 4 holes
in the back panel in preparation for fixing it to the
wall.
9.
Using the drilling guide provided, drill 4 fixing holes
in the wall.

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OPTYMATM Control three-phase Operation and Maintenance Guide
10.
Using the holes made in point 9 above, screw the
back panel to the wall using 4 screws of a suitable
length for the wall thickness. Fit a rubber washer
(supplied) between each screw and the housing
back panel.
Installing the unit
(continued)
11.
Now do the electrical wiring as shown below.
Electrical wirings
• For the electrical wiring please refer to the wiring
instruction and technical characteristics of the
controller being installed.
• The controller power supply must be on a
dedicated line, and must be equipped with a
suitable device to protect against indirect contacts
upstream of the line (differential interrupter).
• Do not route power supply wiring and signal
wiring (probes/sensors and digital inputs)
in the same raceways or ducts.
• Do not use multi-polar cables which have wires
connectedtoinductive/powerloads and signalling
wires (e.g. probes/sensors and digital inputs).
• Minimise the length of connector wires so that
wiring does not twist into a spiral shape, as this
could have a detrimental effect on the elec-
tronics.
• If a probe/sensor extension is required, the wires
must have a diameter of at least 1 mm2.
• All wiring must be of a diameter suitable for the
relevant power levels. The degree of insulation
must be compatible with the applied voltages.
Preferably use cables with flame-retardant
insulation and a low smoke emission where fire
regulations apply.
• It is essential to connect the clamp marked PE
to the earth of the supply system.
If necessary, please check the eectiveness of
the earthing system.
• Do not connect to the PE clamp conductors
any dierent than the external protection.

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OPTYMATM Control three-phase Operation and Maintenance Guide
1.
Re-attach the front panel to the lower part of the
housing by inserting the two hinges in their seats.
Front panel connection
2.
Bend the hinges and rotate the front panel
downwards 180° to gain access to the inside of the
housing and then reconnect the electronic card
connector.
3.
When using Alarm/Aux relay, connect the wiring
directly to the electronic card clamps.
It is advisable to route these wires alongside the
connection cables from the electronic card and the
housing back panel.
Re-attach the front panel and reconnect the elec-
tronic card connector as shown below.

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OPTYMATM Control three-phase Operation and Maintenance Guide
Checks before use
• Having completed the wiring, please check with
the wiring diagram to ensure it has been done
correctly.
• Check that the screw clamping is correct.
• If possible, check that the outside protection
devices function correctly.
• Calibrate the motor circuit breaker for the
compressor (if present) correctly as shown on the
following pages.
• After powering up the control, please check
the correct current absorption on the loads,
and after it has been running for a few hours
check that the screws on the terminal blocks
are sufficiently tight (including power supply
line connection).
Warning:
Please disconnect the power sectioning power
supply upstream of the line and secure it with
a padlock for max. safety, before tightening
the screws. Before any operation, use a
voltage detector to check that there is no
voltage.

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OPTYMATM Control three-phase Operation and Maintenance Guide
1.
When starting the system for first time, it is advisable
to calibrate the motor circuit breaker on the
compressor power circuits. Use an ammeter to check
the effective absorption.
Calibrating the compressor motor circuit breaker
2.
Calibrate the motor circuit breaker based on the
measured absorption. The set up value must not
exceed that recommended by the compressor
manufacturer.
Warning:
An incorrect calibration may cause compressor
breakdown or bad intervention of the motor circuit
breaker.
3.
To calibrate use the control screw on the front of
motor circuit breaker.
Step-by-step instructions for calibrating the motor
circuit breaker for the compressor are given below:

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OPTYMATM Control three-phase Operation and Maintenance Guide
1.
Close the front panel, making sure that all the wires
are inside the housing and that the housing seal is
located securely in its seat
Closing the control
2.
Tighten the front panel using the 4 screws, making
sure the rubber washers are used on the head of
each screw.
Replace the screw cover on the right-hand side.
3.
Power up the control and carry out thorough reading/
programming of all the parameters.
Below is a step by step description on how to
calibrate the motor circuit breaker dedicated to the
compressor.

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OPTYMATM Control three-phase Operation and Maintenance Guide
Control panel
Front keypad
AUXILIARY RELAY CONTROL
(on the version with alarm relay controls the relay
manual if parameter AU=1)
UP / MUTE WARNING BUZZER
STAND BY
(The LED flashes if the system shuts down)
Room temperature SETTING / SET key
DOWN / MANUAL DEFROST
ROOM LIGHT

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OPTYMATM Control three-phase Operation and Maintenance Guide
LED display
1. Cold room temperature / parameters
2. Stand-by (flashes on stand-by. Outputs are de-
activated)
3. Room light (flashes if door switch is activated)
4. Cold (indicates activation of compressor)
5. Fans
6. Defrosting
7. Auxiliary
8. Alarm/warning
General
To enhance safety and simplify the operator’s work,
the OPTYMATM Control has two programming
levels; the rst level (Level 1) is used to congure
the frequently-modified SETPOINT parameters. The
second programming level (Level 2) is for general
parameter programming of the various controller
operating modes.
It is not possible to access the Level 2 programming
directly from Level 1: you must exit the programming
mode first.
Setting and displaying the setpoints
1. Press the SET key to display the current SETPOINT
(temperature)
2. Hold down the SET key and press the () or ()
keys to modify the SETPOINT.
Release the SET key to return to cold room
temperature display: the new setting will be saved
automatically.
Symbols used
For practical purposes the following symbols are used:
• () the UP key is used to increase values and mute the alarm.
• () the DOWN key is used to decrease values and force defrosting.

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OPTYMATM Control three-phase Operation and Maintenance Guide
Level 1 - Programming (User Level)
To gain access to the Level 1 configuration menu
proceed as follows:
1. Press the () and () keys simultaneously and
keep them pressed for a few seconds until the first
programming variable appears on the display.
2. Release the () and () keys.
3. Select the variable to be modified using the ()
and () key.
4. When the variable has been selected it is
possible to:
• display the setting by pressing SET key
• modify the setting by pressing the SET key
together with the () and () key.
When configuration values have been set
exit the menu by pressing the () and ()
keys simultaneously for a few seconds until the
cold room temperature reappears.
5. The new settings are saved automatically when
you exit the configuration menu.
List of Level 1 variables (User Level)
Variables Explanation Value Default
r0 Dierential above main SETPOINT*
* SETPOINT see page 10
0.2 - 10 K 2K
d0 Defrost interval (hours) 0 - 24 hours 4 hours
d2 End-of-defrost setpoint.
Defrosting will not take place if the temperature detected by the defrost
sensor is greater than d2 (If the sensor is faulty, defrosting is timed)
-35 - 45 °C 15°C
d3 Max defrost duration (minutes) 1 - 240 min 25 min
d7 Drip duration (minutes)
At the end of defrost, the compressor and fans remain at standstill for time
d7 and the defrost LED on the front panel flashes.
0 - 10 min 0 min
F5 Fan pause after defrost (minutes)
Allows fans to be kept at standstill for time F5 after dripping. This time
begins at the end of dripping. If no dripping has been set, the fan pause
starts directly at the end of defrost.
0 - 10 min 0 min
A1 Minimum temperature alarm
Allows user to define a minimum temperature for the room being
refrigerated. Below value A1 an alarm trips: the alarm LED flashes, the
displayed temperature flashes and the buzzer sounds to indicate the
problem.
- -45°C
A2 Maximum temperature alarm
Allows user to define a maximum temperature for the room being
refrigerated. Above value A2 an alarm trips: the alarm LED flashes, the
displayed temperature flashes and the buzzer sounds to indicate the
problem.
- +45°C
tEu Evaporator sensor temperature display Displays
evaporator
temperature
(displays
nothing if
dE =1)
read
only

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OPTYMATM Control three-phase Operation and Maintenance Guide
Level 2 - Programming (Installer Level)
To access the second programming level press the
UP () and DOWN () keys and the LIGHT key
simultaneously for a few seconds.
When the first programming variable appears the
system automatically goes to stand-by.
1. Select the variable to be modified by pressing the
UP () and DOWN () keys.
When the parameter has been selected it is
possible to:
• view the setting by pressing the SET key.
• modify the setting by holding the SET key
down and pressing the () or () key.
2. When the configuration settings have been
completed, exit the menu by pressing the
() and () keys simultaneously and keep
them pressed until the room temperature
reappears.
3. Changes are saved automatically when you exit
the configuration menu.
4. Press the STAND-BY key to enable electronic
control.
List of Level 2 variables (Installer Level)
Variables Explanation Value Default
AC Door switch status 0 = normally open
1 = normally closed
0
F3 Fan status with compressor o 0 = fans run continuously
1 = fans only run when
compressor is working
1
F4 Fan pause during defrost 0 = fans run during defrost
1 = fans do not run during defrost
1
dE Sensor presence
If the evaporator sensor is disabled defrosts are
carried out cyclically with period d0: defrosting
ends when an external device trips and closes the
remote defrost contact or when time d3 expires.
0 = evaporator sensor present
1 = no evaporator sensor
0
d1 Defrost type, cycle inversion (hot gas) or with
heater elements
1 = hot gas
0 = element
0
Ad Not to be used
Ald Minimum and maximum temperature
signalling and alarm display delay
1 - 240 min 120 min
C1 Minimum time between shutdown and
subsequent switching on of the compressor.
0 - 15 min 0 min
CAL Correction of sensor signal -10 - +10 0
Pc Compressor protection contact status 0 = NO
1 = NC
0 = NO
doC Compressor safety time for door switch: when
the door is opened, the evaporator fans shut down
and the compressor will continue working for time
doC, after which it will shut down.
0…5 minutes 0
Fst Fan shutdown temperature
The fans will stop if the temperature value detected
by the evaporator sensor is higher than this value.
-45 - +45°C +45°C
Fd Fan dierential below Fst 0 - +10K 2K

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OPTYMATM Control three-phase Operation and Maintenance Guide
Variables Explanation Value Default
tA NO – NC alarm relay switching 0 = activates when alarm is on
1 = deactivates when alarm is on
1
AU Auxiliary/alarm relay control
(only on version with relay fitted)
0 = alarm relay
1 = manual auxiliary relay
controlled via AUX key
2 = automatic auxiliary relay
managed by StA temp. setting
with 2°C differential
3 = relay disabled
4 = pump-down function (page 21)
5 = free voltage contact for
condensing unit (AUX relay and
compressor relay in parallel)
0
StA Temp. setting for aux. relay -45…+45°C 0
In1 Man-in-cold-room alarm
Select input INP1 on the board as compressor
protection alarm or as man-in-cold-room alarm
(contact NC).
0 = compressor protection
1 = man-in-cold-room alarm
0
P1 Password type of protection
(active when PA does not equal 0)
0 = only display set point
1 = display set point, AUX, light
access
2 = access to programming not
permitted
3 = access to second level
programming not permitted
3
PA Password
(see P1 for the type of protection)
0...999
0 = not active
0
reL Software release indicates software version Read
only
Continued...
Switching on the OPTYMATM Control three-phase
After correctly wiring the electronic control,
power up at 400 V AC; the display panel will
immediately emit a beep and all the LEDs will come
on simultaneously for a few seconds.
Compressor activation/deactivation conditions
The OPTYMATM Control three-phase activates the
compressor when the cold room temperature
exceeds setting + dierential (r0); it deactivates the
compressor when the cold room temperature is
lower than the setting.
Manual defrosting
To defrost, just press the dedicated key (see page 16)
to activate the elements relay. Defrosting will not
take place if the end-of-defrost temperature setting
(d2) is lower than the temperature detected by the
evaporator sensor. Defrosting ends when the end of-
defrost temperature (d2) or maximum defrost time
(d3) is reached.