Danfoss Optyma OP-HGZ D48E Series User manual

© Danfoss | DCS (CC) | 2022.11 AN433834055224en-010101 | 1
1 – Introduction
These instructions pertain to Optyma
Commercial D48 Version used for
refrigeration systems. They provide
necessary information regarding safety and
proper usage of this product.
The condensing unit includes following:
• Liquid Receiver
• Filter Drier
• Sight Glass
• Low / High Pressure Switch - KP15
• Suction Filter
• Oil Separator
• Solenoid Valve
• Crankcase Heater
• Quick connections - Suction / Discharge
Valve
• Electrical Box - IP65 with LED signal
• 2 X Fan Speed Controler
• Housing
2 – 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.
• Don’t expose the packaging to rain or
corrosive atmosphere.
• Store the unit between -35°C and 50°C.
• After unpacking, check that the unit is
complete and undamaged.
3 – Installation precautions
Do not braze as long the condensing unit
is under pressure.
Never place the unit in a flammable
atmosphere.
IPlace 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.
• 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 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 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.
4 – Installation
• The unit must be securely installed on a
stable and rigid support and fixed from the
beginning.
• 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 with 19mm
thick insulation.
Instructions
Optyma™ Commercial D48 Version
OP-HGZXXXD48E
OP-HGZ 080 D48 E
1 2 3 4 5 6 7
1 Application
H = HBP/Universal
2 Design
G = Condensing unit with hermetic compressor, two fans
3 Compressor Oil
Z = Polyolester oil (POE) 175PZ, Reciprocating Compressor MTZ
4 Compressor type and model
MTZ Series for hermetic MBP
5 Platform
D = Micro-channel technology
6 Product configuration
48
7 Electrical code:
E = 400V 3Ph 50Hz Comp. & 230V 1Ph Fan Motor
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 nitro- gen 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 posi-
tion (maximum offset from the vertical: 15°)
Designation system
Warnings

© Danfoss | DCS (CC) | 2022.11
Instructions
2 | AN433834055224en-010101
5 – 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.
6 – 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 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.
7 – Electrical connections
• Switch off and isolate the main power
supply.
• Ensure that power supply cannot 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.
• For units with a 3-phase compressor,
correct phase sequence for compressor
rotation direction shall be observed.
• 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.
8 – 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 slow
charging of the system to 4 – 5 bar.
• 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.
9 – 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.
• 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.
10 – Start-up
• Never start the unit when no refrigerant is
charged.
• All service valves must be in the open
position.
• 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. It must start promptly.
If the compressor does not start, check
wiring conformity, voltage on terminals
and sequence phase.
• Eventual reverse rotation of a 3-phase
compressor can be detected by following
phenomena; unit doesn’t start, 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 low pressure
gauge shall show a declining pressure and
the high pressure indication on the high
pressure gauge shall show an increasing
pressure.
11 – 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 operating limits.
• 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.
12 – 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.
• Keeptheunitcleanandverifytheabsenceof
rust and oxidation on the unit components,
tubes and electrical connections.
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.

Instructions
© Danfoss | DCS (CC) | 2022.11 AN344017165464-00010 | 3
• Switch off the unit at main switch before
remove any panel from the condensing
unit.
• Removesurface dirt, leaves,fibers, 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.
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.
13 - 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 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.
14 – Disposal
Danfoss recommends that
condensing units and oil should be
recycled by a suitable company at its
site.

© Danfoss | DCS (CC) | 2022.11
Instructions
4 | AN433834055224en-010101
OP-HGZXXXD48E
Attachments A L P X Y Z
HGZ080 to 100 725 1210 810 20 25 500
HGZ125 to 160 985 1510 810 20 25 500

Instructions
© Danfoss | DCS (CC) | 2022.11 AN344017165464-00010 | 5
Electrical code E (HGZ080 to 125) - 400V 3Ph 50Hz
WD1
WD2
Legend
Q1 Motor Circuit Breaker
F1 Fuse
K1 Contactor
VS Solenoid Valve
CP Compresor
S1 Room Thermostat
S2 Gas Thermostat
C1/C2 Fan Capacitor
M1/M2 Fan Motor
A1 Monitoring Relay
B1/B2 Fans Speed Control
B3 Pressure Switch
Electrical code E (HGZ144 to 160) - 400V 3Ph 50Hz
Legend
Q1 Motor Circuit Breaker
F1 Fuse
K1 Contactor
CH1 Main Switch
VS Solenoid Valve
CP Compresor
S1 Room Thermostat
S2 Gas Thermostat
C1/C2 Fan Capacitor
M1/M2 Fan Motor
A1 Monitoring Relay
B1/B2 Fans Speed Control
B3 Pressure Switch
Cable ID
BK Black
BU Blue
RD Red
WH White
GR Green
BR Brown
GY Grey
Cable ID
BK Black
BU Blue
RD Red
WH White
GR Green
BR Brown
GY Grey

6 | AN433834055224en-010101 © Danfoss | DCS (CC) | 2022.11