Product Guide For Propane Applications Preface This catalogue contains two sections. The first section is related to products which are intended to be applied in systems located in an environment according to ATEX definition (Zone 2). These products are manufactured under consideration of appropriate standards and directives. The second section is only related to products intended to be used in systems with R290 refrigerant but having appropriate solution in order to prevent explosion risk at any time (non-risk zone). The definition of “non-risk zone” is related to the environment of the installed device and no special product requirement is needed except material compatibility of part in contact with refrigerant. These products are not ATEX certified may under no circumstance be used within areas with explosive or flammable atmosphere and that the owner, designer and installer are responsible to ensure strict compliance with related regulation and avoid any such risk. Products in section 1: Products are intended for use in systems located in an environment according definition of ATEX (Zone 2) Page04 – 45 Products in section 2: Products are intended for use in non explosive environment (Products do not comply with ATEX requirements) Page 46 – 58 General Information Technical data provided herein is collected with scrutiny. However, errors and misprinting remain reserved. The technical data is presented for informational purposes only and they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described or their use or applicability. Technical data may be updated; should you require confirmation with respect to a specific value, please contact Emerson Climate Technologies GmbH and clearly state the information you require. Emerson Climate Technologies GmbH and/or its affiliates (collectively “Emerson”) shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors. Products, specifications, designs and technical data contained in this document are subject to modification by us without prior notice. Illustrations are not binding. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any product remains solely with the purchaser and end-user. The information given herein is based on data and tests which Emerson Climate Technologies GmbH believes to be reliable. Such information is intended for use by individuals having the appropriate technical knowledge and skills, at their own discretion and risk. Our products are designed and adapted for stationary application. When using our products in mobile applications, our products might fail. The suitability for such mobile applications has to be assured by the plant manufacturer; for this purpose appropriate tests might be necessary. 2 Contents Important considerations ........................................................................................................................................................................................................................ 4 ATEX Zone 2 Definition ........................................................................................................................................................................................................................ 4 Device classification........................................................................................................................................................................................................................ 4 European directives........................................................................................................................................................................................................................ and standard 5 Compliance and Marking ........................................................................................................................................................................................................................ 5 Section 1: Products for use in Zone 2 according ATEX definition ........................................................................................................................................................................................................................ 6 Introduction ......................................................................................................................................................................................................................... 7 ZH Copeland Scroll™ for R290 (Propane) Technical Bulletin ......................................................................................................................................................................................................................... 8 Capacity......................................................................................................................................................................................................................... Data 9 ZB Copeland Scroll™ for R290 (Propane) Technical Bulletin ......................................................................................................................................................................................................................... 10 Capacity......................................................................................................................................................................................................................... Data 11 Electronic Expansion Valves EX4-7-…FLR Versions and M12 Connector EVC05A Technical........................................................................................................................................................................................................................ Bulletin 13 Operating Instruction ........................................................................................................................................................................................................................ 15 Thermo™-Expansion Valves TX3-…FLR Technical........................................................................................................................................................................................................................ Bulletin 19 Operating Instruction ........................................................................................................................................................................................................................ 22 Solenoid Valves Series 200RB…-FLR Technical........................................................................................................................................................................................................................ Bulletin 25 Operating Instruction ........................................................................................................................................................................................................................ 27 Operating Instruction ASC… + PG9-ATEX (H.T.P.S.r.l.) ........................................................................................................................................................................................................................ 29 PT5-…-FLR Pressure Transmitter Technical........................................................................................................................................................................................................................ Bulletin 31 Operating Instruction ........................................................................................................................................................................................................................ 32 PS4-…ATEX Pressure Switch with fixed setting Technical........................................................................................................................................................................................................................ Bulletin 34 Operating Instruction ........................................................................................................................................................................................................................ 35 Hermetic Liquid Line Filter Driers ADK-…FLR Technical........................................................................................................................................................................................................................ Bulletin 37 Operating Instruction ........................................................................................................................................................................................................................ 39 Moisture Indicator MIA…-FLR Technical........................................................................................................................................................................................................................ Bulletin 41 Operating Instruction ........................................................................................................................................................................................................................ 43 Section 2: Product material compatible with R290 only for non-explosive environment ........................................................................................................................................................................................................................ 46 EC3-P32/-P33 Superheat Controller & Standard ECD-002 Technical........................................................................................................................................................................................................................ Bulletin 48 Electronic Expansion Valves EXM/L Series Technical........................................................................................................................................................................................................................ Bulletin 50 EXD-HP1/2 Stand-alone Superheat Controller Technical........................................................................................................................................................................................................................ Bulletin 53 Oil Management OM3-020P TraxOil Technical........................................................................................................................................................................................................................ Bulletin 55 CSS-25U / CSS-32U / CSS-32W Compressor Soft Starter Technical........................................................................................................................................................................................................................ Bulletin 57 3 a. Important Considerations • The products are intended to be sold in EU and EFTA • Using inaccurate design operating conditions for countries where European directives and standards are selection of products might lead to wrong selection/ in place and considered. Other countries may require results. In this case, the selected products might additional approval of local authorities/ regulations. be oversized or undersized and consequently lead to improper operation of the device in the system. • Documentation is in English language. System manufacturers shall consider this fact. If the transmission of • Only specified products in this document have been information in local language as per requirement of intended for use with R290. ATEX directive is needed, system manufacturer is to take care of proper translation. • It is advisable to share the related information with own consultant or notify body in order to make sure the applicability of products for any specific system • The operating instructions results from risk assessment under consideration of hazardous zone where system and it must be taken into account during design and supposed to be operated. manufacturing of system. b. ATEX Zone 2 Definition Location of equipment Group II: Intended for use in other places Category Explosive atmospheres Explosive gas Zone 3 Unlikely Gas 2 c. Device Classification • Non-electrical operating device without potential of electrostatic charge: - Thermo expansion valves, sight glasses, solenoid valves body (without coil), filter driers • Electrical operating device contains a housing with sufficient protection design/construction: 4 - Compressor, pressure transmitters, coils of solenoid valves and electronic expansion valves • Electrical operating device with maximum permitted electrical operating supply voltage/current: - Pressure switches and electronic expansion valves d. European Directives and Standard The following directives and standards have been considered for compliance of products in this document: • PED (Pressure Equipment Directive) • ATEX 94/9/EC (Equipment and protective systems intended for use in potentially explosive atmospheres Directive) • LVD cannot be used when ATEX is used • EMC (Electromagnetic Compatibility Directive) • Guidelines on the application of Directive ATEX 94/9/EC • EN60335 (Safety of Household and similar electrical appliance, Part 1 & 40) • EN60079 (Explosive atmospheres, Part 1, 10-1, 11, 14, 15 and 18) • EN378 (Refrigerating systems and heat pumps - Safety and environmental requirements) • EN12284 (Refrigeration systems and heat pumps. Valves: Requirements, testing and marking) • EN12178 (Refrigeration systems and heat pumps. Liquid level indicating devices: Requirements, testing and marking) • EN14276-1 (Refrigeration systems and heat pumps. Vessels: Requirements, testing and marking) • EN12263 (Refrigeration systems and heat pumps. Safety switching devices for limiting pressure: Requirements, testing and marking) • EN16084 (Refrigeration systems and heat pumps. • Qualification of tightness of components and joints) e. Compliance and Marking Product type Directive PED EMC ATEX Not applicable Not applicable Marking ThermoTM Expansion Valve : TX3-…-FLR Filter Drier : ADK-…-FLR Sight Glass : MIA-…-FLR Solenoid Valve : 200RB-…-FLR Solenoid Valve Coil + Plug : ASC24V + PG9 ATEX Not applicable Not applicable Solenoid Valve Coil + Plug : ASC230V + PG9 ATEX Pressure Transmitter : PT5-…-FLR Applicable Electronic Expansion valve : EX4-7...FLR Applicable Not applicable Electrical plug and cable assembly : EVC05A Pressure Switch : PS4-…ATEX Applicable Not applicable Applicable 5 Section 1: Products for use in Zone 2 according ATEX definition 6 1 Products for use in Zone 2 according to ATEX definition Introduction Many end-users, equipment and compressor manufacturers are investigating ways to minimize their impact on the environment. Improving system architectures, using a refrigerant with lower global warming potential (GWP) can significantly improve the carbon footprint of an installation. R290 is one of the most-discussed refrigerants which has long been known for its good performance as refrigerant but is flammable and consequently brings about strict considerations for system manufacturers in terms of system design and operation. The specified listed products in this section have been released for use in systems using R290 as a refrigerant by considering information related to each product as follows: Product family Scroll Compressor Electronic Expansion Valves Thermo TM Expansion Valves Solenoid Valves Coil + Plug Pressure Transmitters Pressure Switches Product type Pages ZH*KCU 8-9 ZB*KCU 10 - 11 EX4-7…-FLR 12 - 14 & 15 - 17 EVC05A 12 - 14 & 18 TX3-P…-FLR 19 - 24 200-RB3/RB4/RB6…-FLR 25 - 28 ASC24V + PG9 ATEX ASC230V + PG9 ATEX PT5-30L-FLR PS4-W1 808301 0.6/1.8 bar PS4-W1 808300 20/26 bar 29 30 - 32 33 - 35 Filter Driers ADK-03.../-05.../-08…/-16.../30.../-41.../-75…-FLR 36 - 39 Moisture Indicator / Sight Glass MIA...-FLR 40 - 43 7 Technical Bulletin ZH Copeland Scroll™ for R290 (Propane) Propane (R290) is a flammable natural refrigerant which has long been known for its good performances. It has zero ozone depletion potential, negligible global warming potential, as well as excellent thermodynamic properties. R290 systems require in average half the charge of hydrofluorocarbons (HFCs). Emerson is launching a full line-up of propane Copeland Scroll compressors designed for chillers and heat pump applications. This line-up meets Emerson reliability standards and is classified ATEX Group II. • • • • • • • Axial and radial compliance Dedicated oil for propane ATEX compliance IP65 (IEC 60529) No sight-glass, no Schrader valve Hermetic compressor Wide operating envelope Single Capacity (kW) 0 5 10 65 Condensing Temperature °C 50 45 II Group II gas atmosphere other than mines susceptible to fire damp 3 Category 3 - Equipment that is intended for use in areas where explosive atmospheres are unlikely to occur in normal operation and if they do occur, are likely to do so infrequently and for a short period only. It must ensure a normal/suitable level of protection for normal operation G G - Gas: Explosive atmospheres caused by mixtures of air and gases, vapors, mists 40 35 30 25 20 Ex nA 15 10 -5 5 0 10 15 20 25 Electrical equipment of Group II is subdivided according to the nature of explosive gas atmosphere for which it is intented. A typical Group IIA gas is propane T2 T2 - Temperature Classification by maximum permissible surface temperature: 300°C Evaporating Temperature °C 10K Superheat Future release Technical Overview Model 1 Ph Displacement 3 Ph (m3/h) Heating capacity (kW)* COP Length / Width/ Sound Height pressure (mm) @1 m (dBA)** Net weight (kg) ZH04KCU-PFZN ZH04KCU-TFMN 5.8 4.4 3.2 60 243 / 242 / 364 23 ZH06KCU-PFZN ZH06KCU-TFMN 8.0 6.2 3.2 61 243 / 242 / 406 27 ZH08KCU-PFZN ZH08KCU-TFMN 10.0 7.7 3.3 64 243 / 242 / 419 28 ZH09KCU-PFZN ZH09KCU-TFMN 11.7 9.0 3.2 62 247 / 241 / 438 38 ZH11KCU-PFZN ZH11KCU-TFMN 14.4 10.9 3.3 63 247 / 241 / 438 38 - ZH13KCU-TFMN 17.1 13.0 3.3 64 250 / 246 / 450 40 * Conditions Evaporating -7°C, Condensing 50°C, Superheat 10K, Subcooling 4K ** @ 1m: sound pressure level at 1m distance from the compressor, free field condition 8 35 Ex nA - Non Sparking. Protection for Category 3G devices according to EN 60079-15. Suitable for use in Zone 2 IIA 0 -10 30 ATEX Protection against explosion 60 -15 25 Ex 55 -20 20 ATEX Compressor Classification 70 -25 15 * Propane Variable Speed compressors in development Conditions Heating : Evaporating -7°C, Condensing 50°C, Superheat 10K, Subcooling 4K 75 -30 Tandem Heating Operating Envelope R290 -35 ZH*KCU Copeland Scroll™ for R290 R290 Scroll Compressor Line-Up* Features and Benefits Technical Bulletin ZH Copeland Scroll™ for R290 (Propane) Capacity Data Condensing temperature °C 70 65 60 55 50 45 40 35 30 25 20 R290 Heating Capacity in kW Evaporating temperature °C R290 10 5 0 -5 -10 -15 -20 -25 -30 6.1 8.4 10.5 12.2 15.1 17.6 6.4 8.7 10.9 12.7 15.7 18.2 6.6 9.0 11.3 13.2 16.2 18.9 6.9 9.4 11.7 13.7 16.8 19.5 7.1 9.7 12.1 14.2 17.4 20.2 7.4 10.1 12.5 14.7 18.0 20.8 7.6 10.4 12.9 15.2 18.6 21.5 7.9 10.8 13.3 15.7 19.2 22.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 5.4 7.4 9.2 10.7 13.3 15.5 5.6 7.6 9.5 11.1 13.7 16.0 5.8 7.9 9.8 11.5 14.2 16.5 6.0 8.2 10.2 11.9 14.7 17.1 6.2 8.5 10.5 12.3 15.2 17.6 6.4 8.7 10.9 12.7 15.7 18.1 6.6 9.0 11.2 13.1 16.1 18.6 6.8 9.3 11.5 13.6 16.6 19.2 7.0 9.6 11.8 14.0 17.1 19.6 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 4.7 6.5 8.1 9.4 11.7 13.7 4.9 6.7 8.3 9.7 12.0 14.1 5.1 6.9 8.6 10.0 12.4 14.5 5.2 7.1 8.9 10.3 12.8 14.9 5.4 7.3 9.1 10.7 13.2 15.3 5.5 7.6 9.4 11.0 13.6 15.7 5.7 7.8 9.7 11.3 13.9 16.2 5.8 8.0 9.9 11.7 14.3 16.6 6.0 8.2 10.2 12.0 14.7 17.0 6.2 8.5 10.4 12.3 15.1 17.3 0.0 0.0 0.0 0.0 0.0 0.0 4.2 5.7 7.2 8.3 10.3 12.1 4.3 5.9 7.3 8.5 10.6 12.4 4.4 6.0 7.5 8.7 10.8 12.7 4.5 6.2 7.7 9.0 11.1 13.0 4.6 6.3 7.9 9.2 11.4 13.3 4.8 6.5 8.1 9.5 11.7 13.6 4.9 6.7 8.3 9.7 12.0 14.0 5.0 6.9 8.6 10.0 12.3 14.3 5.1 7.1 8.8 10.3 12.6 14.6 5.3 7.2 9.0 10.5 12.9 14.9 5.4 7.4 9.1 10.8 13.2 15.2 3.7 5.1 6.4 7.3 9.1 10.8 3.8 5.2 6.4 7.5 9.3 10.9 3.8 5.2 6.6 7.6 9.5 11.1 3.9 5.4 6.7 7.8 9.7 11.3 4.0 5.5 6.9 8.0 9.9 11.6 4.1 5.6 7.0 8.2 10.1 11.8 4.2 5.7 7.2 8.4 10.3 12.1 4.3 5.9 7.3 8.6 10.6 12.3 4.4 6.0 7.5 8.8 10.8 12.5 4.5 6.2 7.7 9.0 11.0 12.8 4.6 6.3 7.8 9.2 11.3 13.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 3.3 4.6 5.8 6.7 8.3 9.7 3.4 4.7 5.8 6.8 8.4 9.9 3.5 4.7 5.9 6.9 8.6 10.0 3.5 4.8 6.0 7.0 8.7 10.2 3.6 4.9 6.2 7.2 8.9 10.4 3.6 5.0 6.3 7.3 9.0 10.6 3.7 5.1 6.4 7.5 9.2 10.7 3.8 5.2 6.5 7.6 9.4 10.9 3.9 5.3 6.6 7.8 9.6 11.1 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 2.9 4.0 5.1 5.9 7.3 8.6 3.0 4.1 5.1 5.9 7.4 8.7 3.0 4.1 5.2 6.0 7.5 8.8 3.0 4.2 5.3 6.1 7.6 8.9 3.1 4.3 5.4 6.2 7.7 9.0 3.1 4.3 5.5 6.3 7.8 9.2 3.2 4.4 5.5 6.4 8.0 9.3 3.3 4.5 5.6 6.5 8.1 9.4 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 2.5 3.5 4.4 5.1 6.4 7.5 2.6 3.5 4.5 5.2 6.4 7.6 2.6 3.6 4.5 5.2 6.5 7.6 2.6 3.6 4.6 5.3 6.6 7.7 2.7 3.7 4.6 5.4 6.7 7.8 2.7 3.7 4.7 5.4 6.8 7.9 2.8 3.8 4.8 5.5 6.9 8.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 2.1 3.0 3.8 4.4 5.5 6.5 2.2 3.0 3.9 4.5 5.5 6.5 2.2 3.1 3.9 4.5 5.6 6.6 2.2 3.1 3.9 4.5 5.6 6.6 2.3 3.2 4.0 4.6 5.7 6.7 2.3 3.2 4.0 4.7 5.8 6.8 Compressor model ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN ZH04KCU-TFMN ZH06KCU-TFMN ZH08KCU-TFMN ZH09KCU-TFMN ZH11KCU-TFMN ZH13KCU-TFMN 9 ZB Copeland Scroll™ for R290 (Propane) Technical Bulletin Emerson Climate Technologies is offering a full range of propane Copeland Scroll compressors. The new ZB*KCU Copeland Scroll compressor range with R290 is the ideal choice for self-contained medium-temperature applications. These compressors are also suitable for refrigeration chiller and small cascade systems. The complete compressor range of propane scrolls meets Emerson´s reliability standards and is ATEX Group II classified. Propane (R290) is a flammable natural refrigerant which has long been known for its good performance. It has zero ozone depletion potential, negligible global warming potential (GWP), as well as excellent thermodynamic properties. R290 systems require in average half the charge of hydro-fluorocarbons (HFCs). These features make R290 suitable for the upcoming F-gas regulations. Operating Envelope R290 ATEX compliance IP65 (IEC 60529) Terminal Box Fully hermetic design, no sight-glass, no Schrader valve Wide operating envelope Dedicated oil for propane Ideal for self-contained medium-temperature display cases Suitable for refrigeration chiller and small cascade systems Light weight, compactness and high efficiency Axial and radial compliance II 3G Ex nA IIA T2 70 60 Condensing Temperature °C Features and Benefits • • • • • • • • • • ZB*KCU Copeland Scroll™ for R290 50 40 30 20 10 0 -35 -30 -20 -25 -15 -10 -5 5 0 10 15 Evaporating Temperature °C ZB*KCU Compressor Range ZB Scroll Cooling Capacity (kW) 0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 EN12900 Evaporating -10C, Condensing 45C, Superheat 10K, Subcooling 0K 3 Ph** Sound pressure @1 m (dBA) *** Oil quantity (l) 3 Ph** Stub discharge (inch) 3 Ph** Stub suction (inch) Locked rotor current (A) Cooling Capacity (kW) Maximum operating current (A) Displacement (m3/h) Motor version / code Nominal (hp) Net weight (kg) Technical Overview Length / Width / Height (mm) ZB12KCU 2.0 5.8 2.8 3/4 1/2 1.3 243/243/364 25.9 TFM 4.1 26 60 ZB17KCU 2.5 8.0 3.9 3/4 1/2 1.5 243/242/387 27.2 TFM 5.2 32 61 ZB20KCU 3.5 10.0 5.0 3/4 1/2 1.5 243/242/400 28.1 TFM 6.8 46 62 ZB25KCU 4.0 11.7 5.7 3/4 1/2 1.9 247/241/451 39.5 TFM 8.2 64 65 ZB31KCU 5.0 14.4 7.0 3/4 1/2 1.9 247/241/451 37.3 TFM 10.1 64 65 ZB37KCU 6.0 17.1 8.3 3/4 1/2 1.9 250/246/438 39.5 TFM 11.8 74 65 ZB49KCU 8.0 21.4 10.4 1 1/4 1 1/4 1.9 246/256/442 39.5 TFM 15.9 102 68 Model 10 ZB Copeland Scroll™ for R290 (Propane) Technical Bulletin Capacity Data Condensing temperature °C 60 55 50 45 40 35 30 25 20 R290 Cooling capacity in kW Evaporating temperature °C R290 -30 Compressor model 10 5 0 -5 -10 -15 -20 -25 4.8 4.0 3.3 2.8 2.3 1.8 1.5 0.0 0.0 ZB12KCU-TFMN 6.5 5.5 4.5 3.7 3.1 2.5 2.0 0.0 0.0 ZB17KCU-TFMN 8.2 6.8 5.7 4.7 3.8 3.0 2.4 0.0 0.0 ZB20KCU-TFMN 9.6 8.1 6.7 5.5 4.5 3.7 0.0 0.0 0.0 ZB25KCU-TFMN 11.8 9.9 8.2 6.8 5.6 4.5 0.0 0.0 0.0 ZB31KCU-TFMN 13.8 11.6 9.7 8.0 6.6 5.3 0.0 0.0 0.0 ZB37KCU-TFMN 17.2 14.5 12.1 10.0 8.2 6.7 0.0 0.0 0.0 ZB49KCU-TFMN 5.1 4.3 3.6 3.0 2.5 2.0 1.6 1.2 0.0 ZB12KCU-TFMN 7.0 5.9 4.9 4.1 3.3 2.7 2.2 1.7 0.0 ZB17KCU-TFMN 8.8 7.4 6.2 5.1 4.1 3.3 2.6 2.0 0.0 ZB20KCU-TFMN 10.4 8.7 7.3 6.0 4.9 4.0 3.2 0.0 0.0 ZB25KCU-TFMN 12.7 10.7 8.9 7.4 6.0 4.9 3.9 0.0 0.0 ZB31KCU-TFMN 14.8 12.5 10.5 8.7 7.1 5.8 4.7 0.0 0.0 ZB37KCU-TFMN 18.5 15.7 13.1 10.9 9.0 7.3 5.8 0.0 0.0 ZB49KCU-TFMN 5.5 4.6 3.9 3.2 2.6 2.1 1.7 1.3 1.0 ZB12KCU-TFMN 7.5 6.3 5.3 4.4 3.6 2.9 2.4 1.9 1.5 ZB17KCU-TFMN 9.4 8.0 6.6 5.5 4.5 3.6 2.9 2.2 1.7 ZB20KCU-TFMN 11.1 9.3 7.8 6.4 5.3 4.3 3.4 2.7 0.0 ZB25KCU-TFMN 13.6 11.4 9.6 7.9 6.5 5.3 4.2 3.3 0.0 ZB31KCU-TFMN 15.8 13.4 11.2 9.3 7.7 6.3 5.1 4.0 0.0 ZB37KCU-TFMN 19.8 16.8 14.1 11.7 9.7 7.9 6.4 5.0 0.0 ZB49KCU-TFMN 5.8 4.9 4.1 3.4 2.8 2.3 1.8 1.5 1.1 ZB12KCU-TFMN 8.0 6.7 5.6 4.7 3.9 3.1 2.5 2.0 1.6 ZB17KCU-TFMN 10.1 8.5 7.1 5.9 4.8 3.9 3.1 2.5 1.9 ZB20KCU-TFMN 11.8 9.9 8.3 6.9 5.7 4.6 3.7 2.9 2.3 ZB25KCU-TFMN 14.4 12.2 10.2 8.5 7.0 5.7 4.6 3.6 2.8 ZB31KCU-TFMN 16.7 14.2 12.0 10.0 8.3 6.8 5.5 4.3 3.4 ZB37KCU-TFMN 21 17.8 15.0 12.5 10.4 8.5 6.9 5.5 4.2 ZB49KCU-TFMN 6.2 5.2 4.4 3.6 3.0 2.4 2.0 1.6 1.2 ZB12KCU-TFMN 8.5 7.2 6.0 5.0 4.1 3.4 2.7 2.2 1.7 ZB17KCU-TFMN 10.6 9.0 7.5 6.3 5.2 4.2 3.4 2.7 2.0 ZB20KCU-TFMN 12.5 10.5 8.8 7.3 6.0 4.9 3.9 3.1 2.4 ZB25KCU-TFMN 15.2 12.9 10.8 9.0 7.4 6.1 4.9 3.9 3.0 ZB31KCU-TFMN 17.7 15.0 12.7 10.6 8.8 7.2 5.9 4.7 3.7 ZB37KCU-TFMN 22.2 18.8 15.9 13.3 11.0 9.1 7.3 5.9 4.6 ZB49KCU-TFMN 6.5 5.5 4.6 3.9 3.2 2.6 2.1 1.7 1.3 ZB12KCU-TFMN ZB17KCU-TFMN 8.9 7.6 6.3 5.3 4.4 3.6 2.9 2.3 1.8 11.2 9.5 8.0 6.6 5.5 4.5 3.6 2.9 2.2 ZB20KCU-TFMN 13.2 11.1 9.3 7.8 6.4 5.2 4.2 3.3 2.6 ZB25KCU-TFMN 16.0 13.6 11.4 9.5 7.9 6.4 5.2 4.2 3.2 ZB31KCU-TFMN 18.5 15.8 13.3 11.2 9.3 7.6 6.2 5.0 3.9 ZB37KCU-TFMN 23.3 19.8 16.7 14.0 11.7 9.6 7.8 6.3 4.9 ZB49KCU-TFMN 6.9 5.8 4.9 4.1 3.4 2.8 2.2 1.8 1.4 ZB12KCU-TFMN 9.4 7.9 6.7 5.6 4.6 3.8 3.0 2.4 1.9 ZB17KCU-TFMN 11.7 9.9 8.4 7.0 5.8 4.7 3.8 3.1 2.4 ZB20KCU-TFMN 0.0 11.7 9.8 8.2 6.7 5.5 4.4 3.5 2.8 ZB25KCU-TFMN 0.0 14.3 12.0 10.0 8.3 6.8 5.5 4.4 3.5 ZB31KCU-TFMN 0.0 16.5 14.0 11.7 9.8 8.1 6.6 5.3 4.2 ZB37KCU-TFMN 0.0 20.7 17.5 14.7 12.2 10.1 8.3 6.7 5.3 ZB49KCU-TFMN 0.0 6.1 5.1 4.3 3.6 2.9 2.4 1.9 1.5 ZB12KCU-TFMN 0.0 8.3 7.0 5.8 4.8 3.9 3.2 2.6 2.0 ZB17KCU-TFMN 0.0 10.4 8.7 7.3 6.1 5.0 4.0 3.2 2.6 ZB20KCU-TFMN 0.0 0.0 10.3 8.6 7.1 5.8 4.7 3.7 2.9 ZB25KCU-TFMN 0.0 0.0 12.6 10.5 8.7 7.2 5.8 4.7 3.7 ZB31KCU-TFMN 0.0 0.0 14.6 12.2 10.2 8.4 6.9 5.6 4.5 ZB37KCU-TFMN 0.0 0.0 18.3 15.3 12.8 10.6 8.7 7.0 5.6 ZB49KCU-TFMN 0.0 0.0 5.4 4.5 3.7 3.1 2.5 2.0 1.6 ZB12KCU-TFMN 0.0 0.0 7.3 6.1 5.0 4.1 3.4 2.7 2.2 ZB17KCU-TFMN 0.0 0.0 9.1 7.6 6.3 5.2 4.2 3.4 2.7 ZB20KCU-TFMN 0.0 0.0 0.0 9.0 7.4 6.1 4.9 3.9 3.1 ZB25KCU-TFMN 0.0 0.0 0.0 11.0 9.1 7.5 6.1 4.9 3.9 ZB31KCU-TFMN 0.0 0.0 0.0 12.7 10.6 8.8 7.2 5.9 4.7 ZB37KCU-TFMN 0.0 0.0 0.0 16.0 13.3 11.0 9.1 7.4 5.9 ZB49KCU-TFMN 11 Technical Bulletin Electronic Expansion Valves EX4-7-…FLR Versions and M12 Connector EVC05A Emerson Climate Technologies’ EX4-7-…FLR are stepper motor driven valves for precise control of refrigerant mass flow in air conditioning, refrigeration, heat pumps, close control, and industrial process cooling applications. Features • • • • • • • • • • • • • Fully hermetic design Stepper motor driven Very fast full stroke time High resolution and excellent repeatability Bi-flow versions with positive shut-off in both flow directions Positive shut-off function to eliminate the use of an additional solenoid valve Linear flow capacity Extremely wide capacity range (10 … 100%) Continuous modulation of mass flow Direct coupling of motor and valve for high reliability (no gear mechanism) Ceramic slide and port for accurate flow and minimal wear Corrosion resistant stainless steel body and connections II 3G Ex nA IIA T3 Gc X EX4-…FLR EX7-…FLR EVC05A • The qualification /certification of EX4-7-…FLR is valid only in conjunction with EVC05A (M12 Connector) Features EVC05A (ifm electronic GmbH) • Vibration and shock resistance • Protection: BVS 08 ATEX E 109 U IECEx BVS 08.0041 U • Marking: II 3G Ex nA IIC Gc II 2D Ex tD IIIC Db IP65/ IP67 Cable and Connector Assembly Type Part no. Length EVC05A 800439 5m Connector Connector type to driver type board or to valve controller M12 Loose wires Selection Table Type Part no. EX4-I21FLR 800430 EX4-M21FLR 800431 EX5-U21FLR 800432 EX6-I21FLR 800433 EX6-M21FLR 800434 EX7-I21FLR 800440 EX7-M21FLR 800441 EX4-U31FLR 800435 EX5-U31FLR 800436 Flow pattern Nominal capacity range [kW] 2...17 EX6-I31FLR 800437 Bi-flow 800438 (Heat pump) EX7-I31FLR 800442 EX7-M31FLR 800443 3/8” ODF 5/8” ODF 10 mm ODF 16 mm ODF 7/8” (22 mm) ODF 7/8” ODF 1-1/8” ODF 22 mm ODF 28 mm ODF 1-1/8” ODF 1-1/8” ODF 28 mm ODF 28 mm ODF 2...17 5/8” (16 mm) ODF 5/8” (16 mm) ODF 5…51.6 7/8” (22 mm) ODF 7/8” (22 mm) ODF 12…124 30…340 EX6-M31FLR Outlet connection 5/8” (16 mm) ODF 5…51.6 Uni-flow Inlet connection 1 …124 30…340 1-1/8” ODF 1-1/8” ODF 28 mm ODF 28 mm ODF 1-1/8” ODF 1-1/8” ODF 28 mm ODF 28 mm ODF Electrical connector Special M12 plug Note: The valves are delivered without cable/connector assembly (order separately). Nominal capacity at +38°C liquid temperature, +4°C evaporating temperature and 1K subcooling. For other operating condition, see the next page. 12 Technical Bulletin Electronic Expansion Valves EX4-7-…FLR Versions and M12 Connector EVC05A Quick Selection (included1.5 bar pressure drop for liquid line components and distributor) Condensing temperature °C 75 70 65 60 55 50 45 40 35 30 20 R290 15 Capacity in kW Evaporating temperature °C 10 5 0 -5 17 17 16,9 16,6 52 52 51 51 R290 Valve type -10 -15 -20 -25 -30 -35 16,4 16 15,6 15,2 14,8 14,3 13,8 EX4…FLR 50 49 47 46 45 43 42 EX5…FLR 124 124 123 121 119 117 114 111 108 104 100 EX6…FLR 342 341 338 333 328 321 313 305 296 286 276 EX7…FLR 17,6 17,7 17,6 17,5 17,2 17 16,7 16,3 15,9 15,4 15 EX4…FLR 54 54 53 53 52 52 51 49 48 47 45 EX5…FLR 128 129 128 127 126 124 121 119 116 112 109 EX6…FLR 353 354 352 350 345 340 334 326 318 309 300 EX7…FLR 17,9 18 18,1 18 17,9 17,7 17,4 17,1 16,7 16,4 15,9 EX4…FLR 54 55 55 55 54 54 53 52 51 50 48 EX5…FLR 130 131 132 131 130 129 127 125 122 119 116 EX6…FLR 358 361 362 361 358 354 349 342 335 327 319 EX7…FLR 17,8 18,1 18,3 18,3 18,2 18,1 17,9 17,7 17,4 17 16,7 EX4…FLR 54 55 55 56 55 55 54 54 53 52 51 EX5…FLR 130 132 133 133 133 132 131 129 127 124 121 EX6…FLR 357 363 366 366 365 363 359 354 348 341 334 EX7…FLR 17,5 17,9 18,2 18,3 18,4 18,3 18,2 18 17,8 17,5 17,2 EX4…FLR 53 54 55 56 56 56 55 55 54 53 52 EX5…FLR 127 130 132 134 134 134 133 131 130 128 125 EX6…FLR 350 359 364 367 368 367 365 361 357 351 344 EX7…FLR 16,9 17,5 17,9 18,1 18,3 18,4 18,3 18,2 18 17,8 17,5 EX4…FLR 51 53 54 55 56 56 56 55 55 54 53 EX5…FLR 123 127 130 132 133 134 133 133 131 130 128 EX6…FLR 338 350 358 363 367 368 367 365 361 356 351 EX7…FLR 15,9 16,7 17,3 17,7 18 18,2 18,2 18,2 18,1 17,9 17,7 EX4…FLR 48 51 53 54 55 55 55 55 55 54 54 EX5…FLR 116 122 126 129 131 132 133 132 132 130 129 EX6…FLR 318 335 346 355 360 364 365 364 362 358 354 EX7…FLR 14,6 15,6 16,4 17 17,5 17,7 17,9 17,9 17,9 17,8 17,7 EX4…FLR 44 47 50 52 53 54 54 54 54 54 54 EX5…FLR 106 114 120 124 127 129 130 131 130 130 129 EX6…FLR 292 313 329 341 350 355 358 359 359 357 353 EX7…FLR 12,8 14,2 15,3 16,1 16,7 17,1 17,4 17,5 17,6 17,6 17,5 EX4…FLR 39 43 46 49 51 52 53 53 53 53 53 EX5…FLR 93 104 111 117 122 125 127 128 128 128 127 EX6…FLR 256 285 306 322 334 343 348 351 352 352 350 EX7…FLR 10,3 12,3 13,8 14,9 15,7 16,2 16,7 16,9 17,1 17,1 17,1 EX4…FLR 31 37 42 45 48 49 51 51 52 52 52 EX5…FLR 75 90 100 108 114 118 121 123 124 125 125 EX6…FLR 206 247 276 298 314 325 333 339 342 343 343 EX7…FLR 5,3 8,7 10,7 12,1 13,1 13,8 14,3 14,7 14,9 15,1 EX4…FLR 16 26 32 37 40 42 44 45 45 46 EX5…FLR 39 63 78 88 95 101 104 107 109 110 EX6…FLR 107 174 214 242 262 277 287 295 299 302 EX7…FLR Select the valve type from tables for capacity value corresponding to system (evaporator) cooling capacity. 13 Electronic Expansion Valves EX4-7-…FLR Versions and M12 Connector EVC05A Technical Bulletin Technical Data EX4-7-...FLR Valves MOPD (maximum operating pressure differential) 30 bar Max. working pressure, PS 35 bar Max. system test pressure 38.5 bar Ambient temperature Storage temperature -20…+60°C -40…+70°C Medium inlet temperature Bi-flow version: Uni-flow version: Marking 529, DIN 40050 stainless steel body and fittings acc. to directive 94/9/EC II 3G Ex nA IIA T3 Gc X IP67 with M12 Connector EVC05A Humidity 5 to 95% r.H. Connections ODF stainless steel fittings Shock 20 g at 11 ms 80 g at 1 ms TS: -40…+80°C TS: -50…+100°C Vibration for non-connected and 4 g fastened valve (0 to 1000 Hz, 1 octave /min.) Material Protection accordance to IEC Net weight (kg) 0.5 kg (EX4), 0.52 kg (EX5), 0.60 kg (EX6), 1.1 kg (EX7) Package and delivery (individual) without electrical connector Accessories M12 Connector EVC05A Electrical Data EX4-7…-FLR Valves Stepper motor type Bi-polar, phase current by chopper control (constant current) Electrical connection 4 pin terminal via plug Nominal supply voltage to the valve U 24 VDC Step mode 2 phase full step, half step or microstep Step angle 1.8° per step +8% Stepping rate 500 Hz Total number of steps EX4-6-...FLR: 750 full steps EX7-…FLR: 1600 full steps Winding resistance per phase EX4-6-…FLR: 13 Ohm +10% EX7-…FLR: 8 Ohm +10% Driver supply voltage range 18 … 36 VDC Phase current, operating EX4-6-…FLR: 500 mA EX7-…FLR: 750 mA Full travel time EX4-6-…FLR: 1.5 seconds EX7-…FLR: 3.2 seconds Holding current EX4-6-…FLR: 100 mA EX7-…FLR: 250 mA Reference position Mechanical stop at fully closed position Material body housing: TPU orange; sealing: Viton Material nut Stainless steel 316L / 1.4404 Technical Data EVC05A (ifm electronic GmbH) Operating voltage 36 VDC in conjunction with EX4-7-…FLR Current rating 800 mA in conjunction with EX4-7-…FLR Design angled Tightening torque for knurled nut 1.2...1.5 Nm Ambient temperature 0.18 Kg Connection PUR cable / 5 m; 4 x 0.34 mm² (42 x Ø 0.1 mm); Ø 4.9 mm; halogen-free -20…+60°C Protection IP 67 Approval BVS 08 ATEX E 109 U IECEx BVS 08.0041 U 14 Weight Marking II 3G Ex nA IIC Gc II 2D Ex tD IIIC Db IP65/IP67 Electronic Expansion Valves EX4-7-…FLR Versions Operating Instructions General Information Mounting Location EX4-7…-FLR are stepper motor driven valves for precise control of refrigerant mass flow, released for R290 in refrigeration, air conditioning, heat pumps, industrial cooling process and close control systems. • The motor needs to be pointed downward or sideways (Fig. 1). • For best result, locate the valve as close as possible to the distributor or inlet of evaporator. Warning The qualification /certification of EX4-7-…FLR is valid only in conjunction with EVC05A (Plug & Cable assembly). The listed products are electrical devices and are in compliance with EN60079-0/-15 and directive 94/9/EC therefore rated / marked as: II 3G Ex nA IIA T3 Gc X Safety Instructions • Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Good ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves, eye protection, etc.) has to be used. • In a severely contaminated system, avoid breathing acid vapors and avoid contact with skin from contaminated refrigerant / lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Do not release any refrigerant into the atmosphere! • Ensure that the system piping is grounded. • Do not exceed the specified maximum ratings for pressure, temperature, voltage and current. • Do not operate valve connected directly to supply voltage. Use suitable stepper motor driver. • Do not operate system before all cable connections are completed. • Do not operate the valve when the compressor is not running. • Do not operate the valve when system is under vacuum except for closure of valve before refrigerant charging. • Before installation or service disconnect all voltages from system and device. • Do not use any other fluid media without prior approval of Emerson. • Ensure that design, installation and operation are according to European and national standards/ regulations. Installation • Direction of refrigerant flow must match with arrow on the label (except bi-flow valves). • Check for sufficient refrigerant charge/subcooling and make sure no flash gas is present at the inlet of valve before attempting to check valve operation. • Install an Emerson sight glass MIA…-FLR and an ADK….-FLR filter before the valve. Warning • All valves are delivered at half open. Do not charge system before closure of valve. See operating instructions of used driver/controller. • The interior parts of valve must be protected against moisture and water at any time. It is not permitted to use water, steam or any other solvent to the inside of valve for cleaning purpose. Recommended external pipe connection: Outside diameter Nominal pipe connection Min. (mm) Max. (mm) 3/8“ 9.47 9.55 5/8” / 16 mm 15.80 16.05 7/8” / 22 mm 21.95 22.25 1-1/8” 28.50 28.63 10 mm 9.95 10.05 28 mm 27.95 28.05 Brazing (Fig. 2) • Perform and consider the brazing joint as per EN 14324. • Before and after brazing clean tubing and brazing joints. • Minimize vibrations in the piping lines by appropriate solutions. • Do not exceed the max. body temperature of 120 °C! • Use flux and silver rod having a minimum of 30% silver. Pressure Test • After completion of installation, a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • Max. system test pressure: 38.5 bar 15 Operating Instructions Electronic Expansion Valves EX4-7-…FLR Versions Warning • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. Tightness Test • Conduct a tightness test according to EN 378-2 with appropriate equipment and method to identify leakages of external joints. The allowable leakage rate must be according system manufacturer’s specification. Electrical Connection: Warning • Entire electrical connections have to comply with local regulations. • Improper wiring will result wrong direction of rotation, no rotation of stepper motor or controller malfunction. Wiring / Mounting of Plug: (Fig. 4-6) • 2 = White, 4 = Black, 3 = Blue, 1= Brown • Use only ATEX approved prewired M12 Connector assembly EVC05A for connection to the valve. • See also EVC05A operating instructions for plug mounting and required protection. • There is no specific requirement for positioning of plug on pins (see Fig. 5). • Ensure that the cables are mounted without tension; always leave the cable a bit loose. • Ensure that cables are not mounted near sharp edges. • Do not bend or mechanically stress the cable outlet, maintain a clearance of 20 mm to neighboring parts. • During operation the connector EVC05A must be protected by an appropriate housing against external mechanical damage or shock (min. required protection up to a mechanical action of 7 J - in accordance with EN60079-0). • Cable end of EVC05A must be connected to a driver/ controller which is ATEX approved or located out of hazard zone. - If driver/controller is located out of hazard zone, appropriate ATEX approved cable gland shall be used in boundary of hazard zone and out of hazard zone. - If the cable needs to be extended in hazard zone, it is mandatory to use ATEX approved type coupling or junction box. • Supply voltage to the valve shall never exceed 36 VDC at any time. Service / Maintenance • Defective EX4-7-…FLR valves must be replaced, they cannot be repaired. • Disconnect electrical power to driver/controller before service. • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. • For motor check: - Remove cable plug from valve under no voltage. - Use an Ohm meter with suitable range. - Measure windings resistance per phase at opposite placed pins acc. Fig. 6 and data as in the table below. • The lowest pressure inside system must be at least 0.4 bar higher than ambient pressure at any time. Failure to do so could accumulate air inside the system and create an explosive mixture over time. Technical Data Type EX4-6-…FLR Max. allowable working pressure PS Operating temp. at motor Refrigerant: R290 Nominal Supply Voltage to the valve U Max. Current Imax Winding resistance per phase Marking acc. to directive 94/9/E Fig. 1 max 120°C • See the wiring diagram of used driver or controller. Operation 16 Uni-flow versions:–50°C…+100°C Bi-flow versions: -40°C…+80°C see Fig. 3 Wiring / Mounting to Driver / Controller • See operating instructions of used electronic driver/ controller. • Perform a functional test of electrical circuit before charging the system with refrigerant. 35 bar Connection Fig. 2 EX7-…FLR Ag ≥ 30% 24 VDC 24 VDC 0.5 A 0.75 A 13 Ω ± 10% 8 Ω ± 10% Yes Yes Operating Instructions Electronic Expansion Valves EX4-7-…FLR Versions Fig. 3 Fig. 4 EX4-7-....FLR Fig. 5 EXV Fig. 6 Flow pattern Part. no. Ø A x Ø F(ODF) B C D E H1 H2 EX4-I21FLR 800430 3/8" x 5/8" 8 45 55 11 113 25 EX4-M21FLR 800431 10 x 16 mm 8 45 55 11 113 25 800432 5/8" x 7/8" (16 x 22 mm) 11 55 65 16 113 25 800433 7/8" x 1-1/8" 16 65 75 19 113 25 EX6-M21FLR 800434 22 x 28 mm 16 65 75 19 113 25 EX7-I21FLR 800440 1-1/8" x 1-1/8" 20 78 83 20 158 42 EX/-M21FLR 800441 28 x 28 mm 20 78 83 20 158 42 EX4-U31FLR 800435 16 x 16 mm (5/8" x 5/8") 11 55 55 11 113 25 EX5-U31FLR 800436 7/8" x 7/8" (22 x 22 mm) 16 65 65 16 113 25 800437 1-1/8" x 1-1/8" 19 75 75 19 113 25 800438 28 x 28 mm 19 75 75 19 113 25 EX7-I31FLR 800442 1-1/8” x 1-1/8” 20 83 83 20 158 42 EX7-M31FLR 800443 28 x 28 mm 20 83 83 20 158 42 EX5-U21FLR EX6-I21FLR Uni-flow EX6-I31FLR Bi-flow EX6-M31FLR Sequence for driving of stepper motor and valve Reverse Number Direction direction of steps Valve is opening Valve is closing Step 1 Identification code of pins for electrical connections to third party drivers/controllers 2 â 3 1 - + - Current direction + Step 2 - + + - Step 3 - + - + Step 4 + - - + Remark â 4 The sequence is repeated from step 5 to 8 similar to step 1 to 4 Step 5 + - + - Step 6 - + + - Step 7 - + - + Step 8 + - - + Remark The sequence is repeated from step 9 to 12 similar to step 1 to 4 â â 17 Operating Instructions M12 Connector ECV05A Functions and Features 15,5 II3G (Group II, category 3G, apparatus for gas atmosphere). Complies with the requirements of the standard EN 60079-15. 26,5 36,5 • Use in hazardous areas according to the classification M12x1 14 • Use in hazardous areas according to the classification II3G (Group II, category 20, apparatus for dust atmosphere). Complies with the requirements of the standards lEC 60079-0 and lEC 60079-31. • EC component certificate: BVS 08ATEX E 109 U • lEC Ex component certificate: IECEx BVS 08.0041 U • Marking: Wiring Core colors • BK • BN • BU • WH black brown blue white II3G Ex nA IIC Gc (see table Operating temperature range) II20 Ex tb IIIC Db IP65/IP67 Operating temperature range -20…+60°C 1 BN 2 WH 3 BU 4 BK 5 not used for connection cables and jumpers with angled M12 plug and angled M12 sockets Caution: Not for interrupting current! Installation / Set-up The M12 connectors must only be installed connected and set up by qualified staff. The qualified staff must have knowledge of protection classes, regulations- and provisions for apparatus in hazardous areas. Check whether the classification (see “Marking” above and marking on the M12 connector) is suitable for the application. Installation Remarks / Installation • • • • • • • • • 18 Adhere to the relevant national regulations and provisions. Avoid electrostatic charging on plastic units and cables. Protect the M12 connectors efficiently against damage. The cables must be firmly laid and effectively protected against damage. The relevant installation regulations must be adhered to. For the technical data please refer to the data sheet. (see Technical Bulletin EX4-7-…-FLR). Avoid direct radiation with high UV components (sunlight); mount the unit in a protected place. M12 plugs may only be opened or closed in a sufficiently clean environment. Connectors must always be closed with a counterpart. They may be left open in the field only briefly for servicing purposes. Special Conditions for Safe Operation • The M12 connectors were tested in accordance with table 8 of EN 60079-0/table 5 of EN 61241-0 for group II and for a low mechanical risk with impact energy of 4 joules. • Do not separate the connectors when energized. • Secure the connector by tightening the nut sufficiently. Tightening torque approx. 1.2 Nm to • 1.5 Nm. This tightening torque is ensured as follows: - Hand-fasten the coupling nut (0.4 to 0.5 Nm). - Then turn by 3 notches using a screwdriver across the flats 14. • The connector conforms to the requirements for an M12 connector in EN 61076-2-101. The counterpart must also conform to this standard. • Always refer to the operating-instructions as space restrictions may not allow markings to be applied to the unit. Maintenance / Repair The unit must not be modified nor can it be repaired. In case of a fault please contact the manufacturer. The data sheets, the EC component certificates or IEC Ex component certificates are available from the manufacturer on request. Technical Bulletin ThermoTM - Expansion Valves TX3-…FLR Emerson Climate Technologies’ TX3-…FLR series of ThermoTM-Expansion Valves are designed for commercial refrigeration and heat pump applications operated with R290. The TX3-…FLR is ideal for those applications requiring compact size combined with stable and accurate control over wide load and evaporating temperature ranges. Features • • • • • • Brazing connections with straight through configuration Stainless steel power element resists corrosion Large diaphragm provides smoother and consistent valve control External equalizer External superheat adjustment Packaging units with 24 pieces, no single packs TX3-…FLR Selection Table Without MOP Nominal capacity [kW] With MOP Connection size Inlet x Outlet Type Part no. Type Part no. Equalizer 3.7 TX3-P23 FLR 801981M TX3-P33 FLR 801988M Ext. 1/4" 1/4" x 3/8" 5.4 TX3-P24 FLR 801982M TX3-P34 FLR 802013M Ext. 1/4" 3/8" x 1/2" 8.0 TX3-P25 FLR 801983M TX3-P35 FLR 802014M Ext. 1/4" 3/8" x 1/2" 11.0 TX3-P26 FLR 801984M TX3-P36 FLR 802015M Ext. 1/4" 3/8" x 1/2" 13.5 TX3-P27 FLR 801985M TX3-P37 FLR 802016M Ext. 1/4" 1/2" x 5/8" 16.1 TX3-P28 FLR 801986M TX3-P38 FLR 802017M Ext. 1/4" 1/2" x 5/8" 22.0 TX3-P29 FLR 801987M TX3-P39 FLR 802018M Ext. 1/4" 1/2" x 5/8" Nominal capacity at +38°C liquid temperature, +4°C evaporating temperature and 1K subccoling. For other operating condition, see the next page. Guideline TX3-…FLR will be delivered with sufficient higher superheat setting to make sure match of valve with poor performance of evaporator. The setting can be lowered for high efficient evaporators capable to operate at lower superheat. The following table can be used as guideline: Evaporating temperature Readjustment, turn -40 -1 -35 -1 -30 -1-1/8 -25 -1-1/8 -20 -1-1/8 -15 -1-1/8 -10 -1 -5 -3/4 0 -1/2 5 -1/8 10 -1/3 19 Technical Bulletin ThermoTM - Expansion Valves TX3-…FLR Quick Selection (included1.5 bar pressure drop for liquid line components and distributor) Condensing temperature °C 75 65 55 50 40 30 20 R290 Capacity in kW Evaporating temperature °C R290 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 3.3 3.3 3.2 3.2 3.1 3.1 2.6 2.2 1.9 1.6 1.3 1.0 TX3-P23/33FLR 4.8 4.7 4.7 4.6 4.5 4.4 3.8 3.2 2.7 2.2 1.8 1.5 TX3-P24/34FLR 7.2 7.1 7.0 6.9 6.8 6.6 5.7 4.8 4.0 3.4 2.8 2.2 TX3-P25/35FLR 9.8 9.8 9.7 9.5 9.3 9.1 7.8 6.6 5.5 4.6 3.8 3.1 TX3-P26/36FLR 12.1 12.0 11.8 11.6 11.4 11.1 9.5 8.1 6.8 5.6 4.6 3.8 TX3-P27/37FLR 14.4 14.2 14.1 13.8 13.6 13.2 11.3 9.6 8.1 6.7 5.5 4.5 TX3-P28/38FLR 19.6 19.5 19.2 18.9 18.5 18.1 15.5 13.1 11.0 9.2 7.5 6.1 TX3-P29/39FLR 3.2 3.2 3.2 3.2 3.2 3.1 2.7 2.3 1.9 1.6 1.3 1.1 TX3-P23/33FLR 4.6 4.7 4.7 4.6 4.6 4.5 3.9 3.3 2.8 2.3 1.9 1.6 TX3-P24/34FLR 7.0 7.0 7.0 6.9 6.8 6.7 5.8 5.0 4.2 3.5 2.9 2.4 TX3-P25/35FLR TX3-P26/36FLR 9.6 9.6 9.6 9.5 9.4 9.2 8.0 6.8 5.8 4.8 4.0 3.3 11.7 11.7 11.7 11.6 11.5 11.3 9.7 8.3 7.1 5.9 4.9 4.0 TX3-P27/37FLR 13.9 14.0 14.0 13.8 13.7 13.4 11.6 9.9 8.4 7.0 5.8 4.8 TX3-P28/38FLR 19.0 19.1 19.1 18.9 18.7 18.4 15.9 13.6 11.5 9.6 8.0 6.5 TX3-P29/39FLR 3.3 3.3 3.4 3.4 3.4 3.4 2.9 2.5 2.2 1.8 1.5 1.3 TX3-P23/33FLR 4.7 4.8 4.9 4.9 4.9 4.9 4.3 3.7 3.1 2.7 2.2 1.8 TX3-P24/34FLR 7.1 7.2 7.3 7.4 7.4 7.3 6.4 5.5 4.7 4.0 3.3 2.8 TX3-P25/35FLR TX3-P26/36FLR 9.7 9.9 10.0 10.1 10.1 10.0 8.8 7.6 6.5 5.5 4.6 3.8 11.9 12.2 12.3 12.4 12.4 12.3 10.7 9.3 7.9 6.7 5.6 4.7 TX3-P27/37FLR 14.2 14.5 14.7 14.7 14.7 14.6 12.8 11.0 9.4 8.0 6.7 5.5 TX3-P28/38FLR 19.4 19.8 20.0 20.1 20.1 20.0 17.4 15.1 12.9 10.9 9.1 7.6 TX3-P29/39FLR 3.4 3.6 3.6 3.7 3.7 3.7 3.3 2.8 2.5 2.1 1.8 1.5 TX3-P23/33FLR 5.0 5.1 5.3 5.3 5.4 5.4 4.7 4.1 3.5 3.0 2.5 2.1 TX3-P24/34FLR 7.5 7.7 7.9 8.0 8.1 8.1 7.1 6.2 5.3 4.5 3.8 3.2 TX3-P25/35FLR 10.2 10.6 10.8 11.0 11.1 11.1 9.7 8.5 7.3 6.2 5.2 4.4 TX3-P26/36FLR 12.5 13.0 13.2 13.4 13.5 13.5 11.9 10.4 8.9 7.6 6.4 5.3 TX3-P27/37FLR 14.9 15.4 15.8 16.0 16.1 16.1 14.2 12.3 10.6 9.1 7.6 6.4 TX3-P28/38FLR 20.4 21.1 21.5 21.8 22.0 22.0 19.4 16.8 14.5 12.4 10.4 8.7 TX3-P29/39FLR 3.0 3.2 3.4 3.5 3.6 3.6 3.2 2.8 2.5 2.1 1.8 1.5 TX3-P23/33FLR 4.3 4.7 4.9 5.1 5.2 5.3 4.7 4.1 3.6 3.1 2.6 2.2 TX3-P24/34FLR 6.5 7.0 7.3 7.6 7.8 7.9 7.0 6.2 5.3 4.6 3.9 3.3 TX3-P25/35FLR 8.9 9.6 10.1 10.4 10.7 10.8 9.6 8.4 7.3 6.3 5.3 4.5 TX3-P26/36FLR 10.9 11.7 12.3 12.7 13.0 13.2 11.8 10.3 9.0 7.7 6.5 5.5 TX3-P27/37FLR 13.0 14.0 14.7 15.2 15.5 15.8 14.0 12.3 10.7 9.2 7.8 6.5 TX3-P28/38FLR 17.8 19.1 20.0 20.7 21.2 21.5 19.1 16.8 14.6 12.5 10.6 8.9 TX3-P29/39FLR 2.1 2.6 2.9 3.1 3.2 3.4 3.0 2.7 2.4 2.1 1.8 1.5 TX3-P23/33FLR 3.1 3.7 4.1 4.4 4.7 4.9 4.4 3.9 3.4 3.0 2.5 2.1 TX3-P24/34FLR 4.6 5.5 6.2 6.7 7.0 7.3 6.6 5.9 5.1 4.5 3.8 3.2 TX3-P25/35FLR 6.4 7.6 8.5 9.1 9.6 10.0 9.0 8.0 7.0 6.1 5.2 4.4 TX3-P26/36FLR 7.8 9.3 10.4 11.2 11.8 12.2 11.0 9.8 8.6 7.5 6.4 5.4 TX3-P27/37FLR 9.3 11.1 12.4 13.3 14.0 14.6 13.1 11.7 10.3 8.9 7.6 6.4 TX3-P28/38FLR 12.7 15.1 16.9 18.2 19.2 19.9 18.0 16.0 14.0 12.2 10.4 8.8 TX3-P29/39FLR 1.2 1.9 2.3 2.6 2.9 2.7 2.4 2.2 1.9 1.6 1.4 TX3-P23/33FLR 1.7 2.7 3.4 3.8 4.1 3.8 3.5 3.1 2.7 2.4 2.0 TX3-P24/34FLR 2.5 4.1 5.1 5.7 6.2 5.8 5.3 4.7 4.1 3.6 3.0 TX3-P25/35FLR 3.5 5.6 6.9 7.8 8.5 7.9 7.2 6.4 5.7 4.9 4.2 TX3-P26/36FLR 4.3 6.9 8.5 9.6 10.4 9.7 8.8 7.9 6.9 6.0 5.1 TX3-P27/37FLR 5.1 8.2 10.1 11.4 12.4 11.5 10.5 9.4 8.2 7.1 6.1 TX3-P28/38FLR 6.9 11.2 13.8 15.6 16.9 15.8 14.3 12.8 11.3 9.7 8.3 TX3-P29/39FLR Select the valve type from tables for capacity value corresponding to system (evaporator) cooling capacity. 20 Valve type Technical Bulletin ThermoTM - Expansion Valves TX3-…FLR Technical Data Compatibility R290 Seat leakage < 1% nominal capacity Maximum working pressure PS: 35 bar Connection ODF, copper Factory test pressure PT: 38.5 bar Charges CFC free Burst pressure 175 bar Protection salt spray test Medium temperature range -45°C…+75°C Weight ~ 0.5 kg (individual) Maximum bulb temperature +71°C Pack quantity 24 (no single pack) Dimensions [mm] N External Equalize Connection N H H K L M F K L M F A B A D 43,3 B D C C 30° +/-2° Body Type Connection size [inch] Roughing in dimensions [mm] Inlet Outlet A B F H TX3-...3-FLR 1/4” 3/8” 43.3 44.1 7.9 7.9 TX3-...4-FLR 3/8” 1/2” 44.1 44.1 7.9 9.5 TX3-...5-FLR 3/8” 1/2” 44.1 44.1 7.9 9.5 TX3-...6-FLR 3/8” 1/2” 44.1 44.1 7.9 9.5 TX3-...7-FLR 1/2” 5/8” 44.1 44.5 9.5 12.7 TX3-...8-FLR 1/2” 5/8” 44.1 44.5 9.5 12.7 TX3-...9-FLR 1/2” 5/8” 44.1 44.5 9.5 12.7 N K L M 44.5 86.5 64.7 54.4 Bulb Dimensions of bulb [mm] D (length) ØC 53.2 12.8 Capillary tube length 1.5 m 21 Operating Instructions ThermoTM - Expansion Valves TX3-…FLR General Information TX3-…FLR are Thermo-Expansion Valves for superheat control. Fig. 1 The listed products are not in scope of ATEX product directive 94/9/EC as they do not incorporate an own source of ignition. TX3-…FLR must be installed in an appropriate housing to protect them from mechanical damage or shock. Safety Instructions • Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves, eye protection, etc.) has to be used. • In a severely contaminated system, avoid breathing acid vapors and avoid contact with skin from contaminated refrigerant / lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Do not release any refrigerant into the atmosphere! • Do not exceed the specified maximum ratings for pressure and temperature. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Observe and avoid mechanical damage of component housing. • Ensure that design, installation and operation are according to European and national standards/ regulations. Installation (Fig. 1, 2) • Valves may be installed in any position, but should be located as close as possible to the distributor or evaporator inlet. • Attach the remote bulb to the suction line (Fig. 2) as close to the evaporator outlet as possible. Securely fasten the bulb with straps provided. Insulate bulb with a suitable material. Ensure that the capillary is mounted without tension, always leave the capillary a bit loose and it should not be strangulated. Maintain also a clearance from the capillary to other objects. The capillary should not be in contact with other objects. 22 Fig. 2 <7/8” / 22 mm Ø • Connect equalizer line (1/4” or 6 mm tube) to valve and suction line. Be sure that it cannot siphon oil from the suction line (Fig. 1). • The expansion valve must be free of all contaminants. Install an Emerson filter drier before the valve. Recommended external pipe connections: Nominal pipe connection Outside diameter Min. (mm) Max.(mm) 1/4” 6.30 6.38 3/8” 9.47 9.55 1/2” 12.62 12.73 5/8” 18.80 15.90 7/8” 22.15 22.25 1-1/8” 28.50 28.63 6 mm 5.95 6.05 10 mm 9.95 10.05 12 mm 11.96 12.05 16 mm 15.95 16.05 22 mm 21.95 22.06 28 mm 27.95 28.05 Operating Instructions ThermoTM - Expansion Valves TX3-…FLR Brazing (Fig. 3) Superheat Adjustment (Fig. 4) • Perform and consider the brazing joint as per EN 14324. • Before and after brazing clean tubing and brazing joints. • To avoid oxidization, it is advised to purge the system with an inert gas such as nitrogen while brazing. TX3-…FLR are factory set to a standard setting (s. Technical Bulletin). If the superheat must be adjusted proceed as follows: 1. Remove seal cap from bottom of valve. 2. Turn adjustment screw clockwise to increase and counterclockwise to decrease superheat. Do not exceed max. body temperature of 120°C! Fig. 3 120°C max Warning: There are approx. 13 turns on the adjustment stem (from left to right stop). When stop is reached any further turning will damage valve. Changes in superheat (K) per stem turn depending on evaporating temperature and refrigerant; see below. 30 minutes are required for the system to stabilize after the adjustment is made. Superheat change (K) per stem turn • Be sure liquid line is connected to inlet of TX3-… FLR (marked “IN” on valve body). • Minimize vibrations in the piping lines by appropriate solutions. Pressure Test • After completion of installation, a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • Max. system test pressure: 38.5 bar. Warning • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. Evaporating temperature R 290 -40°C -30°C -20°C -10°C 0°C 10°C 20°C 4.8 3.6 2.7 2.1 1.7 1.4 1.1 3. Determine superheat according to Fig. 4. 4. Replace and tighten seal cap (hand-tighten with more than 2 Nm). 5. Check for external leakage. Fig. 4 T ( C ) - T ( C) = sh (K) P Tightness Test Conduct tightness test according to EN 378-2 with appropriate equipment and method to identify tightness of external joint. The allowable leakage rate must be according system manufacturer’s specification. Operation • Check for sufficient refrigerant charge and be sure no flash gas is present before attempting to check the expansion valve operation. • Check/measure superheat. 23 Operating Instructions ThermoTM - Expansion Valves TX3-…FLR Service / Maintenance • Defective TX3-…FLR must be replaced; they cannot be repaired. • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. Technical Data of TX3 -…FLR TX3 types, not listed in the following table, are not released for use with flammable refrigerants! Type Part no. TX3-P23FLR 801981M TX3-P24FLR 801982M TX3-P25FLR 801983M TX3-P26FLR 801984M TX3-P27FLR 801985M Charge Recommended evaporating temperature TX3-P28FLR 801986M Liquid -40°C...+20°C TX3-P29FLR 801987M TX3-P33FLR 801988M TX3-P34FLR 802013M TX3-P35FLR 802014M TX3-P36FLR 802015M TX3-P37FLR 802016M TX3-P38FLR 802017M TX3-P39FLR 802018M • Max. allowable working pressure PS : 35 bar • Test pressure PT : 38.5 bar • Released / compatible for : R290, mineral-, alkyl benzene and ester lubricants 24 Technical Bulletin Solenoid Valves Series 200RB…-FLR 200RB…-FLR are normally closed solenoid valves for various application duties. Features • • • • • Normally closed Pilot operated requires minimum operating pressure differential Compact size Extended fittings: No disassembly necessary for brazing ATEX compliance coil and plug in 24VAC/50Hz and 230VAC/50Hz - as a kit available 200RB…-FLR + ASC… + PG9 ATEX Coil and Plug II 3G Ex nA IIA T3 Gc U II 2G IIC T6 Gb Selection Table Valves Type Part no. 200RB 3T3-FLR (mm) 801323 200RB 3T3-FLR 801445 200RB 4T10-FLR 801446 200RB 4T4-FLR 801447 200RB 4T3-FLR 801448 200RB 4T12-FLR 801449 200RB 6T4-FLR 801450 200RB 6T12-FLR 801451 200RB 6T5-FLR 801452 Kv-Value [m3/h] Capacity [kW] Liquid line duty 0.4 7.3 Connections Solder / ODF [mm] [inch] 10 3/8” 10 0.9 1/2” 17.3 3/8” 12 1/2” 1.6 12 30.4 16 5/8” Note: Nominal capacity at +38°C condensing temperature +4°C evaporating temperature, 1 K subcooling and 0.15 bar pressure drop. Selection Table Coil + Plug Type Part no. Description ASC24V + PG9 ATEX 801123 Kit consisting of coil, plug and clip (blue) ASC230V + PG9 ATEX 801124 Kit consisting of coil, plug and clip (blue) Technical Data Valve Max. allowable working pressure PS Test pressure PT Operating temperature range TS Technical Data Coil + Plug 31 bar 34.1 bar -40°C…+120°C Supply voltage ASC3-EX24VAC ASC3-EX230VAC 24VAC ±10% 230VAC ±10% Frequency 50 Hz Ambient temperature range -10°C…+50°C Protection class IP65 Plug PG9-ATEX (H.T.P. S.r.l.) Cable length 3m II 3G Ex nA IIA T3 Gc U, Max. ambient temperature -40°C…+50°C Marking (Coil & Plug) II 2G IIC T6 Gb, 25 Technical Bulletin Solenoid Valves Series 200RB…-FLR Quick Selection (0.15 bar pressure drop) Condensing R290 Temperature °C 15 70 65 60 55 50 45 40 30 25 Capacity in kW Evaporating temperature °C R290 Valve type 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 4.6 4.5 4.4 4.2 4.1 4.0 3.8 3.7 3.5 3.4 3.3 3.1 -45 3.0 200RB3…FLR 10.9 10.6 10.3 10.0 9.7 9.4 9.0 8.7 8.4 8.0 7.7 7.4 7.0 200RB4…FLR 19.2 18.6 18.1 17.5 17.0 16.4 15.9 15.3 14.7 14.1 13.5 12.9 12.4 200RB6…FLR 5.1 5.0 4.9 4.7 4.6 4.4 4.3 4.2 4.0 3.9 3.7 3.6 3.4 200RB3…FLR 12.1 11.8 11.5 11.2 10.8 10.5 10.2 9.9 9.5 9.2 8.8 8.5 8.2 200RB4…FLR 21.2 20.7 20.2 19.6 19.0 18.5 17.9 17.3 16.7 16.1 15.5 14.9 14.3 200RB6…FLR 5.6 5.5 5.3 5.2 5.1 4.9 4.8 4.6 4.5 4.3 4.2 4.1 3.9 200RB3…FLR 13.3 12.9 12.6 12.3 12.0 11.6 11.3 11.0 10.6 10.3 9.9 9.6 9.3 200RB4…FLR 23.3 22.7 22.2 21.6 21.0 20.5 19.9 19.3 18.7 18.1 17.5 16.9 16.2 200RB6…FLR 6.1 5.9 5.8 5.7 5.5 5.4 5.2 5.1 5.0 4.8 4.7 4.5 4.4 200RB3…FLR 14.4 14.1 13.7 13.4 13.1 12.8 12.4 12.1 11.7 11.4 11.0 10.7 10.3 200RB4…FLR 25.2 24.7 24.1 23.6 23.0 22.4 21.8 21.2 20.6 20.0 19.4 18.8 18.1 200RB6…FLR 6.5 6.4 6.3 6.1 6.0 5.8 5.7 5.6 5.4 5.3 5.1 5.0 4.8 200RB3…FLR 15.5 15.2 14.8 14.5 14.2 13.8 13.5 13.1 12.8 12.4 12.1 11.7 11.4 200RB4…FLR 27.2 26.6 26.1 25.5 24.9 24.3 23.7 23.1 22.5 21.9 21.2 20.6 20.0 200RB6…FLR 7.0 6.9 6.7 6.6 6.4 6.3 6.2 6.0 5.9 5.7 5.6 5.4 5.2 200RB3…FLR 16.6 16.2 15.9 15.6 15.2 14.9 14.6 14.2 13.9 13.5 13.1 12.8 12.4 200RB4…FLR 29.1 28.5 27.9 27.4 26.8 26.2 25.6 24.9 24.3 23.7 23.1 22.4 21.8 200RB6…FLR 7.5 7.3 7.2 7.0 6.9 6.7 6.6 6.4 6.3 6.1 6.0 5.8 5.7 200RB3…FLR 17.6 17.3 17.0 16.6 16.3 16.0 15.6 15.3 14.9 14.5 14.2 13.8 13.5 200RB4…FLR 31.0 30.4 29.8 29.2 28.6 28.0 27.4 26.8 26.2 25.5 24.9 24.3 23.6 200RB6…FLR 8.3 8.2 8.1 7.9 7.8 7.6 7.5 7.3 7.2 7.0 6.9 6.7 6.5 200RB3…FLR 19.7 19.4 19.1 18.7 18.4 18.0 17.7 17.3 16.9 16.6 16.2 15.8 15.5 200RB4…FLR 34.7 34.1 33.5 32.9 32.3 31.6 31.0 30.4 29.8 29.1 28.5 27.8 27.2 200RB6…FLR 8.8 8.6 8.5 8.3 8.2 8.0 7.9 7.7 7.6 7.4 7.3 7.1 7.0 200RB3…FLR 20.8 20.4 20.1 19.7 19.4 19.0 18.7 18.3 18.0 17.6 17.2 16.8 16.5 200RB4…FLR 36.5 35.9 35.3 34.7 34.1 33.4 32.8 32.2 31.5 30.9 30.2 29.6 28.9 200RB6…FLR 9.1 8.9 8.8 8.6 8.5 8.3 8.2 8.0 7.9 7.7 7.5 7.4 200RB3…FLR 20 21.5 21.1 20.8 20.4 20.1 19.7 19.3 19.0 18.6 18.2 17.8 17.5 200RB4…FLR 37.7 37.1 36.5 35.8 35.2 34.6 33.9 33.3 32.6 32.0 31.3 30.7 200RB6…FLR Select the valve type from tables for capacity value corresponding to system (evaporator) cooling capacity. For other pressure drop than 0.15, please use the below correction factors. Correction factors KΔP ΔP, bar 0.05 0.1 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 KΔP 1.73 1.22 1.0 0.87 0.77 0.71 0.65 0.61 0.58 0.55 0.52 0.50 0.48 0.46 Dimensions [mm] Type A B Connection / ODF D 200RB 3T3-FLR (mm) 126 8 10 mm 88.3 200RB 3T3-FLR 126 8 3/8” 88.3 200RB 4T10-FLR 126 8 10 mm 88.3 200RB 4T4-FLR 126 10 1/2” 88.3 200RB 4T3-FLR 126 8 3/8” 88.3 200RB 4T12-FLR 126 10 12 mm 88.3 200RB 6T4-FLR 126 10 1/2” 88.3 200RB 6T12-FLR 126 10 12 mm 88.3 M8 200RB 6T5-FLR 126 13 16 mm & 5/8” 88.3 A 26 D C C B B Operating Instructions Solenoid Valves Series 200RB…-FLR General Information Recommended external pipe connection 200RB…-FLR are solenoid valves for open or close of refrigerant flow. The listed products are not in scope of ATEX product directive 94/9/EC as they do not incorporate an own source of ignition. Min. (mm) Max. (mm) 3/8” 9.47 9.55 1/2“ 12.62 12.73 5/8“ 15.80 15.90 10 mm 9.95 10.05 12 mm 11.96 12.05 16 mm 15.95 16.05 200RB…-FLR must be installed in an appropriate housing to protect them from mechanical damage or shock. Safety Instructions • Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves, eye protection, etc.) has to be used. • In a severely contaminated system, avoid breathing acid vapors and avoid contact with skin from contaminated refrigerant/lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. Outside diameter Nominal pipe connection Mounting Location (Fig. 1, 2) • Allow sufficient clearance above the valve for removal of Coil. Valves may be mounted in horizontal or vertical lines (Fig. 1). Up-side down position is not allowed and can cause mal-function (Fig. 2). Fig. 1 WARNING: Do not use a solenoid valve as a safety shut-off valve or for service purpose. • Do not release any refrigerant into the atmosphere! • Do not exceed the specified maximum ratings for pressure, temperature. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Ensure that the system piping is grounded. • Before installation or service disconnect voltage from system and device. • Observe and avoid mechanical damage of component housing. • Ensure that design, installation and operation are according to European and national standards/ regulations Installation • Do not dent, bend, or use the enclosing tube as a lever. A damaged enclosing tube may result in coil burnout, inoperative valve or leakage. • Direction of flow must match with arrow on valve body. Fig. 2 Brazing (Fig. 3) • • • • Perform and consider the brazing joint as per EN 14324. Before and after brazing clean tubing and brazing joints. Do not disassemble valve for brazing. To avoid oxidization, it is advised to purge the system with an inert gas such as nitrogen while brazing. • Do not exceed max. body temperature of 120°C. 27 Operating Instructions Solenoid Valves Series 200RB…-FLR Fig. 3 Service / Maintenance max. 120°C • Defective 200RB…-FLR must be replaced; they cannot be repaired. • Before any service disconnect electrical power of the coil and use permanent magnet to keep the valve open while emptying the system. • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. • Warning: Never remove energized coil from valve. This applies also for testing purposes. Technical Data of 200RB... -FLR • Internal parts must be protected from foreign material and moisture. An Emerson filter drier is recommended to be installed. • Minimize vibrations in the piping lines by appropriate solutions. Pressure Test • After completion of installation, a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • Max. system test pressure: 34.1 bar. Warning • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. Tightness Test Conduct tightness test according to EN 378-2 with appropriate equipment and method to identify tightness of external joint. The allowable leakage rate must be according system manufacturer’s specification. Operation • Before operation let the parts cool down to a temperature < 40°C. • Cycle valve several times. A distinct “click” should be heard each time the solenoid coil is energized. Note: Emerson solenoid valves are equipped with a continuous-duty coil, which when energized for an extended period of time becomes hot. This is normal. 28 • • • • • Max. allowable working pressure PS: 31 bar Test pressure PT: 34.1 bar Operating Temperature Range TS: -40°C…+120°C Max. ambient temperature: -40°C…+50°C Released / compatible for: R290, mineral-, alkyl benzene and ester lubricants • Standards: EN 12284 200RB types, not listed in the following table, are not released for use with flammable refrigerants! Type Part no. 200RB 3T3-FLR (mm) 801323 200RB 3T3-FLR 801445 200RB 4T10-FLR 801446 200RB 4T4-FLR 801447 200RB 4T3-FLR 801448 200RB 4T12-FLR 801449 200RB 6T4-FLR 801450 200RB 6T12-FLR 801451 200RB 6T5-FLR 801452 Operating Instructions Coil ASC…+ PG9 ATEX General Information ASC-230VAC /ASC-24VAC + PG9 ATEX is a coil and plug for use with propane. Types and Markings We generate two kits contain coil (old coil from Bobinage France), electrical plug and blue clip. Kit 1 II 3G Ex nA IIA T3 Gc U Coil: ASC-230VAC ATEX Electrical Plug: PG9-ATEX II 2G IIC T6 Gb Kit 1 Coil: ASC-230VAC ATEX Electrical Plug: PG9-ATEX II 3G Ex nA IIA T3 Gc U Electrical Connection • Entire electrical connections have to comply with local regulations. • Ensure that the cables are mounted without tension; always leave the cable a bit loose. • Ensure that cables are not mounted near sharp edges. • Do not bend or mechanically stress the cable outlet, maintain a clearance of 20 mm to neighboring parts. • Make sure a fuse installed ahead of coil at appropriate location (non ATEX environment or explosive protective switch box). Figure 1 II 2G IIC T6 Gb These components must be installed in an appropriate housing to protect them from mechanical damage or shock. Safety instructions Warning: It is not permitted to disconnect the plug from coil while the power is ON during operation or standby. • Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability, sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and • Eye damage. Proper protective equipment (gloves, eye protection, etc.) has to be used. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Do not exceed the specified maximum ratings for voltage. • Before installation or service disconnect voltage from system and device. • Do not energize coil unless it is attached to the valve. • Observe and avoid mechanical damage of component housing. • Installation of Coil: (Fig. 1) • Place coil over the enclosing tube. Coil may be rotated 360° for ease of wiring. • Press coil housing down firmly, secure (1) and close (2) the coil retainer Wiring 1. Cable with three wires has to be connected to terminal 1 and 2 and (ground) on the plug terminal box. 2. Place the delivered gasket on the coil and insert the already wired PG9-ATEX Plug on the coil. Tighten screw (little gasket!) with 0.1 Nm. Pay attention to small gasket under the screw. (Fig. 2) Figure 2 29 Operating Instructions Coil ASC…+ PG9 ATEX Operation Technical Data • Note: ASC coils are intended for continuous-duty, which when energized for an extended period of time, it becomes hot. This is normal. • Before energizing the valve be sure that the source voltage and frequency matches that on the coil label. • Supply voltage variation: 230 VAC ±10% 24 VAC ±10% • Frequency: 50 Hz • Ambient temperature range: -10… +50°C • Protection class: IP65 H.T.P. High Tech Products Srl Operating instructions Solenoid Field Attachable connector Connectors DIN EN175301-803 G1-G2 series Connectors DIN EN175301-803 M1-M2 series Connectors DIN EN175301-803 P1-P2 series Via Lesina, 45 24030 Brembate di Sopra (BG) – Italy Tel. +39.035.692509 / fax +39.035.203291 VAT: IT02622450167 www.webhtp.eu - [email protected] Sede Legale: Via G. Quarenghi, 11 – 24122 BERGAMO (BG) - ITALY II 2 GD IIC T6 Gb II 2D Ex tb IIIC T85°C Db IP65/IP67 SECURITY WARNING Before doing any of the above described operation , please make sure that cable is not under power supply and there are not current sources nearby. The connectors must be protected to reduce the risk of impact. • • • • • • • • • • • Before to proceed with the following steps, please be assured that the installation-operating zone is free from dust. Dust presence may affect “IP” protection performances. Double check the following product ratings: V max , I max , Temp max If needed, peel the cable jacket and the wires using suitable tools. Unscrew the cable gland, the grommet and the washer from the connector and put them on the cable you want to connect Using a screwdriver, open the connector inserting the tool into the opposite lid. Connect the wires according to the electrical plan to the wire clamps on the connector terminal block. MAKE SURE THE WIRES ARE CONNECTED CORRECTLY BY CHECKING THAT THE POLES INDICATION (1,2,.. GND) WHICH IS PRINTED ABOVE THE CONNECTOR FITS WITH WIRE COLOR AND/OR CONNECTION ACCORDING TO THE INSTALLATION DRAWING. Close the connector, be assured the gland is suitably tight. Connect the connector to the solenoid, putting between the solenoid and the coil the gasket, which is included in the package. Fit the fixing screw (included in the package) and screw it tightly to the solenoid using the suitable screwdriver. Now it’s possible to give power and check the solenoid operation.\ IF, FOR ANY REASON, YOU NEED TO UNCOUPLE THE CONNECTOR FROM THE SOLENOID MAKE PREVIOUSLY SURE THE POWER IS OFF This connector complies with the applicable norms (for its protection class only) contained in European directive 94/9/CE 30 Technical Bulletin PT5-…-FLR Pressure Transmitter Pressure Transmitters convert a pressure into a linear electrical output signal. Features • Thin-film stainless steel sensor with output signal 4 to 20 mA and 2-wire connection • Specially calibrated pressure ranges with +1% accuracy performance • Fully hermetic • Protection class IP65 • Minimum lot size 20 pieces • II 3G Ex nC IIB T4 Gc X PT5-…FLR Selection Table Type PT5-30L-FLR Part no. multi-pack Pressure connection 802389M 6 mm tube x 40 mm long Cable length 6.0 m Marking Mark acc. 2004/108/EC, EN61326 Emission (Group 1, Class B) & immunity (industrial locations) II 3G Ex nC IIB T4 Gc X Technical Data Dimensions [mm] Supply voltage (polarity protected) Nominal : 24VDC Range : 7…30VDC Permissible noise & ripple Influence of supply voltage < 1 Vp-p Load resistance R ≤ Ub - 7.0V L 0.02A Response time ≤ 5 ms Pressure sensing range 0…30 bar corresponding to 4…20 mA Max. working pressure PS 35 bar Test Pressure PT 38.5 bar 6000±20 Maximum ≤ 24 mA 4…20 mA 24 Ø22 -20...+80°C -20…+80°C -40…+100°C Protection class (EN 60529) IP65 Vibration at 10…2000Hz 20 g according to IEC 60068-2-6 Materials Housing, pressure connector and diaphragm with medium contact Stainless steel 316L, 1.4534 40.5 30 million load cycles with 1.3 times of nominal pressure Ø26 -0.05 3-0.2 Sensor lifetime approx. 46 Output signal Temperatures: Transport and storage Operating ambient housing Medium brown / U+ green / U- < 0,02 % FS/V 1±0.2 Ø6±0.1 Ø6.7±0.2 31 Operating Instructions PT5-…-FLR Pressure Transmitter General Information Installation (Fig. 1) Pressure Transmitters convert a pressure into a linear electrical output signal. • Mounting directions per Fig. 1 in order to prevent the collection of contaminant in pressure sensing element. PT5-...-FLR meets explosion protection requirements for electrical equipment, equipment group II, equipment categories 3G, in ignition protection class “nC” as hermetically sealed device in explosion group IIB and temperature class T4. They are marked with: Brazing (Fig. 2) II 3G Ex nC IIB T4 Gc X PT5-…-FLR must be installed in an appropriate housing to protect them from mechanical damage, shock and light. • Perform and consider the brazing joint as per EN14324. • Before and after brazing clean tubing and brazing joints. • Minimize vibrations in the piping lines by appropriate solutions. • Use of flux and silver rod having a minimum of 30% silver. Fig. 1 Safety Instructions • Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves, eye protection, etc.) has to be used. • In a severely contaminated system, avoid breathing acid vapors and avoid contact with skin from contaminated refrigerant / lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Do not release any refrigerant into the atmosphere! • Do not exceed the specified maximum ratings for pressure, temperature, voltage and current. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Ensure that the system piping is grounded. • Before installation or service disconnect all voltages from system and device. • Observe and avoid mechanical damage of housing in order to maintain protection class. • Ensure that design, installation and operation are according to European and national standards/ regulations. 32 Fig. 2 max. 120°C Ø 6.0 ± 0.1mm Pressure Test • After completion of installation, a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • Max. system test pressure: 38.5 bar. Operating Instructions PT5-…-FLR Pressure Transmitter Warning • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. Tightness Test Conduct tightness test according EN378-2 with appropriate equipment and method to identify tightness of external joints. The allowable leakage rate must be according system manufacturer’s specification. Technical Data of PT5 -…-FLR: • • • • • • • • Max. allowable working pressure PS: 35 bar Test pressure PT: 38.5 bar Supply voltage: 7V...30V DC, class 2 Output signal: 4 mA…20 mA Protection class (EN 60529): IP65 Medium temperature: -40°C…+100°C Ambient temperature: -20°C…+80°C Released / compatible for: R290; mineral-, alkyl benzene and ester lubricants • Cable length (2 wire): 6.0 m Marking Electrical Connection • Entire electrical connections have to comply with local regulations. • Ensure that the cables are mounted without tension; always leave the cable a bit loose. • Ensure that cables are not mounted near sharp edges. • Do not bend or mechanically stress the cable outlet, maintain a clearance of 20 mm to neighboring parts. Wiring • PT5-…-FLR are in compliance with European EMC directive and bear CE-marking. • Connection cables should not be extended beyond standard 6 m length, otherwise entire system needs to be verified from the system manufacturer for free system signal emissions and immunity for conformity to EMC directive and standards. • Signal line should not be installed parallel with power lines to avoid electrical interference. • Ensure polarity for connection of 2-wire cable to controller: • +24V DC to be connected to brown wire • Output Signal / 0V to be connected to green wire • • Mark according 2004/108/EC, EN61326 Emission (Group 1, Class B) and immunity (industrial locations) II 3G Ex nC IIB T4 Gc X PT5 types not listed in the following table are not released for use with flammable refrigerants! Type Range Part no. PT5-30L-FLR 0…30 bar 802389M Operation • Perform a functional test of electrical circuit before charging the system with refrigerant. Service / Maintenance • Defective PT5-…-FLR must be replaced; they cannot be repaired. • Disconnect electrical power before service. • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. 33 Technical Bulletin PS4-…ATEX Pressure Switch with fixed setting Features • • • • • • High and low pressure switches With molded cable Protection IP67 TÜV approved Minimum lot size 100 pieces Other settings are not available Marking • • PS4-…ATEX ENEC05 and CE0035 according to PED 97/23/EC II 3G ExnA IIA T2Gc U Selection Table Type Part no. Setting [bar] Cut-out Cut-in Contact function Application Pressure connection PSL open on falling pressure low pressure 6 mm PSH open on rising pressure high pressure 6 mm EN 12263 Low pressure switches with automatic reset; Open on falling pressure PS4-W1 808301 0.6/1.8 bar ATEX 808303* 0.6 1.8 High pressure switches with automatic reset; Open on rising pressure PS4-W1 808300 20/26 bar ATEX 808302* 20 26 Note: *) Singlepack Technical Data Dimensions [mm] Max. allowable working pressure PS: PS4-W1 808301 0.6/1.8 bar ATEX PS4-W1 808300 20/26 bar ATEX 17 bar 37.2 bar Test pressure PT: PS4-W1 808301 0.6/1.8 bar ATEX PS4-W1 808300 20/26 bar ATEX 30 bar 41 bar Electrical rating: 50 mA max. at 24 VDC Vibration resistance (10 ... 250 Hz) 4g Electrical connection Cable version Cable color 18 AWG 0.8 mm2, 600 V (max. 125°C) LP: (blue) HP: (black) Type of electrical contact: Single pole single throw (SPST) Protection class (EN60259) IP67 Temperature range: Medium: -35°C…+135°C Ambient: -30°C…+65°C Storage: -30°C…+80°C Cable length 3m Marking 50 mm 44 mm ENEC05 and CE0035 acc. to PED 97/23/EC II 3G ExnA IIA T2Gc U It is manadatory to protect pressure switch against supply voltage higher than 30 VDC and operating current over 50 mA at any time. 34 Operating Instructions PS4-…ATEX Pressure Switch with Fixed Setting General Information The Pressure Controls PS4-…ATEX are intended to monitor the pressure and to act as a safety device. The listed products are electrical operated switches with ignition source and are in compliance with EN 60079 / directive 94/9/EC therefore rated / marked as: II 3G ExnA IIA T2Gc U PS4…ATEX must be installed in an appropriate housing to protect them from mechanical damage or shock. Safety Instructions • Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves, eye protection, etc.) has to be used. • In a severely contaminated system, avoid breathing acid vapors and avoid contact with skin from contaminated refrigerant / lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Make sure that the high pressure switch is installed on high pressure side and low pressure switch on low pressure side of system. Failure to do will result in system without protection against high and low pressure and consequently risk of explosion and human injury. • Do not release any refrigerant into the atmosphere! • Do not exceed the specified maximum ratings for pressure, temperature, voltage and current. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Ensure that the system piping is grounded. • Before installation or service disconnect voltage from system and device. • Observe and avoid mechanical damage of housing in order to maintain protection class. • Ensure that design, installation and operation are according European ATEX Directive, as well as the according national standards / regulations are respected. Installation (Fig. 1) • PS4-…ATEX pressure controls should not be exposed to gas pulsations. When pulsations can be expected, use a pulsation damper or a capillary tube connection (min. 1m). • Mounting directions per Fig. 1 in order to prevent the collection of contaminant in pressure sensing element. Fig. 1 Brazing (Fig. 2) • Perform and consider the brazing joint as per EN 14324. • Before and after brazing clean tubing and brazing joints. • Minimize vibrations in the piping lines by appropriate solutions. Fig. 2 max. 70°C 6 +- 0.13 mm 35 Operating Instructions PS4-…ATEX Pressure Switch with Fixed Setting Pressure Test Technical Data of PS4 -...ATEX: • After completion of installation, a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • The max. system test pressure shall be 30 bar for low pressure side and 41 bar for high pressure side. • • • • • • • Warning • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. • • • • Tightness Test Conduct tightness test according to EN 378-2 with appropriate equipment and method to identify tightness of external joints. The allowable leakage rate must be according system manufacturer’s specification. Electrical Connection • Entire electrical connections have to comply with local regulations. • Ensure that the cables are mounted without tension; always leave the cable a bit loose. • Ensure that cables are not mounted near sharp edges. • Do not bend or mechanically stress the cable outlet, maintain a clearance of 20 mm to neighboring parts. Max. allowable working pressure PS: (see table below) Test pressure PT: (see table below) Protection class (EN 60529): IP67 Ambient temperature (housing): -30°C…+65°C Storage / transportation temperature: -30°C…+80°C Medium temperature: -35°C…+135°C Released / compatible for: R290, mineral- and alkyl benzene, ester lubricants Electrical rating: 50 mA max. at 24 VDC max Function: Pressure limiter, type approval EN 12263, PSL/PSH Pressure controls PS4…ATEX are factory preset to specific switch points (see label). The set points cannot be modified. Type of electrical contact: Single pole single throw (SPST) Marking - ENEC05 and CE0035 according to PED 97/23/EC II 3G ExnA IIA T2Gc U PS4 types, not listed in the following table, are not released for use with flammable refrigerants! Type Part no. Settings PS PT PS4-W1 808301 0.6/1.8 bar ATEX 17 bar 30 bar PS4-W1 808303* 0.6/1.8 bar ATEX 17 bar 30 bar PS4-W1 808300 20/26 bar ATEX 37.2 bar 41 bar PS4-W1 808302* 20/26 bar ATEX 37.2 bar 41 bar Note: *) Singlepack Operation • Perform a functional test of electrical circuit before charging the system with refrigerant. Service / Maintenance • Defective PS4-…ATEX must be replaced; they cannot be repaired. • Disconnect electrical power before service. • The lowest pressure inside system must be at least 0.4 bar higher than ambient pressure at any time. Failure to do so could accumulate air inside the system and create an explosive mixture over time. • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. 36 Technical Bulletin Hermetic Liquid Line Filter Driers ADK-…FLR ADK-…FLR filter driers are used for protection of systems against contaminant. Features • • • • • • • • • • Solid block Hermetic design Rugged steel shells Corrosion resistant epoxy paint Cushioned flow for non-turbulent performance High water adsorption capacity High acid adsorption capacity High filtration capacity / efficiency No CE marking according art. 3.3 PED 97/23 EC Max. working pressure PS: 35 bar ADK-…FLR Selection Table Type Part. no Connection ODF Flow capacity [kW] Pressure drop 0.07 bar 0.14 bar ADK-032S FLR 803650 1/4" 9.6 14.1 ADK-036MMS FLR 803651 6 mm 8.8 13.1 ADK-052S FLR 803652 1/4" 11.8 18.7 ADK-056MMS FLR 803653 6 mm 10.9 16.4 ADK-053S FLR 803654 3/8" 17.9 26.4 ADK-0510MMS FLR 804066 10 mm 17.9 26.4 ADK-082S FLR 804067 1/4" 13.1 19.0 ADK-086MMS FLR 804068 6 mm 11.7 17.5 ADK-083S FLR 804069 3/8" 18.0 26.4 ADK-0810MMS FLR 804070 10 mm 18.0 26.4 ADK-084S FLR 804071 1/2" 29.3 44.2 ADK-0812MMS FLR 804072 12 mm 28.8 43.2 ADK-163S FLR 804073 3/8" 20.5 29.3 ADK-1610MMS 804074 10 mm 20.5 29.3 ADK-164S FLR 804075 1/2" 39.4 54.7 ADK-1612MMS FLR 804076 12 mm 35.4 53.1 ADK-165S FLR 804077 5/8" / 16 mm 54.4 79.3 ADK-304S FLR 804078 1/2" 39.5 56.5 ADK-305S FLR 804079 5/8" / 16 mm 57.8 79.9 ADK-307S FLR 804080 7/8" / 22 mm 72.6 114.5 ADK-417S FLR 804081 5/8" / 16 mm 85.3 128.0 ADK-757S FLR 804082 7/8" / 22 mm 115.5 173.3 Correction Factors ADK Use following simplified formula for operating conditions other than -15°C / +30°C Qn = Qo x Kt Qn : Nominal flow capacity Qo : Required cooling capacity Kt : Correction factor for evaporating and liquid temperature 37 Technical Bulletin Hermetic Liquid Line Filter Driers ADK-…FLR Correction factor Kt Evaporating temperature [°C] Liquid temperature °C 20 15 10 5 0 -5 -10 -15 -20 70 1.58 1.62 1.66 1.71 1.77 1.83 1.89 1.96 65 1.43 1.46 1.50 1.54 1.58 1.63 1.68 1.73 60 1.30 1.33 1.37 1.40 1.44 1.48 1.52 55 1.20 1.23 1.26 1.29 1.32 1.35 50 1.12 1.14 1.17 1.19 1.22 45 1.05 1.07 1.09 1.11 1.13 40 0.98 1.00 1.02 1.04 35 0.93 0.95 0.96 30 0.88 0.90 0.91 25 0.84 0.85 20 - 0.81 -25 -30 -35 2.03 2.11 2.20 2.29 1.79 1.86 1.92 2.00 1.56 1.61 1.66 1.72 1.78 1.39 1.42 1.46 1.51 1.55 1.60 1.25 1.28 1.31 1.34 1.38 1.42 1.46 1.16 1.19 1.21 1.24 1.28 1.31 1.34 1.06 1.08 1.11 1.13 1.16 1.19 1.22 1.25 0.98 1.00 1.02 1.04 1.06 1.08 1.11 1.14 1.16 0.93 0.94 0.96 0.98 1.00 1.02 1.04 1.07 1.09 0.86 0.88 0.89 0.91 0.93 0.95 0.96 0.98 1.00 1.03 0.82 0.84 0.85 0.87 0.88 0.90 0.91 0.93 0.95 0.97 Technical Data Max. working pressure PS 35 bar Shell Steel Test pressure PT 38.5 bar Paint Epoxy powder paint Medium temperature TS -45…+65°C Protection 500+ Hours salt spray test Ambient temperature -45…+65°C Package Individual packaged Fluid group II Standards EN 14276-1 Solder connections Copper, ODF Marking HP Dimensions [mm] Type ADK-032S-FLR ADK-036MMS-FLR ADK-052S-FLR ADK-056MMS-FLR ADK-053S-FLR ADK-0510MMS-FLR ADK-082S-FLR ADK-086MMS-FLR ADK-083S-FLR ADK-0810MMS-FLR ADK-084S-FLR ADK-0812MMS-FLR ADK-163S-FLR ADK-1610MMS-FLR ADK-164S-FLR [mm] Connection ODF A ØF 1/4" 70.1 44.0 6 mm 70.1 44.0 1/4" 85.3 63.5 6 mm 85.3 63.5 3/8" 84.8 63.5 10 mm 84.8 63.5 1/4" 102.7 63.5 6 mm 102.6 63.5 3/8" 102.1 63.5 10 mm 102.1 63.5 1/2" 102.5 63.5 12 mm 102.6 63.5 3/8" 126.6 63.5 10 mm 126.6 63.5 1/2" 127.0 63.5 12 mm 127.0 63.5 ADK-165S-FLR 5/8" / 16 mm 127.6 63.5 ADK-304S-FLR 1/2" 193.6 76.2 ADK-305S-FLR 5/8" / 16 mm 194.2 76.2 ADK-307S-FLR 7/8" / 22 mm 193.6 76.2 ADK-417S-FLR 5/8" / 16 mm 199.9 88.9 ADK-757S-FLR 7/8" / 22 mm 337.4 88.9 ADK-1612MMS-FLR 38 ØF A Operating Instructions Hermetic Liquid Line Filter Driers ADK-…FLR General Information ADK-…FLR filter driers are used for protection of systems against contaminant. The listed products are not in scope of ATEX product directive 94/9/EC as they do not incorporate an own source of ignition. ADK-…FLR must be installed in an appropriate housing to protect them from mechanical damage or shock. Safety Instructions • Read operating instructions thoroughly. Nonobservance can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves. eye protection. etc.) has to be used. • In a severely contaminated system, avoid breathing acid vapors and avoid contact with the skin from contaminated refrigerant/lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Do not release any refrigerant into the atmosphere. • Do not exceed the specified maximum ratings for pressure and temperature. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Do not use on any other fluid media without prior approval of Emerson. Use of fluids not listed could result in chemical deterioration of the desiccant in filter drier. • Ensure that design, installation and operation are according to European and national standards/ regulations. Mounting Location • For best results locate the filter drier as close as possible to the inlet of expansion device. If using a liquid line solenoid valve and/or moisture indicator. Locating filter drier upstream will provide protection for the solenoid valve and the moisture indicator will measure the effectiveness of the drier. • Protect the filter drier against sunrays and vibration. Installation • Do not remove seal caps until ready for installation in order to minimize entering of moisture and dirt. Avoid damaging the connections! • Direction of refrigerant flow must match with arrow on the label. Reverse flow reduces the filtering ability and increases the pressure drop through the filter drier. Recommended external pipe connection: Outside diameter Nominal pipe connection Min. (mm) Max. (mm) 1/4” 6.30 6.38 3/8” 9.47 9.55 1/2” 12.62 12.73 5/8” 15.80 15.90 7/8” 22.15 22.25 1-1/8” 28.50 28.63 6 mm 5.95 6.05 10 mm 9.95 10.05 12 mm 11.96 12.05 16 mm 15.95 16.05 22 mm 21.95 22.06 28 mm 27.95 28.05 Brazing (Fig. 1) • Perform and consider the brazing joint as per EN 14324. • Before and after brazing clean tubing and brazing joints. • Minimize vibrations in the piping lines by appropriate solutions. max. 330°C • Filter driers may be installed in any position within the liquid line. Direction of refrigerant flow must be observed. 39 Operating Instructions Hermetic Liquid Line Filter Driers ADK-…FLR Pressure Test • After completion of installation. a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • Max. system test pressure: 38.5 bar. ADK types not listed in the following table are not released for use with flammable refrigerants! Type Part no. ADK-032S-FLR 803 650 ADK-036MMS-FLR 803 651 ADK-052S-FLR 803 652 ADK-056MMS-FLR 803 653 • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. ADK-053S-FLR 803 654 ADK-0510MMS-FLR 804 066 ADK-082S-FLR 804 067 ADK-086MMS-FLR 804 068 ADK-083S-FLR 804 069 Tightness Test ADK-0810MMS-FLR 804 070 ADK-084S-FLR 804 071 ADK-0812MMS-FLR 804 072 ADK-0163S-FLR 804 073 ADK-0160MMS-FLR 804 074 ADK-164S-FLR 804 075 ADK-0162MMS-FLR 804 076 ADK-165S-FLR 804 077 ADK-304S-FLR 804 078 ADK-305S-FLR 804 079 ADK-307S-FLR 804 080 ADK-417S-FLR 804 081 ADK-757S-FLR 804 082 Warning Conduct a tightness test according to EN 378-2 with appropriate equipment and method to identify tightness of external joints. The allowable leakage rate must be according system manufacturer’s specification. Operation • After leakage test start system and after sufficient running time check color of moisture indicator for moisture level. We recommend the use of Emerson moisture indicators. • In systems with excessive moisture it may be necessary to replace the filter drier for several times in order to bring moisture in the system to a safe level. Service / Maintenance • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. • Disconnect electrical power before service. • Always install a new filter drier when existing ones become saturated with moisture and foreign materials. • Do not attempt to dry out a used filter drier. Technical Data of ADK -…FLR • • • • Max. allowable working pressure PS: 35 bar Test pressure PT: 38.5 bar Temperature Range TS: -45°C…+65°C Released / compatible for: R290, mineral- and alkyl bezene, ester lubicants • Standards: EN 14276-1 40 Technical Bulletin Moisture Indicator MIA…-FLR Features • • • • • • Fully hermetic Lower Pressure drop Corrosion free stainless steel body Crystal Indicator element for long lifetime and reliability Easily determination of moisture content Sensitive indicator with calibrated four colors. Conforms to requirement of most compressor manufacturers • Large clear viewing area • ODF extended tube configurations suitable MIA Moisture Indicator for all commercial applications Selection and Dimensions [mm] 30 A ION UT CA WE T DR Y B Type MIA 014FLR MIA 038FLR MIA 012FLR MIA 058FLR MIA 078FLR MIA 118FLR Part no. For tube Height outside A diameter [mm] Length B [mm] Weight [g] 805895 1/4’’ 25.7 98.0 60 805896 3/8’’ 28.5 109.0 70 805897 1/2’’ 31.8 113.0 75 805898 5/8’’ 31.8 108.5 85 805899 7/8’’ 37.8 122.5 150 805900 1 1/8’’ 43.5 122.5 190 Type MIA M06FLR MIA M10FLR MIA M12FLR MIA M28FLR MIA M10S-FLR MIA M12S-FLR Part no. For tube Height outside A diameter [mm] Length B [mm] Weight [g] 805901 6 mm 25.9 98.0 60 805894 10 mm 28.5 109.0 70 805902 12 mm 28.5 113.0 75 805903 28 mm 43.5 122.5 190 805904 10 mm 28.7 119 75 805905 12 mm 28.5 113 75 41 Technical Bulletin Moisture Indicator MIA…-FLR Technical Data Maximum working pressure PS 35 bar Pressure drop negligible Test pressure PT 49.5 bar Operating temperature TS -40…+100°C Medium compatibility R290, mineral-, alkyl benzene and ester lubricants 5.0 x 10-6 mbar l/sec = 4.9 x 10-6 cc/sec Connections ODF extended copper tubes, solder connections only External leakage (100% - production tested with Helium - Spectrometer) Standards EN 12178 Determining the Moisture Content with the Color Code Refrigerant Liquid temperature °C Moisture content in mg water per kg refrigerant (ppm) Blue Dry R290 Purple Fuchsia Rose Caution Caution wet 25 2 4 9 14 38 5 8 18 29 52 10 16 36 59 Note: In area “Caution” and “Caution wet” filter drier should be changed. 42 Operating Instructions Moisture Indicator MIA…-FLR General Information Installation MIA…-FLR are sight glasses with moisture indicator. The listed products are not in scope of ATEX product directive 94/9/EC as they do not incorporate an own source of ignition. • Do not remove seal caps until ready for installation in order to minimize entering of moisture and dirt. Avoid damaging the connections! MIA…-FLR must be installed in an appropriate housing to protect them from mechanical damage or shock. • The MIA…-FLR is fully hermetic and cannot be disassembled. Recommended external pipe connection: Safety Instructions • Read operating instructions thoroughly. Nonobservance can result in device failure, system damage or personal injury. • According to EN 13313 it is intended for use by persons having the appropriate knowledge and skill. • R290 requires special handling and care due to its flammability. Sufficient ventilation is required during service of the system. Contact with rapidly expanding gases can cause frostbite and eye damage. Proper protective equipment (gloves. eye protection. etc.) has to be used. • In a severely contaminated system. avoid breathing acid vapors and avoid contact with skin from contaminated refrigerant / lubricants. Failure to do so could result in injury. • Ensure that the system is correctly labeled with applied refrigerant type and a warning for explosion risk. • Do not release any refrigerant into the atmosphere! • Do not exceed the specified maximum ratings for pressure and temperature. • Before opening any system make sure pressure in system is brought to and remains at atmospheric pressure. • Ensure that design. installation and operation are according to European and national standards/ regulations. Nominal pipe connection Outside diameter Min. (mm) Max. (mm) 1/4 “ 6.30 6.38 3/8“ 9.47 9.55 1/2“ 12.62 12.73 5/8“ 15.80 16.05 7/8“ 22.15 22.25 1-1/8” 28.50 28.63 6 mm 5.95 6.05 10 mm 9.95 10.05 12 mm 11.96 12.05 28 mm 27.95 28.05 Brazing (Fig. 1) • Perform and consider the brazing joint as per EN 14324. • Before and after brazing clean tubing and brazing joints. • To avoid oxidization, it is advised to purge the system with an inert gas such as nitrogen while brazing. Do not exceed the maximum temperature of 100°C. Fig. 1 max. 100°C Mounting Location • MIA…-FLR has to be installed only in the liquid line, otherwise the humidity reading can show wrong values. • MIA…-FLR is bi-directional and may be installed in any position which allows visual access to the indicator window itself. • The moisture indicator is normally located after the filter drier and before the expansion valve. • To avoid overheating it is advised to make the join at one end and cool the indicator completely before repeating the procedure on the other end connection. • Minimize vibrations in the piping lines by appropriate solutions. 43 Operating Instructions Moisture Indicator MIA…-FLR Fig. 2 Refrigerant R290 ppm Liquid temperature o C Blue / Dry Purple Fuchsia / Caution Rose / Caution wet 25 2 4 9 14 38 5 8 18 29 52 10 16 36 59 Pressure Test Technical Data of MIA… -FLR • After completion of installation, a pressure test must be carried out according to EN 378 for systems which must comply with European pressure equipment directive 97/23/EC. • Max. system test pressure: 38.5 bar. • • • • Max. allowable working pressure PS: 35 bar Test pressure PT: 49.5 bar Medium temperature TS: -40°C…+100 °C Released / compatible for: R290, mineral- and alkyl benzene, ester lubricants • Standards: EN 12178 Warning • Failure to do so could result in loss of refrigerant and personal injury. • The pressure test must be conducted by skilled persons with due respect regarding the danger related to pressure. Tightness Test MIA types not listed in following table are not released for use with flammable refrigerants! Type Part no. MIA 014-FLR 805895 MIA 038-FLR 805896 MIA 112-FLR 805897 Humidity Reading (Fig. 2) MIA 058-FLR 805898 • The humidity content in mg Water per kg refrigerant (ppm) can be identified by the color code in Fig. 2. • A minimum period of 12 hours is recommended after installation before attempting to determine system moisture content. • In case of indicator is showing fuchsia or rose color the change of the filter drier is required. MIA 078-FLR 805899 MIA 118-FLR 805900 MIA M6-FLR 805901 MIA M10-FLR 805894 MIA M12-FLR 805902 MIA M28-FLR 805903 MIA M10S-FLR 805904 MIA M12S-FLR 805905 Conduct tightness test according to EN 378-2 with appropriate equipment and method to identify tightness of external joint. The allowable leakage rate must be according system manufacturer’s specification. Service / Maintenance • Defective MIA…-FLR must be replaced; they cannot be repaired. • Disconnect electrical power before service. • Before any debrazing ensure that the flammable refrigerant is pumped out of the system and the room around the system is well vented so no refrigerant left. 44 45 2 Products for non explosive environment Product material compatible with R290 only for Non explosive environment Page Content Products Superheat Controllers EC3-P32*/EC3-P33* and ECD-002* Technical Bulletin ……......................................................……………………………………... 48 Electronic Expansion Valves EXM/L Series Technical Bulletin ……......................................................………………………………......... 50 Stand-alone Superheat/Economizer Controller EXD-HP1/2 Technical Bulletin ……......................................................………………………………......... 53 Oil Management OM3-020P TraxOil Technical Bulletin ……......................................................………………………………......... 55 Compressor Soft Starter CSS-25U/CSS-32U/CSS-32W Technical Bulletin ……......................................................………………………………......... 57 *) These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. 46 Technical Bulletin EC3-P32 / -P33 Superheat Controller & Standard ECD-002 EC3-P32 / -P33 are stand-alone universal superheat controllers. EC3-P32 offers remote access with built-in TCP/IP Ethernet communications and WebServer functionality. Any standard WebBrowser (e.g. Internet Explorer® or Mozilla Firefox) can be used for monitoring or parameter setting. EC3-P33 has no network communication. Features EC3-P33 / EC3-P32 EC3-P32 • Superheat control in conjunction with Emerson stepper motor driven Electrical Control Valves EX4-7…-FLR • Selectable refrigerants: R290, R1234Ze, R1234yf, R32, R1270 (The valves compatibility release for R290 and R32 for time being) • Low superheat alarm and MOP function • Feed through of 4…20 mA signal from evaporator pressure sensor to analogue output. This may also be connected to pressure input of any other controller to avoid need for multiple pressure sensors • Monitoring of sensors and sensor wiring and detection of sensor and wiring failures • Intelligent alarm management in order to protect the compressor i.e. fail safe operation • Integral rechargeable battery to close electrical control valve in case of power loss • Electrical connection via plug-in type screw terminals • Aluminum housing for DIN rail mounting EC3-P33 with ECD-002 Additional Features EC3-P32 only • • • • High superheat alarm Low pressure switch function/alarm Freeze protection function/alarm Pump down function Selection Table Description Type Part No. EC3-P33 807858 K03-X33 807645 Display / keypad unit (opt.) ECD-002 807657 Superheat Controller EC3-P32 807857 K03-X32 807644 Superheat Controller Terminal kit EC3-P33 Terminal kit EC3-P32 These devices have potential ignition source and do not comply with ATEX requirem ents. Installation only in “non explosive location ”. Selection Table Accessories Description Temperature sensor Pressure transmitter Type Part no. Cable length 3.0 m ECN-N30 804496 Cable length 6.0 m ECN-N60 804497 Cable length 12.0 m ECN-N99 804499 0…30 bar PT5-30L FLR 802389M 47 Technical Bulletin EC3-P32 / -P33 Superheat Controller & Standard ECD-002 Wiring Diagram EC3-P33 Non-explosive environment 2: White 4: Black 3: Blue 1: Brown wire G: Remote control panel, system controller H: Alarm relay, dry contact; Relay coil is not energized at alarm condition or power off EC3-P32 Non-explosive environment Network Connection EC3-P32 only The use of the relay is essential to protect the system in case of power failure if the communications interface or the ECD-002 are not utilized. I: Digital input (0V/open = Stop; 24V/closed = Start) J: Transformer Class II, 24VAC secondary / 25VA K: Third party controller (can use analog output signal of EC3) O: Pump down relay, dry contact; Relay is energized during normal operation. Note: The internal resistor of a third party controller must fulfill the following conditions: Supply voltage 12VDC: R ≤ 200Ω Supply voltage 24VDC: R ≤ 800Ω 48 Cross over cable Connection via router Technical Bulletin EC3-P32 / -P33 Superheat Controller & Standard ECD-002 Technical Data EC3-P32 / -P33 Supply voltage 24VAC ±10%, 50/60Hz Digital input 24 V AC ±10%, 50-60HZ ECD-002 24 V DC ±10% Power consumption 25VA max. including connected ECV and display / keyboard Internal battery charging time Approximately 2 hours if battery is fully empty Plug-in connector size Removable screw version wire size 0.14…1.5 mm2 Ground connection Vibration Supply 6.3 mm spade earth connector LED indicators Marking Protection class ECD-002 Display Unit via connecting cable Valve opening, valve closing, alarm, demand Numeric segmental display. IP 20 (DIN EN60529) 4 g, 10-1000 Hz From EC3 Series Controller Display LED 2½-digits, red, with automatic decimal point between ±19.9, switchable between °C and °F Temperature storage -20…+65°C operating 0…+60°C 1…+25°C for optimum battery life Applied detective Connecting cable ECC-Nxx or standard CAT5 patch cord with RJ45 connectors Temperature storage -20…+65°C operating 0…+60°C EMC EN 61326, EN 50081, EN 61000-6-2, LVD EN 61000-4-2, EN 61000-4-3, EN 61000-4-4, Humidity 0…80% r.h. non condensing ROHS EN 61000-4-5, EN 61000-4-6, EN 61000-4-11 Protection class IP65 (mounting in front Humidity 0…80% r.h. non condensing (DIN EN 60529) panel with gasket) Weight ~ 800 g Weight ~ 52 g Mounting DIN rail mounted Mounting Panel mount (71 x 29 mm cutout) These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. 49 Technical Bulletin Electronic Expansion Valves EXM/L Series EXM/EXL EXM/EXL Unipolar stepper motor driven Electronic Expansion Valves are for precise control of refrigerant mass flow in heat pumps, heating units, air conditioning and close control applications. The valve is not released for refrigeration applications such as cold room and refrigeration display cabinet. Features • Hermetic design • Continuous, linear modulation of mass flow • Bi-flow with same capacity in normal and reverse flow direction • High MOPD: 40 bar in normal flow direction • Unipolar stepper motor • Removable coils in two versions: 12VDC/24VDC • Fine resolution: 500 pulses (half steps) or 250 full steps • Protection class of molded coil is IP65 (acc. EN 60529) excluding the cable end terminals (JST). • Reliability: 225 million pulses at 40 bar differential pressure • Bulk packing, boxes of 10 pieces Valve series Description Type Valve less coil EXM Part No. Nominal Capacity (kW) R290 EXM-B0A 800399M 1.6 EXM-B0B 800400M 4.9 EXM-B0D 800401M 10.3 EXM-B0E 800402M 12.1 Coil 12VDC EXM-125 800403M - Coil 24VDC EXM-24U 800415M - Valve less coil EXL EXM/EXL with Coil Coil 12VDC Connections Size / Style 1/4” ODM - EXL-B1F 800405M 15.0 1/4” ODF EXL-B1G 800406M 20.3 8 mm ODM EXL-125 800407M - EXL-24U 800416M - - Note: Nominal capacities at +38°C condensing temperature, +4 °C evaporating temperature and 1K subcooling. These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. Wiring EXM-125/EXL-125 (12 VDC, 5 wires coil) EXM-24U/EXL-24U (24 VDC, 5 wires coil) White White Winding 1/2 Winding 1/2 Red (common) M Orange M Orange Winding 3/4 Yellow Winding 3/4 Blue Brown (Common) 50 Yellow Blue Technical Bulletin Electronic Expansion Valves EXM/L Series Winding Number 1/2 3/4 Commons Recommended half step pulsing/switching mode Wire Color 1 2 3 4 5 6 7 8 Remark White ON ON OFF OFF OFF OFF OFF ON Orange OFF OFF OFF ON ON ON OFF OFF Yellow OFF ON ON ON OFF OFF OFF OFF Blue OFF OFF OFF OFF OFF ON ON ON 12V: Brown 24V: Red ON ON ON ON ON ON ON ON 1) The pulse sequence 1 to 8 will be repeated for further pulses in order to open the valve. 2) The pulse sequence 8 to 1 will be repeated for further pulses in order to close the valve. Valve movement mode (pulsing/switching sequence) Valve open: 1 → 2 → 3 → 4 → 5 → 6 → 7 → 8 Valve close: 8 → 7 → 6 → 5 → 4 → 3 → 2 → 1 Quick Selection (included 1.5 bar pressure drop for liquid line components and distributor) Condensing temperature (°C) 70 65 60 55 50 45 40 35 Capacity (kW) Evaporating Temperature (°C) R290 R290 15 10 5 0 -5 -10 -15 -20 -25 -30 1.5 4.5 9.6 11.3 14.1 19 1.5 4.7 9.8 11.6 14.4 19.5 1.5 4.7 9.9 11.7 14.5 19.7 1.5 4.6 9.8 11.6 14.4 19.4 1.5 4.5 9.5 11.2 13.9 18.8 1.4 4.3 9 10.6 13.2 17.9 1.3 3.9 8.3 9.8 12.2 16.4 1.1 3.5 7.3 8.6 10.7 14.5 1.5 4.5 9.6 11.3 14.1 19 1.5 4.7 9.9 11.7 14.5 19.6 1.6 4.8 10 11.9 14.7 19.9 1.6 4.8 10 11.8 14.7 19.9 1.5 4.7 9.8 11.6 14.4 19.5 1.5 4.5 9.5 11.2 13.9 18.7 1.4 4.2 8.9 10.5 13 17.6 1.3 3.8 8.1 9.6 11.9 16.1 1.5 4.5 9.5 11.3 14 18.9 1.5 4.7 9.9 11.7 14.5 19.6 1.6 4.8 10.1 11.9 14.8 20.1 1.6 4.8 10.2 12 14.9 20.1 1.6 4.8 10.1 11.9 14.7 19.9 1.5 4.6 9.8 11.6 14.3 19.4 1.5 4.4 9.3 11 13.7 18.5 1.4 4.1 8.7 10.3 12.8 17.3 1.5 4.5 9.4 11.1 13.8 18.7 1.5 4.7 9.9 11.6 14.4 19.5 1.6 4.8 10.1 12 14.8 20.1 1.6 4.9 10.2 12.1 15 20.3 1.6 4.8 10.2 12 14.9 20.2 1.6 4.7 10 11.8 14.7 19.8 1.5 4.6 9.7 11.4 14.2 19.2 1.4 4.3 9.2 10.8 13.4 18.2 1.4 4.4 9.3 11 13.6 18.4 1.5 4.6 9.8 11.5 14.3 19.4 1.6 4.8 10.1 11.9 14.8 20 1.6 4.9 10.2 12.1 15 20.3 1.6 4.9 10.3 12.1 15 20.4 1.6 4.8 10.2 12 14.9 20.1 1.5 4.7 9.9 11.7 14.5 19.6 1.5 4.5 9.5 11.2 13.9 18.8 1.4 4.3 9.1 10.8 13.4 18.1 1.5 4.6 9.6 11.4 14.1 19.1 1.5 4.7 10 11.8 14.6 19.8 1.6 4.8 10.2 12 15 20.2 1.6 4.9 10.3 12.1 15.1 20.4 1.6 4.8 10.2 12.1 15 20.3 1.6 4.8 10 11.9 14.7 19.9 1.5 4.6 9.7 11.5 14.3 19.3 1.4 4.2 8.9 10.5 13.1 17.7 1.5 4.5 9.5 11.2 13.9 18.8 1.5 4.7 9.9 11.6 14.4 19.5 1.6 4.8 10.1 11.9 14.8 20.1 1.6 4.9 10.2 12.1 15 20.3 1.6 4.9 10.2 12.1 15 20.3 1.6 4.8 10.1 12 14.8 20.1 1.5 4.7 9.9 11.7 14.5 19.6 1.3 4.1 8.7 10.2 12.7 17.2 1.4 4.4 9.3 10.9 13.6 18.4 1.5 4.6 9.7 11.5 14.2 19.2 1.6 4.7 10 11.8 14.6 19.8 1.6 4.8 10.2 12 14.9 20.2 1.6 4.8 10.2 12.1 15 20.2 1.6 4.8 10.1 12 14.9 20.1 1.5 4.7 10 11.8 14.6 19.7 1.3 4 8.4 10 12.4 16.7 1.4 4.3 9 10.7 13.3 17.9 1.5 4.5 9.5 11.2 13.9 18.9 1.5 4.7 9.8 11.6 14.4 19.5 1.6 4.8 10 11.9 14.7 19.9 1.6 4.8 10.1 12 14.9 20.1 1.6 4.8 10.1 11.9 14.8 20 1.5 4.7 10 11.8 14.6 19.8 1.3 3.9 8.2 9.6 12 16.2 1.4 4.2 8.8 10.4 12.9 17.4 1.4 4.4 9.3 11 13.6 18.4 1.5 4.6 9.7 11.4 14.2 19.2 1.5 4.7 9.9 11.7 14.5 19.6 1.6 4.8 10 11.8 14.7 19.9 1.6 4.8 10 11.9 14.7 19.9 1.5 4.7 9.9 11.7 14.6 19.7 Valve Type EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G EXM-B0A EXM-B0B EXM-B0D EXM-B0E EXL-B1F EXL-B1G 51 Technical Bulletin Electronic Expansion Valves EXM/L Series Technical Data MOPD (maximum operating pressure differential) 40 bar in normal flow 33 bar in reverse flow Bi-flow direction Normal: Connection A to B Reverse: Connection B to A Max. working pressure PS 45 bar Valve installation Coil upside or to vertical within ± 90° External leakage ≤ 3 gram / year Package and delivery 10 pieces CE marking Not required Connections, A and B EXM: ¼” ODM EXL: ¼” ODF and 8 mm ODM Weight Valve EXM: 65 g, EXL: 76 g Coil EXM: 124 g, EXL: 156 g Temperature range TS Liquid refrigerant Ambient Relative humidity -30…+70°C -30…+60°C 95% Air seat leakage at 10 bar differential pressure Typically 150 cm3/min. These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. Electrical Data Stepper motor type Uni-polar, constant voltage Electrical connection 12 VDC coil: 5 wires 24 VDC coil: 5 wires Supply voltage 12 VDC coil: 12V ± 10% 24 VDC coil: 24V ± 10% Phase current, operating 12 VDC coil: 260 mA 24 VDC coil: 130 mA Winding resistance per phase 12 VDC coil: 46 Ohm 24 VDC coil: 185 Ohm Insulation resistance Min. 100 MΩ at 500 VDC Cable length 1 meter Step mode Half step = one pulse Total number of pulses 500 half step (250 full step) Pulsing rate 30…90 pulses (half step) per sec Full travel time 16.6 seconds at 30 pulse/sec 5.5 seconds at 90 pulse/sec Reference position Mechanical stop at fully close position at 520 pulses Valve starts to open at: 32 pulses ± 20 pulses Insulation class E Protection class Coil IP65 excluding cable and terminal (JST) Dimensions (mm) Valve series 52 Description Type Diameter Length (mm) C D E F (mm) (mm) (mm) (mm) EXM-… 1/4 “ ODM 8 17.3 78 36 36.3 EXL-… 1/4 “ ODF / 8 mm ODM 8 21.8 90 42 42 Coil E (mm) F (mm) EXM-… 52.5 32 EXL-… 59 34 Technical Bulletin EXD-HP1/2 Stand-alone Superheat Controller EXD-HP1/2 are stand-alone universal superheat controllers for heat pumps, heating units, air conditioning and precision cooling such as telecom and shelter applications. Features • Self-adapting superheat control in conjunction with EMERSON stepper motor driven electronic expansion Valves EXM/EXL • Discharge hot gas temperature control by wet refrigerant vapor/vapor injection to compressor • EXD-HP1: Controller with one EXV output • EXD-HP2: Controller with two independent EXV outputs • Controllers as slave with Modbus (RTU) communication capability. All data (read/write) accessible by any third party controller having modbus communication (RTU) • Upload/download key (accessory) for transmission of parameter settings among controllers with the same setting • Low pressure switch and freeze protection function • Manual positioning of valve(s) • Limitation of evaporating pressure (MOP) • Low/high superheat alarm • Monitoring of sensors and sensor wiring and detection of sensor and wiring failures • Integrated display (3-digits LEDs) and key board • Electrical connection via plug-in type screw terminals (included with controller) • DIN rail mounting housing • OEM product: Box order quantities: 20 pieces (Multi-pack) Selection Table Type Description Controllers EXD-HP1 with 1 EXV output EXD-HP2 with 2 EXV outputs Valves/Coils EXM-B0A EXM-B0B Electronic expansion valve EXM-B0D EXM-B0E EXM-125 Coil 12 VDC EXL-B1F Electronic expansion valve EXL-B1G EXL-125 Coil 12 VDC Temperature Sensor ECP-P30 Temperature sensor with 3 m cable Pressure Sensor Suction pressure (Refrigerant) PT5-07M/PT5-07T -0.8…7 bar (R22, R134a, R407C) PT5-18M/PT5-18T 0 ...18 bar (R410A, R32 /suction pressure) PT5-30M/PT5-30T 0 ...30 bar (R410A, R32 / Intermediate pressure) Plug and cable assembly for pressure sensors PT4-M15 1.5 m cable length PT4-M30 3.0 m cable length Part No. Multipack Single pack 807836M 807837M - 800399M 800400M 800401M 800402M 800403M 800405M 800406M 800407M - - 804495 802350M / 802370M 802351M / 802371M 802352M / 802382M 802350 / 802370 802351 / 802371 802352 / 802382 804803M 804804M 804803 804804 Note: For further detail please see Technical Bulletin of EXM/L and PT5…FLR. These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. 53 Technical Bulletin EXD-HP1/2 Stand-alone Superheat Controller Technical Data EXD-HP1/2 Supply voltage 24 VAC/DC ±10% Protection class IP 20 Power consumption EXD-HP1: Max. 15VA EXD-HP2: Max. 20VA Housing Self-extinguishing ABS Digital inputs EXD-HP1: Two, each potential free EXD-HP2: Three each potential free Mounting DIN rail mounted Relay output SPDT contacts, AgSnO Inductive (AC15) 24 V AC : 1 A Resistive: 24 VAC/DC: 4 A Temperatures storage operating -20…+65°C -10…+60°C Plug-in connector size Removable screw version wire size 0.14 … 1.5 mm2 Relative humidity 0…85% RH non condensing Applied directive LVD, EMC, RoHS, Weight 175 g Compliance with DIN EN60335-1 DIN EN 55014-1, DIN EN 55014-2 Marking Input Sensors, Output Valves Description Specification Temperature input ECP-P30 (3 meter cable length) Range: -30°C…+150°C Pressure sensor input PT5 Signal: 4…20 mA Electronic expansion valves (stepper motor) output EXM and EXL series MOPD Table Min. Max. (°C) Default R410A -40 +45 +15 R32 -40 +30 +15 R407C -40 +48 +15 Description R22 -40 +50 +13 R134a -40 +66 +15 R290 -40 +50 +15 Dimensions (mm) 54 Technical Bulletin Oil Management OM3-020P TraxOil The OM3-020P TraxOil oil management is a self-contained system which provides both functions of oil level monitoring and active oil level balancing including alarm relay activation for compressor protection Features • Supply 24VAC or 230VAC • 3 Zone Level Control by using precise Hall-Sensor measurement, not prone to errors by foaming or light like optical sensors • SPDT output contact for compressor shut down or alarming, rating 230VAC / 3A • Easy installation by sight-glass replacement and front side mounting without nuts • Self-contained unit with oil level sensor and integral solenoid to manage oil level supply • Alarm, status and level indication by LED’s • Braze adapter suitable for Copeland Compressors • Recommended by leading compressor manufacturers • Adapter with brazing connection for Copeland Compressors OM3-020P TraxOil with ASC3 Coil Selection Table 1. Type main body Description Part no. 2. Type braze adapter Description Part no. 805270 OM0-CCP 22.5 mm 805260 OM3-020P Other Required Parts Supply voltage 24V Supply voltage 230V 3. Solenoid Coil 3. Solenoid Coil Type Part no. ASC3-24VAC 801079 50 HZ, 17 VA 4. Cable Assembly Power Supply and Solenoid Type Part no. ASC3-230VAC 801077 50 Hz, 17 VA 4. Cable Assembly with 230V module OM3-P30 805151 24V, 3 m OM-230V-3 805161 230V, 3 m OM3-P60 805152 24V, 6 m OM-230V-6 805162 230V, 6 m OM3-P100 805153 24V, 10 m These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. OM3-020P has special O-rings released for propane, installation in combination with OM0-CCP brazing adapter only. 55 Technical Bulletin Oil Management OM3-020P TraxOil Technical Data Markings: under: Low Voltage Applied Standards: Materials: Directive 2006/95/EC. Body and Adapter Aluminum (EN AW 6060) EMC Directive 89/336/EC Screws Stainless Steel (ISO 4762) Sight Glass Nickel-plated Steel (ISO 2081) Flow rate at 0.9 ltr/min. water at 20°C ambient EN 12284, EN 378, EN 61010, EN 50081-1, EN 50082-1 P =3.5 bar Max. working pressure PS: 35 bar Orientation of base unit: Horizontal, +/- 1° Max. test pressure PT: 39 bar Level control: 40%...60% of sight glass height Burst Pressure: 175 bar Alarm contact: max. 3A, 230VAC OM3/4 with 24VAC ASC3 coil 24VAC±10%, 50 Hz, 17VA Time Delay Alarm: 20 sec. OM3/4 with OM-230V-x module 230VAC±10%, 50 Hz, 17VA Time Delay Filling: 10 sec. Solenoid valve MOPD 21 bar Protection class IP65 (IEC529/EN 60529) Vibration resistance (EN60068-2-6) max. 4 g, 10…250 Hz Medium temperature -20…+80°C Ambient/Storage temperature -20…+50°C Medium compatibility R290 SPDT dry contact Supply voltage / total power: Weight: 24V System 750…920 g incl. adapter 230V System 1100…1270 g incl. adapter Oil connection 7/16”-20 UNF male. with strainer and O-ring (replaceable. see acc.) Dimensions [mm] Base Unit with Adapter and Coil ASC3 Adapter OM0-CCP 118 118 22 60 Scroll ZB*ZKU 17.6 38.5 95.6 95.6 128 OM-230V-x Module 41 53 8 91 45 19 21 56 1,5 Ø2245±0.05 40 CSS-25U / CSS-32U / CSS-32W Compressor Soft Starter Technical Bulletin The first VDE certified Compressor Soft Starter for safety of household. It is used for switching, protection and starting current limitation of single phase compressors in residential heat pumps, refrigeration and air-conditioning applications. Features • For motors with maximum operating current up to 25A / 32A • Limitation of starting current to less than 45A; PCN 805209 less than 30A • Self adjusting for use in 50 Hz or 60 Hz supply • Self adjusting to motor current - no manual adjustment or calibration necessary • Alarm relay output • Start capacitor for improved motor acceleration is switched off after start • Low voltage shutdown • Locked rotor recognition and shutdown • Delay function to limit number of motor starts per hour • Thyristor protected contactor for long life • No extra motor contactor needed • Self diagnostics • Mounting clip for easy installation allows DIN rail mounting in two directions • Easy wiring by cage type screw terminals CSS-…U: 4mm2 cross section terminals CSS-…W: 6mm2 cross section terminals CSS-32U Soft Starter CSS-32W Soft Starter Selection Table Type Part no. CSS-32U 805204 CSS-32U 805204M CSS-32W 805211 CSS-32W 805211M CSS-25U 805205 CSS-25U 805205M CSS-25U 805209 CSS-25U 805209M Screw terminals Nom. compr. current Max. start current Compressor Soft Starter incl. mounting clip 4 mm2 32A max 45 A Box with 20 pieces. mounting clips 4 mm2 32A max 45 A Compressor Soft Starter incl. mounting clip 6 mm 2 32A max 45 A Box with 20 pieces. mounting clips 6 mm 2 Description 32A max 45 A Compressor Soft Starter incl. mounting clip 2 4 mm 25A max 45 A Box with 20 pieces. mounting clips 4 mm2 25A max 45 A Compressor Soft Starter Imax 30 A incl. mounting clip 4 mm 2 25A max 30 A Box with 20 pieces. mounting clips 4 mm 2 25A max 30 A These devices have potential ignition source and do not comply with ATEX requirements. Installation only in “non explosive location”. Accessory Type Part no. Description K00-003 807663 3-pol screw connector to alarm output for wires up to 2.5 mm2; bag with 50 pieces 57 CSS-25U / CSS-32U / CSS-32W Compressor Soft Starter Technical Bulletin Technical Data Operating voltage 230V 50 / 60 Hz nominal Alarm relay. AgNi (SPDT) 250V~ / 3A Nominal compressor CSS-32U / - 32W : 32A max. Resistive (AC1) max. 30V= / 3A current CSS-25U Flexible cable cross section Maximum start current CSS-32U / -32W : 45A CSS-32U/-25U all terminals 0.25…4 mm2 CSS-25U (805 205) : 45A CSS-32W (R, RC, L terminals) 0.25…6 mm2 CSS-25U (805 209) : 30A Flexible cable cross section Operating temperature -20…+55°C non condensing alarm output connector K00-003 0.25…2.5 mm2 Storage temperature -20…+65°C non condensing Max. vibration (at 10 to 1000 Hz) 4g Start capacitor 200…240 uF Weight 430 g 0.5…5 Min Protection acc. IEC 529 IP20 Low voltage switch gear EN 60335-1 Safety of household and Time delay after stop : 25A max. Standards EN 60947-1 and control gear EN 60947-4-2 similar electrical appliances - Contactors and motor-starters - EN 60335-2-40 Part 2-40 Particular requirements AC semiconductor motor for electrical heat pumps. controllers and starters EMC 2004/108/EC air-conditioners and dehumidifiers Electromagnetic Compatibility ROHS 2002/95/EC Restriction of Hazardous (EMC) Directive LVD 2006/95/EC Substances Directive Low Voltage Directive Marking , VDE Reg.-Nr. D967 / D663 Dimensions [mm] R RC L N Uc S Ø4.5 CSS-32U Compressor Soft Starter PCN: 805 200 230Vac / 50Hz / 60Hz loper max 32A Made in Germany VDE L N C run 75 60 R RC F L N C PE R M 1 ~ ON S Uc S CSS Compressor Spft Starter A1 A1 AC A2 UA Ø4.5 AC A2 60 80 66 60 60 Mounting Clip 82 58 140 59 Emerson Climate Technologies at a Glance and brands with our global engineering, design and distribution capabilities to create reliable, energy efficient climate systems that improve human comfort, safeguard food, and protect the environment. TGE-185-EN-1603 Emerson Climate Technologies is the world’s leading provider of heating, ventilation, air conditioning, and refrigeration solutions for residential, industrial and commercial applications. We combine technically superior products and services from our industry leading divisions For more details, see www.emersonclimate.eu Emerson Climate Technologies - European Headquarters - Pascalstrasse 65 - 52076 Aachen, Germany Tel. +49 (0) 2408 929 0 - Fax: +49 (0) 2408 929 570 - Internet: www.emersonclimate.eu The Emerson Climate Technologies logo is a trademark and service mark of Emerson Electric Co. Emerson Climate Technologies Inc. is a subsidiary of Emerson Electric Co. Copeland is a registered trademark and Copeland Scroll is a trademark of Emerson Climate Technologies Inc.. All other trademarks are property of their respective owners. Emerson Climate Technologies GmbH shall not be liable for errors in the stated capacities, dimensions, etc., as well as typographic errors. Products, specifications, designs and technical data contained in this document are subject to modification by us without prior notice. Illustrations are not binding. © 2016 Emerson Climate Technologies, Inc.
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