Seresco NE Series Dehumidifier Installation, Operation & Maintenance Manual

Issue Date : 2011-09-30
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2
Table of Contents
Issue Date : 2011-09-30
Section
Section Title
A
Warnings, Cautions and Notices
B
C
D
E
Page(s)
Warnings, Cautions and Notices
A-1
Refrigerant Handling Practices
A-1
NE/NP/NV Series General Information
General Information
B-1
Unit Description
B-1
Component Descriptions
B-2
Product Nomenclature
B-7
Unit Label
B-11
Further Information
B-12
Pre-installation Requirements
Pre-installation Requirements
C-1
Receiving Checklist
C-1
Shipping Damage Instructions
C-1
Storage
C-2
Mechanical Installation
Mechanical Installation
D-1
Lifting and Rigging Procedures
D-1
Unit Assembly
D-1
Duct Connections
D-1
Piping and Unit Connections
D-2
Drain Pans – Condensate Drain
D-2
Blower Motor Brace
D-3
Field Installed OACs
D-4
Factory Start-up Supervision
D-7
Electrical Installation
Electrical Installation
E-1
Main Panel Power Connection
E-1
Control Wiring
E-2
Websentry Connection
E-3
Remote Operator Panel
E-4
Table of Contents
F
G
H
X
Y
Start-up
Start-up
F-1
Pre-Startup Checklist
F-1
Start-up Procedure
F-3
Factory Start-up Supervision
F-6
NE/NP/NV Series Operation
Sequence of Operation
G-1
CommandCenter Operation
G-5
Routine Maintenance
Routine Maintenance
H-1
Routine Maintenance Checklist
H-1
Component Maintenance
H-2
Refrigerant Charging Procedure
H-4
Outdoor Air Balancing
H-7
Mechanical Vestibule Access Steps
H-9
Troubleshooting
Troubleshooting
X-1
Troubleshooting Steps
X-1
Contacting Service and Technical Support
X-1
Websentry Troubleshooting
X-2
Warranty
Warranty
Z
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Annex
Y-1
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Section A - Warnings, Cautions and Notices
Warnings, Cautions and Notices
Throughout this manual, warnings, cautions and notes appear when special care must be taken to avoid potential hazards
that could result in mechanical or electrical damage, personal injury or death.
WARNING Indicates a potentially hazardous situation which could result in serious injury or
death if handled improperly.
CAUTION Indicates a potentially hazardous situation which could result in moderate injury or
equipment damage if handled improperly.
Note : Indicates a situation that could result in equipment damage if handled improperly.
Refrigerant Handling Practices
Refrigerants composed of chlorofluorocarbons (CFCs) and hydrochlorofluorocarbons (HCFCs) have a catastrophic effect on
the earth's protective ozone layer when released to the atmosphere. Seresco Technologies Inc. advocates the responsible
handling of all refrigerants. Consult the appropriate Material Safety Data Sheets (MSDS) for further information. Follow all
laws in your area that apply to the handling, reclaiming, recovering and recycling of refrigerants and associated equipment.
WARNING System contains oil and refrigerant under high pressure. Recover refrigerant to relieve
pressure before opening the system. Refer to the unit label to determine the refrigerant type. Do not use
non-approved refrigerants, refrigerant substitutes, or refrigerant additives. Failure to follow proper
procedures or the use of non-approved refrigerants, refrigerant substitutes, or refrigerant additives could
result in death, serious injury or equipment damage.
WARNING Use only dry nitrogen with a pressure regulator for pressurizing the unit. Do not use
acetylene, oxygen, compressed air or mixtures of the aforementioned for pressure testing. Do not use
fixtures of a hydrogen-containing refrigerant and air above atmospheric pressure for pressure testing as
they may become flammable and could result in an explosion. Refrigerant, when used as a trace gas should
only be mixed with dry nitrogen for pressurizing units. Failure to follow these recommendations could
result in death, serious injury or equipment damage.
A-1
Section A - Warnings, Cautions and Notices
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A-2
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Section B - NE Series General Information
General Information
Use this manual to install, operate and maintain your Seresco Technologies Inc. (Seresco) NE Series dehumidification unit.
Carefully review the procedures and instructions in this manual to minimize installation and operation difficulties. Every
Seresco dehumidification unit is accompanied by a label that identifies the unit serial number, mechanical, refrigeration and
electrical operating information. This information is required when ordering parts or requesting service for a Seresco
dehumidification system. Seresco also publishes a comprehensive natatorium design guide which provides a wealth of
information on how to design a pool. See www.serescodehumidifiers.com for more information.
Unit Description
Seresco's NP Series advanced dehumidifiers are designed for residential or commercial indoor pools and other various
dehumidification requirements. The unit is comprised of components such as fans, compressors, refrigeration coils, filters,
dampers and pumps.
Figure B-1. Typical refrigeration circuit for NE Series units
B-1
Section B - NE Series General Information
Issue Date : 2011-09-20
Component Descriptions
The following components are commonly used on Seresco Technologies Inc.'s NP Series of dehumidifiers. Detailed
technical information can be found in the annex and in the respective manufacturer's IOM manual(s).
Check Valves
A single direction flow valve, typically installed on the discharge line of the compressor and used to prevent back-flow of
liquid refrigerant. Extends the life of the compressor.
ORD/ORI Valves (R-407C) or LAC Valve (R-410A)
Head pressure control valves, used as a means of controlling head pressure in the refrigeration system. Can either be fixed or
manually adjustable. By keeping the head pressure at stable conditions, the efficiency of the system increases.
Solenoid Valves
Two-way valves used as a means of controlling refrigerant flow through the system depending on mode of operation (e.g.
Air conditioning, or reheat).
Thermostatic Expansion Valve
Precisely selected to provide optimal refrigerant flow to the evaporator coils and factory adjusted to maintain superheat
conditions within 18-20 °F.
Ball Valves (2-way and 3-way)
Manual two-way valves are used as shut-off valves, most commonly used to shut off refrigerant flow to allow field
installation of remote condensers. Actuated three-way valves used to modulate flow when in different modes of operation.
Rotolock Valves
Manual shut-off valve used to isolate the compressor(s) and receiver to allow ease of serviceability and component
replacement.
B-2
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B - NE Series General Information.doc
Plate Heat Exchanger
Plate heat exchangers are compact in size and efficient at exchanging waste refrigerant heat to a secondary fluid loop. This
secondary fluid is then pumped to a fluid cooler or internal water coil.
Co-axial Heat Exchanger
Used as a condenser to exchange waste refrigerant heat to the pool water.
Receiver
Stores liquid portion of the refrigerant charge. They are equipped with external sight glasses to allow the refrigerant level to
be monitored. If the bottom sight glass is not floating, the system is undercharged. If the top sight glass is floating high, the
system is overcharged.
Suction Accumulator
Used to trap any potential liquid flood-back to the compressor, prolonging system life.
Filter Drier
Keeps moisture out of the system and contains potential contaminants that have entered the refrigeration system. Larger
units are equipped with removable filter-drier cores for ease of serviceability.
High / Low Pressure Switches
Hi/Lo pressure switches are installed as a safety mechanism to prevent the system pressures from leaving the normal
operating range.
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Section B - NE Series General Information
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Figure B-2. Pressure transducer (3-wire) and switch (2-wire)
Oil Safeties
Safety device to monitor oil levels in the system. Proper oil levels in the compressor are vital to its proper operation and life.
Figure B-3. Example oil safety, actual model may vary
Relief Valve
Installed on liquid receivers and used as an emergency pressure release. Opens if component's maximum allowable pressure
is reached in the system to prevent damage.
Flow Switch
Safety device used to trigger a no water flow fault if no fluid flow is detected.
B-4
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B - NE Series General Information.doc
Sensors
Sensors mounted within the unit are key to Seresco's control systems which are capable of running the system without
human intervention.
Relative Humidity
Located between the filters and evaporator coil(s), measures the relative humidity of air entering the unit from the pool
space.
Temperature
Stainless steel sensors mounted throughout the unit to provide temperature data to the automated controls system. Sensors
measure the temperature of air leaving the evaporator coil(s), air being exhausted from the unit, air brought in from the
outdoors, and air returning to the pool space.
Figure B-4. Pool water sensor
Figure B-5. Sensor in well
Figure B-6. Evap coil sensor
Additionally, sensors mounted in copper wells determine the suction and discharge refrigerant line temperatures. On units
with pool water heating, pool water temperature is recorded both when entering and leaving the co-axial heat exchanger.
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Section B - NE Series General Information
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Pressure Transducers
Figure B-7. Pressure switch (2-wire) and transducer (3-wire)
A low pressure transducer measures pressure on the suction line, while a high pressure transducer measures the pressure on
the (compressor) discharge line.
Product Nomenclature
The product nomenclature is a 27 character alpha-numeric sequence that completely describes the options present on the
dehumidification unit.
Table B-1. Seresco Technologies Inc. Nomenclature Definition
Series
Dash
Tonnage
Dash
Pool Heater
Cabinet
Configurations
B-6
Version 3.2
Natatorium Environmental Control Series
NE
Natatorium Protocol Series
NP
Natatorium Ventilation Series
NV
Dash
-
2 ton
002
...16 ton
016
18 ton
018
...80 ton
080
10 ton “double decker”
210
...32 ton “double decker”
232
Dash
-
No Pool Water Heater
N
Pool Water Heater
P
Double walled - Return plenum - Bottom
B
Double walled - Horizontal Return
C
Horizontal -single wall Standard
H
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B - NE Series General Information.doc
Dash
Indoor/Outdoor
Dash
AC Options
Outdoor
Air Options
Exhaust Fan
Supply Air
Orientation
External
Static Pressure
Horizontal - single wall - Mirrored
M
Vertical - single wall Mirrored
N
Double walled - Return plenum - Right Side
R
Double walled - Return plenum - Left Side
S
Double walled - Return plenum - Top
T
Vertical - single wall Standard
V
Special
Z
Dash
-
Indoor Unit
I
Exterior Unit
X
Dash
-
Outdoor Air Cooled Condenser
A
Glycol Cooled By a Fluid Cooler
G
Air Handler (Chilled Water Coil)
H
Water Cooled - Variable Flow (< 65F Water Loop)
M
No Air Conditioning (All AC components removed)
N
Packaged/Integral Air Cooled Condenser
P
Water Cooled - Variable Flow (70-85F Water Loop)
V
None
0
Duct Connection Collar Only
1
Duct Collar c/w Manual Damper & Filter
2
OA Inlet Motorized Damper & Filter
3
Purge/Economizer Motorized Damper (In addition to OA Motorized Damper Option)
4
Heat Recovery Package with Motorized Damper and Time Clock
5
Heat Recovery Package Option on OA with Additional Purge/Economizer Option
6
Unit mounted Exhaust fan (Required with HR)
E
Unit mounted Exhaust fan and Purge/Economizer Fan
F
None
N
Unit mounted Purge/Economizer Fan
P
Bottom Supply
B
Top Right Supply
D
Horizontal - Loopback
E
Top Loopback End Supply
F
Top Left Supply
G
Horizontal (Straight Through)
H
Top Horizontal End Supply
J
Left (oriented with airflow air turns left out of unit)
L
Right (oriented with airflow air turns right out of unit)
R
Top Supply
T
0.5"
0
0.75"
4
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Section B - NE Series General Information
Issue Date : 2011-09-20
1.0"
1
1.5"
5
2.0"
2
Other
3
X
Supply Air CFM
XY times 10 to the N
Y
N
Space Heating
Type
Heating Control
Details
Unit Supply
Voltage
Unit Controls
Refrigerant
B-8
Unit mounted electric Heater - Separate power connection
D
Unit mounted electric heater - Single point power connection
E
Unit mounted gas heating
G
Remote by others
N
Unit mounted steam coil
S
Remote electric heater supplied by Seresco
T
Unit mounted hot water coil
W
Remote electric modulating heater supplied by Seresco
X
Remote hot water coil supplied by Seresco
Y
Remote steam coil supplied by Seresco
Z
Standard control signals: Valve and power supply by others
0
2 stages factory wired electric heating control
1
Modulating - factory supplied and wired valve
2
On/Off - factory supplied and wired Valve
3
Supply isolated 50 VA power for remote valve ( valve by others)
4
Modulating factory wired electric heating control
5
Supply On/Off Valve & 50 VA power for remote valve installation
6
Supply Modulating Valve & 50 VA power for remote valve installation
7
208/1
A
230-240/1
B
208/3
C
230-240/3
D
460-480/3
E
575-600/3
G
Electro-mechanical
0
Command Touch Screen
1
Command Center
2
Command Center c/w Building Communication
3
Command Center c/w Remote Panel
4
Command Center c/w Building Communications & Remote Panel
5
R410A
A
R407C
C
R22
R
Non fused Disconnect
D
Issue Date : 2011-09-20
B - NE Series General Information.doc
Disconnect
Warranties
Fused Disconnect
F
No Disconnect
N
Standard - 2yrs on driveline, coils, and compressor
0
2 yrs on driveline and compresor, 5 yrs on coils
1
2 yrs on driveline and compressor, 10 yrs on electrofined coils
2
2 yrs on driveline and coils, 5 years on compressor
3
2 yrs on driveline, 5 yrs on compressor and coils
4
2yrs on driveline, 5 yrs on compressor, 10 yrs on electrofined coils
5
2yrs on driveline and coils, 10 yrs on compressor
6
2yrs on driveline, 10 yrs on compressor, 5 years on coils
7
2yrs on driveline 10 yrs on compressor and electrofined coils
8
5yrs on driveline, 2 yrs on compressor and coils
9
5yrs on driveline and coils, 2 yrs on compressor
A
5yrs on driveline, 2 yrs on compressor, 10 years on electrofined coils
B
5yrs on driveline and compressor, 2 yrs on coils
C
5yrs on driveline, compressor and coils
D
5 yrs on driveline and compressor, 10 yrs on electrofined coils
E
5 yrs on driveline, 10 years on compressor, 2 yrs on coils
F
5 yrs on driveline and coils, 10 yrs on compressor
G
5 yrs on driveline, 10 years on compressor and electrofined coils
H
9
Section B - NE Series General Information
Unit Label
B-10
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Issue Date : 2011-09-20
B - NE Series General Information.doc
Further Information
For further information, please visit our website at www.serescodehumidifiers.com. Feel free to browse our
website and watch informative videos on every aspect of our products.
11
Section C - Pre-installation Requirements
Issue Date : 2011-09-30
Pre-installation Requirements
Seresco Technologies Inc. inspects and fully tests each dehumidifier in all operating modes before it ships from the factory.
The unit can suffer damage in transit. Check the equipment thoroughly for both visible and concealed damage before you
sign the receiving papers. Document any damage in writing on the carrier’s bill of lading to ensure that damage claims are
handled promptly. If the unit has been damaged, obtain a claim form from the carrier. Promptly fill out and return the form,
and notify Seresco Technologies Inc. of any damage.
Note : Damage claims or missing parts must be filed with the freight carrier.
Receiving Checklist
Note : The shipping protection provided by the factory is for transport purposes only and should not be
relied on to protect the unit in storage or on the job site.
Note : Seresco is not responsible for any shipping damages. Should your unit arrive damaged, please
follow the instructions in Shipping Damage Instructions to resolve the situation. Delivery cannot be refused
on the basis of shipping damages.
Upon receipt, please check the following components for damage:
Verify the proper operation of latches and hinges on all access doors
Inspect all coils for damage to the fin surface coating, headers or coil connections
Manually rotate the fan wheel to ensure free movement of the shaft, bearings and drive
Inspect the fan housings for any foreign objects
Inspect and test all piping for possible shipping damage
Check the tightness of bolts on the fan structure and coils
Inspect fan isolator shipping brackets
Shipping Damage Instructions
Seresco Technologies Inc. ships freight on board (FOB), meaning that the unit belongs to the customer as soon as the
delivery truck leaves the factory. If damage has occurred to the unit during shipment, follow these instructions:
1. Specifically note the extent of the damage in detail on the freight bill. Clear photographs of the damaged
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Section C - Pre-installation Requirements
Issue Date : 2011-09-30
components are required.
2.
Report all claims of shipping damage to the delivering carrier immediately and coordinate a carrier
inspection if necessary.
3. Contact Seresco Technologies Inc. by email at [email protected] or by phone at (613)-7413603 and dial 2 for the soonest available tech support technician. Have the unit serial number (8-digit) and
nomenclature designation (23 digit alpha-numeric sequence starting with the series designation) on hand.
These may be found on the unit label along with other performance and electrical information.
4.
Do not attempt to repair the unit without consulting the Seresco Technologies Inc. Service and Tech
Support Department. It is the receiver's responsibility to provide reasonable evidence that damage was not
incurred after delivery.
Storage
Protection from the elements is required for any unit that will be stored on the job site or a holding area before installation.
For long term storage, a controlled indoor environment is highly recommended. All factory-applied shipping protection
should be removed before the unit is put into storage. Shipping protection material is not suitable protection for short or
long-term storage.
Note :
Standard Seresco warranties expire 24 months from the date of shipment.
See section Y – Warranties for further information.
C-2
Section D - Mechanical Installation
Issue Date : 2011-09-30
Mechanical Installation
WARNING Heavy objects ! Do not use cables (chains or slings) except as shown. Each of the
cables (chains or slings) used to lift the unit must be capable of supporting the entire weight of the unit.
Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for an even unit lift.
Other lifting arrangements may cause damage to equipment, serious injury or death of personnel. Always
place, assemble, and suspend single sections. Do not lift units in windy conditions. Do not raise units
overhead with personnel below unit.
WARNING Improper lifting procedure ! Test lift the unit 24 inches to verify proper operation of
lifting equipment and positioning of lift points such that the unit is level. Failure to properly lift the unit
could result in equipment damage, serious injury or death. Seresco Technologies Inc. is not responsible for
the improper use of lifting equipment.
WARNING When lifting unit, appropriate personal protection equipment (PPE) such as steeltoed boots and hard hats must be worn to avoid potentially serious injury.
Lifting and Rigging Procedures
Determine the approximate centre of gravity before lifting the unit. Consult unit design drawings provided in
the submittal documents to determine total weight and weight distribution.
Never assemble split sections before lifting them to the installation location. Always lift sections as received
from the factory.
Lift sections using the provided lifting lugs
To avoid damage, do not attach intake or exhaust hoods prior to lifting the unit into place.
Unit Assembly (Split Units Only)
Under special conditions, the unit may be split into two or more sections to ease the installation process. Base angles are
attached using 3/8” bolts, and inside angles are bolted using 5/16” bolts. Ensure that all provided holes are used. Caulk
seams on the outside of the unit to make the join air-tight. Install the standing seam roof rib.
D-1
Section D - Mechanical Installation
Issue Date : 2011-09-30
Duct Connections
All duct connections should be installed in accordance with local and national standards. To ensure the highest fan
efficiency, duct turns and transitions should be made to minimize air friction losses and turbulence. See supplied unit
drawing from the submittal for location and size of unit duct connections. Use only flexible duct connectors to connect to
the unit.
Piping and Unit Connections
See the unit label for unit connection line sizes. The installer must endeavour to ensure that all industry standards for
refrigeration component installation are met. This includes but is not limited to; proper line sizing, materials, nitrogen
purging, brazing with Silfos 5 or better (NO SOFT SOLDER), evacuation, cleanliness, traps, long radius elbows and system
charging.
Drain Pans - Condensate Drain
The dehumidifier is a draw through configuration as a result the entire cabinet is under negative pressure. Without a P-trap,
condensate will not drain and the unit will overflow into your mechanical room.
Per Figure 5 pitch the condensate drain line a minimum of 1/8” per linear foot, and support the pipe with codeapproved hangers at least every 5 feet.
If the drain line passes through an unconditioned space, heat tracing is required to prevent the condensate in the
drain from freezing.
When gravity disposal is not possible, a condensate pump can be used. Follow the pump manufacturer’s installation
instructions.
Figure D-1. P Trap
D-2
Section D - Mechanical Installation
Issue Date : 2011-09-30
Blower Motor Brace
Upon installation remove ONLY lower bolt from all four corners shown in Figure D-2 (Detail A). The top of the bolt will
be spray-painted yellow for easy identification. The plug fan sits on spring dampers to minimize vibration translated to the
unit from the fan motor. During shipping, the fan assembly is fixed such that the springs are compressed and cannot
oscillate. Removing these bolts on installation ensures that the the fan vibrations will be dampened correctly.
Figure D-2. Blower Motor Brace
Figure D-3. Double motor assembly – remove horizontal brace on front wall
D-3
Section D - Mechanical Installation
Issue Date : 2011-09-30
Field Installed Outdoor Air Cooled Condensers and Fluid Coolers
This condenser is used in air conditioning mode where it rejects unneeded heat from the space to outdoors. Proper
installation is essential to ensure it can function as intended. Proper airflow and refrigerant piping are paramount. Ensure an
appropriate maximum ambient air temperature has been specified. Ensure the unit has proper airflow per Figure D-4. A
perimeter of free area equal to its width must be provided. Use line sizes as specified by Seresco. To avoid potential seasonal
system charge problems, ensure the installed line lengths are never longer than indicated on the plans and specifications. If
the condenser is installed above the dehumidifier, ensure the hot gas line has proper oil traps. Contact Seresco if the
condenser is installed more than eight (8) feet below the dehumidifier. The installer must endeavour to ensure that all
industry standards for refrigeration component installation are met. This includes but is not limited to; proper line sizing,
materials, nitrogen purging, brazing with Silfos 5 or better (NO SOFT SOLDER), evacuation, cleanliness, traps, long radius
elbows and system charging. Install the remote condenser on a level, hard surface. Bolt the condenser in place.
Figure D-4. Typical Outdoor Condenser Installation
Refrigerant Piping of Remote Condensers
NE and NP series dehumidifiers are equipped with isolation valves and access valves located in the blower compartment. Do
not open the isolation valves until all exterior piping is leak checked and evacuated. The last outdoor condenser vacuum can
be broken with liquid refrigerant (R-407C or R-410A as applicable). Monitor the exact amount of refrigerant added, as the
total system charge must be per the unit nameplate. The NE and NP series dehumidifiers have refrigerant pipe stubs for the
line set connection inside the cabinet. Use standard commercial refrigeration piping practices when installing the
refrigeration piping between the dehumidifier and the remote air-cooled condenser.
Hot Gas and Liquid line sizes should be per unit nameplate. The stubs inside the unit will be the correct sizes
D-4
Section D - Mechanical Installation
Issue Date : 2011-09-30
for line lengths up to 50’
Do not exceed 50’ total line length or install the condenser more than 8’ below the unit. Consult Seresco before
installing the outdoor air-cooled condenser more then 8 feet below or more than 50 feet away from the
dehumidifier.
Per Figure 2, install an oil trap at the start of and at every 15 feet of vertical lift in the hot gas discharge line as
shown. Pitch horizontal lines a minimum of 1/2” every 5 feet in the direction of flow. All piping must be clean
and de-burred. Keep copper chips and foreign materials out of the tubing. A nitrogen purge while brazing is
paramount to reduce the chances of oxidation in the pipes.
Keep the Hot Gas and Liquid lines a minimum of 2” apart to prevent heat transfer. Insulate the hot gas line in
all areas where a person may come in contact with the line and be in danger of a burn.
When all piping work is complete, check for leaks by pressurizing the remote condenser and line set with dry
nitrogen. If no leaks are detected, the circuit is ready to be evacuated. Evacuate the condenser and piping to a
minimum 250 microns. Isolate the piping for ONE HOUR to verify that the system is free from leaks, moisture,
and non-condensables. For further details on proper vacuum and evacuation procedures, see section H – Routine
Maintenance.
Figure D-5. Typical Outdoor Condenser Installation
D-5
Section D - Mechanical Installation
Issue Date : 2011-09-30
Charging of Remote Condensers
Once a proper evacuation has been accomplished the system is ready for charging. The outdoor air-cooled condenser
requires a field charge by the installing contractor. The field charge required depends on the size of the condenser and the
length of the piping. The unit nameplate will show the exact field charge required. The last vacuum can be broken with
liquid refrigerant. Monitor the exact amount of refrigerant added, as the total system charge must be per the unit nameplate.
Connect the control wiring to the terminals provided inside the electrical compartment of the dehumidifier and outdoor
condenser. Refer to the low voltage wiring schematic for details. The condenser fan(s) will not operate until this is complete.
Once you have charged and checked the condenser and line set for leaks, open the service valves located in the compressor
compartment of the dehumidifier. There is an access valve in the liquid line after the pump down valve. The pump down
valve can be manually closed during start-up mode via the controller. Add only as much refrigerant as is needed to get to the
total charge indicated on the nameplate. Never charge liquid into the suction line access valve! The receiver has 2 sight
glasses with float balls to help ensure the maximum and minimum refrigerant levels are easily met.
Fluid Cooler Installation
Fluid cooled units come with a separate pump for the fluid loop. NP Series units have an internal pump and expansion tank
for the glycol loop. PVC piping is highly recommended for fluid cooler installation.
D-6
Section D - Mechanical Installation
Issue Date : 2011-09-30
Factory Start-up Supervision
Seresco Technologies Inc. factory start-up supervision can be purchased with the equipment. A factory start-up
includes several key services:
The expertise of a factory-trained technician who will supervise the commissioning of the equipment.
This Seresco representative will assist the installing contractor with filling out the Start-Up Report.
They will also inspect the installation to make sure that the dehumidifier has been properly integrated with
the rest of the equipment on the job site.
Finally, they can train the maintenance personnel to operate and service the equipment if necessary.
A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring
that the system is ready for start-up when the Seresco representative arrives. If the system is not ready, Seresco
reserves the right to bill the contractor for a second visit. When the installing contractor is confident the system
will be ready, contact the Seresco Sales representative to schedule the start-up. Please call at least two weeks
before the desired start-up date to prevent scheduling conflicts.
Items required for Start-Up
A service technician and a fully stocked service vehicle.
A set of refrigerant manifold gauges.
Air balancing equipment (magnehelic differential pressure gauge).
Volt/Amp/Ohm meters.
A digital thermometer w/clamp on sensors.
A halogen leak detector, R410a or R407c and a scale.
Items to be Completed Before Start-up
Refrigerant leak-check (with halogen leak detector) and inspect the unit for internal concealed damage.
Level and support the dehumidifier properly.
Install the outdoor air duct filters and damper (if applicable).
Install the condensate P- trap and drain lines and prime P-trap.
Pipe the remote condenser fan pressure controls to the condenser hot gas lines (if applicable).
Evacuate and leak-check the remote condenser line set (if applicable).
Tighten all electrical connections and verify that the line voltage is correct for the unit.
Install all controls and verify that all field wiring matches the schematic.
Fill and heat the pool and room to design conditions.
Install the pool water piping and a flow meter (if applicable). Purge all air from pool lines.
A complete system air balancing.
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Section D - Mechanical Installation
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D-8
Issue Date : 2011-09-30
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Section E - Electrical Installation
Electrical Installation
WARNING Disconnect all electric power, including remote disconnects, before servicing. Follow
proper lockout procedures to ensure that the unit is not accidentally powered. For variable frequency
drives, refer to the appropriate section of the manual. Verify with a voltmeter that all capacitors have
discharged. Failure to disconnect power and discharge capacitors before servicing could result in serious
injury or death.
Note : Use copper conductors only ! Unit terminals are not designed to accept other types of conductors.
Use of aluminium or other wiring may result in galvanic corrosion or overheating.
Note : Properly seal all penetrations made in the outer walls. Failure to due so may result in
unconditioned air entering the unit, water infiltrating the insulation or serious equipment damage. Ensure
that all metal shards and filings are swept to avoid possible corrosion or damage to electrical components.
Main Panel Power Connection
The field-installed power supply wires and over current devices must be sized to handle the minimum ampacity of the
dehumidifier without exceeding the maximum fuse size rating. Both the MCA and MOP are indicated on the unit
nameplate. Figure E-1 shows typical power wiring connections. Single-phase units require 3 wires, 2 power and one ground.
Three-phase units require 3 power wires and one ground wire. Connect the power supply wires to the main power
distribution block located inside the unit main electrical panel. For units with electric heaters and single-point power
connections, the power distribution block is located in the heater. For units with electric heaters and dual-point power
connections, the unit and heater must be powered independently. For units with mounted disconnects, ensure that the power
is brought first to the disconnect and then the power distribution block. Always verify the nameplate voltage before
connecting to the unit.
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Section E - Electrical Installation
Issue Date : 2011-09-30
Figure E-1. Main power distribution block
Control Wiring
Seresco Technologies Inc.'s dehumidifiers have all necessary sensors unit mounted and setpoints pre-programmed at the
factory. Remote duct heaters, outdoor air-cooled condensers, auxiliary pool water heaters and remote exhaust fans all require
interfacing with the dehumidifier. The common connection terminals are identified in Table E-1. For a complete list of
terminal connections and functions, refer to section Z – Annex.
Table E-1. Control Terminals
Pin
I/O's
Description
6
DI14
Freezestat
7
DI15
Firestat
7
AO01
Modulated Heat
Connector J7
Connector J8
Connector J9
1,2
DO24
Space Heater, Stage 2
3,4
DO23
Space Heater, Stage 1
5,6
DO22
Exhaust Fan 2
7,8
DO21
Exhaust Fan 1
9 , 10
DO20
Outdoor Air Damper
1,2
DI19
Outdoor Air Condenser 1
3,4
DI18
Outdoor Air Condenser 2 (Ver. 5.x only)
5,6
DI17
Auxiliary Pool Heater, Pool 2
7,8
DI16
Auxiliary Pool Heater, Pool 1
Connector J10
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Issue Date : 2011-09-30
Section E - Electrical Installation
WebSentry Connection
Requires RJ45 ethernet connection to the unit.
To get access to WebSentry® you need to register a user id with Seresco. Follow these instructions.
1) Go to the Seresco web page at http://www.serescodehumidifiers.com.
2) Select the Login link in the upper right corner.
3) Select the ‘Click here to register’ link in the WebSentry® login box.
4) Fill in the registration form and submit it. The email address will be your user id.
Follow these instructions to login to WebSentry® and view your Seresco unit.
1) Go to the Seresco web page at http://www. serescodehumidifiers.com.
2) Select the Login link in the upper right corner.
3) Enter login credentials in the WebSentry® login box and click Submit button.
4) Once you have logged in you will see a list of all Seresco units you have access to. The very first time you login
the list is empty since you do not yet have permission to see any unit (see Gain Access to Unit).
5) Too see more detailed information for a unit, click the job name link.
6) The main Conditions page shows you the current conditions including a trend graph showing the room
temperature, humidity and optionally the pool water temperature over the past 4 hours.
You can also see current setpoints, logs and some basic unit configuration by selecting the appropriate menu link.
Gain Access to Unit
To gain access to a Seresco unit you need to know the serial number of the unit and the last 6 characters of the MAC
address. The latter is printed on a bar code label on the control board where the network cable is plugged in. You can also
find this information from the System Info page from the key pad (accessible from User Settings). If you are not able to get
to this information you can also contact Seresco and someone will be able to help you get access to the unit.
Controlling Unit
To gain control of unit so that you can change setpoint, restart unit or modify some factory settings, you first have to
Connect to unit and have it maintain a live connection. By default the unit connects once a minute to upload latest sensors
readings and log entries and then disconnects again. Typically this does not take more than one second.
To get a live connection, click the Connect button on any page that has a Connect button. Keep pressing Connect button or
Web browser refresh button until Connect button changes to a Save and Refresh button.
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Section E - Electrical Installation
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Another indication that unit is live is that the time stamp in the header under the job name changes to Live. Normally the
time stamp tells you the last time the unit connected to the WebSentry® server.
Once a live connection has been established you can change any unit parameter like setpoints and factory settings. From the
conditions page you can also start and stop the main blower and restart the unit. If unit is equipped with a purge feature, you
can also initiate purge from the conditions page.
Remote Operator Panel (ROP)
The Remote Operator Panel (ROP) looks identical to the local keypad but instead of being connected to the main control
board using a data ribbon cable, it uses a RS-485 serial port communication interface. Cat3 or Cat5 twisted pair cables must
be used between the ROP and the main CommandCenter control board.
The other difference between the local keypad and the ROP is that the ROP has its own processor and memory where the
menu system is stored opposed to the local keypad which just a “dumb” terminal displaying the menu system as controlled
by the main control board.
When installing or replacing the ROP you can run into several issues that will prevent the ROP from working properly. This
document covers all steps you need to take to ensure a good communication between ROP and main control board.
Testing Remote Operator Panel at the unit
To rule out any type of problem with the wiring between the unit and the ROP location, use a 3’-5’ wire and connect the
ROP to the main board right at the unit. All troubleshooting guides in this document applies to both testing ROP at the unit
and at its final location.
NOTE! When doing any rewiring like moving wires from J8 to JCOM or moving ROP between final location and testing it
at the unit, make sure the dip switches are in the off position (towards the 1 & 2 label on the dip switch socket). Do not move
to on position until powered up and red LED (L1) is lit up.
Using proper cable
We recommend using a twisted pair Cat3 or Cat5 cable. What is important is that the two signal wires are twisted together.
Twisting the signal wires together acts as a noise filter. If not using this type of cable you can run into communication issues.
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Section E - Electrical Installation
Issue Date : 2011-09-30
Especially if the ROP is far away from the unit. For easier troubleshooting, use the following coloured wires.
Table E-2. ROP Connections
Cat3/Cat5 Wire
Remote Keypad
Orange
J8-1 (+24V)
White/Orange
J8-2 (GND)
Blue
J8-5 (+ 485)
White/Blue
J8-6 (- 485)
J8
Pin 1
Pin 2
Pin 5
Pin 6
JCOM
Pin 5
Pin 4
Pin 6
Pin 7
Connecting wires
Before doing any wiring, ensure there is no power over the wires. Either power unit off or unplug terminal (J8 or JCOM) to
where the ROP is connected. Connect wires to main control board terminal as listed in Table 1. By default you should be
using terminal J8. JCOM is only used as a backup RS-485 port or when more than one RS-485 port is needed. Open up the
back of the ROP and feed wires through the hole of the back plate and connect wires to terminals as listed in Table E-2.
Check communication
Power up unit or plug in terminal block again. If the two power wires are wired correctly you should now see the red L1
LED light lit up in the ROP. If there is power you can now safely activate the signal wires. You do this by moving the two
dip switches (SW1) next to the green terminal block towards the top of the ROP. This is easiest done by using a small flat
head screw driver.
If signal wires are wired up correctly you should see the main sensor screen within a few seconds (possibly the system
startup screen).
If the screen is blank, you see the Welcome screen for more than 10 seconds, or see other messages indicating the ROP is
trying to establish communication, continue reading this document to help you troubleshoot the problem.
No power to ROP (LED L1 not lit up)
First make sure unit is powered up and that the terminal block (J8 or JCOM) is plugged into the main control board.
Make sure wires are wired as listed in Table 1. Make sure that the terminal in the ROP is grabbing onto the copper and not
the insulation. Check this at the main control board as well. There could possible be a kink in the cable causing a broken
wire. Test ROP at unit using a short cable. Try both J8 and JCOM in case there still is no power connecting to J8. If still no
power you most likely have a failed ROP terminal board.
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Section E - Electrical Installation
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Power to ROP but showing a blank screen
There should never be a blank screen when there is power to the ROP. At the minimum the ROP should show that it is trying
to connect to the main control board. There are only two reasons why there is a blank screen. The ROP has a contrast dial. It
might have been moved so that there is no contrast at all resulting in a blank screen. The contrast dial is a white dial in the
upper left corner next to the terminal board. Use a small screw driver to adjust it. If you see no change at all on the screen
when adjusting the dial, then this is not the problem. The second reason for a blank screen is if the menu program has been
erased from memory. A static chock could possible cause this. All ROP’s are tested at the factory so there should have been a
program installed when the ROP was shipped from factory. Once again, to really rule out a wiring issue, test the ROP using
a short cable right at the unit.
Power to ROP but not establishing a connection
First thing to check is that the two dip switches has been moved up to activate the signal wires. Make sure wires are wired as
listed in Table E-1. Make sure that the terminal in the ROP is grabbing onto the copper and not the insulation. Check this at
the main control board as well. There could possible be a kink in the cable causing a broken wire. Test ROP at unit using a
short cable. Try both J8 and JCOM in case there still is no communication when wired to J8. If still no communication, read
the next section to do one more last test.
Check for communication attempt
From the main control board you are able to look at data streams for anyone of the 3 serial ports. We can use this to
determine if the ROP at least is getting some message through to the main control board. Start up the unit in Service Mode.
Go to the Main Menu (1) and then Service (6) – Network (3) – Console (2). Use arrow keys to select port. Port D is RS-485
on J8 and Port C is RS-485 on JCOM. Select 1 to start serial port monitor console. If there is communication you should see
a bunch of characters within a few seconds. You should also see them changing every few seconds. Stop by pressing 2 or the
Back key. If there is no character stream them most likely the RS-485 communication chip on either the ROP or the main
controller board has failed. There is no way to check which one so if you do not have a second ROP a second board to test
with, there is no way to know. With our newer boards (4.1 and later) we have two RS-485 ports as discussed in this
document so the chances that both communication chips have failed are very small. For these boards we will replace the
ROP with a new one. For older units using a 3.1 board or older, there was only one RS-485 port so for these units we have to
replace both the main controller board and the ROP.
If there is a character stream but still no communication at the ROP, check the serial port communication settings to make
sure they have not been changed. See next section. Check serial port configuration settings. From the Main Menu, go to
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Section E - Electrical Installation
Factory Settings (5) – Network (5) – Serial Ports (2). Then select either Port C (JCOM) or Port D (J8) depending on which
terminal you are testing. User should be set to Seresco, Baud Rate to 57600, Databits to 8, Parity to None. The timer Reply
Delay should be at least 500 but new recommendation is 750. The timer Invalid Data should be set to 1000.
Echo Test is by default set to Yes but you can try setting this to No to see if this will establish a connection. By default a RS485 is echoing back every sent message back to the sender. Our controller is using this to test for a robust connection. We
have however seen cases where the RS-485 communication chip partially has failed where it no longer echoes back sent
messages but otherwise functions just fine. By setting the Echo Test to No we can test for this fault.
If you did any configuration change but still no communication you can try doing a System Restart to see if it this will help.
Either power off unit in between or unplug ROP terminal from board to cycle the ROP. If you still are not being able to
establish communication after doing these steps, we have an unknown fault and the ROP needs to be replaced. If this already
is a new ROP, we need to replace the board.
ROP shows Version Mismatch
If the ROP display show Version Mismatch it means you are connecting a ROP to a unit running a software version with
which the ROP is not compatible. Get a new ROP with a version compatible with the software version on the unit.
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Section F - Startup
Issue Date : 2011-09-30
Start-Up
WARNING Disconnect all electric power, including remote disconnects and discharge all motor
start/run capacitors before servicing. Follow proper lockout procedures to endure the unit cannot
accidentally be powered. For variable frequency drives or other energy storing components, refer to the
appropriate manufacturer's literature for allowable waiting periods for discharge of capacitors. Verify with
a voltmeter that all capacitors have discharged. Failure to disconnect power and discharge capacitors
before servicing could result in serious injury or death.
WARNING Rotating components ! During installation, testing, servicing and troubleshooting of
this product it may be necessary to measure the speed of rotating components. Have a qualified or licensed
service individual who has been properly trained in handling exposed rotating components perform these
tasks. Failure to follow all safety precautions when exposed to rotating components could result in serious
injury or death.
WARNING Live electrical components ! During installation, servicing and troubleshooting of
this product, it may be necessary to work with live electrical components. Have a licensed electrician or
other qualified individual perform these tasks. Failure to follow all electrical safety precautions when
exposed to live electrical components could result in serious injury or death.
Pre-Startup Checklist
A complete start-up is required to ensure that all systems have been configured to ensure optimal and reliable unit operation.
Final adjustments should be made when all space and water temperatures are at design conditions. The use of auxiliary or
portable air heaters may be required to heat the room. Read this section thoroughly before attempting to commission the
Seresco Technologies Inc. dehumidifier. Ensure that the unit installation conforms to all recommendations made by Seresco
Technologies Inc. in this manual. Complete the pre start-up section of the warranty registration / start-up form provided in
section Z – Annex.
Note : Do not use the unit as a construction site heater. Construction material will infiltrate the unit and
can significantly deteriorate unit performance and lifespan.
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Issue Date : 2011-09-30
General Checks
Ensure that the unit has been installed on a level location
Check to ensure all packing materials and shipping brackets have been removed from the unit
Verify that any remote space heating coil is installed in the supply air duct (after the unit) and not in the
return air duct (before the unit)
Ensure supply and return air ducts have been connected
Verify damper operation and alignment, as damper blade position may change in shipment
Check that air filters are clean, in place and positioned properly
Remove any debris from the unit interior
Close and secure all unit access door in the airstream
Inspect electrical connections to the unit and unit controllers
Connections should be clean and secure
Compare the actual wiring with provided wiring diagrams
Reference the controls section of this manual for more details on factory mounted controls
Leave this manual with the unit
Fan/Motor-Related Checks
Ensure that fan assembly braces have been removed
Rotate all fan wheels manually to confirm they turn freely in the proper direction
Inspect fan motor and bearings for proper lubrication
Coil-Related Checks
Ensure coil and condensate drain piping connections are complete
Check the piping and valves for leaks. Open and close the valves to check operation
Remove all foreign material from the drain pan
Test the drainage and prime the P-trap by pouring water into the drain pan
Note : For units with water cooled air conditioning. The use of untreated or improperly treated water in
coils may result in scaling, corrosion, erosion, algae or slime. It is recommended that the services of a
qualified water treatment specialist be engaged to determine what water treatment, if any, is required.
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Electrical Checks
Check nameplate for power requirements and confirm that it matches the available power supply
Voltage must be within ±10% of nameplate voltage. Verify that all field wiring matches provided wiring
schematics. Inspect and tighten all field and factory wiring
Leave power on and allow 24 hours of crankcase heater operation before attempting start-up.
Ensure that the control wiring has been installed to the outdoor condenser / cooler if applicable
Ensure all peripheral controls and sensors are connected and wired correctly
Pool Water Checks
For units with pool water heaters only. Energize the circulating pump and establish water flow. Inspect the
piping and repair any water leaks. Ensure that control wiring has been installed between the unit and the
auxiliary pool water heater
Refrigerant Line Checks
Verify that all service valves in the refrigeration lines are open
Leak test (with halogen leak detector) all factory and field piping. Shipping and handling may have caused
refrigerant leaks inside the dehumidifier
Start-up Procedure
All appropriate fields and sections of the warranty registration / start-up form should be completed. A proper start-up
requires that the unit be run and monitored in all modes of operation at design conditions with the operating data recorded
on the forms provided in section Z – Annex. Seresco's service technicians review every report to ensure all aspects of the
system are functioning within normal operating parameters. Carefully follow the process detailed in the start-up report. If
the space is not at design conditions at the time of start-up, a follow-up visit for final adjustment and balancing is required.
Mail or fax the completed warranty registration / start-up form back to Seresco to validate your unit's warranty See section
Y – Warranty for further information. If you do not have a start-up report, call Seresco for a new copy or download a PDF
version from www.serescodehumidifiers.com.
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Section F - Startup
Issue Date : 2011-09-30
Note : Warranty is void unless, upon start-up of the unit, the “Warranty Registration and Start-up
Report” is completed and sent to the factory within one week of initial start-up. This report will also
register the compressor warranty with the compressor manufacturer.
Power Turned ON (or after power failure)
When powered, the blower begins to operate immediately and will do so continuously. The microprocessor initiates a selftest and runs systems diagnostics algorithms. If all systems check out, the microprocessor used sensor feedback to resume
normal unit operation. The microprocessor will confirm that the compressor has been off for at least five minutes using its
internal clock.
The CommandCenter keypad display should show current sensor readings and the main menu. For keypad layout and
function refer to section G – Nx Series Unit Operation, under CommandCenter operation.
Check time and set-points by doing the following:
Current Time: 1-Main Menu, 4-User Settings, 2-Date&Time
Set-points: 1-Main Menu, 1-Setpoints
Check remote operator panel response, if applicable, and record all data on the start-up forms.
Check Component Operation
To force component operation, do the following:
1-Main Menu, 6-Service, 2-Forced Contacts
To activate, switch component status from OFF/No to ON/Yes, to switch off do the reverse
Ventilation components (under 2-Ventilation) to check include (as applicable) the main blower, condenser fan(s), damper(s),
exhaust fan(s) and purge fan(s) (also known as exhaust 2). Ensure proper, uninhibited rotation of the fans, check and record
amperage readings on the start-up forms.
For heating components (3-Heating), first check whether the space heating option is staged or modulating. To activate
modulated heating, select the modulated option, then use the up and down arrows followed by Enter to select the desired
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Section F - Startup
Issue Date : 2011-09-30
heating load. To activate Staged heating, enable stage 1 (and stage 2 if applicable).
Note : for units equipped with a gas water boiler and modulated valve, activate stage 1 first to start the
circulating pump(s), then activate modulated heating as described above.
CAUTION Ensure that the main blower is on while testing the heating system or compressor.
Enabling the Compressor(s)
Compressors are disabled after testing at the factory to prevent their accidental non-supervised start-up. To start the
compressor(s):
1-Main Menu, 5-Factory Settings, 4-Compressor, 1-Enabled and switch to Yes to enable the compressor
Ensure that design conditions (return air temperature and relative humidity) are established, the main blower is running, and
a gauge set is attached to verify compressor rotation and performance. Make sure that gauge readings correspond to unit
pressure sensor readings shown on the keypad.
Forced Modes
Check unit condition under different modes of operation by doing the following:
Set forced demands: 1-Main Menu, 6-Service, 1-Forced Demands, 1-Compressor 1
To run the unit in dehumidification mode, choose Dehumidify and check pressure, temperature readings. Allow the
compressor to run for 20-30 minutes and ensure that the superheat is within 19-22°F, making adjustments if required. Record
all data.
To run the unit in dehumidification and pool heat modes, select Pool Heat while the compressor is still running. Make sure
that design water flow is provided to the unit. Record actual water flow GPM and pressure.
Confirm and record superheat data. Deselect dehumidification and pool heat modes by selecting OFF/No and allow the
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Section F - Startup
Issue Date : 2011-09-30
compressor to pump down.
To run the unit in air conditioning mode, select 2-A/C, then air conditioning and pool heat modes. Follow procedure
outline above, recording all data on the start-up forms.
For units with two or more compressors, complete the process for each compressor individually, and finally both together.
To restart the unit in normal mode, do the following:
1-Main Menu, 6-Service, 6-Commission, 2-Commissioned and switch to ON/Yes
1-Main Menu, 3-System, 3-System Restart, 1-Yes
After the system shuts down and restarts, select Normal Mode
Submit the completed start-up report by Fax: 1-613-741-3375 or e-mail: [email protected].
Factory Start-up Supervision
Seresco Technologies Inc. factory start-up supervision can be purchased with the equipment. A factory start-up includes
several key services:
The expertise of a factory-trained technician who will supervise the commissioning of the equipment.
This Seresco representative will assist the installing contractor with filling out the Start-Up Report.
They will also inspect the installation to make sure that the dehumidifier has been properly integrated with
the rest of the equipment on the job site.
Finally, they can train the maintenance personnel to operate and service the equipment if necessary.
A factory start-up does not include installation assistance. The installing contractor is responsible for ensuring that the
system is ready for start-up when the Seresco representative arrives. If the system is not ready, Seresco reserves the right to
bill the contractor for a second visit. When the installing contractor is confident the system will be ready, contact the Seresco
Sales representative to schedule the start-up. Please call at least two weeks before the desired start-up date to prevent
scheduling conflicts.
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Section F - Startup
Issue Date : 2011-09-30
Items required for Start-Up
A service technician and a fully stocked service vehicle.
A set of refrigerant manifold gauges.
Air balancing equipment (magnehelic differential pressure gauge).
Volt/Amp/Ohm meters.
A digital thermometer w/clamp on sensors.
A halogen leak detector, R410a or R407c and a scale.
Items to be Completed Before Start-up
Refrigerant leak-check (with halogen leak detector) and inspect the unit for internal concealed damage.
Level and support the dehumidifier properly.
Install the outdoor air duct filters and damper (if applicable).
Install the condensate P- trap and drain lines and prime P-trap.
Pipe the remote condenser fan pressure controls to the condenser hot gas lines (if applicable).
Evacuate and leak-check the remote condenser line set (if applicable).
Tighten all electrical connections and verify that the line voltage is correct for the unit.
Install all controls and verify that all field wiring matches the schematic.
Fill and heat the pool and room to design conditions.
Install the pool water piping and a flow meter (if applicable). Purge all air from pool lines.
A complete system air balancing.
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Issue Date : 2011-09-30
Issue Date : 2011-09-30
Section G - NE Series Unit Operation
NP Series Unit Operation
Sequence of Operation
The standard sequence of operation for a Seresco dehumidifier is relatively simple. Whenever the compressor operates, the
evaporator is always dehumidifying and cooling the return air. The heat removed from the air at the evaporator, as well as
the heat from the compressor's action, must be rejected to one of three heat sinks; room air, pool water (if applicable) or
outdoors. The microprocessor will direct the heat to where it is needed based on room conditions.
Dehumidification Mode
Dehumidification Mode occurs when the space requires dehumidification. The air discharged from the unit is drier and
approximately 20°F warmer than when it entered. This mode engages when the return air relative humidity is above the setpoint. The hot gas is condensed in the reheat coil, returning heat to the room air.
Air Conditioning Mode
Air Conditioning Mode occurs when the room air requires only cooling, all of the refrigerant hot gas is directed outdoors,
either directly (outdoor air cooled condenser, etc) or indirectly (water cooled, outdoor air fluid cooler, etc). The air
discharged from the unit has been dehumidified and is about 15°F cooler than when it entered. In stage one air
conditioning, the compressor starts (if not already operating in dehumidification mode), the evaporator sees nominal air
flow, and the hot gas condenses at the outdoor air cooled condenser or equivalent. In stage two air conditioning, the system
performs as in stage one air conditioning, except the evaporator bypass damper closes to maximize air moving across the
evaporator coil.
Pool Heating Mode
If the unit is in dehumidification or air conditioning mode, there is free heat available in the system to heat the pool water.
This pool water heating mode engages if the pool water drops below the set-point. Water heating alone will not start the
compressor, thus there must be a pre-existing demand for this mode to operate. When in pool water heating mode, the pool
water control valve directs hot refrigerant through the coaxial heat exchangers. This system also acts as a refrigerant
subcooler, increasing system efficiency and capacity. If there is no other demand for the compressor to operate, the
microprocessor sends a signal to the external auxiliary pool water heater (provided by others). No additional controls are
required to operate the auxiliary water heater.
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Section G - NE Series Unit Operation
Issue Date : 2011-09-30
Continuous Blower Operation
Units have been factory wired for continuous blower operation. This helps prevent air stratification and stagnation. This is
also required to ensure that the sensors produce accurate data.
Compressor Start Sequence
All Seresco NE/NP Series units have a pump down sequence and anti-short cycle timer. When a demand requires the
compressor to operate, the following sequence occurs: blower operation is confirmed by the microprocessor and anti short
cycling timer (ASCT) sequence completes, the pump down solenoid valve opens, the low pressure safety switch will activates
at 25psig, and the compressor starts.
Space Heating Option
The microprocessor control is designed to control a space-heating coil mounted locally or remotely. When the room
temperature drops below the set point, the microprocessor will send a signal to start the heating coil.
Purge
Used for complete air changeover in pool environment after super-chlorination. Return air damper is completely closed,
resulting in all air from the pool space being exhausted, while fresh air is brought in from the outdoors. Also used for
economizer cooling when conditions warrant.
Heat Recovery
The energy a room loses from the exhaust air, as a result of the fresh air requirements, can represent up to 50 % of the
room's heating requirements. Approximately 50-60 % of this exhaust heat can be recaptured with a heat recovery loop. By
doing so it supplies heat to warm the cold outside air and can provide generous energy savings to the room to reduce heating
costs. During freezing weather conditions the outdoor air can provide much of the dehumidification required, and
minimizing the time the compressors run offsetting some of the running electrical costs.
Our typical energy recovery loop consists of two glycol coils: one in the outside air intake and the other in the exhaust airstream. The coils are connected in counter-flow closed loop piping system. The system comprises an inline fluid cooled
pump, an air separator, and in some larger systems a pressure tank and pressure gauge. By circulating a glycol mixture,
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Issue Date : 2011-09-30
Section G - NE Series Unit Operation
typically 30%, we can extract enough heat from exhaust air stream to preheat the outside air intake to about 50-60% of the
room temperature. Extracting more heat from the exhaust air stream is possible but would also lead to possibly freezing of
the exhaust air and would require a more complex and costly system of frost prevention. Keeping our effectiveness down to
50-60% reduces initial cost and keeps things simple.
Figure G-1. Heat recovery loop
Types of Solutions
We recommend and typically use ethylene glycol in our systems but local codes or building requirements may specify
propylene glycol mixtures. The higher viscosity of propylene means a stronger pump is required or a lower circulating water
flow will occur. So it is best to contact the factory if a switch from one glycol to another is preferred. It is important to use
corrosion inhibitors and in the correct amount. When adding the corrosion inhibitor solution please followed the suggested
instructions for the required quantity of fluid. Seresco strongly recommends that the glycol, if not already mixed, be mixed
with distilled water. Topping up and pressurizing the system can be done with clean tap water. In municipalities where local
tap water has a high mineral content, Seresco strongly advises the use of distilled water to prevent “sludging” and premature
failure.
Annual testing should be made of the fluid solution to ensure the adequate glycol concentrations and corrosion inhibitor
protection. Freeze point and PH test strips are available from your local plumbing supply house. It is important to ensure the
solution will not freeze in the case of a power failure or that it is not acidic and will corrode the system. The glycol mix
should be replaced after 5 years or when quality is deem unsatisfactory and cannot be restored.
G-3
Section G - NE Series Unit Operation
Issue Date : 2011-09-30
Filling or Refilling the Glycol Loop
When filling the system please insure all air has been removed. Air in the system will cause corrosion and improper
functioning of the pump. Do not run the pump for any extent time with air in the system it will foam up the glycol and this
will make it difficult to remove the air. If this happens pressurize the system with some water to about 15 PSI and let stand
overnight. Before restarting vent as much air as possible running the pump for very short burst to move the water and any
possible air bubbles around slowly to the vents. For systems with a pressure tank keep the system under a 10-15 PSI positive
pressure to ensure no air get into the system. If the system is left dry for any period of time electrically disable the pump to
avoid it possible coming on without fluid in the system. Please keep record, near the unit, the type of glycol used; ethylene or
propylene, the two types should not be mixed. Keep careful track of what percentage by volume was used and when it was
changed. And the last time it was checked.
G-4
CommandCenter Operator Panel
Introduction
This document describes the different features of the Operator Panel (local or remote)
that is used with the Seresco units.
Startup Screens
When the unit start up you will see the following menu screen. A 60 second timer is
started and if no selection is made before timer expires, Normal Mode will automatically
be selected.
1.
2.
Normal Mode
Service Mode
Selecting Normal Mode will take you to the main sensor screen. If the voltage monitor
fault signal is not active, blower will start right away. If voltage monitor fault signal is
active, 60 second timer will continue running. When timer expires, the voltage monitor
fault signal will be checked again. If signal now is cleared, the blower will start,
otherwise blower will remain off and there will be a voltage monitor fault alarm.
Navigation Mode and Edit Mode
The menu system implements two different modes where the keys have different
meanings. Navigation mode is used to navigate the menu system and Edit mode is used
when changing data.
The following keys are used in Navigation mode:



Keys 1-3 (and 4-6) are used to select a menu item. If there are more than 6 menu
items, menu items will be listed 1-3 on every screen.
Up and Down arrows are used to scroll up or down a page. Arrows at the top right
corner indicates which direction you can scroll. If no more than 6 items either down
or up arrow will be displayed (no scrolling “around corner”). If more than 6 menu
items, both arrows will be displayed and you can scroll “around the corner”.
Obviously no arrows when 3 or less menu items.
Back key takes you back to previous menu level.
OperatorPanel_4.14.4
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

Enter key has a special meaning. From any menu screen it will take you directly back
to the main screen (the sensor screen). If you now press the Back key it will take you
back to the screen where you were before pressing Enter. On the sensor screen you
can still use the Up and Down arrows to scroll up and down a page and the Back key
will still take you back to where you were before pressing Enter. If you press 1
however (Main Menu) the back shortcut is lost (it’s not a true history list yet).
Key 3 on the sensor screen is another hidden feature. It will toggle sensor readings
between displaying values with a one decimal prevision and no precision. Default is
no precision. This applies to all temperatures and the humidity level.
To enter Edit mode you select the number key corresponding to the data item you want to
edit on a navigation screen with data items. To indicate that you are in edit mode, the data
value is highlighted.
The following keys are used in Edit mode:
 Keys 1-3 are not used.
 Up and Down arrows are used to scroll up and down in the value list. More info
about different types of data items later in this document.
 Back key takes you back to navigation mode and cancel any changed data. Data is
with other words not saved when you press the Back key.
 Enter key will save the data and most of the time take you directly back to
navigation mode (covered under data types).
Data Types
Most of the data (properties) you can change are changed using values in a selection list.
You use the Up and Down arrows to scroll up and down in the selection list. You can
scroll “around the corner”. For data items with only two selection items (e.g. Yes/No),
you can use either the up or down key to toggle between the two values.
Most Integer values are edited as lists with a min and max range. The value might also be
restricted to be changed in specific increments (e.g. 5, 10, 15, 20, …). In a few rare cases
integer values are entered one digit a time. When entering edit mode, the integer value
will be displayed as a five digit zero padded number. To enter a number less than 5 digits,
leave the first digits at 0. Press Enter until all digits are set.
Date and Time values are edited in a special way. Using date as an example, when
entering edit mode, the year (or last two digits of the year) will be highlighted. Use Up
and Down arrows to change year. When done, press Enter. Now the month will be
highlighted and you change it in the same way. Press Enter again and the day is
highlighted. Pressing Enter a final time will save the new date. Pressing Back at any time
when editing the date will cancel the change operation and take you back to navigation
mode.
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A time value is entered in the same way as a date.
An IP address is entered the same way as date and time except that you edit one digit at a
time.
Passwords are entered one digit at a time pressing Enter after each digit.
Information Messages
Certain actions and certain conditions will generate information messages. Information
messages will popup over current menu screen. The message can be cleared by pressing
either key 1 or 2. Key 1 will clear current message and key 2 will clear all queued
messages. Messages can be of three different types. Short, Long or Confirmed. A short
message will be cleared automatically after 3 seconds (default). A long message will be
cleared after 5 minutes (default). A confirmed message will never be cleared (unless there
is a system restart) and have to be cleared by pressing key 1 or 2.
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Menu Structure Quick Reference
The root menu screen is where you see all the sensors and one menu option that takes you
to the Main Menu. Some menu selections are dependent on current unit configuration
and will not always be displayed. These menu selections are marked as Optional.
For data menu items, the default value is displayed in the summary.
1.
2.
Setpoints
1.1.
Temperature
1.2.
Humidity
1.3.
Pool Temp
1.4.
Economizer
1.5.
Freeze Stat
1.6.
Purge Temp
1.7.
Heat Recovery
[Optional]
[Optional]
[Optional]
[Optional]
Schedule
2.1.
Empty
2.1.1.
Day(s)
2.1.2.
On
2.1.3.
Off
* 2.2 – 2.3 same as 2.1
3.
System
3.1.
3.1.1.
3.2.
3.3.
3.4.
3.5.
3.5.1.
3.5.2.
3.5.3.
3.5.4.
3.5.5.
3.6.
Ventilation
Blower
Purge
System Restart
Alarm Log
System Status
Environment
Compressor
Ventilation
Network
Serial Ports
System Info
OperatorPanel_4.14.4
* Purge must be enabled.
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4.
User Settings
Display
4.1.1.
Backlight
4.1.2.
Reset Display
4.2.
Date & Time
4.2.1.
Date
4.2.2.
Time
4.2.3.
Zone
4.2.4.
Daylight
4.2.5.
Date Format
4.2.6.
Time Format
4.2.7.
Synch
4.3.
User Password
4.3.1.
Enabled
4.3.2.
Password
4.3.3.
Retention
4.4.
Remote OP
4.4.1.
Version Info
4.4.2.
RS-232 Port
4.4.3.
RS-485 Port
4.1.
5.
* Only visible on Remote OP
Factory Settings
5.1.
System
5.1.1.
Role
5.1.2.
Fire Reset
5.1.3.
Temp Unit
5.1.4.
Rem Control
5.1.5.
Rem Cntrl 2
5.2.
Ventilation
5.2.1.
Purging
5.2.2.
Stabilize
5.2.3.
Freeze Stat
5.2.4.
Frzstat Delay
No Airflow
5.2.5.
5.2.6.
Dirty Filter
5.2.7.
Exhaust OL
5.2.8.
BP Damper 50%
5.2.9.
BP Damp Stable
OperatorPanel_4.14.4
* External freezestat sensor
Page 5
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5.3.
Environment
5.3.1.
A/C
5.3.1.1.
A/C
5.3.1.2.
Deg*Min On
5.3.1.3.
Deg*Min Off
5.3.1.4.
Learning
5.3.1.5.
OACC Off
5.3.2.
Heating
5.3.2.1.
Type
5.3.2.2.
Deg*Min On
5.3.2.3.
Deg*Min Off
5.3.2.4.
Modulated Step
5.3.2.5.
Stage 2 On
5.3.2.6.
Heat Off
5.3.2.7.
Reset Offset
5.3.2.8.
Reset Delay
5.3.2.9.
Reset Time
5.3.2.10.
Cold Start
5.3.2.11.
Cold Level
5.3.2.12.
Save Heating
5.3.2.13.
Learning
5.3.2.14.
Emergency Heat
5.3.3.
Humidity
5.3.3.1.
Deg*Min On
5.3.3.2.
Deg*Min Off
5.3.3.3.
Temp Offset
5.3.3.4.
High Humidity
5.3.3.5.
Float Setpoint
5.3.4.
Pool Heating
5.3.4.1.
Enabled
5.3.4.2.
2 Pools
5.3.4.3.
Comp Heat
5.3.4.4.
Waterflow Dly
5.3.4.5.
Waterflow Rec
5.3.4.6.
Min Out Temp
5.3.4.7.
Max Out Temp
5.3.5.
Deadbands
5.3.5.1.
Air Temp Low
5.3.5.2.
Air Temp High
5.3.5.3.
Humidity Low
5.3.5.4.
Humidity High
5.3.5.5.
Pool Temp Low
5.3.5.6.
Pool Temp High
5.3.5.7.
Heat Rec Low
5.3.5.8.
Heat Rec High
OperatorPanel_4.14.4
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5.3.6.
Sensors
5.3.6.1.
Outdoor Air
5.3.6.2.
Supply Air
5.3.6.3.
Refresh Sens
5.3.6.4.
Min Sample
5.4.
Compressor
5.4.1.
Enabled
5.4.2.
Compressors
5.4.3.
Refrigerant
5.4.4.
Oil Alarm
5.4.5.
Partial Mode
5.4.6.
Partial Transit
5.4.7.
Min Startup
5.4.8.
Stabilize
5.4.9.
Fault Delay
5.4.10.
Min Run Time
5.4.11.
Min Stop Time
5.4.12.
Alarm Stop
5.4.13.
Anti Block
5.4.14.
Wakeup Mode
5.4.15.
Wakeup Time
5.4.16.
SucTempL Dly
5.4.17.
SucTempH Dly
5.4.18.
DisTempL Dly
5.4.19.
LP Alarm
5.4.20.
LP Start
5.4.21.
LP Max
5.4.22.
HP Min
5.4.23.
HP A/C
5.4.24.
LP Pumpdown
5.4.25.
PumpDown Count
5.4.26.
PumpDown Delay
5.4.27.
Superheat
5.4.28.
Valve Cycle
5.4.29.
Valve Open
5.4.30.
Pump Fault
5.5.
Network
5.5.1.
TCP/IP
5.5.1.1.
DHCP
5.5.1.2.
IP
5.5.1.3.
Mask
5.5.1.4.
GW
5.5.1.5.
DNS
5.5.1.6.
Time
5.5.1.7.
Link Monitor
OperatorPanel_4.14.4
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5.5.2.
Serial Ports
5.5.2.1.
Port B (RS-232)
5.5.2.1.1.
User
5.5.2.1.2.
Baud Rate
5.5.2.1.3.
Databits
5.5.2.1.4.
Parity
5.5.2.1.5.
Flow Control
5.5.2.1.6.
Reply Delay
5.5.2.2.
Port C (RS-485)
5.5.2.2.1.
User
5.5.2.2.2.
Baud Rate
5.5.2.2.3.
Databits
5.5.2.2.4.
Parity
5.5.2.2.5.
Echo Test
5.5.2.3.
Port D (RS-485)
5.5.2.3.1.
User
5.5.2.3.2.
Baud Rate
5.5.2.3.3.
Databits
5.5.2.3.4.
Parity
5.5.2.3.5.
Echo Test
5.5.3.
WebSentry
5.5.3.1.
Enabled
5.5.3.2.
Use DNS
5.5.3.3.
IP
5.5.3.4.
Port
5.5.3.5.
Comm Interval
5.5.3.6.
Comm Segment
5.5.3.7.
Stay Alive
5.5.4.
BACnet
5.5.4.1.
Enabled
5.5.4.2.
Interface
5.5.4.3.
Device ID
5.5.4.4.
Port
5.5.5.
Modbus
5.5.5.1.
Device ID
5.5.6.
LON
5.5.6.1.
Refresh Rate
OperatorPanel_4.14.4
Page 8
[Optional]
[Optional]
[Optional]
9/30/2011
5.6.
IO Configuration
5.6.1.
Sensor Calibration
5.6.1.1.
Rel Humidity
5.6.1.2.
Return Air
5.6.1.3.
Supply Air
5.6.1.4.
Outdoor Air
5.6.1.5.
Pool In
5.6.1.6.
Pool Out
5.6.1.7.
HP 1
5.6.1.8.
LP 1
5.6.1.9.
Evap 1
5.6.1.10.
Suction 1
5.6.1.11.
HP 2
5.6.1.12.
LP 2
5.6.1.13.
Evap 2
5.6.1.14.
Suction 2
5.6.1.15.
Discharge 1
5.6.1.16.
Discharge 2
5.6.1.17.
Exhaust Air
5.6.1.18.
Reheat Temp
5.6.1.19.
Pool 2 In
5.6.1.20.
Pool 2 Out
5.6.2.
Sensor Type
5.6.2.1.
Rel Humidity
5.6.2.2.
Return Air
5.6.2.3.
Outdoor Air
5.6.2.4.
HP 1
5.6.2.5.
LP 1
5.6.2.6.
Suction 1
5.6.2.7.
HP 2
5.6.2.8.
LP 2
5.6.2.9.
Suction 2
5.6.2.10.
Discharge 1
5.6.2.11.
Discharge 2
5.6.2.12.
Exhaust Air
5.6.2.13.
Reheat Temp
5.6.3.
Analog Inputs
5.6.3.1.
Samples
5.6.3.2.
Sample Rate
5.6.4.
Digital Inputs
5.6.4.1.
Samples
5.6.4.2.
Sample Rate
OperatorPanel_4.14.4
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6.
Service
Force Demands
6.1.1.
Compressor 1
6.1.1.1.
Dehumidify
6.1.1.2.
A/C
6.1.1.3.
Pool Heat
6.1.2.
Compressor 2
6.1.3.
Compressor 3
6.1.4.
Compressor 4
6.1.5.
All Compressors
6.1.5.1.
Dehumidification
6.1.5.2.
A/C
6.1.5.3.
Pool Heat
6.2.
Force Contacts
6.2.1.
Reset All
6.2.2.
Ventilation
6.2.2.1.
Blower
6.2.2.2.
OA Damper
6.2.2.3.
Open Damper
6.2.2.4.
Close Damper
6.2.2.5.
Exhaust Fan 1
6.2.2.6.
Exhaust Fan 2
6.2.2.7.
OACC
6.2.3.
Heating
6.2.3.1.
Heater 1
6.2.3.2.
Heater 2
6.2.3.3.
Mod Heat
6.2.3.4.
Pool 1 Heater
6.2.3.5.
Pool 2 Heater
6.2.3.6.
Heat Recovery
6.2.4.
Compressor 1
6.2.4.1.
Power
6.2.4.2.
Heat Reclaim
6.2.4.3.
A/C
6.2.4.4.
Pump Down
6.2.4.5.
Pool Heat
6.2.5.
Compressor 2
6.2.6.
Compressor 3
6.2.7.
Compressor 4
6.2.8.
System
6.2.8.1.
System On
6.2.8.2.
Aux
6.3.
Network
6.3.1.
Ping
6.3.2.
Console
[Optional]
6.1.
OperatorPanel_4.14.4
Page 10
[Optional]
[Optional]
[Optional]
[Optional]
[Optional]
[Optional]
9/30/2011
6.4.
6.5.
6.6.
Clear Alarm Log
Clear All Logs
Commission
6.6.1.
Tested
6.6.2.
Commissioned
OperatorPanel_4.14.4
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Menu Structure Description
This is a more detailed description of each menu item.
1.
Setpoints
If user password has been enabled, you will need to enter the password before you
can change any setpoint.
2.
Schedule
If user password has been enabled, you will need to enter the password before you
can change the schedule.
You can enter up to 3 scheduled items. Each item determines when the room is
Occupied by specifying a start time and a stop time. You also specify which day
of the week the scheduled item applies (Monday-Sunday, Workdays, Weekends
or All).
If there are conflicting items then the priority goes to day items (Monday-Sunday)
followed by Workday and Weekends and last All. Use this to your advantage by
specifying a default schedule using All and then add a schedule item for days
where the default does not apply (e.g. Weekends, Sunday).
3.
System
3.1.
Ventilation
Currently you can only turn the blower on or off on this screen. Note that
the blower might not come when turning it on. There can be an alarm
condition preventing it from starting (e.g. blower overload, voltage
monitor fault or firestat).
When selecting Normal Mode at startup, the blower will automatically be
set to On. To not run the blower you will have to go to this menu and turn
blower off. There might be up to a minute delay before blower starts due
to the voltage monitor fault signal not begin cleared.
When selecting Service Mode at startup, the blower will be set to Off.
3.2.
Purge
By selecting the Purge menu item you will get to the Purge activation
screen. At this screen you can set the length of time the system will purge
and start/stop purging.
At the bottom of the screen you can see the current status. It can show Off,
PendingPurge or number of minutes remaining of ongoing purge.
OperatorPanel_4.14.4
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PendingPurge means that we are waiting for the compressor(s) to stop
before we can start purging. The compressors have been notified that they
need to stop
Note that you only can start purge if Purge has been enabled under Factory
Settings.
3.3.
System Restart
When selecting System Restart you will see a confirmation screen where
you have to confirm that you want to restart the system. Pressing 2 or the
Back button will cancel this request.
3.4.
Alarm Log
This is the alarm log. It lists all alarms since the alarm log last was cleared
(from the Service menu). Last alarm at the top. The top line shows the date
for select alarm. You select an alarm by using the Up and Down arrows.
Selected alarm is indicated by an arrow in the left margin. The alarm log
will scroll one alarm at a time rather than a page at a time.
3.5.
System Status
The status screen shows the status for different internal system
components. It’s main purpose is for troubleshooting a running system
where the information here can be passed back to tech support.
The status feature has been grouped into 4 areas. Environment shows
status for the environment control (Air Temp, Humidity and Pool Heat)
including air heater, pool heater and heat recovery.
The compressor area shows the status for all compressors in the system.
Each compressor uses two lines. The first line is the operational status.
The second line (starting with ->) lists the status of the compressor valves
and contactor as a two letter code. The codes are in the following order:
CC
PD
RH
AC
PH
Compressor Contactor
Pump Down Valve
Reheat Valve
A/C Valve
Pool Heating Valve
The ventilation area shows the status of the different ventilation related
components including the OACC.
The network area shows the status for network related components.
The serial ports area show serial port status.
OperatorPanel_4.14.4
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3.6.
4.
System Info
The System Info screen lists some useful information when
troubleshooting the system like Software and Board version, current IP
and MAC address and optional configuration settings.
User Settings
4.1.
Display
Properties controlling the Operator Panel display including backlight.
Reset Display controls how long time the operator panel will wait at a
screen other than the sensor screen before returning to the sensor screen.
4.2.
System Clock
System time properties. Here you can set the date, time, time zone and if
daylight savings is in effect. You can also set what date time format that
should be used.
Date is always edited in Year-Month-Day syntax and the time is always
edited in 24-hour clock format not matter what the format settings are.
Time zone can be set to -3:30, -4:00 to -10:00 and GMT time.
The daylight property only determines if an extra hour should be added to
the current time. No automatic detection if we need to add the extra hour.
If time synchronization is enabled, this property will be set by the
synchronization feature.
The following date formats are supported:
Y-M-D, D/M/Y, M/D/Y and M D, Y.
The last format will be spelled out as Jan 1, 2006.
Clock is either a 12 or 24-hour clock.
Note that if the unit is connected to the Internet, you do not need to set the
clock. The clock will automatically be synchronized with a time server.
Time zone and date/time formats still needs to be set.
4.3.
User Password
Here you can enable user passwords (disabled by default). You can also
change the user password and set for how long the user password
protected menu items should stay open after they have been unlocked
(retention time).
OperatorPanel_4.14.4
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4.4.
Remote OP
This menu selection is only visible on a remote OP (operator panel
connected to the board using a serial port).
Under version info you can see the software version of the remote OP as
well as the minimum main board software version required to be able to
communicate with a main board.
RS-232 and RS-235 are used to configure the remote OP end of the serial
port interface. Only a subset of the serial port parameters are available
compared to what you can configure from the main board serial port
configuration. See 5.5.2 for description of parameters.
5.
Factory Settings
To reach these settings you need to enter a service password.
5.1.
System
The Role property is used in units with more than 2 compressor circuits or
when two units control the same space. One unit (or master board) is
configured as Master while second unit (or slave board) is configured as a
slave. Default role is Single Unit.
Fire Reset property controls how the system will recover after a Fire
Alarm. Set to auto, system will automatically go back to normal once the
alarm is cleared. If set to Manual, a System Restart is required to make the
system operational again.
Use Temp Unit property to set temperature unit to be used in the system
(Celsius or Fahrenheit).
Use the Rem Control and Rem Cntrl 2 properties to enable remote
control for a specific device or option. The remote input signal is used to
control the selected device or option.
OperatorPanel_4.14.4
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5.2.
Ventilation
Purging enables and disables the purging feature.
Stabilize is how long time system will wait for sensors to stabilize after
blower has started. Compressor will not be able to start until sensors are
stable.
Freeze Stat enables detecting freeze status from an external source
connected to a digital input.
Frzstat Delay is the Freeze Stat alarm debounce timer.
No Airflow property is the No Airflow debounce timer.
Dirty Filter property is the Dirty Filter debounce timer.
Exhaust OL property is used to control for how long the exhaust fan will
be locked out after it trips on an overload alarm.
BP Damper 50% sets the time it takes to open the bypass damper
halfway starting from fully closed.
BP Damp Stable timer is the amount of time the bypass damper will wait
after it has adjusted the damper and checking if it needs to be adjusted
more.
5.3.
5.3.1.
Environment
A/C
Set the A/C property to No to disable A/C control.
The Deg*Min On/Deg*Min Off properties controls for how long
the control logic will wait until adding or removing a Cooling
stage after a stage has been added/removed.
Use the Learning option to disable the learning feature and just
use deadbands as turning on/off points.
OACC Off controls for how long the OACC will run before
stopping after there no longer is an A/C demand.
5.3.2.
Heating
Type sets heating type.
OperatorPanel_4.14.4
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The Deg*Min On/Deg*Min Off properties controls for how long
the control logic will wait until adding or removing a Heating stage
after a stage has been added/removed.
Modulated Step defines the increments for the modulated signal
when heater is configured as a modulated heater.
Stage 2 On controls when the second stage digital output will be
turned on for a modulated heater. First stage is turned on when
heating is started.
Heat Off controls the off point for a modulated heater (0 or 10
volts).
Use Reset Offset to set number of degrees below setpoint at which
the unit will consider there is a heating problem (heater not
working).
Use Reset Delay to control for how long a heating issue condition
need to last before heating control will be reset and start all over
again.
Use Reset Time to control for how long the heating control will be
in reset mode before starting to heat again.
Cold Start determines under what temperature we consider being
in cold conditions at startup of unit.
Use Cold Level to set the startup heating level when starting up in
cold conditions.
Save Heating determines for how long last heating level will be
saved when a unit is restarted or shutdown.
Use the Learning option to disable the learning feature and just
use deadbands as turning on/off points.
Enabling Emergency Heat will disable normal auxiliary heating
control. Instead the compressor will be started to provide heat if
the space gets too cold.
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5.3.3.
Humidity
The Deg*Min On/Deg*Min Off properties controls for how long
the control logic will wait until adding or removing a
Dehumidification stage after a stage has been added/removed.
Temp Offset property is the offset from the return air temperature
where dehumidification will not operate. If temperature is outside
this range, dehumidification ill not come on even the humidity is
above the high deadband. However, if dehumidification already is
running, the will keep on running even if the temperature moves
outside the range.
High Humidity property is the offset above setpoint at which
dehumidification will start no matter what the return air
temperature is.
Float Setpoint property is used to enable/disable the floating
humidity setpoint feature. This feature dynamically sets the
humidity setpoint based on the outdoor air temperature as follows:
More than 50 F
Between 30 F and 50 F
Between 10 F and 30 F
Less than 10 F
50%
45%
40%
35%
There is a 2 degree deadband when moving to a higher setpoint so
that moving from 40% to 45% will not happen until outdoor air
reaches 32 F.
5.3.4.
Pool Heating
Set Enabled property to Yes to enable pool heating.
Set the 2 Pools property to Yes to enable heating of a second pool
using compressor circuit 2. Set to Bypass to support pool bypass
valves on older units.
Comp Heat property controls how compressor pool heating valve
and auxiliary pool heater is being utilized. For Normal setting, unit
will use both heating resources in the most efficient way. Forced
will force compressor on to heat pool even when there is no other
compressor demand. Auxiliary heater will not be used for this
setting. For Disabled setting compressor pool heating is disabled
and only auxiliary heater will be used to heat the pool.
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Waterflow Dly property is the number of seconds unit will wait
before checking for a waterflow problem after pool water heating
is started (using compressor pool heating valve).
Waterflow Rec property controls for how long a waterflow alarm
will stay active and pool heating will remain in recovery mode.
After this time, the pool heating control will go back trying to heat
pool again if there still is a demand for it and compressor is
running. Note that auxiliary pool heater will still be used when
recovering from a waterflow alarm.
Min Out Temp and Max Out Temp properties controls the range
in which the Pool Out temperature has to be in relation to the Pool
In temperature when using compressor to heat the pool. If outside
this range, a Waterflow Alarm will be tripped with reason Pool
Out.
5.3.5.
Deadbands
This section is used to configure setpoint deadbands. Air
temperature and pool temperature setpoints can be set in 1/10th of a
degree.
5.3.6.
Sensors
Outdoor Air property control whether the outdoor air sensor
should be used in control logic.
Supply Air property control whether the outdoor air sensor should
be used in control logic.
Refresh Sensor property sets how often sensors will be read.
Sensor reading will also be generated when there is a change in
the sensor reading. Refreshing sensors on a regular basis prevents
us from getting stuck with no sensor readings for a long time when
the system is stable.
Min Sample property controls for how many seconds we will wait
at the minimum between two sensor readings before using a new
sensor value sample in our calculations.
5.4.
Compressor
Use Enabled property to enable or disable usage of compressors.
Compressors are disabled by default when unit is shipped and still in
Commission mode.
Compressors configures number of compressors used in the system.
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Accepted values are 1 to 4 and Tandem.
Refrigerant sets the type of Refrigerant used in the system. This will
affect some of the pressure levels used to control the compressors.
Oil Alarm sets if the system supports Oil alarms. Note! This feature is
currently not implemented but will be very soon.
Use the Partial Mode property to control if unit will be using partial
heating mode for compressors. Partial heating mode is when both the
reheat and the A/C valves are open. When this property is set to No for a 2
compressor unit, there still is a partial heating stage when both
compressors are running where one compressor is running in full reheat
and the other compressor is running in full A/C. The only thing this
property is preventing is that one compressor have both valves open at the
same time.
The Partial Transit property should only be changed after talking to a
Seresco engineer. It is used to solve a problem where both the A/C and
Reheat solenoids are open and one of them closing but not closing
properly. Set this property to 0 to disable this feature.
Min Startup timer controls the minimum time compressor will wait
before starting compressor even if minimum Low Pressure level is met.
Stabilize timer controls for how long time the compressor will run before
we enable the Low Pressure alarm. During this time the system will still
monitor for a low pressure level reaching vacuum levels using the low
pressure transducer.
Fault Delay timer controls the time between each check to see if Low
Pressure is below maximum allowed and High Pressure is above minimum
allowed. Timer starts when compressor starts and then after every check
for as long as compressor is running.
Min Run Time timer controls the minimum time the compressor has to
run before it can be stopped.
Min Stop Time control the minimum time the compressor has to be
stopped before being started again after a normal stop.
Alarm Stop control the minimum time the compressor has to be stopped
before being started again after an alarm.
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The Anti Block timer is used when deciding if the compressor should be
started even if the low pressure has not reached minimum level. It is also
used decide for how long we will wait for the low pressure to reach its
shutoff level before stopping the compressor anyway.
Wakeup Mode timer controls for how long the compressors needs to be
inactive and we will start the compressor in wakeup mode. In wakeup
mode, the valves will be open for a longer time before closing them
according to demand. We do this to settle the refrigerant after a long time
of inactivity.
Wakeup Time timer controls for how long all valves will be open when
the compressor is in wakeup mode.
SucTempL Dly is the debounce delay timer for the low suction
temperature alarm.
SucTempH Dly is the debounce delay timer for the high suction
temperature alarm.
DisTempL Dly is the debounce delay timer for the low discharge
temperature alarm.
LP Alarm pressure setting controls at what Low Pressure level
compressor will trip on Low Pressure alarm once it is past Stabilize state.
LP Start pressure setting controls at what minimum Low Pressure level
compressor will start. Note that there also are some timers controlling
when compressor can start (Min Startup and Anti Block).
LP Max pressure setting controls the maximum Low Pressure level we
allow the compressor to run at. A check against this level is done
intermittently defined by Fault Delay timer.
HP Min pressure setting controls the minimum High Pressure level we
allow the compressor to run at. A check against this level is done
intermittently defined by Fault Delay timer.
HP A/C pressure setting controls at what High Pressure level Outdoor Air
Condenser will start if any compressor A/C valve is open.
LP Pumpdown pressure setting controls at what Low Pressure level
compressor will do an idle pump down when compressor is not running.
PumpDown Count property controls how many idle pump downs we can
have within the Pumpdown Delay period without locking out idle pump
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down feature until next system restart. Set to 0 to disable idle pump down
feature.
PumpDown Delay property defines the period in which we can have no
more then PumpDown Count idle pump downs.
Superheat controls the minimum superheat level. This parameter is used
when calculating the minimum Suction temperature as described in the
document Alarm Descriptions.
Valve Cycle is used together with the Valve Open timer when adjusting
reheat valve position. This timer is the full cycle where Valve Open is the
time the valve will be open. For instance, cycle set to seconds and open
timer set to 5 seconds means valve will open for 5 seconds and then be
closed for 55 seconds.
Valve Open timer determines for how long valve will be open in a full
valve cycle (see Valve Cycle).
5.5.
5.5.1.
Network
TCP/IP
Set DHCP to use Dynamic IP and set it to No to use Static IP. In
the first case, the IP, Mask, GW and DNS property will be set
automatically and you will be able to see what they are set to (as
soon as a network connection has been detected and a DHCP
server has been found).
IP is the systems IP address.
Mask is the network mask.
GW is the IP address for the gateway.
DNS is the IP address for the Domain Name Server.
Time is the IP address for the time server (used to synchronize the
clock).
Link Monitor is how often the system will check that there still is
a physical network link. If you unplug the Ethernet cable, it can
take up to this time before it is detected.
5.5.2.
Serial Ports
Port properties are the same for all ports except where noted.
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User defines the user of the port. Default is Seresco which means
the port is opened for inbound traffic using the Seresco protocol.
Other users are other protocols like LON and Modbus as well as
3&4 compressor slave board communication.
Baud Rate, Databits and Parity defines your common serial port
configuration parameters.
Flow Control defines if hardware flow control should be used.
Can only be configured for the RS-232 port (port B).
Echo Test defines if we will do an echo test every time we
transmit data over the port. Normally all data should be echoed
back and therefore adding the echo test enable us to have one more
test to ensure data was transmitted with no errors. However, if
there is a minor hardware problem with the port chip, this will
cause the port not to work at all. Disabling the echo test might
enable us to still use the port even with the hardware error.
Reply Delay defines for how long we will wait for a reply message
before considering it a communication fault.
5.5.3.
WebSentry
These properties controls WebSentry connection.
Set Enabled to No to disable WebSentry. You can do this if you
temporarily want to disable WebSentry connections. Also you
should do this if a unit is not connected to the Internet to avoid
unnecessary attempts trying to detect a physical network link.
Use DNS controls if DNS should be used to resolve the IP address
associated with the hard coded WebSentry server name. You
should set this to No if there seems to be a problem resolving the
IP address and instead use the IP property to define the IP address.
IP is the WebSentry server IP address. Use this property to
configure the IP address or to see what it is if DNS is enabled.
Port is the WebSentry port to connect to. This is configurable in
case the port will change in the future.
Comm Interval is how often the system will try to connect to the
WebSentry server between disconnects.
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Comm Segment is how often the system will try to connect to the
WebSentry server between disconnects when we can not transmit
all non-sent data in one session.
Stay Alive is how long the TCP connection will stay active from
the last time a message was received from the WebSentry server.
Normally the WebSentry server should disconnect before this time.
5.5.4.
BACnet
These properties controls BACnet connections and are only
available if the CommandCenter has been loaded with BACnet
support.
Set Enabled to Yes to enabled BACnet. It is disabled by default.
Set Interface to BACnet interface type. Currently only Ehernet
and IP is supported.
Use Device ID to set a unique device ID for unit on the BACnet
network.
Port can be used to change the default port setting.
5.5.5.
Modbus
Use these properties to configure Modbus communication.
5.5.6.
LON
Use these properties to configure LON-Modbus gateway
communication.
5.6.
5.6.1.
5.6.2.
IO Configuration
Sensor Calibration
All sensor calibration values are changed the same way. You use
the up and down arrow to change the value to a few steps above or
below 0.
Sensor Type
The sensor types controls how an input signal is translated into a
value. Note that some sensors that are available under sensor
calibration are not available under sensor types. These are
temperature sensors that never should be disabled and for which
there are no other sensor type that can be used except Thrm.
The following sensor types are available:
 None, disables sensor.
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









6.
Volt, old voltage sensor type where an internal table is used
to map signal to correct conversion formula.
Thrm, thermistor sensor to be used for all temperature
sensors.
GS-RA, Greystone return air sensor.
GS-RH, Greystone RH sensor.
SG-LP, Saginomiya Low Pressure transducer.
SG-HP, Saginomiya High Pressure transducer.
JC-RH, Johnson Controls RH sensor.
JC-LP, Johnson Controls Low Pressure transducer.
JC-HP, Johnson Controls High Pressure transducer.
BMS, Building Management System controlled sensor.
Future use and not fully implemented yet.
5.6.3.
Analog Inputs
The Samples and Sample Rate properties are used to fine tune the
way analog inputs are read and translated into sensor readings. A
sensor reading is the average of all read samples.
5.6.4.
Digital Inputs
The Samples and Sample Rate properties are used to fine tune the
way digital inputs are read and translated into alarms or other
inputs. A digital input will signal a state change when all samples
are the same and are different from current saved state.
Service
To reach these settings you need to enter a service password.
6.1.
Force Demands
Use Force Demand to simulate compressor demands. This feature is used
to test the mechanics of the compressors. Select compressor to test.
Three properties can be changed for each compressor. Reheat controls the
Reheat valve, A/C controls the A/C valve and Pool Heat controls the Pool
Heat/Pool Bypass valves. Turning on just Pool Heat will not turn on the
compressor.
6.2.
Force Contacts
Force Contacts is used to test all the Digital Outputs. This overrides any
internal control of corresponding features and is just a away to physically
test that a contact is working. One exception is the Compressor Power
contact that will cause the compressor control state machine to go into a
special forced mode state. We need to do this to ensure that we still will
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detect compressor safeties like high pressure when the compressor is
running.
Compressor 2 - 4 contacts will only be available if system has been
configured for more than one compressor.
Selecting Reset All will reset all contacts back to the Off position.
6.3.
6.3.1.
Network
Ping
The ping feature is used to test the IP network.
To use ping, set the ping address and then select start. The first result line
shows the IP addresses you are pinging from (units IP address) and the
second line will show 4 time values in milliseconds.
Ping will send 4 messages to specified address and measure in
milliseconds how long it will take to get a reply. If no reply within 5
seconds the result will show Fail for that particular ping request.
6.3.2.
Console
The console is currently only used to monitor serial port messages. Select
the serial port to monitor by using the arrows keys. Select 1 to start
monitoring. To stop/pause messages, you can press key 2 anytime. Press
Enter to clear the screen. Select back top stop console or to go back and
select another serial port.
6.4.
Clear Alarm Log
Selecting Clear Alarm Log will display a confirmation screen where you
have to confirm that you want to clear the alarm log. Pressing 2 or the
Back button will cancel this request.
6.5.
Clear All Logs
Even though you only can look at the alarm log from the control panel,
there are several other logs used as well. These logs can be read using
WebSentry if the unit is connected to Internet.
Use Clear All Logs to clear all the logs and not just the alarm log.
6.6.
Commission
When control board initially is configured loaded with the latest control
software, unit is prepared to make it safe and easy to use when testing unit
before delivery to customer. When test completed, the Tested option is
changed to Yes and can never be changed back again.
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When unit has been tested, the compressor Enabled property will be
changed to No.
When Commissioned option still is set to No, unit will start up in service
mode. It is not possible to start the unit in Normal Mode. The blower can
be started anytime but to enable the compressors and to be able to change
the Commissioned option, a factory password is required.
When changing Commissioned to Yes, all the logs will be cleared and the
unit will do a system restart. Now at startup you will see the normal
startup screen with 2 selections, Normal Mode and Service Mode.
The Commissioned option can be changed back to No if needed.
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Section H - Routine Maintenance
Issue Date : 2011-09-20
Routine Maintenance
WARNING Disconnect all electrical power, including remote disconnect, and discharge all
energy storing devices before servicing. Follow proper lockout procedures to ensure the power cannot be
accidentally energized. Failure to follow provided safety warnings and labels could result in serious injury
or death.
WARNING When it is necessary to work with live electrical components, have a licenced
electrician or other qualified persons perform the required maintenance.
WARNING Danger or moving mechanical parts, high voltage power, elevated pressure and
temperature ! When performing maintenance activities, lock out the unit to prevent accidental start-up.
When service is required, call a qualified refrigeration mechanic.
Routine Maintenance Checklist
Seresco Technologies Inc.'s products are built for dependable and safe operation with minimum maintenance. Periodic
maintenance is required, however, to ensure continuous safety and maximum operating efficiency. Suggested maintenance
operations are listed in the table below with the recommended service intervals. Please note that these are general guidelines
and should be adjusted accordingly to match facility operating conditions.
Table 1. Routine Maintenance Requirements
Frequency
Maintenance Operation
Weekly
Observe unit weekly for any change in running condition and unusual noise
Monthly
Clean or replace air filters if clogged or dirty
Verify that all set-points are correctly programmed as specified by the facility operator
Inspect and clean drain pans
Tighten electrical connections if required
Check and tighten, if requires, pool water hose clamps and sensor mounts
Quarterly
Inspect coils for dirt build-up
Check that the P-trap is primed (filled with water). It is good practice to to pour some water into
the drain pan to ensure that the P-trap is primed and operational
Check and lubricate motor bearings. Refer to the motor manufacturer's instructions
Check outdoor air louvres for accumulation of dust and clean as required
H-1
Section H - Routine Maintenance
Issue Date : 2011-09-20
Inspect the unit casing for corrosion. If damage is found, clean and repaint the affected surface
with a rust-resistant primer
Clean the fan wheel(s) and motor shaft(s)
Inspect and clean drain pans
Check damper operation
Inspect electrical components, wiring and insulation
Yearly
Rotate the fan wheel(s) and check for obstructions and rubbing
Lubricate motors as directed by motor manufacturer
Check gasket condition on all doors to ensure an airtight seal
Check for loose external or internal parts, paying careful attention external components
Check bolts on compressors, motor mounts, unit bases and coils and tighten if required
Verify that the airflow around the remote condenser or dry cooler is unobstructed
Component Maintenance
Filters
Replace filters when dirty. Check filters located in main filter wall, outside air intake and exhaust fan opening. Filters should
slide out of their tracks without difficulty. Replace with filters of equivalent size and rating. See section Z - Annex for filter
sizes and quantities.
Drain Pans
WARNING Hazardous chemicals ! Cleaning agents can be highly acidic or alkaline. Handle all
chemicals carefully and use appropriate personal protective equipment (PPE). Refer to the cleaning agent
manufacturer's Materials Safety Data Sheet (MSDS) for safety and handling information. Failure to follow
all safety instructions could result in serious injury or death.
Note : Do not walk on the drain pans. Doing so will cause damage and impair drainage.
To clean drain pans:
H-2
1.
Disconnect all electrical power to the unit
2.
Remove any standing water
3.
Scrape solid foreign material off of the drain pan and vacuum to remove particulate matter
Section H - Routine Maintenance
Issue Date : 2011-09-20
4.
Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA approved
sanitizer designed for HVAC use. Immediately rinse with fresh water to prevent corrosion
5.
Allow to dry completely before putting the unit back into service. Dispose of all contaminated
materials
Impellers / Fans
To clean fan blades:
1.
Disconnect all electrical power to the unit
2.
Scrape solid foreign material off of the fan blades and vacuum to remove particulate matter
3.
Thoroughly clean any contaminated area(s) with a mild bleach and water solution or an EPA approved
sanitizer designed for HVAC use. Immediately rinse with fresh water to prevent corrosion
4.
Allow to dry completely before putting the unit back into service. Dispose of all contaminated
materials
Motors
Inspect fan motors periodically for excessive vibration or temperature. For bearing lubrication and other maintenance
activities, see manufacturer's literature provided in the appendix.
Coils
WARNING Hazardous pressures ! Coils containing refrigerant under pressure must not be
cleaned using a solution over 150 ºF. Failure to follow these safety precautions could result in coil bursting,
which could result in serious injury or death.
To clean coils:
1.
Disconnect all electrical power to the unit
2.
Wearing the appropriate personal protective equipment (PPE), use a soft brush to remove loose debris
from the coil
3.
Install a block-off to prevent spray from going through the coil and into a dry section of the unit and /
or system ductwork
4.
Mix a high quality coil cleaning detergent with water according to the manufacturer's instructions
5.
Place the mixed solution in a garden pump-up sprayer or high-pressure sprayer. If a high-pressure
H-3
Section H - Routine Maintenance
Issue Date : 2011-09-20
sprayer is to be used:
a) Maintain minimum nozzle spray angle of 15 degrees
b) Spray perpendicular to the coil face
c)
keep the nozzle at least 6 inches from the coil
d) Do not exceed 60 psi
6.
Spray the leaving side of the coil first, then the entering air side
7.
Thoroughly rinse both sides of the coil and the drain pan with cool, clean water
8.
Straighten any coil fins that have been bent during the cleaning process
9.
Confirm the drain line is clear
10. Replace all panels and parts and restore electrical power to the unit
11. Dispose of all contaminated materials
Insulation
Note : Microbial growth ! Wet interior insulation can become an amplification site for microbial growth
(mold), which may cause odours and damage to the equipment and building materials. If there is evidence
of microbial growth on the interior insulation, the insulation should be removed and replaced prior to
operating the system.
Accumulated dirt and other organic matter exposed to water or extended periods of high relative humidity (60 percent or
higher) can support microbial growth, which must be removed to prevent the unit from becoming a contaminant source. If
evidence of contamination exists, determine and eliminate the cause, remove the contamination and sanitize the affected
area.
Refrigerant Charging Procedure
Repairs or maintenance on refrigerant containing components or pipes will require reclaiming and then charging the unit.
The procedure outlined below demonstrates the correct method for charging refrigerant loops on Seresco Technologies Inc.'s
dehumidifiers.
Pressure Testing Procedure
Perform a pressure test before vacuuming and charging the system to ensure that there are no leaks.
Pressure test the pipes for at least four hours using nitrogen at 350 psi when using R-407C refrigerant or
H-4
Section H - Routine Maintenance
Issue Date : 2011-09-20
500 psi when using R-410A refrigerant
Perform soap tests at all joints
If the pressure drops by more than 10 psi over the four-hours, then the test has failed
Evacuate the nitrogen
Vacuuming Procedure
It is crucial to vacuum the system to ensure that there will be no contamination when the unit is charged with refrigerant.
The whole system or only a portion can be put under vacuum. Make sure to replace the oil in the vacuum pump before every
use.
Fasten hoses as shown in the attached diagram
Attach a Micron gauge to monitor vacuum levels in the system.
The vacuum should be below 500 microns. Check the gauge after 15 minutes, it should not have
increased by more than 15 – 20%.
If 500 microns is not reached after 1 hour, redo the pressure test. Soap test everything including the
hose connections.
Break the vacuum by opening the rotolock valve on the receiver or by charging the receiver using 5 – 10
lb of refrigerant.
Close the tank, all solenoid and ball valves before removing the vacuum gauge and vacuum hose.
Units 8 tons and larger feature a removable core filter drier. In order to clean the core only a portion of the system needs to
be evacuated.
Close the rotolock valve on the receiver outlet and pump down all the refrigerant in to the receiver
Remove, clean and replace the filter dryer core
Draw vacuum from the line as shown in the diagram.
Repeat the bullet points listed above, but note that vacuum may only reach 600 – 800 Microns due to small refrigerant leaks
through the rotolock valve at the receiver. There are several possible causes which could prevent the vacuum pump from
reaching 500 Microns. Ensure that all hose connections are tight. Contaminants in the lines could cause the vacuum pump to
reach full vacuum very slowly. Traces of refrigerant could also be impeding the vacuum.
Charging Procedure
Check the unit label for the proper refrigerant type (R-407C or R-410A)
Turn the stem on the receiver rotolock counter-clockwise to “back-seat” the stem (close the rotolock)
H-5
Section H - Routine Maintenance
Issue Date : 2011-09-20
Partially connect the charging hose and purge the line before fully connecting the hose
Figure H-1. Rotolock valve with cap (left, highlighted) and without the cap exposing the stem (right)
If charging the unit:
“Front seat” the stem by turning clockwise.
Charge the system with the required amount of refrigerant. Watch the pressure closely because the
system will charge quickly.
Back seat the stem again before disconnecting disconnect the hose.
If only charging 5-10lb to break the vacuum:
Turn the stem counter-clockwise to the halfway position.
Charge the required amount of refrigerant. This will be very quick.
Back seat the stem again before disconnecting the hose.
H-6
Section H - Routine Maintenance
Issue Date : 2011-09-20
Outdoor Air Balancing
The amount of outdoor air introduced into the unit varies by season. Seresco Technologies Inc. provides manual balancing
dampers with all outdoor air equipped units. Even if a unit mounted motorized air damper is installed, the manual damper
will also be installed. There are two types of manual dampers depending on the size of the unit.
NE/NP-004 to -016 and NE/NP-2xx Series
Note that the Outdoor Air filter box contains two perforated sliding plates as shown in Figure H-1. Adjust the manual
damper by turning the black knob to slide one plate along the other. Align the holes for maximum air flow or misalign the
holes to block or dampen the airflow.
Figure H-2. Outdoor Air Filter Box
For NE/NP/NV-018 to NE/NP/NV-120
To adjust the outdoor air balance, first remove the filters. The manual damper consists of two perforated plates, one of which
slides on top of the other. To adjust the air balance loosen all the screws and slide the plate to obtain the desired setting. Retighten all the screws.
H-7
Section H - Routine Maintenance
Figure H-3. Outdoor Air Filter Box
Figure H-4. Outdoor Air Tightening Screw (highlighted)
H-8
Issue Date : 2011-09-20
Issue Date : 2011-09-20
Section H - Routine Maintenance
Mechanical Vestibule Access Steps
The service steps displayed in Figure H-5 act as a step ladder giving easy access to the mechanical vestibule. The best place
to store the steps is on right of the vestibule between the compressor stand and the unit wall. Place them into the slots at the
front of the vestibule stand as shown and make sure they are secure before stepping on or placing any weight on them.
Figure H-5. Compressor stand step
Note that for unit models NE-018 to NE030 there is a lower step placement available on the outside of the unit as shown
below.
Figure H-6. Mechanical vestibule step on base rail
H-9
Section H - Routine Maintenance
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
H-10
Issue Date : 2011-09-20
Section X - Troubleshooting
Issue Date : 2011-09-20
Troubleshooting
This section is intended to be used as a diagnostic aid only. For detailed repair procedures, contact Seresco Technologies
Inc.'s service department.
Two user-friendly service tools are critical in troubleshooting any issues with Seresco's dehumidification systems: the
WebSentry remote monitoring software and automated system alarm logs. WebSentry remote monitoring software allows
the collection of comprehensive unit performance data and space conditions via the Internet. This option is default on all
units with CommandCenter controls and has proven to be an extremely effective service tool. To function correctly, this
requires the unit to be connected to a local network with Internet access. System Alarm Logs detail information on alarm
situations, including the type of alarm, faults and time to help service technicians narrow down possible cause(s) of the
problem(s).
Troubleshooting Steps
1.
Collect information from unit owner/maintenance team about problem(s)
2.
Refer to the provided Installation, Operation and Maintenance manual and the unit label for additional
information
3.
Perform a basic visual inspection of the unit
4.
Check the System Alarm Log for the latest alarm(s)
CAUTION If the unit is powered down: before powering up the system again, ensure that it is safe
to do so.
5.
Refer to the list of common problems provided below for probable causes and suggested solutions
6.
If you require further assistance, please feel free to contact Seresco's Service and Technical Support (STS)
department
Contacting Seresco Service and Technical Support (STS)
The next availible service technician can be reached by phone at (613)-741-3603, followed by 2, or by e-mail at
[email protected]. When contacting Seresco STS, please have the following information on hand:
−
Your name
−
Service company name
−
Phone number
−
Seresco unit serial number (8 digit number on the unit label i.e. 11011800)
X-1
Section X - Troubleshooting
Issue Date : 2011-09-20
WebSentry Connection Troubleshooting Guide
Ethernet cable connected and operating
First thing to check is that the Ethernet cable has been hooked up properly and is operating normally. Use the LED’s by the
Ethernet socket to verify this. The LED’s are the two white square components on the mini board with the Ethernet socket.
The one closest to the socket should be solid green and indicates a solid physical connection. Unplug cable at the unit or at
the other end and this LED will go blank.
If cable is connected at both end and the LED still does not lit up, it is very possible the Ethernet socket itself is faulty.
Connecting a network cable between a laptop and unit can determine that indeed the Ethernet socket is faulty and that there
is not a faulty router port or faulty cable.
The second LED is yellow and will blink when there is communication.
Firewall settings
The unit will try to connect to the WebSentry server once a minute using port 1030. Server name is websentry.seresco.net.
Use ping to determine IP address associated with this IP address if this is needed for any firewall settings.
If network has a firewall, port 1030 must be open for communication or at least for the IP assigned to unit or the MAC
address for the unit or to/from the Seresco domain name or server IP.
The MAC address can be found under System Info using the local keypad. ‘*’ translates to 00:90:C2 so that if MAC shows
*:D1:2A:49 the full MAC address is 00:90:C2:D1:2A:49.
Checking network communication status
Check status of network communication from the local keypad. From main screen select Main Menu (1) - System (3) System Status (5) - Network (4).
TCP/IP should be saying Up. If it says PendingUp, there is a problem with establishing a physical connection. Network
cables and router/switch needs to be checked. Ensure light over port where unit is connected is lit up.
WebSentry will say Idle when waiting to connect to server (connects once a minute). When connected you will either see
Receive or Send. If it shows Connecting for several seconds it means there is a problem establishing a connection to the
server. Usually it will toggle between Idle and Connecting when a proper connection is not established. Check TCP/IP and
WebSentry configuration settings.
X-2
Issue Date : 2011-09-20
Section X - Troubleshooting
Checking TCP/IP configuration settings
Unit can be configured for dynamic or static IP. From main screen select Main Menu (1) - Factory Settings (5) - Network (5)
- TCP/IP (1). If asked for a password at Factory Settings selection, enter 813.
DHCP set to Yes is for dynamic IP and if set to no, unit is configured for Static IP.
Dynamic IP
You should see an IP and Mask assigned (* means 255). This is assigned by the router to which the unit is connected. On
second page you should also see IP's assigned to GW (Gateway) and DNS.
If any of these IP’s are not assigned properly (showing 0.0.0.0 for instance), there is a problem with the router assigning IP
info to the unit.
Static IP
IP, Mask, GW and DNS all have to be configured correctly or unit will not be able to communicate with the WebSentry
server. This information should be known by the IT group managing the local network.
Check WebSentry configuration settings
By default the unit is configured to use DNS (Domain Name Server) to translate the Seresco domain name to the
appropriate WebSentry IP address. Before software version 4.8.0, domain name www.seresco.net was used. Starting from
version 4.8.0, domain name websentry.seresco.net is used.
If the IP is changing between an IP address and 0.0.0.0, there is a problem with the domain name lookup. In this case you
can try to configure a static IP for the WebSentry server.
Change Use DNS to No and then change the IP address to IP of websentry.seresco.net (currently 97.74.200.218).
Testing Internet access from unit
Unit has a Ping feature that can be used to test that unit can connect to any IP address on the local network as well as to any
IP over Internet.
To use the Ping feature you have to start the unit in Service Mode. From main screen select Main Menu (1) - System (3) System Restart (3) and then press Yes (1) to confirm.
When unit starts up you will have a selection menu. Select Service (2).
X-3
Section X - Troubleshooting
Issue Date : 2011-09-20
To access the Ping feature, select Main Menu (1) – Service (6) – Network (3) – Ping (1). If asked for a password at Service
selection, enter 813.
To test connection to WebSentry server, make sure IP (selection 1) is set to 97.74.200.218. Press 2 to start Ping request.
The 3rd line shows the current IP address assigned to the unit. The 4th line will either have 4 time values or the text Fail (up
to 4 times). The time values indicate number of milliseconds for Ping message to go to WebSentry server and back.
Testing Internet access and WebSentry access from unit Ethernet cable
A simple test you can do to make sure there is Internet access from the Ethernet cable connected to our unit is to connect
this cable into a laptop and accessing any web site using a web browser.
If unit is configured for static IP, you should configure the laptop with the exact same TCP/IP configuration. How this is
done is not covered in this document.
IMPORTANT! Make sure WiFi connection is disabled when testing Ethernet cable.
A secondary test to ensure you can communicate with the Seresco WebSentry server is to use the Telnet command to
establish a connection to the server.
Open up the Command Prompt window. Enter the command:
telnet 97.74.200.218 1030
You should now see a blank screen with a prompt. Hit any two characters. The text Seresco WebSentry should now be
displayed followed by Connection to host lost. This verifies that you can open up a connection to the port used by the
WebSentry server and that this port is not blocked by any firewall.
If the connection failed it most likely is a firewall issue. Port 1030 must be open for communication or at least for the IP
assigned to the Seresco unit.
Contact Factory
If everything in this document has been tested and everything indicates that the communication should be working, we are
dealing with an unknown fault. Contact Seresco for further advice.
X-4
Issue Date : 2011-09-30
Section Y - Warranty
Warranty
General Policy
This warranty applies to the original equipment owner and is not transferable. Seresco Technologies Inc.
warrants as set forth and for the time periods shown below that it will furnish, through a Seresco Technologies
Inc. authorized installing contractor or service organization, a new or rebuilt part for a factory installed part
which has failed because of defect in workmanship or material.
Warranty Void Unless Registered
Warranty is void unless, upon start-up of the unit, the “Warranty Registration and Start-up Report” is
completed and sent to the factory within one week of initial start-up. This report will also register the
compressor warranty with the compressor manufacturer.
Initial 90-day Warranty
During the first 90 days from initial start-up and prior to the completion of the 24th month from date of
shipment, whichever comes first and subject to prior written approval from the factory, Seresco Technologies
Inc. will provide and/or reimburse the required labour, materials, and shipping and handling costs incurred in
the replacement or repair of a factory installed defective part. Only the labour required to replace the defective
part is warrantied – travel time, diagnostic time, per diems, truck charges, etc. are not covered under this
warranty.
WebSentry Conditional One Year Extended Labour Warranty
The factory labour warranty shall be extended for a total of 12 months from initial start-up and prior to the
completion of the 24th month from date of shipment, whichever comes first and subject to prior written
approval from the factory. The provided equipment must be connected and communicating to Seresco's
WebSentry online control and monitoring service for the entire term of the warranty extension. Seresco
Technologies Inc. will provide and/or reimburse the required labour, materials, and shipping and handling
costs incurred in the replacement or repair of a factory installed defective part. Only the labour required to
replace the defective part is warrantied – travel time, diagnostic time, per diems, truck charges, etc. are not
covered under this warranty.
Two Year Parts Warranty
If any factory installed part supplied by Seresco Technologies Inc. fails because of a defect in workmanship or
material prior to the completion of the 24th month from date of shipment, Seresco Technologies Inc. will
Y-1
Section Y - Warranty
Issue Date : 2011-09-30
furnish a new or rebuilt part F.O.B. factory. No labour reimbursement will be made for expenses incurred in
making field adjustments or parts replacement outside the Initial 90-day Warranty. Seresco Technologies Inc.
reserves the right to have the defective part returned to the factory in order to determine the warranty
applicability. Parts shipping and handling costs (to and from the factory) are not covered outside of the Initial
90-day Warranty.
Replacement Part Warranty
If a replacement part provided by Seresco Technologies Inc. under this warranty fails due to a material defect
prior to the end of the Two Year Parts Warranty (or the end of the extended warranty period if applicable) or 12
months from date of the replacement part shipment, whichever comes first, Seresco Technologies Inc. will
furnish a new or rebuilt part F.O.B. factory.
Applicability
This warranty is applicable only to products that are purchased and installed in the United States and Canada.
This warranty is NOT applicable to :
1.
Products that have become defective or damaged as a result of the use of a contaminated water
circuit or operation at abnormal water temperatures and/or flow rates
2.
Parts that wear out due to normal usage, such as air filters, belts and fuses. 2. Refrigerant lost during
the parts warranty will be reimbursed in accordance to the current market price of refrigerant at the
time of repair. Seresco Technologies Inc. will not be responsible for refrigerant lost from the system
due to improperly installed contractor piping to the remote outdoor air cooled condenser.
3.
Refrigerant coils that corrode due to improperly balanced pool chemistry or corrosive air quality.
4.
Components that have been relocated from their original placement at the factory.
5.
Any portion of the system not supplied by Seresco Technologies Inc.
6.
Products on which the model and/or serial number plates have been removed or defaced.
7.
Products which have become defective or damaged as a result of unauthorized opening of
refrigeration circuit, improper wiring, electrical supply characteristics, poor maintenance, accidents,
transportation, misuse, abuse, fire, flood, alteration and/or misapplication of the product.
8.
Products not installed, operated and maintained as per Seresco Technologies Inc. Owner’s Manual.
9.
Products on which payment is in default.
Limitations
This warranty is given in lieu of all other warranties. Anything in the warranty notwithstanding, any implied
warranties of fitness for particular purpose and merchantability shall be limited to the duration of the express
warranty. Manufacturer expressly disclaims and excludes any liability for consequential or incidental damage
Y-2
Issue Date : 2011-09-30
Section Y - Warranty
for breach of any express or implied warranty.
Where a jurisdiction does not allow limitations or exclusions in a warranty, the foregoing limitations and
exclusions shall not apply to the extent of the legislation, however, in such case the balance of the above
warranty shall remain in full force and effect.
This warranty gives specific legal rights. Other rights may vary according to local legislation.
Force Majeure
Seresco Technologies Inc. will not be liable for delay or failure to provide warranty service due to government
restrictions or restraints, war, strikes, material shortages, acts of God or other causes beyond Seresco
Technologies Inc. control.
Optional Five Year Compressor Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement compressor for 60 months from the date of shipment
provided the factory installed compressor fails as a result of manufacturing defect and is returned to the factory
with transportation prepaid. This extended compressor warranty is subject to all the terms of the standard
Seresco Technologies Inc. warranty but applied to the compressor only.
No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,
will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.
Optional Five Year Airside Coil Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement Airside Coil for 60 months from the date of shipment
provided the failed coil is returned to the factory with transportation prepaid. This extended coil warranty is
subject to all the terms of the standard NE Series warranty but applied to the coil only.
No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,
will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.
This warranty is contingent to the proper maintenance of pool water chemistry including a pH of between 7.2
and 7.6 free chlorine not exceeding 2.0 ppm and combined chlorine maintained at less than 0.3 ppm. These
Y-3
Section Y - Warranty
Issue Date : 2011-09-30
parameters are to be measured and recorded daily and be available for review upon request.
Optional 10 Year Airside Coil Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement Airside Coil for 120 months from the date of shipment
provided the failed coil is returned to the factory with transportation prepaid. This extended coil warranty is
subject to all the terms of the standard NE Series warranty but applied to the coil only.
No charges attributed to the replacement of a component, except as detailed in above Initial 90-day Warranty,
will be allowed unless specifically granted in writing beforehand by Seresco Technologies Inc.
This warranty is contingent to the proper maintenance of pool water chemistry including a pH of between 7.2
and 7.6 free chlorine not exceeding 2.0 ppm and combined chlorine maintained at less than 0.3 ppm. These
parameters are to be measured and recorded daily and be available for review upon request.
Optional Five Year Driveline Warranty
This extended warranty must be purchased before the shipment of the unit.
Seresco Technologies Inc. will provide a replacement part for the following components:
Supply fan motor
Supply fan motor starter
Exhaust fan motor
Exhaust fan motor starter
Pool water heater solenoid valves & valve coils
Liquid expansion solenoid valves & valve coils
Air-cooled condenser solenoid valves & valve coils
Blowers
Driveline warranty exists for 60 months from the date of shipment provided the factory installed component
fails as a result of manufacturing defect and is returned to the factory with transportation prepaid. This
extended driveline warranty is subject to all the terms of the standard Seresco Technologies Inc. warranty but
applied to the listed parts only.
No charges attributed to the replacement of a component will be allowed unless specifically granted in writing
beforehand by Seresco Technologies Inc.
Y-4
Issue Date : 2011-09-30
Section Z - Annex
Unit Component Specifications
&
Component Service Sheets
Z-1
Section Z - Annex
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
Z-2
Issue Date : 2011-09-30
Rotating Electrical Machines
Installation Instructions
NEMA - IEC
W Range
Totally enclosed fan-cooled (TEFC)
three-phase motors with squirrel cage
for low voltage, with antifriction bearings.
Installation & Maintenance
Introduction
Where an eyebolt is provided with the motor, this
coating is damaged, it should be made good. The
All ac induction motors are designed for long life and
should be screwed down until its shoulder is firmly
component should be cleaned and the protective
low running costs. Careful installation and mainte-
seated against the face of the stator frame to be lift-
coating reapplied. Under no circumstances should
nance will ensure that you achieve reliable operation
ed. Eyebolts are normally designed for a vertical lift.
rust be merely covered over.
and optimum efficiency. For motors with specific
duties, such as brake motors, single phase motors
For lifting lug or trunnion torques, see table below:
refer to your supplier.
Drain holes
Lifting lug bolt torques
and motors installed within hazardous areas, please
Motors of frame size 160 /254T and above have
Type
Metric
NEMA
/CSA
Bolt
dia*
Torque
drain holes fitted with drain plugs as standard.
Nm
Lbf.FT
Alternatively, the drain plugs can be provided loose
63
-
-
-
-
71
-
-
-
-
80
56
-
-
-
90
143/5T
100L
112M
182/4T
-
-
-
M12*
-
-
be vibration free. if this is not possible, it is strongly
available together with tools and equipment neces-
132S/M
213/5T
M12*
-
-
recommended that the motors be stood on thick
sary for safe working practice. If there are any safety
160M/L
254/6T
M12*
-
-
blocks of rubber or other soft material.
concerns, do not install or attempt to operate the
motor. Please contact your supplier for advice or
180M/L
284/6T
M16*
-
-
M10*
M10*
M10*
M10*
M16*
M16*
M16*
M16*
M20*
M20*
M20*
52
52
52
52
220
220
220
220
400
400
400
38
38
38
38
162
162
162
162
295
295
295
Pre-installation requirements
Warning
Handling and lifting of electric motors must only be
undertaken by authorised personnel. Full product
documentation and operating instruction must be
assistance.
Receipt
Before any motor is accepted on site, it should be
inspected carefully against the following checklist:
a) Check that the description on the
consignment note agrees with your order
specification.
200L
324T
225S
326T
225M
364T
250S
365T
250M
404T
280S
405T
280M
444T
315S
445T
315M
504Z
315L
505Z
355S/M/L 585/6/7Z
in the terminal box if specifically requested.
Bearings
To avoid static indentation, the storage area should
Where the exposure to some vibration is unavoidable, the shaft should be locked in position to avoid
static indentation of the bearings.
Shafts should be rotated by hand one quarter of a
revolution weekly.
Roller bearings may be fitted with a shaft locking
device. This should be kept in place during storage.
Grease
b) Check that the rating, speed etc are in
accordance with your requirements.
c) Check for any damage, rust, dirt, foreign
substance etc. Where an instance of
* Lifting lugs secured with bolts and nuts. High ten-
Factory-fitted bearings use a grease with a recom-
sile socket headed bolts and special square nuts
mended shelf life of two years. If stored for a longer
must be used. Aluminum frame motors should have
period the grease may need to be replaced*.
eyebolt firmly screwed down (without overtighten-
Shielded bearings have a storage life of five years
ing), to ensure that the collar is fully seated.
and a further two years operational life following
installation.
droppage or loss is evident or suspected, it may
be necessary to unpack the goods to
Where two eyebolts/lifting lugs are used with inclined
establish the full extent of the problem.
loading, the maximum safe working load quoted on
*Wash all bearing parts with a non-contaminating
Wherever possible, damage should be
the lifting arrangement must not be exceeded.
solvent. Lightly pack the bearings with grease applying a 25% fill by volume into the bearing and hous-
recorded, photographed and witnessed.
Storage
ings. Run the motor on no-load to distribute grease
Report any damage to the carriers and
If motors have to be stored before installation, pre-
and reduce losses.
your supplier as soon as possible, quoting
the motor and/or order number and
cautions should be taken to prevent deterioration:
shipping reference.
Environment
Where heaters are fitted, and the storage environ-
Depending on the site conditions, it may be neces-
ment has wide humidity and temperature variations,
it is strongly recommended they be energised.
specified, is correct. Manually turn the
sary to create a suitable stores area to hold the
motor prior to installation. Packing cases are not
shaft and check for smooth, quiet rotation.
waterproof.
Warnings should be placed on the motors to
make operatives aware of the live heaters.
Electric motors should not be transported
Motors should be stored in a dry, vibration free and
by rail, as vibration from this method of
clean area at normal ambients (-20°C to 40°C),
Insulation resistance
transport has been known to cause
unless other arrangements have been agreed.
During extended storage, a three-monthly insulation
d) Check that the direction of rotation, if
Heaters
test is recommended to avoid possible lengthy dry-
brinelling of bearings.
Where low temperature ambient storage is anticipat-
ing out periods when installing.
Lifting
ed, special precautions should be taken with the
Eyebolts, lifting lugs and lifting trunnions supplied
type of grease, no plastic parts etc to ensure trouble-
The insulation resistance between phases and
with the motor are designed to support only the
free start-up.
between the phase and earth should be checked
and maintained above 10 Megohm.
weight of the motor, not the weight of the motor and
any ancillary equipment attached to it. Be absolutely
Motors must be stored away from corrosive or
sure that cranes, jacks, slings and lifting beams are
chemically damaging fumes. Before placing motors
capable of carrying the weight of equipment to be
into storage, machined components should be care-
If a lower reading is measured, use one of the recommended drying out methods until an acceptable
lifted safely.
fully inspected. Bearings and shafts are normally
reading is obtained. If heaters are fitted but not ener-
covered with a corrosion resistive barrier. If this
gised, they should be used in future.
1
Installation & Maintenance
Installation
overheating or undue voltage drop.
its of its design voltage and frequency.
It is the users or certified electricians reponsibility to ensure correct earthing and protection in
Cable terminations
Standard motors will operate without damage on any
voltage within the range of the nameplate voltage.
accordance with applicable national and local
All cable terminations should be tightly secured.
requirements and standards.
Mains lead terminal lugs should be in face-to-face
The supply cables must be capable of carrying the
contact with the motor lead lugs and securing nuts
full load current of the motor (see motor nameplate)
Location
and lockwashers screwed firmly over the connection.
without overheating or excessive voltage drop under
Motors must be installed with adequate access for
There should be no nuts or lockwashers fitted
starting conditions.
routine maintenance. A minimum of 0.75m of work-
between the mains and motor lugs.
Grounding
ing space around the motor is recommended, particular attention at the fan inlet (50mm) is necessary to
Wiring should be carried out or checked by a quali-
All motors fitted with an grounding terminal, in or
facilitate airflow. Ensure that there is sufficient free
fied electrician and equipment must be earthed in
adjacent to the terminal box to enable connection to
area in front of the air intake.
accordance with current regulations. The equipment
an effective earthing bond. The terminal is designed
Where several motors are installed in close proximi-
must be correctly fused and isolated. All covers must
be in position prior to running.
for connecting the correct size of copper earth connector. If a different material is to be used, please
refer to your supplier.
ty, care must be taken to ensure that there is no recirculation of exhausted warm air, as this will reduce
All fixing bolts and electrical connections should be
the effectiveness of the cooling system.
checked and tightened if necessary after 100-200
An earthing bond should not be terminated
hours of operation.
under the motor fixture bolts or terminal cover
screws. The ground lead could be overlooked
Foundations must be solid, rigid, level and where
possible free from any external vibration.
Warning
on reconnection after maintenance.
Isolate power supply to motor before commencing
Mechanical
any routine cleaning or maintenance work.
Auxiliary electrical items
Where auxiliaries are fitted, the characteristics
Drain holes
Prior to installation, remove drain plugs if fitted. If
Drying out procedures
should be checked. Example: RTDs (Resistance
any water has accumulated, the integrity of all gaskets, sealants etc should be checked. Drain plugs
It is preferable to dismantle the motor to the point
where the rotor is removed. This is not essential but
Temperature Detectors), should have their resistances checked against manufacturer’s figures.
should be put back into place after draining.
the drying out process will take longer in the assembled state. The temperature of the windings and the
Auxiliaries should be checked for continuity prior to
Alignment
insulation resistance should be monitored at regular
connection to the control circuitry.
When the application calls for direct coupling, the
intervals. On initial application of heat, the insulation
shafts must be correctly aligned in all three planes.
resistance will drop quickly and then start to rise
Do not apply more than 6V across the thermistor for
Bad alignment can be a major source of noise and
slowly until level. On discontinuation of the drying
continuity check.
vibration.
process, a further rise in resistance will occur.
Allowance must be made for shaft end-float and
There are several methods which can be used:
Ensure all control gear and associated metering/pro-
thermal expansion in both axial and vertical planes.
1) Place the motor in a warm (typically 40°C),
tection circuits have been checked fully.
Control gear
It is preferable to use flexible drive couplings.
dry airstream (fan or convector heater) or
in a warm oven with a temperature not
It is imperative that any overload trip and emer-
Motors fitted with angular contact or duplex bear-
exceeding 80°C. This method is preferred if the
gency shutdown circuits are working correctly
ings, must always be run loaded.
motor is dismantled.
before the motor is energised. All covers must
2) Connect the motor to a low voltage* three
be in position.
Slide rails and slide bases
phase supply and inject a current not
Slide rails and bases are available for all motors in
exceeding 50% of the full load current into
Where a motor is fitted with a separately driven fan
the product range to provide adjustable mounting.
the stator winding (*approximately 10% of
unit, the interlocks and thermal overload protection
Fabricated steel rails and bases are the standard
the line voltage). If this is carried out on an
circuits must be operative.
offer as they are suitable for all relevant mounting
assembled motor, it is possible though
arrangements.
unlikely that the motor will turn. If so, the
Rotation
rotor should be locked in position.
Before coupling the motor to the drive, run the motor
Installation:
1) They must be installed on a flat surface.
3) Connect two phases in parallel, and the
third in series. Apply a low voltage ac or dc
2) They must have a secure location.
suply up to a maximum of 50% of full load
3) Drive and driven shaft must be parallel.
current. The stator winding temperature must not
Electrical connection
Connection diagrams
The connection diagram is shown on the leaflet
enclosed in the motor terminal box or diagram inside
the terminal box lid and provides supply details and
All covers must be in place.
be allowed to exceed 80°C. In practice, the frame
To reverse the direction of rotation, interchange any
should not be hot to the touch, to guard against
two incoming supply leads.
internal overheating and consequent damage to
the insulation.
4) Where heaters are fitted, these can be
energised.
the required winding connection. The cables used
should be capable of carrying the full load current of
Supply
the motor (see motor nameplate), without
It is important that a motor is operated within the lim-
2
briefly to check rotation.
Installation & Maintenance
Starting
not generally recommended to use two pole motors
the correct position (if in doubt, contact
Motors are rated by the output required, the number
for belt drive applications.
your supplier).
of starts per hour, the load curve/inertia and environmental considerations.
Motor modifications
Operating outside the contractual parameters may
Warning
thermally overload the motor, eg too many starts per
All modifications should be carried out by a trained
hour, or mechanically stress components, eg over-
operative. Do not work under suspended load and
Bearings, grease, bearing change
speeding.
use correct lifting equipment.
Grease
Regreasable bearings are pre-packed with a lithium
Refer to starter literature for methods of start
Changing terminal box position
or lithium complex based grease.
and safety precautions to be taken.
(on multi-mount motors)
Note:
If drain holes were present they may now be
1) Lift motor, using eyebolt or lifting lugs
Running
After one hour of running, check the general vibration levels. If these are excessive, check alignment
(and belt tensioning if belt driven).
provided
2) Slacken / remove the foot fixing bolts
on one foot
3) Pull the foot away from the frame
4) Repeat stages 2 to 3 on the other foot
Some initial bearing noise may be present during the
running-in period. This is normal because the grease
5) Lower the motor onto two pieces of
timber
has to settle down within the bearing. This noise
should disappear after a few hours of operation.
6) Remove the eyebolt or lifting lugs
7) Rotate the motor until the terminal box is
Check that the motor runs up smoothly and within
8) Refit the eyebolt or lifting lugs on the
in the correct position.
the permitted run-up time. Note that repeated start-
machined pads at the top of the motor
ing in quick succession may lead to a thermal over-
(diagonally opposite corners for lifting
load of the motor.
lugs). Ensure that lifting lugs are in
positioned at the top of the motor.
Other lithium based greases of a similar consistency
would be compatible. See table below for some
alternatives:
Alternative lithium complex greases
Grease
Reference
Manufacturer
Energrease
Castrol
Luplex
Unirex
Sovereign
Mobilgrease
Liplex
Hytex
Retinax
LGHT3
LC2
LMX
M2
N2
LS
HP
EP2
EP2
LX
BP
Castrol
Century
Esso
Gulf
Mobil
Shell
Texaco
Shell
SKF
contact with all machined faces and that
Where a special grease has been supplied, this will
Fitting couplings and alignment
the correct bolts and nuts are used.
be indicated on the motor nameplate.
Extreme care must be exercised in lining up cou-
Tighten the bolts to the correct torque.
plings as misalignment can be detrimental to the
9) Remove fan cover
Regreasing
shaft and bearings. For direct drives, we recommend
10) Remove the endshield bolts at both ends
Standard regreasing facilities, where provided, are
that flexible couplings are used. Please ensure that
the alignment instructions given by the coupling
of the motor.
11) Slacken drive end bearing cap or
situated on the periphery of the drive end and nondrive endshields.
manufacturer are followed.
clamping screws to allow endshield
spigot to disengage.
Do not at any time force in the fitting of couplings,
12) If grease nipples are fitted, disengage
Grease relief is via a:
a) Diaphragm relief valve.
pulleys etc. All motors are provided with a threaded
both endshield spigots and rotate the
b) Rotating grease relief flinger.
hole in the drive end shaft to assist fitting and
endshields through 90° until the grease
c) Plugged grease chute.
removal. A bolt should be used in this hole and a nut
nipples are at the top, or the desired
with a large washer used to press the coupling or
pulley against the shoulder of the shaft. Care must
also be taken to ensure that the motor bearings are
not subjected to end-thrust caused by the two halves
of the couplings being squeezed too tightly together.
Please ensure that all couplings, belts, pulleys etc
are properly and permanently guarded against accidental contact while the motor is running.
position.
13) Refit endshield bolts and tighten to the
correct torque.
14) Retighten the bearing cap screws at the
For motors with open bearings and without grease
relief facilities, the old grease must be cleaned out
from time to time by removing the bearing cap
and/or endshield. The bearing and housing must
drive end, replacing the washers
under the bolt heads. Tighten screws to
then be re-packed with grease and reassembled. Do
not overfill the bearing housing - it should not be
the correct torque.
more than a quarter full of grease after reassembly.
15) Lift motor using the eyebolt hooks or the
lifting lugs.
16) Strip paint from the pads where the feet
Motors with sealed for life bearings usually employ a
polyurea EA6 grease. These should be fitted with
Care should be taken to ensure fixing bolts are cor-
are to be fitted and apply a thin film of
new bearings based on the bearing life stated in the
rectly tightened.
grease for corrosion protection on bare
product catalogue.
surfaces.
Belts drives
Please ensure that the V-belts are of the same manufacture and have the same dimensions. Also
ensure that the belts are correctly tensioned in
accordance with the manufacturer’s recommenda-
17) Refit the feet in the reverse order of
dismantling (steps 2 and 3).
18) Ensure the feet are fully in contact with
the machined faces. Tighten all bolts to
the correct torque.
tions. If the V-belts are not tensioned correctly, it can
19) Repeat stages 18 to 19 on the other foot.
cause belt and pulley wear and/or shaft and bearing
20) Prime and paint all machined surfaces
damage. When replacing belts, it is recommended
that all belts be replaced at the same time. It is also
3
left exposed by the changes.
21) Refit fan cover with the greasing hole in
An overgreased bearing will cause overheating of
the bearing with the possible escape of the grease,
loss of lubrication qualities, leading to ultimate bearing failure.
Installation & Maintenance
cover caps. Apply a film of non-setting
Standard regreasing facilities
jointing compound on bare machined
Type
Metric
NEMA
Regreasing
facility
63-180*
56-286
on request
200-355
324-587
standard
• No excessive vibration
protection.
• No loose fasteners
4) Fit flange ring onto spigot positioning fixing holes,
flange hole positions.
5) Bolt ring into position, using the same
Lubrication procedure
The following procedure should be adopted:
1) Wipe clean the grease gun fitting and the
size socket head bolts as used on the feet.
These are supplied with the flange ring kit.
6) Tighten the bolts to correct torque.
Some motors will have one way grease
• Cables and earth are sound
• Sealing of the motor and gland plate in
good condition
• Insulation resistance adequate, imperative
this
is checked after a prolonged shut-down
• Regrease required, particularly large
output 2 pole motors
• Bearing condition
regions around the motor grease fittings.
2) Remove the grease relief plug if fitted.
lugs/eyebolts
surfaces for sealing and corrosion
where applicable, to provide either BS or DIN
* Bearings are double shielded and pre-packed
with grease for life
• No significant corrosion of the lifting
Change from ball/ball to roller/ball construction
200 - 355 ~ 324T - 586 frame
Note:
Smoke extraction motors or motors on safety
valves which should be left in place.
1) Isolate motor before commencing work.
critical applications should be rewound, to the
approximately 4 to 10 shots depending
2) Remove fan cover and fan.
original specification, after 40,000 hours of oper-
on frame size.
3) Remove bearing cap screws.
ation. If variable speed employing unipolar
4) Remove endshield at both ends.
switching the period is reduced to 30,000 hours
minutes in order that excess grease may
5) Remove bearing circlips at both ends.
and reduced again to 20,000 hours for bipolar
be expelled before refitting the relief plug.
Bearings fitted with rotating grease relief
6) Remove preload washer at non-drive end.
7) Replace drive end ball bearing with new
switching. In all cases refer to your supplier.
3) Add a small quantity of grease,
4) Allow motor to run for approximately 10
or through grease valves will relieve
automatically. Grease may not be
expelled from the motor during filling due to
internal cavities/pipes filling or relief via seals.
5) On initial start up or after relubrication,
‘bearing noise’ may result from the new
grease moving around the bearing. This
noise is normal and will disappear after a
few hours of running.
Bearing change
When fitting new bearings, the parts should be
lightly lubricated with grease.
roller bearing and refit circlip.
8) Remove non-drive end ball bearing and
inner bearing cap.
9) Fit new non-drive end inner bearing cap
be eased off their spigots.
10) Examine existing non-drive end ball
bearing and either refit or replace.
stator, taking care not to damage the stator bore
12) Re-pack bearings with new grease in
and both stator and rotor windings.
accordance with recommendations.
13) Ensure the lip on both oilseals is
Having dismantled the motor, maintenance can be
greased.
a)
b)
c)
carried out to remove all dirt. For this purpose, the
use of an air line supplying dry compressed air
spacer O/D is the same
under comparatively low pressure is best, as a high
as the bearing O/D
velocity airstream can force dirt into the spaces
bearing spacer supplied is fitted into
between the windings and insulation etc. Grease-
the non-drive end and endshield
removing solvents should only be used very sparing-
bearing recess
ly to avoid damage to impregnating varnish or insu-
slots in inner bearing caps are
lation.
aligned with endshield grease chutes
d)
correct location for bearing cap by
Motors should be re-assembled in the reverse order
e)
the use of a stud
bolts are torqued up to
from dismantling, remembering to ease endshields
onto bearings and spigots. Do not use force. On re-
recommended figures
assembly oilseals to mating faces should be lubricat-
should be taken.
The bearing should then be quickly slipped into
ed. If oilseals are worn or damaged during disman-
place, ensuring that the bearing is in contact with the
shaft shoulder.
The rotor can now be carefully withdrawn from the
11) Refit non-drive end bearing circlip.
tion heating. The temperature must be controlled to
120°C maximum. Suitable handling precautions
sion. Loosen and remove bearing cover screws and
endshield bolts/studs. The endshields should then
On larger motors, it is easier to raise the temperature of the bearing using an oil bath, oven or induc-
clamped, pinned or knurl located to the shaft exten-
drive end inner bearing cap.
sure on the inner race only using a short length of
tube placed over the motor shaft.
Remove the fan cover and the fan which is keyed,
with shallow recess (identical to existing
14) Refit both endshields and check that:
The bearing should be driven onto the shaft by pres-
Periodic maintenance
Maintenance
tling then they should be replaced before continuing.
Ongoing maintenance
When cool, ensure that the bearing is clean and
Induction motors by their very nature require very lit-
Before starting the motor, check that the rotor
charge the bearing with the recommended quantity
tle maintenance. However a regular regime of
revolves freely. Ensure that the electrical connec-
of grease. Bearings and housings should be approx-
inspection is recommended to ensure minor prob-
tions are correct and terminal nuts tight (see section
imately a quarter full.
lems do not escalate to breakdowns. Typical inter-
- Electrical Connection).
vals would be 2000 hours of operation or 3 months,
Fitting flange adaptor (where applicable)
whichever is the sooner.
Spares and repairs
1) If required, remove foot as detailed in
terminal box position change.
Checklist:
When ordering spares, it is important to state the
motor serial number to ensure that the correct
2) If required, reposition terminal box and
• No visible damage, ie fans cracked, fan
spares will be supplied.
lifting lugs.
3) Clean paint off the drive end endshield
spigot and remove all the plastic bolt-hole
4
cowls bent, foot cracked etc
• No accumulation of dust or fibres on the
frame or around the fan inlet
Installation & M a i n t e n a n c e
Notes
Fixing bolts, nuts, studs, screws, spacers or washers
Contact must be made prior to any remedial action
are not included with these parts and, if required,
being taken under warrantee
should be clearly specified on the order in addition to
the part description number. The fixing duty and part
Please quote the motor serial number in all such
description reference number for which they are
cases with full details of the problem.
required, should also be clearly stated.
Exploded view of a typical standard ac motor
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
5
Part description
Flange endshield
Endshield fixing bolt
Drive end endshield
Rotor assembly
Flinger (when fitted)
Drive end oil seal (when fitted)
Preload washer
Drive end bearing
Stator assembly with or without feet
Eyebolt (when fitted) or dual lifting lug
Bearing retention circlip
Non-drive end bearing
Non-drive end endshield
Endshield fixing bolt
Bearing circlip
Ref
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
Part description
Non-drive end oilseal (when fitted)
Fan
Fan circlip
Fan cover
Fan cover screw and washer
Foot fixing bolts and washer (where applicable)
Feet
Terminal board (when fitted)
Terminal box to frame gasket
Terminal box
Internal earth terminal
Terminal box lid gasket
Terminal box lid
Pad mounting bracket
Face endshield
Bearing Information
Bearing references and oil seals for horizontally-mounted motors only
IEC Type
Bearings(1)
Oil seals(2)
European
BS
Polarity
Drive end
Non-drive end
Drive end
63
63
All
62022Z
62022Z
71
80M
71
80M
All
All
60032Z
62042Z
60032Z
60032Z
15 x 24 x 5(3)
17 x 28 x 6(3)
20 x 30 x 7(3)
15 x 24 x 5(3)
17 x 28 x 6(3)
15 x 24 x 5(3)
90S/L
90S/L
All
62052Z
62032Z
100L
100L
All
62062Z
62052Z
25 x 35 x 7(3)
30 x 42 x 7(3)
17 x 28 x 6(3)
25 x 37 x 7(3)
112M
112M
All
62062Z
62052Z
132S/M
132S/M
All
62082Z
63052Z
30 x 42 x 7(3)
40 x 52 x 7(3)
25 x 37 x 7(3)
25 x 37 x 7(3)
160M/L
180M/L
160M/L
180M/L
All
All
63092Z
63102Z
63072Z
63082Z
45 x 60 x 8(3)
50 x 65 x 8(3)
35 x 47 x 7(3)
40 x 52 x 7(3)
200LX
200LX
All
6312
6312
225S
225S
All
6313
6313
225M
225M
All
6314
6314
250ME
250S
2
6314
6314
60 x 80 x 8(3)
65 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
60 x 80 x 8(3)
65 x 90 x 10 (4)
70 x 90 x 10 (4)
70 x 90 x 10 (4)
280SE
250M
315SE
280M
315ME
315S
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
315M
315M
315L
315L
355S/M/L
355S/M/L
6316
6314
6318
6314
6318
6316
6319
6316
6319
6316
6319
6316
6319
6316
6324
80 x 110 x 10(3)
70 x 90 x 10 (4)
280S
6316
6314
6318
6314
6318
6316
6319
6316
6319
6316
6319
6316
6319
N316
N324
80 x 110 x 10(3)
70 x 90 x 10(4)
280ME
4 up
2
4 up
2
4 up
2
4 up
2
4 up
2
4 up
2
4 up
2
4 up
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
75 x 100 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
70 x 90 x 10 (4)
90 x 120 x 12 (3)
75 x 100 x 10 (4)
Non-drive end
115 x 145 x 14(3) 115 x 145 x 14(3)
(1) Frame sizes 80 and 90 have bearings with CN clearances, frame sizes 100 to 355 have bearings with C3 clearance ‘medium’ series
(2) Sizes given are in mm, and represent bore x outside diameter x width
Material: (3) Nitrile rubber (4) Silicon rubber
Bearing references and oil seals for horizontally-mounted motors only
NEMA Type
Frame
56
143/5T
182/4T
213/5T
254/6T
284/6T
324T
326T
364T
365T
404/5T
444/7T
504/5
(1)
(2)
6
Bearings(1)
Oil seals (2)
Polarity
Drive end
Non-drive end
All
All
All
All
All
All
All
All
All
2
4 up
2
4 up
2
4 up
2
4 up
62042Z
62052Z
62062Z
62082Z
63092Z
63102Z
6312
6313
6314
6314
6316
6314
6318
6316
6319
6316
6319
60032Z
62032Z
62052Z
63052Z
63072Z
63082Z
6312
6313
6314
6314
6316
6314
6318
6316
6319
6316
6319
Drive end
15 x 24 x 5(3)
17 x 28 x 6(3)
30 x 42 x 7(3)
40 x 52 x 7(3)
45 x 60 x 8(3)
50 x 65 x 8(3)
60 x 80 x 8(3)
65 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
90 x 120 x 12 (3)
70 x 90 x 10(4)
90 x 120 x 12 (3)
90 x 120 x 12 (3)
90 x 120 x 12 (3)
Non-drive end
15 x 24 x 5(3)
17 x 28 x 6(3)
25 x 37 x 7(3)
25 x 37 x 7(3)
35 x 47 x 7(3)
40 x 52 x 7(3)
60 x 80 x 8(3)
65 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
70 x 90 x 10(4)
90 x 120 x 12(3)
70 x 90 x 10(4)
90 x 120 x 12(3)
90 x 120 x 12(3)
90 x 120 x 12(3)
Frame sizes 56 to143/5T have bearings with CN clearances, frame sizes 182T to 505 have bearings with C3
clearance ‘medium’ series
Sizes given are in mm, and represent bore x outside diameter x width
Material: (3) Nitrile rubber (4) Silicon rubber
Connection Diagrams - IEC Frames
7
Connection Diagrams - NEMA
8
Fault Finding - Three Phase Induction Motors
Motor will not start
Supply or starter trips out at
start
1. Fault with supply.
1. Check for correct voltage at
motor terminals.
2. Motor or load locked up.
2. Make sure motor and load
are free to turn.
3. Wrong connection in control 3. Check to ensure contactors
circuit.
operate.
1.. Fit new fuses, reset circuit
breakers, etc.
2. Remove clamps, locks etc.
1. Wrong or loose
connections.
1. Fix up connections.
1. Check all lugs are properly
crimped or soldered, and
connections are tight.
2. Motor overloaded.
2. Check load performance
data against motor
performance data.
3. Inertia of load too high.
3. Measure voltage at motor
terminals while motor starting.
4. Low voltage due to volt drop 4. Check settings of overload
in cables.
and circuit breaker and allow
for starting current.
5. Overload or circuit breaker
incorrectly set or sized.
Motor starts but has no torque. 1. Incorrect connection.
Motor does not reach full speed
or takes a long time to
2. Delta wound motor
accelerate
connected in star.
1. Check connection diagram
and nameplate data.
2. Check load performance
data against motor
performance data.
3. Star/Delta starter staying in 3. Measure voltage at motor
star.
terminals while motor starting.
3. Sort out control circuit.
2. Change motor for correct
size.
3. Change cables for correct
size.
4. Correct setting of overload
or breaker or change.
1. Sort out and correct
connections.
2. Check timer and starter
control circuit.
3. Change motor for correct
size.
4. Inertia of load too high.
5. Motor overloaded.
4. Change cables for correct
size.
6. Low voltage due to drop in
cables.
Motor overheating
1. Motor overloaded.
2. Ineffective cooling.
Temperature of air.
Look for build up of dirt
3. Excessiive ambient.
4. Wrong connections.
5. Delta wound motor in star.
6. Motor ‘Single Phasing”.
1. Check load performance
data.
2. Check fan and air flow.
1. Fix problem with load or fit a
larger motor.
2. Clean motor. Sort out cool
ing of air temp. and flow.
3. Check connection diagram
and nameplate data.
4. Check volts and amps on all
three phases.
5. Check nameplate
3. Sort out connections.
6. Check phase to phase
voltage accurately.
6. Balance supply or accept
unbalance
1&2. Check connection
diagram
1&2. Sort out and correct
connections at motor terminals.
3. Measure voltage at motor
terminals.
3. Connect supply voltage.
4. Restore supply to all phases
5. Correct voltage or frequency
7. Wrong voltage or frequency.
8. Supply voltage unbalanced.
No load amps in excess of full
load amps.
1. Incorrect connection.
2. Star wound motor
connected Delta.
3. Voltage in excess of
nameplate.
4. Motor supplied for a
4. Compare supply voltage and
different voltage or frequency. frequency to nameplate.
9
4. Change motor for correct
voltage and frequency.
Fault Finding - Three Phase Induction Motors
Mechanical noise or vibration.
Noisy bearings. Bearings
overheating
1. Thrust from load or
misalignment..
1. Check gaps between cou
pling halves and alignment.
1. Re-align couplings.
2. Damaged bearings, too
much grease, no grease, or
foreign matter in grease.
2&3. Turn shaft slowly by hand 2&3. Clean bearing housing,
change bearings and repack
and feel for roughness or
stiffness. Check for bent shaft with fresh grease.
or fan rubbing.
3. Rotor pulling or foreign
matter in air gap.
4. Out of balance load,
coupling or pulley.
5. Excessive belt pull.
Motor amps in excess of
nameplate full load amps on
load.
4. Run motor disconnected
from load and then with pulley
or coupling removed.
5. Run motor without belts.
4. Fix up out of balance items.
5. Loosen belt tension.
6. Motor foundations not ridgid 6. Check design and
construction foundations.
performance data.
6. Increase strength of
foundations.
1. Motor overloaded
1. Check load and
performance data.
2. Measure voltage at motor
terminals.
3. Check nameplate data.
1. Fix problem with load or fit
larger motor.
2. Fix problem, maybe with
larger cables.
3. Correct voltage or frequency
4. Wrong connections.
4. Check nameplate data..
4. Sort out and correct.
5. Motor “Single Phasing”.
5&6 Check volts and amps in
all three phases.
5&6 Resore balanced supply
to all three phases.
2. Low voltage supply
3. Wrong voltage and
frequency.
6. Supply voltage unbalanced
Excessive electrical noise
7. Motor speed not matched to 7. Measure motor speed and
load.
check load requirements.
1. Wrong connections
1. Check connections.
7. Change motor for correct
motor speed.
1. Fix connections.
2. Wrong voltage.
2. Check voltage with
nameplate.
3. Check volts and amps on all
three phases.
1. Measure phase to phase
voltage accurately.
2. Correct voltage.
1. Watch shaft rotation.
1. Swap any two phases of
supply.
3. Motor “Single Phasing”
Unbalanced amps in different
phases when motor loaded
1. Unbalanced power supply.
Motor runs in wrong direction
1. Wrong connections.
10
3. Restore supply to all phases
1. Balance supply or accept
unbalance
Customer Service
CALL TOLL FREE - NORTH AMERICA:
1-800-463-8917
OR
1-800-668-6779
FAX:
416-675-6885
847-253-9880
Quebec only:
1-888-668-9843
Fax:514-636-4253
www.brookcromptonna.com
Every care has been taken to ensure the accuracy
of the information contained in this publication, but,
due to a policy of continuous development and
improvement the right is reserved to supply
products which may differ slightly from those
illustrated and described in this publication
Brook Crompton
264 Attwell Drive
Toronto, Ontario M9W 5B2
Tel: 416 675-3844
Fax: 416 675-6885
Internet: www.brookcromptonna.com
Printed in Canada
15/09/04 - 2004.W.OI Issue 1
© Copyright 2002. Brook Crompton. All rights reserved
Issue Date : 2011-09-30
Z - Electric Heaters
Electric Space Heaters
Electric space heaters can be mounted in one of two ways. Unit-mounted heaters are mounted inside the unit
or on the supply air opening. Remotely mounted heaters are mounted in the duct-work and are not supplied by
Seresco Technologies Inc. Electric heaters are offered in single or dual point power connection options. Single
point power means that a single power line is feeding both the electric heater and the unit. Power is brought to
the a power distributor block in the heater from which the unit is powered. This configuration is standard for
unit-mounted residential installations. A dual point power configuration means that the unit and electric heater
are powered from different sources. This is standard for larger installations. Refer to the unit nomenclature
located on the label to see which configuration is used for your unit.
The heater is controlled by an external signal, typically either dry contact, 24VAC power or 0-10 VDC signal,
but this may vary depending on the installation. Each heater is equipped with two bi-metal thermal switches to
protect heating elements from overheating (See Wiring Diagram). During installation, connection or servicing
exercise caution. Refer to local electrical codes and manufacturer's instructions when working with electric
heaters.
Staged Electric Heaters
Electric heaters can come in either single stage or two stage configurations. Single stage electric heaters energize
an external (closed contact) electric heater contactor, providing full output. These heaters are typically used for
small kW applications. Two stage electric heaters split the signal into two separate contacts which each
energize separate stage contactors. This gives better control over heater output (i.e. 50% or 100%) based on
temperature requirements.
Modulating Electric Heaters
Modulating electric heaters use both the modulating (SCR) and the fixed step controller to ensure precise
temperature control and high efficiency. Heater total output is divided between up to nine stages, including an
SCR modulating stage. The modulating heating stage, usually 25% larger than the other heating stages, is
proportionally controlled by CRISTAL CONTROLS SCR and the other heating stages are controlled by the
electronic step controller.
Based on an external control signal (usually 0 – 10 VDC), the step controller activates step controlled stages one
after another as needed. The SCR stage automatically fills the gaps between step controlled stages providing
fully proportional control over the heaters entire kW range.
1
Z - Electric Heaters
Figure 1 : Single Phase 2 Stage Electric Heater
Figure 2 : Three Phase 2 Stage Electric Heater
2
Issue Date : 2011-09-30
Issue Date : 2011-09-20
Z - Electric Heaters
Figure 3 : Modulating Electric Heater
3
Z - Electric Heaters
Technical Sheet – Steps Controller
Models:
CCE-4 : 4 ON/OFF stages + 1 SCR stage
CCE-8 : 8 ON/OFF stages + 1 SCR stage
Power supply
24 Vac, 1 VA
Outputs (ON-OFF stages)
1 Amp max., 120Vac max.
Zero SCR
Adjustable
Span SCR
Adjustable
Span input
Adjustable (Min 2 ON/OFF + 1 SCR)
Input signal
0-135 Ohms, 0-10 Vdc, 0-5 Vdc,
4@20mA
Operation temperature
- 40 to +160 �(- 40 @ +72 �)
Storage temperature
- 40 to +160 �(- 40 @ +72 �)
Dimensions : CCE-4
210 mm X 56 mm X 30 mm
8 1/4” X 2 3/16’’ X 1 3/16’’
Dimensions : CCE-8
210 mm X 108 mm X 30 mm
8 1/4” X 4 1/4” X 1 3/16”
Figure 4 : CCE Control Wiring
4
Issue Date : 2011-09-30
Z - Electric Heaters
Issue Date : 2011-09-20
Control signal:
0 – 10 VDC:
put a jumper between pins 4 and 5,
bring control signal to pins 2 and 6 (pin 2 must be a ground, DCC, pin 6 is a 0-10 VDC signal)
4-20 mA:
put a jumper between pins 2 and 5,
bring control signal to pins 2 and 5 (pin 2 must be a ground)
24 VAC power supply:
24 power: Pin 8
24 com:
Pin 1 (pin 1 must be grounded)
Stages control:
SCR (modulating): Pins 9 and 10 (see diagram)
ON/OFF (steps):
Respective pairs 11-12, 13-14 etc
5
Z - Electric Heaters
Issue Date : 2011-09-30
Adjustment Procedure
Note that CCE step controllers are adjusted upon installation. If it is determined that an adjustment is necessary,
follow the following procedure.
Potentiometers' functions:
“SPAN D'ENTREE”
- Used to adjust/enable number of stages/steps
“SPAN DU SCR”
- Used to adjust the SCR's span between two stages. To adjust, turn clockwise
“ZERO DU SCR”
- Used to set the starting (zero) point of the SCR
1. Set the step controller to the desired mode (0-10 VDC or 4-20mA).
2. Set the control signal to 50%.
3. Adjust the “Span d’entrée” until half the stages are lit.
4. Set the control signal at 100% and ensure all stages are lit, readjusting the “Span d’entrée” if needed.
5. If adjustments were necessary at point 4, repeat points 3 and 4 until no further adjustment is needed.
6. Set the control signal at 50% and, if necessary, adjust the “Zéro du SCR” to obtain a 50% modulation output.
7. Set the control signal at 0% and make sure that all stages and the modulating output are off. If the modulating
output does not turn off decrease “Span du SCR” and bring back the control signal to 50%. If needed adjust the
“Zéro du SCR” to obtain a 50% modulation output.
8. Set the control signal at 100% and make sure all stages and the modulating output are open (without modulation).
If the modulating output is still modulating, increase the “Span du SCR” , bring back the control signal to 50% and
if needed, re-adjust the “Zéro du scr” to obtain a 50% modulation on the modulating output.
9. If adjustments were necessary at point 8, repeat points 7 and 8 until no further adjustment is required.
10. Finally, set the control signal at 0% and make sure all stages are off. Set the control signal at 100% and make
sure all stages gradually turn on. Between each stage, the modulating output should be modulating from 0% to
100%. Also make sure that the modulating output does not take too long to begin after a stage kicked in or reaches
the 100% too quickly before the next stage kicks in. In the event that the modulating output is not acting
progressively (too long to begin or reaches 100% too quickly), increase the “Span du SCR” and repeat procedure
from point 6.
6
Ball Valve Product Data
Technical Data/Submittal
Three-way Threaded Equal Percentage Ball Valves with
Fail-safe Actuators
NEMA 4
Perfection is Our Drive
Valve Specifications
Static Pressure/Temp:
360 PSI / 250°F (600 WOG)
Service:
Chilled water, hot water, up to 50% Glycol
Flow Characterizing Disc:
Glass Filled Polymer
Body Material:
Forged Brass ASTM B283
End Connections:
Brass NPT
Stem:
Brass
Stem Seals:
EPDM O-Rings
Ball:
Nickel-plated brass
Ball Seals:
Teflon Seals with EPDM O-Rings
Angle of Rotation:
0–90°
Three-way valve coil and bypass
streams flow simultaneously
through the ball. Bypass Cv is
always 80% of coil Cv so there is
always enough pressure drop in
bypass mode. Three-way overflow problems are eliminated.
E
Dimensions
(nominal)
(measured in inches unless noted)
Flow characterizing disc:
Equal percentage flow
mirrors equal percentage coil
characteristic.
F
B
B
G
G
F
Molded from GE NORYL,
a blend of a polymide with
reinforced modified polymer
PPE for retention of mechanical
properties, chemical resistance,
and dimensional stability.
A
A
C
C
A: Length
B:HEIGHT
C:LENGTH
F:HEIGHT
G:HEIGHT
FNPT
FNPT
D:DEPTH
SIZE
FNPT
FNPT
FNPT
(NOT SHOWN)
0.5
2.6
2.9
6.5
3.0
7.5
2.4
0.75
2.8
2.9
6.6
3.0
7.5
2.0
1
2.8
3.3
6.6
3.0
7.5
2.0
1
3.0
3.4
6.7
3.0
8.0
2.6
1
4.2
3.6
7.3
3.0
9.0
3.3
1.25
3.0
3.4
6.7
3.0
8.0
2.5
1.25
3.6
3.6
7.0
3.0
8.6
2.8
1.5
3.5
3.6
7.0
3.0
8.8
2.8
1.5
4.0
4.1
7.2
3.0
9.6
3.3
2
4.0
4.1
7.2
3.0
9.7
3.3
2
5.0
4.5
7.7
3.0
10.8
3.8
2.5
5.3
4.8
7.8
3.0
11.0
4.0
Because the disc is press fit
into the ball where flow exits,
the valve is able to modulate
where differential pressure is
over 160 psi without affecting
the disc.
Tapered shape means the
back of the disc is too large to
be forced through the ball’s
port.
Good chemical resistance to:
alcohol, alkalis (base), cooling
and heating system liquids
(ethylene and propylene glycol),
chlorinated water, detergents/
cleaners. Poor chemical
resistance to acids (high
concentration), hydrocarbons,
ketones, phenol.
©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 07-11/01/07-15
Ball Valve Product Data
Technical Data/Submittal
Three-way Threaded Equal Percentage Ball Valves with
Fail-safe Actuators
NEMA 4
Perfection is Our Drive
Select valve body (B3B.5-0.33N), then actuator (BSP-35A1U). Part no.: B3B.5-0.33N+BSP-35A1U.
3-Way Valve
Cv
(1∆P)
Full
Port
Fail-safe Actuator, 24 VAC
Floating
0/2-10 VDC
Point
BSP-35A1U BSP-35F1U BSP-35P1U
On/off
Size
Close-off
Please check valve/actuator
choice below
B3B.5-0.33N
B3B.5-0.59N
B3B.5-1.0N
B3B.5-2.4N
B3B.5-4.3N
B3B.5-8.0N
B3B.75-0.40N
B3B.75-0.66N
B3B.75-1.4N
B3B.75-2.4N
B3B.75-3.8N
B3B.75-11N
B3B1-0.40N
B3B1-0.65N
B3B1-1.3N
B3B1-2.3N
B3B1-3.5N
B3B1-10N
B3B1-8.6N
B3B1-22.3N
B3B1-14.9N
B3B1-4.5N
B3B1-30.8N
B3B1.25-19.4N
B3B1.25-12.7N
B3B1.25-4.1N
B3B1.25-8.7N
B3B1.25-34.1N
B3B1.25-26.8N
B3B1.5-13.4N
B3B1.5-4.0N
B3B1.5-8.3N
B3B1.5-32.0N
B3B1.5-23.5N
B3B1.5-61.1N
B3B2-23.9N
B3B2-56.7N
B3B2-38.2N
B3B2-108.5N
B3B2-82.6N
B3B2.5-38.1N
B3B2.5-74.1N
B3B2.5-99.5N
0.33
0.59
1.0
2.4
4.3
8.0
0.40
0.66
1.3
2.4
3.8
11
0.40
0.65
1.3
2.3
3.5
10
8.6
22.3
14.9
4.5
30.8
19.4
12.7
4.1
8.7
34.1
26.8
13.4
4.0
8.3
32.0
23.5
61.1
23.9
56.7
38.2
108.5
82.6
38.1
74.1
99.5
X
X
X
X
X
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
3/4”
3/4”
3/4”
3/4”
3/4”
3/4”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1”
1-1/4”
1-1/4”
1-1/4”
1-1/4”
1-1/4”
1-1/4”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
2”
2”
2”
2”
2”
2-1/2”
2-1/2”
2-1/2”
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
50 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
40 psi
Piping Configurations
AB
A
B
Mixing - fluid enters through two inlets (A,B)
and exits through one outlet (AB)
Accessories. Add to list price (part no. example).
Single aux. switch (B3B3-49N+BSP-35P1U+AB-AS1)
Double aux. switch (B3B3-49N+BSP-35P1U+AB-AS2)
1,000 Ohm Potentiometer (B3B3-49N+BSP-35P1U+AB-P1K)
10,000 Ohm Potentiometer (B3B3-49N+BSP-35P1U+AB-P10K)
Options. Add to list price (part no. example). Call for delivery.
120/230 VAC power supply (B3B3-49N+BSP-35P2U)
AB
A
Stainless steel stem (B3S3-49N+BSP-35P1U)
Integrated 5,000 Ohm pot. (B3B3-49N+BSP-35P1U-P5K)
Integrated 4-20 mA working range (B3B3-49N+BSP-35P1U-I20)
10-ft cable (B3B3-49N+BSP-35P1U-C3M)
Note: For Actuator Detail, See Fail-Safe Actuator Product Data, Tab #4
B
Diverting - fluid enters through one inlet (AB)
and exits through two outlets (A,B)
©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 07-11/01/07-16
Ball Valve Product Data
Flow Rates
Three-way Threaded
1 These valves are full port and do not have the linearizing insert.
2 Close-off pressures measured with 35 in-lb. actuator. The close-off pressure is the maximum allowable pressure drop
across the valve body when the valve is fully closed.
3 Cv is defined as the quantity of water in GPM at 60°F that will flow through a given valve with a pressure drop of 1PSI. The 1.0 PSI pressure differential column in the table below is equivalent to the Cv value.
Perfection is Our Drive
FLOWRATE (GPM) @ DIFFERENTIAL PRESSURE (PSI)
LINE
SIZE
MODEL
NO.
FULL1
PORT
CLOSEOFF∆P 2
2-Position
HVAC Apps
HVAC Modulating Applications
Cv3
1/2”
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
7.0
B3B.5-0.33N
0.2
0.33
0.4
0.5
0.5
0.6
0.6
0.7
0.7
0.7
0.9
1.0
B3B.5-0.59N
0.4
0.59
0.7
0.8
0.9
1.0
1.1
1.2
1.3
1.3
1.6
1.9
0.7
1.0
1.2
1.4
1.6
1.7
1.9
2.0
2.1
2.2
2.6
3.2
B3B.5-1.0N
50 PSI
B3B.5-2.4N
B3B.5-4.3N
3/4”
3.8
4.2
4.5
4.8
5.1
5.4
6.3
7.6
6.8
7.4
8.0
8.6
9.1
9.6
11.4
13.6
8.0
9.8
11.3
12.6
13.9
15.0
16.0
17.0
17.9
21.2
25.3
0.40
0.5
0.6
0.6
0.7
0.7
0.8
0.8
0.9
1.1
1.3
B3B.75-0.66N
0.5
0.66
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.7
2.1
B3B.75-1.4N
0.9
1.3
1.6
1.8
2.1
2.3
2.4
2.6
2.8
2.9
3.4
4.1
50 PSI
B3B.75-2.4N
•
1.7
2.4
2.9
3.4
3.8
4.2
4.5
4.8
5.1
5.4
6.3
7.6
2.7
3.8
4.7
5.4
6.0
6.6
7.1
7.6
8.1
8.5
10.1
12.0
34.8
7.8
11.0
13.5
15.6
17.4
19.1
20.6
22.0
23.3
24.6
29.1
B3B1-0.40N
0.3
0.40
0.5
0.6
0.6
0.7
0.7
0.8
0.8
0.9
1.1
1.3
B3B1-0.65N
0.5
0.65
0.8
0.9
1.0
1.1
1.2
1.3
1.4
1.5
1.7
2.1
B3B1-1.3N
0.9
1.3
1.6
1.8
2.1
2.3
2.4
2.6
2.8
2.9
3.4
4.1
B3B1-2.3N
1.6
2.3
2.8
3.3
3.6
4.0
4.3
4.6
4.9
5.1
6.1
7.3
50 PSI
B3B1-10N
2.5
3.5
4.3
4.9
5.5
6.1
6.5
7.0
7.4
7.8
9.3
11.1
7.1
10.0
12.2
14.1
15.8
17.3
18.7
20.0
21.2
22.4
26.5
31.6
6.1
8.6
10.5
12.1
13.6
14.9
16.1
17.2
18.2
19.2
22.7
27.2
B3B1-22.3N
15.8
22.3
27.3
31.5
35.3
38.6
41.7
44.6
47.3
49.9
59.0
70.5
B3B1-14.9N
10.5
14.9
18.2
21.1
23.6
25.8
27.9
29.8
31.6
33.3
39.4
47.1
B3B1-4.5N
3.2
4.5
5.5
6.4
7.1
7.8
8.4
9.0
9.5
10.1
11.9
14.2
B3B1-30.8N
21.8
30.8
37.7
43.6
48.7
53.3
57.6
61.6
65.3
68.9
81.5
97.4
B3B1.25-19.4N
•
B3B1.25-12.7N
B3B1.25-4.1N
40 PSI
B3B1.25-8.7N
B3B1.25-34.1N
•
13.7
19.4
23.8
27.4
30.7
33.6
36.3
38.8
41.2
43.4
51.3
61.3
9.0
12.7
15.6
18.0
20.1
22.0
23.8
25.4
26.9
28.4
33.6
40.2
2.9
4.1
5.0
5.7
6.4
7.0
7.6
8.1
8.6
9.1
10.7
12.8
6.1
8.7
10.6
12.3
13.7
15.0
16.2
17.3
18.4
19.4
22.9
27.4
107.8
24.1
34.1
41.8
48.2
53.9
59.1
63.8
68.2
72.3
76.2
90.2
B3B1.25-26.8N
19.0
26.8
32.8
37.9
42.4
46.4
50.1
53.6
56.9
59.9
70.9
84.7
B3B1.5-13.4N
9.5
13.4
16.4
18.9
21.1
23.2
25.0
26.7
28.4
29.9
35.4
42.3
B3B1.5-4.0N
2.8
4.0
4.9
5.7
6.4
7.0
7.5
8.1
8.5
9.0
10.7
12.7
B3B1.5-8.3N
5.8
8.3
10.1
11.7
13.1
14.3
15.5
16.5
17.5
18.5
21.9
26.1
101.3
B3B1.5-32.0N
•
40 PSI
22.6
32.0
39.2
45.3
50.6
55.5
59.9
64.0
67.9
71.6
84.7
B3B1.5-23.5N
16.6
23.5
28.8
33.3
37.2
40.8
44.0
47.1
49.9
52.6
62.3
74.4
B3B1.5-61.1N
43.2
61.1
74.8
86.4
96.6
105.8
114.3
122.2
129.6
136.6
161.6
193.2
B3B2-23.9N
16.9
23.9
29.3
33.8
37.8
41.4
44.7
47.8
50.7
53.4
63.2
75.6
B3B2-56.7N
40.1
56.7
69.4
80.2
89.7
98.2
106.1
113.4
120.3
126.8
150.0
179.3
27.0
38.2
46.8
54.0
60.4
66.2
71.5
76.4
81.0
85.4
101.1
120.8
B3B2-108.5N
76.7
108.5
132.9
153.4
171.6
187.9
203
217
230
243
287
343
B3B2-82.6N
58.4
82.6
101.2
116.8
130.6
143.1
154.5
165.2
175.2
184.7
219
261
120.5
40 PSI
B3B2-38.2N
B3B2.5-38.1N
2-1/2”
3.4
6.1
5.7
B3B1-8.6N
2”
2.9
5.3
0.3
B3B1-3.5N
1-1/2”
2.4
4.3
B3B.5-8.0N
B3B.75-11N
1-1/4”
1.7
3.0
B3B.75-0.40N
B3B.75-3.8N
1”
10.0
B3B2.5-74.1N
B3B2.5-99.5N
40 PSI
•
26.9
38.1
46.7
53.9
60.2
66.0
71.3
76.2
80.8
85.2
100.8
52.4
74.1
90.8
104.8
117.2
128.3
138.6
148.2
157.2
165.7
196.1
234
70.4
99.5
121.9
140.7
157.3
172.3
186.1
199.0
211
223
263
315
©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 07-11/01/07-18
Ball Valve Product Data
Flow Rates Adjusted for Piping Geometry
Three-way Threaded
Perfection is Our Drive
Valve
Size
1/2”
Line Size
Through Cv
0.5
0.75
1
0.33
--
0.3
0.3
0.59
--
0.6
0.6
1.0
--
1.0
1.0
2.4
--
2.3
2.3
4.3
--
4.0
3.8
--
8.0
--
7.9
5.7
--
0.40
--
--
0.4
0.4
0.4
--
0.66
0.66
0.66
0.66
3/4”
1”
1-1/4”
1-1/2”
2”
1.25
1.5
1.3
--
1.3
1.3
1.3
2.4
--
2.4
2.39
2.38
3.8
--
3.8
3.74
3.7
11.0
--
2
2.5
3
10.4
9.78
9.4
0.40
--
0.40
0.40
0.40
0.40
0.40
0.65
--
0.65
0.65
0.65
0.65
0.65
1.3
--
1.3
1.3
1.3
1.3
1.3
2.3
--
2.3
2.3
2.3
2.3
2.3
3.5
--
3.5
3.5
3.5
3.5
3.5
4.5
--
4.5
4.5
4.5
4.4
4.4
8.6
--
8.5
8.4
8.3
8.2
8.2
10.0
--
9.9
9.7
9.6
9.5
9.4
14.9
--
14.6
14.1
13.5
13.3
13.1
22.3
--
21.2
19.9
18.4
17.7
17.3
30.8
--
28.0
25.2
22.3
21.1
20.5
4
4.1
--
4.4
4.4
4.4
4.4
4.4
7.7
--
8.3
8.2
8.2
8.2
8.1
8.7
--
14.8
14.5
14.3
14.2
14.0
12.7
--
35.0
31.5
29.6
28.6
27.6
19.4
--
39.0
34.3
31.9
30.7
29.4
34.1
--
79.1
53.3
45.5
42.0
39.0
4.0
--
4.0
4.0
4.0
4.0
8.3
--
8.2
8.2
8.2
8.2
13.4
--
13.3
13.2
13.2
13.1
23.5
--
23.1
22.7
22.4
22.1
32.0
31.0
30.0
29.3
28.6
61.1
54.9
49.7
46.9
44.1
23.9
--
23.8
23.7
23.5
38.2
--
37.8
37.3
36.62
56.7
--
55.5
54.0
52.0
108.5
--
100.7
92.3
83.3
©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 07-11/01/07-20
Fail-Safe Actuator Product Data
Technical Data/Submittal
Electric Actuator Type BE(P)
Electronic Fail-Safe, 88/132 in-lb Minimum Torque, BE NEMA 2 / BEP NEMA 4
Protection
Degree
Model
Min. Torque
(in-lb)
Power Supply
24VDC,
120/230VAC
Power
Consumption
Max.
Perfection is Our Drive
Power
Consumption
Damper Area
approx. sq-ft
BE Series
On/Off Control, 90 Second Running Time Drive, 60 Second Running Time Fail-safe
BE-88A1U
BE-88A2U
BEP-88A1U
BEP-88A2U
BE-132A1U
BE-132A2U
BEP-132A1U
BEP-132A2U
NEMA 2
NEMA 2
NEMA 4
NEMA 4
NEMA 2
NEMA 2
NEMA 4
NEMA 4
88
88
88
88
132
132
132
132
24
120/230
24
120/230
24
120/230
24
120/230
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
22
22
22
22
33
33
33
33
Directional Control, 90 Second Running Time Drive, 30 Second Running Time Fail-safe
BE-88D1U
BE-88D2U
BEP-88D1U
BEP-88D2U
BE-132D1U
BE-132D2U
BEP-132D1U
BEP-132D2U
NEMA 2
NEMA 2
NEMA 4
NEMA 4
NEMA 2
NEMA 2
NEMA 4
NEMA 4
88
88
88
88
132
132
132
132
24
120/230
24
120/230
24
120/230
24
120/230
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
22
22
22
22
33
33
33
33
Floating Point Control, 90 Second Running Time Drive, 30 Second Running Time Fail-safe
BE-88F1U
BE-88F2U
BEP-88F1U
BEP-88F2U
BE-132F1U
BE-132F2U
BEP-132F1U
BEP-132F2U
NEMA 2
NEMA 2
NEMA 4
NEMA 4
NEMA 2
NEMA 2
NEMA 4
NEMA 4
88
88
88
88
132
132
132
132
24
120/230
24
120/230
24
120/230
24
120/230
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
22
22
22
22
33
33
33
33
Proportional Control 0/2-10VDC, 90 Second Running Time Drive, 30 Second Running Time Fail-safe
BE-88P1U
BE-88P2U
BEP-88P1U
BEP-88P2U
BE-132P1U
BE-132P2U
BEP-132P1U
BEP-132P2U
NEMA 2
NEMA 2
NEMA 4
NEMA 4
NEMA 2
NEMA 2
NEMA 4
NEMA 4
88
88
88
88
132
132
132
132
24
120/230
24
120/230
24
120/230
24
120/230
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
20.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
9.0VA
12.0VA
22
22
22
22
33
33
33
33
Note: See binder tab no. 5 for actuator accessories/options product data.
Technical Data Electric Actuator Type BE(P)
Characteristic
Nominal voltage
24 V
AC 24 V +/-20%, 50/60 Hz, DC 24 to 36 V +/-10%
120/230 V
AC 90-264 V, 50/60 Hz
Electrical connection
3-ft plenum rated cable, 1/2-inch conduit fitting
Starting current
Synchronization
Rotation direction
Angle of rotation
Manual adjustment
Shaft mounting
.5 A for approx. 40 Sec
+/- 5%
Selectable via switch L/R (CCW/CW) or by L/R mounting
Max. 95°
Standard allen key positioning without disengaging gears
Centered, Ø 0.3in [8mm]-0.8in [20mm]; ◊ 0.2in [6mm]-0.6in [14mm]
90 sec (+/- 5%), during normal operation; independent of load;
Fail-safe operation approx. 30 sec
Mechanical
< 35 dB (A), Fail-safe operation < 60 dB (A)
-22 to +122°F [-30 to +50°C]
-40 to +176°F [-40 to +80°C]
5 to 95% RH non-condensing (excludes NEMA 4 models)
ISO - 9001
Running time
Position indicator
Noise emission level
Ambient temperature
Storage temperature
Humidity
Quality Standard
Agency listings
Weight
Maintenance
(Listing for all 120/230 V power supply models is pending)
Elodrive type BE(P) actuators
are designed and produced
for long lasting, reliable and
quiet operation of air control
dampers and temperature
control valves. BE(P) type
actuators feature EloSafeTM
electronic fail-safe technology which uses goldcap
capacitors to drive the actuator to the fail-safe position in
the event of an interruption
of power. EloSafe capacitors
store six times the energy
required to drive the actuator
to the fail-safe position under
full torque load. Thermal
compensation allows EloSafe
actuators to deliver the full
rated torque even at the
lowest ambient temperature
rating. A universal selfcentering mounting clamp
and anti-rotation strap are
included with all models.
All Elodrive models feature
durable Elodrive brushless DC
motor technology and easy
manual positioning.
Highlights of the EloSafe
series of actuators:
100% self-locking even
without voltage.
Full specified torque through out the entire 90°
fail-safe function
Remains in a defined
fail-safe position with 100% self-locking
Fail-safe function also
possible when control signal (2-10 V) is missing
2.1 lb [950 g]
Maintenance free
©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 04-11/01/07-7
Fail-Safe Actuator Product Data
Technical Data Electric Actuator Type BE(P)
On/Off
Wiring schematics
On/Off
black
white
red
black
Directional
Wiring schematics
Directional
black
white
red
black
light blue
light blue
Floating Point
Wiring schematics
Floating Point
black
white
red
black
light blue
light blue
green
green
Proportional 0/2-10 V
Input signal
0-10 V or 2-10 V selectable via switch
Input impedance
>100 kΩ
Output signal
DC 0/2-10 V for 0-100%
white
black
Wiring schematics
Proportional 0/2-10 V
black
red
light blue
light blue
yellow
green
gray
Standard delivery includes:
0.3[6.5]
0.3[6.5]
0.9
[22.8]
Position indicator
Centric clamp adaptor
Mechanical rotation limit stops
Allen key
Operation manual
2.4 [60]
3.1 [7.9]
0.7
[19]
6.8 [173.6]
2.6 [66.6]
0.3 [6.5]
2.1 [53.6]
0.3[6.5]
All Dimensions in inches and metric [mm]
Anti-rotation strap
7.6 [194]
7.8 [199]
©Elodrive USA • 866-356-3748 • www.elodriveusa.com • Content subject to change without notice • Doc No.: 04-11/01/07-8
Solenoid Valves
200RD Model
2
1
R-11
R-12
R-22
R-113
R-114
R-115
R-123
R-124
R-125
R-134a
R-401A
R-401B
R-402A
R-402B
R-404A
R-407A
Coil
Model
100RB
200RB
R-407B
R-407C
R-410A
R-500
R-502
R-507
240RA
500RB
540RA
AH
DM
MM
ASC2
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
ü
Refrigerant Compatibility
Verify Coil
Compatibilidad con Refrigerantes
Verifique la Bobina
Verifique a bobina
Compatibilidade do Refrigerante
Vérifier la bobine
Compatibilité du réfrigérant
3
AM
4
5
Do Not Bend Enclosing Tube
Flow Follows Arrow
Valve Orientation
No doble el casquillo del Embolo de la Aguja
El Flujo sigue la Flecha
Orientación de Válvulas
Não danifique o tubo de apoio da bobina
Barra Indica Posição do Fluido
Orientação da Válvula
Ne pas plier le tube
L’écoulement doit suivre la flèche
Orientation de la valve
6
T < 250°F (121°C)
7
Type T
Solder Techniques
Coil Installation
Técnicas para Soldar
Técnicas de Soldagem
Instalación de la Bobina
Instalação da bobina
Technique de soudure
l’installation de la bobine
9
AM Coil Electrical Data
Maximum Amps
Inrush
Holding
VA
Holding
24/50
2.0
0.96
23
24/60
1.6
0.74
18
Transformer Selection
120/50
0.45
0.21
25
120/60
0.36
0.16
19
Selección del Transformador
208/50
0.19
0.08
17
Selecione transformador capacidade suficiente
Sélection du transformateur
VAC/Hz
208/60
0.15
0.06
12
220/50
0.24
0.10
24
240/60
0.19
0.08
19
480/50
0.11
0.05
24
480/60
0.09
0.04
19
10
11
225 in.-lb.
(25.4 N•m)
200RD 7-12
350 in.-lb.
(39.5 N•m)
t
t
t
t
200RD 2-6
Manual Override
Vástago de Operación Manual
Acionamento manual
Ouverture manuel de la tige
50 in.-lb.
(5.6 N•m)
Disassembly - must use new gasket when
reassembling - retorque per table above
Desmontaje - cuando este remontando usar una nueva
empaquetadora - reajuste utilizando la tabla encima
Desmontagem - quando for remontar é necessário
usar uma nova gaxeta - reaperte utilizando a tabela acima
Désassemblé - doit utiliser un nouveau segment lors du
réassemblage - rétorqué selon la table si dessus
Emerson Climate Technologies and the Emerson Climate Technologies logo are trademarks and service
marks of Emerson Electric Co. © 2004 Emerson Electric Co.
PA-00326 Apr 2009
200RD
Solenoid Valves & Coils
R-410A
The 200RD is a pilot-operated, 2-way, normally closed,
R-410A valve. 200RD valves are used for liquid, discharge, or suction gas refrigerant service.
Features
• One coil fits all valve sizes
• Extended ends for easy installation (standard)
• Long-life molded coils
• PTFE O-ring for superior external sealing
Specifications
• Maximum fluid temperature:
• Maximum working pressure:
• Minimum operating pressure drop:
• MOPD:
• UL/CUL file number:
Options
• Available in 5 orifice sizes
• Manual stem or mounting stud
• Bi-Flow operation-conversion either factory assembled or
with kit except 200RD 7,9 & 12
NOTE:
250°F
680 psig
2 psi
550 psig
MP604
Mounting enclosing tube more than 90o off vertical up
position is not recommended.
Nomenclature example: 200RD 4T3M VLC
200R
D
4
T
3
M
VLC
Valve Series
Design
Series
Port Size
(in 1/16”)
Connection Type
T = Copper Extended Ends
Connection Size
(In 1/8”)
M = manual stem
T = mounting stud
(optional)
Coil*
*NOTE: Valves are shipped without the solenoid coils (VLC = Valve Less Coil). See available coil assemblies.
Ordering Information and Nominal * Liquid Capacity - Tons (kW)
PCN
1
2
Standard
Valve
Mounting
Stud1
Manual
Stem2
Description
Connection Size
066158
066179
–
200RD 2 T 2
1/4 ODF
066159
066180
–
200RD 2 T 3
3/8 ODF
066160
–
–
200RD 3 T 2
1/4 ODF
066161
066182
066203
200RD 3 T 3
3/8 ODF
066162
066183
066204
200RD 3 T 4
1/2 ODF
066163
066184
066205
200RD 4 T 3
3/8 ODF
066164
066185
066206
200RD 4 T 4
1/2 ODF
066165
066186
006207
200RD 4 T 5
5/8 ODF
066166
066187
066208
200RD 5 T 3
3/8 ODF
066167
066188
066209
200RD 5 T 4
1/2 ODF
066168
066189
066210
200RD 5 T 5
5/8 ODF
066169
066190
066211
200RD 6 T 4
1/2 ODF
066170
066191
066212
200RD 6 T 5
5/8 ODF
Add “T” to the end of description for Mounting Stud
Add “M” to the end of the description for Manual Stem
2004FC-118 (Q4/09)
Capacities based on ARI standard.
*See Extended Capacity Tables for ratings at a wide range of conditions.
8
R-410A
3.2 (11.3)
4.5 (15.8)
7.3 (25.7)
7.7 (27.1)
8.8 (30.9)
200RD
Solenoid Valves & Coils
With Extended Ends
With Extended Ends
Valve
2 IN. REQUIRED
FOR COIL REMOVAL
1.77
200RD 2T2
200RD 2T3
200RD 3T2
200RD 3T3
200RD 3T4
200RD 4T4
200RD 4T5
200RD 5T3
200RD 5T4
200RD 5T5
200RD 6T3
200RD 6T4
200RD 6T5
0.85
3.41
0.59
C
A
B
Port Size
1/8
3/16
Valve Repair Kit
Gasket Kit
Gasket Kit KG10025 (PCN 049190)
(contains 12 pieces - each of
PTFE and neoprene O-rings)
Coil Assembly
See coil assemblies for availability.
Bi-Flow Conversion Kit
KS30387 (PCN 066224)
2004FC-118 (Q4/09)
9
1/4 ODF
3/8 ODF
1/4 ODF
3/8 ODF
1/2 ODF
1/4
5/16
3/8
Exploded View
& Parts Kit Data
“K” indicates part is supplied in
valve repair kit KS30386. (PCN 066223)
Conn. Size & Style
5/8 ODF
3/8 ODF
1/2 ODF
5/8 ODF
3/8 ODF
1/2 ODF
5/8 ODF
A
B
2.42
4.62
2.50
3.25
2.31
2.50
3.25
2.31
2.50
3.25
5.00
6.50
4.62
5.00
6.50
4.62
5.00
6.50
C
0.25
0.31
0.25
0.31
0.38
0.50
0.31
0.38
0.50
0.31
0.38
0.50
Technical
Help Guide
Thermal Expansion Valves
Solenoid Valves
System Protectors
Regulators
Oil Controls
Temperature Pressure Controls
Basic Rules of Good Practice
Troubleshooting Guide
2008
Introduction
This Technical Guide from Emerson Climate Technologies provides a detailed explanation on the operation of common refrigeration system components
such as thermal expansion valves, solenoid valves, system protectors, regulators, oil controls and temperature pressure controls. Also included in this guide is
a listing of the basic rules of good practice and a detailed troubleshooting guide.
This guide is designed to fill a need which exists for a concise, elementary text
to aid servicemen, salesmen, students and others interested in refrigeration and
air conditioning. It is intended to cover only the fundamentals of refrigeration and
air conditioning theory and practice. Detailed information for specific products is
available from manufacturers of complete units and accessories. Used to supplement such literature, and to improve general knowledge of refrigeration and air
conditioning, this guide should prove to be very helpful.
Emerson Climate Technologies, a business of Emerson, is the world’s
leading provider of heating, ventilation, air conditioning and refrigeration solutions
for residential, industrial and commercial applications. The group combines bestin-class technology with proven engineering, design, distribution, educational and
monitoring services to provide customized, integrated climate-control solutions for
customers worldwide. Emerson Climate Technologies’ innovative solutions, which
include industry-leading brands such as Copeland Scroll and White-Rodgers,
improve human comfort, safeguard food and protect the environment.
Emerson Climate Technologies - Flow Controls Division is a leading
manufacturer of valves, controls and system protectors commonly applied in
air conditioning and refrigeration systems worldwide. The company continues
to pioneer the control of refrigerant flow through innovative, high performance
components, such as thermal expansion valves and filter driers.
2008
Table of Contents
Thermal Expansion Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Internal Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Factory Setting of TXVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
External Equalizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TXV Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Application Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Balanced Port TXVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
M.O.P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Other TXV Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emerson TXVs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
What are Solenoid Valves? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Principles of Solenoid Operation . . . . . . . . . . . . . . . . . . . . . . . . 15
Types of Solenoids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Emerson Solenoid Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
System Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Filter-driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
HFC Refrigerants and POE Lubricants . . . . . . . . . . . . . . . . . . . 22
Clean-up Procedure for Compressor Motor Burnout . . . . . . . . 25
Emerson System Protectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Suction Line Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Applications of EPRs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Crankcase Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Headmaster Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Liquid Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Oil Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Temperature Pressure Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Basic Rules of Good Practice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2008
Thermal Expansion
Valves
2008
Thermal Expansion Valves
is charged with the same refrigerant as that in the system.
The power assembly pressure (P1), which corresponds to the saturation pressure of the refrigerant gas
temperature leaving the evaporator, moves the TXV pin
in the opening direction.
Opposed to this opening force on the underneath
side of the diaphragm and acting in the closing direction are two forces: the force exerted by the evaporator
pressure (P2) and that exerted by the superheat spring
(P3). In the first condition, the TXV will assume a stable
control position when these three forces are in balance
(P1 = P2 + P3). See figure 1A.
Thermal Expansion Valves
The most commonly used device for controlling the
flow of liquid refrigerant into the evaporator is the thermostatic expansion valve (TXV). Also known as thermal
expansion valves, TXVs are precision devices designed
to regulate refrigerant liquid flow into the evaporator in
exact proportion to evaporation of refrigerant liquid in
the evaporator.
Refrigerant gas leaving the evaporator can be regulated since the TXV responds to the temperature of the
refrigerant gas leaving the evaporator and the pressure in the evaporator. This controlled flow prevents the
return of refrigerant liquid to the compressor. The TXV
controls the flow of refrigerant by maintaining a pre-determined superheat.
An orifice in the TXV meters the flow into the evaporator. Flow is modulated as required by a needle type
plunger and seat, which varies the orifice opening. The
needle is controlled by a diaphragm subject to three
forces:
1. The power element and remote bulb pressure (P1)
2. The evaporator pressure (P2)
3. The superheat spring equivalent pressure (P3)
These forces are shown in Figure 1.
P1 = 45.4 PSIG
If the temperature of the refrigerant gas at the
evaporator outlet (remote bulb location) rises above the
saturation temperature corresponding to the evaporator
pressure as it becomes superheated (P1 greater than
P2 + P3), the TXV pin moves in an opening direction.
When the temperature of the refrigerant gas leaving
the evaporator decreases, the pressure in the remote
bulb and power assembly also decreases and the combined evaporator and spring pressure cause the TXV pin
to move in a closing direction (P1 less than P2 + P3).
For example, when the evaporator is operating with
R-134a at a temperature of 40°F or a pressure of 35
psig and the refrigerant gas leaving the evaporator at
the remote bulb location is 45°F a condition of 10°F
superheat exists. Since the remote bulb and power assembly are charged with the same refrigerant as that
used in the system R-134a, its pressure (P1) will follow
its saturation pressure-temperature characteristics. With
the liquid in the remote bulb at 45°F, the pressure inside
the remote bulb and power assembly will be 40 psig
acting in an opening direction. Beneath the diaphragm
and acting in a closing direction are the evaporator pressure (P2) of 35 psig and the spring pressure (P3) for a
10°F superheat setting of 5 psig (35 psi + 5 psi = 40 psi)
making a total of 40 psig. The TXV is balanced, 40 psig
above and 40 psig below the diaphragm.
P2 = 35 PSIG
P3 = 10.4 PSIG
A
35 PSIG = 40°F
35 PSIG = 40°F
B
C
35 PSIG = 50°F
TXV with internal
equalizer on evaporator with
no pressure drop.
Fig. 1
The following sections describe the operation and application of single-outlet TXVs in two general categories:
internally equalized and externally equalized.
Internal Equalizer
Three conditions are present in the operation of a
TXV:
1. The balanced forces
2. An increase in superheat
3. A decrease in superheat
The remote bulb and power element make up a
closed system (power assembly), and in the following
discussion, it’s assumed that the power assembly
Thermal Expansion Valves
Changes in load cause the TXV pin to move:
• Increasing the superheat will cause the TXV to open
• Decreasing the superheat will cause the TXV to close
External Equalizer
A TXV with an external equalizer is required when the
pressure drop through the evaporator is substantial:
• 3°F for residential air conditioning
• 2°F for commercial air conditioning
• 1°F for refrigeration low temperature range
This is because the pressure drop will hold the TXV
in a fairly “restricted” position and reduce system capacity. The evaporator should be designed or selected for
the operating conditions and the TXV selected and applied accordingly.
For example, an evaporator is fed by a TXV with an
internal equalizer, where a sizable pressure drop of 10
psi is present (See fig. 3). The pressure at point “C”
is 25 psig or 10 psi lower than at the TXV outlet, point
“A”, however, the pressure of 35 psig at point “A” is the
pressure acting on the lower side of the diaphragm in a
closing direction. With the TXV spring set at a compression equivalent to 10°F superheat or a pressure of 10.4
psig, the required pressure above the diaphragm to
equalize the forces is (35 + 10.4) or 45.4 psig. This pressure corresponds to a saturation temperature of 50°F.
The refrigerant temperature at point “C” must be 50°F
if the TXV is to be in equilibrium. Since the pressure at
this point is only 25 psig and the corresponding saturation temperature is 28°F, a superheat of (50°F - 29°F) or
21°F is required to open the TXV.
This increase in superheat, from 10°F to 21°F means
that more of the evaporator surface needs to be used
to produce this higher superheated refrigerant gas. The
evaporator surface available for absorption of heat is reduced and the evaporator is starved before the required
superheat is reached.
Factory Settings of TXVs
The factory superheat setting of TXVs is made with
the TXV pin just starting to move away from the seat.
The superheat necessary to get the pin ready to move is
called static superheat.
TXVs are designed so that an increase in superheat
of refrigerant gas leaving the evaporator is needed for
the TXV pin to open to its rated position.
This added superheat is known as gradient. For example, if the factory static is 6°F superheat, the operating superheat at the rated stroke or pin position (full load
rating of TXV) will be 10°F to 14°F superheat (See
fig. 2).
Manufacturers usually furnish the adjustable type
TXV with a factory static superheat setting of 6°F to
10°F unless otherwise specified.
When using non-adjustable TXVs, it’s important that
they are ordered with the correct factory superheat
setting. For manufacturer’s production lines it is recommended that an adjustable TXV be used in a pilot model
lab test to determine the correct factory superheat setting before ordering the non-adjustable type TXV.
If the operating superheat is raised unnecessarily
high, the evaporator capacity decreases, since more of
the evaporator surface is required to produce the superheat needed to operate the TXV.
A minimum change of superheat to open the TXV is
important because it provides savings in first cost of the
evaporator and cost of operation.
The TXV described so far is internally equalized,
where the evaporator pressure at the TXV outlet is
admitted internally and allowed to exert its force beneath
the diaphragm. In the next section the externally equalized TXV will be discussed.
P1 = 45.4 PSIG
A
P2 = 35 PSIG
P3 = 10.4 PSIG
35 PSIG = 40°F
25 PSIG = 29°F
B
25 PSIG = 50°F
C
TXV with internal
equalizer on evaporator with
10 PSI drop.
Fig. 3
Since the pressure drop across the evaporator increases with load, the restricting effect becomes worse
when the demand on the TXV capacity is greatest.
Thermal Expansion Valves
To compensate for an excessive pressure drop
through an evaporator, the TXV must be externally
equalized. The equalizer line should be connected to
the suction line at the evaporator outlet, past the remote
bulb location so that the true evaporator outlet pressure
is exerted beneath the TXV diaphragm. The operating
pressure on the TXV diaphragm is now free from any
effect of the pressure drop through the evaporator, and
the TXV will respond to the superheat of the refrigerant
gas leaving the evaporator.
When the same conditions of pressure drop exist in a
system with an externally equalized TXV (see fig. 4), the
same pressure drop still exists through the evaporator,
however, the pressure under the diaphragm is now the
same as the pressure at the end of the evaporator, point
“C”, or 25 psig.
This change from 10°F to 11°F in the operating
superheat is caused by the change in the pressuretemperature characteristic of R-134a at the lower
suction pressure of 25 psig.
P1 = 35 PSIG
Location of External Equalizer
P2 = 25 PSIG
A
P3 = 10 PSIG
The external equalizer line must be installed beyond
the point of greatest pressure drop. Since it may be difficult to determinate this point, it is best to connect the
equalizer line to the suction line at the evaporator outlet
on the compressor side of the remote bulb location.
(See fig. 4 & 5). When the external equalizer is connected to a horizontal line, always make the connection
at the top of the line to avoid oil logging in the equalizer
line.
On a multi-evaporator system including two or more
evaporators each fed by a separate TXV, the external
equalizer lines must be installed so that they will be free
from the effect of pressure changes in the evaporators
fed by other TXVs. At no time should the equalizer lines
be joined in a common line to the main suction line.
If individual suction lines from the separate evaporator outlets to the common suction line are short, then
install the external equalizer lines into the separate
evaporator suction headers, or as described in the preceding paragraph.
When the pressure drop through the evaporator is
not substantial, install the external equalizer connection
at one of the return bends midway through the evaporator. This equalizer location will provide smoother TXV
control when used in conjunction with an Evaporator
Pressure Regulator. Anytime a control valve is installed
in the suction line, the external equalizer line for the TXV
must be connected on the evaporator side of the control
valve or regulator.
Never cap or plug the external equalizer connection
on a TXV, as it will not operate. If the TXV is furnished
with an external equalizer feature, the external equalizer
line must be connected.
35 PSIG = 40°F
B
25 PSIG = 29°F
C
25 PSIG & 40°F
TXV with external
equalizer on evaporator with
10 PSI pressure drop.
Fig. 4
The required pressure above the diaphragm for equilibrium is (25 + 10) or 35 psig. This pressure, 35 psig,
corresponds to a saturation temperature of 40°F and
the superheat required is now (40°F minus 29°F) 11°F.
The external equalizer has lowered superheat from 22°F
to 11°F. The capacity of a system having an evaporator with a sizable pressure drop will be increased by a
TXV with the external equalizer when compared to an
internally equalized TXV.
When the pressure drop through an evaporator is
substantial, or when a refrigerant distributor is used at
the evaporator inlet, the TXV must have the external
equalizer feature for best performance.
An externally equalized TXV is required when a liquid
distributor is used. Although a multi-circuit evaporator
may not have an excessive pressure drop, the liquid
distributor will introduce a pressure drop, because the
distributor is installed between the TXV outlet and the
evaporator inlet (See fig. 5).
Thermal Expansion Valves
suring superheat, install a calibrated pressure gauge in
a gauge connection at the evaporator outlet. In the absence of a gauge connection, a tee installed in the TXV
external equalizer line can be used just as effectively.
A refrigeration type pocket thermometer with appropriate bulb clamp or an electric thermometer with thermocouples may be used to measure gas temperature.
The temperature element from the thermometer
should be taped to the suction line at the point of remote
bulb location and must be insulated. Thermometers will
give an average reading of suction line and ambient if
not insulated. Assuming an accurate gauge and thermometer, this method will provide accurate superheat
readings.
Superheat
A vapor is said to be superheated whenever its
temperature is higher than the saturation temperature
corresponding to its pressure. The superheat equals the
temperature increase above the saturation temperature
at that pressure. For example, a refrigeration evaporator is operating with R-134a at 35 psig suction pressure
(See fig. 6). The R-134a saturation temperature at 35
psig is 40°F. As long as any liquid exists at this pressure,
the refrigerant temperature will remain 40°F as it evaporates or boils off in the evaporator.
P1 = 45.5 PSIG
P2 = 35 PSIG
P3 = 10.4 PSIG
Approximate Methods
of Reading Superheat
35 PSIG = 40°F
A
When a gauge connection is not available and the
TXV is internally equalized there are two ways of estimating superheat. Neither of these methods will yield an
exact superheat reading.
The first is the two-temperature method, which uses
the difference in temperature between the evaporator
inlet and outlet as the superheat. The error is caused by
the pressure drop in the evaporator. When the pressure
drop between the evaporator inlet and outlet is 1 psi or
less, the two-temperature method will yield fairly accurate results. But evaporator pressure drop is usually not
known and will vary with load. For this reason, the twotemperature method cannot be relied on for absolute
superheat readings. The error in this method is negative
and always shows a lower superheat.
The second method involves taking the temperature
at the evaporator outlet and using the compressor suction pressure as the evaporator saturation pressure. The
error is caused by the pressure drop in the suction line
between the evaporator outlet and the compressor suction gauge. On packaged equipment and close-coupled
installations, the pressure drop and resulting error are
usually small. But on large built-up systems or systems
with long runs of suction lines, considerable error can
result. Since estimates of suction line pressure drop are
usually not accurate enough to give a true picture of the
superheat, this method cannot be relied on for absolute
values. The error in this method is positive and always
shows a higher superheat.
The only method for checking superheat that will
yield an absolute value involves a pressure and temperature reading at the evaporator outlet.
By realizing the limitations of these approximate
methods and the direction of the error, it is often pos-
35 PSIG = 40°F
B
C
35 PSIG = 50°F
TXV with internal
equalizer on evaporator with
no pressure drop.
Fig. 6
As the refrigerant moves along in the coil, the liquid
boils off into a vapor. The liquid is completely evaporated at point B because it has absorbed enough heat to
change the refrigerant liquid to a vapor. The refrigerant
gas continues along the coil and remains at the same
pressure (35 psig); however, its temperature increases
due to continued absorption of heat. When the refrigerant gas reaches the end of the evaporator (point “C”) its
temperature is 50°F. This refrigerant gas is now superheated and the superheat is 10°F. (50°F minus 40°F).
The amount of superheat depends on how much refrigerant is being fed into the evaporator by the TXV and
the heat load to which the evaporator is exposed.
Superheat Adjustment
The function of a TXV is to control the superheat of
the suction gas leaving the evaporator. If superheat is
within reasonable limits, the TXV is operating in a satisfactory way. If superheat cannot be checked directly, it
is important to know the size and direction of whatever
error is present.
The pressure and temperature of the refrigerant suction gas passing the TXV remote bulb are required for
an accurate determination of superheat. When mea-
Thermal Expansion Valves
ASHRAE tables should be consulted for determining
pressure drops in liquid and suction line.
Here is the procedure for properly selecting a TXV:
sible to determine that the cause of the trouble call is
because of improper methods of instrumentation rather
than any malfunction of the TXV.
When troubleshooting in mountain areas (such
as Denver, Colorado or Salt Lake City, Utah) use a
Pressure-Temperature chart that has correct readings
such as Emerson Climate Technologies’ 5,000 ft. pocket
chart. Gauge pressures will read lower than they would
at sea level.
1. Determine pressure drop across TXV: using the
maximum and minimum condensing pressures, subtract
the evaporating pressure from each to get the total highto-low side pressure drop. From these values subtract
the other possible pressure losses– piping and heat
exchanger losses; pressure drop thru accessories; vertical lift pressure drop; and the pressure drop across the
refrigerant distributor.
2. Consider the maximum and minimum liquid temperatures of the refrigerant entering the TXV and select the
correction factors for those temperatures from the table
below the capacity ratings. Determine the corrected capacity requirement by dividing the maximum evaporator
load in tons by the liquid correction factors.
3. Select the TXV size from the proper capacity table for
the evaporator temperature, pressure drop available,
and corrected capacity requirement.
4. Select the proper thermostatic charge based on the
evaporator temperature, refrigerant, and whether a
Maximum Operating Pressure (see MOP section) type
charge is needed.
TXV Selection
Proper TXV size is determined by the BTU/HR or
tons load requirement, the pressure drop across the
TXV, and the evaporator temperature. Do not assume
that the pressure drop across the TXV is equal to the
difference between discharge and suction pressures at
the compressor. This assumption could lead to incorrect
sizing of the TXV.
The pressure at the TXV outlet will be higher than the
suction pressure at the compressor because of the frictional losses through the distribution header, evaporator
tubes, suction lines, fittings, and hand valves. On rack
systems, the EPR valve also adds substantial pressure
drop.
The pressure at the TXV inlet will be lower than the
discharge pressure at the compressor because of frictional losses created by the length of liquid line, valves
and fittings, and vertical lift. The only exception is if the
TXV is installed considerably below the receiver and
static head built up is more than enough to offset frictional loses. The liquid line should be properly sized for
its actual length plus equivalent length due to fitting and
hand valves. Vertical lift in the liquid line adds pressure
drop and thus static head must be included.
The pressure drop across the TXV will be the difference between the discharge and suction pressures at
the compressor less the pressure drops in the liquid line,
through the distributor, evaporator, and suction line.
5. Determine connections and whether an externally
equalized model is required. Always use an externally
equalized TXV when a distributor is used.
A solid column of liquid refrigerant is required for
proper TXV operation. Calculate the pressure drop
in the liquid line to determine if there will be enough
subcooling to prevent flash gas. If the subcooling of the
liquid refrigerant from the condenser is not adequate,
then a heat exchanger, liquid subcooler, or some other
means must be used to get enough subcooling to ensure solid liquid entering the TXV at all times.
Emerson Climate Technologies has prepared
extended TXV capacity tables. These tables can be
found in the Emerson catalog. Always select a TXV
based on operating conditions rather than nominal TXV
capacities.
Thermal Expansion Valves
sion and faulty remote bulb contact with the line.
On lines smaller than 7/8” OD the remote bulb may
be installed on top of the line. With 7/8” OD and over,
the remote bulb should be installed at the position of
about 4 or 8 o’clock. (See fig. 8)
It is good practice to insulate the bulb with a material
which will not absorb moisture.
Application Tips
For best evaporator performance, the TXV should be
installed as close to the evaporator as possible and in
an easily-accessible location for adjustment and servicing. On pressure drop and centrifugal type distributors,
apply the TXV as close to the distributor as possible.
(See fig.7)
Remote Bulb Well
A remote bulb well will improve the sensitivity of the
remote bulb. This occurs with short coupled installations
and installations with large suction lines (2-1/8” OD or
larger). Remote bulb wells should be used when low
superheat is desired or where converted heat from warm
rooms can influence the remote bulb. (See fig. 9).
Remote Bulb Location
Never install a remote bulb in a location where the
suction line is trapped (See fig. 10). If the liquid refrigerant collects at the point of remote bulb location the TXV
operation will be erratic.
Since evaporator performance depends on good TXV
control, and TXVs respond to the temperature change of
the refrigerant gas leaving the evaporator, care must be
given to types of remote bulbs and their locations. The
external remote bulb meets the requirements of most
installations. The bulb should be clamped to the suction
line near the evaporator outlet on a horizontal run. If
more than one TXV is used on adjacent evaporators or
evaporator sections, make sure that remote bulb of each
TXV is applied to the suction line of the evaporator fed
by that TXV.
Clean the suction line thoroughly before clamping the
remote bulb in place. When a steel suction line is used,
paint the line with aluminum paint to reduce future corro-
Thermal Expansion Valves
Large fluctuations in superheat in the suction gas are
usually the result of trapped liquid at the remote bulb
location. Even on properly designed suction lines, it is
sometimes necessary to move the remote bulb a few
inches from the original location to improve TXV performance.
On multi-circuit evaporators fed by one TXV, install
the remote bulb at a point where the suction gas has
had an opportunity to mix in the suction header. Tighten
clamps so that the remote bulb makes good contact with
the suction line. NEVER APPLY HEAT NEAR THE
REMOTE BULB LOCATION WITHOUT FIRST REMOVING THE REMOTE BULB.
direction allows the superheat of the gas to increase still
further.
In response to the rising superheat during the time
lags, the TXV has moved further in the opening direction, overshooting the control point and allowing more
refrigerant to flow to the evaporator than can be boiled
off by load.
When the TXV finally responds to the over-feeding of
the evaporator coil, it closes and will tend to again overshoot the control point and remain overly throttled until
most of the liquid refrigerant has left the evaporator.
The ensuing time delay before the TXV moves in the
opening direction allows superheat of the suction gas
to again rise beyond the control point. This cycle, being
self-propagating, continues to repeat.
Experience has shown that a TXV is more likely to
hunt at low load conditions when the TXV pin is close to
the valve seat. This is because of an unbalance between the forces which operate the TXV.
Besides the three main forces that operate the TXV,
the pressure difference across the TXV port also acts
against the port area and depending on TXV construction, tends to force the TXV either open or closed.
When operating with the pin close to seat, the following will occur:
With the TXV closed, there is liquid pressure on the
inlet side of the pin and evaporator pressure on the
outlet.
When the TXV starts to open allowing flow to take
place, the velocity through the TXV throat will cause a
point of lower pressure at the throat, raising the pressure
difference across the pin and seat.
This sudden rise in pressure differential while acting
on the port area will tend to force the TXV pin back into
the seat. When the TXV again opens, the same type of
action occurs and the pin bounces off the seat with a
rapid frequency. This phenomenon is more frequently
encountered with the larger conventional ported TXVs
as compared to balance ported TXVs as the force
caused by the pressure differential is magnified by the
larger port area.
Most TXVs, when properly selected and applied, will
overcome these factors and operate with virtual no hunting over a fairly wide load range.
Conventional ported TXVs will operate satisfactory to
somewhat below 50% of nominal capacity depending on
evaporator design, refrigerant piping, size and length of
evaporator, and rapid changes in loading.
Nothing will cause a TXV to hunt quicker than unequal feeding of the parallel circuits by a distributor or
unequal air loading across the evaporator circuits.
Hunting
“Hunting” of TXVs is defined as the alternate overfeeding and starving of the refrigerant flow to the
evaporator. Hunting is characterized by extreme cyclic
changes in the superheat of the refrigerant gas leaving
the evaporator and the evaporator or suction pressure.
Hunting is a function of the evaporator design, length
and diameter of tubing in each circuit, load per circuit,
refrigerant velocity in each circuit, temperature difference (TD) under which the evaporator is operated, arrangements of suction piping and application of the TXV
remote bulb. “Hunting” can be reduced or eliminated by
the correct rearrangement of the suction piping, relocation of the bulb and use of the recommended remote
bulb and power assembly charge for the TXV.
Operation at Reduced Capacity
The conventional TXV is a self-contained direct operated regulator which is inherently susceptible to hunting
because of its design and the design of the system to
which it is applied.
The ideal flow rate would require a TXV with perfect
dynamic balance, capable of instantaneous response
to any change in evaporation (anticipation) and with a
means of preventing the TXV from over shooting the
control point because of inertia (compensation). With
these features a TXV would be in phase with the system
demand at all times and hunting would not occur.
A conventional TXV does not have built in anticipating
or compensating factors. A time lag will exist between
demand and response, along with the tendency to over
shoot the control point. The conventional TXV may get
out of phase with the system and hunt. An example of
overshooting occurs when the load increases, causing
the superheat of the suction gas to increase. The time
interval between the instant the remote bulb senses the
increase and causes the TXV pin to move into opening
Thermal Expansion Valves
Balanced Port TXV Operation
Balance Ported Pin
In conventional TXVs, as the pressure drop across
the TXV port changes due to changes in head pressure
or suction pressure, the operating superheat of the TXV
will vary.
Depending on the operating conditions under which
the superheat was originally set, this “unbalance” can
sometimes result in compressor flooding or evaporator
starvation. A unique design concept called “Balanced
Port” cancels the effect of this pressure unbalance, permitting the TXV to operate at a fairly constant superheat
over a wide range of operating conditions.
There are 2 fundamental Balanced Port designs:
Double Ported Design (Figure 11a) – In this design,
there are 2 paths for the refrigerant to flow. One path
creates a force that tends to push the pin in the “open”
direction; whereas the other path creates a force pushing the pin in the “closed” position. These paths are designed in such a way that the forces generated in each
path are equal to one another, resulting in a “balanced”
design.
Single Ported Design (Figure 11b) – In this design, the
valve pin has a shoulder added that is on the inlet side
of the valve. The high pressure times the area of the
shoulder results in an upward (closing) force. The pressure differential across the pin results in a “downward”
force. By designing the shoulder carefully, the downward
force is negated or “balanced”.
Any refrigeration system which experiences changes
in operating pressures because of varying ambient, gas
defrost, heat reclaim, or swings in evaporator load will
benefit from using a balanced port TXV.
Equal Areas
Equal Forces
Inlet Pressure
Eliminates Imbalance Forces
Fig. 11b
M.O.P.
Maximum Operating Pressure (sometimes referred
to as Motor Overload Protection) is the ability of a TXV
to close down, starve, or shut off if the suction pressure
should approach a dangerously high predetermined limit
condition. These conditions could overheat a suction
cooled compressor or load the crankcase with too dense
a vapor pressure. With the TXV in a closed condition the
compressor has a chance to gain pull the suction back
down to satisfactory operating conditions. Once below
the MOP, the TXV will re-open and feed normally or until
there is an overload again.
Power Element Charges
There are several basic types of charges in use
today. Most common are the: liquid charge; gas charge;
liquid cross-charge; gas cross-charge; and the adsorption charge.
Liquid Charges
IN
IN
OUT
IN
OUT
OUT
BALANCED CAGE
ASSEMBLY
Fig. 11a
The power element contains the same refrigerant
as the system in which the TXV is used. When manufactured, it is put into the remote bulb in a liquid state.
Volume is controlled so that within the design temperature range some liquid always remains in the bulb.
Therefore, the power element pressure is always the
saturation pressure corresponding to the temperature of
the remote bulb.
OUT
IN
CONVENTIONAL
CAGE ASSEMBLY
Fig. 11
Thermal Expansion Valves
Liquid charges have the following properties:
•Not subject to cross-ambient control loss
•Little or no superheat at start-up
•Superheat increase at lower evaporator temperatures
•Slow suction pressure pulldown after start-up
As in liquid charges, the remote bulb can be filled
with the same refrigerant as the system refrigerant (producing a gas charge). Or, it can be filled with a different
refrigerant, producing a gas cross-charge.
Adsorption Charges
REFRIGERANT CODE NAMES
ARI Standard 750-2007 recommends the
following color coding of the TXVs:
R-12
R-22
R-502
R-134a
R-410A
R-404A
R-507A
White
Green
Orchid
Light Blue
Rose
Orange
Blue Green (Teal)
Liquid Cross-Charges
Liquid cross-charges means that the power element
contains a liquid refrigerant different from the system
refrigerant in which the TXV is used. The pressure temperature curve of the charge crosses the curve of the
system refrigerant.
Liquid cross-charge advantages are:
•Moderately slow pull down
•Insensitive to cross-ambient conditions.
•Damped response to suction line temperature changes
(reduces tendency for TXV hunting)
•Superheat characteristics can be tailored for special
applications
Gas & Gas Cross-Charges
Using a gas charge in place of a liquid alters the
operational characteristics, because gas is compressible. At some predetermined temperature, the gas in the
remote bulb becomes superheated, limiting the force it
exerts. This produces higher superheats at higher evaporator pressures and is labeled the Maximum Operating
Pressure (MOP) effect.
Any MOP point temperature depends on how that
bulb was charged and where it will be used. All gas
charges are susceptible to cross-ambient control loss
when the power element is colder than the remote bulb.
They respond faster, but tend to hunt for the proper
operating level, so a ballast is often added to the remote
bulb to reduce that tendency.
The final type of charge is adsorption. In adsorption,
solids hold large quantities of gas, not by taking them
into the body of the solid, as in absorption, but by gathering them and holding them on the surface of the solid
without chemical reaction.
The vapor penetrates into the cracks and furrows of
the solid, allowing far greater capacity than possible with
absorption.
The advantage of an adsorption charge is that in a
fixed volume, the quantity of vapor adsorbed varies with
the temperature and the system. So it can be used to
exert operating pressure as a function of temperature.
Typical adsorbents include: charcoal, silica gel, activated alumina.
What happens with an adsorption charge
Which Charge to Use?
Here are some typical examples of applications by
refrigerant charge:
Liquid Charge
Ice makers, pilots, liquid injection valves
Liquid Cross-Charges
Commercial refrigeration (low & medium temp.), ice
makers, transport refrigeration and air conditioning
Gas Charge
Air conditioning (including mobile), water chillers
Gas Cross-Charge
Heat pumps and air conditioning
MOP
Maximum Operating Pressure
10
Thermal Expansion Valves
TXV SUPERHEAT ADJUSTMENT
Other TXV Considerations
Degrees of SH Per Turn
Solenoid Liquid Stop Valves
The TXV is produced as a tight seating device. But
if the TXV is exposed to dirt, moisture, corrosion, and
erosion the TXV will not be able to positively shut off.
If the remote bulb is installed in a location where during
the “off’ cycle it is influenced by a higher ambient temperature than the evaporator, the valve will open and admit liquid to the evaporator. Installing a Solenoid Liquid
Stop Valve ahead of any TXV is highly recommended.
Valve “Total
R-22
R-134a R-404A/507A R-410A
Family Turns”+20°F -20°F +20°F +20°F -20°F +40°F
TCLE
32
0.8
1.5
1.0
0.5
1.0
N/A
HF
10
2.2
4.2
3.8
1.8
3.2
N/A
A
8
3.0
5.0
4.5
2.0
4.0
2
TRAE
10
2.2
4.2
3.8
1.8
3.2
N/A
C
12
–
–
–
–
–
4
Turn adjustment clockwise to increase superheat, counterclockwise to decrease superheat. To return to approximate
original factory setting, turn adjustment stem counterclockwise
until the spring is completely unloaded (reaches stop or starts
to “ratchet”). Then, turn it back in one half of the “Total Turns”
shown on the chart.
Filter-Driers for System Protection
To protect the precision working parts of control
valves from dirt and chips which can damage them and
make them inoperative, and to protect the entire system
from the damaging affects of moisture, sludge and acids, a filter-drier should be installed on every system.
Fig. 15
Pressure Switch Setting
On TXVs with M.O.P., a Pressure Switch must be set
to cut in at a pressure lower than M.O.P. rating of the
TXV.
Emerson TXVs
Emerson’s TXVs are designed for a wide range of air
conditioning, refrigeration, heat pump, and chiller applications. Emerson uses stainless steel power elements
that will not corrode.
Emerson’s integral TXV line includes valves for commercial and refrigeration applications, and heat pump
and residential applications. The “Take-A-Part Series”
TXVs are available for almost any type of application,
temperature range, or refrigerant. Emerson also offers a
complete line of specialty TXVs.
Factory Superheat Setting
Unless otherwise specified, all Emerson TXVs will
be preset at the factory at a bath temperature which is
pre- determined by the charge symbol or the MOP rating. The bath temperature at which the TXV superheat is
set is coded alphabetically in the superheat block on the
TXV nameplate, as shown in Fig. 15.
11
For example, a TXV with “10A” stamped in the nameplate superheat block is set for 10°F static superheat
with a 32°F bath. A TXV stamped “10C” is set for 10° of
static superheat with a 0°F bath.
When ordering a TXV for an exact replacement,
specify the code letter and the superheat setting desired. When ordering for general stock, it is not necessary to specify either the superheat or the code letter,
since the standard setting will cover most applications
and minor superheat adjustments may be made in the
field.
Thermal Expansion Valves
Emerson “T” Series TXVs [except “W”-(MOP),
G-(MOP) or GS-(MOP) gas charged types] may be
installed in any location in the system. The gas charged
type must always be installed so that the power assembly will be warmer than the remote bulb. The remote
bulb tubing must not be allowed to touch a surface colder than the remote bulb location. If the power assembly
or remote bulb tubing becomes colder than remote bulb,
the vapor charge will condense at the coldest point and
remote bulb will lose control.
For exact TXV selection (i.e., refrigerant tonnage,
connections, equalizer style, cap tube length, adjustment and proper application, air conditioning, commercial, low temperature) refer to Emerson catalog.
To help you match the correct charge to your specific
application, see the TXV Charge Code Selector on the
next page. Also provided here are some typical examples of applications by refrigerant charge.
Emerson MOP
Gas Cross-Charge – CA, AA
Heat pumps and air conditioning
The Emerson “W” charge can be supplied with the
MOP feature if needed for system protection. This need
rarely occurs in modern day refrigeration except such
conditions as immediately after defrost or on gasoline
driven compressors such as truck refrigeration.
For special applications, other charges may be used
from time to time. For help in selecting a charge with
Motor Overload Protection (if required by compressor
manufacturer) see the table below and the TXV Charge
Selector on page 13.
APPLICATION
R134a
R22
COMMERCIAL
MW35
HW65
*W65
LOW TEMP.
MW15
HW35
*W45
Liquid Charge – L
Ice makers, pilots, liquid injection valves
Liquid Cross-Charges – C, Z
Commercial refrigeration (low & medium temp.), ice
makers, transport refrigeration and air conditioning
Gas Charge – G
Air conditioning (including mobile), water chillers
Gas Cross-Charge – HAA
Heat pumps and air conditioning
W(MOP)
Maximum Operating Pressure
Refrigerant Code Names
ARI Standard 750-2007 recommends the following color coding of thermostatic
expansion valves: R-12 White; R-22 Green; R-502 Orchid; R-40 Red;
R-500 Orange. Uncommon refrigerants with no designated color should use Blue.
R404A/R507A
* Add refrigerant code as follows: S = R404A, P = R507A
NOTE: MOP not available with Rapid Response Bulb.
Superheat adjustment of “W–MOP” charged TXVs
will change the MOP point. An increase in superheat
setting will lower the MOP point and a decrease in superheat setting will raise the MOP.
ASHRAE
TRADE OR
REF. NO.
CHEMICAL NAME
TABLE 1 – Maximum Dehydration Temperature (in °F)
REFRIGERANT L
R134a
195
R22
160
R404A/R507A 150
R717
N/A
THERMOSTATIC CHARGE
C
Z
G WMOP/CA X
190 250 250 250 N/A
160 185 250 250 N/A
150 170 250 250 N/A
N/A 150 N/A N/A 200
The table above refers to the maximum dehydration temperatures when the bulb and TXV body are subjected to the same
temperature. On A, L, C, Z, and X charges, 250°F maximum
TXV body temperature is permissible (if the bulb temperature) does not exceed those shown in the table.
NOTE: Emerson charges “A”, “C” and “Z” are liquid crosscharges.
12
R-12
R-22
R-502
R-134a
R-404A
R-401A
R-507A
R-410A
EMERSON
CODE
COLOR
Dichlorodifluoromethane
White
Chlorodifluoromethane
Green
22/115
Purple
Tetrafluoroethane
LIGHT Blue
125/134a/143A
ORANGE
22/152A/124
CORAL
125/143A
TEAL
32/125
ROSE
EMERSON
CODE
LETTER
F
H
R
M
S
X
P
Z
Thermal Expansion Valves
TXV Charge Code Selector
Applications
Operating Ranges
MC/FC
MZ/FZ
MW15/FW15 (MOP)
MW35/FW35 (MOP)
MW55
HCA/HAA AIR COND. & HEAT PUMP
HW/HW100
HC
HW65 (MOP)
HZ
SC/RC
SZ/RZ
SW45/RW45 (MOP)
ZW195
R-134a/R-12
Domestic Refrigerators and Freezers, Ice Makers,Dehumidifiers,
Transport Refrigeration, Medium Temperature Supermarket
Equipment,Medium Temperature Commercial Equipment
R-22
Residential Air Conditioners &Heat Pumps, Commercial and
Industrial Chillers, Medium Temperature Supermarket
Equipment, Commercial Air Handlers
R-404A/R-507A/R-502
Low Temperature Cases, Ice Makers, Commercial Air Handlers,
Conditioners, Soft Ice Cream Machines, Environmental Chambers
R-410A
-50
-40
-30
-20
-10
0
+10
+20
+30
+40
+50
TXV Replacement Charge Symbols Cross Reference
Old Bulb Charges vs. New Replacement Bulb Charge
AIR CONDITIONING
OLD CHARGE
REPLACEMENT
FW
FG55
FW55
FQ55
FGA
FLA
FGS
FWS
FC
FWS
HW
HG100
HW100
HQ100
HGA
HLA
HW85
HGS
HWS
HC
HCA
HC
HW85
HWS
RW
RW110
RWS
RC/SC/PC
RWS
COMMERCIAL REFRIGERATION
OLD CHARGE
REPLACEMENT
REFRIGERANT R12/R134a
F or FL
FC
FC
FW
FG35
FW35
FW35
FQ35
—
—
FGS35
FGS35
FWS
FWS
REFRIGERANT R22
H or HL
HC
HC
HW
HG65
HW65
HW65
HQ65
—
—
HGS65
HGS65
HWS
HWS
REFRIGERANT R502/R404A/R507A
RL
RC/SC/PC
RW
RW65
RW65
RWS
RWS
LOW TEMPERATURE
OLD CHARGE
REPLACEMENT
—
—
FWZ
—
FW15
FW15
—
FZ
—
FW15/MW15
—
—
FWS
FZ/MZ
FX
FWS
FZ/MZ
FX
—
—
HWZ
—
HW35
HQ35
—
HZ
—
HW35
—
—
HWS
HZ
HX
HWS
HZ
HX
—
RWZ
RW35
RWS
RZ
—
RZ
RW45/SW45
RWS
RZ/SZ/PZ
NOTE: ALL OTHER CHARGE SYMBOLS MUST BE REPLACED WITH AN IDENTICAL MODEL OR AT THE OPTION OF THE EMERSON TECHNICAL SERVICE DEPARTMENT WHO MAY MAKE ENGINEERING AUTHORIZED SUBSTITUTION OF EQUIVALENT TYPE TO PROVIDE EQUIVALENT OPERATION AND PERFORMANCE.
NOTE: FOR FIELD REPLACEMENT PURPOSES, HC CAN BE USED TO REPLACE HCA.
13
Solenoid Valves
14
2008
Solenoid Valves
Solenoid Valves
In most refrigeration applications, it is necessary to
start or stop the flow in a refrigerant circuit to automatically control the fluids in the system. An electrically
operated solenoid valve is usually used for this purpose.
Its basic function is the same as a manually operated
shut off valve, but by being solenoid actuated, it can be
positioned in remote locations and may be conveniently
controlled by simple electrical switches.
Solenoid valves can be operated by a thermostatic
switch, float switches, low pressure switches, high pressure switches or any other device for making or breaking
an electric circuit, with the thermostatic switch being the
most common device used in refrigeration systems.
What Are Solenoid Valves?
A solenoid valve consists of two distinct but integral
acting parts, a coil and a valve. See drawing below for
complete valve anatomy.
Direct Acting Solenoid Anatomy
Enclosing Tube
Top Plug
Assembly
Return Spring
Plunger Assembly
Collar
O-Ring
Body
Assembly
The coil is nothing more than electrical wire wound
around the surface of a cylindrical form usually of circular cross section. When an electric current is sent thru
the windings, they act as an electromagnet. The force
field that is created in the center of the solenoid is the
driving force for opening the valve. Inside is a moveable
magnetic steel plunger that is drawn toward the center
of the coil when energized.
The valve contains an orifice through which fluid
flows when open. A needle or rod is seated on or in the
orifice and is attached directly to the lower part of the
plunger.
When the coil is energized, the plunger is forced
toward the center of the coil, lifting the needle valve off
of the orifice and allowing flow. With a normally-closed
valve, when the coil is de-energized, the weight of the
plunger and in some designs, a spring, causes it to fall
and close off the orifice, thus stopping the flow through
the valve. Less common are normally-open valves which
are open when the coil is de-energized.
Principles of Solenoid Operation
Solenoids are either direct acting or pilot operated.
The application determines the need for either of these
types. The direct acting valve is used on valves with low
capacities and small port sizes. The pilot operated type
is used on the larger valves, eliminating the need for
larger coils and plungers.
1. Direct Acting
In the direct acting type valve, as discussed under
Solenoid Valve operation, the plunger is mechanically
connected to the needle valve. When the coil is energized, the plunger pulling the needle off the orifice is
raised into the center of the coil. A direct acting valve will
operate from zero pressure differential to its maximum
rated pressure differential, regardless of the line pressure.
The direct acting type valve is only used on small
capacity circuits because of the increased coil size that
would be required to counter the large pressure differential of large capacities. The required coil would be
large, uneconomical, and not feasible for large capacity
circuits. To overcome this problem on large systems,
pilot operated solenoid valves are used.
15
Solenoid Valves
2. Pilot Operated Valve
The pilot operated solenoid valve uses a combination
of the solenoid coil and the line pressure to operate. In
this type valve the plunger is attached to a needle valve
covering a pilot orifice rather than the main port. The
line pressure holds an independent piston or diaphragm
closed against the main port. See figures 2a and 2b.
When the coil is energized, the plunger is pulled into the
center of the coil, opening the pilot orifice. Once the pilot
port is opened, the line pressure above the diaphragm is
allowed to bleed off to the low side or outlet of the valve,
thus relieving the pressure on the top of the diaphragm.
The inlet pressure then pushes the diaphragm up and
off of the main valve port and holds it there allowing full
fluid flow. When the coil is de-energized, the plunger
drops and closes the pilot orifice. Pressure starts to build
up above the diaphragm by means of a bleed hole in the
piston diaphragm until it and the diaphragm’s weight and
spring cause it to close on the main valve port. A pilot
operated solenoid valve requires a minimum pressure
difference of several pounds between inlet and outlet to
operate.
Figures 1A and 1B show a simple schematic
of a Direct Acting Solenoid Valve in operation.
FIG. 1A DE-ENERGIZED
FIG. 1B ENERGIZED
Figures 2A and 2B show a simple schematic
of a Pilot Operated Solenoid Valve in operation.
FIG. 2A DE-ENERGIZED
Types of Solenoids
There are different types of solenoid valves for different applications. The three main types of valves are the
2-way, 3-way, and 4-way valves. The 2-way valve is the
most common.
2-Way Valves
The 2-way valve controls fluid flow in one line. It has
an inlet and an outlet connection. This valve can be of
the direct acting or pilot operated type of valve depending on the need. When the coil is de-energized, the 2way valve is normally closed. Although normally closed
is the most widely used, two-way and three-way valves
are manufactured to be normally open when the coil is
de-energized. See Figure 3 for an example of a 2-way
valve.
FIG. 2B ENERGIZED
Figure 3
NOTE: 2-way valves are usually designed to have
flow in one direction only. Some valves may be modified
to have flow in both directions. A “bi-flow” kit must be
used.
16
Solenoid Valves
Solenoid Valve Selection
Minimum Operating Pressure Differential
The selection of a Solenoid Valve for a control application requires the following information:
1. Fluid to be controlled
2. Capacity required
3. Maximum operating pressure differential (MOPD)
4. Electrical characteristics
5. Maximum working pressure required (MWP)
The capacities of Solenoid Valves for normal liquid
or suction gas refrigerant service are given in tons of
refrigeration at some nominal pressure drop and standard conditions. Manufacturers’ catalogs provide extended tables to cover nearly all operating conditions for
common refrigerants. Follow the manufacturer’s sizing
recommendations. Do not select a valve based on line
size. Pilot operated valves require a pressure drop to
operate and selecting an oversize valve will result in the
valve failing to open. Undersized valves result in excessive pressure drops.
The solenoid valve selected must have a MOPD rating equal to or greater than the maximum possible differential against which the valve must open. The MOPD or
Maximum Operating Pressure Differential considers the
inlet and outlet valve pressures. If a valve has a 500 psi
inlet pressure and a 250 outlet pressure, and a MOPD
rating of 300 psi it will operate, since the pressure difference (or 500-250) is less than the 300 MOPD rating.
If the pressure difference is larger than the MOPD, the
valve will not open.
Consideration of the maximum working pressure
required is also important for proper and safe operation.
A solenoid valve should not be used for an application
when the pressure is higher than the valve maximum
working pressure. Solenoid valves are designed for a
given type of fluid so that the materials of construction
will be compatible with that fluid. Special seat materials and synthetics may be used for high temperature
or ultra-low temperature service. Special materials are
required for corrosive fluids. Special attention to the
electrical characteristics is also important. Required
voltage and Hertz must be specified to ensure proper
selection. Valves for DC service often have different internal construction than valves for AC applications, so it
is important to study the manufacturer’s catalog information. Solenoid valves should never be used as a Safety
Shut Off unless specifically designed and rated for that
service.
50 psig
50 psig
194 psig
sP = 0 psig
200 psig
sP = 6 psig
NOTE: No minimum pressure differential – valve
will not operate.
NOTE: Pressure differential greater than minimum
– valve will operate.
17
Solenoid Valves
Installation
Emerson Solenoid Valves
Solenoid Valves having a spring loaded piston or diaphragm may be installed and operated in any position,
but installing more than 90° from vertical is not recommended since dirt or debris may collect in the solenoid
area and prevent it from operating. An adequate strainer
or filter drier should be installed ahead of each solenoid
valve to keep scale, pipe dope, solder, and other foreign
matter out of the valve.
When installing a solenoid valve, be sure the arrow
on the valve body points in the direction of refrigerant
flow.
When brazing valves with extended solder type connections do not use too hot a torch and point the flow
away from the valve. These valves do not normally need
to be disassembled before installation; if the valve does
not have extended connections, disassemble the valve
before brazing. Wet rags or chill blocks are recommended during brazing. They are needed to keep the
valve body cool so that body distortion on close-coupled
valves will not occur. Allow the valve body to cool before
replacing the valve’s operating insides to ensure that the
seat material and gaskets are not damaged by the heat.
When reassembling, do not over torque.
Emerson offers a complete line of refrigerant solenoid
valves for refrigeration and air-conditioning applications.
As part of Emerson’s commitment to the industry, each
valve undergoes stringent Emerson testing to ensure
fail-safe operation. And, with the lowest external leak
rates in the industry, Emerson solenoid valves ensure
precise refrigerant flow, preventing system failures and
aiding in environmental protection.
Application Overview
Application
Product Family
Liquid, Suction Line Service
or Hot Gas By-Pass
Pressure Differential Valve for Gas Defrost
18
240RA/540RA
50RB
100RB
200RB/500RB
710RA
713RA
System Protectors
19
2008
System Protectors
Liquid line and suction line filter-driers are often
referred to as System Protectors because they remove
harmful elements from the circulating refrigerant before
serious damage results.
Keeping the system clean and free of foreign contaminants that can restrict the operation of valves, block
capillary tubes or damage compressors is the best way
to assure trouble-free operation. These contaminants
can be solids, such as metal filings, flux, dust and dirt.
Other equally menacing contaminants are solubles,
such as acid, water, resins and wax.
No matter how many precautions are taken during
assembly and installation or servicing of a system,
contaminants can find a way into the system. Filterdriers are designed to protect a system during operation.
It is the function of this all important unit to remove those
residual elements that can attack and eventually destroy
the system components.
MWP-680
Filtration Capacity
Solid particles or semi-solids such as sludges
circulating in a refrigerant system can destroy valve
seats, plug control valves, and score cylinder walls or
compressor bearings. These contaminants can be the
result of manufacturing, servicing, or can be generated
during normal system operation.
It is important to remove these contaminants as
quickly as possible and prevent them from returning to
the system. Properly specified filter-driers are designed
to trap and hold large quantities of these contaminants
while maintaining low pressure drop during their service
life.
Moisture Capability
Moisture in a refrigeration system can cause frozen
valves, copper plating, damaged motor insulation, corrosion, and sludges. Filter-driers remove and retain moisture through one or more desiccants. The most popular
and effective desiccant in use today for the removal of
moisture is molecular sieve which can hold three to four
times the water of other commercial absorbents.
Moisture capacity of a filter-drier is normally given
in drops of water per ARI Standard 710. These rated
capacities are in addition to any residual moisture that
might be absorbed during manufacturing.
Acid Pick-Up Capability
Various organic acids result during the decomposition
of the refrigerant and oil in a system. This decomposition
can be the result of moisture in the system, excessive
temperatures, air, or exposure to foreign substances in
the system. It is important that acid in a system is absorbed as soon as it is formed to prevent the acid from
causing system damage. Activated alumina is the most
popular of the desiccants used to remove acid.
Tests have shown that the amount of acid and resin
pick-up of an adsorbing agent is almost proportional to
the weight of the desiccant. Size or granulation makes
little difference.
There is no industry-approved method for rating acid
removal. So weight of the desiccant provides the handiest measure.
Wax Removal
The ability of a filter-drier to remove wax and resins is
important in low temperature applications that use R-22.
Wax when present in a system tends to solidify on valve
seats and pins, resulting in system malfunctions.
Flow Rate
Published flow rates for filter-driers are established in
accord with ARI Standard 710 for liquid line driers, and
ARI Standard 730 for suction line driers.
20
System Protectors
Absorption vs. Adsorption
One factor to consider in selection is ab- vs. adsorption. Absorption means a material’s ability to take
another substance into its inner molecular structure.
An adsorbed substance doesn’t penetrate the molecular structure. It simply starts building up on the surface of the adsorbent. Walls, cracks, crevices are part of
the surface area and are able to hold other substances,
greatly increasing capacity.
Modern desiccants are extremely porous and have
a large surface area and internal pore volume of a size
and shape to adsorb and retain water molecules.
Types of Filter-Driers
All the liquid line filter-driers on the market today are
a variation of one of two types: the molded core type or
the bead type.
Molded core type filter-driers are manufactured by
mixing desiccants (which remove the soluble contaminants) with a bonding agent, then baking them to give
them permanent shape and to activate the drying ingredients. The results is a porous core which acts as filter
and drying agent.
Compacted bead style filter-driers are manufactured
with the active desiccant in bead or pellet form; no bonding material is used. Rather, compacting comes from
mechanical pressure exerted by a spring. Compacted
bead-style filter-driers usually include an additional filter
network to trap solid contaminants from the refrigerant,
unlike most core styles.
The separate and distinctive filter media can take
various forms that permit depth filtration with greater
solid contaminant capacity and contaminant retention
during start-up and shut- down when turbulent conditions exist.
Compacted bead filter-driers offer the maximum volume of desiccant because filtering and drying is done in
one mass. But, because the core is porous, it does not
hold all solid contaminants; often particles are washed
through channels within in the core when pressures
surge. Better holding power is possible with a more
compacted core. But pressure drops increase inversely.
Compacted bead style filter-drier, Emerson’s EK-Plus
Dirt, Waxes, Acid
Every system has contaminants in it as soon as it is
opened. These contaminants may be insoluble, such as
metal filings not removed in manufacturing, or airborne
dirt that entered when the system was opened. Or they
may be soluble, such as waxes, acids, water and resins
that develop through reactions between air, the refrigerant, or lubricant.
Any of these can cause system failure. Installing an
all-purpose filter-drier can lessen chances for trouble.
There are basic differences to consider: type of filter,
how it filters, and its true capacity.
Most manufacturers rate their filters to ARI Standard
710. But even though two clean filter-driers may be
rated the same, there can be a vast difference in flow as
the quantity of solids picked up increases.
Fig 1. Proper placement of filter-drier in the system
21
System Protectors
HFC Refrigerants and POE Lubricants
2500
2000
Water Content
(ppm)
1500
1000
500
0
Mineral POE Oil
Oil
R-12
R-134a
R-22
R-502
R-404A R-410A
0.2
Total Acid Number
The use of HFC refrigerants and Polyolester (POE)
lubricants for air-conditioning and refrigeration has
generated new system chemistry related problems. New
and redesigned system protectors have been developed
to counter these problems and provide a long, reliable
life for the operating refrigeration system.
Moisture is the major problem causing contaminate
for HFC/POE oil systems just as it was for CFC and
HCFC systems using Mineral oil. Many HFCs can hold
much more water than their CFC counterparts but the oil
differences are much worse than those of the refrigerant. POE oil can hold as much as 10 times more water
than Mineral oils. Evacuation alone has proved ineffective at removing this moisture so a filter-drier is required
to perform this function.
0.15
0.1
0.05
0
0
100
200
300
400
500
600
700
Refrigerant Water Concentration (ppm)
Figure 2
Acid Generation in a 1.5 Ton POE Oil Containing System
Another aspect of POE oil is the ability to keep more
solid particles in suspension than Mineral oil. This is
important in retrofitted systems where pockets of solid
contamination are now flushed from low flow areas and
need to be removed before moving parts in the system
are damaged. The filter-drier for POE oils needs to have
higher solid particle holding capacity with little impact to
refrigerant flow capacity or pressure drop.
The filter-drier should also have improved contaminate removal efficiency as well to ensure that all particles are captured the first time they enter the filter-drier.
The ability to remove smaller particles is also advantageous. The Emerson EK series filter-driers provide a
unique combination of these characteristics to provide
outstanding filtration as shown in Figure 4.
Water poses a new problem for POE oils above and
beyond those experienced with Mineral oil. POE oil will
react with water to form organic acids at normal operating conditions in refrigerating and air-conditioning systems. This reaction starts at water levels as low as 75
ppm. These acids attack system components including
motor insulation and metallic parts, reducing system life.
To combat the detrimental effects of water in HFC
and POE oil systems it is imperative to hold moisture
levels as low as possible. Water level must be maintained less than 50 ppm in the refrigerant and the same
for the oil.
125
Moisture Level (ppm)
100
75
HMI
50
Typical
Sightglass
25
0
75
100
125
R-134a Refrigerant Temperature
Figure 3
Dry Indication Water Level
22
System Protectors
Flow Restriction
Suction Filter-Driers
EK
Typical drier
Solid Contamination Captured
Figure 4
Filtration Capability of Filter-driers
The filter-driers for use in HFC and POE oil systems
must maintain the system dry and free of any acids generated. However, since water capacity is of primary importance the filter-drier should contain a higher percentage of molecular sieve than was required for CFC and
HCFC systems. But molecular sieve alone is not enough
since it has almost no organic acid capacity. An organic
acid removal desiccant must be used such as activated
alumina to ensure low acid levels are maintained. The
filter-drier should also have higher filtration capacity
and efficiency. The EK series of filter-driers provides the
best combination of these properties to ensure the long,
trouble-free life of any air-conditioning or refrigeration
system.
The moisture indicating sightglass must also indicate
moisture levels less than 50 ppm moisture. Also, it must
be able to perform this function at the temperature of the
liquid line on which it is placed. Many sightglasses cannot perform this function at all liquid line temperatures.
This low level indication ability is needed to ensure that
the system moisture never exceeds the level at which
organic acid formation starts. The Emerson HMI moisture indicating sightglass provides this low level detection ability.
The function of filter-driers in refrigeration and air
conditioning systems is to trap moisture and harmful
contaminants. But their use in the liquid line still tends
to be thought of as the “standard” application; including
them also in the suction line hasn’t yet become standard practice to the same degree.
A filter-drier in the liquid line essentially protects the
system controls – solenoid valves, expansion valves,
and pressure regulators. The function of the filter or
filter-drier in the suction line is specifically to protect the
compressor against contaminants.
Such protection is encouraged by compressor manufacturers in any case, but there are two circumstances
that make suction line filters or filter-driers advisable.
Emerson ASD suction line filter-drier
Field Built-up Systems
It is practically impossible to avoid contamination
when assembling a refrigeration system in the field. Dirt,
moisture, metal particles, and copper oxide from brazing all can be present in the system despite the greatest
care, and all can damage are reduce the service life of
the compressor.
In large and complex systems, such as a single
system serving several food cases throughout a supermarket, it is a generally accepted practice to install a
cartridge-type filter in the suction line. Then, because of
the virtual certainty of contamination during assembly of
the system, the initial cartridge is removed and replaced
after the first few days of system operation.
When considering the price of a compressor, the cost
of protecting it with a suction line filter is insignificant.
23
System Protectors
Internal Design
Internally, suction line filter-driers employ the
same types of elements as liquid line units. One
is the core type, in which the filter-drier consists of
a rigid, cylindrical, porous core that may perform
both the filter and drier functions, or be used in
combination with a separate accordion-type filter
element.
The core type filter-drier is available either in a
hermetically sealed configuration or in take-apart
designs with a replaceable element.
The latest advancement is the bead-type unit,
in which the desiccant is compacted into the shell.
This design offers several advantages over older
types, including lower pressure drop, more desiccant surface area, and greater capacity.
Cross-section shows desiccant beads surrounding
accordion-type filter element
Application Tips
Using a liquid line filter-drier as a suction line
filter-drier is not recommended. A suction line
filter-drier should provide for greater capacity than
a liquid line unit, for better compressor protection
and for less pressure drop. Two access valves
are required to measure pressure drop across the
suction line filter-drier.
Typical system arrangements show suction line filter-drier
installed ahead of the compressor.
24
System Protectors
Compressor Burnout
A compressor burnout can be expected to release a
variety of pollutants into the system, including acids. The
clean-up procedure below describes the use of system
protectors in cleaning up a system.
Clean-Up Procedure for Compressor Motor Burnout
1. Determine the extent of the burnout. For mild burnouts where contamination has not spread thru the system it
may be economical to save the refrigerant charge, if the system has service valves on the compressor. A severe
burnout exists if the oil is discolored, an acid odor is present, and contamination products are found on the high
and low side. In this condition, caution should be exercised to avoid breathing the acid vapors. Also, avoid skin
contact with the contaminated liquid.
2. Thoroughly clean and replace all system controls such as TXVs, solenoids, check valves, and reversing valves.
Remove all strainers and filter-driers.
3. Install replacement compressor and make a complete electrical check.
4. Make sure that the suction line near the compressor is clean. Install an over-sized liquid line filter-drier and a
suction line filter-drier.
5. Pressure and leak-test the system according to unit manufacturer’s recommendations.
6. Triple evacuate to at least 200 microns. Break the vacuum with clean, dry refrigerant at 0 psig.
7. Charge the system through an Emerson EK filter-drier to equipment manufacturer’s recommendations.
8. Start the compressor and put the system in operation. Record the pressure drop across the suction line filterdrier on the enclosed label and apply label to the side of the shell.
9. Replace the suction line filter-drier if the pressure drop becomes excessive.
10.Observe the system during the first 4 hours. Repeat step 9 as often as required, until no further change in pressure drop is observed.
11.After the system has been in operation for 48 hours, check the condition of the oil with an acid test kit. If the oil
test indicates an acid condition, replace the liquid and suction line filter-driers.
12.Check the system again after 2 weeks of operation. If the oil is still discolored, replace the liquid and suction line
filter-drier.
13.Clean-up is finished when the oil is clean and odor-free, and is determined to be acceptable with the acid test
kit.
For detailed burnout clean-up procedure and recommendations, consult the RSES Service Manual, Section 91.
25
System Protectors
Filter-Driers for Heat Pumps
A heat pump is essentially a refrigeration system that can flow in either direction. The key to its
operation is a four-way reversing valve that routes
the discharge gas from the compressor.
Depending on whether the system is cooling or
heating, the indoor and outdoor coils swap roles,
taking turns serving as the condenser and evaporator.
Since conventional refrigerant control components are designed for unidirectional operation,
their use in heat pumps requires installation in
pairs, one for each direction, with check valves
routing the flow through or around them. Today,
because of the growing use of heat pumps, components such as thermostatic expansion valves
are available in bi-directional versions, as are
filter-driers.
Schematic of a basic heat pump system.
Removing Contaminants
Just like any other refrigeration system, heat
pump system components need filter-drier protection to remove solid and soluble contaminants.
This may be handled several ways.
First, in systems with one-way expansion
valves and check valves, a one-way filter-drier
might be installed in series with a check valve.
This would be a “part-time” arrangement, in that
filtration would be provided in only one direction.
Second, a one-way filter-drier might be installed with each of the check valves, so that one
provides filtration in each direction.
Third, the simplest arrangement is to install a
bi-directional filter-drier in the common liquid line.
Used in combination with a bi-directional thermostatic expansion valve such as Emerson’s HF series, the complexity of multiple expansion valves,
check valves, and filter-driers can be completely
eliminated.
Emerson BKF bi-directional pump filter-drier
One-Way Flow, Both Ways
Inside a bi-directional filter-drier the refrigerant
always flows the same direction regardless of which
way the refrigerant is flowing through the system. The
internal flow in this case is controlled by an inlet flapper
valve and an outlet poppet valve on each side of the
desiccant core. As the liquid enters the filter-drier from
either direction, the inlet flapper valve routes it to the
outside of the desiccant core. After it flows through to
the inside of the desiccant core, it exits through the opposite poppet valve.
The purpose of the arrangement shown below is to
prevent contaminants collected in one direction from being flushed back out when the flow reverses.
26
System Protectors
Simplifying While Servicing
Cross section showing BFK internal components
INTERNAL
CONSTRUCTION
Inlet
Flapper
Valve
Molded Desiccant Block
When servicing or repairing heat pump systems,
especially older units, it’s a good idea to simplify them
by replacing unidirectional driers and check valves with
bi-directional driers. When a bi-directional filter-drier
is installed, check valves, and filter-driers can all be
replaced at once with copper tubing.
Inlet
Flapper
Valve
Outlet
Poppert
Valve
Outlet
Poppert
Valve
Inlet
Flapper
Valve
Steel Retaining Screen
Inlet
Flapper
Valve
Final Filter Pad
Steel Retaining Screen
Refrigerant flow either direction passes from
outside to inside of desiccant core
BASIC FLOW
PATTERNS
Cooling
Cycle
Heating
Cycle
Emerson System Protectors
Emerson filter-driers were redesigned for increased
water removal capacity to reach these low moisture
levels. However, since no system is entirely without
water on startup some organic acids will be generated
and must be removed. The desiccant formulation for
the Emerson EK series of filter-driers was designed to
provide the best mix of water capacity and acid capacity
to ensure that harmful contaminates are removed. This
desiccant mixture contains molecular sieve and activated alumina. The molecular sieve is specifically designed
to provide maximum drying in today’s systems. The
activated alumina is ideal for capturing the large organic
acids that the molecular sieve cannot.
Replace two check valves and two
expansion valves with one EMERSON
Bi-directional Thermal Expansion Valve
Emerson 4-way
Reversing Valve
Expansion Device
Filter-Drier
Check Valve
Emerson
Discharge
Muffler
Remove both filter-driers &
replace each with a piece of
copper tube
Expansion Device
Emerson
Suction Line
Compressor Filter-Drier
Install One BFK
in a convenient
Location in Common
Liquid Line
Filter-Drier
Check Valve
Bi-directional components allow simplification of system
27
Regulators
2008
28
Regulators
Types of Regulators:
Suction Line Regulators
EVAPORATOR
PRESSURE
REGULATOR
Suction line regulators provide a wide variety of refrigerant control functions, but are mainly used for regulating suction gas pressures. These regulators provide
a method of balancing the output of the refrigeration
system with the load requirements. Two basic types are
covered here:
1) Upstream pressure regulators, which control from an
inlet pressure signal.
2) Downstream pressure regulators, which control from
an outlet pressure signal.
EVAPORATOR
PRESSURE
REGULATOR
EXTERNAL
STRAINER
EXTERNAL
STRAINER
RECOMMENDED
RECOMMENDED
NOTE: HIGH SIDE PILOT
PRESSURE REQUIRED
FOR EPRBS
60 PSIG
HIGH
EVAPORATOR
PRESSURE
50 PSIG
INTERMEDIATE
EVAPORATOR
PRESSURE
NOTE: HIGH SIDE PILOT
PRESSURE REQUIRED
FOR EPRBS
20 PSIG
LOW
EVAPORATOR
PRESSURE
Figure 1: Evaporator Pressure Regulators
used in multiple system.
Application of
Evaporator Pressure Regulators
EPR Installation
Evaporator Pressure Regulators are normally used
on multiple-compressor refrigeration systems fed by
TXVs, low side floats or solenoid liquid valve and float
switch combination. They are used whenever a minimum evaporator pressure or temperature is desired.
Controlling from an inlet side pressure signal, they
prevent upstream pressure from going below a pre-set
point.
EPR valves are used on brine or water chillers to prevent freeze-up during low load periods, by keeping the
refrigerant saturation pressure above the fluid freezing
temperature. Similarly, they may be used to prevent frost
formation on fan coil evaporators. They may also be
used to provide a given evaporator saturation pressure
to produce the required evaporation/room temperature
difference, (especially useful where humidity control is
required). On multiple evaporator systems where different evaporator temperatures are required, EPR valves
will hold the saturation pressure at the required set point
above the common system suction pressure. Here, the
EPRs prevent lowering of the desired temperature in the
warmer evaporators, while the compressor continues
operating to satisfy the coldest evaporators. See
figure 1.
EPRs may be installed at the compressor rack or
close to the evaporator.
Suction line regulators can be direct acting or internally piloted such as an Emerson IPR regulator. These
are hermetically sealed, non-repairable valves for use
on low capacity systems.
For higher sensitivity and accurate control, an externally piloted EPRB regulator will provide control of larger
units. These are repairable in the line. The EPRB valve
is a lightweight, brass body valve which eliminates the
need for normal system pressure drop needed to make
the valve move through the full stroke. This is accomplished by using compressor discharge gas to pilot the
regulator.
Combining an EPRB with a suction stop or shut off is
done with the EPRBS models. When the pilot solenoid is
de-energized, the valve closes. This eliminates the cost
of a separate suction solenoid and offers a tight shut off.
Figure 2: Cutaway view of an EPRBS.
29
Regulators
Upstream Regulators
Series EPRB & IPR
The sole function of the Evaporator Pressure Regulator is to prevent the evaporator pressure from falling
below a predetermined pressure setting. This enables
the system to meet certain load requirements over a
wide range of conditions and offers improvement over
the simple “on-off” compressor control usually provided
by thermostats or pressure switches.
These are all upstream regulators which can be
selected from the capacity charts available. Combining the regulator with a suction stop or shutoff solenoid
will cause the regulator to act as a suction stop valve.
Certain basic design operating condition data must be
determined to properly apply the regulator. For best
results, follow the simple procedure outlined below.
To select the proper regulator port size, the following
information is required:
1. System refrigerant (R134a, R22, R404A/R507A).
2. The required pressure setting (lowest allowable
evaporator pressure and corresponding refrigerant
saturation temperature).
3. The system suction pressure at the regulator outlet
(suction pressure where compressor capacity balances with system load) making allowance for any
common suction line pressure drop.
4. Pressure drop across regulator port. Subtract suction
pressure (3) from regulator set point (2).
5. Evaporator load in tons at regulator setting (required
minimum evaporator saturation temperature).
Downstream Pressure Regulators
Suction pressure regulators are used to prevent
compressor motor overload. By throttling the suction gas
flow during high load conditions, the compressor motor
is permitted to remain within current draw limitations.
Often referred to as holdback valves, crankcase pressure regulators or suction pressure regulators, they also
serve many other useful applications.
A downstream pressure regulator can be direct acting
such as an OPR valve. These are hermetically sealed,
non-repairable outlet pressure regulators for use on low
capacity systems.
Adjustable Range Table
Valve
EPRB(S)-12 thru -20
IPR-6, -10
OPR-6, -10
Adjustable Range
0 to 110 psig
0 to 50 psig
30 to 100 psig
65 to 225 psig
0 to 60 psig
50 to 130 psig
100 to 225 psig
With the above information, select the proper regulator as follows:
1. Select the valve extended capacity table from that
page which covers the system refrigerant.
2. Find the required evaporator saturation temperature
column.
3. For the available regulator pressure drop, find the
rated capacity for each regulator port size.
4. Select the proper port size from the capacity which
matches the evaporator load.
Standard Voltage & Frequencies Table
Voltage
24
120
208-240
Cycles
50-60 Hz, AC
Figure 3: EPRB(S) Brass Body
Upstream Pressure Regulator with Suction Stop Option
30
Regulators
Crankcase Regulators
Normally open, the CPR (Fig. 4) closes when compressor pressure rises above the pre-set maximum,
forcing the valve back onto its seat. As suction pressure
drops, the valve starts to reopen, maintaining a balance.
Fig 5. Cutaway of evaporator pressure regulator
(Emerson EPRB).
Where to Apply Regulators
Fig 4. Cutaway of crankcase pressure
regulator (Emerson OPR)
How to Apply Regulators
It isn’t normally necessary to apply both an EPR and
a crankcase regulator. Most installations only utilize an
EPR.
Typical installations of EPRs are in supermarket
systems, large chillers, and industrial processes where
large amounts of heat must be absorbed. Smaller
(including residential) systems of less than 5 tons are
usually equipped with compressors designed to operate
well within 30°-40°F variations.
One of the advantages of suction line regulators in
supermarkets is that by adding EPRs you can control
the operating temperatures of the individual cases in a
single loop system.
EPRs are most commonly used on multiple evaporator systems, installed in the branch lines close to
the required control source. They are used for indirect
temperature control. They also maintain evaporator
pressure during defrost, conserving power, expediting
the defrost and reducing flood back.
CPRs are usually only applied if the system is being
continually “over-pressured,” causing the compressor
to be overloaded. If you suspect that’s the case, check
the amp draw on the compressor while it’s running. If it’s
higher than the plate rating, the system may be a CPR
candidate.
31
Regulators
HeadMaster Head Pressure Controls
The application of air-cooled condensers for yearround operation, or during periods of low ambient
temperature, requires some means of control to maintain adequate condensing pressures that ensure proper
system performance. It is essential that proper liquid
refrigerant pressure be controlled to:
1) Maintain liquid subcooling and prevent liquid line
flash gas.
2) Provide adequate pressure at the inlet side of the
Thermostatic Expansion Valve to get enough pressure drop across the valve port.
3) Properly operate systems with hot gas defrost or hot
gas bypass.
4) Provide adequate temperature for operation of heat
reclaim systems.
Without proper control of condensing pressure a
refrigeration system might not perform properly and
components can be damaged. Emerson’s HeadMaster
Control offers an efficient and economical approach to
this common industry problem on air cooled condensers.
The HeadMaster 3-Way Head Pressure Control
eliminates the need for special piping or multiple control valves. As a single unit it simplifies piping and cuts
installation costs.
As ambient air temperature falls, an uncontrolled air
cooled condenser will exhibit a corresponding decrease
in head pressure. As the discharge (bypass) pressure
falls, it no longer counters the dome charge pressure
and the diaphragm moves downward, moving the pushrod and seat disc toward the bottom seat. This allows
discharge (bypass) gas to be metered into the receiver,
creating a higher pressure at the condenser outlet. The
higher pressure at the condenser outlet reduces the flow
from Port C and causes the level of condensed liquid to
rise in the condenser.
The flooding of the condenser with liquid cuts the
available condensing surface. The result is to raise the
pressure in the condenser and maintain an adequate
high side pressure. Figure 7 illustrates a typical application of the 3-way control valve. This system is perhaps the most economical and reliable way to control
discharge pressure. The three-way valve as shown in
figure 6 is a fixed, non-adjustable valve. The wholesaler
replacement setting is normally furnished for a pressure
corresponding to 95° to 98°F condensing temperature
for the given system refrigerant.
HeadMaster HP Operation
The HP control is a three-way modulating valve
controlled by the discharge pressure. The charged dome
exerts a constant pressure on top of the diaphragm. At
high ambient air temperature, bypass gas entering Port
B is allowed under the diaphragm where it counters the
pressure of the dome charge. This upward push on the
diaphragm allows the seat disc to seal against the top
seat, preventing flow from Port B (discharge gas) while
flow from Port C is unrestricted (see figure 6).
Figure 6: HeadMaster HP Valve CutAway View
Figure 7: Typical 3-Way Valve
Head Pressure Control Application
As with all head pressure control applications, additional liquid receiver capacity is required to prevent loss
of a liquid seal in the receiver when the condenser is
flooded. The receiver must be large enough to hold the
total system charge. The total system charge consists of
the following:
1. An operating charge which is the amount of refrigerant needed to operate the system during summer
(high ambient temperature) conditions.
2. An additional charge equaling the amount of refrigerant required to flood the condenser with liquid. The
condenser must be filled with liquid to a point where
a minimum head pressure is created for cold weather
(low ambient temperature) conditions.
32
Regulators
NOTE: Should the outdoor temperature fall below design conditions, more refrigerant will be required.
The total above is the total charge needed for satisfactory system performance during the lowest expected
ambient air temperature conditions. During summer
operation the receiver must be sized to safely hold the
total system charge. Good refrigeration practice states
that the total system charge should not exceed 80% of
the receiver capacity.
from happening, make sure fan controls are set to operate at pressures above the HP valve setting.
HP Series Capacity & Selection
CAUTION:
1. The HP control should not be used on a system
which does not have a liquid receiver or on one with
a receiver which is too small. If the receiver does not
have adequate storage space, the refrigerant will
back up in the condenser to produce excessively high
discharge pressures during high ambient air temperatures, with could cause system damage or personal
injury.
2. The HP control should be used only on systems
which employ a Thermostatic Expansion Valve.
Installation of HP HeadMaster Series
Head pressure control systems are used on refrigeration systems that are temperature operated. The
compressor is started by a thermostat or the system
operates on a pump down cycle, where the thermostat
controls the liquid line solenoid valve and the compressor starts on a rise in suction pressure with a low pressure switch.
On systems that are pressure operated, migration of
the refrigerant to the cold condenser on the “off” cycle
should be prevented. If the system does not operate on a pump down cycle, migration can take place
through some compressors, from the suction line to the
condenser. Crankcase heaters will prevent liquid from
condensing in the crankcase, but will not stop migration
to the cold condenser. If the system is properly charged,
the filled condenser will permit the excess to remain in
the receiver and low side.
Under some conditions where the receiver is located
in a warm ambient, a check valve in the liquid drain line
between the HeadMaster control and the receiver may
be required to prevent the liquid receiver pressure from
equalizing to that of the condenser during the “off” cycle.
This enables the system to start on a pressure switch.
Some systems may require a time delay on the low
pressure switch. Condenser fans should not be cycled
when using the HeadMaster control. The sudden changes in high side pressure caused by fan cycling will result
in erratic Thermostatic Expansion Valve performance,
and shortened head pressure control life. To prevent this
The nominal HP control capacity in tons for various
refrigerants is shown in Table 1 for R134a, R22 and
R404A/R507A. The nominal capacity is based on 100°F
liquid, 40°F evaporator and the pressure drop shown.
To get capacities in tons at other liquid and evaporator
conditions, multiply the nominal capacity at the desired
pressure drop by the correction factor given in the
catalog for the liquid temperature and evaporator
temperature.
Table 1 – Nominal Capacity (tons)
Pressure Drop – PSI
Valve Refrigerant
1
2
3
4
5
HP-5
2.0 2.9 3.6 4.1 4.6
HP-8
R-134a
5.5 7.8 9.6 11.0 12.4
HP-14
14.0 19.8 24.2 28.3 31.7
HP-5
2.2 3.2 3.9 4.5 5.0
HP-8
R-22
6.0 8.5 10.5 12.0 13.5
HP-14
14.7 20.8 25.6 29.7 33.8
HP-5
1.5 2.1 2.6 3.0 3.3
R-404A
HP-8
3.9 5.5 6.7 7.8 8.7
R-507A
HP-14
10.1 14.3 17.6 20.5 23.0
Based on 100°F liquid and 40°F evaporator
NOTE: Not recommended for systems utilizing patented subcooling coils in conjunction with low head pressure systems or
on sytems where the condensate line bypassses the receiver
in order to maintain subcooling effect in the liquid line.
NOTE: Do not select a valve for a capacity rating exceeding 5 psi pressure drop from Port C to Port B or for
a system with more than 20 psi pressure drop across
the condenser.
During normal ambient conditions, the available liquid
subcooling in the condenser will be adequate to cover
the pressure drop through the HeadMaster control.
If a valve is selected for a given flow rate, the resulting pressure drop must not cause the liquid pressure to
drop below saturation and produce flash gas. If enough
sub-cooling is not available to cover this pressure drop,
it is suggested that more than one valve be installed in
parallel to lower the pressure drop to tolerable limits.
Do not parallel valves of different capacities. Liquid
drain lines from the condenser to receiver are sized for a
velocity of 150 ft./min. or less.
33
Regulators
Hot Gas Bypass
HP Parallel Piping
Demand continues to mount for improved comfort
conditioning combined with lower operating costs. New
architectural designs have created real problems for
contractors and engineers to maintain humidity control at reduced loads, and to control load variations.
Refrigeration and air conditioning systems are usually designed to provide a given capacity at maximum
conditions. These operate with little fluctuation throughout a narrow load range. However, only the larger size
machines make any provisions for operation at reduced
capacity. In some systems, integral cylinder unloading,
gas engine drives with variable speed control, or even
several smaller systems, provide a logical solution.
Additional Refrigerant
Function – Hot Gas Bypass Method
On most systems, an added refrigerant will be required. It is essential to have enough to completely fill
the condenser for the lowest ambient condition. To accurately determine the added refrigerant charge required
to fill the condenser, find the total length of condenser
tubing in feet, and multiply by pounds of refrigerant per
foot for a given size tubing.
Many manufacturers now recommend use of a
modulating control valve to provide a metered flow of
compressor discharge gas to the system low side, in a
proportion that will balance the system capacity to the
load demand. This is commonly known as the hot gas
bypass method. It permits full modulation of capacity
on all types of reciprocating compressors, and extends
capacity reduction below the last step of cylinder unloading.
The system must provide a means of bypassing high
pressure refrigerant to the system low pressure side, to
maintain operation at a given minimum suction pressure. Proper bypass control can be accomplished by a
modulating type pressure regulator, which opens on a
decrease in valve outlet pressure.
Factory Settings
The HeadMaster Control is factory-set to provide
an average condensing temperature consistent with
good system performance. The complete type number
includes the service reference code, port size, connection size and style. When ordering, be sure to specify
the complete type number.
UL File No. SA5312
CSA File No. LR44005
Operation of Bypass Valves
Bypass pressure regulators are grouped into the following categories:
1. Direct acting conventional port valves (figure 3)
2. Direct acting balanced port valves (figure 4). Any of
these regulators are available with either an adjustable setting, or a fixed, non adjustable setting.
Figure 4: Balance port CPHE adjustable field-serviceable
hot gas bypass regulator.
Figure 3: DGRE adjustable hot gas bypass regulator.
34
Regulators
Applications: Hot Gas Bypass to
Compressor Suction Line
Figure 6 shows the most common hot gas bypass
system. In this system, the bypass line is taken directly
from the compressor discharge line, through a bypass
regulator, and into the suction line at the compressor.
Although the hot gas bypass regulator is considered a
downstream control, there is a big difference in function
between a Crankcase Regulator and a hot gas regulator.
Pilot operated bypass valve main regulators have
a long stroke stem with a restrictor plug characterized
by either a parabolic or vee port restrictor plug design.
This prevents the valve from operating close to the seat
where pressure differential unbalance may occur, eliminating the need for a balanced port design.
The characterized port will provide smooth bypass
flow modulation. Pilot operated valves usually have the
extra features of a manual opening stem for testing or
emergency operation, flanged connections, synthetic
tight seating seats, and replaceable parts. Hot gas
bypass valves can be applied to a system in several
ways, differing only in the point to which the hot gas is
to be bypassed. Several mixing methods are available.
The one recommended is piped so that discharge gas is
admitted to the suction line to flow against the direction
of the suction gas as in figure 6.
Applications: Bypass to Evaporator Inlet
Another method is to bypass the hot discharge gas to
the evaporator inlet, usually between the Thermal Valve
and the refrigerant distributor (see figure 7). This provides distinct advantages. The artificial load imposed on
the evaporator causes the Thermal Valve to respond to
the rise in superheat, eliminating the need for the liquid
injection valve. The evaporator serves as an excellent
chamber to provide homogeneous mixing of the gases
before reaching the compressor.
Hot gas bypass into the evaporator is suggested
when the evaporator elevation is below the compressor, to prevent oil trapping caused by low velocity at low
loads. This assures proper oil return. Although there
are many advantages to this system, it is not used on a
multiple coil system, or where the evaporator sections
may be located a distance from the compressor. The
coil should be a free draining circuiting design to prevent
the increase in velocity, due to forcing a large quantity of
trapped liquid out of the low side, which in some cases
may have enough volume to flood the compressor
crankcase. Separate regulators must be used for each
evaporator when bypassing to multiple evaporators
located below the compressor to help oil return.
LIQUID
INJECTION
SOLENOID VALVE
Figure 6: Hot gas bypass using type LCL
liquid injection valve.
Figure 7: Direct acting hot gas regulator admitting flow
between TEV and venturi distributor.
Bypass to flooded evaporators and suction line
accumulators also present special cases. Contact the
equipment manufacturer or the bypass control valve
manufacturer for specific, detailed information.
Solenoid Valve for Positive Shut-off &
Pump-down Cycle
It is recommended that a solenoid valve be installed
ahead of the bypass regulator. This permits the system
to operate on an automatic pump-down cycle.
35
Regulators
Thermal Valves for Liquid Injection
Application and Installation
When hot gas is bypassed directly into the suction
line, it is necessary to make some provision for desuperheating the gas returning to the compressor. Without a
small Thermal valve to lower suction gas temperature to
tolerable limits, compressor damage may occur. Standard Thermal Valves cannot be adjusted for control over
20°F superheat and, therefore, are not recommended.
Liquid Injection Thermal Valves with special adjustment
ranges are used to conform to compressor manufacturer
temperature recommendations.
To simplify selection, Emerson has developed Liquid
Injection Thermal Valves with four basic adjustment
ranges. These are designated as models A, B, C and D.
The adjustable superheat range chart (page 11) shows
the proper power assembly charge symbol suffix for a
given saturated suction temperature and a given superheated suction gas temperature entering the compressor.
Nearly all Thermal valves for liquid injection may be
internally equalized. However, if pressure drop occurs
at the valve outlet due to a distributor, spray nozzle or
other restrictive device, externally equalized valves may
be needed.
Model LER and LIR valves are furnished with a 1/4”
SAE male flare external equalizer as standard. Other
models must include the code letter “E” to specify the
1/4” SAE male flare external equalizer connection.
Example: LCLE and LJLE.
Liquid injected into a gas to be desuperheated should
be injected in a way which provides a homogeneous
mixing of the liquid and superheated gas. Desuperheating hot gas bypass in the suction line may be accomplished in several ways.
The preferred method is to bullhead the hot gas and
liquid injection in a tee to permit good mixing before it
enters the suction line. A good mix with the suction gas
may be gained by injecting the liquid/hot gas mixture
into the suction line at a 45° angle against the flow of
suction gas to the compressor. See figure 6.
For suction lines 7/8” OD and smaller, the bypass
mixture may be introduced into a tee rather than an
angle connection. For lines larger than 2-5/8” OD, introduce the desuperheated bypass mixture into a 90° ell
inserted against the flow of suction gas to the compressor.
Arranging a bypass directly into a suction accumulator is often a convenient way to get proper desuperheating of suction gas.
Introducing the hot gas and liquid into the suction line
with separate connections is not recommended.
NOTE: Excessive suction gas superheat can cause
serious damage to the compressor. As a safety precaution, the bypass line solenoid valve should be wired in
series with a discharge line thermostat.
Special Applications
On systems where evaporator pressure regulators
are used, better control can be reached by installing
the bypass regulator equalizer line on the downstream
(outlet) side of the EPR so it responds to compressor
suction pressure, not evaporator pressure. This results
in nearly constant evaporator load balance. See figure 8.
Figure 8
36
Regulators
Adjusting the Set Point
Application Tips
The suction pressure at which the valve opens is
selectable by increasing or decreasing the load on the
spring by turning an adjusting screw. To set it, the evaporator must be cooled down by shutting off the fans,
blocking off the airflow, or some other means, until the
suction pressure drops to at least five pounds below the
desired set point. Then, by allowing the pressure to be
raised by the bypass gas, the spring load can be varied
until the valve closes at precisely the desired set point.
The pressure is set to maintain an evaporator temperature just above that at which frost forms.
• In systems that use a Venturi type distributor, the
bypass gas should be fed into the system between
the outlet of the expansion valve and the inlet to the
distributor. For pressure drop distributors that use an
orifice, the inlet must be between the orifice and the
inlet to the distributor.
• The hot gas bypass line should be insulated to minimize system heat loss.
• In systems with sequential compressor unloading, the
valve should be set to start opening at two to three
pounds below the last stage of unloading, because
compressor unloading is considerably more efficient
and should be used before resorting to bypassing.
• For oil return considerations, the bypass line must
feed in ahead of the evaporator when the evaporator
is installed below the compressor.
• The hot gas bypass valve should be installed as close
as practical to the condensing unit, to reduce condensing ahead of it.
• In systems that operate on a pump down cycle, there
must be a solenoid valve or some other means of
shutoff in the bypass line.
37
Oil Controls
38
2008
Oil Controls
Oil Controls
Any time that compressors are operated in a parallel operation (Suction and Discharge lines manifolded
together), an oil control system in needed to ensure that
each compressor has enough oil to operate properly.
Oil control systems are sometimes as basic as a
common line connected between compressors to allow
oil and gas equalization. This is usually referred to as a
“passive” oil system. Although this may suffice on twocompressor systems, compressor racks of three or more
compressors almost always have an “active” system
since even small differences in crankcase pressures can
cause oil starving. This system uses an oil separator to
capture most of the oil from the compressor discharge
gas since some oil is carried out of the compressor
with the refrigerant. Several types of oil separators are
commonly used in these applications. The older style is
called an impingement type while newer, more efficient
types are the centrifugal and coalescing types.
After the oil is separated from the refrigerant, it collects in the bottom of the oil separator where it is fed
directly to the crankcase in a high-pressure oil system
using oil controls on the compressor crankcases.
To
Condenser
Compressor
Discharge
Filter-Drier
Common Suction
Oil Separator
Reservoir
OMB
OMB
OMB
Differential
Pressure Valve
Reservoir
Compressor
Discharge
Filter-Drier
Common Suction
To
Condenser
Oil
Separator
OMB
OMB
On all oil systems, it is important to install an oil filter
downstream of the oil separator to ensure a supply of
clean oil to the compressors.
Emerson Oil Controls
A high-pressure oil system can use an Emerson OMB
oil control mounted on the compressor crankcase. The
OMB is a device which uses a reverse Hall-effect magnetic float to activate a solenoid to allow oil to flow into
the crankcase whenever the level falls below 1/2sight
glass level. It is designed to operate at oil pressures up
to 350 psid.
OMB
High-Pressure Oil System
A low-pressure oil system incorporates a separate oil
reservoir which is downstream of the separator. Oil separators
in low-pressure oil systems have a float valve in the bottom to
allow excess oil to pass to the reservoir whenever the level is
high enough in the separator to open the valve. The pressure
in the oil reservoir is usually held 20-30 psi above the crankcase pressure through a differential check valve. This lower
pressure allows mechanical oil floats, which use a float valve
which opens when the crankcase oil level falls below 1/sight
glass, to be used to feed oil into the compressor crankcases.
The mechanical floats cannot be used on high-pressure oil
systems because the oil pressure entering them would be too
high and cause them to not be able to control the oil level.
OMB
Low-Pressure Oil System
OMB
39
Temperature
Pressure Controls
40
2008
Temperature-Pressure Controls
tion are capillary type of sensors, which do not have a
bulb, instead, their capillary serves as the bulb directly.
Charges and sensor types are matched to temperature ranges and other application specific characteristics. TS1 thermostats come with one of three charge
types: vapor charges, adsorption charges or liquid
charges. The application temperature range covered by
each charge type is shown below:
Temperature Pressure Controls
Temperature pressure controls serve a number of
purposes in refrigeration systems, including the control
of compressor cycling, pump-down, defrost control,
pressure limiting, loss of charge freeze protection and
fan speed control.
TS1 Introduction
The TS1 Series is Emerson’s adjustable thermostats
for application in refrigeration and heat pump systems.
In these systems, thermostats provide space temperature control, high/low temperature alarming or defrost
termination. By operating an electrical contact, a temperature value is kept inside a certain limit.
Liquid Charge
Housing Variants
Vapour Charge
Adsorption Charge
TS1 controls are top operated. Top operated
controls have adjustment spindles at the top and a
display scale, showing temperature setpoint and differential, at the front. A knob which may be permanently
plugged onto one of the adjustment spindles comes with
every control. Frost monitors and room thermostats are
derivatives of top operated thermostats. They differ by
their sensors and other features to suit their target
applications.
-148°F
TS1 Top Operated
Temperature Sensing
TS1 thermostats sense temperature by a thermal
system, consisting of temperature charge, bulb, capillary
and bellows. The temperature charge changes its pressure based on the refrigerant temperature to be sensed.
The sensor is the part of the system which is in thermal
contact with the refrigerant. The capillary connects the
sensor with the bellows and the bellows contracts or
expands depending on the temperature, causing the
thermostat to operate the electrical contacts. An excep-
-58
32
122
212
302
392°F
Vapor Charge – Sensor Type A, E, P
These sensing elements always sense from the coldest point on the capillary, coil, bulb or power element
head. For proper operation, the coldest point must be at
the part of the sensor which is exposed to the medium
temperature to be sensed. The sensing location should
be at least 4 degrees F colder than the other parts of the
thermal system.
To avoid unwanted effects of heat transfer, for example from a cold wall, vapor charged thermostats come
with an integrated bellows heater (not for frost monitors),
which is rated for 230V applications. For other applications, the heater must be disabled or a bellows heater
with a different rating should be used.
Besides the bellows heater, room thermostats are
supplied with an insulation console for the same reason.
Sensor type ‘A’ is a coiled bulb sensor with two meter
capillary, which may be used with or without a bulb well.
Style ‘E’ is a coil sensor for space temperature sensing,
and type ‘P’ is a capillary type of sensor which can be
wrapped around a heat exchanger’s surface to sense
the coldest point on the heat exchanger for frost protection applications.
Vapor charges respond faster to temperature changes than adsorption and liquid charges.
41
Temperature-Pressure Controls
Adsorption Charge – Sensor Type F
Adsorption charged sensor types operate on a temperature dependent adsorption material, which is inside
the bulb only. These sensor types always respond to
temperature changes at the bulb only. This makes them
suitable to applications where it is not always defined
which part of the thermal system the coldest point is
(cross ambient applications). An example for such applications is defrost control.
Adsorption charges are slower in response to temperature changes than vapor charges.
Liquid Charge – Sensor Type C
Liquid charge sensors of type ‘C’ always sense from
the warmest point of the thermal system. The sensing
location must always be 4 degrees F warmer than other
parts of the thermal system.
Setpoints
TS1 are adjustable controls with adjustment spindles
for range and differential. Note that manual reset controls and some other controls have a fixed differential
and no differential spindle. By turning the range spindle,
the upper setpoint is defined and by adjusting the differential spindle, the differential and the lower setpoint is
defined.
The dependency between upper and lower setpoint is
always as follows:
lower setpoint = upper setpoint – differential
The following two rules should be kept in mind:
➯ an adjustment of the range spindle always affects
both upper and lower setpoint.
➯ an adjustment of the differential spindle affects the
lower setpoint only.
The controls are equipped with display scale and
pointers to show the approximate settings.
Top operated controls have display scales in units °C
and °F, front operated controls have a display scale in
units °C.
For precise setting of the controls, external thermometers must be used.
Electrical Contacts
TS1 temperature controls are equipped with high
rated double snap action contacts for shatter-free and
reliable operation.
All contacts in these controls are designed as Single
Pole Double Throw (SPDT) contacts. One contact may
be used for control and the other contact for alarm/status indication or auxiliary control.
Gold plated contacts are available on request for low
electrical loads, for example in electronic signaling applications.
For applications using a supply voltage other than
230V and for applications using gold plated contacts,
the bellows heater of vapor charged thermostats (sensor
style A, E or P – not for frost monitors function C or D)
must be disabled.
Contact Function
Thermostat contacts TS1 are labeled 1-2-4 where ‘1’
refers to the common pole, ‘2’ refers to the lower setpoint and ‘4’ refers to the upper setpoint.
The contact function for automatic and manual reset
versions is as described below.
Automatic Reset
On temperature rise above the upper setpoint,
contacts 1-open and contacts 4 close. On decreasing
temperature lower setpoint contacts 4 open and contacts close.
2
4
1
-
+
Automatic reset contact function
Manual Reset Low Temperature
On decreasing temperature below the lower setpoint,
contacts 1-4 open, contacts close and latch. Only on
temperature rise above upper setpoint and after pressing the manual reset button contacts will open and
contacts 4 will close again.
2
-
4
1
+
Manual reset low temperature contact function
Manual Reset High Temperature
On increasing temperature above the upper setpoint,
contacts 1-open, contacts 4 close and latch. Only on
falling temperature below lower setpoint and after pressing the manual reset button, contacts 4 will open and
contacts 1-will close again.
2 4
-
1
+
Manual reset high temperature contact function
42
Temperature-Pressure Controls
For operational safety, all TS1 with manual reset are
designed as trip-free controls, i.e. pressing the manual
reset button while the temperature has not reached its
reset threshold will not operate the electrical contacts.
Should the inner bellows leak, then the larger surface area of the outer bellows creates a larger force
and causes the pressostat to a pre-empted cut out. This
represents a fail-safe function. Standard controls for
refrigeration applications are equipped with a bronze
bellows and can be used with all common HFC, HCFC
and CFC refrigerants.
Bellows Heater
TS1 with vapor charges, i.e. sensor types A, E, P
(not frost monitors function C or D) have a bellows
heater wired across the contacts in the following way.
4
1
2
+
Ω
Single Pressostat PS1
Bellows heater
PS1/PS2 Introduction
The PS1/PS2 Series is Emerson’s adjustable pressostats for application in refrigeration and heat pump
systems.
In these systems, pressure controls serve control
and protection functions. Examples of control are
compressor cycling, pump-down or defrost control.
Protection includes pressure limiting and cut out against
excessive pressures, against loss of charge or for freeze
protection.
Dual Pressostat PS2
Pressure Connectors
Pressure Sensing
All pressures mentioned in this document are understood as gauge pressures. PS1/PS2 controls sense
pressure by bellows which expand or contract when
exposed to medium pressure.
High pressure limiters and pressure cut outs with
type approval according to EN 12263 feature a double
bellows design. The inner bellows serves as the operating bellows and is enclosed by the outer bellows featuring a larger surface area.
A variety of pressure connectors, including male
and female flare type connectors, capillary and solder
connectors are available. The standard connector is a
7-16”-20 UNF male flare connector, which, in its high
pressure versions, is equipped with a snubber to protect
against pressure pulsations.
Electrical Contacts
PS1/PS2 pressure controls are equipped with high
rated double snap action contacts for shatter-free and
reliable operation.
All contacts in these controls are designed as Single
Pole Double Throw (SPDT) contacts. One contact may
be used for control and the other contact for alarm/status indication or auxiliary control. Dual Pressostats PS2
come with two independently actuated SPDT contacts,
providing for even further application flexibility by allowing for a variety of wiring options.
43
Temperature-Pressure Controls
Setpoints
PS1/PS2 are adjustable controls with external adjustment spindles for range and differential. Note that
manual reset controls have a fixed differential and no
differential spindle. By turning the range spindle, the
upper setpoint is defined and by adjusting the differential
spindle, the differential and the lower setpoint is defined.
The dependency between upper and lower setpoint is
always as follows:
-
The following two rules should be kept in mind:
➯ an adjustment of the range spindle always affects
both upper and lower setpoint.
➯ an adjustment of the differential spindle affects the
lower setpoint, only.
The controls are equipped with display scale and pointers to show the approximate settings. The display scales
are printed in relative pressure units “bar” and “psi”. For
precise setting of the controls, external gauges must be
used.
Contacts on Dingle Pressostats, PS1 are labeled
1-2-4 where ‘1’ refers to the common pole, ‘2’ refers to
the lower setpoint and ‘4’ refers to the upper setpoint.
This is true for all types of controls, irrespective whether
they are low pressure controls, high pressure controls,
manual or automatic reset types.
The contact function for automatic and manual reset
versions is as described below.
Automatic Reset
When pressure rises above the upper setpoint,
contacts 1-2 open and contacts 1-4 close. On decreasing temperature lower setpoint contacts 1-4 open and
contacts 1-2 close.
2
P
4
1
+
Manual reset low pressure contact function
lower setpoint = upper setpoint – differential
Contact Function
2
P
Manual Reset High Pressure
When pressure rises above the upper setpoint,
contacts 1-2 open, contacts 1-4 close and latch. Only on
falling pressure below lower setpoint and after pressing the manual reset button, contacts 1-4 will open and
contacts 1-2 will close again.
2 4
P
-
1
+
Manual reset high pressure contact function
For operational safety, all PS1/PS2 with manual
reset are designed as trip-free controls, i.e. pressing the
manual reset button while the pressure has not reached
its reset threshold will not operate the electrical contacts.
As Dual Pressostats PS2 have two sets of contacts,
their function is the same as on Single Pressostats PS1
with the only difference that the contact labels are preceded by an additional index. One side of the control is
labeled 11-12-14 and the second side is 21-22-24.
The contact function of controls with convertible reset
is as described above but depends on the position of the
convertible reset toggle, i.e. automatic or manual reset
position.
4
1
- +
Automatic reset contact function
Manual Reset Low Pressure
When pressure drops below the lower setpoint,
contacts 1-4 open, contacts 1-2 close and latch. Only
on pressure rise above upper setpoint and after pressing the manual reset button contacts 1-2 will open and
contacts 1-4 will close again.
44
Temperature-Pressure Controls
PSC Pressure Switch
The Flow PSC is a Pressure Switch with fixed switchpoint settings.
Features
• Maximum Operating Pressure up to 623 psig Test
Pressure up to 696 psig
• Standard factory settings from stock in small volumes
• High and low pressure switches
• High temperature version with snubber for direct compressor mounting (Range 6)
• Direct mounting reduces the number of joints and thus
avoiding potential leakage
• Precise setting and repeatability
• IP 65 protection if used with the cables with plug
PSC
Options
•For direct mounting on a pressure connection
(free standing) or with a capillary tube
•Direct compressor head mounting with high
temperature bellows and snubber
-reduces the number of joints
-avoids potential leakage
-saves high cost of flexible hose
•TÜV approved versions for high and low pressure
•Micro-switch for narrow pressure differentials
•Gold plated contacts for low voltage/current
applications
•Cables with plug ordered separately
4
1
2
P
+
-
Single Diaphragm
PSC Introduction
PSC is equipped with a SPDT snap action contact,
switching from 1-2 to 1-4 on rising pressure and from 4
to on falling pressure (see diagram). Several models are
available:
• Low pressure switch, with automatic or manual reset
• High pressure switch, with automatic or manual reset
• DIN/TÜV approved safety high pressure limiter with
automatic reset
• DIN/TÜV approved safety high pressure cut-out, with
internal or external manual reset
Bellows (Pressure Range 6)
TÜV approval for pressure switches can be reached
either by using a double diaphragm (Pressure range
1-5) which acts in a fail-safe mode or by a single pressure element (Bellows, Pressure range 6) which is able
to resist to >Mio. cycles between 50% and 100% of the
maximum operating pressure (see 4.6.1 of EN 12263).
45
Temperature-Pressure Controls
FSX Introduction
Description of control behavior
FSX electronic speed controllers are designed to
control the speed of fan motors in commercial refrigeration system depending on condensing pressure changes. It is suitable for single phase. FSX can be used in
air-cooled condensers, air-cooled condensing units and
air-conditioning units.
Using variable fan speed controllers offers the
following benefits in commercial refrigeration or airconditioning applications:
• Head pressure can be kept high enough to ensure
proper operation of the expansion valve, and sufficient
mass flow through the expansion valve to feed the
evaporator. This maintains the required cooling capacity.
• Efficiency increase of the compressor by controlling
the head pressure, improved performance and energy
saving for the complete system.
• The noise fan motors can be kept at a minimum by
avoiding permanent on/off cycling.
FSX control behavior can be easily described by
looking at the function of output voltage versus input
pressure (see figure 1) and by dividing it into maximum,
proportional and minimum range.
Supply Output
Voltage Voltage
99%
230 V
Maximum range
Minimum
50% range
Cut-off
0%
Proportional range
Proportional range: Pressure (bar)
FSX-41_: 2,5 bar
FSX-42_: 3,8 bar
FSX-43_: 4,6 bar
Figure 1 – FSX Output Voltage Versus Input Pressure
FSX-43S
In the maximum range, the FSX provides a constant
output voltage of about 1% below the supply voltage.
The fan runs at maximum speed.
Along the proportional range the output voltage varies between maximum and minimum voltage of approximately 50% of the supply voltage. This causes the fan
speed to slow down from maximum speed to minimum
speed.
Further decrease of pressure in the minimum range
leads to cut-off of the fan motor. Increase of input pressure will start the motor with a hysteresis of approximately 10 psig to avoid cycling (Fig. 1).
The pressure from which motor is cut off (FSX), see
column “pressure range” in the selection chart. The proportional range is fixed at:
36 psig for FSX-41_/FSM-41_
55 psig for FSX-42_/FSM-42_
66 psig for FSX-43_/FSM-43_
46
Basic Rules of
Good Practice
47
2008
Basic Rules of Good Practice
Basic Rules of Good Practice
Doing a good job in any line of work almost always involves following some basic “good practice” rules, and servicing refrigeration systems is no exception. Knowing and observing such basic rules, to the point that it becomes
automatic, can prevent a lot of problems by cutting them off at the pass before they have a chance to happen.
A list of DO’s, procedures that should be followed, and a list of DON’Ts representing pitfalls that should be
avoided are presented here to promote the general adoption of good servicing practices and a better understanding of the WHYs behind them. An occasional quick review may serve to reinforce awareness and help make their
application second nature.
DOs
DO maintain test instruments in good working order and periodically check
them against accurately calibrated instruments.
Good diagnoses can’t be made with faulty inputs.
DO familiarize yourself with the operation of a control before attempting to
make adjustments or repairs.
If you don’t understand how a control is supposed to function, you can’t be sure if
it’s defective or not. When you know what you’re doing, you achieve good results
on purpose; when you don’t know what you’re doing, you achieve good results only
by accident.
DO make it a practice to check suction gas superheat at the compressor.
Too low superheat may result in liquid flood-back, while high superheats cause
high discharge temperatures. Always follow equipment manufacturers’ instructions.
DO replace filter-driers or replaceable cartridges whenever it’s necessary to
open a system for service.
Regardless of how careful you are, it’s virtually impossible to prevent the entry of
moisture and other contaminants while the system is open. Driers or cartridges
cannot be successfully activated in the field for reuse. A new filter drier or cartridge
is cheap insurance for a compressor.
DO use an accurate moisture indicator in the liquid line to watch out for
moisture contamination.
It is the single most common contaminant, and it can lead to a variety of problems
including acid, sludge, and freeze-ups.
DO check expansion valve superheat by using the temperature-pressure
method.
This involves measuring the suction line pressure at the evaporator outlet and then
referring to the appropriate temperature-pressure chart to determine the saturation temperature. Subtracting this temperature from the suction line temperature
measured at the remote bulb gives you the operating superheat, which should be
adjusted to the equipment manufacturer’s specifications.
48
Basic Rules of Good Practice
DON’T be a “parts-changer.”
DON’Ts
Analyze problems based on the symptoms, and determine the specific cause before making any changes or repairs. Emerson’s Troubleshooting Guide describes
a wide variety of problems that may be encountered, and their probable causes.
DON’T think of a TXV as a temperature or pressure control.
Thinking of it as a superheat control is basic to achieving optimum system performance.
DON’T attempt to use any control for any application other than the one it
was designed for.
Using a pressure regulator for a pressure relief valve, or any similar substitution,
is not good practice and almost certainly won’t deliver proper performance. Misapplications can lead to equipment damage and even injury. When doubt exists,
check with the manufacturer.
DON’T energize a solenoid coil while it is removed from the valve.
Without the magnetic effect of the solenoid core, the coil will burn out in a matter
of seconds.
DON’T install a previously used filter-drier or replaceable cartridge.
It could introduce contaminants that it has picked up since its removal from a
system.
DON’T select solenoid valves by line size or port size, but by valve capacity.
They must also be compatible with the intended application with regard to the
specific refrigerant used, the maximum opening pressure differential (MOPD), the
maximum working pressure (MWP), and the electrical characteristics. Never apply a valve outside of its design limits or for uses not specifically catalogued.
DON’T rely on sight or touch for temperature measurements.
Use an accurate thermometer. Once again, you can’t get accurate diagnoses
with faulty inputs.
49
Troubleshooting
Guide
50
2008
SYSTEM TROUBLESHOOTING GUIDE
System
Problem
Discharge
Pressure
Suction
Pressure
Superheat
Overcharge
Undercharge
Liquid
Restriction
(Drier)
Low
Evaporator
Airflow
Dirty
Condenser
Low Outside
Ambient
Temperature
Inefficient
Compressor
TXV Bulb
Loose
Mounted
TXV Bulb
Lost
Charge
Poorly
Insulated
Bulb
51
Subcooling
Amps
Troubleshooting Expansion Valves
Superheat Is Too Low -- TXV Feeds Too Much
Problem
Symptoms
1) Liquid Slugging
Valve Feeds
2) Low Superheat
Too Much
3) Suction Pressure Normal or High
Causes
Corrective Action
Oversized Valve
Replace with correct size valve
Incorrect Superheat Setting
Adjust the superheat to correct setting
Moisture
Replace the filter-driers; evacuate the system
and replace the refrigerant
Dirt or Foreign Material
Clean out the material or replace the valve
Incorrect Charge Selection
Select proper charge based on refrigerant type
Incorrect Bulb Location
Relocate the bulb to proper location
Incorrect Equalizer Location
Relocate the equalizer to proper location
Plugged Equalizer (Balanced Port Valve)
Remove any restriction in the equalizer tube
Superheat Is Too High -- TXV Doesn't Feed or Doesn't Feed Enough
Problem
Valve
Doesn't
Feed or
Doesn't
Feed
Enough
Symptoms
1) Evaporator Temperature Too High
2) High Superheat
3) Low Suction Pressure
Causes
Corrective Action
Short of Refrigerant
Add correct amount of refrigerant
High Superheat
Change superheat setting
Flash Gas In Liquid Line
Remove source of restriction
Low or Lost Bulb Charge
Replace power element or valve
Moisture
Replace driers or evacuate the system and
replace refrigerant
Plugged Equalizer (Conventional Valve)
Remove restriction in equalizer tube
Insufficient Pressure Drop or Valve Too
Small
Replace existing valve with properly sized valve
Dirt or Foreign Material
Clean out material or replace valve
Incorrect Charge Selection
Select correct charge
Incorrect Bulb Location
Move bulb to correct location
Incorrect Equalizer Location
Move equalizer to correct location
Charge Migration (MOP Only, Vapor
Charges)
Move valve to a warmer location or apply heat
tape to powerhead
Wax
Use charcoal drier
Wrong equalizer Type Valve
Use externally equalized valve
Rod Leakage (Balanced Port Valve)
Replace valve
Heat Damaged Powerhead
Replace powerhead or valve
No Superheat At Start Up Only
Problem
Symptoms
Valve Feeds 1) Liquid Slugging
Too Much At 2) Zero Superheat
Start Up
3) Suction Pressure Too High
Causes
Corrective Action
Refrigerant Drainage
Use pump down control; Install trap at the top
of the evaporator
Compressor or Suction Line in a Cold
Location
Install crankcase heater; Install suction solenoid
Partially Restricted or Plugged External
Equalizer (Balanced Port Valve)
Remove restriction
Liquid Line Solenoid Won't Shut
Replace powerhead or valve
Superheat Is Erratic Or Hunts
Problem
System
Hunts or
Cycles
Symptoms
1) Suction Pressure Hunts
2) Superheat Hunts
3) Erratic Valve Feeding
Causes
Corrective Action
Bulb Location Incorrect
Reposition Bulb
Valve Too Large
Replace with correctly sized valve
Incorrect Superheat Setting
Adjust superheat to correct setting
System Design
Redesign system
52
Superheat Appears Normal -- System Performs Poorly
Problem
Valve Doesn't Feed Properly
Symptoms
1) Poor System Performance
2) Low or Normal Superheat
3) Low Suction Pressure
Causes
Corrective Action
Unequal Circuit Loading
Make modification to balance load
Flow From One Coil Affecting
Another Coil
Correct piping
Low Load
Correct conditions causing low load
Mismatched Coil/Compressor
Correct match
Incorrect Distributor
Install correct distributor
Evaporator Oil-Logged
Increase gas velocity through coil
Troubleshooting Solenoid Valves
Problem
Normally Closed Valve Will Not Open
-orNormally Open Valve Will Not Close
Causes
Corrective Action
Movement of plunger or diaphragm restricted
a) Corroded parts
b) Foreign material lodged in valve
c) Dented or bent enclosing tube
d) Warped or distorted body due to improper
brazing or crushing in vice
Clean affected parts and replace parts as
required. Correct the cause of corrosion or source
of foreign materials in the system.
Improper wiring
Check electrical circuit for loose or broken
connections. Attach voltmeter to coil leads and
check voltage, inrush and holding currents
Faulty contacts on relays or thermostats
Check contacts in relays and thermostats. clean or
replace as required.
Voltage and frequency rating or solenoid coil not
matched to electrical supply:
a) low voltage
b) high voltage
c) incorrect frequency
Check voltage and frequency stamped on coil
assembly to make certain it matches electrical
source. If it does not, obtain new coil assembly
with proper voltage and frequency rating:
a) Locate cause of voltage drop and correct.
Install proper transformer, wire size as needed. Be
sure all connections are tight and that relays
function properly.
b) Excessively high voltage will cause coil burnout.
Obtain new coil assembly with proper voltage
rating.
c) Obtain new coil assembly with proper frequency
rating.
Oversized Valve
Install correct sized valve. Consult extended
capacities tables.
Valve improperly assembled.
Assemble parts in proper position making certain
none are missing from valve assembly.
Coil Burnout
a) Supply voltage at coil too low (below 85% of
rated coil voltage)
b) Supply voltage at valve too high (more than
10% above coil voltage rating)
c) Valve located at high ambient
a) Locate cause of low voltage and correct (check
transformer, wire size, and control rating)
b) Locate cause of high voltage and correct
(install proper transformer or service)
c) Ventilate the area from high ambient. Remove
covering from coil housing
d) Plunger restricted due to: corroded parts,
d) Clean affected parts and replace as required.
foreign materials lodged in valve, dented or bent Connect cause of corrosion or source of foreign
enclosing tube or warped or distorted body due to material in the system
improper brazing or curshing in vise
e) With valve closed, pressure difference across e) Reduce pressure differential to less than
valve is too high preventing valve from opening
300psi
f) Improper wiring. Inrush voltage drop causing
f) Correct wiring according to valve manufacturers'
plunger to fail to pull magnetic field due to:
instructions. Solder all low voltage connections.
- Wiring the valve to the load side of the motor
Use correct wire size.
starter
- Wiring the valve in parallel with another
appliance with high inrush current draw
- Poor connetions, especially on low voltage,
where connections should be soldered
- Wire size of electrical supply too small
g) Electrical supply (voltage and frequency) not
g) Check coil voltage and frequency to ensure
matched to solenoid coil rating
match to electrical service rating. Install new coil
with proper voltage and frequency rating.
53
Problem
Causes
Normally Closed Valve Will Not Close
-orNormally Open Valve Will Not Open
Corrective Action
Diaphragm or plunger restricted due to: corroded
parts, foreign material lodged in valve, dented or
bent closing tube, or warped body due to
improper brazing or crushing in vise
Clean affected parts and replace parts as
required. Correct the cause of corrosion or source
of foreign materials in the system. Install a filterdrier upstream of solenoid valve
Manual opening stem holding valve open
With coil de-energized, turn manual stem in
counter clockwise direction until valve closes
Closing spring missing or inoperative
Re-assemble with spring in proper position
Electrical feedback keeping coil energized, or
switch contacts not breaking circuit to coil
Attach voltmeter at coil leads and check for
feedack or closed circuit. Correct faulty contacts
or wiring
Reverse pressures (outlet pressure greater than
inlet pressure), or valve installed backwards
Install check valve at valve outlet, or install with
flow arrow in proper direction
Problem
Causes
Valve Closes, But Flow Continues
(Seat Leakage)
Corrective Action
Foreign material lodged under seat
Clean internal parts and remove foreign material
Valve seat damaged
Replace valve or affected parts
Synthetic seat materials chipped
Replace valve or affected parts
Valve improperly applied or assembled
Replace valve with proper valve or re-assemble
Special Considerations For Industrial Solenoid Valves
Symptoms
Causes
High Internal Seat Leakage (high temperature
steam up to 400°)
Corrective Action
Wrong Seat Elastomer Used (Buna N)
Use Valve with Teflon Seat Elastomer
External Leakage (high temperature steam up to
Wrong Gasket Material Used (Neoprene)
400°)
Use Ethylene Propylene Gasket
High Internal Seat Leakage (high temperature
steam up to 250° or water up to 210°)
Wrong Seat Elastomer Used (Buna N)
Use Valve with Ethylene Propylene Seat
Elastomer
External leakage (high temperature steam up to
250° or water up to 210°)
Wrong Gasket Material Used (Neoprene)
Use Ethylene Propylene Gasket
Troubleshooting Ball Valves
Symptoms
Causes
Corrective Action
Doesn't Flow
Valve Isn't Open
Turn Stem
Leak at Access Schrader Valve
Schrader Valve Isn't Tight
Tighten Schrader Valve
Leak at Stem
Valve Stem is Leaking
Replace Valve
Excessive Pressure Drop
Valve Isn't Fully Open
Turn Stem to Open Valve
Troubleshooting System Protectors
Allowable Pressure Drop -- Permanent Installation
Evaporator Temperature
Refrigerant
40°F
20°F
0°F
-20°F
-40°F
R12, R134a
2.0
1.5
1.0
0.5
-
R22, R410A
3.0
2.0
1.5
1.0
0.5
R502, R404A/507
3.0
2.0
1.5
1.0
0.5
Troubleshooting Storage Devices
Suction Line Accumulators
Problem
Oil Not Returning to Compressor
Causes
Corrective Action
Bleed Hole in U-Tube Plugged
Replace Accumulator; Install Filter Ahead of
Accumulator
U-Tube Broken Off
Replace Accumulator
Accumulator Too Large for Application
Replace with Smaller Accumulator
Accumulator Installed Incorrectly
Re-Install with Correct Inlet & Outlet Connections
54
Liquid Refrigerant Receivers
Problem
Causes
Flashing In Liquid Sight Glass Downstream Of
Receiver
Corrective Action
Receiver Outlet Not Fully Open
Open Valve Fully
On Receivers with Top Outlet Connections, the
Dip Tube may be Broken Off Or Plugged
Replace Receiver
Receiver Installed Upside Down
Re-Install Receiver Correctly
Troubleshooting Oil Controls - OMB
Problem
Oil Level Too High In Sight Glass
Causes
OMB out of calibration
Replace OMB
Too much oil in system
Remove oil from oil separator or reservoir until
proper level is maintained
Too much oil coming back from evaporator
Check system piping design for:
- Proper velocities
- P-traps at the bottom of all suction risers
- Piping pitched to compressor
- Overlapping or defrosts that are not staggered
Debris under solenoid valve seat
Unscrew solenoid valve, clean & replace
Problem
Oil Level Too Low In Sight Glass
Problem
Causes
Corrective Action
Oil separator or reservoir empty
Add oil to maintain a liquid seal in the bottom of
the separator or reservoir
Plugged oil line filter
Replace filter
Plugged inlet strainer(s) on OMB
Remove and clean strainer on all affected OMB
Solenoid coil defective
Replace coil
Power loss to OMB
Check power to OMB. Green light should be lit.
Causes
Corrective Action
Flood back through suction; Increase superheat
on expansion valve; Refrigerant condensing in oil
separator - add heater to oil separator and/or
adjust system setting to eliminate flood back
Liquid refrigerant in oil
Foaming In Sight Glass
Problem
Corrective Action
If so equipped, liquid injection overfeeding
Correct liquid injection overfeed
Excess quantity of oil in crankcase
Remove excess oil
Causes
Corrective Action
"Filling" light remains on even though level is 1/2
Replace OMB
above sight glass
Alarm light on all the time
Replace OMB
Intermittent oil return from system
Check system piping design for:
- Proper veloicties
- P-traps at the bottom of all suction risers
- Piping pitched to compressor
- Overlapping or defrosts that are not staggered
Nuisance Oil Alarms
Troubleshooting Oil Separators
Problem
Causes
Oil outlet valve closed or partially closed
Reduced or No Oil Feed to Compressor
Hot Gas Entering Compressor
Corrective Action
Open oil outlet valve
Inadequate oil charge in system
Add oil in system
Oil float defective or dirty (will not open)
Disassemble and clean or replace defective float
component (flanged versions); Replace oil
separator (welded version).
Separator too small for application
Replace separator with larger size
Oil float defective or dirty (will not close)
Disassemble and clean or replace defective float
component (flanged versions); Replace oil
separator (welded version).
55
Troubleshooting Regulators
Problem
Causes
Pilot inlet filter screen obstructed
Erratic Pressure Control
Corrective Action
Clean or replace.
Piston bleed hole restriction
Excessive dirt in pilot/solenoid
Regulator Will Not Open
(EPRBS Version)
Disassemble valve and clean. Replace if
necessary.
Piston bleed hole restriction
Coil is damaged or not energized
Verify coil is energized. Replace if necessary.
Piston bleed partially obstructed
Disassemble and clean regulator.
Excessive Pressure Drop Across the Regulator Pilot or solenoid leaking internally
Refer to extended capacities table. Install correct
sized regulator.
Regulator undersized
Piston bleed port obstructed
Pilot inlet filter screen obstructed
Regulator Hunting
(Fluctuations in Controlled Pressure)
Regulator Will Not Provide Pressure Control
Regulator Will Not Close
(EPRBS Version)
Replace pilot assembly.
Clean or replace.
Regulator oversized
Refer to extended capacities table. Install correct
sized regulator.
Regulator and TXV have control interaction
Turn off pilot pressure. Ensure regulator is wide
open. Adjust superheat to required setting. Turn
pilot pressure back on.
Regulator and cylinder unloaders have control
interaction
The unloader should be set to control at least 5
psig lower than regulator.
Pilot inlet filter screen obstructed
Clean or replace.
Pilot inlet pressure is too low
Increase pressure to a minimum of 25 psi higher
than the main valve outlet pressure.
Locate and remove the stoppage or dirt. Replace
Piston jammed due to excessive dirt; Inoperative
pilot. A broken diaphragm can be detected by
pilot or broken diaphragm
checking for leaks around the adjusting stem.
Dirt under seat
Disassemble and clean.
Excessive piston seal leakage
Replace bell piston assembly.
Plugged pilot filter
Clean or replace.
Pilot supply turned off or restricted
Verify pilot inlet pressure is at least 25 psig
greater than valve outlet.
Excessive dirt in pilot/solenoid
Replace pilot assembly.
Troubleshooting Hot Gas Regulators
Problem
Causes
Low Suction Pressure - Valve Open
Will Not Bypass - Valve Not Open
Suction Pressure Swings Erratically
Bypass Continuously - Suction Pressure High
Setpoint Drifts
Corrective Action
Valve undersized
Replace valve with correct size
1. Solenoid (if present) not energized
2. Valve sticking closed
3. Not set properly
4. Bad pilot
1. Repair (replace solenoid coil)
2. Replace
3. Recalibrate
4. Replace
Oversized valve
Replace valve with correct size
1. Manual stem screwed down
2. Valve sticking open
3. Bad pilot
1. Back stem out
2. Repair/replace valve
3. Replace pilot
Bad pilot
Replace pilot
Troubleshooting Crankcase Regulators
Problem
Valve Won't Adjust or Is Erratic
Valve Throttles Constantly
Causes
Corrective Action
With system running, open the valve adjustment
to open the valve and flush away the contaminant.
If this fails, replace valve.
Dirt under seat
Re-adjust bypass and/or CPR valve so that the
On system equipped with Hot Gas Bypas Valves,
CPR setting is higher than the discharge bypass
the bypass valve setting is higher than CPR
valve
TXV with MOP feature used with the CPR
To improve pull-down time, replace TXV with
equivalent without MOP feature
Valve setting is too low
Re-adjust the CPR to a higher setting - see
adjustment procedure
Temperature Pull-Down After Defrost is Too Long
56
Problem
Causes
Compressor tripping on Internal Thermal
Protector - Fails to Start-Up and Run Long
Enough to Pull Down Temperature
Corrective Action
CPR setting too high
Re-adjust the CPR to a lower setting - see
adjustment procedure
CPR setting is too low
Valve Fails to Open
Valve defective - bellows leak, pressurizing the
upper adjustment assembly
Replace valve
Troubleshooting Head Pressure Controls
Problem
Causes
Low Head Pressure During Operation
System Runs High Head Pressure
-orCycles on High Pressure Cut-Out
Corrective Action
Valve unable to throttle "C" port
1. Foreign material wedged between "C" port
seat and seat disc
2. Power element lost its charge
3. Insufficient winter-time system charge
1. Artificially raise head pressure and tap valve
body to dislodge foreign material
2. Change valve
3. Add refrigerant per Table 3
Wrong charge pressure in valve for refrigerant
Change valve
Receiver exposed to low ambient conditions is
acting as condenser
Insulate the receiver
Hot gas bypass line restricted or shut off
Clear obstruction or open valve
Compressor not pumping, restriction in liquid
line, low side causing very low suction pressure
Change or repair compressor; clear obstruction
or other reason for low suction pressure
Condenser fan not running or turning in wrong
direction
Replace or repair fan motor, belts, wiring or
controls as required
Fan cycling
Run condenser fan continuously while system is
running
Pressure drop through condenser exceeds
allowable 20 psi forcing "B" port partially open
Repipe, recircuit, or change condenser as
required to reduce condenser pressure drop to
less than 20 psi
Condenser undersized or air flow restricted or
short circuiting
Increase size of condenser or remove air flow
restriction or short circuit as required
"B" port wedged open due to foreign material
between seat and seat disc
Artificially reduce head pressure below valve
setpoint and tap valve body with system running
to dislodge foreign material
"B" port seat damaged due to foreign material
Change valve
Wrong charge pressure in valve for refrigerant
Excessive system charge or air in system
Purge or bleed off refrigerant or noncondensables as system requires
Obstruction or valve closed in discharge or
condenser drain line
Clear obstruction or open valve
Liquid line solenoid fails to open
Check solenoid
CHARGING THE SYSTEM - THEORETICAL METHOD
Weighing the Charge (Method has practical limitations)
Add refrigerant until the sight glass is clear and free of bubbles.
Determine refrigerant required to fill the condenser, see Table 3 below. Add this additional amount.
Table 3 - Refrigerant lbs. per ft.*
Condenser Tube Size - O.D. (in inches)** and Ambient Temperature ° F
Refrigerant
3/8"
40°
0°
1/2"
5/8"
-20°
-40°
40°
0°
-20°
-40°
40°
0°
-20°
-40°
.167
R134a
.051
.054
.055
.057
.095
.099
.102
.105
.150
.157
.164
R22
.051
.054
.055
.056
.094
.099
.102
.104
.150
.159
.163
.167
R404A/R507A
.053
.056
.058
.059
.098
.104
.107
.109
.157
.166
.171
.175
* Return bends: 3/8” O.D. - 20 ft; 1/2 O.D. - 25 ft.; 5/8 O.D. - 30 ft. (equivalent length of tubing/return bend)
** Wall thickness: 3/8” O.D. - .016”; 1/2 O.D. - .017”; 5/8 O.D. - .018”
57
NOTES
58
Emerson Climate Technologies
Flow Controls Division
St. Louis, Missouri 63141
(314) 569-4500
WEBSITE: www.emersonclimate.com/flowcontrols
E-MAIL: [email protected]
Form No. 2004FC-141 R4 (4/08)
Emerson Climate Technologies and the Emerson Climate Technologies logo are service marks and trademarks of Emerson
Electric Co. All other trademarks are property of their respective owner. © 2008 Flow Controls Division. Printed in the USA.
ICM 450
Programmable Three Phase Voltage
Monitor with 25-Fault Memory
Protects motors from premature failure
and burnouts
Installation, Operation & Application Guide
For more information on our complete range of American-made
products – plus wiring diagrams, troubleshooting tips and more,
visit us at www.icmcontrols.com
Specification
Input
•Line Voltage: Universal, 190-630 VAC
•Frequency: 50-60 Hz
•Load Side Monitoring: Optional
•Control Voltage: 18-240 VAC
•Frequency: 50-60 Hz
Output
•Type: Relay, SPDT
•Voltage Range: 240VAC @ 10A maximum
•Frequency: 50-60 Hz
Control Operating Temperature
•Operating Temperature: -40ºF to +167ºF (-40ºC to +75ºC)
•Storage Temperature: -40ºF to +185ºF (-40ºC to +80ºC)
LCD Operating Temperature
•Operating Temperature: -4ºF to +167ºF (-20ºC to +75ºC)
Mechanical
•Mounting: Surface mount using (2) #8 screws
•Terminations: Screw terminals
•Weight: 12 ounces (341 grams)
Dimensions
•6 1/2” L, 4 1/4” W, 1 3/8” H (16.5 cm. L, 10.8 cm. W, 3.5 cm. H)
Parameters
Phase Unbalance Protection
•Voltage Unbalance: 2-20% adjustable
Over/Under Voltage Protection
•Under Voltage: 2-25% adjustable
•Over Voltage: 2-25% adjustable
Phase Loss Protection
•Phase Loss Condition: Equals 25% of nominal for any given phase; system will shut down and a fault will be recorded should this occur
Delay on Break Timer
•Control Voltage: 18-240 VAC
•Time Delay: 0 to 10 minutes adjustable
Fault Interrogation Delay
•Time Delay: 0 to 15 seconds adjustable
•Provides a delay between fault detection and system shutdown - helps to
eliminate nuisance trips or unnecessary shutdowns
Caution
Installation of the ICM450 shall be performed by trained technicians only.
Adhere to all local and national electric codes.
Disconnect all power to the system before making any connections.
Installation
1.Using (2) #8 screws, mount the ICM450 in a cool, dry, easily accessible
location in the control panel.
2.Connect voltage as shown in Figure 1 (below). Leave existing line and load
side connections intact on the contactor.
3.Load side monitoring is optional (unit may be used to monitor line side
only). Wire the contactor and optional control voltage monitoring as in
Figures 2 and 3 (below).
Note: Load/line wire must be rated for 3-phase voltage rating, 20ga
minimum.
4.Upon application of power, the ICM450 will be on line and will begin to
monitor the system.
Figure 1
Incoming 3-phase
voltage from load or
“back” side of contactor
(optional)
LOAD
3
LOAD
2
LOAD
1
LINE
3
LINE
2
LINE
1
Incoming 3-phase voltage from
line or “front” side of contactor
The incoming 3-phase voltage is
used to power up the ICM450 as
well (190-600)
Figure 2
•Terminals 1 and 3 are the control signal input terminals
•“Control Mode” is turned ON or OFF in setup
6 5 4
•With “Control Mode” set to “ON,” there must be a
3
voltage present on terminals 1 and 3 for the relay
output terminals 4 and 6 to close; this voltage can be
supplied from a thermostat, pressure switch, etc.
•When the voltage on these terminals is re-applied, * Switch can be
thermostat,
the unit will not re-energize until the delay on break apressure
(0-10 minutes) time has elapsed
switch, etc.
•Use of terminals 1 and 3 is optional; they will be
Control Voltage
(18-240 VAC)
ignored if the “Control Mode” is set to “OFF”
1
Short pins
when using
24 VAC
control
voltage
Figure 3
6 5 4
3
1
•Terminals 4 and 6 are “dry,” normally open
contacts
•Terminals 4 and 6 are closed when power is
within specifications
•Terminals 4 and 6 open when there is a fault
condition or loss of control signal
Contactor Coil
Contactor Voltage (18-240 VAC)
ICM450 Wiring Diagrams
2-Pole Contactor
3-Pole Contactor
L03
LI3
LI1
LINE LINE LINE
3
2
1
LOAD LOAD LOAD
3
2
1
LOAD LOAD LOAD
3
2
1
LINE LINE LINE
3
2
1
LI1
LI2
Control
Voltage
Control
Voltage
L01
L01
L02
L02
LI2
LI3
L03
* Thermostat, pressure switch, etc.
* Thermostat, pressure switch, etc.
L0AD
L0AD
Setting the Parameters
1.
2.
3.
4.
Press the green SETUP button to enter Setup mode. Setup LED will light.
Use the
and
arrows to change user parameters.
Scroll through setup by pressing and releasing the SETUP button.
When the last parameter has been set, the phase average will be
displayed and the Setup LED will automatically turn OFF.
Button Functions
Press arrows to scroll through
and select user parameter
settings in Setup mode.
HOLD down for fast edit.
Press to enter
Setup mode
and select user
parameters.
Hold for
voltage display
a b, b c, a c
(simultaneously).
Press to read faults.
Hold for 5 seconds
to clear faults and
reset memory.
Parameters
Parameter
Line
Voltage
Delay On
Break
Description
Average phase to phase
line voltage
Range
190-600
Amount of time between
0-10
the load de-energizing and minutes
re-energizing
Default
208
.1
minute
Recommended
Nameplate
Voltage
4 minutes**
Fault Interrogation
Amount of time before
the load de-energizes due
to a non-critical fault*
0-15
seconds
15
seconds
7-8 seconds**
%
Over/Under
Voltage
Maximum/minimum phase
to phase average voltage,
respectively
2-25%
20%
12-15%**
% Phase
Unbalance
Amount of allowable
voltage unbalance
2-20%
20%
4-5%**
Reset
Mode
AUTO or number of
times the load can be
re-energized after a load
side fault before a manual
reset is necessary
Note:When monitoring
line side only, the
reset mode will
always be AUTO
AUTO,
0-10
AUTO
AUTO
Control
Mode
With control mode set
to OFF, the load will
energize if no 3- phase
fault conditions exist;
with control mode ON,
the load will energize if no
fault conditions exist and
control voltage is present
at terminals 1 and 3 of
the ICM450
ON
or
OFF
ON
Based on wiring
* Non-critical faults are faults such as High/Low Voltage and Phase Unbalance.
Critical faults, such as Phase Loss and Phase Reversal, have a fault
interrogation of under 2 seconds and it is not user adjustable.
** For best recommendations, consult manufacturer of equipment.
Fault Conditions
Press and release fault button to scroll through all saved faults.
Note: For initial setup, press and hold FAULT for 5 seconds to
remove any previously stored faults.
Fault
Problem
Corrective Action
Back
Phase
Loss
Not all three of the
phases on the load side
are present
1. Re-energize the contactor.
2. If the fault reappears after the load energizes:
a. Turn all power OFF
b. Check all load side connections
c. Check the contacts of the contactor for debris
or excess carbon.
Back
Phase
Rev
Loads 1, 2, or 3 are not
in sequence (not 120º
phase shifted)
1. Turn OFF all power.
2. Swap any 2 phases on the load side of the
ICM450 only (example: swap load 1 and load 2) *
3. Re-apply power.
Back
Phase
Unbal
A voltage unbalance
between the three load
phases exceeds the
unbalance setpoint
1. Press the READ button to observe the present
load voltages. Check system for unbalance cause.
2. Increase the fault interrogation time if necessary.
3. Increase the percent unbalance setting if
necessary.
Front
Over
Volt
Average phase-phase
voltage exceeds the
maximum percentage
1. Check system for over-voltage cause.
2. Increase the percent over-voltage setting if
necessary.
3. Increase the fault interrogation time if necessary.
Front
Phase
Loss
Not all three of the
phases on the line side
are present
1. Press and hold the READ button on the phase
monitor or use an AC voltmeter to carefully
measure all three phase-phase line voltages
(example: Line 1 Line 2, Line 2 Line 3, Line
3 Line 1).
2. Repair the missing phase.
Front
Phase
Rev
Lines 1, 2, or 3 are not
in sequence (not 120º
phase shifted)
1. Turn OFF all power.
2. Swap any 2 phases on the line side of the ICM450
(example: swap load 1 and load 2)*
3. Re-apply power.
Front
Phase
Unbal
A voltage unbalance
between the three line
phases exceeds the
unbalance setpoint
1. Press the READ button to observe the present
load voltages. Check system for unbalance cause.
2. Increase the fault interrogation time if necessary.
3. Increase the percent unbalance setting if
necessary.
Front
Under
Volt
Average phase-phase
voltage is below the
minimum percentage
1. Check system for under-voltage cause.
2. Increase the percent under-voltage setting if
necessary.
3. Increase the fault interrogation time if necessary.
* Only swap phases during initial setup, not after the ICM450 has been in operation without
errors.
Troubleshooting
Problem
LCD
Readout
Load will not
energize
LED Status
Corrective Action
Phase
Avg.
All LEDs Off
Confirm that the control input
(terminals 1 & 3) is properly
connected and configured (see
Pages 1 and 3)
Load will not
energize
Phase
Avg.
Load LED Off,
Fault LED
blinking
Press FAULT to observe the
current fault; correct the
condition of the first fault that
appears (see Fault Conditions,
Page 4 for a list of corrective
actions)
Fault LED
blinks
repeatedly
while load is
energized
Phase
Avg.
Fault LED
Blinking,
Load LED On
Indicates there are faults
saved in the memory, press
FAULT rapidly to scroll through
saved faults; to clear the
faults, press and hold FAULT
for more than 5 seconds
Load will not
de-energize
when control
voltage is OFF
Phase
Avg.
Load LED On,
Control LED Off
The control mode setting is
OFF; press SETUP to get to
the control mode. Press
to
set the control mode ON
Setup LED
is on while
load is being
energized
Anything
Other Than
Phase Avg.
Setup LED On,
Load LED On
To exit the setup mode, press
either READ or FAULT
Load will not
energize
Reset
Fault LED
Blinking
Unit in lockout; maximum
number of retries in manual
reset mode has been reached;
to reset unit, press FAULT and
hold for more than 5 seconds
Load turns ON
and OFF
repeatedly
Readout is
Irrelevant
Fault LED
Blinking
Fix load side fault; press FAULT
to observe condition; the delay
on break period may be too
short; press SETUP to enter
the delay on break mode;
press
to lengthen the delay
ONE-YEAR LIMITED WARRANTY
The Seller warrants its products against defects in material or
workmanship for a period of one (1) year from the date of manufacture.
The liability of the Seller is limited, at its option, to repair, replace or
issue a non-case credit for the purchase prices of the goods which are
provided to be defective. The warranty and remedies set forth herein
do not apply to any goods or parts thereof which have been subjected
to misuse including any use or application in violation of the Seller’s
instructions, neglect, tampering, improper storage, incorrect installation
or servicing not performed by the Seller. In order to permit the Seller
to properly administer the warranty, the Buyer shall: 1) Notify the
Seller promptly of any claim, submitting date code information or any
other pertinent data as requested by the Seller. 2) Permit the Seller to
inspect and test the product claimed to be defective. Items claimed
to be defective and are determined by Seller to be non-defective are
subject to a $30.00 per hour inspection fee. This warranty constitutes
the Seller’s sole liability hereunder and is in lieu of any other warranty
expressed, implied or statutory. Unless otherwise stated in writing,
Seller makes no warranty that the goods depicted or described herein
are fit for any particular purpose.
7313 William Barry Blvd., North Syracuse, NY 13212
(Toll Free) 800-365-5525 (Phone) 315-233-5266 (Fax) 315-233-5276
www.icmcontrols.com
LIA164-4
ICM 450
Programmable Three Phase Voltage Monitor
Settings for Seresco NE series dehumidifiers
Parameters
Line voltage
Dealay on break
Fault delay
Overvoltage
Undervoltage
Phase unbalance
Reset Mode
Control Mode
Default settings Seresco Settings
208 V
See Name Plate
.1 minute
1 minute
15 sec
5 sec
20%
5%
20%
5%
20%
3%
AUTO
AUTO
ON
OFF
Note: Please reffer to ICM 450 manual. Consult Seresco if settings' change is required
Z - Refrigerant Pressure Table
Issue Date : 2011-09-30
Table 1. Pressure – Temperature Relation
Temperature [F]
Pressure [psi g]
R-410a
R-407c
18
75.2
34.8
22
82.3
39.1
26
89.7
43.6
30
97.5
48.4
34
105.7
53.4
38
114.4
58.9
42
123.6
64.6
46
133.2
70.6
50
143.3
77.1
55
156.6
106.0
60
170.7
116.2
65
185.7
127.0
70
201.5
138.5
75
218.2
150.6
80
235.9
163.5
85
254.6
177.0
90
274.3
191.3
95
295.0
106.4
100
316.9
222.3
105
339.9
239.0
110
364.1
256.5
115
389.6
274.9
120
416.4
294.2
125
444.5
314.5
130
474.0
335.7
135
505.0
357.8
140
537.6
380.9
145
571.7
405.1
150
607.6
430.3
155
645.2
456.6
1
SPORLAN REF. & A/C PRODUCTS
SPORLAN REF. & A/C PRODUCTS
Sporlan
Refrigeration and
Air Conditioning
Products
Oil Level Controls
Suction Filters
Oil Filters
See•All
Head Pressure Control Valves
Solenoids
Three-Way Heat Reclaim Valves
TEV
Crankcase Pressure Regulating Valves
Catch-All
Discharge Bypass Valves
Evaporator Pressure Regulating Valves
632
THERMOSTATIC EXPANSION VALVES
SPORLAN THERMOSTATIC EXPANSION VALVES
• Selective Thermostat Charges — Designed to provide optimum performance for all applications — air conditioning
and heat pump, medium and Low temperature refrigeration.
• Thermostatic Element Design — Long lasting and field proven stainless steel diaphragm and welded element
construction.
• Diaphragm Design — Large flat diaphragm permits precise valve control.
• Replaceable Thermostatic Elements — Field replaceable elements on all standard valves.
• Accessible Internal Parts — Durable, leak proof body joint construction allows the valve to be disassembled, and
the internal parts cleaned and inspected.
• Materials of Construction — Pin and port material offer maximum protection against corrosion and erosion.
• Silver Soldered Connections — For leak proof, high strength connection-to-body joints.
• Adjustable Superheat Design — All standard valves are externally adjustable.
VALVE NOMENCLATURE/ORDERING INSTRUCTIONS
Combine the letters and numbers in the following manner to obtain the complete valve designation. Also include all
connection Sizes and the capillary tube length.
CONVENTIONAL VALVES:
S
Body
Type:
FB,F,
EF,G,
EG,
RI,RC,
S,
EBS*,
O*,
V**,
W**
V
E
-
8
-
GA
5/8”ODF
Solder
X
7/8”ODF
Solder
Sporlan Code - REFRIGERANT Element Label Color Code
E” specifies
external
F - R-12 Yellow
V - R-407A – Green equalizer.
E - R-13 - Blue
N - R-407 Lt. Brown Omission of
letter “E”
S - R-408A -Purple
V - R-22 -Green
indicates
G - R-23 - Blue
F - R-409A -Yellow
valve with
R - R-502 - Purple
M - R124 - Blue
internal
J- R134a -Blue
W - R-503 - Blue
equalizer.
X - R-401A Pink
P - R-507 - Teal
e.g.
L - R-402ASand
W - R-508B - Blue
EGV-1-C
S- R-404A Orange A - R-717 – White
Thermostatic
Charge
Nominal
Capacity
in Tons
Inlet
Connection
Outlet
Connection
Size
and
Style
1/4” ODF
Solder
X
External
Equalizer
Connection
Size
and
Style
Size
and
Style
5’
X
Capillary
Tubing
Length
(Inches
or Feet)
BALANCE PORTED VALVES:
EBF
V
E
-
AA
Port
Size
22 (V)
407C (N)
407A (V)
Body
Type:
BF,SBF,
EBF
134a (J)
12 (F)
401A (X)
409A (F)
404A (S)
502 (R)
408A (S)
507 (P)
402A (L)
“E” specifies
external
equalizer.
Omission of
letter “E”
indicates
valve
with internal
equalizer.
AAA
AA
A
B
C
AAA
AA
A
B
C
AAA
AA
A
B
C
AAA
AA
A
B
C
-
Nominal
Capacity
in Tons
1/8 thru 1/3
1/2 thru 2/3
3/4 thru 1-1/2
1-3/4 thru 3
3-1/4 thru 5-1/2
1/8 thru 1/5
1/4 thru 1/3
1/2 thru 1
1-1/4 thru 1-3/4
2 thru 3
1/8 thru 1/5
1/4 thru 1/3
1/2 thru 1
1-1/4 thru 2
2-1/4 thru 3
1/8 thru 1/5
1/4 thru 1/3
1/2 thru 1
1-1/4 thru 2
2-1/4 thru 3
C
Thermostatic
Charge
3/8”
Extended
ODF Solder
1/2”
Extended
ODF Solder
X
1/4”
Extended X
ODF Solder
Inlet
Connection
Outlet
Connection
External
Equalizer
Connection
Size
and
Style
Size
and
Style
Size
and
Style
*EBS and O valves are balance ported valves, but follow conventional valve nomenclature.
**V and W valves have dual port semi-balance design.
633
X
30”
Capillary
Tubing
Length
(Inches)
THERMOSTATIC EXPANSION VALVES
• Balanced Port Design — Provides perfect pin and port alignment, and prevents changes in pressure drop across
the valve from influencing Valve operation. Provides excellent control on applications with widely varying operating
conditions.
• Pin Carrier Design (Conventional Valves) — Provides precise pin and port alignment, and tighter seating.
THERMOSTATIC EXPANSION VALVES
SPORLAN SELECTIVE CHARGES ENGINEERED FOR PEAK PERFORMANCE FOR EACH SPECIFIC
APPLICATION
RECOMMENDED THERMOSTATIC CHARGES*
12
409A
APPLICATION
THERMOSTATIC EXPANSION VALVES
AIR CONDITIONING
COMMERCIAL
REFRIGERATION 50°F
TO -10°F
LOW TEMPERATURE
REFRIGERATION 0°F
TO -40°F
EXTREME LOW
TEMP.REFRIGERATION
-40°F TO -100°F
22
407A
134a
401A
FCP60
—
JCP60 XCP60
—
VCP100
—
—
—
VGA
—
—
—
—
—
—
FC
—
JC
XC
—
VC
—
—
—
—
—
—
—
—
—
—
—
—
—
—
FZ
—
—
—
FZP
—
—
—
—
VZ
—
—
—
VZP40
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
VX
—
—
—
—
—
REFRIGERANT
402A 404A
408A
—
—
—
—
—
—
—
LC
—
—
—
—
—
LZ
LZP
—
—
—
LX
407C
502
—
—
—
—
NCP100
—
—
NGA
—
SCP115
—
RCP115
—
—
—
—
NC
—
SC
—
RC
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
SZ
—
RZ
SZP
—
RZP
—
—
—
—
—
—
SX
—
RX
ACTUAL
THERMOSTATIC
CHARGES
—
—
FCP60
—
—
VCP100
—
—
VGA
—
—
SCP115
—
—
FC
—
—
VC
—
—
SC
PC
—
PC
— AC, AL
AC, AL
—
—
FZ
—
—
FZP
—
—
VZ
—
—
VZP40
PZ
—
SZ
PZP
—
SZP
— AZ, AL
AZ, AL
—
—
VX
507
717
PX
—
SX
* APPLICATION FACTORS:
1. The Type ZP charges have essentially the same characteristics as the Type Z charge with one exception: they produce a
pressure limit Maximum Operating Pressure (MOP). ZP charges are not intended as replacements for Z charges. Each
should be selected for its own unique purpose.
2. All air conditioning and heat pump charges are intended for use with externally equalized valves.
3. Type L liquid charges are also available for most commonly used refrigerants in most element sizes.
4. If in doubt as to which charge to use, contact Sporlan Valve Company, Washington, Missouri with complete system data.
5. The Type X charges are not to be used with “EBS” and “O” valves.
IMPORTANT NOTES:
A. R-134a air conditioning and commercial refrigeration applications are using R-12 or R-409A or
R-401A valves.
B. R-404A commercial refrigeration applications are using R-502 or R-408A valves.
C. R-404A and R-507 low temperature refrigeration applications are using R-502 or R-402A or
R-408A valves.
634
THERMOSTATIC EXPANSION VALVES
QUICK REFERENCE GUIDE — REFRIGERATION VALVES
VALUE
TYPE
F
G
EG
FB
BF
SBF
EBF
S
EMC
CONNECTION
TYPES
VALVE DESCRIPTION AND APPLICATION
1/5
thru
3
1/8
thru
2
1/8
thru
2
SAE Flare
1/5
thru
3
1/8
thru
2
1/8
thru
2
ODF Solder
1/5
thru
3
1/8
thru
2
1/8
thru
2
SAE Flare
Forged brass bar body, externally adjustable valve for
small capacity refrigeration systems. Inlet connection
has a removable 100 mesh strainer. Typical
applications: Refrigerated cases, coolers, freezers and
small capacity air conditioners.
1/5
thru
3
1/8
thru
2
1/8
thru
2
ODF Solder
Same as the Type G valve except it features ODF
solder connections and a forged brass inlet fitting with
a removable 100 mesh strainer which can be cleaned
and/or replaced without moving the valve from the line.
1/4
thru
8
1/4
thru
5
1/4
thru
6
SAE Flare
or
ODF Solder
1/3
thru
5
1/4
thru
3
1/4
thru
3
SAE Flare
1/3
thru
5
1/4
thru
3
1/4
thru
3
Extended
ODF Solder
1/3
thru
5
1/4
thru
3
1/4
thru
3
Extended
ODF Solder
Same as the Type BF valve except it features ODF
solder connections.
2
thru
10
2
thru
6
2
thru
7
ODF Solder
Brass bar body, externally adjustable valve. General
purpose valve for air conditioning and refrigeration
applications.
0.64
thru
2.34
0.46
thru
1.69
0.42
thru
1.51
ODF Solder
635
Small brass bar body, externally adjustable valve for
small capacity refrigeration systems. SAE flare inlet
connection has a removable 100 mesh strainer. Typical
applications: Refrigerated cases, coolers, freezers.
Same as the Type F valve except it features ODF
solder connections. The inlet connection has a 50
mesh strainer. Typical applications: Refrigerated
cases, coolers, freezers.
Small brass body valve available only with straight
through connections and external adjustment. Typical
applications: Small capacity air conditioning and
refrigeration applications where an external adjustment
is desired
Same physical size as the Type F valve with SAE flare
connection except it features a balanced port
construction. Inlet connection has removable 100 mesh
strainer. Typical applications: Small capacity refrigeration
that operates over widely varying operating conditions.
Same as the Type BF valve except it features ODF
solder connection and a forged brass inlet fitting with a
removable 100 mesh strainer which can be cleaned
and/or replaced without removing the valve from
the line.
Multi-capacity two part valve designed to perform
effectively over the range of load conditions inherent
with most refrigeration systems. Large port is for pull
down load and smaller port to control holding loads.
THERMOSTATIC EXPANSION VALVES
EF
NOMINAL CAPACITY
RANGE (Tons)
R-404A
R-22
R-134a
&
R-507
THERMOSTATIC EXPANSION VALVES
PART
NO*
SPORLAN MODEL**
TYPE F
THERMOSTATIC EXPANSION VALVES
FF-1-1/2-C 3X4 SAE 30"
FF-1-C 3X4 SAE 30"
FFE-1-C 3X4 SAE 30"
FFE-2-C 3X4 SAE 30"
FJ-1/2-C 2X4 SAE 30"
FJ-1/4-C 2X4 SAE 30"
FJ-1/4-Z 2X4 SAE 30"
FR-1/4-Z 2X4 SAE 30"
FRE-1/2-C 3X4 SAE 30"
FRE-1/2-Z 3X4 SAE 30"
FRE-1/2-ZP 3X4 SAE 30"
FRE-1/4-Z 2X4 SAE 30"
FRE-1-1/2-C 3X4 SAE 30"
FRE-1-1/2-Z 3X4 SAE 30"
FRE-1-1/2-ZP35 2X4 SAE 30"
FRE-1-ZP 3X4 SAE 30"
FRE-2-Z 3X4 SAE 30"
FRE-2-ZP 3X4 SAE 30"
FS-1/2-C 2X4 SAE 30"
FS-1/4-C 2X4 SAE 30"
FS-1/4-ZP 2X4 SAE 30"
FSE-1/2-Z 2X4 SAE 30"
FSE-1/2-ZP35 2X4 SAE 30"
FSE-1/4-ZP 2X4 SAE 30"
FSE-1/4-ZP30 2X4 SAE 30"
FSE-1-C 3X4 SAE 30"
FV-1/4-C 2X4 SAE 30"
FVE-1/2-C 3X4 SAE 30"
FVE-1/4-C 2X4 SAE 30"
FVE-1-1/2-C 3X4 SAE 30"
FVE-1-C 3X4 SAE 30"
FVE-2-C 3X4 SAE 30"
FVE-3-C 3X4 SAE 30"
PART
NO*
SPORLAN MODEL**
EFF-1/4-Z 2SX3 ODF 30"
EFJ-1/2-C 2SX3 ODF 30"
EFJ-1/4-C 2SX4 ODF 30"
EFS-1/4-C 2SX3 ODF 30"
EFS-1/4-Z 2SX3 ODF 30"
EFS-1-Z 3X4 ODF 30"
EFSE-1/2-Z 3X4 ODF 30"
EFSE-1/4-Z 3X4 ODF 30"
EFSE-1/6-Z 2X4 ODF 30"
EFVE-1/2-C 3X4 ODF 30"
EFVE-1/2-L1 3X4 ODF 30"
EFVE-1/3-C 2X4 ODF 30"
EFVE-1/3-C 3X4 ODF 30"
EFVE-1/3-L1 3X4 ODF 30"
EFVE-1/5-C 2X4 ODF 30"
EFVE-1-C 3X4 ODF 30"
*(
SPORLAN MODEL**
TYPE BF
TYPE FB
BFF-A-C 3X4 SAE 30"
BFJE-A-C 3X4 SAE 30"
BFJE-B-C 3X4 SAE 30"
BFR-A-C 3X4 SAE 30"
BFRE-A-Z 3X4 SAE 30"
BFRE-A-ZP 3X4 SAE 30"
BFRE-B-C 3X4 SAE 30"
BFRE-B-Z 3X4 SAE 60"
BFRE-B-ZP 3X4 SAE 30"
BFSE-AA-ZP 3X4 SAE 30"
BFSE-A-C 3X4 SAE 30"
BFSE-C-ZP 3X4 SAE 30"
BFV-AA-C 3X4 SAE 30"
BFV-A-C 3X4 SAE 30"
BFVE-AAA-C 3X4 SAE 30"
BFVE-AA-C 3X4 SAE 30"
BFVE-A-C 3X4 SAE 30"
BFVE-B-C 3X4 SAE 30"
FBS-1/4-C 3SX4 ODF 30"
FBS-1/4-Z 2SX4 ODF 30"
FBS-1/4-ZP 3SX4 ODF 30"
FBSE-1/2-C 3SX4X2 ODF 30"
FBSE-1/4-C 3SX4X2 ODF 30"
FBSE-1/4-ZP 3SX4X2 ODF 30"
FBSE-1\2-ZP 3SX4 ODF 30"
FBSE-1-1\2-C 3SX4 ODF 30"
FBSE-1-1\2-ZP 3SX4 ODF 30"
FBSE-1-C 3SX4 ODF 30"
FBSE-1-Z 3X4X2 ODF 30"
FBSE-1-ZP 3SX4 ODF 30"
FBSE-2-C 3SX4X2 ODF 30"
FBSE-2-Z 3X4X2 ODF 30"
FBSE-2-ZP 3SX4X2 ODF 30"
FBSE-3.5-C 4X7X2 ODF 60"
FBSE-3.5-ZP 4X7X2 ODF 30"
FBSE-3-C 4X7X2 ODF 60"
FBSE-3-ZP 4X7X2 ODF 30"
FBSE-4.5-C 4X7X2 ODF 60"
FBSE-4.5-ZP 4X7X2 ODF 30"
FBSE-6-C 5X7X2 ODF 60"
FBSE-6-ZP 5X7X2 ODF 30"
FBV-1/4-C 2*SX4 ODF 30"
TYPE G
GRE-1-1/2-ZP 3X4 SAE 5'
GRE-1-ZP 3X4 SAE 5'
GVE-1-C 3X4 SAE 5'
GVE-3/4-C 3X4 SAE 5'
GVE-3/4-ZP 3X4 SAE 5'
GVE-3-C 3X4 SAE 5'
TYPE FB
TYPE EF
PART
NO*
FBFE-1-C 3SX4X2 ODF 30"
FBJE-1/2-CP60 3X4X2 ODF 30"
FBJE-1/2-Z 3X4X2 ODF 30"
FBR-1/2-Z 2X4 SAE 30"
FBR-1/4-Z 2X4 SAE 30"
FBS-1/2-C 3SX4 ODF 30"
FBS-1/2-Z 2SX4 ODF 30"
FBS-1/2-ZP 3SX4 ODF 30"
IMPORTANT NOTE:
FBV-1/4-C 3*SX4 ODF 30"
FBV-1/4-ZP40 3SX4 ODF 30"
FBVE-1/2-ZP40 3*SX4X2 ODF 30"
FBVE-1/4-C 3*SX4X2 ODF 30"
FBVE-1/4-ZP40 3*SX4X2 ODF 30"
FBVE-1\2-C 3*SX4 ODF 30"
FBVE-1-1/2-ZP40 3*SX4X2 ODF 30"
FBVE-1-1\2-C 3*SX4 ODF 30"
FBVE-1-C 3*SX4 ODF 30"
FBVE-1-ZP40 3*SX4X2 ODF 30"
FBVE-2.5-C 4X5X2 ODF 60"
FBVE-2.5-ZP40 4X5X2 ODF 30"
FBVE-2-C 4X5X2 ODF 30"
FBVE-2-ZP40 4X5X2 ODF 30"
FBVE-3-C 4X5X2 ODF 60"
FBVE-3-ZP40 4X5X2 ODF 60"
FBVE-4-C 4X7X2 ODF 60"
FBVE-4-ZP40 4X7X2 ODF 60"
FBVE-5-C 4X7X2 ODF 60"
FBVE-5-ZP40 4X7X2 ODF 60"
FBVE-6-C 4X7X2 ODF 60"
FBVE-6-GA 4X5X2 ODF 30"
FBVE-6-ZP40 4X7X2 ODF 60"
FBVE-8-C 5X7X2 ODF 60"
FBVE-8-ZP40 5X7X2 ODF 60"
00*S - with Insert Strainer
Connection Sizes are in eighths of
inch – (3x4 means 3/8” inlet x 1/2”
outlet).
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service Center for part number and pricing.
636
THERMOSTATIC EXPANSION VALVES
PART
NO*
SPORLAN MODEL**
TYPE EG
*(
SPORLAN MODEL**
PART
NO*
EGV-1/2-ZP40 3X4 ODF 5'
EGV-1/3-C 3X4 ODF 5'
EGV-1/3-Z 3X4 ODF 5'
EGV-1/5-C 3X4 ODF 5'
EGV-1/5-Z 3X4 ODF 5'
EGV-1-C 3X4 ODF 5'
EGV-3/4-C 3X4 ODF 5'
EGV-3/4-Z 3X4 ODF 5'
EGV-3/4-ZP 3X4 ODF 5'
EGV-3/4-ZP40 3X4 ODF 5'
EGVE-1/2-C 3X4 ODF 5'
EGVE-1/2-L1 3X4 ODF 5'
EGVE-1/2-Z 3X4 ODF 5'
EGVE-1/2-ZP40 3X4 ODF 5'
EGVE-1/3-C 3X4 ODF 5'
EGVE-1/5-C 3X4 ODF 5'
EGVE-1-1/2-C 3X4 ODF 5'
EGVE-1-1/2-Z 3X4 ODF 5'
EGVE-1-1/2-ZP40 3X4 ODF 5'
EGVE-1-C 3X4 ODF 5'
EGVE-1-Z 3X4 ODF 5'
EGVE-1-ZP40 3X4 ODF 5'
EGVE-2-C 3X4 ODF 5'
EGVE-2-Z 3X4 ODF 5'
EGVE-2-ZP40 3X4 ODF 5'
EGVE-3/4-C 3X4 ODF 5'
EGVE-3/4-L1 3X4 ODF 5'
EGVE-3/4-X 3X4 ODF 5'
EGVE-3/4-Z 3X4 ODF 5'
EGVE-3/4-ZP 3X4 ODF 5'
EGVE-3/4-ZP40 3X4 ODF 5'
EGVE-3-C 3X4 ODF 5'
EGVE-3-Z 3X4 ODF 5'
EGVE-3-ZP40 3X4 ODF 5'
EGX-1/2-C 3X4 ODF 5'
TYPE SBF
SBFF-AA-ZP 3X4 ODF 30"
SBFF-A-ZP 3X4 ODF 30"
SBFFE-AA-ZP 3X4 ODF 30"
SBFFE-A-ZP 3X4 ODF 30"
SBFFE-B-ZP 3X4 ODF 30"
SBFJ-AAA-C 3X4 ODF 30"
SBFJ-AA-C 3X4 ODF 30"
SBFJ-A-C 3X4 ODF 30"
SBFJ-B-C 3X4 ODF 30"
SBFJE-AAA-C 3X4 ODF 30"
SBFJE-AA-C 3X4 ODF 30"
SBFJE-A-C 3X4 ODF 30"
SBFJE-B-C 3X4 ODF 30"
SBFJE-C-C 3X4 ODF 30"
SBFP-AAA-C 3X4 ODF 30"
SPORLAN MODEL**
SBFP-AAA-Z 3X4 ODF 30"
SBFP-AA-C 3X4 ODF 30"
SBFP-AA-Z 3X4 ODF 30"
SBFP-A-C 3X4 ODF 30"
SBFP-B-C 3X4 ODF 30"
SBFPE-AAA-C 3X4 ODF 30"
SBFPE-AA-C 3X4 ODF 30"
SBFPE-AA-Z 3X4 ODF 30"
SBFPE-B-C 3X4 ODF 30"
SBFPE-C-C 3X4 ODF 30"
SBFR-AAA-Z 3X4 ODF 30"
SBFR-AAA-ZP 3X4 ODF 30"
SBFR-AA-C 3X4 ODF 30"
SBFR-AA-Z 3X4 ODF 30"
SBFR-AA-ZP 3X4 ODF 30"
SBFR-A-C 3X4 ODF 30"
SBFR-A-ZP 3X4 ODF 30"
SBFR-B-C 3X4 ODF 30"
SBFRE-AAA-C 3X4 ODF 30"
SBFRE-AAA-Z 3X4 ODF 30"
SBFRE-AA-Z 3X4 ODF 30"
SBFRE-A-Z 3X4 ODF 30"
SBFRE-B-Z 3X4 ODF 30"
SBFS-AAA-C 3X4 ODF 30"
SBFSE-AAA-ZP 3X4 ODF 30"
SBFSE-AA-C 3X4 ODF 30"
SBFSE-AA-ZP 3X4 ODF 30"
SBFSE-A-C 3X4 ODF 30"
SBFSE-A-ZP 3X4 ODF 30"
SBFSE-B-C 3X4 ODF 30"
SBFSE-B-Z 3X4 ODF 30"
SBFSE-B-ZP 3X4 ODF 30"
SBFSE-C-C 3X4 ODF 30"
SBFSE-C-Z 3X4 ODF 30"
SBFSE-C-ZP 3X4 ODF 30"
SBFV-AAA-C 3X4 ODF 30"
SBFV-AAA-Z 3X4 ODF 30"
SBFV-AA-C 3X4 ODF 30"
SBFV-AA-Z 3X4 ODF 30"
SBFV-AA-ZP40 3X4 ODF 30"
SBFV-A-C 3X4 ODF 30"
SBFV-B-C 3X4 ODF 30"
SBFVE-AAA-C 3X4 ODF 30"
SBFVE-AAA-ZP40 3X4 ODF 30"
SBFVE-AA-C 3X4 ODF 30"
SBFVE-AA-Z 3X4 ODF 30"
SBFVE-AA-ZP40 3X4 ODF 30"
SBFVE-A-C 3X4 ODF 30"
SBFVE-A-Z 3X4 ODF 30"
SBFVE-A-ZP 3X4 ODF 30"
SBFVE-A-ZP40 3X4 ODF 30"
SBFVE-B-C 3X4 ODF 30"
SBFVE-B-Z 3X4 ODF 30"
SBFVE-B-ZP40 3X4 ODF 30"
SBFVE-C-C 3X4 ODF 30"
SBFVE-C-Z 3X4 ODF 60"
SBFVE-C-ZP40 3X4 ODF 30"
PART
NO*
SPORLAN MODEL**
TYPE EBF
EBFF-AAA-C 3X4 ODF 30"
EBFF-A-C 3X4 ODF 30"
EBFFE-A-C 3VX4 ODF 30"
EBFFE-B-C 3X4 ODF 30"
EBFLE-A-C 3X4 ODF 30"
EBFLE-A-Z 3X4 ODF 30"
EBFPE-C-C 3X4 ODF 30"
EBFPE-C-Z 3X4 ODF 30"
EBFR-A-C 3EX4 ODF 30"
EBFRE-AA-Z 3VX4 ODF 30"
EBFRE-AA-ZP 3VX4 ODF 30"
EBFRE-A-Z 3EX4 ODF 30"
EBFRE-A-Z 3X4 ODF 30"
EBFRE-A-ZP 3EX4 ODF 30"
EBFS-AAA-ZP 2X4 ODF 30"
EBFSE-AAA-Z 2SX4 ODF 30"
EBFSE-AAA-ZP 3VX4 ODF 30"
EBFSE-AA-C 3X4 ODF 30"
EBFSE-A-C 3VX4 ODF 30"
EBFSE-A-Z 3VX4 ODF 30"
EBFSE-B-C 3VX4 ODF 30"
EBFSE-B-Z 3VX4 ODF 30"
EBFSE-B-ZP 3X4 ODF 30"
EBFSE-C-C 3X4 ODF 30"
EBFSE-C-Z 3X4 ODF 30"
EBFSE-C-ZP 3VX4 ODF 30"
EBFV-AAA-C 3EX4 ODF 30"
EBFV-AA-C 3EX4 ODF 30"
EBFV-AA-Z 3EX4 ODF 30"
EBFV-AA-ZP40 3EX4 ODF 30"
EBFV-A-C 3EX4 ODF 30"
EBFV-B-C 3X4 ODF 30"
EBFVE-AAA-C 3X4 ODF 30"
EBFVE-AA-C 3EX4 ODF 30"
EBFVE-AA-CP100 3VX4 ODF 30"
EBFVE-AA-Z 3EX4 ODF 30"
EBFVE-AA-ZP40 3EX4 ODF 30"
EBFVE-A-C 3EX4 ODF 30"
EBFVE-A-Z 3X4 ODF 30"
EBFVE-A-ZP40 3VX4 ODF 30"
EBFVE-B-C 3X4 ODF 30"
EBFVE-B-CP100 3X4 ODF 30"
EBFVE-B-Z 3X4 ODF 30"
EBFVE-B-ZP40 3X4 ODF 30"
EBFVE-C-C 3X4 ODF 30"
EBFVE-C-CP100 3X4 ODF 30"
EBFVE-C-ZP40 3VX4 ODF 30"
IMPORTANT NOTES:
E – Elbow Inlet
V – 877 Series (100 Mesh) Strainer
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service Center for part number and pricing.
637
THERMOSTATIC EXPANSION VALVES
EGFE-1/2-C 3X4 ODF 5'
EGFE-1/4-C 3X4 ODF 5'
EGFE-1-C 3X4 ODF 5'
EGFE-2-C 3X4 ODF 5'
EGJ-1/4-C 3X4 ODF 5'
EGJ-1/6-C 3X4 ODF 5'
EGJ-1/8-C 3X4 ODF 5'
EGJE-1/6-C 3X4 ODF 5'
EGJE-1/8-C 3X4 ODF 5'
EGJE-1-1/2-C 3X4 ODF 5'
EGP-1/2-C 3X4 ODF 5'
EGP-1/4-C 3X4 ODF 5'
EGP-1/6-C 3X4 ODF 5'
EGP-1/8-C 3X4 ODF 5'
EGPE-1/2-C 3X4 ODF 5'
EGPE-1/4-C 3X4 ODF 5'
EGPE-1/8-C 3X4 ODF 5'
EGPE-1-1/2-C 3X4 ODF 5'
EGPE-1-C 3X4 ODF 5'
EGPE-2-C 3X4 ODF 5'
EGR-1/2-C 3X4 ODF 5'
EGR-1/2-Z 3X4 ODF 5'
EGR-1/2-ZP 3X4 ODF 5'
EGR-1/4-C 3X4 ODF 5'
EGR-1/4-Z 3X4 ODF 5'
EGR-1/6-C 3X4 ODF 5'
EGR-1/8-C 3X4 ODF 5'
EGR-1/8-Z 3X4 ODF 5'
EGR-1-C 3X4 ODF 5'
EGRE-1/4-Z 3X4 ODF 5'
EGRE-1/6-C 3X4 ODF 5'
EGRE-1/8-C 3X4 ODF 5'
EGRE-1-ZP40 3X4 ODF 5'
EGRE-2-C 3X4 ODF 5'
EGRE-2-Z 3X4 ODF 5'
EGSE-1/2-C 3X4 ODF 5'
EGSE-1/2-Z 3X4 ODF 5'
EGSE-1/2-ZP 3X4 ODF 5'
EGSE-1/4-C 3X4 ODF 5'
EGSE-1/4-ZP 3X4 ODF 5'
EGSE-1-1/2-C 3X4 ODF 5'
EGSE-1-1/2-Z 3X4 ODF 5'
EGSE-1-1/2-ZP 3X4 ODF 5'
EGSE-1-C 3X4 ODF 5'
EGSE-1-X 3X4 ODF 5'
EGSE-1-Z 3X4 ODF 5'
EGSE-1-ZP 3X4 ODF 5'
EGSE-2-C 3X4 ODF 5'
EGSE-2-ZP 3X4 ODF 5'
EGV-1/2-C 3X4 ODF 5'
EGV-1/2-Z 3X4 ODF 5'
PART
NO*
THERMOSTATIC EXPANSION VALVES
PART
NO*
SPORLAN MODEL**
PART
NO*
SPORLAN MODEL**
PART
NO*
SPORLAN MODEL**
TYPE KT
TYPE S
THERMOSTATIC EXPANSION VALVES
SRE-1/2-C 4X5 ODF 5'
SRE-1/2-ZP 4X5 ODF 5'
SRE-1-1/2-C 4X5 ODF 5'
SRE-1-1/2-Z 4X5 ODF 5'
SRE-1-1/2-ZP 4X5 ODF 5'
SRE-1-C 4X5 ODF 5'
SRE-1-ZP 4X5 ODF 5'
SRE-2-L1 4X5 ODF 5'
SRE-4-Z 4X7 ODF 5'
SSE-1/4-C 3X4 ODF 5'
SSE-10-ZP 5X7 ODF 5'
SSE-10-ZP 7X9 ODF 5'
SSE-2-C 4X5 ODF 5'
SSE-2-ZP 4X5 ODF 5'
SSE-3-C 4X7 ODF 5'
SSE-3-L1 4X7 ODF 5'
SSE-3-ZP 4X7 ODF 5'
SSE-3-ZP40 4X7 ODF 5'
SSE-4-C 4X7 ODF 5'
SSE-4-ZP 4X7 ODF 5'
SSE-6-C 4X7 ODF 5'
SSE-6-C 5X7 ODF 5'
SSE-6-X 5X7 ODF 5'
SSE-6-Z 5X7 ODF 5'
SSE-6-ZP 5X7 ODF 5'
SSE-7-C 5X7 ODF 5'
SSE-7-ZP 5X7 ODF 5'
SVE-1/2-C 4X5 ODF 5'
SVE-10-C 5X7 ODF 5'
SVE-1-1/2-C 4X5 ODF 5'
SVE-1-1/2-L1 3X4 ODF 5'
SVE-1-1/2-Z 3X4 ODF 5'
SVE-1-1/2-ZP40 4X5 ODF 5'
SVE-15-C 7X11 ODF 5'
SVE-15-CP100 7X9 ODF 5'
SVE-1-C 4X5 ODF 5'
SVE-1-ZP40 4X5 ODF 5'
SVE-2-C 4X5 ODF 5'
SVE-2-L1 4X5 ODF 5'
SVE-2-ZP40 4X5 ODF 5'
SVE-3-C 4X5 ODF 5'
SVE-3-L1 4X5 ODF 5'
SVE-3-L2 4X5 ODF 5'
SVE-3-ZP40 4X5 ODF 5'
SVE-4-C 4X7 ODF 5'
SVE-4-L1 4X7 ODF 5'
SVE-4-X 4X7 ODF 5'
SVE-4-ZP40 4X7 ODF 5'
SVE-5-C 4X7 ODF 5'
SVE-8-C 5X7 ODF 5'
SVE-8-L1 5X7 ODF 5'
SVE-8-Z 5X7 ODF 5'
*(
TYPE EMC
EMC-10-PC 3X4 ODF 5'
EMC-10-SC 3X4 ODF 5'
EMC-10-SZ 3X4 ODF 5'
EMC-10-VC 3X4 ODF 5'
EMC-10-VZ 3X4 ODF 5'
EMC-11-SZ 3X4 ODF 5'
EMC-20-PC 3X4 ODF 5'
EMC-20-SC 3X4 ODF 5'
EMC-20-VC 3X4 ODF 5'
EMC-21-PC 3X4 ODF 5'
EMC-21-SC 3X4 ODF 5'
EMC-21-VC 3X4 ODF 5'
EMCE-10-JC 3X4 ODF 5'
EMCE-10-PC 3X4 ODF 5'
EMCE-10-SC 3X4 ODF 5'
EMCE-10-SZ 3X4 ODF 5'
EMCE-10-VC 3X4 ODF 5'
EMCE-10-VZ 3X4 ODF 5'
EMCE-11-SZ 3X4 ODF 5'
EMCE-11-VZ 3X4 ODF 5'
EMCE-12-SC 3X4 ODF 5'
EMCE-12-SZ 3X4 ODF 5'
EMCE-12-VC 3X4 ODF 5'
EMCE-12-VZ 3X4 ODF 5'
EMCE-13-SZ 3X4 ODF 5'
EMCE-13-VZ 3X4 ODF 5'
EMCE-20-JC 3X4 ODF 5'
EMCE-20-PC 3X4 ODF 5'
EMCE-20-SC 3X4 ODF 5'
EMCE-20-VC 3X4 ODF 5'
EMCE-21-JC 3X4 ODF 5'
EMCE-21-PC 3X4 ODF 5'
EMCE-21-SC 3X4 ODF 5'
EMCE-21-VC 3X4 ODF 5'
EMCE-22-JC 3X4 ODF 5'
EMCE-22-PC 3X4 ODF 5'
EMCE-22-SC 3X4 ODF 5'
EMCE-22-VC 3X4 ODF 5'
EMCE-23-PC 3X4 ODF 5'
EMCE-23-SC 3X4 ODF 5'
EMCE-23-VC 3X4 ODF 5'
KT-43-FC 5’(1.5M) ELEMENT
KT-43-FZ 5’(1.5M) ELEMENT
KT-43-FZP 5’(1.5M) ELEMENT
KT-43-PC 5’ ELEMENT
KT-43-RC 5’(1.5M) ELEMENT
KT-43-RZ 30"(.75M) ELEMENT
KT-43-RZP 5’(1.5M) ELEMENT
KT-43-VC 5’(1.5M) ELEMENT
KT-43-VZ 5’(1.5M) ELEMENT
KT-43-VZP 5’(1.5M) ELEMENT
KT-53-FC 5’ ELEMENT
KT-53-FZ 5’(1.5M) ELEMENT
KT-53-FZP 5’(1.5M) ELEMENT
KT-53-RC 5’ ELEMENT
KT-53-SZ 5’ ELEMENT
KT-53-SZP 5’ ELEMENT
KT-53-VC 5’ ELEMENT
KT-53-VZ 5’(1.5M) ELEMENT
KT-53-VZP 5’(1.5M) ELEMENT
KT-83-FC 5’ ELEMENT
KT-83-SC 5’ ELEMENT
KT-83-SZ 5’ ELEMENT
KT-83-SZP ELEMENT
KT-83-VC 5’ ELEMENT
KT-45-ZGA, 30" ELEMENT
IMPORTANT NOTES:
A. R-134a air conditioning and
commercial refrigeration
applications are using R-12 or
R-409A or R-401A elements.
B. R-404A commercial refrigeration
applications are using R-502 or
R-408A elements.
C. R-404A and R-507 low temperature
refrigeration applications are using
R-502 or R-402A or R-408A elements.
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service Center for part number and pricing.
638
THERMOSTATIC EXPANSION VALVES
SPORLAN THERMOSTATIC EXPANSION VALVES
QUICK REFERENCE GUIDE — AIR CONDITIONING VALVES
NOMINAL CAPACITY RANGE (Tons)
VALVE TYPE
R-22
R-134a
R-404A &
R-507
CONNECTION
TYPES
VALVE DESCRIPTION AND APPLICATION
—
—
ODF Solder
2 thru 10
2 thru 6
2 thru 7
ODF Solder
Brass bar body, externally adjustable valve. Inlet has a
permanent 12 mesh strainer. General purpose valve for
air conditioning and refrigeration applications.
8 & 11
5&7
6 & 7-1/2
Extended ODF
Solder
Same physical size as the Type S valve except it
features extended ODF connections and a balanced
port construction.
15 thru 70
9 thru 40
9 thru 45
ODF Solder
Brass bar body, externally adjustable valve. Inlet has a
permanent 12 mesh strainer. General purpose valve for
air conditioning and refrigeration applications.
ODF Solder or
FPT Flange
Cast bronze body, externally adjustable valve with
flange connections. Inlet has a 12 mesh strainer. This
valve type features a dual port semi-balanced design.
This valve type provides valve capacities greater than
the Type M, and is suitable for air conditioning and
refrigeration applications. Flanges for the Type V are
interchangeable with the Type M.
ODF Solder
Flange
Cast bronze body, externally adjustable valve with
flange connections. Inlet has a 12 mesh strainer. This
valve type features a dual port semi-balanced design
and it is primarily for large capacity chillers. This valve
type provides the largest valve capacities available for
flange connection TEVs.
52 thru 100
135 & 180
35 thru 55
80 & 110
38 thru 70
—
• R-22 M Valves With GA & CP 100 Thermostatic chargers are also available
639
THERMOSTATIC EXPANSION VALVES
2 thru 6
Compact and adjustable thermostatic expansion valve
with an internal check valve to allow reverse flow on
heat pump applications. Valve also can be used for
refrigerant 410A applications.(2 ton through 6 ton) RC
valve replaces RI valve.
THERMOSTATIC EXPANSION VALVES
SPORLAN THERMOSTATIC EXPANSION
VALVES
Type-RC
ELEMENT SIZE No. 83, Knife Edge
Joint. Standard Tubing Length 5 Feet.
REFRIGERANT
(Sporlan Code)
Outlet
1/2
5/8
GA or
CP100
External
Equalizer
Only
RCVE-2
RCVE-3
RCVE-4
RCVE-5
RCVE-6
RCZE-2
RCZE-3
RCZE-4
RCZE-5
RCZE-6
22 (V)
7/8
5/8
Type-EBS
410A (Z)
TYPE &
REFRIGERANT CAPACITY
(SPORLAN
CODE)
External
Equalizer
Only
22 (V)
EBSVE-8
EBSVE-11
Inlet
Outlet
5/8
7/8
GA or
CP100
REFRIGERANT
(Sporlan
Code)
22 (V)
OVE-15
OVE-20
OVE-30
OVE-40
OVE-55
OVE-70
External Equalizer
Only
THERMOSTATIC
CHARGES
ELEMENT
SIZE
NUMBER
Balanced Port Construction ELEMENT SIZE
No. 83 and 33, Knife Edge Joint,
Standard Tubing Length 5 Feet
STANDARD
CONNECTIONS
(in. ODF
Solder)
Inlet
22(V)
Outlet
1/2
5/8
3/8
1/2
1/2
5/8
STANDARD
CONNECTIONS
(in. ODF Solder)
GA or
CP100
7
Inlet
Outlet
1-5/8
2-1/8
G only
Type-V
7/8
GA or
CP100 1-1/8
1/2
GA
Only
63
WVE135
WVE180
1-1/8
83
3/8
ELEMENT SIZE No. 63, Small Capacity No. 7 Large
Capacity —Gasket Joint, Standard Tubing Length
10 Feet, Flange Ring Size —2-3/4” OD x 3-3/16” ID.
Type-O
REFRIGERANT
(Sporlan
Code)
Outlet
Type-W
STANDARD
CONNECTIONS
(in. Extended
ODF Solder)
TYPE &
CAPACITY
THERMOSTATIC
CHARGES
AVAILABLE
Balanced Port Construction ELEMENT SIZE No. 83,
Knife Edge Joint, Standard Tubing Length 5 Feet
Inlet
THERMOSTATIC
CHARGES
AVAILABLE
Inlet
STANDARD
CONNECTIONS
(In. ODF Solder)
ELEMENT SIZE No. 63, Gasket Joint,
Standard Tubing Length 5 Feet Flange
Ring Size — 1-3/4” OD x 1-1/2” ID.
1-3/8
33
Type &
CAPACITY
REFRIGERANT
(Sporlan Code)
External
Equalizer
Only
VVE-52
VVE-70
VVE-100
22 (V)
THERMOSTATIC
CHARGES
AVAILABLE
THERMOSTATIC
CHARGES
AVAILABLE
TYPE &
CAPACITY
ELEMENT
SIZE
NUMBER
22 (V)
SVE-2
SVE-3
SVE-4
SVE-5
SVE-8
SVE-10
TYPE &
CAPACITY
THERMOSTATIC EXPANSION VALVES
REFRIGERANT TYPE &
(Sporlan Code) CAPACITY
STANDARD
CONNECTIONS
(in. ODF Solder)
THERMOSTATIC
CHARGES
AVAILABLE
With internal check valve.
R-22 ELEMENT SIZE No. 43, Knife Edge Joint,
Standard Tubing Length 30 Inches
R-410A ELEMENT SIZE No. 45, Knife Edge Joint,
Standard Tubing Length 30 Inches
Type-S
GA or
CP10
0
STANDARD
CONNECTIONS
(In. Extended
ODF Solder)
Inlet
Outlet
1-3/8
1-3/8
TEV REPLACEMENT ELEMENTS
Item Descriptions
640
KT-43-VGA 30”
KT-43-VCP100 30”
KT-33-VGA 60”
KT-33-VCP100 60”
KT-53-VGA 60”
KT-53-VCP100 60”
KT-83-VGA 60”
KT-83-VCP100 60”
KT-63-VGA 10”
KT-63-VCP100 10”
THERMOSTATIC EXPANSION VALVES
THERMOSTATIC EXPANSION VALVE CAPACITIES FOR REFRIGERANTS (Tons of Refrigeration)
AIR CONDITIONING AND HEAT PUMP APPLICATIONS
NOMINAL
CAPACITY
RC
RC
RC
RC
RC
EBS
EBS
O
O
O
O
O
O
S
S
S
S
S
S
S
V
V
V
W
W
2
3
4
5
6
8
11
15
20
30
40
55
70
2
3
4
5
8
10
15
52
70
100
135
180
2.30
3.20
4.20
5.00
6.01
8.51
11.50
15.00
22.20
30.50
40.30
55.00
73.00
2.00
3.20
4.50
5.20
8.00
10.00
15.00
52.00
73.00
100.00
143.00
180.00
LIQUID TEMPERATURE ENTERING TEV (°F)
REFRIGERANT
22
410A
60°
70°
80°
90°
100°
110°
120°
130°
140°
—
—
—
—
—
These factors include corrections for liquid refrigerant density and
net refrigerating effect and are based on an evaporator temperature
of 40° F.
CORRECTION FACTOR, CF LIQUID TEMPERATURE
1.23 1.17 1.12 1.06 1.00 0.94 0.88 0.82 0.76
1.32 1.24 1.16 1.08 1.00 0.92 0.83 0.73 0.62
PRESSURE DROP ACROSS TEV (PSI)
REFRIGERANT
2.76
3.83
5.03
5.99
7.20
—
—
—
—
—
—
—
—
—
—
—
—
—
—
75
100
125
150
160
175
200 225
250
275
CORRECTION FACTOR, CF PRESSURE DROP
22
40°F EVAPORATOR TEMPERATURE
0.87 1.00 1.12 1.22 — 1.32 1.41 1.50 1.58
1.66
410A
0.68 0.79 0.88 0.97 1.00 1.05 1.12 1.19 1.25
1.31
641
TEV CAPACITY = TEV RATING X CF LIQUID TEMPERATURE X
CF PRESSURE DROP —
Example: Calculate the actual capacity of a nominal 2 ton, R-22,
Type RC valve at 40° F evaporator, 80° F liquid temperature entering the TEV, and 75 psi pressure drop across the TEV:
TEV capacity = 2.30 (from rating chart) x 1.12 (CF liquid temperature) x 0.87 (CF pressure drop)
= 2.24 tons
THERMOSTATIC EXPANSION VALVES
VALVE
TYPES
REFRIGERANT
22
410A
RECOMMENDED THERMOSTATIC CHARGES
VCP100, VGA
N, ZGA
EVAPORATOR TEMPERATURE (°F)
40°
40°
THERMOSTATIC EXPANSION VALVES
SPORLAN THERMOSTATIC EXPANSION VALVE
PART NUMBERS
Type EBS Series Valves
Type S Series Valves
EBSVE-11-GA5/8X7/8OD
EBSVE-8-CP1005/8X7/8
EBSVE-8-GA5/8X7/8ODF
EBSVE11CP1005/8X7/8O
THERMOSTATIC EXPANSION VALVES
Part No
SVE-10-GA5/8X7/8ODF
SVE-15-GA7/8X1-1/8ODF
SVE-2-GA1/2/5/8ODF
SVE-3-GA1/2X5/8ODF
SVE-4-GA1/2X7/8ODF
SVE-5-GA1/2X7/8ODF
SVE-8-GA5/8X7/8ODF
SVE10CP1005/8X7/8ODF
SVE15CP1007/8X11/8OD
SVE2-CP1001/2X5/8OD
SVE3-CP1001/2X5/8OD
SVE4-CP1001/2X7/8OD
SVE5-CP1001/2X7/8OD
SVE8CP1005/8X7/8ODF
DESCRIPTION
SVE-10-GA 5/8X7/8 ODF
SVE-15-CP100 7/8X1-1/8 ODF
SVE-2-GA 1/2X5/8 ODF
SVE-3-GA 1/2X5/8 ODF
SVE-4-GA 1/2X7/8 ODF
SVE-5-GA 1/2X7/8 ODF
SVE-8-GA 5/8X7/8 ODF
SVE-10-CP100 5/8X7/8 ODF
SVE-15-CP100 7/8X1-1/8 ODF
SVE-2-CP100 1/2X5/8 ODF
SVE-3-CP100 1/2X5/8 ODF
SVE-4-CP100 1/2X5/8 ODF
SVE-5-CP100 1/2X5/8 ODF
SVE-8-CP100 5/8X7/8 ODF
Type RC Series Valves
Part No
RCVE-2-GA3/8X1/2ODF
RCVE-3-GA3/8X1/2ODF
RCVE-4-GA1/2X1/2ODF
RCVE-4-GA1/2X5/8ODF
RCVE-5-GA1/2X1/2ODF
RCVE-5-GA1/2X5/8ODF
RCVE-6-GA1/2X1/2ODF
RCVE-6-GA1/2X5/8ODF
RCZE-2-GA3/8X1/2ODF
RCZE-3-GA3/8X1/2ODF
RCZE-4-GA1/2X1/2ODF
RCZE-5-GA1/2X5/8ODF
RCZE-6-GA1/2X5/8ODF
DESCRIPTION
RCVE-2-GA 3/8X1/2 ODF
RCVE-3-GA 3/8X1/2 ODF
RCVE-4-GA 1/2X1/2 ODF
RCVE-4-GA 1/2X5/8 ODF
RCVE-5-GA 1/2X1/2 ODF
RCVE-5-GA 1/2X5/8 ODF
RCVE-6-GA 1/2X1/2 ODF
RCVE-6-GA 1/2X5/8 ODF
RCZE-2-GA 3/8X1/2 ODF
RCZE-3-GA 3/8X1/2 ODF
RCZE-4-GA 1/2X1/2 ODF
RCZE-5-GA 1/2X5/8 ODF
RCZE-6-GA 1/2X5/8 ODF
Part No
DESCRIPTION
EBSVE-11-GA 5/8X7/8 ODF
EBSVE-8-C100 5/8X7/8 ODF
EBSVE-8-GA 5/8X7/8 ODF
EBSVE-11-CP100 5/8X7/8 ODF
Type O Series Valves
Part No
OVE-20-GA7/8X7/8ODF
OVE15CP1007/8X11/8O
OVE15GA7/8X1-1/8ODF
OVE20CP1007/8X1-3/8OD
OVE20GA7/8X1-1/8ODF
OVE30CP1001-1/8X1-3/8O
OVE30GA1-1/8X1-3/8OD
OVE40CP10011/8X13/8O
OVE40CP10011/8X15/8O
OVE40GA1-1/8X1-3/8OD
OVE40GA1-1/8X1-5/8OD
OVE55CP10011/8X13/8O
OVE55CP10011/8X15/8O
OVE55GA1-1/8X1-3/8OD
OVE55GA1-1/8X1-5/8OD
OVE70CP10011/8X13/8O
OVE70CP10011/8X15/8O
OVE70GA1-1/8X1-3/8OD
OVE70GA1-1/8X1-5/8OD
DESCRIPTION
TXV, VALVE 7/8X7/8 ODF
OVE-15-CP100 7/8X1-1/8 ODF
OVE-15-GA 7/8X1-1/8 ODF
OVE-20-CP100 7/8X1-3/8 ODF
OVE-20-GA 7/8X1-1/8 ODF
OVE-30-CP100 1-1/8X1-3/8 ODF
OVE-30-GA 1-1/8X1-3/8 ODF
OVE-40-CP100 1-1/8X1-3/8 ODF
OVE-40-CP100 1-1/8X1-5/8 ODF
OVE-40-GA 1-1/8X1-3/8 ODF
OVE-40-GA 1-1/8X1-5/8 ODF
OVE-55-CP100 1-1/8X1-3/8 ODF
OVE-55-CP100 1-1/8X1-5/8 O
OVE-55-GA 1-1/8X1-3/8 ODF
OVE-55-GA 1-1/8X1-5/8 ODF
OVE-70-CP100 1-1/8X1-3/8 ODF
OVE-70-CP100 1-1/8X1-5/8 ODF
OVE-70-GA 1-1/8X1-3/8 ODF
OVE-70-GA 1-1/8X1-5/8 ODF
Type V Series Valves
Part No
VVE-100-GA13/8X13/8
VVE-52-GA13/8X138OD
VVE-70-GA13/8X13/8OD
VVE100CP10013/8X13/8
VVE52CP10013/8X13/8
VVE70CP10013/8X13/8O
DESCRIPTION
VVE-100-GA 1-3/8X1-3/8 ODF
VVE-52-GA 1-3/8X1-3/8 ODF
VVE-70-GA 1-3/8X1-3/8 ODF
VVE-100-CP100 1-3/8X1-3/8 ODF
VVE-52-CP100 1-3/8X1-3/8 ODF
VVE-70-CP100 1-3/8X1-3/8 ODF
Type W Series Valves
Part No
WVE-135-GA15/8X21/8
WVE135CP10015/8X21/8
642
DESCRIPTION
WVE-135GA 1-5/8X2-1/8 ODF
WVE-135-CP100 1-5/8X2-1/8 ODF
SOLENOID VALVES
SPORLAN SOLENOID VALVES
Refrigerants 22, 134a, 402A, 404A, 407C, 502, 507
SPECIFICATIONS
6 Proven Benefits of Sporlan Solenoid Valves
• Molded coil for most sizes.
• Class “F” temperature rating – Coil types MKC-1, OMKC-1, MKC-2, and OMKC-2.
• Extremely rugged, simple design – few parts.
• “E” Series may be brazed without disassembly.
• Tight closing through use of synthetic seating material.
• Can be used on Refrigerants 22, 134a, 401A, 402A, 404A, 407C, 502 and 507 because of high MOPD ratings.
Sporlan Solenoid Valves are made in two general types, normally closed and normally open. The normally closed types
may be further sub-divided into direct acting and pilot operated types.
SOLENOID VALVES
The Sporlan “E” series solenoid valves feature extended solder type connections as standard. One important benefit to the
user is that all valves in the “E” series can be installed without disassembly using either low or no silver content brazing alloy.
The “E” series is interchangeable with the “B” series; solder type valves, providing the overall length can be accommodated.
All valves in the “E” series have the same capacities as the “B” series with the exception of the E42.
Its capacity is approximately 15% greater than the MA42.
All Sporlan solenoid valves are designed for liquid, suction and discharge gas applications.
Most Sporlan Solenoid Valves are listed by Underwriters’ Laboratories, Inc. –Guide No. Y10Z – File No.MH4576 and
Canadian Standards Association –Guide 440-A-O, Class 3221, File 19953 and CE provisions of the LVD 73/23/EEC.
LIQUID CAPACITY SELECTION TABLE
PART NO
“E”
SERIES
VALVE
E3
E5
E6
E9
E10
E14
E19
E25
E34
—
E42
—
PART NO
“E”
SERIES
VALVES
E3
E5
E6
E9
E10
E14
E19
E25
E34
—
E42
—
R-22
1
0.9
1.6
2.9
4.7
6.4
9.1
13.9
23.8
33.2
60.9
73.5
109
2
1.3
2.3
4.0
6.6
9.1
12.9
19.8
33.8
47.0
82.3
104
147
3
1.6
2.8
4.9
8.1
11.1
15.8
24.2
41.4
57.6
98.2
127
175
4
1.9
3.3
5.7
9.3
12.8
18.2
28.0
47.8
66.5
111
147
199
5
2.1
3.6
6.4
10.4
14.3
20.3
31.4
53.5
74.4
123
164
219
1
0.8
1.5
2.7
4.4
6.0
8.5
13.0
22.2
31.0
56.7
68.6
101
2
1.2
2.1
3.8
6.2
8.5
12.0
18.4
31.5
43.8
76.7
96.9
137
404A
1
0.6
1.1
1.9
3.1
4.2
6.0
9.2
15.7
22.0
40.8
48.6
72.8
2
0.9
1.5
2.7
4.4
6.0
8.5
13.1
22.3
31.1
55.2
68.8
98.5
3
1.1
1.9
3.3
5.4
7.3
10.4
16.0
27.4
38.1
65.8
84.2
118
4
1.2
2.1
3.8
6.2
8.5
12.0
18.5
31.6
44.0
74.6
97.2
133
5
1.4
2.4
4.2
6.9
9.5
13.4
20.7
35.4
49.2
82.2
109
147
1
0.8
1.5
2.6
4.3
5.9
8.4
12.8
21.9
30.5
56.4
67.6
101
2
1.2
2.1
3.7
6.1
8.3
11.8
18.2
31.0
43.2
76.3
95.6
136
TONS OF REFRIGERATION**
R-134a
R-401A
PRESSURE DROP – psi*
3
4
5
1
2
3
4
1.3
1.5
1.8
2.0
0.9
1.6
1.9
2.3
2.6
3.0
3.4
1.6
2.8
3.3
4.1
4.6
5.3
5.9
2.9
4.9
5.7
6.6
7.5
8.7
9.7
4.7
8.1
9.3
9.1 11.1 12.8
10.4 12.0 13.4 6.4
14.7 17.0 18.9 9.1 12.9 15.8 18.2
22.6 26.1 29.2 14.0 19.8 24.3 28.1
38.6 44.6 49.9 23.9 33.8 41.4 47.9
53.7 62.0 69.4 33.3 47.1 57.7 66.6
91.5 104 114 61.0 82.5 98.0 112
119 137 153 73.6 104 127 147
163 185 204 109 147 176 199
TONS OF REFRIGERATION**
407C
502
PRESSURE DROP – psi*
3
4
5
1
2
3
1.5
1.0
1.7
1.9
0.6
0.8
2.6
1.8
3.0
3.4
1.0
1.5
4.5
3.2
5.2
5.8
1.9
2.6
7.4
5.2
8.6
9.6
3.0
4.3
10.2 11.8 13.2 4.2
7.2
5.9
14.5 16.7 18.7 5.9
8.4 10.2
22.3 25.8 28.8 9.0 12.8 15.7
38.0 44.0 49.2 15.5 21.9 26.8
53.0 61.2 68.4 21.5 30.5 37.4
91.1 103 114 39.5 53.4 63.7
117 135 151 47.7 67.4 82.5
163 184 203 70.4 95.3 114
R-402A
5
2.1
3.7
6.4
10.4
14.4
20.4
31.4
53.6
74.5
123
165
220
1
0.6
1.1
1.9
3.1
4.2
6.0
9.2
15.7
21.9
40.4
48.5
72.1
2
0.9
1.5
2.7
4.4
6.0
8.5
13.0
22.2
31.0
54.6
68.5
97.5
3
1.1
1.9
3.3
5.3
7.3
10.4
16.0
27.3
38.0
65.1
83.9
116
4
1.2
2.1
3.8
6.2
8.5
12.0
18.5
31.5
43.9
73.8
96.9
132
5
1.4
2.4
4.2
6.9
9.4
13.4
20.7
35.3
49.0
81.4
108
145
4
1.2
2.1
3.7
6.0
8.3
11.8
18.1
30.9
43.1
72.8
95.1
130
5
1.4
2.4
4.1
6.7
9.3
13.2
20.3
34.6
48.2
80.2
106
143
507
4
1.2
2.1
3.7
6.0
8.3
11.8
18.2
31.0
43.2
72.2
95.3
129
5
1.4
2.4
4.1
6.8
9.3
13.2
20.3
34.7
48.3
79.5
107
142
1
0.6
1.0
1.9
3.0
4.2
5.9
9.0
15.4
21.5
39.8
47.6
71.0
2
0.8
1.5
2.6
4.3
5.9
8.3
12.8
21.8
30.4
53.8
67.3
96.1
3
1.0
1.8
3.2
5.2
7.2
10.2
15.7
26.8
37.3
64.2
82.4
115
*Do not use below 1 psi pressure drop, except Types E3 and A3 valves.
**Capacities are based on 40° F evaporator and 100° F liquid. Valve types whether Normally Closed or Normally Open have the same
capacities, i.e., B10 or OB10, E10 or OE10.
Solenoid valves for brine applications – consult Sporlan Valve Company, Washington, MO.
643
SOLENOID VALVES
SPORLAN SOLENOID VALVES
SPECIFICATIONS
Refrigerants 22, 134a, 402A, 404A, 407C, 502, 507
SOLENOID VALVES
PART NOE Series Extended Connections
Without Manual Lift Stem
With Manual Lift Stem Normally Closed
E3S120
E3S130
E5S120
E5S130
E6S130
E6S140
E9S240
E10S240
E10S250
E14S250
E19S250
E19S270
E25S270
E25S290
E34S290
E34S2110
E42S2130
E42S2170
—
—
—
—
ME6S130
ME6S140
ME9S240
ME10S240
ME10S250
ME14S250
ME19S250
ME19S270
ME25S270
ME25S290
ME34S290
ME34S2110
ME42S2130
ME42S2170
SOLENOID PARTS KITS
Part No.
KS-B6/E6
KS-B9/E9
KS-B10/E10
KS-B14/E14
KS-B19/E19
KS-B25/E25
KS-B34/E34
KS-B42/E42
SOLENOID COILS
Coil Type and Voltage
MKC-1 and MKC-2 – 24 JAQ and CAQ
MKC-1 and MKC-2 – 120 JAM and CAM
MKC-1 and MKC-2 – 208-240 JAN and CAN
MKC-1 and MKC-2 – Dual JAU and CAU
644
CONNECTIONS (in)
PORT SIZE (in)
MOPD psi AC
—
3/8 ODF Solder
1/4 ODF Solder
3/8 ODF Solder
3/8 ODF Solder
1/2 ODF Solder
1/2 ODF Solder
1/2 ODF Solder
5/8 ODF Solder
5/8 ODF Solder
5/8 ODF Solder
7/8 ODF Solder
7/8 ODF Solder
1-1/8 ODF Solder
1-1/8 ODF Solder
1-3/8 ODF Solder
1-5/8 ODF Solder
2-1/8 ODF Solder
.101
.101
.150
.150
3/16
3/16
9/32
5/16
5/16
7/16
19/32
19/32
25/32
25/32
1
1
1-5/16
1-5/16
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
300
WATTS
10
10
10
10
10
10
15
15
15
15
15
15
15
15
15
15
15
15
THREE-WAY HEAT RECLAIM VALVES
THREE WAY HEAT RECLAIM VALVES
Sporlan Heat Reclaim Valves are tight synthetic seating three way
valves designed specifically to divert hot gas from the normal to
auxiliary condenser.
“C” TYPE
OPERATION
“B” TYPE
“B” AND “C” TYPE
Reclaim (Reheat) Condenser – Energized – When the pilot
valve is energized, high side pressure is permitted to flow thru
the lower pilot port. At the same time the upper pilot port is
closed to suction. High side pressure on top of the piston
moves the piston-seat assembly to close the normal
condenser port and open the reclaim (upper) main port. With
the upper pilot port closed there is no high to low side bleed
loss with the system operating in the reclaim mode.
HEAT RECLAIM SYSTEMS
PART NO*
• With Head Pressure Control
• With Split Condenser Control
• With Integral Check Valve
When employing heat reclaim on a refrigeration system, the
addition of head pressure controls is important not only to
maintain liquid pressure at the expansion valve inlet, but also to
assure availability of quality hot gas at the reclaim heat
exchanger. Split condenser controls are important to minimize
the required refrigerant charge for wintertime operation. And,
integral check valves are important to minimize installation
costs.
Sporlan Model
10G711B 120/50-60 JAM
10G79B 120/50-60 JAM
12D11B LESS COIL
12D11C LESS COIL
12D13B LESS COIL
12D13B-SC LESS COIL
12D13C LESS COIL
16D17B LESS COIL
16D17B-SC LESS COIL
16D17C LESS COIL
8D7B 208-240/50-60 JAN
8D7B DUAL JAU
8D7C LESS COIL
8D9B DUAL JAU
8D9B LESS COIL
8D9B-CV 24/50-60 LAQ
8D9C LESS COIL
Note: SC - split condenser; CV - check valve.
*(
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.
645
THREE-WAY HEAT RECLAIM VALVES
Normal (Outdoor) Condenser – De-energized – With the pilot valve
de-energized, high side pressure is prevented from entering the cavity
above the piston-seat assembly. At the same time the upper pilot port
is opened to suction pressure. The resulting pressure differential
across the piston moves the piston-seat assembly to close the reclaim
(upper) main port. When the upper pilot port is open, the cavity above the
piston is open to suction. Pump out of the reclaim condenser is controlled
by the bleed rate through the piston. After the reclaim condenser has been
pumped out, and the valve continues to operate in the normal condenser
mode, all flow ceases, thus eliminating high to low side bleed and the
resulting capacity loss.
Normal (Outdoor) Condenser – De-energized – With the
pilot valve de-energized, high side pressure is prevented from
entering cavity above the piston-seat assembly. At the same
time the upper pilot port is opened to suction pressure. The
resulting pressure differential across the piston moves the
piston-seat assembly to close the reclaim (upper) main port.
The non bleed piston prevents high to low side bleed with the
system operating in the normal condenser mode.
FILTER DRIERS
SPORLAN CATCH-ALL SEALED TYPE
The universal acceptance of the Catch-All Filter Drier
is due to its unique molded porous core, consisting of a
blend of highly effective desiccants. The quality
features built into it assure years of service on any
refrigeration system.
ACID — The Catch-All Filter Drier is unexcelled in
acid removal ability. The hydrochloric, hydrofluoric,
and various organic acids are adsorbed and held by
the desiccant in a manner similar to the adsorption of
moisture. Tests have demonstrated that the CatchAll Filter Drier will remove over 10 times as much
MOISTURE — The Catch-All Filter Drier removes
moisture from the refrigerant by adsorbing and retaining acid as the desiccant used in most driers. This ability,
along with its excellent ability to clean up the oil, is
it deep within the desiccant granules.
responsible for the excellent field performance in
FOREIGN MATTER — The Catch-All Filter Drier will
cleaning up severely contaminated
filter out scale, solder particles, carbon, sludge, dirt, or
systems.SPECIAL APPLICATIONS — A special
any other foreign matter with negligible pressure drop.
“HH” core Catch-All Filter Drier is available to
Fine particles that would go through an ordinary
remove wax which frequently causes difficulty on low
strainer are removed down to a minimum size in one
temperature Refrigerant 22 and 502 systems. For cap
pass filtration. The large filtering area of the Catch-All
tube systems, use the C-032-CAP or CW-032-CAP
Filter Drier core permits it to collect a large amount of
Catch-All which has fittings suitable for attaching to
dirt without plug up.
any size capillary tube.
OIL SLUDGE AND VARNISH — Even the best
Remember…It’s not how much moisture you
refrigeration oils break down to produce varnish, sludge, remove from a refrigeration system that counts,
and organic acids. Only the Catch-All Filter Drier is
it’s how little moisture is left
capable of removing these products of oil decomposition.
SEALED TYPE – Liquid Line and Suction Line
SPECIFICATIONS
FILTER DRIERS
LIQUID LINE TYPE
SUCTION LINE
TYPE
SAE Flare
ODF Solder
ODF Solder
C-032
C-033
C-052
—
C-053
C-082
—
C-083
C-084
C-162
—
C-163
C-164
C-165
—
—
C-303
C-304
C-305
—
—
—
C-413
C-414
C-415
—
—
—
C-032-S
C-033-S
C-052-S
C-0525-S
C-053-S
C-082-S
C-0825-S
C-083-S
C-084-S
C-162-S
C-1625-S
C-163-S
C-164-S
C-165-S
—
C-167-S
C-303-S
C-304-S
C-305-S
C-306-S
C-307-S
C-309-S
—
C-414-S
C-415-S
C-417-S
C-419-S
—
—
—
—
—
C-607-S
C-609-S
COMPACT STYLE
CONNECTION
SIZE (in.)
—
—
—
C-084-S-T-HH
—
—
—
C-164-S-T-HH
C-165-S-T-HH
C-166-S-T-HH
C-167-S-T-HH
—
—
C-305-S-T-HH
C-306-S-T-HH
C-307-S-T-HH
C-309-S-T-HH
—
—
—
C-417-S-T-HH
C-419-S-T-HH
C-437-S-T-HH
C-439-S-T-HH
C-4311-S-T-HH
C-4313-S-T-HH
C-607-S-T-HH
C-609-S-T-HH
1/4
3/8
1/4
5/16
3/8
1/4
5/16
3/8
1/2
1/4
5/16
3/8
1/2
5/8
3/4
7/8
3/8
1/2
5/8
3/4
7/8
1-1/8
3/8
1/2
5/8
7/8
1-1/8
7/8
1-1/8
1-3/8
1-5/8
7/8
1-1/8
C-144-S-TT-HH
C-145-S-TT-HH
C-146-S-TT-HH
C-147-S-TT-HH
C-149-S-TT-HH
1/2
5/8
3/4
7/8
1-1/8
VOLUME OF
DESICCANT
(cu in.)
3
5
9
16
30
41
OVERALL
LENGTH (in.)
SAE Flare
4.19
4.69
4.75
—
5.19
5.62
—
6.06
6.31
6.25
—
6.75
6.94
7.25
—
—
9.69
9.88
10.19
—
—
—
9.56
9.94
10.25
—
—
—
48
60
—
—
14
ODF
Solder
3.81
3.88
4.19
4.38
4.31
5.12
5.31
5.25
5.44
5.75
5.94
5.88
6.00
6.31
6.75
6.93
8.88
9.00
9.25
9.65
9.80
9.75
—
9.05
9.35
9.81
9.75
10.34
10.62
10.94
10.94
16.00
16.00
4.14
4.38
4.83
4.97
4.93
SOLDER
SOCKET
DEPTH (in.)
0.38
0.44
0.38
0.44
0.44
0.38
0.44
0.44
0.50
0.38
0.44
0.44
0.50
0.62
0.62
0.75
0.44
0.50
0.62
0.62
0.75
0.96
—
0.50
0.62
0.75
0.90
0.75
0.94
1.00
1.06
0.75
0.90
0.50
0.66
0.66
0.75
0.96
DIAMETER
of BODY
(in.)
1.75
2.44
2.62
3.00
3.00
3.50
4.75
3.00
4.44
Listed by Underwriters Laboratories Inc. – Guide SMGT-File No. SA-1756A& B. Maximum Rated Pressure of 650 psi, except for
the C-140 Series which has a maximum pressure of 450 psi.
646
FILTER DRIERS
SPORLAN CATCH-ALL REPLACEABLE CORE TYPE
The rugged construction of the Replaceable Core Catch-All has proven itself in the field for
many years. The design features include:
1. The famous molded porous core for maximum
4. A complete line of fitting sizes
contaminant removal. The core cannot swell,
— all with copper fittings;
5. No plastic parts are used — all
powder, or pack—assuring ease of installation
and removal;
internal parts are plated steel;
2. The bolt and nut attachment of the end plate
6. A corrosion resistant powder
paint protects the exterior of the
provides simple and trouble free installation;
3. The internal construction gives a one piece
shell.
assembly and assures proper core alignment;
REPLACEABLE CORE TYPE
TYPE
NUMBER OF
CORES
1
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
4
4
4
4
3
3
3
4
4
4
4
4
4
CORE PART NO
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-48, RC-4864, or RC-4864-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
RCW-100, RC-10098, or RC-10098-HH
OPTIONAL SECONDARY FILTER – ORDER SEPARATELY
Filter Part No.
Description
Quantity Required
FS-480
FS-960
Filter for C-480 Series Shell
1
FS-1440
FS-19200
647
VOLUME OF
DESICCANT (cu in)
48
48
48
48
48
48
48
96
96
96
96
96
96
144
144
144
144
144
192
192
192
192
300
300
300
400
400
400
400
400
400
MOUNTING
BRACKETS
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-685
A-175-2
A-175-2
A-175-2
A-175-2
A-175-2
A-175-2
A-175-2
A-175-2
A-175-2
OVERALL
LENGTH (in)
9.15
9.15
9.30
9.30
9.50
9.60
9.60
14.84
14.84
15.04
15.04
15.14
15.14
20.58
20.58
20.68
20.68
20.68
26.22
26.22
26.22
26.22
26.22
27.94
28.06
28.06
34.56
34.57
34.44
34.81
35.12
FILTER DRIERS
C-485,C-485-G
C-485-T
C-487,C-487-G
C-487-T
C-489-T,C-489-G
C-4811-T,C-4811-G
C-4813-T,C-4813-G
C-967,C-967-G
C-967-T
C-969,C-969-G
C-969-T
C-9611-T,C-9611-G
C-9613-T,C-9613-G
C-1449,C-1449-G
C-1449-T
C-14411,C-14411-G
C-14411-T
C-14413-T,C-14413-G
C-19211,C-19211-G
C-19211-T
C-19213,C-19213-G
C-19213-T
C-30013,C-30013-G
C-30013-T
C-30017-T,C-30017-G
C-40017,C-40017-G
C-40017-T
C-40021-T,C-40021-G
C-40025-T,C-40025-G
C-40029-T,C-40029-G
C-40033-T,-C-40033-G
CONNECTIONS (in)
ODF Solder
5/8
5/8
7/8
7/8
1-1/8
1-3/8
1-5/8
7/8
7/8
1-1/8
1-1/8
1-3/8
1-5/8
1-1/8
1-1/8
1-3/8
1-3/8
1-5/8
1-3/8
1-3/8
1-5/8
1-5/8
1-5/8
1-5/8
2-1/8
2-1/8
2-1/8
2-5/8
3-1/8
3-5/8
4-1/8
FILTER DRIERS
SPORLAN CATCH-ALL FILTER DRIERS
LIQUID LINE RATINGS AND SELECTION RECOMMENDATIONS
FILTER DRIERS
TYPE
C-032
C-032-CAP
C-032-S
C-032-F
C-032-FM
C-033
C-033-S
C-052
C-052-S
C-052-F
C-052-FM
C-0525-S
C-053
C-053-S
C-082
C-082-S
C-0825-S
C-083
C-083-S
C-084
C-084-S
C-162
C-162-S
C-1625-S
C-163
C-163-S
C-164
C-164-S
C-165
C-165-S
C-303
C-303-S
C-304
C-304-S
C-305
C-305-S
C-307-S
C-414
C-414-S
C-415
C-415-S
C-417-S
C-419-S
C-607-S
C-609-S
RATINGS AT ARI STANDARD CONDITIONS
SELECTION RECOMMENDATIONS (Tons)
Water Capacity-Drops
Refrigeration
Air Conditioning
SURFACE Refrigerant Refrigerant Refrigerant Refrigerant Refrigerant
Refrigerant Flow
Commercial & Low Field Replacement
FILTERING
Capacity**
22
134a
404A/507 50
407C
410A
Temperature
or Field Built Up
AREA
(Tons at 1 psi ΔP)
60 PPM
50PPM
PPM
50 PPM
50 PPM
Equipment
Systems
75°F 125° F 75° F 125° F 75° F 125° F 75° F 125° F 75° F 125° F 22 134a 404A 407C 410A 12 & 22 404A, 502 12 & 22, 407C &
507
134a
& 507
134a
410A
9
15
21
61
146
240
50
119
196
67
158
261
48
114
188
71
169
279
58
138
227
52
123
202
17
40
65
27
63
104
1.5
1.3
1.0
1.3
1.4
3.5
3.8
3.2
3.5
2.3
2.6
3.2
3.5
3.4
3.7
2.1
1.9
1.4
1.9
2.0
3.4
4.1
4.7
3.1
3.8
4.3
2.3
2.7
3.1
3.1
3.8
4.3
3.3
4.0
4.5
2.1
3.7
4.5
5.2
8.7
9.6
1.9
3.3
4.2
4.7
7.9
8.8
1.4
2.4
3.0
3.4
5.9
6.4
1.9
3.3
4.2
4.7
8.0
8.8
2.0
3.5
4.4
5.0
8.5
9.4
2.1
3.7
4.5
5.2
10.1
11.0
13.8
15.9
4.6
5.3
10.1
11.0
14.9
16.9
21.6
11.5
12.4
15.8
17.5
22.1
24.3
29.1
33.2
1.9
3.3
4.2
4.7
9.3
10.1
12.6
14.5
4.2
4.7
9.3
10.1
13.6
15.5
19.8
10.5
11.4
14.5
16.1
20.3
22.3
26.6
30.4
1.4
2.4
3.0
3.4
6.8
7.3
9.2
10.6
3.0
3.4
6.8
7.3
9.9
11.3
14.4
7.6
8.3
10.6
11.8
14.8
16.3
19.5
22.3
1.9
3.3
4.2
4.7
9.3
10.1
12.7
14.6
4.2
4.7
9.3
10.1
13.7
15.5
19.9
10.5
11.4
14.6
16.2
20.4
22.4
26.8
30.7
2.0
3.5
4.4
5.0
9.8
10.7
13.4
15.5
4.4
5.0
9.8
10.7
14.5
16.4
21.0
11.1
12.1
15.4
17.1
21.5
23.7
28.4
32.4
20
48
78
33
346
297
396
285
424
345
307
100
158
119
53
696
567
756
545
809
658
586
189
302
227
67
936
713 1017
733 1088
885
788
254
407
305
106
1392 1134 1512 1090 1618 1316 1172
378
604
454
1/4
1/4
1/4
1/2
1/2
1/3
1/3
1/3
3/4
thru
1
3/4
thru
2
1/2 1/2
thru thru
1-1/2 1-1/2
1/2
thru
1
3/4
thru
2
1
thru
2
1 1-1/2
thru thru
2
3
3/4
thru
2
1
thru
5
1-1/2
thru
5
3
thru
5
3
thru
5
2
thru
5
3
thru
7-1/2
4
thru
10
5
thru
10
5
thru
12
5
thru
10
5
thru
12
7-1/2
thru
15
15
15
10
15
20
*The filtration area is equal to the core surface area plus the large internal surface available for depth filtration.
†20 drops = 1 gram = 1cc.
**Based on 86 F liquid line temperature and a refrigerant flow of 3.1 pounds per minute per ton of Refrigerant 134a; 2.9 pounds per minute per ton of
Refrigerant 22; 3.9 pounds per minute per ton for Refrigerant 404A; 2.9 pounds per minute per ton for Refrigerant 407C; 2.8 pounds per minute per ton for
Refrigerant 410A and 4.1 pounds per minute per ton for Refrigerant 507. Ratings in accordance to ARI Standard 710.
NOTES:
1. R-12 water capacity values are approximately 15 percent greater than R-134a. R-502 water capacities are similar to R-404A and R-507.
2. The variation in flow ratings of filter-driers having the same size core and shell is caused by the difference in connection sizes used.
648
FILTER DRIERS
SPORLAN CATCH-ALL SUCTION LINE FILTER DRIER RECOMMENDATIONS
FOR CLEAN-UP AFTER BURNOUT AND NEW SYSTEMS
SYSTEM CAPACITY IN HORSEPOWER
Refrigerant 22 & 407C
CONNECTIONS
(in.)
Number of
ODF Solder
Cores
CORE
PART NO
C-084-S-T-HH
1/2
5.44
0.50
C-164-S-T-HH
1/2
6.00
0.50
C-165-S-T-HH
5/8
6.31
0.62
C-166-S-T-HH
3/4
6.75
0.62
C-167-S-T-HH
7/8
6.93
0.75
C-305-S-T-HH
5/8
9.25
0.62
C-306-S-T-HH
3/4
9.65
0.62
C-307-S-T-HH
7/8
9.80
0.75
C-309-S-T-HH
1-1/8
9.75
0.96
9.81
0.75
9.75
0.96
C-417-S-T-HH
7/8
C-419-S-T-HH
1-1/8
Sealed
Type Filter
Driers
Sealed
Type Filter
Driers
C-437-S-T-HH
7/8
10.34
0.75
C-439-S-T-HH
1-1/8
10.74
0.96
C-4311-S-T-HH
1-3/8
10.94
1.00
C-4313-S-T-HH
1-5/8
10.94
1.06
C-607-S-T-HH
7/8
16.00
0.75
C-609-S-T-HH
1-1/8
16.00
0.96
C-144-S-TT-HH
1/2
4.14
0.50
C-145-S-TT-HH
5/8
4.38
0.62
C-146-S-TT-HH
3/4
4.83
0.69
C-147-S-TT-HH
7/8
4.97
0.75
C-149-S-TT-HH
1-1/8
4.93
0.96
C-30013-G
1-5/8
C-30017-G
2-1/8
C-40017-G
2-1/8
C-40021-G
2-5/8
C-40025-G
3-1/8
C-40029-G
3-5/8
C-40033-G
4-1/8
2.62
3.00
Refrigerant
12, 134a, 404A, 502 & 507
Temporary
Temporary
Installation
Installation
Permanent Cores for
Permanent
Cores for
Installation
Cleanup;
Installation
Cleanup;
with Cores
Filter
with Cores
Filter
Elements
Elements
after Cleanup
after Cleanup
1
1/2
1
2
3
2
3.00
5
3.50
7-1/2
Select these
types on
basis of
permanent
installation
3
4
Select these
types on
basis of
permanent
installation
4.75
3.00
10
5
5
3
2
1
3
2
5
3
4.44
3
4
25
50
15
25
30
60
20
30
RC-10098-HH
or
RC-10098
*See page for RSF shells.
CATCH-ALL SUCTION LINE FILTER DRIER SELECTION INSTRUCTIONS
Selection of the proper Catch-All Suction Line Filter Drier will
depend upon the intended usage. Either the “Permanent
Installation with Cores” or “Temporary Installation Cores for
Cleanup; Filter Elements after Cleanup” column may be used.
When the best possible system protection is desired, the
“Permanent with Cores” column should be used for selection.
These recommendations are made on the basis of a low pressure
drop, and as a result the cores can be left in the shell for
maximum drying and acid removal when the system returns to
normal operation delivering its full rated capacity.
An alternate selection that is satisfactory and less
expensive is to install cores temporarily for cleanup, and then
remove these cores and install filter elements after cleanup.
Because of the larger system capacity, the pressure drop
through the temporarily installed cores will be somewhat larger
than normal, but still within the limits. After cleanup, the use of filter
elements will assure a minimum pressure drop when the system is
in normal operation. The low pressure drop through the filter
elements assures maximum energy savings during normal
operation. Cleanup of the system can be accomplished with either
the standard core (RC-10098) or the charcoal core
(RC-10098-HH).
SIGNIFICANCE OF THE PART NUMBER
The letters and numerals in the Catch-All part number each
have a significance. The “C” indicates Catch-All, and “CW”
indicates the High Water Capacity Catch-All. The FIRST TWO
OR THREE DIGITS indicate cubic inches of desiccant. The
LAST ONE OR TWO DIGITS indicate fitting size in eighths. For
sealed models, a “-S” following the last digit indicates solder
fittings, and NO LETTER indicates a flare fitting. Replaceable
core models (C-420 and larger) only have solder connections
and the “-S” is omitted.
Examples: C-083 is 8 cu. in. and 3/8 in. flare, C-309-S is 30 cu.
in. and 1-1/8 in. solder, C-19213 is 192 cu. in. and 1-5/8 in.
solder.
Other suffix letters indicate special qualities. For example:
“-T” indicates a pressure tap consisting of a Schrader type
access valve on the inlet end of the Catch-All.
“-HH” indicates a charcoal style core for wax removal and
cleanup after a hermetic motor burnout.
649
FILTER DRIERS
REPLACEABLE
CORE TYPE*
SEALED TYPE
COMPACT STYLE
SEALED TYPE
TYPE NUMBER
SOLDER
LENGTH SOCKET WIDTH
(in.)
(in.)
DEPTH
(in.)
FILTER DRIERS
REPLACEABLE CORES AND PLEATED FILTER ELEMENTS
Cores for replaceable core type filter-driers are molded
with the same desiccants that are used in the popular
sealed filter-driers.
Cores are individually packed in metal cans, fully
activated and hermetically sealed against moisture and
dirt.
Filter elements are dried and packed in individuals
sealed metal cans. This method of packaging prevents
the element from picking up moisture from the
atmosphere
Each can contains a “triple gasket” consisting of a new
end plate gasket, an end plate gasket for certain
competitive filter-driers, and a core gasket where
desired. See the specifications on Page * for the number
of cores required for each type drier.
RC-4864 — Activated Core — Order as separate item —
Fits types C-480 thru C-19200 Series Shells. This is the
standard core suitable for most installations in the liquid
or suction line.
RCW-48 — High Water Capacity Core — Order as
separate item — Fits types C-480 thru C-19200 Series
shell. Designed specially for use with POE
lubricants. This core should be used on systems that
have a ruptured water cooled condenser, or that have
been exposed to the atmosphere, or for some reason
have a high amount of moisture in the system.
RC-4864-HH— Activated Charcoal Core— Order as
separate item — Fits types C-480 thru C-19200 Series
Shells. This core should be used for wax removal, and
for clean-up of systems that have had a hermetic motor
burnout.
RPE-48-BD — Filter Element — Order as separate
item — Fits types C-480 thru C-19200 Series
Shells and Replaceable Suction Filter (RSF)
Shells. This element should be used in RSF shells
installed in the suction line to obtain the lowest
possible pressure drop. In cleaning up a system
after a hermetic motor burnout, cores should be
used first. After clean-up, the filter element should
be installed.
RC-10098 —Activated Core — Order as a separate
item — Fits types C-30,000 and C-40,000 Series
Shells. This is the standard core suitable for liquid
and suction line applications.
RCW-100 — High Water Capacity Core — Order
as separate item — Fits types C-30,000 and C40,000 Series Shells. Designed specially for use
with POE lubricants. This core should be used on
systems that have a ruptured water cooled
condenser, or that have been exposed to the
atmosphere, or for some reason have a high
amount of moisture in the system.
RC-10098-HH — Activated Charcoal Core — Order
as separate item — Fits types C-30,000 and C40,000 Series Shells. This core should be used for
wax removal, and for clean-up of systems that have
had a hermetic motor burnout.
RPE-100 — Filter Element — Order as separate
item — Fits types C-30,000 and C-40,000 Series
Shells. This filter element should be used in the
suction line to obtain the lowest possible pressure
drop after cores were used for system clean-up.
HH STYLE CATCH-ALL FOR WAX REMOVAL
FILTER DRIERS
U.S. PATENT NUMBER 3,407,617
Small amounts of wax are often a problem on low temperature
systems. Even well engineered systems frequently contain
minute quantities of wax which are sufficient to clog expansion
valve screens or cause sticking of the valve. Sporlan has
developed a special blend of desiccants including activated
charcoal which removes small amounts of wax in the liquid line
before this wax can cause trouble at the expansion valve.
These Catch-All Filter Driers have been very successful in
correcting trouble jobs in the field.
By installing HH Style Catch-All Filter Driers in the liquid line of
all low temperature systems these wax problems can be
entirely prevented. In addition to their wax removal ability, these
filter driers will remove all of the other harmful contaminants
that the standard filter driers remove.
The following Catch-All Filter Driers are available with the HH
core to meet the needs of low temperature systems. For
dimensions, refer to the specifications for standard filter
driers or consult Bulletin 40-10.
650
PART NO.
C-052-HH
C-082-HH
C-083-HH
C-162-HH
C-163-HH
C-163-S-HH
C-164-HH
C-164-S-HH
C-165-HH
C-165-S-HH
CONNECTIONS
(in.)
1/4 SAE Flare
1/4 SAE Flare
3/8 SAE Flare
1/4 SAE Flare
3/8 SAE Flare
3/8 ODF Solder
1/2 SAE Flare
1/2 ODF Solder
5/8 SAE Flare
5/8 ODF Solder
PART NO.
CONNECTIONS
(in.)
C-303-HH
3/8 SAE Flare
C-304-HH
1/2 SAE Flare
C-304-S-HH
1/2 ODF Solder
C-305-HH
5/8 SAE Flare
C-305-S-HH
5/8 ODF Solder
C-414-HH
1/2 SAE Flare
C-415-HH
5/8 SAE Flare
C-417-S-HH
7/8 ODF Solder
RC-4864-HH Replaceable Core
RC-10098-HH
FILTER DRIERS
REVERSIBLE HEAT PUMP FILTER-DRIER
DESIGN BENEFITS
• A short overall length for easy installation.
• Drier operates in either flow direction with low pressure drop.
• Proven metal check valves used in construction — no synthetic materials.
• The Sporlan dependable molded core used for maximum filtration ability. When the flow
direction reverses, dirt already collected remains in the filter-drier.
• A carefully engineered blend of desiccants for maximum water capacity and acid removal
ability. The HPC-160-HH Series also has the HH style core with activated charcoal which
offers maximum ability to remove oleoresin and other reactive chemical constituents in the oil.
• Same rugged construction as used in the Catch-All.
SPECIFICATIONS -FOR NEW INSTALLATIONS AND HFC SYSTEM USE
Dimensions
Part No
HPC-103
HPC-103-S
HPC-104
HPC-104-S
Flow Capacity
Tons at 1 psi
ΔP
Connection
Selection
Size Inches Recommendations
Overall Diameter
Tons
Length Inches R-22
Inches
3/8 Flare
6.75
3/8 Solder
5.88
1/2 Flare
1 thru 5
1/2 Solder
6.94
Liquid Capacity
Ounces (Wt.)
@100°F
Water Capacity
Refrigerant
R-22
R-410A
R-410A Drops at 60 ppm Drops at 80 ppm* R-22
75°F
125°F
75°F
125°F
3.4
3.3
4.5
4.4
215
3.00
176
171
105
12.2
R-410A
10.6
6.00
FOR CLEAN-UP AFTER BURNOUT
Dimensions
Part No
Selection
Connection
Flow Capacity
Recommendations Overall Diameter R-22 Tons at 1
Size
Tons
Inches
psi ΔP
Length Inches
Inches
Water Capacity
Refrigerant 22
Drops at 60 ppm
75°F
125°F
Liquid Capacity
Ounces (Wt.)
R-22 @ 100°F
3/8 Flare
1 thru 5
7.78
3.00
3.7
93
81
14.5
HPC-163-S-HH
3/8 Solder
1 thru 5
6.92
3.00
3.7
93
81
14.5
HPC-164-HH
1/2 Flare
1 thru 5
7.95
3.00
4.0
93
81
14.5
HPC-164-S-HH
1/2 Solder
1 thru 5
7.07
3.00
4.0
93
81
14.5
HPC-165-HH
5/8 Flare
1 thru 5
8.28
3.00
4.9
93
81
14.5
HPC-165-S-HH
5/8 Solder
1 thru 5
7.35
3.00
4.9
93
81
14.5
UL and ULc Listed — Guide-SMGT-File No. SA-1756A & B. Core volume is 10 cubic inches for HPC-100 Series and 14 cubic inches for the
HPC-160-HH Series. Core surface filtering area is 18 sq. in. for the HPC-100 Series and 26 sq. in. for the HPC-160-HH Series. HPC-100
Series are rated for 650 psig; HPC-160-HH have a 500 psig rating.
*As of this printing, ARI has not established an EPD for R-410A.
651
FILTER DRIERS
HPC-163-HH
FILTER DRIERS
SUCTION FILTER WITH THE EXCLUSIVE BI-DIRECTIONAL FEATURE
DESIGN BENEFITS
When the Suction Filter is installed
with flow in the opposite direction,
the bypass relief feature is inactive
and will never open, regardless of the
increase in pressure drop.
• Protects the compressor from dirt
• A relief device opens if the filter plugs
• Suitable for use with all brazing alloys
• Maximum corrosion resistance
• Full flow design for low pressure drop
• Complete line of sizes
The “-T” in the part number indicates
that these models are equipped with
an access valve to permit pressure
Sporlan offers an exclusive concept in Suction Filter
drop readings. The access valve will
design — a filter which is Bi-directional. When flow is
be operational provided the Suction
in one direction, the bypass relief feature is active. If
Filters are installed with the bypass
the pressure drop across the element becomes
feature inactive.
excessive the bypass relief will open slightly to
maintain sufficient gas flow and assure proper
cooling of the hermetic motor.
SPECIFICATIONS
Types with bypass relief feature (Bi-directional Flow)
WITHOUT Access
Valve
SF-283-F
—
—
—
—
—
—
—
Part No
WITH Access Valve
CONNECTIONS (in)
FILTER AREA Sq In
3/8 SAE Flare
5/8 ODF Solder
3/4 ODF Solder
7/8 ODF Solder
1-1/8 ODF Solder
1-1/8 ODF Solder
1-3/8 ODF Solder
1-5/8 ODF Solder
28
28
28
28
28
48
48
48
—
SF-285-T
SF-286-T
SF-287-T
SF-289-T
SF-489-T
SF-4811-T
SF-4813-T
Dimensions
Overall Length Inches SOCKET DEPTH Inches
8.78
8.34
8.79
8.93
9.51
12.42
13.10
13.44
—
0.62
0.69
0.75
0.91
0.91
0.97
1.09
SHELL DIAMETER
Inches
3.00
3.00
3.00
3.00
3.00
3.00
3.00
3.00
FILTER DRIERS
Types without bypass relief feature (Single Flow Direction)
WITHOUT Access
Valve
SF-114
SF-114-F
SF-115
SF-115-F
—
—
Part No
WITH Access Valve
CONNECTIONS (in)
FILTER AREA Sq In
1/2 ODF Solder
1/2 ODF Flare
5/8 ODF Solder
5/8 ODF Flare
2-1/8 ODF Solder
2-5/8 ODF Solder
11
11
11
11
388
388
—
—
—
—
SF-6417-T
SF-6421-T
Dimensions
Overall Length Inches SOCKET DEPTH Inches
4.36
5.25
4.60
5.56
1094
1094
0.50
—
0.62
—
1.24
1.38
SHELL DIAMETER
Inches
2.00
2.00
2.00
2.00
4.75
4.75
SELECTION RECOMMENDATIONS
Part No
WITHOUT Access Valve
SF-114
SF-114-F
SF-115
SF-115-F
SF-283-F
—
—
—
—
—
—
—
—
—
WITH Access Valve
CONNECTIONS (in)
—
—
—
—
—
SF-285-T
SF-286-T
SF-287-T
SF-289-T
SF-489-T
SF-4811-T
SF-4813-T
SF-6417-T
SF-6421-T
1/2 ODF
1/2 SAE
5/8 ODF
5/8 SAE
3/8 SAE
5/8 ODF
3/4 ODF
7/8 ODF
1-1/8 ODF
1-1/8 ODF
1-3/8 ODF
1-5/8 ODF
2-1/8 ODF
2-5/8 ODF
NOMINAL SYSTEM HORSEPOWER* Refrigerant
12, 134a, 404A, 502, 507
22, 407C
1/2
1/2
1
1
1/2
1-1/2
1-1/2
3
5
5
5
7
20
30
*Use R-502 horsepower recommendations for R-502A & B and R-508A.
Use R-12 horsepower recommendations for R-501A & B and R-509A. Ratings are in accordance with ARI Standard 730.
652
1
1
2
2
1
4
5
7-1/2
7-1/2
10
12
15
55
60
FILTER DRIERS
REPLACEMENT SUCTION FILTER
The Replaceable Suction Filter shell, used with RPE-48-BD pleated filter element, is designed to be
installed in the suction line of new systems to remove resident contaminants.
DESIGN BENEFITS:
• Low pressure drop
• Can be used with desiccant cores for clean-up after burnout
• Various fitting sizes up to 3-1/89line size
• Access valve supplied for pressure drop measurement or charging
HOW IT’S USED – Sporlan Replaceable Suction Filters are installed in the suction line of air conditioning
systems to remove contaminants that may be in the system at start-up. The Replaceable Suction Filter has
large fittings permitting the use of a small shell on a system with a large line size, resulting in considerable
economy. The angle construction is suitable for flow in either direction, which results in easy installation
even on compact racks. The Replaceable Suction Filters should be used with cores for cleaning up a
system after a hermetic motor burnout. Select the RC-4864, RC-4864-HH or RCW-48 replaceable cores.
After clean-up, install RPE-48-D elements in the shells.
SELECTION – The table below gives information for choosing the proper model for a given system. The
filter elements are supplied in hermetically sealed metal cans.
SELECTION RECOMMENDATIONS WITH FILTER ELEMENTS
PART NO
RSF-487-T
RSF-489-T
RSF-4811-T
RSF-4813-T
RSF-4817-T
RSF-4821-T
RSF-9617-T
RSF-9621-T
RSF-9625-T
CONNECTIONS
Inches
ODF Solder
7/8
1-1/8
1-3/8
1-5/8
2-1/8
2-5/8
2-1/8
2-5/8
3-1/8
NOMINAL SYSTEM HORSEPOWER
Refrigerant
12 & 134a
22 & 407C 404A, 502 & 507
7
8
10
12
20
25
20
30
40
10
15
20
25
35
50
40
50
80
10
12
15
20
25
35
30
40
55
NO. OF
FILTER
ELEMENTS
NO. OF CORES
One
RPE-48-BD
One
RC-4864
or
RC-4864-HH
Two
RPE-48-BD
Two
RC-4864
or RC-4864-HH
OVERALL
LENGTH
Inches
9.30
9.37
9.60
9.60
9.37
9.75
14.96
15.43
15.12
¦Safety screen Part No.: 6171-S is required when cores are used in the RSF shell. Remove the screen when RPE-48-BD elements are used.
UL and ULc Listed — Guide-SMGT-File No. SA-1756A & B.
FILTER DRIERS
ACID TEST KIT
PART NO
TA-1 One Time Acid Test Kit
653
MOISTURE AND LIQUID INDICATORS
See -All Moisture and Liquid Indicators offers these 8 outstanding benefits
1. The See•All Moisture and Liquid Indicator provides a true
moisture indication for Refrigerants 12, 134a, 22, 404A, 407C, 410A,
502 and 507. The See All is also suitable for Refrigerants 401A & B,
402A & B, 408A and 409A. The dark green indicates dry and a bright
yellow indicates wet. The one indicator avoids the confusion found in
models with two elements. You cannot pick the wrong element when
checking the moisture content of the system.
2. RELIABLE and ACCURATELY CALIBRATED COLOR CHANGE
POINTS. The See•All Moisture and Liquid Indicator is accurately
calibrated in parts per million of moisture for each refrigerant. All
moisture indicators change color on the basis of relative saturation of
the refrigerant. Therefore, liquid line temperature must be considered
if an accurate calibration is to be obtained. A color chart is part of the
label, for easy comparison.
3. COLOR CHANGES ARE EASILY DISTINGUISHED and
REVERSIBLE. The indicator’s color differs so widely between WET
and DRY conditions that there is no possibility of confusion between
the two. Colors will reverse as often as moisture concentration in the
system changes.
4. LARGE FULL VIEW SIGHT GLASS. The See•All Moisture and
Liquid Indicator has an extra large crystal clear sight glass for
viewing the refrigerant. Bubbles indicate a shortage of refrigerant or a
restriction in the liquid line.
5. INDICATOR PROTECTED from DISCOLORATION and DIRT.
The indicator is protected by a filter pad and screen. This prevents
washing of the indicator by the refrigerant and protects it from system
contamination and turbulence.
6. REPLACEABLE INDICATOR ELEMENT. The color indicator
paper can be changed on the new fused glass models without
removing the See•All from the line. Replacement is thru the bottom
(see SA-14SU below). Request the K-SA-4 kit.
7. DISASSEMBLY OF THE SMALLER SIZES NOT REQUIRED.The
extended steel fittings on solder models in the smaller sizes make it
unnecessary to disassemble for installation since steel conducts onl
one eighth as much heat as copper.
8. A DOUBLE DUTY PLASTIC CAP is supplied to keep the glass
free from dust, dirt, and grease. It also permits the service engineer
to use his own discretion concerning instructions to his customers on
observing the See•All Moisture and Liquid Indicator.
Specifications
MOISTURE AND LIQUID INDICATORS
CONNEC
-TION
SIZES
Inches
MALE FLARE
Part
No
FEMALE & MALE
FLARE
Overall
Length
Inches
Part
No
Overall
Length
Inches
MALE FLARE X
SWIVEL NUT
Part
No
Overall
Length
Inches
SWIVEL NUT X
SWIVEL NUT
FEMALE FLARE X
SWIVEL NUT
Overall
Length
Inches
Part
No
Part
No
Overall
Length
Inches
SWIVEL NUT X
ODF SOLDER
Part
No
ODF SOLDER
Overall
Length
Inches
Part
No
1/4
SA-12
2.87
SA-12FM
2.56
—
—
—
—
—
—
—
—
SA-12S
3/8
SA-13
3.37
SA-13FM
2.97
SA-13U
3.64
SA-13UU
3.95
SA-13UU
3.19
SA-13SU
4.19
SA-13S
1/2
SA-14
3.81
SA-14FM
3.44
SA-14U
4.13
SA-14UU
4.50
SA-14UU
3.75
SA-14SU
4.62
SA-14S
5/8
SA-15
4.13
—
—
SA-15U
4.44
SA-15UU
4.75
—
—
SA-15SU
4.89
SA-15S
7/8
—
—
—
—
—
—
—
—
—
—
—
—
SA-17S
1-1/8
—
—
—
—
—
—
—
—
—
—
—
—
SA-19S
1-3/8
—
—
—
—
—
—
—
—
—
—
—
—
SA-211
1-5/8
—
—
—
—
—
—
—
—
—
—
—
—
SA-213
2-1/8
—
—
—
—
—
—
—
—
—
—
—
—
SA-217
Overall
Length
Inches
4.62
4.87
6.31
7.97
Listed by Underwriters’ Laboratories, Inc. - Guide SEYW - File No. SA3182
Maximum Rated Pressure – 650 psi. Overall width is: 1.31 in. for 1/4 in. and 3/8 in. sizes, 1.58 in. for 1/2 in. and 5/8 in. sizes, and 1.38 in. for 7/8 in. and
1-1/8 in. sizes. Most solder connections can be used as male fittings as well as female fittings. The 1/4 in. ODF is 3/8 in. ODM, the 3/8 in. ODF is 1/2 in.
ODM, the 1/2 in. ODF is 5/8 in. ODM, and the 5/8 in. ODF is 3/4 in. ODM. Models with female flare and/or swivel nut connections are supplied with a copper
gasket in the fitting.
Moisture Content PPM
LIQUID
LINE
SEE•ALL
TEMP
SHOWS
Green Dry
Chartreuse CAUTION
Yellow WET
REFRIGERANT
12
75° F
Below 5
5-15
Above
15
100° F
75° F
Below 10 Below 30
10-30
30-90
Above
Above
30
90
22
100° F
Below 45
45-130
Above
130
134a
75° F
Below 50
50-200
Above
200
100° F
Below 80
80-225
Above
225
NOTE: Change or add Catch-All Filter-Drier when paper turns from green to chartreuse.
654
502
404A & 507
75° F
100° F
75° F
100° F
Below 10 Below 20 Below 15 Below 30
20-65
30-140
10-45
15-90
Above
Above
Above
Above
65
140
45
90
407C
410A
75° F
75° F
Below 120 Below 75
120-280
75-150
Above
Above
280
150
DISCHARGE BYPASS VALVES
SPORLAN DISCHARGE BYPASS VALVES
APPLICATION — The discharge bypass valve is normally
applied in a branch line off the discharge line. To allow system
pump down control, a solenoid valve or hand valve must be
installed upstream of the discharge DR type bypass valves.
The bypassed hot gas can enter the low side at several
locations; however, two of the possible locations are preferred
because of superior operating performance: into the side
connection of a Sporlan side connection distributor or directly
into the suction line. By using the side connection distributor
method, the system TEV will act as a desuperheating valve to
keep the compressor suction temperature below the
recommended maximum temperature published by the
compressor manufacturer. When the hot gas is bypassed
directly into the suction line, an auxiliary desuperheating TEV
may be required.
The Sporlan line of discharge bypass valves are designed to
provide an economical method of compressor capacity control
in place of cylinder Unloader or to handle unloading
requirements below the last step of cylinder unloading. These
modulating control valves automatically bypass the required
amount of discharge gas to the low side to maintain the
desired minimum evaporator pressure. The valves are
applicable on any refrigeration or air conditioning system that
operates during periods of low load, which can result in coil
icing or short cycling. These valves respond to downstream
pressure changes and open when the evaporator pressure
falls below the valve setting. At normal loads and evaporator
conditions, the valve remains closed and the system operates
in a conventional manner.
The DR line of valves consists of three basic types of valves:
the adjustable models, the adjustable remote bulb models, and
the non-adjustable models.
The SHGB valves are adjustable and pilot operated with a
solenoid stop feature that eliminates the need for a hot gas
solenoid valve. They were developed for use on larger
capacity systems.
SELECTION and CAPACITY RATINGS —The capacities
given in the table below are valve hot gas capacities and not
the capacities of the system on which the valve is to be applied.
To select a valve, first determine the compressor capacity at
the minimum allowable evaporating temperature.
Then the discharge bypass valve must supply the difference
between this compressor capacity and the minimum evaporator
load at which the system is to be operated. The valve pressure
setting will be that pressure at which the bypass valve must
start to open.
Connections – (Standard Connections are in BOLD type).
ADRS(E)-2 – 3/8 in., 1/2 in., 5/8 in. ODF Solder or 3/8 in., 1/2
in., 5/8 in. SAE Flare
ADRP(E)-3 – 1/2 in., 5/8 in. ODF Solder on 1/2 in., 5/8 in. SAE
Flare
ADRHE-6 & DRHE-6 – 5/8 in., 7/8 in., 1-1/8 in. ODF Solder
SHGB(E)-8 – 7/8 in. ODF, 1-1/8 in. ODF Solder
SHGB(E)-15 – 1-1/8 in., 1-3/8 in. ODF Solder
Valves with ODF solder connections are supplied standard with
1/4 in. ODF external equalizer, 1/4 in. SAE Flare external
equalizer available on special order. Pilot operated models are
supplied with 1/4 in. SAE external equalizer.
DISCHARGE BYPASS VALVES
655
DISCHARGE BYPASS VALVES
SPORLAN DISCHARGE BYPASS VALVES
DISCHARGE BYPASS VALVE CAPACITIES — Tons
Capacities based on 6° F evaporator temperature change from closed to rated opening (does not apply to pilot operated models),
discharge temperature 30° F above isentropic compression, 100° F condensing temperature, 0° F subcooling, 25° F superheat at
the compressor and includes both the hot gas bypassed and liquid refrigerant for desuperheating, regardless of whether the
liquid is fed through the system thermostatic expansion valve or auxiliary desuperheating thermostatic expansion valve.
MINIMUM
ALLOWABLE
REFRIGERANT EVAPORATOR
TEMPERATURE
22
134a
401A
402A
404A
407C
502
DISCHARGE BYPASS VALVES
507
PART NO
ADRS-20/30ODF
ADRS-20/305ODF
ADRSE-20/304ODF
ADRSE-20/305ODF
ADRS-20/804ODF
ADRS-20/805ODF
ADRSE-20/803ODF
ADRSE-20/804ODF
ADRSE-20/805ODF
ADRP-30/304ODF
ADRP-30/305ODF
ADRPE-30/304ODF
ADRPE-30/305ODF
ADRP-30/804ODF
ADRP-30/805ODF
ADRPE-30/804ODF
ADRPE-30/805ODF
ADRHE-60/305ODF
40
26
0
–20
40
26
0
40
26
0
40
26
0
–20
40
26
0
–20
40
26
0
–20
40
26
0
–20
40
26
0
–20
ADRI-1-1/4
ADRIE-1-1/4
0/55 0/75 0/100
—
0.58
0.53
0.44 0.64
0.54
0.63 0.60
0.49
0.59 0.50
0.44
0.40 0.43
0.34
0.41 0.39
0.32
0.38 0.31
0.28
0.45 0.48
0.39
0.47 0.45
0.37
0.44 0.36
0.32
—
—
0.54
—
0.65
0.60
0.66 0.72
0.57
0.69 0.63
0.52
—
—
0.55
—
0.67
0.60
0.67 0.71
0.56
0.68 0.61
0.51
—
0.78
0.65
0.61 0.78
0.63
0.74 0.68
0.56
0.68 0.56
0.50
—
—
0.46
—
0.56
0.49
0.55 0.57
0.46
0.55 0.59
0.41
—
—
0.53
—
0.65
0.59
—
0.71
0.57
0.69 0.62
0.52
ADRS-2
ADRSE-2
0/30 0/80
—
3.51
—
3.57
3.90 3.66
3.75 3.65
—
2.67
2.60 2.44
2.46
—
—
2.76
2.97 2.79
2.83 2.74
—
—
—
3.91
—
4.00
4.22 4.04
—
—
—
3.91
—
4.00
4.17 4.02
—
4.25
—
4.25
4.51 4.31
4.33 4.23
—
3.14
—
3.19
3.58 3.28
3.43 3.30
—
—
—
3.87
—
3.96
4.17 4.00
VALVE TYPE & ADJUSTMENT RANGE (psig)
DRHE-6
SHGB-8 SHGB-15
ADRP-3
ADRHE-6
(Adjustable “Remote Bulb” Model)* SHGBE-8 SHGBE-15
ADRPE-3
0/30 0/80 0/30 0/80
25/35
32/44
55/70
65/80
0/100
0/75
—
5.99
—
9.16
—
—
1 9.8
—
15.7
58
—
6.26
—
9.90
—
—
1 6.9
—
15.9
62
7.38 6.61 13.9 10.9
—
—
—
—
16.2
66
7.45 6.64 14.1 11.0
—
—
—
—
16.2
69
—
4.94
—
9.34
9.64
—
—
—
10.9
41
4.95 4.42 9.36 7.26
8.31
—
—
—
10.9
43
4.89
—
9.41
—
—
—
—
—
11.0
46
—
4.95
—
7.99
—
11.0
—
—
12.3
52
5.66 5.04 10.7 8.26
—
9.49
—
—
1 .4
52
5.62 5.01 10.8 8.32
—
—
—
—
12.5
56
—
—
—
—
—
—
—
—
17.3
—
—
6.66
—
10.3
—
—
—
—
17.7
63
—
7.16
—
11.7
—
—
—
—
17.9
63
8.11 7.33 15.3 12.2
—
—
—
—
18.0
64
—
—
—
—
—
—
—
—
17.5
—
—
6.70
—
10.4
—
—
—
21.4
17.7
64
—
7.16
—
11.7
—
—
—
—
17.9
65
8.08 7.28 15.3 12.1
—
—
—
—
17.9
65
—
7.50
—
12.1
—
—
22.9
—
18.6
74
—
7.50
—
12.1
—
19.3
—
—
18.7
75
8.63 7.81 16.3 13.0
—
—
—
—
18.9
76
8.64 7.71 16.5 12.9
—
—
—
—
19.1
77
—
5.28
—
7.85
—
—
—
19.2
14.3
—
—
5.51
—
8.55
—
—
—
16.6
14.5
55
6.64 5.90 12.5 9.62
—
—
—
—
14.7
59
6.68 6.00 12.6 9.91
—
—
—
—
14.8
61
—
—
—
—
—
—
—
—
17.4
—
—
6.60
—
10.2
—
—
—
—
17.7
64
—
7.09
—
11.5
—
—
—
—
17.8
64
8.02 7.25 15.2 12.0
—
—
—
—
17.9
65
DESCRIPTION
ADRS-2 0/30 4 ODF
ADRS-2 0/30 5 ODF
ADRSE-20/304ODF
ADRSE-20/305ODF
ADRS-2 0/80 4 ODF
ADRS-2 0/80 5 ODF
ADRSE-20/803ODF
ADRSE-20/804ODF
ADRSE-20/805ODF
ADRP-3 0/30 4 ODF
ADRP-3 0/30 5 ODF
ADRPE-30/304ODF
ADRPE-30/305ODF
ADRP-3 0/80 4 ODF
ADRP-3 0/80 5 ODF
ADRPE-30/804ODF
ADRPE-30/805ODF
ADRHE-60/305ODF
PART NO
ADRHE-60/805ODF
ADRHE-60/807ODF
ADRHE-60/809ODF
DRHE-6-55/70AR7X7
DRHE-6-55/70AR9X9
SHGBE-8-0/1009ODF
SHGBE-8-0/1007ODF
SHGB-8-0/107ODF
SHGB-8-0/1009ODF
SHGB-15-0/759ODF
SHGB-15-0/7511ODF
SHGBE-15-0/759ODF
SHGBE-15-0/7511 ODF
656
DESCRIPTION
ADRHE-6 0/80 5 ODF
ADRHE-6 0/80 7 ODF
ADRHE-6 0/80 9 ODF
DRHE-6-55/70AR 7 ODF
DRHE-6-55/70AR 9 ODF
SHGBE-8-0/100 9 ODF LESS COIL
SHGBE-8-0/100 7 ODF LESS COIL
SHGB-8-0/100 7 ODF LESS COIL
SHGB-8-0/100 9 ODF LESS COIL
SHGB-15-0/75 9 ODF LESS COIL
SHGB-15-0/75 11 ODF LESS COIL
SHGBE-15-0/75 9 ODF LESS COIL
SHGBE-15-0/75 11 ODF LESS COIL
PRESSURE REGULATING VALVES
CRANKCASE PRESSURE REGULATING VALVES
Crankcase Pressure Regulating Valves are designed to
prevent overloading of the compressor motor by limiting
the crankcase pressure to a predetermined maximum
value during and after a defrost cycle or a normal
shutdown period. These valves automatically throttle the
vapor flow from the evaporator until the compressor can
handle the load.
PART NO*
SPORLAN MODEL
CRO-4-0/20 4X4 ODF LS
CROT-10 0/6011ODF WS
Sporlan manufactures five adjustable models…
CRO-4, CRO-6, CROT-6, CRO-10 and
CROT-10…all models respond only to their outlet
pressure and modulate to prevent the suction pressure
at the compressor from rising above the valve setting.
Since these valves are adjustable, the setting may be
altered to suit the specific system requirements.
CROT-10 0/60 1-1/8"ODF
CROT-10 0/60 7 ODF WS
CROT-10 30/110 7 ODF WS
CROT-12-65/225 9 ODF
CROT-15-65/225 11 ODF
CROT-6 0/60 5 ODF WS
SELECTION and CAPACITY RATINGS
CROT-6 0/60 1/2" SAE
The ratings for these valves vary depending on three
items: design suction pressure after pull down, maximum
allowable suction pressure recommended by the
compressor or unit manufacturer (this is the valve
setting), and pressure drop across the valve. The
difference between the design suction pressure and the
valve setting determines how much of the valve stroke is
used. Therefore, the valve setting should be kept as high
as possible without exceeding the recommendation of
the compressor or unit manufacturer.
CROT-6 0/60 5/8" SAE
CROT-6 0/60 7 ODF WS
CROT-6 30/110 5 ODF WS
CROT-6 30/110 7 ODF WS
*(
) Please contact your local Carlyle Certified Refrigeration
Partner or RCD Customer Service for P/N and Pricing.
HEAD PRESSURE CONTROL VALVES
Sporlan Head Pressure Control for systems with air cooled condensers
can be accomplished with several valve types or combinations. The
valve types are: LAC-4, OROA-5, LAC-5, LAC-10, ORI/ORD
combination and the ORIT/CROT combination.
PART NO*
SPORLAN MODEL
ORD-4-20 5/8 ODF
ORD-4-20 7/8 ODF
ORD-4-25 5/8 ODF
ORD-4-30 5/8 ODF
ORD-4-35 5/8 ODF
ORI-10 65/225 1-1/8"
ORI-10 65/225 1-3/8"
ORI-10 65/225H 7ODF WS
ORI-10 65/225H 11 ODF WS
ORI-6 65/225 5/8" WS
ORI-6 0/50 5 ODF WS
ORI-6 65/225 7/8" WS
ORI-6 65/225H 9ODF WS
ORIT-15-65/225 11 ODF
ORIT-20-65/225 13 ODF
*(
PART NO*
The LAC, OROA, ORI and ORIT are designed for application in
the liquid line and should not be applied in the discharge line for
any reason. Compressor pulsations can greatly shorten the life
of the valves. If any of the valves are applied in any manner
other than described here, the Sporlan warranty is void.
SPORLAN MODEL
OROA-5-100 5/8 ODF WS
OROA-5-100 7/8 ODF WS
OROA-5-150 7/8 ODF WS
OROA-5-180 5/8 ODF WS
OROA-5-180 7/8 ODF WS
OROA-5-220 5/8 ODF WS
IMPORTANT NOTES:
PART NO*
SPORLAN MODEL
LAC-10-100 11X7 ODF LS
LAC-10-100 11X9 ODF LS
LAC-4-100 1/2 ODF LS
LAC-4-180 3/8 0DF LS
LAC-4-190 1/2 ODF LS
LAC-4-210 1/2 ODF LS
LAC-4-240 1/2 ODF LS
LAC-5-100 1-1/8 ODF LS
LAC-5-210 5/8 ODF WS
LAC-5-75 1/2 ODF LS
WS - With Strainer
LS - Less Strainer
PART NO*
SPORLAN MODEL
CROT-12-65/225 9 ODF
CROT-15-65/225 11ODF
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.
657
PRESSURE REGULATING VALVES
CROT-10 30/110 9 ODF WS
CROT-10 30/110 11 ODF WS
PRESSURE REGULATING VALVES
DEFROST DIFFERENTIAL PRESSURE REGULATING VALVES
PRESSURE REGULATING VALVES
DDR-20 VALVE OPERATION
The DDR-20 is designed to create a differential
pressure between its inlet (discharge) pressure and the
receiver pressure.
A solenoid bypass feature is incorporated in the valve
so that the valve can be made to go full open when
there is no need for a differential to be created.
Energizing the solenoid coil opens the valve fully.
LOCATION
The (O)LDR valve is located between the receiver and
the liquid header. The DDR-20 is located in the
discharge line before the condenser.
ADJUSTMENT RANGE AND PRESSURE
SETTINGS
All defrost differential valves are set by turning
the adjusting stem located under the cap on
the pilot differential valve.
The adjustment range is 5 to 50 psig. The
(O)LDR has a factory setting of 18 psid and
the DDR-20 has a factory setting of 30 psid.
Turning the stem clockwise increases the
setting, counterclockwise decreases
the setting.
PART
NO*
SPORLAN MODEL
OLDR-15 11ODF LESS COIL
OLDR-15 9ODF LESS COIL
OLDR-20 13ODF LESS COIL
OLDR-20 17ODF LESS COIL
DDR-20 13 ODF LESS COIL
*(
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.
EVAPORATOR PRESSURE REGULATING VALVES
The Sporlan line of evaporator pressure regulating
(EPR) valves are designed to provide an accurate and
economical means of balancing system capacity and
load requirements during “low” loads and/or while
maintaining different evaporator conditions on multitemperature evaporator systems. These valves control
evaporator temperature by maintaining evaporator
pressure. As the evaporator load increases the ORI
valves will Open on Rise of I nlet pressure above the
valve’s setting to provide more flow capacity to meet the
evaporator load. When the evaporator load decreases
the valves will modulate closed to maintain the pressure
setting of the valve.
Sporlan offers a number of EPR valve types in various
sizes, and with optional features to accommodate
almost any industry requirement. For more complete
information on any of the EPR valve types see your
Sporlan Wholesaler or contact your Sporlan Sales
Engineer.
PART
NO*
APPLICATIONS
• Maintain minimum evaporator temperature to avoid
frost on air coils and provide improved humidity control
• Evaporator temperature control for food merchandisers
(single and multiple evaporator systems)
• Evaporator temperature control on water chilling units
SPORLAN MODEL
PART
NO*
SPORLAN MODEL
ORI-6 0/50 5 ODF WS
SORIT-12 0/100 208-240VAC 9ODF
ORIT-10 0/50 7 ODF WS
SORIT-12-0/100 LC 9ODF
ORIT-10 0/50 11 ODF WS
SORIT-15-0/100 LC 11ODF
ORIT-10 0/50 9 ODF WS
SORIT-20-0/100 LC 13ODF
ORIT-10 30/100 7 ODF WS
SORIT-PI-211S-0/100 LC
ORIT-10 30/100 9 ODF WS
SORIT-PI-25S-0/100 LESS COIL
ORIT-10 30/100 11 ODF WS
SORIT-PI-25SE-0/100 LESS COIL
ORIT-12 0/100 9 ODF
SORIT-PI-27S-0/100 LESS COIL
ORIT-15 0/100 11 ODF
SORIT-PI-27SE-0/100 LESS COIL
ORIT-20 0/100 13 ODF
SORIT-PI-29S-0/100 LESS COIL
ORIT-6 0/50 5/8" SAE
SORIT-PI-29SE-0/100 LESS COIL
ORIT-6 0/50 1/2" SAE
SORIT-PI-311S-0/100 LESS COIL
ORIT-6 0/50 5 ODF WS
SORIT-PI-313S-0/100 LESS COIL
ORIT-6 0/50 7 ODF WS
SORIT-PI-37S-0/100 LESS COIL
ORIT-6 30/100 5 ODF WS
SORIT-PI-39S-0/100 LESS COIL
ORIT-6 30/100 7 ODF WS
SORIT-PI-411S-0/100 LESS COIL
ORIT-PI-25-0/100
SORIT-PI-413S-0/100 LESS COIL
ORIT-PI-27-0/100
SORIT-PI-417S-0/100 LESS COIL
ORIT-PI-29-0/100
SORIT-PI-49S-0/100 LESS COIL
ORIT-PI-311-0/100
SORIT-PI-511S-0/100 LESS COIL
ORIT-PI-39-0/100
SORIT-PI-513S-0/100 LESS COIL
ORIT-PI-411-0/100
SORIT-PI-517S-0/100 LESS COIL
ORIT-PI-413-0/100
ORIT-PI-513-0/100
IMPORTANT NOTES:WS - With Strainer
*(
) Please contact your local Carlyle Certified Refrigeration Partner or RCD
Customer Service for P/N and Pricing.
658
ELECTRONIC TEMP CONTROL SYSTEMS/OIL FILTERS
ELECTRONIC TEMPERATURE CONTROL SYSTEMS
Type CDS-9 and CDS-16
PART NO*
SPORLAN MODEL
CDS-16 11ODF 10'-S ST
CDS-16 11ODF 20'-S ST
CDS-9 7ODF 20'-H
*(
) Please contact your local Carlyle Certified Refrigeration
Partner or RCD Customer Service for P/N and
Pricing.
SERIES OIL FILTER
DESIGN BENEFITS
• High flow capacities with
low pressure drop
• Virtually eliminates the need for oil changes due to
suspended particulate in circulation
• Filter element utilizes an
O-ring seal
• Unsurpassed filtering efficiency
99% removal of 3 micron sized particles
98% removal of 2 micron sized particles
• Inert micro glass filter
material insures lubricant
compatibility
• Element utilizes a pleated design for maximum
surface area
• Unsurpassed filtration capacities ESIGN BENEFITS
• Dimensions allow for easy
replacement of current filter
The Sporlan Catch-All or SF-283-F Suction Filter has been
used for many years as an oil filter in refrigeration rack systems
with mineral or alkylbenzene as the lubricant of choice.
Bearing wear depends upon the size, hardness, and
concentration of particles in circulation. To effectively remove
these small particles, Sporlan developed a new type of oil filter.
With the use of the new polyolester (POE) oils, system
chemistry has changed. Unlike mineral and alkylbenzene oils,
POE oil has solvent like tendencies. POE oil has the ability to
suspend and recirculate small, solid contaminants left from
system installation or retrofit. Analysis of POE oil samples
taken from actual systems have shown the oil to suspend and
recirculate a high concentration of 2-20 micron sized particles,
with the largest percentage between 2-10 microns. Although
some particles are smaller than bearing tolerances, studies
have shown bearing life can still be affected.
The OF Series Oil Filters are designed to be 99% efficient in
removing 3 micron sized particles and yet have sufficient flow
capacity at a low pressure drop. The unsurpassed filtration
ability of the oil filters will assure clean POE, mineral, or
alkylbenzene oil is returned to the compressors. Clean oil
insures proper operation of the oil level control and minimizes
compressor wear. The Sporlan OF Series Oil Filters were
designed to virtually eliminate the need for oil changes
resulting from suspended solid contaminants in circulation.
PART NO*
SPORLAN MODEL
OF-303 OIL FILTER
OF-303-T OIL FILTER
OF-303-BP OIL FILTER
ROF-413-T REPLACEABLE FILTER
OFE-1 OIL FILTER ELEMENT
*(
) Please contact your local Carlyle Certified Refrigeration Partner or
RCD Customer Service for P/N and Pricing.
659
ELECTRONIC TEMP CONTROL SYSTEMS/OIL FILTERS
CDS-9 9ODF 20'-S
OIL LEVEL CONTROL SYSTEM
OIL LEVEL CONTROL SYSTEM
Sporran’s Oil Level Control System Components were
developed to offer the refrigeration industry an oil level
control system of the highest quality. The heart of the
system is the Oil Level Control which when matched
with the Oil Reservoir and Oil Differential Check Valve
maintains a minimum oil level in the compressor
crankcase during all phases of system operation.
The OCV will only relieve pressure from the
reservoir in excess of its fixed set point.
Systems with fluctuating suction pressure as a
result of compressor unlades, staging or other
suction line controls must be fitted with an OCV
with a differential greater than the suction
pressure fluctuation to assure oil flow from the
OR-1-1/2 through the oil level control to the
compressor crankcase.
OIL LEVEL CONTROL SYSTEM
OIL RESERVOIR Type OR-1-1/2
The Sporlan Oil Reservoir (OR-1-1/2) is a holding vessel
to contain the oil that is not within the crankcase, the oil
separator, or in circulation. The OR-1-1/2 has an inlet
and an outlet service valve so it may be isolated from
the rest of the system, or the oil supply from the oil
reservoir to the Oil Level Control can be eliminated for
service. The OR-1-1/2 also contains two sight glasses
so the maximum and minimum oil level can be
observed. The sight glasses are placed on the shell
symmetrically so 1/4 gallon of oil is contained between
the lower sight glass and the bottom of the shell; 1
gallon is contained between the sight glasses; and 1/4
gallon is contained between the upper sight glass and
the top of the shell. This allows the shell to be mounted
vertically with either service valve on top. Depending on
which end of the OR-1-1/2 Oil Reservoir is mounted to
the top, the oil service valves will be pointing either right
or left for piping convenience.
Sporlan offers OCV’s with a 5, 10,
and 20 psi fixed differential setting.
However, Sporlan recommends the use of an
OCV-20 on all field built
up applications.
OIL LEVEL CONTROLS
The purpose of the Sporlan Oil Level Control is
to regulate the flow of oil to the compressor
crankcase to maintain a minimum oil level as
specified by the compressor manufacturer for
any given application.
PART NO*
OIL DIFFERENTIAL CHECK VALVE
Types OCV-5, OCV-10, OCV-20
The Sporlan Oil Level Differential Check Valve (OCV) is
installed on the 3/8 SAE fitting on top of the OR-1-1/2,
and allows pressure to be relieved from the reservoir to
the suction as required to maintain a pressure in the
reservoir at a preset level above the suction pressure.
The pressure differential created by the OCV assures oil
flow from the reservoir to the Oil Level Control providing
there is adequate oil in the reservoir.
NOTE: OL-60CH replaces OL-1CH and OL-2CH;
OL-60FH replaces OL-1FH and OL-2FH models.
SPORLAN MODEL
OL-60CH OIL LEVEL CONTROL
OL-60FH OIL LEVEL CONTROL
OL-60XH OIL LEVEL CONTROL
OR-1-1/2 OIL RESERVOIR
OCV-10 CHECK VALVE
OCV-20 CHECK VALVE
OCV-30 CHECK VALVE
OCV-5 CHECK VALVE
S-OL OIL LEVEL SIGHT GLASS KIT
AOL-A COPELAND ADAPTOR
AOL-K-1 ADAPTOR KIT -OM-1
AOL-R-1 KIT
*(
) Please contact your local Carlyle Certified Refrigeration Partner or RCD
Customer Service for P/N and Pricing.
TEMPERATURE RESPONSIVE MISCELLANEOUS VALVES, REPLACEMENT PARTS, PARTS
KITS, SOLENOID COILS, AND STRAINER
PART
NO*
SPORLAN MODEL
ADRHE-60/307 ODF
ADRHE-60/309 ODF
ADRIE-1-1/4-0/55 3X3 ODF ST
ADRIE-1-1/4-0/75 3X3 ODF ST
825-005 INLET STRAINER 5/8 ODF
825-007 INLET STRAINER 7/8 ODF
825-009 INLET STR 1-1/8 ODF
825-011 INLET STR 1-3/8 ODF
877-003 INLET STRAINER 3/8 ODF
877-004 INLET STRAINER 1/2 ODF
6034 Y-TYPE 1/2 FPT STRAINER
*(
PART
NO*
SPORLAN MODEL
K-PI-E KIT
RK-SORIT-PI-2 0/100
RK-SORIT-PI-3 0/100
RK-SORIT-PI-4 0/100
KS-12DB
KS-12DC
KS-16DB
KS-ORI/CDA-15 INT PARTS KIT
KS-ORI/CDA-20 INT PARTS KIT
K-SORIT-PI KIT
K-Y1005-1 0/100 PILOT ASSY KIT
OMKC-2 120/50-60 JAM
OMKC-2 208-240/50-60 JAN
PART
NO*
SPORLAN MODEL
Y 1037-FV-1-1/2-190 3VX3 ODF 5’
Y 1037-FV-1-190 3VX3 ODF 30’
Y 1037-FV-2-190 3VX3 ODF 5’
Y 1037-FV-3-190 3VX3 ODF 5’
Y 1037-FV-5-190 3VX3 ODF 5’
Y 1037-FV-1/2-190 3VX3 ODF 5’
Y 1037-FV-1/2-220 3VX3 ODF 5’
Y 1037-FV-1/2-230 3VX3 ODF 5’
Y 1037-FV-1/2-250 3VX3 ODF 5’
Y 1037-FV-1/3-190 3VX3 ODF 5’
Y 1037-FV-1-1/2-220 3VX3 ODF 5’
Y 1037-FV-1-1/2-230 3VX3 ODF 5’
Y 1037-FV-1-1/2-250 3VX3 ODF 5’
Y 1037-FV-1-220 3VX3 ODF 5’
Y 1037-FV-1-230 3VX3 ODF 5’
Y 1037-FV-1-250 3VX3 ODF 5’
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.
660
MISCELLANEOUS
PART
NO*
SPORLAN MODEL
ADRHE-60/307 ODF
ADRHE-60/309 ODF
ADRIE-1-1/4-0/55 3X3 ODF ST
ADRIE-1-1/4-0/75 3X3 ODF ST
825-005 INLET STRAINER 5/8 ODF
825-007 INLET STRAINER 7/8 ODF
825-009 INLET STR 1-1/8 ODF
825-011 INLET STR 1-3/8 ODF
877-003 INLET STRAINER 3/8 ODF
877-004 INLET STRAINER 1/2 ODF
PART
NO*
SPORLAN MODEL
K-PI-E KIT
RK-SORIT-PI-2 0/100
RK-SORIT-PI-3 0/100
RK-SORIT-PI-4 0/100
KS-12DB
KS-12DC
KS-16DB
KS-ORI/CDA-15 INT PARTS KIT
KS-ORI/CDA-20 INT PARTS KIT
K-SORIT-PI KIT
K-Y1005-1 0/100 PILOT ASSY KIT
PART
NO*
SPORLAN MODEL
MKC-1 120/50-60 JAM
MKC-1 208-240/50-60 JAN
MKC-1 24/50-60 JAQ
MKC-1-DUAL/50-60 JAU
MKC-2 24/50-60 JAQ
MKC-2 120/50-60 JAM
MKC-2 208-240/50-60 JAN
MKC-2-DUAL/50-60 JAU
OMKC-2 120/50-60 JAM
OMKC-2 208-240/50-60 JAN
6034 Y-TYPE 1/2 FPT STRAINER
*(
) Please contact your local Carlyle Certified Refrigeration Partner or RCD Customer Service for P/N and Pricing.
MISCELLANEOUS
661
Z - Variable Frequency Drives
Issue Date : 2011-09-30
Variable Frequency Drives
As variable frequency drives (VFDs) from multiple manufacturers are used in Seresco Technologies Inc.'s
products, please ensure that you are aware which model is used in your unit before consulting this guide.
Siemens MicroMaster VFDs
WARNING This equipment contains dangerous voltages and controls potentially dangerous
rotating mechanical parts. Non-compliance with Warnings failure to follow the instructions contained in
this manual can result in loss of life, severe personal injury or serious damage to property. Only suitable
qualified personnel should work on this equipment, and only after becoming familiar with all safety
notices, installation, operation and maintenance procedures contained in this manual. The successful and
safe operation of this equipment is dependent upon its proper handling, installation, operation and
maintenance.
WARNING The DC link of all MICROMASTER modules remains at a hazardous voltage level
for 5 minutes after all voltages have been disconnected. Therefore always wait for 5 minutes after
disconnecting the inverter from the power supply before carrying out work on any modules. The drive unit
discharges itself during this time.
This equipment is capable of providing internal motor overload protection in accordance with UL508C section
42. Refer to P0610 (level 3) and P0335. Motor overload protection can also be provided using an external PTC
via a digital input. This equipment is suitable for use in a circuit capable of delivering not more than 10,000
symmetrical amperes (rms), for a maximum voltage of 230/460 V when protected by an H or K type fuse, a
circuit breaker or self-protected combination motor controller controller (for more details see Operating
Instructions Appendix F). Use Class 1 60/75 °C copper wire only with the cross-sections as specified in the
Operating Instructions.
Before installing and commissioning, please read these safety instructions and warnings carefully and all the
warning labels attached to the equipment. Make sure that the warning labels are kept in a legible condition and
replace missing or damaged labels.
Table 1. Maximum permissible ambient temperature
Frame Sizes A-F
50 °C at constant torque (CT) and 100 %
40 °C at variable torque (VT) and 100 %
1
Z - Variable Frequency Drives
Frame Sizes FX and GX
Issue Date : 2011-09-20
40 °C at 100 % permissible output current
MM420
MM440
Figure 1. MM420 Block Diagram
Figure 2. MM440 Block Diagram
Figure 3. MM420 LED Status Display
Figure 4. MM440 LED Status Display
2
Z - Variable Frequency Drives
Issue Date : 2011-09-30
Table 2. Fault Messages
MM420
Fault
Significance
MM440
Fault
Significance
F0001
Overcurrent
F0002
Overvoltage
F0002
Overvoltage
F0003
Undervoltage
F0003
Undervoltage
F0004
Inverter Overtemperature
F0004
Inverter Overtemperature
F0005
Inverter I2t
F0005
Inverter I2t
F0011
Motor Overtemperature I2t
F0011
Motor Overtemperature I2t
F0012
Inverter temp. Signal lost
F0015
Motor temp. Signal lost
F0010
Mains Phase Missing
F0021
Earth Fault
F0022
HW Monitoring Active
F0023
Output Fault
F0024
Rectifier Overtemperature
F0030
Fan Has Failed
F0035
Auto Restart after n
F0040
Automatic Calibration Failure
F0041
Motor Data Identification Failure
F0042
Speed Control Optimization Failure
F0041
Stator resistance measurement failure
F0051
Parameter EEPROM Fault
F0051
Parameter EEPROM Fault
F0052
Powerstack Fault
F0052
Powerstack Fault
F0053
IO EEPROM Fault
F0054
Wrong IO Board
F0060
Asic Timeout
F0060
Asic Timeout
F0070
Communications board setpoint error
F0070
Communications board setpoint error
F0071
No Data for USS (RS232 link) during Telegram Off Time
F0071
USS (BOP Link) setpoint fault
F0072
No Data from USS (RS485 link) during Telegram Off Time
F0072
USS (COM Link) setpoint fault
F0080
Analogue input - lost input signal
F0080
Analogue input - lost input signal
F0085
External Fault
F0085
External Fault
F0090
Encoder Feedback Loss
F0101
Stack Overflow
F0101
Stack Overflow
F0221
PI Feedback below minimum value
F0221
PI Feedback below minimum value
F0222
PI Feedback above maximum value
F0222
PI Feedback above maximum value
F0450
BIST Tests Failure
F0450
BIST Tests Failure
F0452
Belt Failure Detected
3
Z - Variable Frequency Drives
Issue Date : 2011-09-20
Table 3. Alarm Messages
MM420
Alarms
4
MM440
Significance
Alarms
Significance
A0501
Current Limit
A0501
Current Limit
A0502
Overvoltage limit
A0502
Overvoltage limit
A0503
Undervoltage Limit
A0503
Undervoltage Limit
A0504
Inverter Overtemperature
A0504
Inverter Overtemperature
A0505
Inverter I2t
A0505
Inverter I2t
A0506
Inverter Duty Cycle
A0506
Inverter Duty Cycle
A0511
Motor Overtemperature I2t
A0511
Motor Overtemperature I2t
Z - Variable Frequency Drives
Issue Date : 2011-09-30
A0541
A0600
A0700 - AO709
Motor Data Identification Active
RTOS Overrun Warning
CB warning
A0520
Rectifier Overtemperature
A0521
Ambient Overtemperature
A0522
I2C read out timeout
A0523
Output fault
A0535
Braking Resistor Output
A0541
Motor Data Identification Active
A0542
Speed Control Optimization Active
A0590
Encoder feedback loss warning
A0600
RTOS Overrun Warning
A0700 - AO709
CB warning
A0710
CB communication error
A0710
CB communication error
A0711
CB configuration error
A0711
CB configuration error
A0910
Vdc-max controller de-activated
A0910
Vdc-max controller de-activated
A0911
Vdc-max controller active
A0911
Vdc-max controller active
A0912
Vdc-min controller active
A0920
ADC parameters not set properly
A0920
ADC parameters not set properly
A0921
DAC parameters not set properly
A0921
DAC parameters not set properly
A0922
No load applied to inverter
A0922
No load applied to inverter
A0923
Both JOG Left and JOG Right are
A0923
Both JOG Left and JOG Right are
requested
requested
A0952
Belt Failure Detected
A0936
PID Autotuning Active
5
Z - Variable Frequency Drives
Issue Date : 2011-09-20
ABB VFDs
ACS 350
WARNING Ignoring the following instructions can cause physical injury or death, or damage to
the equipment. Only qualified electricians are allowed to install and maintain the drive! Never work on the
drive, motor cable or motor when input power is applied. After disconnecting the input power, always wait
for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive,
motor or motor cable.
Before performing any maintenance activity, ensure by measuring with a multimeter (impedance at least 1
Mohm) that:
1. There is no voltage between the drive input phases U1, V1 and W1 and the ground.
2. There is no voltage between terminals BRK+ and BRK- and the ground.
Do not work on the control cables when power is applied to the drive or to the external control circuits.
Externally supplied control circuits may carry dangerous voltage even when the input power of the drive is
switched off.
Do not make any insulation or voltage withstand tests on the drive.
If a drive whose EMC filter is not disconnected is installed on an IT system [an ungrounded power system
or a high resistance-grounded (over 30 ohms) power system], the system will be connected to earth potential
through the EMC filter capacitors of the drive. This may cause danger or damage the drive.
If a drive whose EMC filter is not disconnected is installed on a corner grounded TN system, the drive will
be damaged.
WARNING Even when the motor is stopped, dangerous voltage is present at the power circuit
terminals U1, V1, W1 and U2, V2, W2 and BRK+ and BRK-
WARNING The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Center for replacement. Make sure that dust
from drilling does not enter the drive during the installation. Electrically conductive dust inside the drive
may cause damage or lead to malfunction. Ensure sufficient cooling.
6
Z - Variable Frequency Drives
Issue Date : 2011-09-30
Operation and Start-up
Do not activate automatic fault reset functions if dangerous situations can occur. When activated, these
functions will reset the drive and resume operation after a fault.
Do not control the motor with an AC contactor or disconnecting device (disconnecting means); use instead
the control panel start and stop keys or external commands (I/O or fieldbus). The maximum allowed
number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is two per minute and
the maximum total number of chargings is 15 000.
If an external source for start command is selected and it is ON, the drive will start immediately after an
input voltage break or fault reset unless the drive is configured for 3 wire (a pulse) start/stop.
When the control location is not set to local (LOC not shown on the display), the stop key on the control
panel will not stop the drive. To stop the drive using the control panel, press the LOC/REM key LOC and
then the stop key.
Figure 5. ACS 350 Block Diagram
7
Z - Variable Frequency Drives
Table 4. Alarm and Fault Codes
8
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
9
Z - Variable Frequency Drives
10
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
11
Z - Variable Frequency Drives
12
Issue Date : 2011-09-20
Issue Date : 2011-09-30
Z - Variable Frequency Drives
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Z - Variable Frequency Drives
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Z - Variable Frequency Drives
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Z - Variable Frequency Drives
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Issue Date : 2011-09-30
Z - Variable Frequency Drives
ACH 550
WARNING The ACH550 adjustable speed AC drive should ONLY be installed by a qualified
electrician.
WARNING Even when the motor is stopped, dangerous voltage is present at the power circuit
terminals U1, V1, W1 (L1, L2, L3) and U2, V2, W2 (T1, T2 T3) and, depending on the frame size, UDC+
and UDC-, or BRK+ and BRK-
WARNING Dangerous voltage is present when input power is connected. After disconnecting the
supply, wait at least 5 minutes (to let the intermediate circuit capacitors discharge) before removing the
cover. Even when power is switched off from the input terminals of the ACH550, there may be dangerous
voltage (from external sources) on the terminals of the relay outputs.
WARNING When the control terminals of two or more drives are connected in parallel, the
auxiliary voltage for these control connections must be taken from a single source which can either be one
of the drives or an external supply. 1-4 ACH550-UH User’s Manual Safety
WARNING Disconnect the internal EMC filter when installing the drive on an IT system (an
ungrounded power system or a high-resistance-grounded [over 30 ohm] power system).
WARNING Do not attempt to install or remove EM1, EM3, F1 or F2 screws while
power is applied to the drive’s input terminals.
WARNING Do not control the motor with the disconnecting device (disconnecting means);
instead, use the control panel keys or commands via the I/O board of the drive. The maximum allowed
number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is five in ten minutes.
WARNING Never attempt to repair a malfunctioning ACH550; contact the factory or your local
Authorized Service Center for repair or replacement.
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Z - Variable Frequency Drives
Issue Date : 2011-09-20
WARNING The ACH550 will start up automatically after an input voltage interruption if the
external run command is on.
Figure 6. Wiring Diagram ACH 550
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Issue Date : 2011-09-30
Z - Variable Frequency Drives
Figure 7. Wiring Diagram ACH 550
19
Z - Startup Report
Issue Date : 2011-09-30
Startup Report - Seresco Technologies Inc.
Project Name
NE Series Model
Location
Serial Number
Site Contact/Tel:
Seresco Rep.
Unit Visual Inspection
Check
Comments
Supply air blowing on exterior doors and windows?
No supply-return air short-circuiting?
Outdoor air connected to Seresco unit?
Exhaust fan installed and operating, away from intake?
Vapor Barrier installed?
Condensate P-Trap installed and filled?
Condensate line tested?
Pool Water piping properly installed?
Auxiliary pool water circulating pump installed?
Pool water flow to spec?
OACC or Dry Cooler installed and wired properly?
Nameplate voltages verified?
Main disconnect installed?
Wiring connections checked & tightened?
Control wiring to aux pool heater installed?
Floor drain in mechanical room?
Chemicals stored in separate ventilated room?
Air balance report on file?
List other external controlled components
WebSentry connected?
Blowers, compressors rotation checked?
Adequate service access provided?
Unit’s leveled and vibration isolated?
Flex connectors used at both duct connections?
What type of refrigerant is used?
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
1 of 4
Z - Startup Report
Issue Date : 2011-09-30
Unit Electrical Data
L1 – L2
L1 – L3
L2 – L3
Nameplate
Unit Voltage (V)
Transformer secondary voltage (V)
Compressor 1 (A)
Compressor 2 (A)
Main Blower 1 (A)
Main Blower 2 (A)
Exhaust Blower 1 (A)
Exhaust Blower2 (A)
Purge Blower 1 (A)
Purge Blower 2 (A)
OACC Motor 1 (A)
OACC Motor 2 (A)
OACC Motor 3 (A)
OACC Motor 4 (A)
Heat Recovery Pump (A)
Hot Water Pump (A)
Hot Water Pump 2(A)
NOTE: Put ALL additional info/comments into Notes section.
Outdoor Air Condensing / Cooling Unit inspection
Check
Comments/Data
OACC or dry cooler located how feet above/below/level with
Seresco Unit?
Oil traps installed for OACC?
Model number of condenser
Field charge added in pounds and refrigerant type
Fluid GPM
Glycol %
Glycol stabilizers added?
Distance from Seresco Unit to OACC or dry cooler (one-way
line length), ft
Hot gas line size (in)
Liquid line size (in)
Pipe size to dry cooler (in)
2 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Z - Startup Report
Issue Date : 2011-09-30
Fluid Temperature entering main unit (F)
Fluid Temperature leaving main unit (F)
Piping and valves installed per spec?
Unit Operating Data and Configurations
Sensor
Operating Data
Reheat
Reheat +
Pool heat
A/C
Unit Configuration
Setpoints
Value
A/C +
Pool heat
Return Air (F)
Return Air (F)
Return Air (% RH)
Return Air (RH)
Supply Air (F)
Pool 1 (F)
Pool 1 In (F)
Pool 2 (F)
Pool 1 Out (F)
Purge (F)
Pool 2 In (F)
HR (F)
Pool 2 Out (F)
Economizer (F)
Outdoor Air (F)
Comp 1 HP (psi)
Air Heating Type
Comp 1 LP (psi)
Clock Set?
Comp 1 Suction (F)
Board #
Comp 1 Discharge (F)
MAC address
Evap 1 (F)
IP address
Superheat 1 (F)
Comp 2 HP (psi)
BACNET?
Comp 2 LP (psi)
LON?
Comp 2 Suction (F)
MODBUS?
Comp 2 Discharge (F)
Evap 2 (F)
Superheat 2 (F)
Exhaust (F)
Reheat (F)
NOTE: Check/verify superheat is
within 18 – 22 F margin; refer to
Pressure -Temperature chart for proper
refrigerant. Adjust if required.
T/B Sight Glasess1
T/B Sight Glasses 2
Moisture Indicator 1
NOTE: For Receiver Sight glasses:
T(top)/B(bottom) make note whether
ball is “UP” or “DOWN”.
Moisture Indicator 2
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
3 of 4
Z - Startup Report
Issue Date : 2011-09-30
Startup Date
Startup Company Name
Startup Company Contact #
Startup Technician Name
Startup Technician Contact #
Notes/Comments/Info
4 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Z - Startup Report
Issue Date : 2011-09-30
Startup Report - Seresco Technologies Inc.
Project Name
NE Series Model
Location
Serial Number
Site Contact/Tel:
Seresco Rep.
Unit Visual Inspection
Check
Comments
Supply air blowing on exterior doors and windows?
No supply-return air short-circuiting?
Outdoor air connected to Seresco unit?
Exhaust fan installed and operating, away from intake?
Vapor Barrier installed?
Condensate P-Trap installed and filled?
Condensate line tested?
Pool Water piping properly installed?
Auxiliary pool water circulating pump installed?
Pool water flow to spec?
OACC or Dry Cooler installed and wired properly?
Nameplate voltages verified?
Main disconnect installed?
Wiring connections checked & tightened?
Control wiring to aux pool heater installed?
Floor drain in mechanical room?
Chemicals stored in separate ventilated room?
Air balance report on file?
List other external controlled components
WebSentry connected?
Blowers, compressors rotation checked?
Adequate service access provided?
Unit’s leveled and vibration isolated?
Flex connectors used at both duct connections?
What type of refrigerant is used?
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
1 of 4
Z - Startup Report
Issue Date : 2011-09-30
Unit Electrical Data
L1 – L2
L1 – L3
L2 – L3
Nameplate
Unit Voltage (V)
Transformer secondary voltage (V)
Compressor 1 (A)
Compressor 2 (A)
Main Blower 1 (A)
Main Blower 2 (A)
Exhaust Blower 1 (A)
Exhaust Blower2 (A)
Purge Blower 1 (A)
Purge Blower 2 (A)
OACC Motor 1 (A)
OACC Motor 2 (A)
OACC Motor 3 (A)
OACC Motor 4 (A)
Heat Recovery Pump (A)
Hot Water Pump (A)
Hot Water Pump 2(A)
NOTE: Put ALL additional info/comments into Notes section.
Outdoor Air Condensing / Cooling Unit inspection
Check
Comments/Data
OACC or dry cooler located how feet above/below/level with
Seresco Unit?
Oil traps installed for OACC?
Model number of condenser
Field charge added in pounds and refrigerant type
Fluid GPM
Glycol %
Glycol stabilizers added?
Distance from Seresco Unit to OACC or dry cooler (one-way
line length), ft
Hot gas line size (in)
Liquid line size (in)
Pipe size to dry cooler (in)
2 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
Z - Startup Report
Issue Date : 2011-09-30
Fluid Temperature entering main unit (F)
Fluid Temperature leaving main unit (F)
Piping and valves installed per spec?
Unit Operating Data and Configurations
Sensor
Operating Data
Reheat
Reheat +
Pool heat
A/C
Unit Configuration
Setpoints
Value
A/C +
Pool heat
Return Air (F)
Return Air (F)
Return Air (% RH)
Return Air (RH)
Supply Air (F)
Pool 1 (F)
Pool 1 In (F)
Pool 2 (F)
Pool 1 Out (F)
Purge (F)
Pool 2 In (F)
HR (F)
Pool 2 Out (F)
Economizer (F)
Outdoor Air (F)
Comp 1 HP (psi)
Air Heating Type
Comp 1 LP (psi)
Clock Set?
Comp 1 Suction (F)
Board #
Comp 1 Discharge (F)
MAC address
Evap 1 (F)
IP address
Superheat 1 (F)
Comp 2 HP (psi)
BACNET?
Comp 2 LP (psi)
LON?
Comp 2 Suction (F)
MODBUS?
Comp 2 Discharge (F)
Evap 2 (F)
Superheat 2 (F)
Exhaust (F)
Reheat (F)
NOTE: Check/verify superheat is
within 18 – 22 F margin; refer to
Pressure -Temperature chart for proper
refrigerant. Adjust if required.
T/B Sight Glasess1
T/B Sight Glasses 2
Moisture Indicator 1
NOTE: For Receiver Sight glasses:
T(top)/B(bottom) make note whether
ball is “UP” or “DOWN”.
Moisture Indicator 2
** TO VALIDATE WARRANTY FILL OUT AND FAX to 1-613-741-3375 **
3 of 4
Z - Startup Report
Issue Date : 2011-09-30
Startup Date
Startup Company Name
Startup Company Contact #
Startup Technician Name
Startup Technician Contact #
Notes/Comments/Info
4 of 4
For tech support call: 1-770-457-3392 ext.2#
OR 1-613-741-3603 ext.4#
THIS PAGE HAS BEEN INTENTIONALLY LEFT BLANK
________________________________________________
Issue Date : 2011-09-30
www.serescodehumidifiers.com
Supersedes : 2011-09-20
Seresco Technologies Inc. has a policy of continuous product and product data improvement and reserves the right to change
design and specifications at any time without prior notification. Only qualified technicians working within their area of
competence should perform the installation and maintenance of equipment referred to in this literature.
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