ALCO CONTROLS EX5 Mode D'emploi

Emerson Electric GmbH & Co
Heerstr.111 - D 71332 Waiblingen
Tel.: 07151 509-0 - Fax.: -200
General information and technical data:
EX5/6/7/8 are stepper motor driven valves for precise control of refrigerant mass
flow in refrigeration, air conditioning, heat pumps, industrial cooling process and
close control systems as:.
- Expansion valves
- Liquid injection for subcooling and desuperheating
- Capacity control; hot gas bypass regulator
- Capacity control; suction pressure regulator
- Head pressure regulator
- Liquid level regulator
- Crankcase pressure regulator
!
Safety instructions:
• Read installation instructions thoroughly. Failure to comply can result in
device failure, system damage or personal injury.
• It is intended for use by persons having the appropriate knowledge and
skill. Before attempting to install the valve make sure pressure in system is
brought to and remains at atmospheric pressure.
• Do not release any refrigerant into the atmosphere!
• Do not use any other fluid media without prior approval of ALCO
Controls. Use of fluid not listed could result in:
Change of hazard category of product and consequently change of
conformity assessment requirement for product in accordance with
European pressure equipment directive 97/23/EC.
• Do not operate valve connected directly to supply voltage. Use applicable
stepper motor driver.
• Switch off all voltages / currents before cabling.
• Do not operate system before all cable connections are completed.
• Do not operate the valve when the compressor is not running.
• Do not operate the valve when system is under vaccum.
• Compliance with local electrical regulations when wiring.
Mounting location:
• Expansion valve and liquid injection application:
- The valve must be installed in horizontal position to vertical position (as
per fig. 1).
- For best result, locate the valve as close as possible to the distributor or
inlet of evaporator.
• Hot gas bypass applications:
- Head of valve with motor must be downward (as per Fig 1).
- Install the valves as far as possible from compressor discharge.
- It is also recommended to install a check valve (2) on main hot gas pipe
going to condenser after branch line into the valve (1) (see Fig. 2).
• Suction line application:
Head of valve with motor must be downward.
Installation:
• The arrow on the valve must point in the direction of refrigerant flow. Except
Bi-flow version.
• EX5/EX6/EX7: Apply proper temperature for brazing of copper to copper as
the fittings of valve are solid copper.
• When brazing, direct flame away from valve. Use wet rags or other suitable
heat protection.
• EX8: The valve is supplied with Rotalock flanges. The fittings are copper
plated steel. Use proper brazing procedure.
• Make sure the gasket is located properly in groove between valve and flange.
• Valve and flange must be aligned so that screw-cap can be easily tightened by
hand
• Tighten the rotalock with 48 Nm.
Leakage test:
• After completion of installation, a test pressure must be carried out as follows:
Technical Data
Type
Maximum working pressure at TS: –50°C to +120°C at
inlet connection
Operating temperature at motor
Connection, DN
Fluid group
Refrigerant: CFC, HCFC, HFC
Date code - Made in A=Germany , K=Czech Republic
Hazard category: PED 97/23/EC
Nominal Supply Voltage U:
Maximum Current Imax.:
Marking
Document Nr.: A6.5.007 / 03
ALCO CONTROLS
–50°C to +80°C
5/8"(16mm)
7/8" (22mm)
not applicable
Replacement for A6.5.007 / 02
Operating Instructions
Electrical Control Valves EX5 / EX6 /EX7 / EX8
- According to EN378 for systems which must comply with European pressure
equipment directive 97/23/EC
- To maximum working pressure of system for other applications
Warning:
1) Failure to do so could result in loss of refrigerant and person injury.
2) The pressure test must be conducted by skilled persons with due respect
regarding the danger related to pressure.
• Protect the valve against vibration. If the total valve weight results in excessive
stress to the piping joints, the valve must be supported by suitable mounting
bracket(s).
• The valve must be protected against contaminants. Install an ALCO filter drier
before the valve.
• Check for sufficient refrigerant charge/subcooling and make sure no flash gas is
present at the inlet of valve before attempting to check valve operation. Install
an ALCO sight glass AMI or MIA before the valve.
Wiring and mounting of plug:
• EX5/EX6 (Fig. 3, A = White, B = Black, C = Blue, D: Brown): Prewired plug
and cable assmbely (EX5-N/L/C...) is ready for connection to the valve. There
is no specific requirement for positioning of plug on pins. Pull the round nut
upward and push the plug on pins on top of the valve. Rotate the nut one turn in
clockwise direction and push the plug. Repeat this procedure until the plug is
tighten.
• EX7/EX8 (Fig. 4):
Terminal block
Terminal
Fasten-screw
Housing
• The plug is equipped with cable gland PG9 (cable diameter max. 8mm, min.
3.5mm).Use proper cable diameter. Wire size min. 0.5 mm
motor current.
- Pull cable through cable gland (7), washer (6), insulation ring (5) and the
housing (4).
- Connect wires to terminals (2). Plug has four terminals (# 1, 2, 3 and 4)
- Pull cable back and insert the terminal-block (1) into housing (4).
- Insert the fasten-screw (3) into the hole on the top of housing (4).
- Tighten cable gland (7). Max. torque 1Nm.
- Put gasket (8) on valve and insert plug on pins of EX7/8 and fasten the screw.
• Note 1: The insertion of plug on pins of EX7/8 is possible only on a certain
position when the flat slot of plug is corresponding to wider pin of EX7/8. (pin
4 is wider than pins 1, 2 and 3)
• Note 2: To maintain IP65, proper installation is mandatory. Loose cable gland
or fasten-screw, missing gasket or washer will result in loss of protection
against moisture.
Wiring to driver/controller:
• See wiring diagram of assosiated driver or controller.
Warning: Improper wiring will result wrong direction of rotation or no rotation
of stepper motor. See installation instruction of electronic board.
Operation:
See operation manual of associated electronic driver/controller.
Service hints:
• Do not apply motor voltage/current out of specified range.
• For motor check, use an ohmmeter with suitable range as shown in Fig. 3
(EX5/EX6) and Fig. 5 (EX7/EX8).
• EX5/6/7/8 has capability of positive shut-off when it is driven to fully close
position.
EX5 EX6
PS: 43 bar PS: 43 bar
–50°C +80°C
7/8"(22mm)
1-1/8"(28mm)
II II
√ √
Kxxxx Kxxxx
- I
24 VDC 24 VDC
0.5 A 0.5 A
√
Date: 24.05.2004
Insulation ring
Washer
Cable gland
Gasket
EX7-... EX8-...
PS: 35 bar PS: 35 bar
–50°C +80°C –50°C +80°C
1-3/8" (35 mm) 1-3/8", 35 mm,
42 mm
II II
√ √
Axxx Axxx
I I
24 VDC 24 VDC
0.75 A 0.8 A
√ √
DWG Nr. EX7EA001000 / PCN 862605
GB
2
is suitable for