ALCO CONTROLS OM3 Serie Instructions De Service

Emerson Electric GmbH & Co OHG
Heerstr.111 - D 71332 Waiblingen
Tel.: 07151 509-0 - Fax.: -200
OM3 is an electronic oil level management system. It uses a Hall sensor to
measure the oil level. The integrated solenoid valve is used to feed missing oil
directly into the compressor sump. If the correct oil level cannot be reached and
oil level comes to the red zone OM3 outputs an alarm signal. The alarm contact
may be used to shut down the compressor.
For application in refrigeration systems and heat pumps according to EN 378.
!
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 opening any system make sure pressure in system is brought to and
remains at atmospheric pressure.
• Ensure supply voltage and current of electric device match rating on OM3
nameplate. Disconnect supply voltage from system and OM3 before
installation or service.
• Do not exceed test pressure.
• Keep temperatures within nominal limits.
• Notes: - Float contains lead and has to be recycled after operation!
- OM3 cannot be combined with OMA Adapters!
System Components (Fig. 1,2,5,6):
1. Screw
2. Washer
3. Sight glass
4. Sight glass O Ring
6. Adapter O-Ring
7. Adapter (Flange or Screw)
8. Compressor O-Ring (optional)
9. Coil connector OM3-Pxx with
screw M3x21 and M3x25
10. Relay Connector OM3-Nxx with
screw M3x21
INSTALLATION WITH FLANGE ADAPTERS (Fig.1, 2):
OM3-CUA (805 030), and OM3-CCC (805 035):
OM3 is ready to install, do not disassemble!
Note: In case of limited space coil and plugs should be mounted prior to
installation to the compressor. Mount coil (12) and secure with blue clip (13).
Then connect OM3-Pxx (9) and OM3Nxx (10) cable assemblies to OM3 and
coil. Recommended torque for the plug screws is 0,15Nm (hand-tight).
• Remove sight-glass from compressor
• Mount O-Ring (8) to adapter (7) acc. Fig. 2
• Mount OM3 to compressor's original sight glass connection
• Use original sight glass screws - threads differ depending on compressor model
• Unit must be installed horizontally for proper functioning (see Fig. 1)
• Mounting torque: see compressor manufacturer's installation instructions
• Install oil supply line to
7/16-20 UNF thread
O-Ring can be removed for cleaning purpose or replacement (see Fig. 5).
INSTALLATION WITH SCREW ADAPTERS (Fig.1, 2, 6):
OM3-CBB (805 032), OM3-CCA (805 033),
OM3-CCB (805 034), OM3-CCD (805 031)
OM3 is not ready to install, for mounting adapter has to be removed.
Note: In case of limited space coil and plugs OM3-Nxx and OM3-Pxx should be
mounted prior to installation to the compressor.
• Remove bolts (1) and spring washer (2)
• Remove adapter (7) and sight glass (3)
• Make shure that O-rings (4,6) stick to sight glass and adapter, all O-rings are
greased and should not fall out
• Screw adapter onto compressor sight glass thread (use mounting torque
specified by the compressor manufacturer) as follows:
OM3-CCB (805 034): locate O-Ring (8) inside compressor sight glass thread -
do not reuse old sight glass O-Ring.
OM3-CBB (805 032): mount O-Ring (8) to the adapter (7).
OM3-CCA (805 033): apply Teflon sealant to adapter thread.
OM3-CCD (805 031) (Fig. 6): locate Teflon gasket (16) into sight glass
connection on the compressor (1-3/4"-12UNF). Apply Rotalockadapter (17)
and Flare nut (20) to the compressors thread. Torque with 90Nm (wrench size
50mm). Then apply Teflon sealant to the ¾"NPT Adapter (18) and screw with
the adapterring into the Rotalockadapter (torque 25Nm).
See Fig. 6 for installation sequence of parts.
Note: Rotalockadapters must be checked for tightness after 1-2 days of operation.
• Insert three bolts (1) with spring washer (2) through sight glass and base unit
(14) (Fig. 2).
• Mount base unit to adapter. Locate grove stamped in adapter ring in line with
main body marking (see Fig. 2).
Document Nr.: A6.5.095 / 02
ALCO CONTROLS
12. Solenoid coil
13. Solenoid clip
14. Base Unit
15. Adapterring
16. Teflon Gasket CCD Adapter
17. Rotalockadapter CCD
18. ¾"-NPT Adapter
19. 7/16"-UNF Oil connector with O-
Ring and protective cap
20. 50 mm Flare nut for
Rotalockadapter CCD
(19). Oil connector with screen and
Replacement for A6.5.095 / 01
Operating Instructions
Oil Management System Series OM3
• Bolt complete assembly (1, 2, 3, 4, 14) to adapter (7) with 7 Nm torque.
Unit must be installed horizontally for proper functioning (see Fig. 1)
• Install oil supply line to 7/16-20 UNF thread (19). Oil Connector with screen
and O-Ring can be removed for cleaning purpose or replacement (see Fig.5).
• Connect OM3-Pxx (9) horizontally per Fig. 4 to Coil and OM3-Nxx (10) cable
assemblies to OM3. Mount coil (12) and secure with clip (13). Recommended
torque for the plug screws is 0,15Nm (hand-tight).
Screw types: small connectors M3x21, large coil connector M3x25.
Leakage test:
• After completion of installation, a pressure test must be carried out as follows:
- 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.
Electrical Wiring (plugs do not require additional gaskets)
• Connect OM3-Nxx (10) cable to relay connection according Fig. 1 and Fig. 3
A = blue (open in Alarm)
B = black (common)
C = brown (closed in Alarm)
Note: Do not switch compressor directly. Use compressor's power relay instead. See
Fig. 3 for connection of OM3 to the safety loop (5) of a rack controller (4).
• Connect OM3-Pxx (9) wires to power supply (i.e. ECT 523 Order No. 804 332)
acc. Fig. 1
To provide correct oil level at any time we recommend to keep OM3 always
powered on; (also during stand-by and shutdown mode of compressor)
Operation (Fig. 3)
OM3 is fully level controlled. The sight glass is divided into three operational
Zones. When level reaches the yellow zone (2) the OM3 starts filling after a
time delay of 10 sec. Further level drop to the red zone (3) will switch the alarm
relay after a time delay of 20 sec.
The current status is indicated with the 3 LEDs according to following table:
LED
• Green
• Green • Yellow
• Yellow
• Red • Yellow
First Installation: after connecting OM3 to power supply and oil level is below
60%, OM3 starts injecting after 10 sec. delay to bring oil immediately to a safe level.
Technical data:
Maximum working 31 bar
pressure:
Leakage test pressure 35 bar
Solenoid MOPD 20 bar
Supply voltage: 24 VAC, 50/60
Hz (+10/-15%)
Solenoid coil ALCO ASC 24
VAC, 50/60 Hz
Current 0,7 A
Alarm switch SPDT
Alarm contact rating 3A/230 VAC
• Marking with CE acc. EMC and Low Voltage Directive
• Compressor table see Fig. 7
• Flow Capacity see Fig. 8
Service:
• Replace Coil Clip (13) any time the coil (12) is removed.
Accessories:
• Differential valve 3,5 bar (ODP-33A Order No.: 800 366)
• Transformer 24VAC (ECT-523, Order No. 804 332)
Date: 02.09.2005
Status / Function
Oil Level in zone 1 (60 - 40%)
Oil Level in zone 1 (60 - 40%) & Injection
Oil Level in zone 2 (40 - 25%) & Injection
Oil Level in zone 3 (25 - 0%) & Injection
Time delay filling
Time delay alarm
Medium compatibility
not released for inflammable
refrigerants or ammonia
Medium temperature:
Storage and transport temp
Ambient temp. (housing):
Protection class
(IEC529/EN60529)
Weight (including coil)
(dep. on adapter)
Oil supply fitting
DWG Nr.: H140H017.001EA/PCN 865033
GB
10sec
20sec
HFC,
HCFC
-20...80 °C
-20...50 °C
-20 ... 50° C
IP65
850 .. 930 g
7/16"-20
UNF (male)