ICE WESTERN SALES LTD.

9765 54 Street SE
Calgary, AB T2C 5J6
Phone: (403) 252-5577
Fax: (403) 252-5556

Installation and User Manual

AH SERIES PACKAGED UNITS

- DX or Chilled Water Cooling
- Gas, Electric, Steam or Hot Water Heat

Models AH-020 to AH-700

5 to 180 Tons
Refrigerant: R-410A, R-407C, R-22, R-134a

NOTE: Prestart-up: Compressors with oil heaters require minimum time or

temperature before starting. ( ie: min 8 hrs, min 120 ºF )
Contents

Contents
1. Description……………………………………………………………………………….….. 3
Hazard Identification Information
Safety Considerations
Unit Description
Refrigeration Piping

2. Model Number Description………………………………………………………………….. 8

Unit Model Number

3. User’s Information……………………………………………………………………………. 9
DX Package Units
Hydronic Cooling & Heating
Gas or Electric Heating
Multiple Unit Operation
Condensate Piping
Normal Thermostat Operation
Night and Vacancy Operation
Gas Heating System
Hot Gas Bypass System
Filter Sizes
Cabinet Construction

4. Delivery……………………………………………………………………………………….. 14
Receipt & Inspection
Storage

5. Installation…………………………………………………………………………………….. 15
General
Handling
Heating and Cooling Systems
Service Clearances
Setting the Unit
Electrical
Standard Control Board
Optional Control Board
Thermostat
Economizer Option
Lockout Modes
Condensate Piping

6. Start-Up……………………………………………………………………………………….. 26
General
Procedures
Air Balancing
Controls
Unit Start-up Checklist

7. Operation & Maintenance………………………………………………………………….. 36

General
Planned Maintenance
Cooling
Condenser Fan
Blower Assembly

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Contents
Gas Furnace
Chilled Water
Filters
Cleaning
Service

8. Pressure-Temperature Chart ……………………………………………………….……. 40

APPENDICES

Solenoid Valves 200RB/500RB Model

Solenoid Valves 240RA/540RA Model
EK, ADK & BOK Filter Drier Installation Instructions
HMI Moisture Liquid Indicator
PS1 Single High and Low Pressure & PS2 Dual Pressure Refrigeration Controls
P70, P72, P170 Series Controls for High Pressure Applications
B Series Balanced-Port Thermal Expansion Valves Installation & Service Instructions
TRAE+ Balanced Port Thermal Expansion Valve Cage
TX6 Thermo Expansion Valves Technical Data
ASC, ASC2, AM, AH, DM, EB, EM, MM, RM Coils Instruction Sheet
EX4 / EX5 / EX6 / EX7 / EX8 Electrical Control Valves Technical Data
EC3-D7x Digital Superheat Controller with EC3-D72 TCP/IP Communication Instructions
System 350 A350P Electronic Proportional Plus Integral Temperature Control

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Description

1. Description

Hazard Identification Information

WARNING
Warnings indicate potentially hazardous situations,
which can result in property damage, severe personal
injury, or death if not avoided.

CAUTION
Cautions indicate potentially hazardous situations,
which result in personal injury or equipment damage
if not avoided.
WARNING
Safety Considerations
Installation and servicing of air-conditioning equipment can be hazardous due to system
pressure and electrical components. Only trained and qualified service personnel should install,
repair, or service air-conditioning equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and
replacing filters. All other operations should be performed by trained service personnel. When
working on air-conditioning equipment, observe precautions in the literature, tags and labels
attached to the unit, and other safety precautions that may apply.
Follow all safety codes, including UL 1995 (Issued: 2005/02/18 Ed:3 UL Standard for Safety
Heating and Cooling Equipment - ) and CSA C22.2#236 (Issued: 2005/02/01 Ed:3 UL Standard
for Safety Heating and Cooling Equipment - ). Wear safety glasses and work gloves. Use
quenching cloth for unbrazing operations. Have fire extinguisher available for all brazing
operations.

WARNING
Before performing service or maintenance
operations on unit, turn off main power switch to unit.
Electrical shock could cause personal injury.

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Description

WARNING
What to do if you smell gas:
1. DO NOT try to light any appliance.
2. DO NOT touch any electrical switch, or use any phone in your building.
3. IMMEDIATELY call your gas supplier from a neighbor’s phone. Follow
the gas supplier’s instructions.
4. If you cannot reach your gas supplier, call the fire department.

5. DO NOT try to light any appliance.

WARNING
DO NOT store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
appliance.

WARNING
Improper installation, adjustment, alteration, service,
or maintenance can cause injury or property damage.
Refer to installation instructions provided with the
unit, and this manual. For assistance or additional
information, consult a qualified installer, service
agency, or the gas supplier.

Unit Description
Figure 1 & 2 shows typical packaged DX cooling unit with the locations of the major
components. These figures are for general information only. See the project’s certified submittals
for actual specific dimensions and locations.

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Description
Figure 1: Typical Component Locations

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Description
Figure 2: Typical Component Locations

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Description

Refrigeration Piping
This Section presents the unit refrigeration piping diagrams (single circuit,
dual stage w/ Hot Gas Bypass System ).

Figure 3: Circuit Schematic

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Model Number Description

2. Model Number Description

Unit Model Number
Model Nom. Casing Voltage Discharge Cooling Heating Heat Humidification
Location Recovery

AH - - - - - - -
a1 a2 a3 b c d1 d2 d3 d4 e1 e2 f1 f2 g1 g2

a1a2a3: Norminal Casing ( 20=2000CFM, 60=6000CFM, 80=8000CFM, 120=12000CFM, 150=15000CFM,

180=18000CFM, 210=21000CFM, 240=24000CFM, 320=32000CFM, 400=40000CFM, 480=48000CFM, 600=60000CFM,
700=70000CFM )

b: Voltage
A = 575~600V/3Ø/60HZ, B = 460~480V/3Ø/60HZ, C = 208~230V/3Ø/60HZ, D = 208~230V/1Ø/60HZ, E=120V/1Ø/60HZ

c: Discharge
T = Top, S = Side, E =End, B =Bottom, AC=Vertical

d1: Refrigerant Type

A = R410A, B = R407C, C = R-22, D = R-134a

d2: Configuration
E = Air Cooled Cond. w/ std. DX Coil
F = Cooling Water Coil
DX = DX Coil

d3: Staging
Circuit & Stage
11 = Single Circuit Single Stage
12 = Single Circuit Dual Stage
13 = Single Circuit 3 Stage
14 = Single Circuit 4 Stage
22 = Dual Circuit 2 Stage
24 = Dual Circuit 4 Stage
26 = Dual Circuit 6 Stage
28 = Dual Circuit 8 Stage
36 = Three Circuit 6 Stage
44 = Four Circuit 4 Stage
48 = Four Circuit 8 Stage

d4: Nominal Tonnage Range of 3 Ton – 180 Ton

e1: Type
GIDM = Indirect Gas Heat ( 4 - Pass Drum & Tube Heat Exchanger )
GIDMH = Indirect Gas Heat ( 4 - Pass Drum & Tube Heat Exchanger ), w/High CFM.
BMA = Direct Gas Heat
BMAE = Electric Heating Unit
DIDM = Indirect Gas Heat ( 4 - Pass Drum & Tube Heat Exchanger )
DIDMH = Indirect Gas Heat ( 4 - Pass Drum & Tube Heat Exchanger ), w/High CFM.
MTI = Indirect Gas Heat ( Multiple Tube Heat Exchanger)
HTDM = Indirect Gas Heat ( 2 - Pass Drum & Tube Heat Exchanger )
SC = Steam Coil
HW = Hot Water Coil
EC = Electric Heating Coil
AC = Air Turnover

e2: Heating Capacity ( from 20 MBH to 7500 MBH) or Electric Capacity ( from 1 KW to 550 KW )

f1: HP = Heat Pipe, HC = Heat Core, EW = Enthalpy Wheel, RA = Run Around Glycol

f2: Size or Capacity

g1: EH = Electric Humidifier, GH = Gas to Steam Humidifier, CD = Evaporative Humidifier

g2: Capacity

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User’s Information

3. User’s Information

WARNING
Failure to observe the following instructions may result
in premature failure of your system, and possible
voiding of the warranty.

DX Package Units
Never cut off the main power supply to the unit, except for complete shutdown.
Always control the system from the thermostat, or control panel, and never at the main power
supply (except in an emergency, or complete shutdown of the system).
During the cooling season, if the airflow is reduced due to dirty air filters, or other reasons, the
cooling coils will get too cold and result in excessive liquid return to the compressor. As the liquid
concentration accumulates, oil is washed out of the compressor leaving it starved for lubrication.
The compressors must be on a minimum of four minutes, and off for a minimum of five minutes.
The cycle rate must not exceed eight starts per hour.
THE COMPRESSOR LIFE WILL BE SERIOUSLY SHORTENED BY RESULTING REDUCED
LUBRICATION, AND THE PUMPING OF EXCESS AMOUNTS OF LIQUID OIL AND
REFRIGERANT.

Hydronic Cooling and Heating

Non-compressorized units may contain chilled water and/or hot water coils. Units are provided
with internal header connections for field piping. Vent and drain connections can be accessed
within the unit.
Piping is to be run via the piping chase inside the coil compartment, accessible through the coil
compartment access door on the front of the unit. Piping to coil header connections must be
supported independently of the coil to prevent undue stress from weakening connections over
time. Allow adequate flexibility for thermal expansion of the piping.
Use proper glycol solutions or brines to help prevent coil freezing. Consult the designer or
project engineer if you have concerns about lower than normal entering air temperature (typically
air temperatures below 40ºF) that could cause coils to freeze.

Gas or Electric Heating

The system is designed to heat a given amount of air each minute of operation. If the amount of
air heated is greatly reduced (approximately 1/3 capacity), the heat exchanger (or heat coil if
electric) temperature will increase above acceptable levels, and will result in shut down by a high
temperature safety switch incorporated into either the heat exchanger, or the heater area.

WARNING
GAS HEAT UNITS – If heat shuts off due to safety
switch, or gas supply shut off failure, then always
close manual gas valve to unit prior to any electrical
service. Prolonged overheating of the heat exchanger
will shorten its life.
Multiple Unit Operation
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User’s Information

When several units are used in conditioning the space, and any are combination heating-
cooling units, all system thermostat switches must be set at either heating, cooling, or set at ‘OFF’.
Do not run part of a system switched to an opposite mode. Cooling only units should be switched
to ‘OFF’ at the thermostat during the heating season.

Wiring Diagrams
A complete set of unit specific wiring diagrams in both ladder and point-to point form are
laminated in plastic and affixed to the inside of the service access door.

Condensate Piping
A drain trap must be connected to the drain connection located on the side or back of the unit. If
codes require a condensate drain line, it should be the same pipe size as the drain nipple and
should pitch downward for its entire length toward the drain.
A “P” Trap could be required and supplied by others. An air break should be used with long runs
of condensate lines.

Normal Thermostat Operation

For Heating
- Set system switch to ‘HEAT’
- Set fan switch to ‘AUTO’ or ‘ON’
- Set the desired temperature

For Cooling
- Set system switch to ‘COOL’
- Set fan switch to ‘AUTO’ or ‘ON’

Air Circulation
- Set the system switch to ‘OFF’
- Set the fan switch to ‘ON’

System Off
- Set the system switch to ‘OFF’
- Set the fan switch to ‘AUTO’
- Do not change temperature setting
- With these settings the system id shut down, except for the 24-volt control system power, and
the compressor crankcase heater (approx. 60W).

Night and Vacancy Operation

To reduce the operation time during low load periods, it is recommended that the temperature
setting be increased by 5 ºF during non-occupied periods of the cooling season in commercial
buildings, such as nights and weekends. Decrease the temperature by 10ºF at these times during
the heating season.

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User’s Information

Gas Heating System

The heating section is for use with natural gas supply pressure of 7” to 14” w.c. The unit may
also utilize propane gas ( If order or after installation of a field conversion kit) with a supply
pressure to the valve of 11” to 12” w.c. The rating plate on the furnace must be inspected to make
sure the unit is stamped for proper gas. A 1/8” pressure tap should be field supplied by the
installer in the piping just ahead of the gas valve.
A centrifugal blower that draws in outside air through a protected opening supplies
combustion air on MTI model. This induced draft blower introduces the air to the blower tubes,
which assures even primary and secondary airflow.
Gas heating units use high efficiency dimpled heat exchanger, for MTI series, it has multiple
tube heat exchanger, for HTDM series, it has 2-pass drum & tube heat exchanger, for GIDM
series, it has 4-pass drum & tube heat exchanger. The instruction of all gas heating system units
please refer to the relevant operation & installation manual attached.

Figure 4: Gas Heat Exchangers

Hot Gas Bypass Systems on DX Units

Some DX cooling units may contain Modulating Hot Gas Bypass systems as factory installed
options. Piping and valves for this systems will be within the casing of the unit w/ access via a
hinged access door.
The purpose of external hot gas bypass is to prevent coil freeze-up and compressor damage
from liquid slugging during periods of low airflow operation, or with low entering air temperatures.
Hot gas bypass is useful when the air conditioning system is subject to variations in load
caused by varying air volume or large proportions of outside air. The hot gas bypass valve meters
discharge refrigerant gas to the distributor downstream of the expansion valve, and at the
entrance to the evaporator distributor tubes. The quantity of the gas varies to control a constant
suction pressure, allowing more gas to flow as suction pressure decreases.
Hot gas bypass is a standard feature on most ICE models
.

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User’s Information

Figure5: Hot Gas Bypass System

Hot Gas Bypass Valve

Filter Sizes

The required filter sizes of unit depend upon the different requirements of each Air Handling
unit.
Please refer to the rating plate of each unit for information about size and quantity of filters.

Cabinet Construction

All Air Handling units are insulated with 1” – 1 1/2 “lb, 2” – 1 1/2 “lb, 2” – 3”lb fiber glass
insulation. All cabinet roof, floor and doors use double-wall satin coat steel.
Please refer to figure 6 for more details of casing construction.

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User’s Information

Figure 6: High Performance Composite Panel

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Delivery

4. Delivery
ALL SHIPMENTS ARE F.O.B. THE FACTORY. IT IS THE RESPONSIBILITY OF THE
RECEIVING PARTY TO INSPECT THE EQUIPMENT UPON ARRIVAL.

Receipt & Inspection

The unit should be inspected for damage that may have occurred in transit. Do the following
upon receipt:
1. Inspect all items for internal, external, and concealed damage before accepting.
2. Assure carrier is in compliance with Bill of Lading instructions.

If damage is found:
1. Note all damage on Bill of Lading immediately:
− Photograph damage if possible
− Do not move or discard damaged packaging materials
2. Call carrier immediately to file a freight claim, and to schedule a freight inspection
3. When damage is repairable, contact ICE Western for replacement parts
4. With permission of carrier, make the repairs
5. Stay in contact with carrier to ensure payment of your claim

If repairs must be made to damaged goods, the factory must be notified before any repair
action is taken. Equipment alteration, repair, or unauthorized manipulation of damaged equipment
without the manufacturer’s consent will void all product warranties. Contact the ICE Western for
assistance with handling damaged goods, repairs, and freight claims.
Verify the equipment against the order documents upon delivery. If what you received does not
match your order exactly, then notify your Sales Representative at once.

Storage

This equipment is designed for indoor or outdoor use. However, if installation will not occur
immediately following delivery, then store equipment in a protected area, and in the proper
orientation as marked on the packaging with all internal packaging in place. Secure all loose-
shipped items.

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Installation

5. Installation

General

The installation of this equipment shall be in accordance with the regulations of authorities
having jurisdiction and all applicable codes. It is the responsibility of the installer to determine and
follow the applicable codes.

NOTE: Low head pressure may lead to poor, erratic refrigerant feed control at the thermostatic
expansion valve. The units have automatic control of the condenser fans which should provide
adequate head pressure control down to 50ºF (10ºC) provided the unit is not exposed to windy
conditions. The system designer is responsible for assuring the condensing section is not exposed
to excessive wind or air recirculation.

CAUTION
Sharp edges on sheet metal and fasteners can
cause personal injury.
This equipment must be installed, operated, and
serviced only by an experienced installation company
and fully trained personnel.

Handling

Be aware of what is contained in the equipment!

Dependent upon the optional accessories that were ordered, this equipment may contain fragile
components and delicate electronics. Although the unit is constructed of sturdy materials, avoid
impacts and handling methods that may damage internal apparatus and structure, or the exterior
painted surfaces of the unit. Take care not to apply destructive force to coils, or other parts
protruding beyond the extents of the unit casing. Always handle the unit by its exterior casing.
Keep equipment free from debris, and construction waste during installation. Foreign materials
may adversely affect unit operation resulting in premature failures that will not be covered by the
manufacturer’s warranty. Attach all service panels, and cover all exposed equipment when work is
not being performed. Leave unit protected from other construction until start-up is to occur.

WARNING
Always wear hand and eye protection when handling,
installing, servicing, or maintaining equipment. Sharp
or pointed edges, moving parts, and flying debris may
cause personal injury.

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Installation

Heating & Cooling Systems

Gas Heating System
The units are equipped with a direct spark ignition system that proves the burner operation with
each call for heat. Power to the ignition control is 24V or 120V. Burner ignition is by a high
intensity spark.
When heat is called for, the cooling system is inoperable except for the indoor blower motor.
Heating is accomplished by firing gas into the heat exchanger assembly.

IMPORTANT NOTICE – All gas-fired heat exchangers are completely tested at the factory before
shipment. This will remove nearly all of the oils that have been used in the manufacturing process,
however trace amounts may remain. When performing the initial start-up at the jobsite, it is highly
recommended that people, or any other living animals, that may be sensitive to the residual odors
or gases, NOT be present in the conditioned space during start-up. In all cases, including the
initial factory firing and testing, all of the gases will be under the minimum acceptable level of
concentration for human occupancy.

WARNING
Those sensitive to odors or gases from trace amounts
of residual oils should NOT be present in the
conditioned space during the start-up of a gas-fired
installation.

Electric Heating System

Heating is accomplished by passing electrical current through a specified amount of resistance
heaters that produce the required heat. The indoor blower motor energizes prior to the heaters.

DX Cooling Section

All direct expansion refrigeration systems are factory assembled, charged with refrigerant,
tested, and operated. These systems include liquid line filter driers, expansion valves, and scroll
compressors or semi-hermetic Carlyle compressors. Compressors are equipped with a positive
pressure forced lubrication system. The air-cooled condenser coil is constructed of copper tubes
and mechanically bonded aluminum fins, and air is pulled through by a propeller fan. The
evaporator coil is draw through type constructed of copper tubes and mechanically bonded
aluminum fins, and may have optional coating for hazardous locations.

Chilled Water or Non-Compressorized Cooling Section

Chilled water, or non-compressorized units, have factory-installed coils. Systems are provided
with internal header connections for field piping.
Coils are constructed of copper tubes and mechanically bonded aluminum fins.

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Installation

Service Clearances

In addition to providing adequate space around the unit for piping coils and drains, access to at
least one side of the unit is always required to allow for regular service and routine maintenance,
which includes filter replacement, drain pan inspection and cleaning, fan bearing lubrication, and
belt adjustment. Provide sufficient space—at least equal to the length of the coil—on the side of
the unit for shaft removal and coil removal. Space, at least equal to the length of the side coil, is
required for coil removal. Space, at least equal to the fin height, is required for top coil. See Figure
7 for servicing space requirements.
For routine maintenance purposes, access normally is obtained through the access doors or by
removing panels. Fan and filter sections are always provided with a service door on one side of
the unit. If requested, doors can be provided on both sides of the unit. Optional service doors are
available for most section types and are provided based on customer request.
If component replacement is required, the top panel also can be removed. If necessary, the unit
can be disassembled. Maintain at least 54” of clearance in front of electrical power devices
(starters, VFDs, disconnect switches and combination). Electrical power devices that are mounted
on the side of the unit typically are up to 12” deep. See Figure 8.

Figure 7: Servicing Space Requirements

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Installation

Figure 8: Service Clearance for Electrical Power Devices

Setting the Unit

Units should always be installed level, and above water drainage routes. Outdoor unit operation
can be affected by wind. It is good practice to position outdoor unit condensing sections away from
prevailing winds.

Protective Shipping Brackets

Before staring the unit, be sure to remove the protective shipping brackets, or bolts.

Ground Setting
Set the unit on a solid slab high enough above the soil grade to allow water to drain away from
the base of the unit. The unit should be set on a slab that has been placed over compact, level
earth. A poured concrete (permanent) slab is recommended.

Roof Setting with Curb

Mount roof curbs first, and locate so duct connections will clear any structural members of the
building. When using the factory curb, make openings in roof decking large enough to allow for
duct penetrations and workspace only. Do not make openings larger than necessary. Set the curb
to coincide with the openings. CURB MUST BE LEVEL.

NOTE: PRIOR TO SETTING UNIT ON CURB – To ensure proper isolation and seal between the
unit and the curb, gasket material MUST BE APPLIED to the curb on ALL SURFACES meeting

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Installation

with the unit.

Hoisting
Lifting lugs are provided on the bottom of the unit.
If cables or chains are used to hoist the unit, they must be of the appropriate length, and care
should be taken to prevent damage to the unit.
It is recommended that the unit be hoisted with the outside air hood (if present) in the shipped
position.
Before lifting unit, be sure that all shipping material is removed. Secure hooks and cables at
all lifting points/lugs provided on the unit.
Prior to setting the rooftop unit onto the roof curb, be sure that the gasket material has been
applied to all curb surfaces meeting with the unit.
Hoist unit to a point directly above the curb and duct openings. Carefully lower and align the
unit’s utility and duct openings so the unit perimeter fits around the curb. Make sure the unit is
properly seated on the curb and is level.

Outside Air Hood (Optional)

Units equipped with outside air intake will have an outside air hood. The outside air hood must
be installed prior to unit operation. Ensure the air hood is properly sealed to prevent leakage.
Outdoor air intake adjustments should be made according to building ventilation, or local code
requirements.

Figure 9: Lifting Lugs

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Installation

WARNING
DO NOT USE OPEN FLAME OR OTHER SOURCE
OF IGNITION FOR LEAK TESTING.
When pressure testing the gas supply piping, the
furnace must be isolated, or disconnected by closing
individual manual shut-off valve from the gas supply.
Gas valve can be damaged if subjected to more than
0.5 PSIG pressure.

WARNING
Install gas fired units so that the flue discharge vent
is located a minimum of 120” from openings through
which combustion products can enter the building.
Never point flue discharge in direction of air intake for
other equipment. Unit location must assure combustion
and ventilation airflows are never obstructed.

Electrical

Check the unit data plate to make sure it matches the power supply. Connect power to the unit
according to the wiring diagram provided with the unit. The power and control wiring may be
brought in through the utility entry. Do not run power and control wires in the same conduit.
Protect the branch circuit in accordance with code requirements. The units must be electrically
grounded in accordance with the National Electric Code, ANSI/NFPA No. 70. In Canada use
current C.S.A. Standard C22.1, Canadian Electric Code Part 1.
Connect power wiring to the terminal block, or optional disconnect switch. The manufacturer
has done all wiring beyond this point, and cannot be modified without affecting the unit’s agency
and/or safety certification, and warranty.
Power can be applied to the unit after the control wiring is connected.

Standard Control Board

This printed circuit board is the central control point for all the electrical components in the unit.
Low voltage terminals are provided for connection to the wall mounted thermostat of the
customer’s selection, or as furnished by ICE Western.
Confirm the optional features that were specified and purchased. This will allow proper selection
of the number of control options listed below that may need additional wiring.
Each Air Handling Unit has a standard Cooling Lock-out feature that prevents the compressor
cooling mode when the outdoor temperature is below 55ºF. Each unit may has a condenser fan
cycle feature that delays the start of the condenser fan until there is satisfactory compressor
discharge pressure.
Eight colored LEDs are furnished on the circuit board to provide status information.
Every unit is furnished with a high and low pressure sensor, as well as an outdoor air
temperature sensor. These sensors provide a signal to the control board that also present a fault
condition or Mode indicator at the LEDs with a code.

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Installation

Figure 10: Power and Control Wiring

Unit Burner Proving System

Optional Control Relay Board Ambistat Temperature Controller

HTDM Unit Control Board

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Installation

Optional Control Board

This Control Relay Board is supplied within the Packaged DX Cooling model when it has been
furnished with certain optional features specified by the customer. Among these are an
Economizer, Return Air Bypass, Hot Gas Bypass and many other optional features according to
the requirements.

Thermostat

The low voltage room thermostat should be located on an inside wall 4 to 5 feet above the
floor where it will not be subjected to drafts, sun exposure or heat from electrical fixtures or
appliances. The control wire size must be large enough to prevent excess voltage drop that
may cause improper operation of the equipment. The Packaged DX Cooling unit control board
has approximately a 1/2 amp current flow through the thermostat. Follow the thermostat
manufacturer’s instructions to set the heat anticipator.

Table1: Low Voltage Thermostat Field Wiring Size

Length of Wire Run

T-stat Load Amps 50 Ft. 100 Ft. 150 Ft.
Less than 1.0 18 ga. 18 ga. 16 ga.

Single Stage Heating & Cooling

The terminals on a single stage thermostat should be connected to the similarly
labeled terminals on the Control Terminal Strip in the Packaged DX Cooling unit.

Multiple Step Compressor Cooling Models

- The Packaged DX Cooling models with multiple step cooling compressor may use multiple step
cooling thermostat connected to the terminals on the Control Terminal Strip in the Packaged DX
Cooling unit.

Economizer Option

The economizer option is used to provide cooling at lower outdoor air temperatures and to
provide a quantity of ventilation air to the occupied space. The economizer option can be selected
with either a sensible outdoor air temperature sensor or an enthalpy sensor that measures the
heat content in the outdoor air. The economizer controller can be field installed or factory
installed by ICE Western as selected by the customer.

Supply Air Temperature Sensor

A supply air temperature sensor is provided within the equipment. This sensor must be installed
in the downstream supply air ductwork at a sufficient distance from the equipment to provide a
correctly mixed supply air temperature back to the unit control board.

Factory Installed

When factory installed the control board will use the outdoor air sensor and the cooling signal

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Installation

from the thermostat to provide a first stage of cooling using the outside air when possible before
starting the compressor and mechanical cooling cycle. The thermostat wiring to the control board
with single or multi-stages should be wired as listed previously.

Lockout Modes

Gas Heating

The heating mode will be locked out if the ignition system safety monitors trip 3 times
during a call for heating.

Electric Heating

The heating mode will be locked out if the high temperature limit switch trips 3 times during
a call for heating.

Cooling

The cooling mode will be locked out if the low pressure switch safety switch trips 3 times
during a call for cooling or dehumidification.
Cooling operation will be locked out if the Outside Air Sensor is missing or defective.
The economizer operation during dehumidification will be locked out if the Air Sensor is
defective.
To reset the lockout condition, reset the tripped device. If the device trips again, call
qualified service technician.

Condensate Piping

AH Packaged DX Cooling units are equipped with a condensate drain connection, and ‘P’
traps are furnished by others. The drain connection must be used and individually trapped to
ensure a minimum amount of condensate accumulation in the drain pans.
Although drainage of condensate directly onto the roof may be acceptable in certain areas, is
not recommended as it can damage some types of roofing, and roofing materials. Refer to local
codes for legalities concerning condensate drainage.
Condensate can be piped to a gutter system, or away from the building into other drainage.
Ideally, condensate will be piped into the building drainage system, in which case the drainpipe
may need to penetrate the roof external to the unit itself.
The drain line should be pitched away from the unit with at least 1/8” of slope per foot. On
longer runs, an air break should be used to ensure proper drainage.
Drain pans in air conditioning equipment have moisture present and require periodic cleaning to
remove build up of algae, and/or bacteria. Cleaning the drain pans reduces the probability of
plugged drain lines and overflow of the pan itself. All cleaning of the drain pans and inside of the
equipment should be done by qualified personnel.

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Installation

Figure 11: DX Coil Piping and Condenser

Figure 12: Scroll Compressor Digital Scroll Compressor

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Installation

Figure 13: Crankcase Heater

ICE WESTERN 25
Start-Up

6. Start-Up

General

ONLY QUALIFIED, AUTHORIZED PERSONNEL SHOULD POWER ON, OR START-UP THIS

EQUIPMENT.

The use of common sense, and good practice in the installation, and start-up of equipment will
prevent many potential problems with the system in the future.
Before starting up the equipment, building construction should be complete, and start-up
personnel should:
- Have a working knowledge of general HVAC and mechanical commissioning procedures and
practices;
- Be familiar with unit functions, features, optional unit accessories, and all control sequences;
- Have appropriate literature on hand for consultation.

Procedures
EQUIPMENT OPERATION DURING CONSTRUCTION IS NOT RECOMMENDED.
CONSTRUCTION SITE POLLUTION CAN AFFECT UNIT OPERATION, AND SERIOUSLY
DEGRADE PERFORMANCE. OPERATION DURING CONSTRUCTION WILL VOID ALL
MANUFACTURER’S WARRANTIES.

Before the structure is occupied, the installation, and/or start-up personnel must take three
essential steps:
1. Pre-Startup Check Out
2. Start-Up
3. Commissioning

Pre-Startup Check Out

All equipment should be thoroughly checked for loose wiring, free spinning condenser fan and
blower wheel, and well fitting access panels. Unit should not be operated without proper ductwork,
and access panels installed, except as required during start-up and air balancing.
Install gauges, voltmeter, and ammeter before start-up. Observe refrigerant pressures during
initial operation. Note, and determine the cause of any excessive sound, or vibration. Follow
procedures outlined below to start each piece of equipment.
1. Verify that the unit is completely and properly installed with ductwork connected.
2. Verify that all construction debris is removed, and that the filters are clean.
3. Verify that all electrical work is complete and properly terminated.
4. Verify that all electrical connections in the unit control panel and compressor terminal box are
tight, and that the proper voltage is connected.
5. Verify all nameplate electrical data is compatible with the power supply.
6. Verify the phase voltage imbalance is no greater than 10%.
7. Verify that gas piping is complete and leak tight.
8. Verify that the shutoff cock is installed ahead of the furnace, and that all air has been bled from
the gas line.
9. Manually rotate all fans and verify that they rotate freely.
10. Verify that the belts are tight and the sheaves are aligned.
11. Verify that all setscrews and fasteners on the fan assemblies are still tight.
12. Verify that the evaporator condensate drain is trapped and that the drain pan is level.
13. If unit is curb mounted, verify that the curb is properly flashed to prevent water leakage.
14. Before attempting to operate the unit, review the control layout description to become familiar

ICE WESTERN 26
Start-Up

with the control locations.

15. Review the equipment and service literature, and the wiring diagrams to become familiar with
the functions and purposes of the controls and devices.
16. Determine which optional controls are included with the unit.
17. Before closing (connecting) the power disconnect switch, open (disconnect) the following unit
control circuit switches:
a. Main Control Panel
- Turn system switch to OFF.
- Electric heat units: turn switch to OFF.
- Turn compressor control circuit switches to OFF.
b. Furnace Control Compartment
- Turn furnace switch to OFF.
- Main Control Panel Switch to OFF.

Start-Up

NOTE:
1. Failure to adhere to the following start-up procedures will void all manufacturer’s warranties.
2. Completed factory test sheets are in the equipment literature packet shipped inside the unit.
Factory run-test readings recorded on the test sheets may be helpful to reference during start-up.

CAUTION
IMPORTANT FOR 3 PHASE UNITS ONLY!

CHECK COMPRESSOR FOR PROPER ROTATION BY STARTING

UNIT ONLY AFTER CONNECTING PRESSURE GAUGES TO
SUCTION AND DISCHARGE LINES. SCROLL COMPRESSORS
WILL BE DESTROYED IF OPERATED IN THE WRONG
DIRECTION.

Sheave Alignment

Mounting:
1. Verify both driving and driven sheaves are in alignment and the shafts are parallel. The center
line of the driving sheave must be in line with the center line of the driven sheave. See figure 12.
2. Verify that all setscrews are still tight before starting drive. Check setscrew and belt tension
after 24 hours of service.

ICE WESTERN 27
Start-Up

Figure 14: Sheave Alignment

Must be
Parallel

Bearing
Center lines must coincide
Motor

Adjustable Sheave

Must be
Parallel

Drive Belt Adjustment

General Rules of Tensioning

1. The ideal tension is the lowest tension at which the belt will not slip under peak load conditions.
2. Check tension frequently during 24-48 hours of operation.
3. Over tensioning shortens belt and bearing life.
4. Keep belts free from foreign material which may cause slippage.
5. Inspect V-belts on a periodic basis. Adjust tension if the belt is slipping. Do not apply belt
dressing. This may damage the belt and cause early failure.

Tension Measurement Procedure

1. Measure the belt span. See figure 13.
2. Place belt tension checker squarely on one belt at the center of the belt span. Apply force to the
checker, perpendicular to the belt span, until the belt deflection equals to belt span distance
divided by 64. Determine force applied while in this position.
3. Compare this force to the values on the drive kit label found on the fan housing.

Figure 15: Drive Belt Adjustment

ICE WESTERN 28
Start-Up

Fan Start-up

1. Verify all duct isolation dampers are open.

2. Verify the fan rotation is correct.
3. a. Put Unit into summer mode at remote panel.
b. Dampers should open then end switch will start blower.
c. Record motor Amps to verify against rated.
4. If damper do not open:
a. Check fuses.
b. Check the manual motor protectors or that the circuit breakers have not tripped.
c. Check the optional phase monitor.

Refrigeration System

I. Capacity control adjustments for Carlyle compressor

Pressure-Operated Control Valve is controlled by suction pressure and actuated by the

discharge pressure. Each valve controls 2 cylinders (one bank). On start-up, controlled cylinders
do not load up until differential between suction and discharge pressures is approximately 25
psi.

ADJUSTMENTS

Control Set Point ( cylinder load-up point ) is adjustable from 0 psig to 86 psig.
Turn adjustment nut clockwise to the bottom stop. In this position, the cylinder load-up
pressure is 86 psig. Control set point is regulated to desired pressure by turning the adjustment
nut counterclockwise. Each full turn clockwise decreases the load-up point by approximately 7.2
psi. Approximately 12 turns changes the pressure from 85 psig to 0 psig.

Pressure Differential between cylinder load-up point and unload point is adjustable from 6
psi to 16 psi.
Turn adjustment screw counterclockwise to the back-stop. In this position, the differential is 6
psi. Differential is set by turning the adjustment screw clockwise. Each full turn clockwise
increases the differential by approximately 0.8 psi. Approximately 5 turns changes the differential
from 6 psig to 10 psig
Electrically-Operated Control Valve is actuated by an electric solenoid, which must be of the
same voltage as the unit control circuit. No adjustments are necessary. When the solenoid is
de-energized, the orifices and passage-ways in the valve are aligned for loaded condition,
shown in figure 14. When the solenoid is energized, the system is unloaded as shown in figure
14.
Suction Cutoff Unload Operation – The capacity control valve shown in figure 14 is the
pressure–operated type, which is the one in the following description. In the electrically-actuated
valve, the function of a similar poppet valve is the same as in the pressure-operated type but it is
moved by a solenoid. The function within the cylinder head is the same for both types of control
valve.

LOADED

When suction pressure rises high enough to overcome control set point spring, the diaphragm
snaps to the left and relieves pressure against the poppet valve. The drive spring moves the
poppet valve to the left and it seats in the closed position.
With poppet valve closed, discharge gas is directed into the unload-piston chamber and
pressure builds up against the piston. When pressure against unloader piston is high enough to
overcome the unloader valve spring, piston moves valve to the right, opening suction port.
Suction gas can now be drawn into the cylinders and the bank is running fully loaded.

ICE WESTERN 29
Start-Up

UNLOADED

As suction pressure drops below set point, control spring expands, snapping diaphragm to
right. This forces poppet valve open and allows gas from discharge manifold to vent through
base of control valve to suction side. Loss of full discharge pressure against unloader piston
allows unloader valve spring to move valve left to closed position. The suction port is blocked,
isolating the cylinder bank from the suction manifold. The cylinder bank is now loaded.

Figure 16: Suction Cut-Off Unloaded Operation

ICE WESTERN 30
Start-Up

II. Adjustments for Dual Pressure Control

( JOHNSON CONTROLS: P70, P72, and P170 Series Controls )

All-Range Controls (Low Side Only)

The low side of All-Range controls displays the CUT IN and CUT OUT setpoints. Turn the
range screw to adjust the cut in and cut out setpoints up or down simultaneously which maintains
the set differential value. Turn the differential screw to adjust the cut out setpoint and change the
differential value.

Dual Pressure Control (High Side)

The high side scale plate of the P70, P72, P170 dual pressure controls display only the CUT
OUT setpoint. Turn the range screw to adjust the cutout setpoint. The differential is fixed at about
65 psi.

To adjust the dual pressure controls:

Set low side cut in setpoint by adjusting low side range screw. All-Range Controls: Turn the
screw clockwise to raise the cut in setpoint.
Adjust the differential screw. All-Range Controls: Turn the screw clockwise to raise the cut out
setpoint.
Set high side cut out setpoint by adjusting high side range screw. Turn screw clockwise to raise
the cut out setpoint. (High side differential is fixed.)

III. Hot Gas Bypass Regulator Adjustments

Install an accurate pressure gauge at the control (sensing) point at the outlet side of the valve.
To adjust the valve, loosen Seal Nut and turn Adjusting Stem clockwise to raise the pressure
or counterclockwise to lower the pressure.
The regulator should be set under actual operating conditions. For hot gas bypass this
condition occurs under minimal system load conditions. The regulator should be adjusted to
maintain minimum desired suction pressure. Hot gas flow through the valve can be detected by
listening to the gas flow through the regulator or by feeling the outlet pipe for warmth. When it is
not possible to simulate minimum load conditions, an approximate setting may be obtained by
adjusting the valve until gas flow begins, observing the gauge reading, and then turning the
adjusting stem counterclockwise for the required number of turns to obtain the desired minimum
pressure. This setting should be checked and readjusted as needed under actual conditions.

IV. Typical Malfunctions Of Solenoid Valve

( SPORLAN: Solenoid Valves )

Coil Burnout
a. Coils burnouts are extremely rare unless caused by one of the following:
b. Improper electrical characteristics.
c. Continuous over-voltage, more than 10%.
d. Under-voltage of more than 15%. This applies only if the operating conditions are such that
reduced MOPD causes stalling of the plunger, which results in excessive current draw.
e. Incomplete magnetic circuit due to the omission of parts such as: coil housing, coil sleeves,
coil spring, coil housing bottom plate or plunger on the MKC molded model coils.
f. Mechanical interference with plunger movement which may be caused by a deformed
enclosing tube.
g. Voltage spike.
h. Valve ambient exceeds 120ºF.
i. Fluid or gas temperatures greater than 240 ºF, while the valve ambient is 120 ºF.

Failure To Open (Normally Closed Types)

a. Coil burned out or an open circuit to coil connections.

ICE WESTERN 31
Start-Up

b. Improper electrical characteristics.

c. In pilot operated valves, dirt, scale or sludge may prevent the piston, disc or diaphragm
from lifting. This could also be caused by a deformed body.
d. High differential pressure that exceeds the MOPD rating of the valve.
e. Diameter reduction of synthetic seating material in pilot port because of high temperatures
and/or pressures, or severe pulsations.

Failure To Close
a. Valve is oversized.
b. In pilot operated valves, dirt, scale or sludge may prevent the piston, disc or diaphragm
from lifting. This could also be caused by a deformed body.
c. Held open by the manual lift stem.
d. In pilot operated valves only, a damaged pilot port may prevent closing.
e. A floating disc due to severe discharge pulses.
f. Have voltage feedback to the coil after the coil de-energizes.

V. Superheat Adjustment Of Thermal Expansion Valves

( EMERSON: T-Series Thermal Expansion Valves )

T-Series Thermal Expansion Valves are factory-set for a static superheat. However, the
superheat should be adjusted for the application. Improper superheat adjustment may result in
system malfunction. To properly adjust thermal expansion valve to other superheat settings:
a. Remove seal cap on side of valve.
b. Turn the adjusting stem in a clockwise direction to increase the superheat, and
counterclockwise to decrease superheat.
NOTE: Allow adequate time between adjustments for system to stabilize before checking
superheat.
c. When the desired superheat setting is achieved, reinstall the seal cap.

Gas Heating

1. Ensure that gas lines have been purged of air

- wait 5 minutes after purging to allow gas to clear before continuing with startup.
2. Turn the unit power on.
3. Turn the unit blower on, and check for correct rotation.
4. If correct, take blower amp readings, and compare to see if the amp draw is within the safety
factor area of the motor. Once correct, turn blower off.
5. Turn on the first stage of heating.
6. Check to see that induced draft motor starts.
7. Check to see that main burner lights within 5 seconds of the heating call.
8. Check gas input and manifold pressure, and adjust if necessary.
9. Ensure blower started after burner ignition.
10. Observe burner flames for light blue color, and even flames across burner (propane flames
will have yellow tips). Set with co analyzer.
11. Check temperature rise across heating section while all stages are on.
12. If temperature rise is within range, turn all heating calls off.
13. Check that blower stops after heat turns off.

Electric Heating

1. Turn the unit power on.

2. Turn the unit blower on, and check for correct rotation.
3. If correct, take blower amp readings, and compare to see if the amp draw is within the safety

ICE WESTERN 32
Start-Up

factor area of the motor. Once correct, turn blower off.

4. Turn on the first stage of heating.
5. Check amp draw of each element of each stage.
6. Check temperature rise across heating section while all stages are on.
7. If temperature rise is within range, turn all heating calls off.
8. Check to see that blower stops.

Optional Equipment

Operation of each of the following, if equipped in the unit, must be checked according to that
item’s manufacturer’s specifications:
- Clogged filter switch
- Supply air smoke detector
- Return air smoke detector
- Hot gas bypass

Commissioning

The commissioning of an HVAC system is the process of achieving, verifying, and documenting
the performance of that system to meet the operational needs of the building. This may not be a
formal process in smaller structures, such as a normal residence, but some form of owner
acceptance will occur. Adjustments made during the commissioning phase may include air
balancing, or configuration of controls, and operational sequences.

Air Balancing
High performance systems commonly have complex air distribution and fan systems. Unqualified
personnel should not attempt to adjust fan operation, or air circulation, as all systems have unique
operating characteristics. Professional air balance specialists should be employed to establish
actual operating conditions, and to configure the air delivery system for optimal performance.

Water Balancing
A hydronic specialist with a complete working knowledge of water systems, controls, and
operation must be employed to properly balance the entire system. Unqualified personnel should
not attempt to manipulate temperatures, pressures, or flow rates, as all systems have unique
operating characteristics, and improper balancing can result in undesirable noises and operation.

Controls
A variety of controls and electrical accessories may be provided with the equipment. Identify the
controls on each unit by consulting appropriate submittal, or order documents, and operate
according to the control manufacturer’s instructions. If you cannot locate installation, operation, or
maintenance information for the specific controls, then contact your sales representative, or the
control manufacturer for assistance.

ICE WESTERN 33
Start-Up

WARNING
Do not alter factory wiring. Deviation from the supplied
wiring diagram will void all warranties, and may result
in equipment damage or personal injury.
Contact the factory with wiring discrepancies.

Figure 17: Gas Burner

ICE WESTERN 34
Start-Up

UNIT START-UP CHECKLIST

MODEL NO: SERIAL NO: .
DATE: TECHNICIAN: .

I. PRE-START-UP:

Verify that all packaging materials have been removed from unit
Verify installation of outdoor air hood
Verify that condensate connection is installed per installation instructions
Verify that all electrical connections and terminals are tight
Check that indoor-air filters are clean and in place
Check that outdoor air inlet screens are in place
Verify that unit is level
Check fan wheels and propeller for location in housing and verify setscrew is tight
Verify that fan sheaves are aligned and belts are properly tensioned
Verify that compressors are rotating in the correct direction
Verify installation of thermostat/space sensor
Verify configuration values for electronic controls
Verify that crankcase heaters have been energized for at least 24 hours

II. START-UP

ELECTRICAL

Supply voltage L1-L2 L2-L3 L3-L1 .

Compressor AMPS – Compressor A1 L1 L2 L3 .

– Compressor B1 L1 L2 L3 .
– Compressor C1 L1 L2 L3 .
Condenser Fan AMPS – Fan #1 L1 L2 L3 .
– Fan #2 L1 L2 L3 .

Supply Fan AMPS L1 L2 L3 .

TEMPERATURES

Outdoor-air temperature ºF DB (Dry Bulb)

Return-air temperature ºF DB ºF WB (Wet Bulb)
Cooling supply air ºF

PRESSURE

Refrigerant suction Circuit A PSIG

Circuit B PSIG
Circuit C PSIG
Refrigerant discharge Circuit A PSIG
Circuit B PSIG
Circuit C PSIG
Oil Pressure A PSIG B PSIG

REFRIGERANT

Type: R22 R407C R410A R134a

Verify refrigerant charge using charging charts

GENERAL

Economizer minimum vent and changeover settings to job requirements

ICE WESTERN 35
Operation & Maintenance

7. Operation & Maintenance

General
Preventive maintenance is the best way to avoid unnecessary expense and inconvenience. Have
this system inspected at regular intervals by a qualified service technician. The required frequency
of inspections depends upon the total operating time and the indoor and outdoor environmental
conditions.

Planned Maintenance
Routine maintenance should cover the following items:
- Tighten all belts, wire connections, and setscrews.
- Clean the evaporator and condenser coils mechanically or with cold water, if necessary. Usually
any fouling is only matted on the entering air face and can be removed by brushing.
- Lubricate the motor and fan shaft bearings.
- Align or replace the belts as needed.
- Clean or replace the filters as needed.
- Check each circuit’s refrigerant sight glass when the circuit is operating under steady-state, full
load conditions. The sight glass should then be full and clear. If it is not, check for refrigerant
leaks. (A partially full sight glass is not uncommon at part load conditions.)
- Check for proper superheat.
- Check for proper subcooling.
- Check for blockage of the condensate drain. Clean the condensate pan as needed.
- Check the power and control voltages.
- Check the running amperage of all motors.
- Check all operating temperatures and pressures.
- Check and adjust all temperature and pressure controls as needed.
- Check and adjust all damper linkages as needed.
- Check the operation of all safety controls.
- Examine the gas furnace.
- Check the condenser fans and tighten their setscrews.
- Lubricate the door latch mechanisms.

Cooling

Coils should be inspected and cleaned at least once per year to ensure there is no
obstruction to airflow.

Evaporator Coil

Dirty evaporator coils will eventually freeze up, and often result in a time consuming, and
expensive service call. Clean filters will help to prevent dirt from accumulating on the evaporator;
however the evaporator should be cleaned annually with a soft bristled brush, and/or a non-
corrosive coil cleaning solution.

Condenser Coil

One of the most overlooked maintenance requirements is the need to keep air moving freely
across air-cooled condensing coils. Dirty condensers, like evaporators, can significantly increase
cooling costs during the year. As a minimum, clean the condenser coil at the beginning of
each cooling season. It is preferable to use a medium pressure water spray from the inside

ICE WESTERN 36
Operation & Maintenance

of the condenser cabinet with a non-corrosive coil cleaning solution. TURN OFF all power to the
unit before cleaning.
Comb out any visible exterior fin damage to help maintain unit efficiency.

Condenser Fan

Always check condenser fan blades to ensure unobstructed, free rotation after manipulating
the unit cabinet in any way, and before turning power back on to the condenser. Clean the fan
blades if they are dirty.

Blower Assembly

Clean blower wheels are necessary to reduce electrical use, maintain capacity and reduce
stress on the unit. The blower wheel and blower section need to be inspected periodically, and
cleaned of dust, or debris.
To inspect and clean the blower; set thermostat to the “OFF” position; turn the electrical power
to the unit to the “OFF” position at the disconnect switch.

Figure 18: Blower Section

Gas Furnace

Planned maintenance is the best way to avoid unnecessary expense and inconvenience. Have
this system inspected at regular intervals by a trained and experienced service technician. The
following service intervals are typical for average situations but will have to be adjusted to you’re
your particular circumstances.

ICE WESTERN 37
Operation & Maintenance

Fuel pressure settings and control settings should be made only by persons thoroughly
experienced with the burner and control system, and must not be tampered with by persons
without such experience.
Always replace covers on burner controls and boxes as the electrical contacts are sensitive to
dust and dirt. Perform maintenance of controls, gas valves, and other components in accordance
with instructions contained in the manufacturer’s bulletins.
Monthly

Check air filters and replace if dirty.

Twice Yearly

1. Burner Air - Check burner fan wheel for dirt buildup and lint. Check combustion air intake louver
and flue box for dirt buildup and accumulation of windborne debris.
2. Cleaning - Inspect flue tubes and combustion chamber, cleaning as required. Keep burner
vestibule clean. Dirt and debris can result in burner air blockages.

Yearly

1. Gas Train - Check all valves, piping and connections for leakage. Inspect and clean flame rod,
ignition electrode, and burner manifold.
2. Condensate Pan/Drain/P-Trap – Check pan, drain, and p-traps for accumulation of debris.
Check that p-traps are filled with water at the start of each cooling season.

Chilled Water

Check remote chiller operations as per the manufacturer’s instructions. Check coolant flow
valves for correct operation and settings.

Filters

Open the filter access door. Slide filters towards you to inspect. Replace old filters with
the size indicated on each filter. Filters should be checked every 30 days and replaced or cleaned
as necessary.

IT IS IMPORTANT TO KEEP FILTERS, COILS, AND BLOWERS CLEAN!

Figure 19: Filter Section

ICE WESTERN 38
Operation & Maintenance

Cleaning

Inspect and clean unit interior at the beginning of each heating and cooling season and as
operating conditions require.
Service

In the event the unit is not functioning correctly and a service company is required, only a
company with service technicians qualified and experienced in both heating and air conditioning
should be permitted to service the systems in order to keep warranties in effect. The service tech
may call ICE Western if assistance is required.

BEFORE CALLING, THE MODEL AND SERIAL NUMBER OF THE UNIT WILL BE NEEDED
FOR ICE WESTERN TO HELP ANSWER QUESTIONS REGARDING THE UNIT.

ICE WESTERN 39
Pressure – Temperature Chart

8. Pressure – Temperature Chart

Temperature R22 R407C R410A R134a

ºF ºC PSIG Liquid Vapor PSIG PSIG
Pressure Pressure
(PSIG) (PSIG)
20 -6.7 43.0 51.6 38.0 78.3 18.4
25 -3.9 48.8 58.2 43.6 87.3 22.1
30 -1.1 54.9 65.2 49.6 96.8 26.1
35 1.7 61.5 72.6 56.1 107 30.4
40 4.4 68.5 80.7 63.1 118 35.0
45 7.2 76.0 89.2 70.6 130 40.1
50 10.0 84.0 98.3 78.7 142 45.5
55 12.8 92.6 108 87.3 155 51.3
60 15.6 102 118 96.8 170 57.5
65 18.3 111 129 106 185 64.1
70 21.1 121 141 117 201 71.2
75 23.9 132 153 128 217 78.8
80 26.7 144 166 140 235 86.8
85 29.4 156 180 153 254 95.4
90 32.2 168 195 166 274 104
95 35.0 182 210 181 295 114
100 37.8 196 226 196 317 124
105 40.6 211 243 211 340 135
110 43.3 226 261 229 365 147
115 46.1 243 280 247 391 159
120 48.9 260 300 266 418 171
125 51.7 278 321 286 446 185
130 54.4 297 342 307 476 199
135 57.2 317 365 329 507 214
140 60.0 337 389 353 539 229
145 62.8 359 - - 573 246
150 65.6 382 - - 608 263

ICE WESTERN 40
Solenoid Valves 1 2

200RB/500RB Model R-11

R-12
R-401B
R-402A
R-22 R-402B
Coil
R-113 R-404A Model
R-114 R-407A AM AH DM MM ASC2
R-115
R-123 R-407B
200RB
ü ü ü ü ü
R-124 R-407C 500RB
ü ü ü
R-125 R-500
R-134a R-502
R-401A R-507

Refrigerant Compatibility Verify Coil

Compatibilidad con Refrigerantes Verifique la Bobina
Compatibilidade do Refrigerante Verifique a bobina
Compatibilité du réfrigérant Vérifier la bobine

3 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 7 8
T < 250°F (121°C) Type F = SAE
Type P = FTP

Type T

Solder Techniques Use Wrench On Valve Body Only Coil Installation

Técnicas para Soldar Utilice la llave sólo en el cuerpo de la Válvula Instalación de la Bobina
Técnicas de Soldagem No corpo use sómente uma chave de boca Instalação da bobina
Technique de soudure Utiliser la clé a molette sur le corps seulement l’installation de la bobine
9 Coil Electrical Data
Maximum Amps VA
VAC/Hz
Inrush Holding Holding
24/50 2.0 0.96 23
24/60 1.6 0.74 18 Transformer Selection
120/50 0.45 0.21 25 Selección del Transformador
120/60 0.36 0.16 19
208/50 0.19 0.08 17 Selecione transformador capacidade suficiente
208/60 0.15 0.06 12 Sélection du transformateur
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

t
t

50 in.-lb.
(5.6 N•m)

t
t

Manual Override
Vástago de Operación Manual
Acionamento manual
Ouverture manuel de la tige

Emerson Climate Technologies and the Emerson Climate Technologies logo are trademarks and service
marks of Emerson Electric Co. © 2004 Emerson Electric Co. PA-00295 Oct 2006
Solenoid Valves 1 2

240RA/540RA Models R-11

R-12
R-401B
R-402A
R-22 R-402B Coil
Model
R-113 R-404A AM AH DM MM ASC2
R-114 R-407A
R-115 240RA
ü ü ü ü ü
R-123
R-124
R-407B
R-407C
540RA
ü ü ü ü ü
R-125 R-500
R-134a R-502
R-401A R-507

Refrigerant Compatibility Verify Coil

Compatibilidad con Refrigerantes Verifique la Bobina
Compatibilidade do Refrigerante Verifique a bobina
Compatibilité du réfrigérant Vérifier la bobine

3 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 7 8 Coil Electrical Data

T < 250°F (121°C) VAC/Hz

Maximum Amps VA
Inrush Holding Holding
24/50 2.0 0.96 23
24/60 1.6 0.74 18
120/50 0.45 0.21 25
120/60 0.36 0.16 19
208/50 0.19 0.08 17
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

Solder Techniques Coil Installation Transformer Selection

Técnicas para Soldar Instalación de la Bobina Selección del Transformador
Técnicas de Soldagem Instalação da bobina Selecione transformador capacidade suficiente
Technique de soudure l’installation de la bobine Sélection du transformateur
240RA Only

t
t

t 50 in.-lb.

t
(5.6 N•m)

Manual Override
Vástago de Operación Manual
Acionamento manual
Ouverture manuel de la tige

Emerson Climate Technologies and the Emerson Climate Technologies logo are trademarks and service
marks of Emerson Electric Co. © 2004 Emerson Electric Co. PA-00296 Oct 2006
EK, ADK & BOK 1 2
Filter Drier R-11
R-12
R-401B
R-402A
Installation Instructions R-22
R-113
R-402B
R-404A
R-114 R-407A
R-115 R-407B
R-123 R-407C
R-124 R-410A
R-125 R-500
R-134a R-502
R-401A R-507

Refrigerant Compatibility System Location

Compatibilidad con Refrigerantes Localización en el Sistema
Compatibilidade do Refrigerante Localização do Sistema
Compatibilité du réfrigérant Emplacement du système

3 4 5

SAE ODF

All Positions OK Remove Seals Flow Follows Arrow

Todas las Posiciones OK Remueva los Empaques El Flujo sigue la Flecha
Todas as Posições São Possíveis Remova os Tampões Barra Indica Posição do Fluido
Toute position OK Enlever les capuchons L’écoulement doit suivre la flèche

6 7
SAE
ODF

Installation Precautions Pressurize And Check For Leaks

Precauciones de Instalación Presurize y Verifique si existen Fugas
Precauções na Instalação Pressurize e Verifique Vazamentos
Précautions d’insatallation Pressuriser et vérifier pour les fuites
Emerson Climate Technologies and the Emerson
Climate Technologies logo are trademarks and
service marks of Emerson Electric Co.
© 2004 Emerson Electric Co.

PA-00292 Jul 2006

Instruction Sheet
PA-00228
January 2008 HMI Moisture Liquid Indicator

HMI Moisture Liquid Indicator

General Information Following installation of a Moisture Liquid Indicator or an
Only one indicated element is required for all common EK filter-drier, the system should be allowed to reach
refrigerants. This element is highly sensitive to moisture equilibrium as previously noted. If a caution or wet
and will gradually change color in direct relation to an system condition is still indicated following this period,
increase or decrease in the moisture content of the the filter-drier or the replaceable cores should be
system. The dry-caution-wet system operating conditions replaced. This practice should be continued until the
are then easily determined by matching the element system has dried and a safe condition is indicated.
color with the two colors displayed on the reference label.
Colors change as often as the system moisture content
changes.
MWP - 680 psig
IMPORTANT: 12 hours is recommended after installation
of the Moisture Liquid Indicator before attempting to
determine the system moisture content.

Safety Instructions
1. Read all instructions thoroughly. Failure to comply
can result in valve failure, system damage, or
personal injury.
2. The indicator element will indicate an unsafe
condition before installation. This is normal and
simply reflects the room humidity condition.
3. The exclusive fused glass eyepiece in the Moisture
Liquid Indicator provides a clear, wide-angle view of
the liquid refrigerant flow so that bubbles or flash gas
are easily seen. This indicates an insufficient system
charge, low head pressure, insufficient liquid
subcooling or some form of restriction in the liquid
line.

Installation Instructions
1. The Moisture Liquid Indicator may be installed
anywhere in the liquid line and in any position. It is
normally installed downstream from the filter-drier
and immediately ahead of the thermal expansion
valve.
2. Extended cooper connections with bar stock body
permits use of any soft solder or commonly used
Figure 1
brazing alloys. When soldering or brazing, direct the
flame away from the body. Wet rags or chill blocks
must be used when brazing to prevent damaging the
Moisture Liquid Indicator. See Figure 1. CAUTION: This product is intended for use on all CFC,
HCFC and HFC refrigerants. Do not use on any
unlisted fluid media without prior approval of the
Emerson Climate Technologies Flow Controls
Division Applications Engineering Department. Use
on fluids not listed above could result in deterioration
of the moisture indicator element. Not for use on
refrigerants classified by ASHRAE standard 34 as
Class A1/A2, A2, A3, B2 and B3.

www.emersonflowcontrols.com

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
Instruction Sheet PS1 Single High and Low Pressure
PA-00281
October 2007 & PS2 Dual Pressure Refrigeration Controls

PS1 Single High and Low Pressure &

PS2 Dual Pressure Refrigeration Controls
THE FLEXIBLE CONTROL INSTALLATION INSTRUCTIONS–GENERAL
• Emerson Type PS1 Single and PS2 Dual Pressure Controls are 1. Cover Removal—Loosen cover screw and lift cover up.
designed for cycling, cutout and alarm applications on the high and 2. Mounting—Mount the control in a protected area with the
low pressure sides of refrigeration systems. included angle mounting bracket and screws, or on a flat
• Standard pressure ranges and construction are ideally suited to surface from the front.
conventional fluorocarbon and new alternative refrigerants (not CAUTION: If other screws are used, use 8-32 screws that
Ammonia). do not penetrate into the control more than 1/8’’.
• High rated single pole double throw (SPDT) switch action on all 3. Pressure Connections/Capillary /Pressure Lines: Proper
PS series controls provides either open or close on pressure installation of capillary and pressure lines will insure
rise (pressure drop) operation to provide maximum application a trouble–free installation.
flexibility. The other switch contact can be used for an alarm or • If the control is mounted on the compressor, all lines
signal function if desired. must be secured to the compressor so they do not
• A convertible reset feature on selected dual pressure controls vibrate independently from the compressor.
allows the user to select either Automatic or Manual Reset • If the control is mounted remote from the compressor
Cutout on the high pressure side. an open coiled vibration loop, 2 to 3 coils, 2 to 3’’
• PS2 Dual Pressure Controls incorporate 2 independent SPDT diameter should be provided between the rigid compressor
switches with factory installed jumper for conventional base and the moving compressor. The lines coming
operation with high and/or low pressure cutout alarm or signal, from the coil should be secured to the base and
if desired. Removal of the jumper on dual pressure controls compressor so the coil takes all the vibration. Avoid
provides totally independent high and low pressure SPDT any “violin string” runs of pressure connection lines.
switch operation. • Sharp bends or kinks must be avoided in the capillary
• The parts package includes a lockplate and knob which allows or pressure lines. Do not allow the lines to rub and
the user to lock both the range and differential screws or the abrade against any moving surface. Avoid any excess-
range or differential screw with a knob on the unlocked screw. ive handling or reforming of the copper lines to
minimize work hardening of the copper.
Details of the Emerson "Flexible" Control options • A generous loop (3 to 4") should be provided in the
are in the installation Instructions. capillary below the control.
Pressure connections should be self-draining. High and
SAFETY INSTRUCTIONS low pressure connections to refrigeration lines should be
1. Read all Instructions thoroughly. Failure to comply can result on the top or now lower than the side of the line to
in control failure, system damage or personal injury. minimize refrigerant oil from entering the line, which
2. Do not use with ammonia or on hazardous or corrosive fluids. slows the control's ability to respond to pressure changes.
3. Do not install in Hazardous Locations. Pressure connections to the compressor body should be
4. Disconnect electrical power before installation. Do not reapply slanted to allow the connection to self-drain to the
power until control installation is complete, wiring connections compressor body.
secured and cover is installed. 4. WARNING: Before making any electrical connections,
5. Before making pressure control connections, depressurize check with a voltmeter as there could be more than one
system and make certain lines are at atmospheric pressure. power source.
5. Electrical Connections – Make certain the load to be
connected is within the electrical rating of the control.
SPECIFICATIONS – SWITCH RATINGS • All wiring should conform to National Electrical Code
Maximum Load 120VAC 240VAC and local regulations. Use 14AWG or larger copper
conductors ONLY.
Full Load Amps 24 FLA 24 FLA See Switch Connection Diagrams later in this installation
Locked Rotor Amps 144 LRA 144 LRA instructions sheet.
• The terminals are of a clamp design. Loosen the
Horsepower 2 HP 3 HP
terminal screw with a Phillips head or small screwdriver,
Pilot Duty 720VA 720VA insert approximately 3/8’’ stripped wire and tighten.
NonInductive 24 amps 24 amps

www.emersonclimate.com/flowcontrols

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
PS1 SINGLE LOW PRESSURE CONTROL SWITCH CONNECTIONS

SINGLE LOW PRESSURE LOW PRESSURE CYCLING LOW PRESSURE

SWITCH RESPONSE OR PUMPDOWN CUTOUT/ALARM

TO DEFROST
TERMINATION SOLENOID

UNLOADER DEFROST
CONTROL TO TERMINATION
UNLOADER

PS1 SINGLE HIGH PRESSURE CONTROL SWITCH CONNECTIONS

SINGLE HIGH PRESSURE HIGH PRESSURE CONDENSER

SWITCH RESPONSE CUTOUT FAN CYCLING

TO CONDENSER
FAN MOTOR

NOTE: In above diagrams, P = Pressure

2
SETTINGS & ADJUSTMENTS

Adjustable Range & Differential Controls Adjustable Range Fixed Differential Controls
or High Side Dual Pressure

Controls may have external

adjustments (shown), or internal
adjustments. If the control has
internal adjustments, the cover
must be removed to access the
adjustment screws.

Procedure
1) Adjust the Range Screw/Pointer to the desired "High Event" Procedure
setting. 1) Adjust the Range Screw to the desired "High Event" setting.
2) Adjust the Differential screw to the desired differential. Low Event = High Event – Fixed Differential
Low Event = High Event – Differential ✧ Adjustment of the Range Screw changes both the high and
✧ Adjustment of the Range Screw changes both high and low events.
low events.
✧ Adjustment of the Differential Screw changes the "Low Event"
only.

Do not set the Low Event below the lowest allowable event Lowest Allowable Events
Low Event – High Event = Differential Low Pressure Control = 27" Hg
High Pressure Control = 50 PSIG

CONTROL SETTING & CHECKOUT

❍ Low Pressure Controls – With an accurate pressure gauge ❍ High Pressure Controls – With a high pressure gauge
attached to the suction service valve, slowly close the liquid attached to a high pressure service port, restrict the air flow
line valve to allow the system to pump down. thru an air-cooled condenser, or reduce the water flow thru a
Observe the control's Low Event Switching Pressure – slowly water-cooled condenser to cause discharge pressure to rise.
open the liquid line to allow suction pressure to rise. Observe Observe the control's High Event Switch Point and adjust as
the control's High Event Switching Pressure – adjust the necessary. Restore normal cooling and observe the control's
control range and differential set points as required to Low Event Switch Point, adjusting as required.
achieve the desired settings.

Before leaving a new control installation, it is best to observe a minimum of 3 cycles to assure proper operation.

LOCKPLATE AND KNOB

KNOB
SCREW The lockplate can be used to lock:
1. Both Range and Differential Screws. Neither setting can be
KNOB adjusted. To use lockplate options 2 or 3, break one end off
the lockplate along the creaseline (see exploded view
diagram at left).
2. Range Screw Only. Range screw is locked so that high event
is fixed – adjusting the differential screw allows low event only
to be changed.
FULL LOCKPLATE
LOCKS BOTH 3. Differential Screw Only. Differential is locked so that
RANGE & differential is fixed – adjusting range screw moves both high
DIFFERENTIAL
and low event up or down together.

Lockplate Installation on Dual Pressure Control

NOTE: If only one screw is

locked, knob can be applied to
unlocked screw.

NOTE: The Range Screw(s) and

Lockplate attachment screw are
cross-drilled to allow the use of a
wire seal.

3
SPECIFICATIONS –
CONTROL MOUNTING
TEMPERATURE & PRESSURE RANGES
Dual Pressure Control Illustrated
Temperature Range -20°F to +140°F
Pressure Range – see control label on box.
Maximum Pressure – During installation and service, the
control's power element should not be exposed to pressure
exceeding those listed in the table below.
Control Range Maximum Allowable Pressure
24" to 42 PSIG 230 PSIG
15" to 100 PSIG 360 PSIG
90 to 450 PSIG 500 PSIG

SPECIFICATIONS – ENCLOSURE
NEMA CLASS I – Mount the control body in an area
protected from the weather, water or excessive moisture,
dirt, dust and corrosive or explosive atmospheres.

MANUAL OPERATION MOUNTING DIMENSIONS

The control can be easily manually operated as illustrated below (Back View)

CONVERTIBLE RESET CONTROLS

The high pressure side of dual pressure controls is
furnished with the convertible reset feature that can be
changed from manual to automatic reset as illustrated and
described below.
❍ With the tab rotated counterclockwise so it does not
touch the manual reset tab, the control will operate
in the manual mode.
With the tab rotated clockwise so it holds the manual
reset tab down fully, the control will operate as an
automatic reset control.

TOP VIEW
(cover off)

SIDE VIEWS
(cover off) MANUAL
RESET AUTO RESET
POSITION POSITION

4
PS2 DUAL PRESSURE CONTROL SWITCH CONNECTIONS
DUAL PRESSURE SWITCH RESPONSE DUAL PRESSURE SWITCH RESPONSE
Low Pressure Side – Cycling pumpdown or cutout. Close high. Open low.
High Pressure Side – Cutout. Open high. Close low.

ISOLATED HIGH/LOW PRESSURE FUNCTIONS –

JUMPER REMOVED
Isolated Low Pressure Switch can be used in separate CONVENTIONAL HOOKUP WITH ALARM
circuit for unloading, low pressure cutout Low Pressure Side – Cycling pumpdown or cutout. Close high. Open low.
with time delay or other functions. High Pressure Side – Cutout. Open high. Close low.

NOTE: In above diagrams, P = Pressure; LP = Low Side Pressure; HP = High Side Pressure

5
 Installation Instructions P70
Issue Date June 12, 2006

P70, P72, and P170 Series Controls for

High Pressure Applications

Application
P70, P72, and P170 Series Controls for High Pressure They may also be used on air, water and other
Applications provide high-side pressure control on noncorrosive fluid applications. Ammonia compatible
commercial refrigeration and air conditioning models are also available.
applications.

IMPORTANT: Except for those models listed ! CAUTION: Risk of Property Damage.
as Refrigeration Pressure Limiting Controls, use the Mount the pressure control separately from the
P70, P72, and P170 Series Controls for High electrical cabinet and seal all electrical piping to
Pressure Applications only as an operating control. prevent ammonia from migrating to electrical
Where failure or malfunction of a P70, P72, or P170 components. Where there may be exposure to
pressure control could lead to personal injury or ammonia, use only ammonia compatible control
property damage to the controlled equipment or modules and pressure connections. System
other property, additional precautions must be shutdown due to improper adjustment may cause
designed into the control system. Incorporate and property damage.
maintain other devices such as supervisory or alarm
systems or safety or limit controls intended to warn The Manual Reset Lockout mechanism does not
of, or protect against, failure or malfunction of the allow the pressure control to automatically reset after
P70, P72, or P170 pressure control. the control has Cutout, providing shutdown capability
for unmonitored equipment. See Manual Reset
x P70C, P70D, P170C, and P170D type models Operation.
with Single-Pole Single-Throw (SPST) Open-High
switch action are the most popular models and are NEMA 1 enclosures are standard on most models.
typically used as high pressure Cutout controls. NEMA 3R enclosures are also available on quanity
The C type models are automatic reset controls. orders.
The D type models have a manual reset lockout Dimensions
mechanism. Some P70C, P70D, P170C, and 2-Mounting Holes
P170D type models are UL Listed as refrigeration 10-32 UNF-2B
Thread 5/16
pressure limiting controls. See Table 2 for 3-1/4 2-13/16
83 8 71
standard models available. 5/16
8
3-1/4
x P70A and P170A type models feature SPST 1 83
5/16
Open-Low switch action and typically are used for 8 25
condenser-fan cycling control. 1-1/8
29
x P70 and P170 Series models with Single-Pole 3/16 Diameter
1-11/16
43
1-7/8 15/16
Double-Throw (SPDT), or 4-Wire, 2-Circuit switch 5 Mounting Hole 49
15/16 (24)
3/16
action allow users to install alarm devices or other 4
3/16
4
(24)
3/8 3/16
control circuits. 10
X
5
2-1/16 Diameter
x P72 Series models have a Double-Pole 53 15/16 1-1/4 Mounting Hole
24 33
Single-Throw (DPST) switch with load-carrying 1-5/16
contacts that can provide direct control of 208-240 34
3-1/16 7/8 (NEMA 1/2 in.)
VAC single-phase motors up to 3 hp, 480 and 600 77 4 22 Conduit Hole
1/16
VAC single-phase noncompressor motors, and 2 101

208-220 VAC 3-phase motors up to 5 hp. See

Table 6. Figure 1: Dimensions for P70, P72, and P170
Pressure Controls with NEMA 1 Enclosures,
Controls are available in several pressure ranges and in. (mm)
are compatible with most common refrigerants.

© 2006 Johnson Controls, Inc. 1

Part No. 24-7664-1938, Rev. D www.johnsoncontrols.com
 Mounting Holes for
Flat Vertical Surfaces
5/8
16 79
Use mounting screws
4-1/16
provided. Longer screws
5/8 104 may damage control.
16

1/2
4-1/16 12
5/8 104 70
15/16 3/8
24 2-11/16 10 2-15/16
74 3/16
68
4 Mounting Holes 5
Universal Mounting
25
5/16 Diameter Bracket
8 (Part No. 271-51)
3/4 in. NPSM
Rigid Conduit
1-9/16 Hole
1-1/4
40
Mount bracket to
31 horizontal surface.
1/2
1-5/8 13
41
Figure 3: Mounting the P70, P72, and P170
Figure 2: Dimensions for P70, P72, and P170 Pressure Controls with NEMA 1 Enclosures,
Pressure Controls with NEMA 3R Enclosures, in. (mm)
in. (mm)
Mounting Pressure Connections
Mount the control in an accessible position, where the P70, P72, and P170 high pressure controls are
control and pressure connection are not subject to connected to the controlled equipment by a capillary
damage. (except ammonia models). These controls are
available with a variety of pressure connection styles.
Mount the pressure control upright and level. Position
the pressure connection line to allow drainage away Follow these guidelines when installing pressure
from control bellows. Locate pressure tap points on the connection lines:
top side of the refrigerant lines to reduce the possibility
of oil, liquids, or sediment accumulating in the bellows, IMPORTANT: If these controls are installed on
which could cause control malfunction. equipment that contains hazardous or regulated
materials, such as refrigerants or lubricants, you
Mount controls with NEMA 1 enclosures on horizontal must comply with all standards and regulations
or vertical flat surfaces. governing the containment and handling of those
Use two screws or bolts through the two outer holes materials.
on the back of the control case to mount the control
directly to a flat, vertical surface. Avoid Sharp Bends in the Capillary Tube
Use the two inner holes with the Universal Mounting Sharp bends can weaken or kink capillary tubes, which
Bracket (and screws supplied) when mounting the may result in leaks or restrictions.
control to a flat, horizontal surface. See Figure 3.
Allow for Slack in the Capillary Tube
Mount controls with NEMA 3R enclosures in a level,
upright position with the bellows and conduit Leaving a little slack in the capillary tube helps
connection facing down. Ensure that all gaskets are in dampen mechanical vibration that can weaken or
place. Mounting NEMA 3R enclosures in any position damage capillary tubes.
other than upright and level may trap water in the
enclosure and submerge internal control components. Coil and Secure Excess Capillary Tubing
Carefully loop any excess capillary tubing into smooth,
IMPORTANT: Use only the mounting screws circular coils (approximately 2 to 3 in.[50 to 75 mm]
supplied with the Universal Mounting Bracket to diameter). Securely fasten the coiled tubing.
avoid damaging internal components. Be careful not Avoid Contact between the Capillary Tubing and
to distort or bend the control case when mounting Sharp or Abrasive Objects
the control to an uneven surface. Using other screws
or bending the control case will void the warranty. Vibration of sharp or abrasive objects in contact with
capillary tubes can result in leaks.

2 P70, P72 and P170 Series Controls for High Pressure Applications Installation Instructions
 L1
Do Not Overtighten Flare Nuts on Pressure L2
Connection Line Fittings Load
M1
Overtightening flare connections may damage the
Line
threads on the flare nuts or flare connectors, and may
result in leaks. Do not exceed 9 ft˜lb (12 N˜m) of torque
when tightening brass flare connections. L1
L2

Avoid Severe Pressure Pulsation at Load

Pressure Connections M1

Install pressure connection lines to pressure tap points Line Open-High switch action:
away from the compressor to minimize the effects of opens on pressure rise.
(C and D Models)
pressure pulsation from reciprocating compressors.
Figure 4: Typical Wiring for SPST Switch
IMPORTANT: After installing the control, (P70A, B, C, D and P170A, C, D Type Models)
evacuate pneumatic and pressure connection lines
to remove air, moisture and other contaminants in a L1
manner consistent with applicable environmental L2
regulations and standards.
Alarm
Load
Wiring 2
1 3
P70, P72, and P170 controls for high pressure
applications are available with several switch options 1 to 3 opens, and 1 to 2 closes
and electrical ratings. Check the label inside the on pressure rise.
control cover for model number, switch action, and
Figure 5: Typical Wiring for SPDT Switch
electrical rating. See Table 1 for switch actions and
(P70E and F Type Models)
models. See Electrical Ratings.
Check the wiring terminal designations on the control L1
switch-block, and refer to the following guidelines and L2
applicable wiring diagrams when wiring the control. Alarm
Alarm
Circuit
M1 Power

! WARNING: Risk of Electrical Shock. Line Load

Disconnect each of multiple power supplies before Line M2

making electrical connections. More than one Main circuit (Line to M2) opens and auxiliary
disconnect may be required to completely circuit (Line to M1) closes on pressure rise.
de-energize equipment. Contact with components
carrying hazardous voltage can cause electric shock Figure 6: Typical Wiring for 4-Wire, 2-Circuit
and may result in severe personal injury or death. Switch (P70J, K and P170K Type Models)

L1
L2
*L3
IMPORTANT: Use only the terminal screws
that are supplied with the switch-block. Using other
Line M2 Load
screws may cause damage to the switch-block and
will void the warranty. Line M1

Line to M1, and Line to M2 open on pressure rise.

IMPORTANT: Use copper conductors only. (*L3 is third supply line in 3-phase applications.)
Make all wiring connections in accordance with local,
national, and regional regulations. Do not exceed the Figure 7: Typical Wiring for DPST Switch
controls. (P72C and D Type Models)

Table 1: Pressure Control Switch Action, Low Events, High Events, Model Types, and Electrical Ratings
Tables References

P70, P72, P170 Series Controls for High Pressure Applications Installation Instructions 3
 Model Types - Electrical
Switch and Action Low Event High Event
Rating Table References
Single-Pole Single-Throw Cutout Cut In P70A, P70B, P170A
(SPST) Open-Low (Opens Line to M1) (Closes Line to M1) See Table 3.
Single-Pole Single-Throw Cut In Cutout P70C, P70D, P170C, P170D
(SPST) Open-High (Closes Line to M1) (Opens Line to M1) See Table 3.
Single-Pole Double-Throw Opens 1 to 2 and Closes 1 to 2 and P70E, P70F
(SPDT) Closes 1 to 3 Opens 1 to 3 See Table 4.
4-Wire, 2-Circuits, Cutout Cut In
P70G, P70H
1-NO, 1-NC (Opens M2 to Line and (Closes M2 to Line and
See Table 5.
Open-Low Closes M1 to Line) Opens M1 to Line)
4-Wire, 2-Circuits, Cut In Cutout
P70J, P70K, P170K
1-NO, 1-NC (Closes M2 to Line and (Opens M2 to Line and
See Table 5.
Open-High Opens M1 to Line) Closes M1 to Line)
Double-Pole Single-Throw Cutout Cut In
P72A, P72B
(DPST) (Opens M1 to Line and (Closes M1 to Line and
See Table 6.
Open-Low M2 to Line) M2 to Line)
Cut In Cutout
(DPST) P72C, P72D
(Closes M1 to Line and (Opens M1 to Line and
Open-High See Table 6.
M2 to Line) M2 to Line)
screw on Manual Reset Lockout models. The differential
Adjustments pressure value is fixed.
Adjustments of the P70, P72, and P170 high
pressure controls vary, depending on the model.
The following guidelines and diagrams illustrate the Condenser Fan Cycling - Open-Low Switch Action
procedures for adjusting these controls. Refer to the Condenser fan cycling pressure controls have a
product label inside the control cover for model scaleplate that displays the Cut In setpoint and
number and switch action. Refer to Table 1 for Differential setting. (See visible scale on the control.)
switch action, low event, and high event for the Turn the range screw to adjust the Cut In setpoint on the
various control models. right side of the scale. Turn the differential screw to
adjust the Differential setting on the left side of the scale
High Pressure Cutout - Automatic Reset (which changes the Cutout pressure value).
High pressure Cutout controls with automatic reset
have a scaleplate that displays the Cut In and IMPORTANT: Do not adjust pointers beyond the
Cutout setpoints. (See the visible scale on the highest or lowest indicator marks on the control’s
control.) Turn the range screw to adjust the Cut In pressure scale. Adjusting pointers beyond indicator
and Cutout setpoints up or down simultaneously, marks may damage screw threads, may cause
while maintaining a constant pressure differential. inaccurate control operation, and will void the
Turn the differential screw to adjust (only) the low warranty.
event on the left side of the scale (which changes
the differential pressure value).

High Pressure Cutout - Manual Reset Lockout

IMPORTANT: Use the pressure control settings
High pressure Cutout controls with the Manual
recommended by the manufacturer of the controlled
Reset Lockout option have a scaleplate that displays
equipment. Do not exceed the pressure ratings of the
the Cutout setpoint. There is no pointer for the Cut In
controlled equipment or any of its components when
setpoint. (See the visible scale on the control.)
checking pressure control operation or operating the
Turn the range screw to adjust the Cutout setpoint controlled equipment.
on the right side of the scale. There is no differential

4 P70, P72 and P170 Series Controls for High Pressure Applications Installation Instructions
 Figure 8: Adjusting P70, P72, and P170 Controls for High Pressure Applications

IMPORTANT: After mounting and wiring On equipment with locked-out controls, first determine
control, attach a reliable set of gauges to the and remedy the cause of the lockout, and allow the
controlled equipment, and operate the equipment sensed pressure to drop at least 70 psig below the
(at least) three cycles at the pressures necessary Cutout setpoint. Then, press and release the reset
to verify control setpoints and proper equipment button on the front of the control to restore operation of
operation. the controlled equipment.

Manual Reset Operation

Pressure controls with the Manual Reset option lock
out when they reach Cutout pressure and must be
manually reset by the user to restart the controlled
equipment. The manual reset mechanism is
trip-free and cannot be overridden by blocking or
tying the reset button down.

P70, P72, P170 Series Controls for High Pressure Applications Installation Instructions 5
Table 2: Standard P70, P72, and P170 Control Models for High Pressure Applications
Model Switch Action Range Differential Pressure Maximum Working
Number Psig (kPa) Psi (kPa) Connection Pressure (MWP)
Psi (kPa)
Condenser Fan Cycling Control Models (for Noncorrosive Refrigerants)
Minimum 35 36 in. Capillary with
100 to 400
SPST (241) 1/4 in. Flare Nut
P70AA-118 psig
Open-Low Maximum 200
(690 to 2758)
(1379) 475
DPST 100 to 400 Minimum 35 (3275)
P72AA-27
Open-Low psig (241)
SPST (690 to 2758) Maximum 200 1/4 in. Male
P170AA-118 (1379)
Open-Low Flare Connector
All-Range Control Models (for Noncorrosive Refrigerants)
Minimum 60 1/4 in. Male
P70CA-2*
(414) Flare Connector
SPST Maximum 150
P70CA-3* Open-High (1034)
P70DA-1*
4-Wire, 2-Circuit
Line-M1 Close-High Manual Reset
P70KA-1* Line-M2 Open-High Lockout
36 in. Capillary with
1/4 in. Flare Nut
Minimum 60
50 to 500 (414) 525
P72CA-2*
DPST (345 to 3448) Maximum 150 (3620)
Open-High (1034)
manual Reset
P72DA-1*
Lockout
Minimum 60
(414)
P170CA-3* SPST
Maximum 150
Open-High
(1034) 1/4 in. Male
P170DA-1* Manual Reset Flare Connector
4-Wire, 2-Circuit Lockout
P170KA-1* Line-M1 Close-High
Line-M2 Open-High
Ammonia-Compatible Models
Minimum 20
SPST (138)
P70AA-119 50 to 300
Open-Low Maximum 120
(827)
Minimum 60 1/4 in. SS 525
(414) Female NPT (3620)
P70CA-5*
SPST 50 to 500 Maximum 150
Open-High (345 to 3448) (1034)
Manual Reset
P70DA-2*
Lockout
Continued on next page . . .

6 P70, P72 and P170 Series Controls for High Pressure Applications Installation Instructions
 Model Switch Action Range Differential Pressure Maximum Working
Number Connection Pressure (MWP)

High Pressure Control Models for High Pressure Non-corrosive Refrigerants

Condenser Fan Adjustable 36 in. Capillary with
P70AA-400
Cycling 100 to 470 35 to 200 1/4 in. Flare Nut
SPST Opens Low (689 to 3241) (241 to 1379) 1/4 in. Male Flare
P170AA-400
Connector
Adjustable 36 in. Capillary with
P70CA-400*
200 to 610 60 to 150 1/4 in. Flare Nut 690
(1379 to 4206) (413 to 1034) 1/4 in. Male Flare (4757)
P170CA-400*
Connector
SPST Opens High
Manual Reset 36 in. Capillary with
P70DA-400*
200 to 610 Lockout 1/4 in. Flare Nut
(1379 to 4206) 1/4 in. Male Flare
P170DA-400*
Connector
* Models that are UL Listed as refrigeration pressure limiting controls. For models not included in this table, contact the
Refrigeration Application Engineering Group at 1-800-275-5676 for details and availability.
Note: See Dimensions and Technical Specifications for additional model information including Maximum Working
Pressure.

Electrical Ratings

Table 3: SPST Electrical Ratings (P70A, B, C, D, and P170A, B, C, D Models)

Hermetic
Compressor
Standard Single-Phase Ratings
Single-Phase
Ratings
120 VAC 208 VAC 240 VAC *480 VAC *600 VAC 208/240 VAC
Motor Full-Load
24 18.7 17 5 4.8 24
Amperes
Motor Locked-Rotor
144 112.2 102 30 28.8 144
Amperes
Non-Inductive Amperes 22 22 22 -- -- --
Pilot Duty 125 VA at 120 to 600 VAC; 57.5 VA at 120 to 300 VDC
* Not for compressor motor loads

Table 4: SPDT Electrical Ratings Standard Differential Switch (P70E Models)

Standard Single-Phase Ratings
120 VAC 208 VAC 240 VAC *277 VAC
Motor Full Load Amperes 16.0 9.2 8.0 7.0
Motor Locked Rotor Amperes 96.0 55.2 48.0 42.0
Non-Inductive Amperes 16.0 16.0 16.0 16.0
Pilot Duty 125 VA at 120 to 600 VAC 125 VA at 24 to 600 VAC
* Rating for P70EC models only

P70, P72, P170 Series Controls for High Pressure Applications Installation Instructions 7
Table 5: 4-Wire, 2-Circuit Electrical Ratings (P70G, H, J, K, and P170K Models)
Standard Single-Phase Ratings
Line-M2 (Main Contacts) Line-M1 (Auxiliary Contacts)
120 208 240 277 *480 *600 120 208 240 277
VAC VAC VAC VAC VAC VAC VAC VAC VAC VAC
Motor Full
Load 16.0 9.2 8.0 -- 5 4.8 6.0 3.3 3.0 --
Amperes
Motor Locked
96.0 55.2 48.0 -- 30 28.8 36.0 19.8 18.0 --
Rotor Amperes
Non-Inductive
16.0 9.2 8.0 7.2 -- -- 6.0 6.0 6.0 6.0
Amperes
Pilot Duty (for
both sets of 125 VA at 24 to 600 VAC; 57.5 VA at 120 to 300 VDC
contacts)
* Not for compressor motor loads

Table 6: DPST Electrical Ratings (P72A, B, C and D Type Models)

Hermetic
Standard Ratings Compressor
Ratings
120 208 240 208 220 *480 *600 208 240
VAC VAC VAC VAC VAC VAC VAC VAC VAC
1Ø 1Ø 1Ø 3Ø 3Ø 1Ø 1Ø 1Ø 1Ø

Motor Full-Load Amperes 24 18.7 17 15.9 15 5 4.8 24 24

Motor Locked-Rotor Amperes 144 112.2 102 95.4 90 30 28.8 144 144
AC Non-Inductive Amperes 24 24 24 24 24 -- -- -- --
DC Non-Inductive Amperes 3 0.5 0.5 0.5 0.5 -- -- -- --
Pilot Duty 125 VA at 120 to 600 VAC; 57.5 VA at 120 to 300 VDC
* Not for compressor motor loads

8 P70, P72 and P170 Series Controls for High Pressure Applications Installation Instructions
 Technical Specifications
Product P70, P72, and P170 Controls for High Pressure Applications
Switch Action P70, P170: SPST; 4-Wire/2-Circuit; or SPDT PENN® switch P72: DPST
Pressure Connection P70, P72 Standard Models P170 Standard Models Ammonia Compatible Models
Various connections 1/4 in. SAE male flare 1/4 in. stainless steel female
available NPT connection
Ambient Temperature P70E and P70F: 50 to 104qF (10 to 40qC)
All Other Models: -40 to 140qF (-40 to 60qC)
Case and Cover NEMA 1 Enclosures: Case is galvanized steel; cover is plated and painted steel.
NEMA 3R Enclosures: Case and cover are plated and painted steel.
Dimensions NEMA 1 Enclosure: 3-1/4 x 4 x 2-1/16 in. (83 x 101 x 53 mm)
(H x W x D) NEMA 3R Enclosure: 4-1/16 x 4-1/16 x 2-15/16 in. (104 x 104 x 74 mm)
Approximate Individual Pack (NEMA 1): 2.4 lb (1.08 kg);
Shipping Weight Bulk Pack (NEMA 1, multiples of 25 controls): 60 lb (27.2 kg)
Compliance For information on specific models, contact the Refrigeration Application Engineering Group
at 1-800-275-5676.
Accessories 271-51 Universal Mounting Bracket (supplied with standard controls)

The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these
specifications, contact the Refrigeration Application Engineering Group at 1-800-275-5676. Johnson Controls, Inc. shall not be liable for
damages resulting from misapplication or misuse of its products.

Controls Group
507 E. Michigan Street
P.O. Box 423 Published in U.S.A.
Milwaukee, WI 53201 www.johnsoncontrols.com

P70, P72, P170 Series Controls for High Pressure Applications Installation Instructions 9
 Controles para Aplicaciones de Presión Alta
Series P70, P72 y P170
Aplicación Estos controles están disponibles en varios rangos de
presión y son compatibles con los refrigerantes más
Los Controles de las Series P70, P72 y P170 para comúnes. También se usan en aplicaciones de aire, agua,
Aplicaciones de Presión Alta proporcionan control de y otros líquidos no corrosivos. También tenemos modelos
presión del lado de alta en aplicaciones de refrigeración compatibles con amoníaco.
comercial y de aire acondicionado.
IMPORTANTE: Con excepción de los modelos listados
como Contoles de Límite de Presión de Refrigeración, el
! PRECAUCION: Riesgo de Daño del
propósito de los controles de las Series P70, P72 y P170 Equipo. El amoníaco es muy corrosivo a componentes
para Aplicaciones de Presión Alta es de controlar equipo de cobre y latón. En aplicaciones de amoníaco se deben
bajo condiciones de operación normales. Donde un mal usar sólo modelos de control y conexiones de presión
funcionamiento o falla de un control de presión P70, compatibles con amoníaco. El control de presión se
P72, o P170 pueda resultar en una condición anormal debe instalar separadamente del gabinete eléctrico y se
de operación, que a su vez pueda causar lesión deben sellar todos los conductos eléctricos para evitar
personal o daño al equipo u otra propiedad, se deben que el amoníaco se filtre a los componentes eléctricos.
instalar otros aparatos (controles limitadores o de
seguridad) o sistemas (de alarma o supervisión) para El mecanismo de Bloqueo de Restablecimiento Manual
advertir o proteger contra éstas fallas o mal no permite que el control se restablezaca
funcionamiento del control de presión P70, P72, o P170, automáticamente después de llegar al punto de
y mantenerse como parte del sistema de control. Desconexión, y proporciona la capacidad de apagado para
equipo no monitoreado. Ver Ajuste de Operación de
x Modelos del Tipo P70C, P70D, P170C y P170D con Restablecimiento Manual.
acción del interruptor de Un Polo – Un Tiro (SPST) Las cajas NEMA 1 son estándares en la mayoría de los
con acción Abren en Alta son los modelos más modelos.
populares y se usan típicamente como controles de
Desconexión de presión alta. Los modelos de tipo C Las cajas NEMA 3R también están disponibles.
son controles con restablecimiento automático. Los Dimensiones
modelos de tipo D tienen un mecanismo de bloqueo
de restablecimiento manual. Algunos modelos del 2 Orificios
2 Orificios de de Montaje
Montaje
tipo P70C, P70D, P170C y P170D están Listados por Hilos 10/32
rosca 10/32 UN/2B
UN/2B 3-1/4 5/16 2-13/16
UL como controles de límite de presión de 83 8 71
refrigeración. 5/16
8
3-1/4
x Los modelos del tipo P70A y P170A están 5/16 1 83
disponibles con interruptor SPST con acción abren en 8 25
Baja y se usan típicamente para controlar el ciclo del 1-1/8
abanico del condensador. 29
1-11/16
x Los modelos de la Serie P70 y P170 tienen un 3/16
1-7/8 15/16
43
interruptor de Un Polos-Dos Tiro (SPDT), o de 4 5
49 15/16 (24)
3/16 3/16 (24)
Alambres-2 Circuitos que permiten que los usuarios 4 4
instalen aparatos de alarma u otros circuitos de 3/8 3/16
X
10 5
control. 2-1/16 Diametro del
53 15/16 1-1/4 Orificio de Montaje
x Los modelos de la Serie P72 tienen un interruptor 24 33
de Dos Polos-Un tiro (DPST) con contactos para 1-5/16
llevar la carga que puede proporcionar control directo 34
3-1/16 7/8 (NEMA ½ pul.)
77 4 Orificio del
22 Orificio Conduit
Conductor
a motores de monofásicos de 208-240 VCA hasta 3 1/16
HP, motores monofásicos de 480 y 600 VCA no de 2 101
compresor y motores trifásicos de 208-220 VCA hasta
5 HP. Refiérese a la Tabla 6.
Figura 1: Dimensiones para los Controles de Presión
P70, P72, y P170 con Cajas NEMA 1, pulg. (mm)

10 P70, P72 and P170 Series Controls for High Pressure Applications Installation Instructions
 Orificios de Montaje para
Superficies Planas y Verticales

Utilize los tonillos de

5/8 montaje provistos. Los
16 79 tornillos mas largos
pueden dañar el control
4-1/16
5/8 104
16

1/2 Soporte de Montaje

4-1/16 12 Universal
5/8 104 70
15/16 3/8 (Número de Parte 271-51)
24 2-11/16 10 2-15/16
74 3/16
68 Instale el soporte a la
25 4 Oriificios de Montaje 5 superficie horizontal
5/16 Diametro
8 Figura 3: Instalación del los Controles de Presión
3/4pulg. NPSM P70, P72 y P170 con Cajas NEMA 1, pulg. (mm)
Conduit
Orificio del Conducto
Rígido
1-1/4 1-9/16 Conexiones de Presión
40
31 Los controles de presión alta P70, P72 y P170 se
1/2
1-5/8 13 conectan al equipo controlado por medio de un capilar
(excepto en modelos para amoníaco). Están disponibles
Figura 2: Dimensiones para Controles de Presión en diferentes tipos de conexión de presión.
P70, P72, y P170 con Cajas NEMA 3R, pulg. (mm)
Siga estas pautas al instalar las líneas de conexión de
Instalación presión:

Instale el control en una posición accesible, donde el IMPORTANTE: Si estos controles se instalan en equipo
control y la línea de conexión de presión no se dañen. que contiene materiales peligrosos o regulados, tal como
Instale el control de presión en una posición vertical y refrigerantes o lubricantes, el instalador y usuario deben
nivelada. Coloque la línea de conexión de presión de observar todas las reglamentaciones que gobiernan el
manera que se pueda drenar lejos del fuelle del control. manejo y contención de esos materiales.
Los puntos de entrada de la presión se deben localizar en
el lado superior de la Lneaa del refrigerante para reducir la Evite Dobleces Agudos en el Tubo Capilar
posibilidad de que el aceite, líquidos, o sedimento se Los dobleces agudos pueden debilitar los tubos del
acumulen en el fuelle, que podría causar un mal capilar, que resultarían en fugas u obstrucciones.
funcionamiento del control.
Permita Soltura en el Tubo Capilar
Instale los controles con cajas NEMA 1 en superficies
planas horizontales o verticales. Dejar el tubo capilar un poco flojo puede ayudar a
amortiguar la vibración mecánica que pueda debilitar o
Use dos tornillos o pernos a través de los dos orificios dañar los tubos capilares.
exteriores en el reverso de la caja de control cuando se
instale directamente en una superficie plana y vertical. Enrolle y Asegure el Exceso del Tubo Capilar
Use los dos orificios internos con el soporte de Instalación Cuidadosamente enrolle cualquier exceso de tubo capilar
Universal (y los tornillos provistos), al instalar el control en en bobinas lisas y redondas (aproximadamente 2 pulg. de
una superficie plana y horizontal. Ver Figura 3. diámetro). Sujete el capilar enrollado.
Instale los controles con cajas NEMA 3R en una posición Evite el Contacto entre el Tubo Capilar y Objetos
nivelada y vertical, con el fuelle y la conexión conduit hacia Agudos o Abrasivos
abajo. Asegúrese que todos los empaques estén en su
La vibración de los objetos agudos o abrasivos que estén
lugar. La instalación de cajas NEMA 3R en cualquier
en contacto con los tubos capilares pueden resultar en
posición otra que vertical y nivelada puede atrapar agua
fugas.
en la caja y sumergir los componentes internos del control.
No Apriete Demasiado las Tuercas Abocinadas en los
IMPORTANTE: Use sólo los tornillos de montaje Conectores de la Línea de Conexión de Presión
provistos con el soporte de Instalación Universal para Si aprieta las conexiones abocinadas demasiado puede
evitar daño a los componentes internos. No tuerza la dañar los hilos en las tuercas abocinadas o los conectores
caja del control cuando instale el control a una superficie abocinados, y resultar en fugas. No exceda 9 pies-lbs (12
irregular. Nm) de torque al apretar las conexiones de latón
abocinadas.

Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión 11
Evite la Pulsación de Presión Severa en las L1
Conexiones de Presión L2

Instale las Líneas de conexión de presión que van a los Carga

puntos de entrada de presión lejos del compresor para M1

minimizar los efectos de pulsación de presión en los Línea Accion de interruptor
abierto - bajo: se abre al
compresores recíprocos. disminuir la presion
(Modelos A y B )
IMPORTANTE: Después de instalar el control, vacíe L1
L2
las líneas del control y conexión de presión de acuerdo
con los reglamentos locales, nacionales y regionales Carga
aplicables para remover el aire, humedad y otros M1
contaminantes
Línea

Alambrado
Figura 4: Alambrado Típico para Interruptores SPST
Los controles P70, P72 y P170 para aplicaciones de (Modelos P70A, B, C, D y P170A, C, D)
presión alta están disponibles con varias opciones de
L1
interruptor y rangos eléctricos. Revise la etiqueta dentro L2
de la tapa del control para el número del modelo, acción
Alarma
del interruptor, y clasificación eléctrica. Ver la Tabla 1 Carga
para las acciones de los interruptores y los modelos. 2
Vea Clasificaciones Eléctricas. 1 3
Revise las designaciones de la terminales alambrado en
el interruptor del control, y refiérase a las siguientes 1a 3 abre, y 1 a 2 cierra
al incrementar la presión
pautas y al diagrama de alambrado aplicable cuando se
instale el control. Figura 5: Alambrado Típico para Interruptores SPDT
(Modelos P70E y F)
! ADVERTENCIA: Riesgo de Descarga L1
Eléctrica. Desconecte la corriente eléctrica antes L2
de iniciar las conexiones eléctricas para evitar una Corriente del
Alarma Circuito de
posible descarga eléctrica. Puede ser necesario
Alarma
ejecutar más de una desconexión para desenergizar el M1
control y el equipo. Carga
Línea

Línea M2
IMPORTANTE: Use los tornillos de terminal
provisos con el interruptor. El uso de otros tornillos de Circuito principal (Línea a M2) se abre
terminal invalidará la garantía y puede dañar el y el circuito auxiliar (Línea a M1) se
interruptor. cierra al incrementar la presión

Figura 6: Alambrado Típico para Interruptores de 4

Alambres - 2 Circuitos (Modelos P70J, K y P170K)
IMPORTANTE: Hace todas las conexiones de
la instalación eléctrica de acuerdo con las
reglamentaciones nacionales, locales, y regionales. L1
L2
Use sólo conductores de cobre. No exceda la *L3
clasificación eléctrica del control.

Línea M2 Carga

Línea M1

Línea a M1 y Línea a M2 se abren al incrementar

la presión (L3 es la tercer línea de suministro
en aplicaciones de 3 fases)

Figura 7: Alambrado Típico para Interruptores DPST

(Modelos P72C y D)

12 Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión
Tabla 1: Controles de Presión Sencilla con Acción del Interruptor, Eventos Bajos, Eventos Altos, Tipos de
Modelo, y Tabla de Referencia de Clasificación Eléctrica
Tipos de Modelos – Tabla
Interruptor y Acción Evento Bajo Evento Alto de Referencia de
Clasificación Electrica
Un Polo-Un Tiro (SPST) Desconexión Conexión P70A, P70B, P170A
Abre en baja (Abre Línea a M1) (Cierra Línea a M1) Ver Tabla 3.
Un Polo-Un Tiro (SPST) Conexión Desconexión P70C, P70D, P170C, P170D
Abre en alta (Cierra Línea a M1) (Abre Línea a M1) Ver Tabla 3.
Abre 1 a 2 y P70E
Un Polo-Dos Tiros (SPDT) Cierra 1 a 2 y Abre 1 a 3
Cierra 1 a 3 Ver Tabla 4.
4-Alambres, 2-Circuitos, Desconexión Conexión
P70G, P70H
1 N.A., 1 N.C. (Abre M2 a Línea y Cierra (Cierra M2 a Línea y Abre
Ver Tabla 5.
Abre en baja M1 a Línea) M1 a Línea)
4-Alambres, 2-Circuitos, Conexión Desconexión
P70J, P70K, P170K
1 N.A., 1 N.C. (Cierra M2 a Línea y Abre (Abre M2 a Línea y Cierra
Ver Tabla 5.
Abre en alta M1 a Línea) M1 a Línea)
Desconexión Conexión
Dos Polos-Un Tiro (DPST) P72A, P72B
(Abre M1 a Línea y (Cierra M1 a Línea y
Abre en baja Ver Tabla 6.
M2 a Línea) M2 a Línea)
Conexión Desconexión
(DPST) P72C, P72D
(Cierra M1 a Línea y (Abre M1 a Línea y
Abre en alta Ver Tabla 6.
M2 a Línea) M2 a Línea)
Ajustes
Los ajustes de los controles de Presión Alta P70, P72 y no cuentan con tornillo de diferencial. El valor de la presión
P170 varían, dependiendo del modelo. Las siguientes del diferencial está fijo.
pautas y diagramas ilustran los procedimientos para
Ciclado del Abanico del Condensador – Acción del
ajustar estos controles. Refiérase a la etiqueta del
Interruptor de Abierto Bajo
producto dentro de la tapa del control para el número del
modelo y la acción del interruptor. Refiérase a la Tabla 1 Los controles de presión que ciclado del abanico del
para la acción del interruptor, evento bajo, y evento alto condensador tienen un placa de escala que despliega el
de los diferentes modelos de control. punto de ajuste de Conexión y el ajuste del Diferencial. (Ver
la escala visible en el control.) Gire el tornillo de rango para
Desconexión de Presión Alta – Restablecimiento
cambiar el punto de ajuste de Conexión en el lado derecho
Automático
de la escala. Gire el tornillo del diferencial para cambiar el
Los controles de Desconexión de Presión Alta con ajuste en el lado izquierdo de la escala (que cambia el valor
restablecimiento automático tienen un placa de escala de presión de Desconexión).
que despliega los puntos de ajuste de Conexión y
Desconexión. (Ver la escala visible en el control). Gire IMPORTANTE: No ajuste los indicadores más
el tornillo de rango para cambiar los puntos de ajuste de allá de las marcas mas alta o mas baja del indicador en la
Conexión y Desconexión, simultáneamente hacia arriba escala de presión del control. El ajuste de los indicadores
y abajo mientras se mantiene un diferencial de presión más allá de éstas marcas puede dañar los hilos del tornillo
constante. Gire el tornillo del diferencial para ajustar y resultar en una operación incorrecta del control.
(sólo) el evento bajo en el lado izquierdo de la escala
(que cambia el valor de presión del diferencial).
IMPORTANTE: Use los ajustes de control de presión
Desconexión de Presión Alta – Bloqueo del recomendados por el fabricante del equipo que va a ser
Restablecimiento Manual controlado. No exceda las clasificaciones de presión del
Los controles de Desconexión de Presión Alta con la equipo controlado ni de cualquiera de sus componentes al
opción de Bloqueo de Restablecimiento Manual tienen verificar la operación de control de la presión o al operar el
un placa de escala que despliega el punto de ajuste de equipo controlado.
desconexión. No existe ningún indicador para el punto
de ajuste de Conexión. (Ver la ecala visible en el
control.). Gire el tornillo de rango para cambiar el punto
de ajuste de Conexión en el lado derecho de la escala.
Los modelos de Bloqueo de Restablecimiento Manual

Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión 13
Paso 1. Establezca evento alto ajustado el tornillo de rango
derecha para incrementar el punto de DESCONEXION
Contr oles de Desconex ión de Presión Alta: Gire el tornillo hacia la izquierda
Contr oles de Ciclado del Albanico del Condensador: Gire el tornillo hacia la izquierda para disminuir el punto de DESCONEXION.
Indicador de Desconexión
Abre en Alta
(Controles de Desconexión Abierto-Alto
Tornillo de Rango Indicador del Punto de Conexión
(Controles de Ciclado del Abanico del
Condensador)

Botón de Restablecimiento Manual

Tornillo del Diferencial (Opción de Bloqueo de
Restablecimiento Manual no
disponible en todos los modelos.)

Escala de Presión Visible

Indicador de CONEXION (Controles de Desconexión

Abre en Alta Modelos de
Abierto-Alto. Tornillo de Tapa
Restabelcimiento Automático solamente)
Indicador de Diferencial (Controles de Ciclado del Abanico del Condensador)
Fuelle

derecha

derecha

Figura 8: Ajuste de Controles P70, P72 y P170 para Aplicaciones de Presión Alta
Operación de Restablecimiento Manual
IMPORTANTE: Después de montar y alambrar el Los controles de presión con la opción de Restablecimiento
control, instale un juego de medidores confiables al Manual se bloquean cuando se alcanzan la presión de
equipo controlado, y opere el equipo (por lo menos) Desconexión y deben restablecerse manualmente por el
tres ciclos bajo las presiones necesarias para verificar usuario para reiniciar el equipo controlado. El mecanismo
los puntos de ajuste del control y la operación del de restablecimiento manual de movimiento libre y no
equipo apropiada. puede restablecerse al bloquear o sujetar el botón de
restablecimiento.
En equipo con los controles bloqueados, determine y
resuelva la razón del bloqueo, y permita que la presión
detectada caiga por lo menos 70 psig más abajo del punto
de ajuste de Desconexión. Después, presione y suelte el
botón de restablecimiento que se localiza al frente del control
para restablecer la operación del equipo controlado.

14 Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión
Table 2: Modelos de Control Estándar P70, P72 y P170 para Aplicaciones de Presión Alta

Número del Acción del Rango Diferencial

Conexión de Presión
Modelo Interruptor psig (kPa) psi (kPa)

Modelos de Control de Ciclado del Abanico del Condensador (para Refrigerantes No Corrosivos)
100 a 400 psig Mínimo 35 (241)
P70AA-118
SPST (690 a 2758) Máximo 200 (1379)
Abre en baja Capilar de 36 pulg.
0 a 150 psig Mínimo 12 (83) con Tuerca Abocinada
P70AA-2
(0 a 1034) Máximo 70 (482) de 1/4 pulg.
DPST
P72AA-27
Abre en baja 100 a 400 psig Mínimo 35 (241)
SPST (690 a 2758) Máximo 200 (1379) Conector Abocinado
P170AA-118
Abre en baja Macho de 1/4 pulg.
Modelos de Control de Todo Rango (para Refrigerantes No Corrosivos)
Conector Abocinado
P70CA-2* Mínimo 60 (414)
SPST Macho de 1/4 pulg.
Máximo 150 (1034)
P70CA-3* Abre en Alta
P70DA-1*
4-Alambres,
2-Circuitos Restablecimiento
P70KA-1* Línea-M1 Cierra en Manual Capilar de 36 pulg.
Alta con Tuerca Abocinada
Línea-M2 Abre en de 1/4 pulg.
Alta

50 a 500 psig Mínimo 60 (414)

P72CA-2*
DPST (345 a 3448) Máximo 150 (1034)
Abre en Alta Restablecimiento
P72DA-1*
Manual
Mínimo 60 (414)
P170CA-3* SPST Máximo 150 (1034)
Abre en Alta
P170DA-1*
4-Alambres, Conector Abocinado
2-Circuitos Restablecimiento Macho de 1/4 pulg.
P170KA-1* Línea-M1 Cierra en Manual
Alta
Línea-M2 Abre en
Alta
Modelos Compatibles con Amoníaco
SPST 50 a 300 psig Mínimo 20 (138)
P70AA-119
Abre en Baja (345 a 2068) Máximo 120 (827)
Mínimo 60 (414) NPT Hembra de Acero
P70CA-5*
SPST 50 a 500 psig Máximo 150 (1034) Inoxidable de 1/4 pulg.
Abre en Alta (345 a 3448) Restablecimiento
P70DA-2*
Manual
* Modelos que son listados por UL como controles de límite de presión de refrigeración.
Nota: Ver Dimensiones y Especificaciones Técnicas para mayor información del modelo que incluye la Presión
Operacional Máxima y las clasificaciones de la Máxima Sobrepresión.

Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión 15
Clasificaciones Eléctricas

Tabla 3: Clasificaciones Eléctricas SPST (Modelos P70A, B, C, D, y P170A, B, C, D)

Clasificaciones
para Compresor
Clasificaciones de Motores Monofásicos Estándares
Hermético
Monofásico
120 VCA 208 VCA 240 VCA *480 VCA *600 VCA 208/240 VCA
Amperios del Motor con 20 18.7 17 5 4.8 20
Carga Completa
Amperios del Motor con 120 112.2 102 30 28.8 120
el Rotor Bloqueado

Amperios No 22 22 22 -- -- --
Inductivos

Servicio Piloto 125 VA de 120 de 600 VCA; 57.5 VA de 120 a 300 VCD
* No es para cargas de motores de compressores.

Tabla 4: Clasificaciones Eléctricas del Interruptor de Diferencial Estándar (Modelos P70E)

Clasificaciones de Motores Monofásicos Estándares

120 VCA 208 VCA 240 VCA 277 VCA*
Amperios del Motor con
16.0 9.2 8.0 7.0
Carga Completa
Amperios del Motor con el
96.0 55.2 48.0 42.0
Rotor Bloqueado
Amperios No Inductivos 16.0 16.0 16.0 16.0
125 VA de 24 hasta 600
Servicio Piloto 125 VA de 120 hasta 600 VCA
VCA
* Clasificaciones para modelos P70EC solamente

Tabla 5: Clasificaciones Eléctricas de 4 Alambres – 2 Circuitos (Modelos P70G, H, J, K, y P170K)

Clasificaciones de Motores Monofásicos Estándares

Línea-M2 (Contactos Principales) Línea-M1 (Contactos Auxiliares)
120 208 240 277 *480 *600 120 208 240 277
VCA VCA VCA VCA VCA VCA VCA VCA VCA VCA
Amperios del Motor
16.0 9.2 8.0 -- 5 4.8 6.0 3.3 3.0 --
con Carga Completa
Amperios del Motor
con el Rotor 96.0 55.2 48.0 -- 30 28.8 36.0 19.8 18.0 --
Bloqueado
Amperios No
16.0 9.2 8.0 7.2 -- -- 6.0 6.0 6.0 6.0
Inductivos
Servicio Piloto (para
ambos juegos de 125 VA de 24 a 600 VCA; 57.5 VA de 120 a 300 VCD
contactos
* No para cargas de motor de compresor

16 Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión
Tabla 6: Clasificaciones Eléctricas DPST (Modelos P72A, B, C y D)
Rangos del
Clasificaciones Estándares Compresor
Hermético
120 208 240 208 220 *480 *600 208 240
VCA VCA VCA VCA VCA VCA VCA VCA VCA
1Ø 1Ø 1Ø 3Ø 3Ø 1Ø 1Ø 1Ø 1Ø

Amperios del Motor con Carga

24 18.7 17 15.9 15 5 4.8 24 24
Completa
Amperios del Motor con el Rotor
144 112.2 102 95.4 90 30 28.8 144 144
Bloqueado
Amperios No Inductivos CA 24 24 24 24 24 -- -- -- --
Amperios No Inductivos CD 3 0.5 0.5 0.5 0.5 -- -- -- --
Servicio Piloto 125 VA de 120 a 600 VCA; 57.5 VA de 120 a 300 VCD
* No es para cargas del motor de compresor

Especificaciones Técnicas
Producto Controles P70, P72 y P170 para Aplicaciones de Alta Presión
Acción del Interruptor P70, P170: SPST; 4-Alambres/2-Circuitos; o Interruptor P72: DPST
SPDT PENN®
Conexión de Presión Modelos Estándares P70, Modelos Estándares Modelos Compatibles con
P72 disponibles con varias P170, conector macho Amoníaco 1/4 pulg. NPT
conexiones. abocinado de 1/4 pulg. conexión hembra de acero
SAE inoxidable
Máxima Presión para rango para rango para rango para rango 50-500
Operacional 0-150 psig: 150 psig 50-300 psig: 100-400 psig: psig: 500 psig (3448
(1034 kPa) 300 psig (2068 kPa) 400 psig (2758 kPa) kPa)
Máxima Sobrepresión para rango para rango para rango para rango 50-500
(non-recurrente) 0-150 psig: 50-300 psig: 100-400 psig: psig: 525 psig (3620
525 psig (3620 kPa) 400 psig (2758 kPa) 475 psig (3275 kPa) kPa)
Condiciones Tipos P70E y P70F: 50 a 104qF (10 a 40qC)
Ambientales Todos los Otros Modelos: -40 a 140qF (-40 a 60qC)
Caja y Tapa Caja NEMA 1: Caja de acero galvanizado; tapa de acero cromado y pintado.
Caja NEMA 3R: Caja y tapa de acero cromado y pintado.
Dimensiones Caja NEMA 1: 3-1/4 x 4 x 2-1/16 pulg. (83 x 101 x 53 mm)
(A x A x P) Caja NEMA 3R: 4-1/16 x 4-1/16 x 2-15/16 pulg. (104 x 104 x 74 mm)
Peso de Embarque Empaque Individual (NEMA 1): 2.4 lb (1.08 kg);
Aproximado Empaque Múltiple (NEMA 1, multiplos de 25 controls): 60 lb (27.2 kg)
Listados de Agencias Para información sobre modelos especificos, contacte al Grupo de Ingeniera de Aplicación
de Refrigeración a 1-800-275-5676.
Accesorios Soporte de Instalación Universal 271-51 (provisto con controles estándares)

Las especificaciones del desempeño son nominales y de acuerdo a estándares aceptables de la industria. Para aplicación en condiciones que
estén fuera de éstas especificaciones, contácte al Grupo de Ingeniería de Aplicación de Refrigeración al 1-800-275-5676. Johnson Controls, Inc.
no será responsable de daños que resulten de una aplicación incorrecta o un mal uso de su productos.

Controls Group
507 E. Michigan Street
P.O. Box 423 Publicado en EE.UU.
Milwaukee, WI 53201 www.johnsoncontrols.com

Instrucciones de Instalación de Controles de Series P70, P72, P170 para Aplicaciones de Alta Presión 17
Instruction Sheet B Series
PA-00266
June 2006 Balanced-Port Thermal Expansion Valves

Installation & Service Instructions

Safety Instructions Installation Instructions
Warning : Before opening any system, make sure the pressure 1. Warning: Before opening any system, make sure the pressure
in the system is brought to and remains at atmospheric pressure. in the system is brought to and remains at atmospheric pressure.
Use approved refrigerant recovery methods when necessary. Use approved refrigerant recovery methods when necessary.
Failure to comply can result in system damage and/or personal
injury. Failure to comply can result in system damage and/or personal
injury.

2. Valves may be installed in any position, but should be located

1, Read installation instructions thoroughly . Failure to follow
instructions may result in valve failure, system damage, or personal as close as possible to the distributor or evaporator inlet.
injury.

2. Do not use on service conditions or fluids not specifically

cataloged, without prior written approval of the Emerson Climate
Technologies Engineering Department. Use of Thermal valves on
applications not specifically cataloged can result in valve failure
and/or system damage.

3. Foreign matter in the Thermal valve may cause diaphragm

3. Protect against excessive vibration, it may cause a tubing break,
which will cause valve failure and/or personal injury failure, flooding, or starving of the valve. Use of an Emerson liquid
line filter-drier is strongly recommended.

4. On valves with solder connections, wrap wet cloths around

valve. Direct torch away from valve to avoid valve damage.
4. Valves are factory set to a specific superheat. If
adjustment is needed, refer to Superheat Adjustment
5. Do not exceed maximum working pressure of 450 psig. - excess section for proper procedure . Improper adjustment of
internal pressure could cause damage to diaphragm, resulting in superheat can result in system damage.
valve malfunction.

5. Proper valve sizing is important. An oversized valve may result

6. Do not exceed maximum working temperature (see Table 1) - in erratic control. An undersized valve considerably reduces
excess temperatures could cause internal damage, resulting in system capacity.
valve malfunction.

6. Be sure valve is installed with its

flow arrow corresponding to the flow
direction thru the piping.

www.emersonflowcontrols.com

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
 page 2

Instruction Sheet B Series

PA-00266
June 2006 Balanced-Port Thermal Expansion Valves

Installation & Service Instructions

7. For BA(E)S, BN(E)S Valves, remove strainer nut and strainer 11. Connect one end of the external equalizer line to the valve.
before brazing. Replace strainer nut. Connect the other end to the suction line slightly downstream from the
remote bulb location and positioned so that it cannot siphon oil from
the suction line.

12. Check for leaks, sufficient system refrigerant charge, and be sure
no flash gas is present before attempting to check valve operation.

13. The expansion valve must be free of all contaminants - install an

Emerson Climate Technologies liquid line filter-drier before the valve.
NOTE:For improve the quality of our valve, we use a neopreon Oring
in the strainer nut, the brazing heat would produce extreme damage
in the piece. Measuring Superheat
1. Determine the suction pressure with an accurate gauge at the
8. Installing connections to valve. an valves evaporator outlet.
with solder connections, wrap wet cloths
around valve. to prevent valve damage
while brazing. Direct torch away from
valve.

9. To replace strainer, remove strainer nut and install new strainer.

Replace nut and torque nut to 50 inch pounds.

10. Attach the remote bulb to the suction line as close to the
evaporator outlet as possible. Position the bulb at the 4 or 8 o’clock
position. Clean surface of suction line where the remote bulb is
to be attached, then securely fasten the bulb with straps provided.
If the remote bulb can be affected by the surrounding ambient, then
the bulb should be insulated with a material that will not absorb water.
On self-contained systems, the suction pressure may be read at the
compressor suction connection

2. From refrigerant pressure-temperature tables, determine saturation

temperature at observed suction pressure (TEMP p).

3. Measure temperature of suction gas at Thermo Valve remote bulb

location (TEMPT).

4. Subtract saturation temperature (read from tables in step 2) from

temperature measured in step 3, the difference is the superheat of
the suction gas.

www.emersonflowcontrols.com

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
 page 3

Instruction Sheet B Series

PA-00266
June 2006 Balanced-Port Thermal Expansion Valves

Installation & Service Instructions

Superheat Adjusment Dimesional Data

Emerson’s Thermal valves are factory set to a specific superheat -

however, the superheat should be adjusted for the application. To
adjust the valve to other superheat settings:

1. Remove the seal cap from bottom of valve.

2. Turn the adjustment screw clockwise to increase superheat and

counterclockwise to decrease superheat.
One complete 360* turn changes the
superheat approximately 3-4°F, regardless
of the refrigerant type. As much as 30
minutes may be required for the system to
stabilize after the adjustment is made.

3. Replace and hand-tighten seal cap.

Caution: There are 10 turns on the adjustment stem. When adjusting

superheat setting - when stop is reached, any further
turning adjustment will damage valve.

Nomenclature Selection

www.emersonflowcontrols.com

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
 page 4

Instruction Sheet B Series

PA-00266
June 2006 Balanced-Port Thermal Expansion Valves

Installation & Service Instructions

Dimesional Data Application & Operation

The BA(E) valve is currently replacing conventional TXV’s on air

conditioning and refrigeration systems with any combination of the
following system operating conditions:

1. Widely varying evaporator loads

2. Widely varying head pressures

3. Widely varying pressure drop available

across the thermostatic expansion valve and
refrigerant distributor

4. Fluctuating or extremely low liquid temps.

Severe conditions are those which drastically increase a conventional

expansion valve’s maximum capacity: high head pressures for
example, also, low liquid temperatures that would be experienced on
a system with mechanical sub coolers during summer operation.
BA(E) high system performance is possible because the large
diaphragm allows the valve to operate with the valve pin controlling
very close to the seat. This provides, stable control at minimum
changes in stroke, enabling a large port to handle small loads.

Problems can occur with refrigeration systems during both high and
low ambient conditions when the condensing temperature is allowed
to follow the ambient. As the evaporator temperature remains
reasonably constant, this results in extreme pressure drop changes
across the valve. These pressure drop changes can result in a
conventional valve not maintaining a constant superheat at the
evaporator outlet. These superheat changes can result in the
evaporator starving in low ambient conditions and flooding in the
higher ambient, depending on the valve design. Another variable
factor for this situation is how low the head pressure is allowed to
decrease. This of course depends on whether heat reclaim is utilized
for heating purposes, or if hot gas will be used for evaporator defrost.

Emerson’s BA(E) Thermal Expansion Valves are

designed to meet the specific demands of refrigerated
display cases, reach-in & walk-in coolers and freezers,
and commercial applications ranging from medium
(+50°F)to low(-50°F) temperature, with proper charge.

www.emersonflowcontrols.com

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
Instruction Sheet
PA-00260
June 2007 TRAE+ Balanced Port Thermal Expansion Valve Cage

TRAE+ Balanced Port Thermal Expansion Valve Cage

SAFETY INSTRUCTIONS CAGE REPLACEMENT INSTRUCTIONS
Warning: Before opening any system, make sure the 1. Before removing superheat adjustment assembly,
pressure in the system is brought to and remains at make sure system is at atmospheric pressure using
atmospheric pressure. Use approved refrigerant recovery EPA approved methods. Failure to comply can result
methods when necessary. Failure to comply can result in in system damage or personal injury.
system damage and/or personal injury. 2. Remove superheat adjustment assembly, superheat
1. Read installation instructions thoroughly. Failure to spring and spring guide. Care must be taken not to
follow instructions may result in valve failure, system damage threads or surface area.
damage, or personal injury. 3. Remove spool and stem assembly.
2. Do not use on service conditions or fluids not 4. Using KT20294 toll provided, remove seat turning in a
specifically cataloged, without prior written approval counter clockwise direction.
of the Emerson Climate Technologies Flow Controls 5. Remove spool and stem assembly from new cage
Division Applications Engineering Department. Use of before installing seat in valve.
thermal expansion valves on applications not 6. Before installing seat, ensure there is no foreign
specifically cataloged can result in valve failure and/ material inside valve or on seat.
or system damage. 7. Lightly oil all seals with same type oil that is in
3. Protect against excessive vibration. If may cause a system.
tubing break which will cause valve failure and/or 8. Carefully install seat taking care not to damage seals
personal injury. or threads. Torque cage 60 to 64 inch pounds.
4. Do not exceed maximum working pressure of 450 9. Reinstall spool and stem assembly.
psig - excess internal pressure could cause damage 10. Reassemble spring guide superheat spring and
to diaphragm, resulting in valve malfunction. adjustment assembly. Torque assembly 400 to 425
5. Do not exceed maximum working temperature (see inch pounds.
table 1) - excess temperature could cause internal 11. Before restarting system, turn adjustment stem
damage, resulting in valve malfunction. counter clockwise until it stops. Then turn clockwise 6
6. Warning: Do not place open flame on or near remote full turns. This will be close to factory superheat
bulb. setting.
NOMINAL CAPACITIES 12. Leak check valve.
R-134a R-22/R-407C R-507/R-404A 13. Adjust superheat to manufacturers’ recommenda-
Valve Type Valve Type Valve Type Cage Kit tions.
TRAE9M* TRAE10H* TRAE8* KT20289
TRAE13M TRAE15H TRAE12 KT20290 POWER ELEMENT
TRAE14M TRAE20H TRAE14 KT20291
TRAE22M TRAE30H TRAE20 KT20292
TRAE30M TRAE40H TRAE30 KT20293
* Select correct charge code. SEAT (K)
Cage Wrench KR20294
Kit Includes:
• Cage SPOOL AND
• Cage Wrench STEM
• Instruction Sheet
TABLE 1 SPRING GUIDE
Maximum Dehydration Temperature °F SPRING
THERMOSTATIC CHARGE ADJUSTING STEM
REFRIGERANT C Z WMOP/CA ASSEMBLY
R12 190 250 250
SPOOL AND STEM ASSEMBLY SEAT
R22 160 185 250
R502 150 170 250
This Table refers to the maximum dehydration
temperatures when the bulb and valve body are
subjected to the same temperature. On L, C, and Z
charges, 250°F maximum valve body temperature is
permissible (if the bulb temperature) does not
exceed those shown in the table.

www.emersonflowcontrols.com

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
 REPLACEMENT PARTS
Part # Description
X-28458 Power Assembly
KT20294 Cage Removal Tool
27676-1 Seal Cap

MEASURING SUPERHEAT SUPERHEAT ADJUSTMENT

1. Determine the suction pressure with an accurate gauge Emerson thermal expansion valves are factory set to a
at the evaporator outlet (see P in figure 2). On self- specific superheat - however, the superheat should be
contained systems, the suction pressure may be read at adjusted for the application. To adjust the valve to other
the compressor suction connections. superheat settings:
2. From refrigerant pressure-temperature tables, determine 1. Remove the seal cap from bottom of valve.
saturation temperature at observed suction pressure 2. Turn the adjustment screw clockwise to increase
(TEMPP). superheat and counterclockwise to decrease superheat.
3. Measure temperature of suction gas at thermal expan- One complete 360° turn changes the superheat approxi-
sion valve remove bulb location (TEMPT). mately 3-4°F, regardless of the refrigerant type. As
4. Subtract saturation temperature (read from tables in step much as 30 minutes may be required for the system to
2) from temperature measured in step 3; the difference stabilize after the adjustment is made.
is the superheat of the suction gas. 3. Replace and hand-tighten seal cap.
Caution: There are 12 turns on the adjustment stem. When
adjusting superheat setting - when stop is reached, any
further turning adjustment will damage valve.

TEMPT – TEMPP = SUPERHEAT

40° – 33° = 7°
EXTERNAL EQUALIZER

69 PSIG = 40°F

T P
40°F 59 PSIG

59 PSIG = 33°F

59 PSIG = 40°F

FIGURE 2
 TX6
Thermo Expansion Valves
Technical Data

ALCO’s TX6 series of Thermo-Expansion Valves are

designed for air conditioning, chillers, rooftops, close control,
A/C transportation, heat pumps, industrial cooling process and
refrigeration applications. The TX6 is ideal for those
applications requiring hermetic / compact size combined with
stable and accurate control over wide load and evaporating
temperature ranges.

Features
• Balance port construction for constant superheat
operation over a wide application range under variation
of condensing pressure
• Six sizes up to 97 kW (R410A)
• Compact size
• Hermetic design

• Brazing connections with straight through configuration

• Long life laser welded stainless steel power element
resists corrosion TX6
• Large diaphragm eliminates disturbances to the valve
and provides smoother and consistent valve control
• Tailored charges for different applications

• External equalizer
• External superheat adjustment
• Brass body

Introduction Construction
Thermo-Expansion Valves control the superheat of refrigerant The valve body is made from brass, the connections are in a
vapour at the outlet of the evaporator. They act as a throttle straight through configuration. The diaphragm movement is
device between the high and low pressure sides of refrigeration transferred to a steel metering pin. When the charge pressure
system and ensure the rate of refrigerant flow into the increases, the diaphragm will be deflected downward and this
evaporator exactly matches the rate of evaporation of liquid motion will be transferred to the pin. The pin will then lift from
refrigerant. Thus the evaporator is fully utilized and no liquid seat and the liquid can pass through orifice.
refrigerant may reach the compressor. The pin design gives the balance port feature. Balance port
When the actual superheat is higher than the setpoint, thermo design will eliminate the undesirable variable influence of inlet
expansion valve feeds the evaporator with more liquid pressure i.e. condensing pressure during different air ambient
refrigerant. Likewise, the valve decreases the refrigerant flow to temperature in systems with aircooled condenser.
the evaporator when the actual superheat is lower than the set The balance port design is only available in one direction as
point. arrow indicates on the valve. This means, when the valve
operates as Bi-flow in heat pump applications, the advantage of
balance port is given in cooling or heating mode.
A spring opposes the force underneath the pin and its tension
can be adjusted by the external stem. The static superheat can
be adjusted by rotation of the stem. Static superheat increases
by turning the stem clockwise and decreased by turning the
stem counter clockwise.

TX6__35011_EN_R06.doc 1 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Description of bulb charges

The application ranges of Thermo expansion valves are Performance of TXV with MOP function, gas charge
heavily influenced by the selected charge.
Static superheat
Liquid charges
The behaviour of Thermo-Expansion Valves with liquid MOP
charges is exclusively determined by temperature changes at
the bulb and not subject to any cross-ambient interference.
Working range
They feature a fast
response time and thus react quickly in the control circuit. Evaporating
Liquid charges cannot incorporate MOP functions. The temperature/
maximum bulb temperatures is limited and shall not exceed the pressure
values, shown in the following table:
Valve operates as superheat control in normal working range
Table 1: and operates as pressure regulator within MOP range.
Refrigerant/Charge Maximum bulb temperature
R 134a / M0 88°C Practical hints:
R 407C / N0 71°C Superheat adjustments influence the MOP:
R 22 / H0 71°C • Increase of superheat: decrease of MOP
• Decrease of superheat: increase of MOP
Gas charges
The behaviour of Thermo-Expansion Valves with gas charges
will be determined by the lowest temperature at any part of the
expansion valve (power assembly, capillary tube or bulb). If any
parts other than the bulb are subject to the lowest temperature,
malfunction of the expansion valve may occur (i.e. erratic low
pressure or excessive superheat). ALCO TX6 with gas charges
always feature MOP functions and include ballasted bulbs.
Ballast in the bulb leads to slow opening and fast closure of the
valve. Maximum bulb temperature is 120°C.

MOP (Maximum Operating Pressure)

MOP functionality is somewhat similar to the application of a
crankcase pressure regulator.
Evaporator pressures are limited to a maximum value to protect
compressor from overload conditions.
MOP selection should be within maximum allowed low pressure
rating of the compressor and should be at approximately 3 K
above maximum evaporating temperature.
Table 2: MOP value, gas charge
MOP Upper limit of evaporating temperature
°C
Code bar °C R407C R22 R 410A R134a
N1 6.9 +17 +14 - - -
H1 6.9 +15 - +12 - -
M1 3.8 +14 - - - +10
Z1 12.1 +16 +14
Note: All pressures are gauge pressure

TX6__35011_EN_R06.doc 2 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Heat pump applications

There are several ways to apply an expansion valve in a heat pump. The following figures are showing the most popular
applications:
1) System with two expansion valves, single Bi-flow filter 3) System with single Bi-flow expansion Valve and Alco
dryer and two check valves suction filter dryer ASD
Four way valve
Four way valve
Outdoor
Outdoor coil
coil

Check valve
BFK
Bi-flow ASD
TX6
Compressor
Compressor

Accumulator Accumulator
Indoor coil Indoor coil

Check valve
Bi-flow application
This type of system employs two expansion valves and two For application of TX6 in Bi-flow as single TXV in heat pumps,
check valves. In this type of application, it is recommended the following subjects need to be considered:
to locate the external equalizer and bulb on the suction line
between reversing valve and suction accumulator (if • TX6 is balance port only in normal flow direction but not in
available) or compressor as shown. reverse flow direction
2) System with single Bi-flow expansion Valve and Alco Bi- • Inlet pressure in reverse flow act on valve pin as closing
flow filter dryer(s) BFK force. This effect is more significant at higher inlet
Four way valve
pressure and lower evaporating temperature
Outdoor
coil •
This effect will prevent the valve from desired opening
percentage in reverse flow dependant to port size of valve,
BFK inlet pressure and evaporating temperature
Bi-flow Based on the above facts, it is necessary to evaluate the
selection of TX6 in Bi-flow application. The following curves and
table are as guidance for proper selection of TX6 in BI-flow
TX6 application.
Compressor

Accumulator
Indoor coil

TX6-N02, Static superheat shifting TX6-N07, Static superheat shifting

Inlet pressure: 8 bar Inlet pressure: 8 bar
8 20

Normal flow Normal flow

16
6 Reverse flow Reverse flow

12
SS, K

SS, K

4
8
2
4

0 0
-30 -25 -20 -15 -10 -5 0 5 10 15 -30 -25 -20 -15 -10 -5 0 5 10 15
To, °C To, °C

TX6__35011_EN_R06.doc 3 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Size of valve Condition in reverse flow Impact on operation of Application of Consideration for
valve valve in Bi-flow performance improvement
High or low operating inlet Negligible
Small port size pressure
(TX6-..2 /..3) High evaporating Negligible Recommended None
temperature
Low evaporating Slightly increase of
temperature superheat
High or low operating inlet Increase of superheat This needs to be - Lower system capacity in
Large port size pressure evaluated * reverse vs. normal flow
(TX6-..4 /..5 /..6 /..7) Higher evaporating Increase of superheat This needs to be - Reduction of compressor
temperature evaluated * capacity
- Oversized valve
Lower evaporating Significant increase of Not
temperature superheat recommended No solution
*) During system design and prototype unit test.

Other Subjects to be considered in Bi-flow applications:

• In an air to water (liquid) systems, it may require a receiver • It is possible to install several Bi-flow filter dryers in
in order to hold excessive refrigerant in one mode of parallel in system with larger capacity
operation
• It is important to provide proper refrigerant distribution
• Do not install the Bulb of TXV between accumulator and through liquid distributor at the inlet of evaporator due to
compressor distance between TXV and distributor

Static superheat setting

The factory setting of a TX6 is made with the valve pin just Capacity
starting to move away from the seat. The superheat increment
necessary to get the pin ready to move is called static Qr = Reserve capacity
superheat (SS). An increase of superheat over and beyond the Qmax.
static superheat (factory setting) is necessary for the valve pin
Qr
to open to its rated capacity. This additional superheat is known
as gradient or opening superheat (OS). Qn
The working superheat (WS), which can be measured in the
field, is the sum of static superheat and opening superheat.
The opening superheat of TXV varies if the selected valve
operates at higher or lower capacities than the rated capacity. It
is highly recommended to select the valve according to the
rated capacity. Using reserve capacity leads to larger opening Superheat (K)
superheat and longer pull down time during start-up or after
defrost. SS OS
Selecting a larger valve than required in a system may lead to
smaller opening superheat and/or hunting of TXV.
WS

Qr ≈ 15% for TX6-..2/3/4/5/6

Qr ≈ 10% for TX6-..7

TX6__35011_EN_R06.doc 4 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Standard superheat setting

Charge Refrigerant/ Refrigerant Setting Given
charge code
Bulb temperature Nominal static Nominal opening
superheat (SS) superheat (OS*)
M0 R 134a
Liquid (no MOP) N0 R 407C
H0 R 22
MOP 3.8 bar M1 R 134a 0°C 3.3 K 3K
MOP 6.9 bar N1 R 407C
H1 R 22
MOP 12.1 bar Z1 R 410A
*) The given opening superheats valid when the capacity of selected valve is equal to the capacity of system at
design / operating conditions. Note : All pressures are gauge pressure.

Nomenclature and identification

TX6 - N 1 7

Valve series
Refrigerant
N: R407C
H: R22
M: R134a
Z: R410A
Charge
0: Liquid
1: Gas MOP (see table 2, page 2)
Capacity size
2, 3, 4, 5, 6, 7 (see page 6 and 7)

TX6__35011_EN_R06.doc 5 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Selection table
Refrigerant Nominal capacity Qn Without MOP With MOP *) Connection size
kW Type PCN Type PCN Equalizer Inlet x Outlet
14.4 TX6-N02 801 651 TX6-N12 801 655 Ext. 1/4" 12mm x 16mm
14.4 TX6-N02 801 653 TX6-N12 801 534 Ext. 1/4" 1/2" x 5/8"
25.6 TX6-N03 801 652 TX6-N13 801 656 Ext. 1/4" 12mm x 16mm
25.6 TX6-N03 801 654 TX6-N13 801 535 Ext. 1/4" 1/2" x 5/8"
35.7 TX6-N04 801 659 TX6-N14 801 667 Ext. 1/4" 16mm x 22mm
35.7 TX6-N04 801 663 TX6-N14 801 536 Ext. 1/4" 5/8" x 7/8"
R 407C 45.2 TX6-N05 801 660 TX6-N15 801 668 Ext. 1/4" 16mm x 22mm
45.2 TX6-N05 801 664 TX6-N15 801 537 Ext. 1/4" 5/8" x 7/8"
66.9 TX6-N06 801 661 TX6-N16 801 669 Ext. 1/4" 22mm x 28mm
66.9 TX6-N06 801 665 TX6-N16 801 538 Ext. 1/4" 7/8" x 1-1/8"
87.3 TX6-N07 801 662 TX6-N17 801 670 Ext. 1/4" 22mm x 28mm
87.3 TX6-N07 801 666 TX6-N17 801 539 Ext. 1/4" 7/8" x 1-1/8"
13.3 TX6-H02 801 551 TX6-H12 801 555 Ext. 1/4" 12mm x 16mm
13.3 TX6-H02 801 549 TX6-H12 801 553 Ext. 1/4" 1/2" x 5/8"
23.7 TX6-H03 801 552 TX6-H13 801 556 Ext. 1/4" 12mm x 16mm
23.7 TX6-H03 801 550 TX6-H13 801 554 Ext. 1/4" 1/2" x 5/8"
33.0 TX6-H04 801 585 TX6-H14 801 593 Ext. 1/4" 16mm x 22mm
R 22 33.0 TX6-H04 801 581 TX6-H14 801 589 Ext. 1/4" 5/8" x 7/8"
41.8 TX6-H05 801 586 TX6-H15 801 594 Ext. 1/4" 16mm x 22mm
41.8 TX6-H05 801 582 TX6-H15 801 590 Ext. 1/4" 5/8" x 7/8"
61.9 TX6-H06 801 587 TX6-H16 801 595 Ext. 1/4" 22mm x 28mm
61.9 TX6-H06 801 583 TX6-H16 801 591 Ext. 1/4" 7/8" x 1-1/8"
80.8 TX6-H07 801 588 TX6-H17 801 596 Ext. 1/4" 22mm x 28mm
80.8 TX6-H07 801 584 TX6-H17 801 592 Ext. 1/4" 7/8" x 1-1/8"
10.3 TX6-M02 801 543 TX6-M12 801 547 Ext. 1/4" 12mm x 16mm
10.3 TX6-M02 801 541 TX6-M12 801 545 Ext. 1/4" 1/2" x 5/8"
18.4 TX6-M03 801 544 TX6-M13 801 548 Ext. 1/4" 12mm x 16mm
18.4 TX6-M03 801 542 TX6-M13 801 546 Ext. 1/4" 1/2" x 5/8"
25.6 TX6-M04 801 569 TX6-M14 801 577 Ext. 1/4" 16mm x 22mm
R 134a 25.6 TX6-M04 801 565 TX6-M14 801 573 Ext. 1/4" 5/8" x 7/8"
32.5 TX6-M05 801 570 TX6-M15 801 578 Ext. 1/4" 16mm x 22mm
32.5 TX6-M05 801 566 TX6-M15 801 574 Ext. 1/4" 5/8" x 7/8"
48.1 TX6-M06 801 571 TX6-M16 801 579 Ext. 1/4" 22mm x 28mm
48.1 TX6-M06 801 567 TX6-M16 801 575 Ext. 1/4" 7/8" x 1-1/8"
62.8 TX6-M07 801 572 TX6-M17 801 580 Ext. 1/4" 22mm x 28mm
62.8 TX6-M07 801 568 TX6-M17 801 576 Ext. 1/4" 7/8" x 1-1/8"
16.0 TX6-Z12 801 510 Ext. 1/4" 12mm x 16mm
16.0 TX6-Z12 801 511 Ext. 1/4" 1/2" x 5/8"
28.0 TX6-Z13 801 512 Ext. 1/4" 12mm x 16mm
28.0 TX6-Z13 801 513 Ext. 1/4" 1/2" x 5/8"
40.0 TX6-Z14 801 514 Ext. 1/4" 16mm x 22mm
R 410A 40.0 TX6-Z14 801 515 Ext. 1/4" 5/8" x 7/8"
50.0 TX6-Z15 801 516 Ext. 1/4" 16mm x 22mm
50.0 TX6-Z15 801 517 Ext. 1/4" 5/8" x 7/8"
74.0 TX6-Z16 801 518 Ext. 1/4" 22mm x 28mm
74.0 TX6-Z16 801 519 Ext. 1/4" 7/8" x 1-1/8"
97.0 TX6-Z17 801 520 Ext. 1/4" 22mm x 28mm
97.0 TX6-Z17 801 521 Ext. 1/4" 7/8" x 1-1/8"
Nominal capacities at +38°C saturated condensing temperature, +4°C saturated evaporating temperature and 1 K subcooling at the inlet of the
expansion valve. Valve selection for other operating conditions see pages 7 to 11.
*) See table 2 on page 2 for MOP values.

TX6__35011_EN_R06.doc 6 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Dimensioning of Thermo-Expansion Valves

To apply proper Thermo-Expansion Valves on a system the
following design conditions must be available:
• Cooling capacity Q0
• Effective pressure differential across TXV ∆p
• Evaporating temperature / pressure
• Lowest possible condensing temperature / pressure
• Liquid temperature at the inlet of TXV
• Refrigerant type

To facilate valve dimensioning for other than the standard

conditions ALCO offers an Excel based Selection Tool. This
can be ordered from all Copeland sales offices. See
www.eCopeland.com for contact addresses, email or phone
numbers.

Otherwise the following formula has to be used:

Cooling capacity x K∆p x Kt = Nominal capacity of TXV

• Select Kt-factor according to refrigerant. liquid and

evaporating temperature from tables on pages 9-11.
• Determine effective pressure differential across the
Thermo-Expansion Valve using condensing pressure.
subtract evaporating pressure and all other possible
pressure losses. Select K∆p-factor from tables
on pages 11 … 12.

Example 1
A valve has to be selected for the following conditions:

Refrigerant R 22
System cooling capacity 45 kW
Evaporating temperature +5°C
Lowest condensing temperature +30°C
Liquid temperature +25°C
Valve without MOP

Calculation:
1. Theoretical pressure differential: 4. Correction factors:
Lowest condensing pressure is Pc = 11.9 bara at +30°C and Correction factor K∆p for the pressure differential 4.5 bar
evaporating pressure is P0 = 5.8 bara at +5°C from table on page 9 for R 22
Differential pressure is Pc - P0 = 11.9 – 5.9 = 6 bar ∆p = 4.5 K∆p = 1.42
2. Pressure losses: Correction factor Kt for liquid and evaporating temperature
Across distributor = 1.0 bar from table on page 9 for R 22 at +25°C / 5°C
Others in piping. solenoid valve. drier. sight glass. fitting. Kt = 0.89
etc. = 0.5 bar 5. Calculation of nominal capacity Q0 x K∆p x Kt = Qn
Total pressure losses = 1 + 0.5 = 1.5 45 x 1.42 x 0.89 = 56.9 kW.
3. Effective pressure differential across valve: You can select the valve from table on page 6.
6.0 – 1.5 = 4.5 bar
It is a TX6-H06 with a nominal capacity of 61.9 kW.

TX6__35011_EN_R06.doc 7 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Dimensioning of Thermo-Expansion Valves for Example 2:

systems with refrigerant R 407C System cooling capacity (R407C) 55 kW
As opposed to single substances (e.g. R 22. R 134a etc.) where Evaporating temperature (dew point) +5°C
the phase change takes place at a constant temperature / Lowest condensing temperature (bubble) +30°C
pressure. the evaporation and condensation of zeotropic blend Liquid temperature +25°C
R407C is in a “gliding” form (e.g. at a constant pressure the
Valve without MOP
temperature varies within a certain range) through evaporators
and condensers. Calculation:
The condensing / evaporating pressure must be determined at 1. Theoretical pressure differential:
saturated temperatures (bubble / dew points) for dimensioning Differential pressure is Pc - P0 = 13.6 – 5.5 = 8.1 bar
of Thermo-Expansion Valves. 2. Pressure losses:
P Across distributor = 1 bar
R407C Others in piping, solenoid valve, drier, sight glass, fitting
(bar)
etc. = 0.6 bar
Total pressure losses = 1 + 0.6 = 1.6
35.5°C
13.6 3. Effective pressure differential across valve:
8.1 - 1.6 = 6.5 bar
30°C 4. Correction factors:
Correction factor K∆p for the pressure differential 9.39 bar
+5°
from table on page 9 for R 407C
C
5.5 ∆p = 6.5 bar K∆p = 1.31
-1°C Correction factor Kt for liquid and evaporating temperature
from table on page 9 for R 407C at +25°C / +5°C
h Kt = 0.85
5. Calculation of nominal capacity Q0 x K∆p x Kt = Qn
55 x 1.31 x 0.85 = 61.2

You can select the valve from table on page 6.

It is a TX6-N06 with a nominal capacity of 66.9 kW.

Dimensioning of Thermo-Expansion Valves for heat

pump applications
Example 3:
A heat pump with following design conditions:

Cooling mode Heating mode (Reverse flow)

Cooling capacity (R 22) 20 kW Heating capacity (R 22) 15 kW
Condensing temperature +45°C Condensing temperature +30°C
Evaporating temperature +5°C Evaporating temperature -10°C
Liquid temerature 45°C Liquid temperature +30°C
Valve without MOP

1. Theoretical pressure differential: 1. Theoretical pressure differential:

Differential pressure is Pc - P0 = 17.3 – 5.8 = 11.5 bar Differential pressure is Pc - P0 = 11.9 – 3.5 = 8.4 bar
2. Pressure losses: total pressure losses = 1.6 2. Pressure losses: total pressure losses = 1.6
3. Effective pressure differential across valve: 3. Effective pressure differential across valve:
11.5 – 1.6 = 9.9 bar 8.4 – 1.6 = 6.8 bar
4. Correction factors: 4. Correction factors:
∆p = 9.9 K∆p = 0.96 ∆p = 6.8 K∆p = 1.16
at +5°C and 45°C Kt = 1.07 at -10°C and 30°C Kt = 0.99
5. Calculation of nominal capacity Q0 x K∆p x Kt = Qn 5. Calculation of nominal capacity Q0 x K∆p x Kt = Qn
20 x 0.96 x 1.07 = 20.5 kW 15 x 1.42 x 0.89 = 17.2 kW.
You can select the valve from table on page 6
TX6-H03 has sufficient capacity in reverse flow for 17.2 kW.
It is a TX6-H03 with a nominal capacity of 23.7 kW.

TX6__35011_EN_R06.doc 8 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Liquid temperature Correction factor Kt Liquid temperature

entering valve R22 Evaporating temperature °C entering valve
°C +20 + 15 +10 +5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 °C
+ 60 1.24 1.25 1.26 1.28 1.30 1.31 1.38 1.58 1.84 2.16 2.56 3.04 3.55 4.23 + 60
+ 55 1.16 1.17 1.19 1.20 1.22 1.23 1.29 1.42 1.72 2.02 2.39 2.83 3.30 3.94 + 55
+ 50 1.10 1.11 1.12 1.13 1.15 1.16 1.21 1.39 1.62 1.89 2.24 2.66 3.10 3.68 + 50
+ 45 1.04 1.05 1.06 1.07 1.08 1.10 1.15 1.31 1.52 1.79 2.11 2.50 2.91 3.46 + 45
+ 40 0.99 1.00 1.01 1.02 1.03 1.04 1.09 1.24 1.45 1.69 2.00 2.37 2.75 3.27 + 40
+ 35 0.94 0.95 0.96 0.97 0.98 0.99 1.03 1.18 1.37 1.61 1.89 2.24 2.60 3.09 + 35
+ 30 0.90 0.91 0.92 0.93 0.94 0.95 0.99 1.13 1.31 1.55 1.83 2.13 2.47 2.93 + 30
+ 25 0.86 0.87 0.88 0.89 0.89 0.90 0.94 1.08 1.25 1.46 1.72 2.03 2.36 2.80 + 25
+ 20 0.83 0.83 0.84 0.85 0.86 0.87 0.90 1.03 1.19 1.40 1.64 1.94 2.25 2.66 + 20
+ 15 0.80 0.81 0.81 0.82 0.83 0.87 0.99 1.14 1.34 1.57 1.86 2.15 2.55 + 15
+ 10 0.78 0.78 0.79 0.80 0.83 0.95 1.10 1.28 1.51 1.78 2.06 2.44 + 10
+5 0.75 0.76 0.77 0.80 0.91 1.06 1.23 1.45 1.71 1.98 2.34 +5
0 0.73 0.74 0.77 0.88 1.02 1.19 1.39 1.65 1.90 2.25 0
-5 0.71 0.74 0.85 0.98 1.14 1.34 1.58 1.83 2.17 -5
- 10 0.72 0.82 0.95 1.10 1.30 1.53 1.77 2.09 - 10
Correction factor K∆p
∆p (bar) 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 8 9 ∆p (bar)
K∆p 4.25 3.00 2.46 2.13 1.90 1.74 1.61 1.50 1.42 1.35 1.28 1.23 1.18 1.14 1.06 1.00 K∆p
∆p (bar) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ∆p (bar)
K∆p 0.95 0.91 0.87 0.83 0.80 0.78 0.75 0.73 0.71 0.69 0.67 0.66 0.64 0.63 0.61 0.60 K∆p

Liquid temperature Correction factor Kt Liquid temperature

entering valve R407C Evaporating temperature °C entering valve
°C +20 +15 +10 +5 0 -5 -10 -15 -20 -25 °C
+ 55 1.23 1.26 1.28 1.31 1.34 1.37 1.40 1.63 1.98 2.42 + 55
+ 50 1.13 1.15 1.17 1.19 1.22 1.24 1.27 1.48 1.79 2.18 + 50
+ 45 1.05 1.06 1.08 1.10 1.12 1.14 1.17 1.35 1.64 2.00 + 45
+ 40 0.98 0.99 1.01 1.02 1.04 1.06 1.08 1.25 1.52 1.84 + 40
+ 35 0.92 0.93 0.94 0.96 0.98 0.99 1.01 1.17 1.41 1.71 + 35
+ 30 0.87 0.88 0.89 0.90 0.92 0.93 0.95 1.10 1.32 1.60 + 30
+ 25 0.82 0.83 0.84 0.85 0.87 0.88 0.90 1.03 1.25 1.51 + 25
+ 20 0.78 0.79 0.80 0.81 0.82 0.84 0.85 0.98 1.18 1.43 + 20
+ 15 0.75 0.76 0.77 0.78 0.80 0.81 0.93 1.12 1.35 + 15
+ 10 0.73 0.74 0.75 0.76 0.77 0.89 1.07 1.29 + 10
+5 0.71 0.72 0.73 0.74 0.85 1.02 1.23 +5
0 0.69 0.70 0.71 0.81 0.98 1.18 0
Correction factor K∆p
∆p (bar) 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 8 9 ∆p (bar)
K∆p 4.78 3.33 2.72 2.36 2.11 1.92 1.78 1.67 1.57 1.49 1.42 1.36 1.31 1.26 1.18 1.11 K∆p
∆p (bar) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ∆p (bar)
K∆p 1.05 1.01 0.96 0.92 0.89 0.86 0.83 0.81 0.79 0.76 0.75 0.73 0.71 0.70 0.68 0.67 K∆p

TX6__35011_EN_R06.doc 9 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Liquid temperature Correction factor Kt Liquid temperature

entering valve R134a Evaporating temperature °C entering valve
°C +20 + 15 +10 +5 0 -5 -10 -15 -20 -25 °C
+ 60 1.27 1.30 1.33 1.36 1.40 1.44 1.48 1.75 2.08 2.46 + 60
+ 55 1.18 1.21 1.23 1.26 1.29 1.33 1.36 1.60 1.90 2.25 + 55
+50 1.10 1.13 1.15 1.17 1.20 1.23 1.26 1.48 1.76 2.07 + 50
+ 45 1.04 1.06 1.08 1.10 1.12 1.15 1.17 1.38 1.63 1.92 + 45
+ 40 0.98 0.99 1.01 1.03 1.05 1.08 1.10 1.29 1.52 1.79 + 40
+ 35 0.92 0.94 0.96 0.97 0.99 1.01 1.03 1.21 1.43 1.68 + 35
+ 30 0.88 0.89 0.91 0.92 0.94 0.96 0.98 1.14 1.35 1.58 + 30
+ 25 0.83 0.85 0.86 0.87 0.89 0.91 0.92 1.08 1.27 1.49 + 25
+ 20 0.80 0.81 0.82 0.83 0.85 0.89 0.88 1.02 1.21 1.41 + 20
+ 15 0.77 0.78 0.79 0.81 0.82 0.84 0.97 1.15 1.34 + 15
+ 10 0.75 0.76 0.77 0.78 0.80 0.93 1.09 1.28 + 10
+5 0.73 0.74 0.75 0.76 0.89 1.04 1.22 +5
0 0.71 0.72 0.73 0.85 1.00 1.17 0
-5 0.69 0.70 0.82 0.96 1.12 -5
- 10 0.68 0.79 0.92 1.07 - 10
Correction factor K∆p
∆p (bar) 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8 ∆p (bar)
K∆p 3.50 2.48 2.02 1.75 1.57 1.43 1.32 1.24 1.17 1.11 1.06 1.01 0.97 0.94 0.90 0.88 K∆p
∆p (bar) 8.5 9 9.5 10 10.5 11 11.5 12 13 14 15 16 17 18 19 20 ∆p (bar)
K∆p 0.85 0.83 0.80 0.78 0.76 0.75 0.73 0.72 0.69 0.66 0.64 0.62 0.60 0.58 0.57 0.55 K∆p

Liquid temperature Correction factor Kt Liquid temperature

entering valve R410A Evaporating temperature °C entering valve
°C + 15 +10 +5 0 -5 -10 -15 -20 -25 -30 -35 -40 °C
+ 60 1,50 1,51 1,53 1,54 1,57 1,59 1,85 2,16 2,55 3,03 3,64 4,42 + 60
+ 55 1,32 1,33 1,35 1,36 1,38 1,40 1,62 1,89 2,23 2,65 3,17 3,84 + 55
+ 50 1,20 1,20 1,21 1,23 1,24 1,26 1,46 1,70 2,00 2,37 2,83 3,42 + 50
+ 45 1,09 1,10 1,11 1,12 1,13 1,15 1,33 1,55 1,82 2,15 2,57 3,10 + 45
+ 40 1,01 1,02 1,03 1,04 1,05 1,06 1,22 1,43 1,67 1,98 2,36 2,84 + 40
+ 35 0,94 0,95 0,96 0,97 0,98 0,99 1,14 1,32 1,55 1,83 2,18 2,63 + 35
+ 30 0,89 0,89 0,90 0,91 0,91 0,92 1,06 1,24 1,45 1,71 2,04 2,45 + 30
+ 25 0,84 0,84 0,85 0,85 0,86 0,87 1,00 1,16 1,36 1,61 1,91 2,30 + 25
+ 20 0,79 0,80 0,80 0,81 0,81 0,82 0,95 1,10 1,28 1,51 1,80 2,16 + 20
Correction factor K∆p
∆p (bar) 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 8 9 ∆p (bar)
K∆p 5,29 3,74 3,05 2,65 2,37 2,16 2,00 1,87 1,76 1,67 1,60 1,53 1,47 1,41 1,32 1,25 K∆p
∆p (bar) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 ∆p (bar)
K∆p 1,18 1,13 1,08 1,04 1,00 0,97 0,94 0,91 0,88 0,86 0,84 0,82 0,80 0,78 0,76 0,75 K∆p

TX6__35011_EN_R06.doc 10 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Technical data
Maximum working pressure CE-Marking
according to PED: Not required
TX6-H/M/N.. PS: 31 bar
TX6-Z12/13/14/15/16/17 PS: 42 bar
Compatibility CFC, HCFC, HFC. Mineral Seat leakage ≤ 1% nominal capacity
and POE lubricants.
Fluid group II Connection ODF copper
Medium temperature range TS -45 to 65°C Power element Laser welding, stainless steel
Charges CFC free Label Pin printing

Charge Refrigerant Recommended evaporating Maximum bulb temperature

temperature range
°C °C
N0 R 407C -25 to +20 71
H0 R 22 -45 to +20 71
M0 R 134a -25 to +30 88
N1. MOP 6.9 bar R 407C -25 to +14 120
H1. MOP 6.9 bar R 22 -45 to +12 120
M1. MOP 3.8 bar R 134a -25 to +10 120
Z1 MOP 12.1 bar R 410A -45 to +14 120

Shipping weight and pack quantity TX6

Pack quantity 12 pcs
Shipping weight 0.65 kg
(individual)

TX6__35011_EN_R06.doc 11 / 12 17.03.2008
 TX6
Thermo Expansion Valves

Dimensions
TX6-….2/3 TX6-….4/5/6/
127

127
102
A1
A2
111
B1
A1
B2
A2

B1

A3 B2
64
A3

B3 64
B3

64
64

Bulb size
Type A1 B1 A2 B2 A3 B3 Capillary tube Diameter Length
∅ mm ∅ mm ∅ mm mm mm mm
TX6-…2 1/2” & 12 mm 9 5/8” & 16 mm 13 1/4” & 6 mm
TX6-…3 1/2” & 12 mm 9 5/8” & 16 mm 13 1/4” & 6 mm
TX6-…4 5/8” & 16 mm 13 7/8” & 22 mm 19 1/4” & 6 mm 8 1500 13 89
TX6-…5 5/8” & 16 mm 13 7/8” & 22 mm 19 1/4” & 6 mm (R410A: (R410A:
TX6-…6 7/8” & 22 mm 19 1-1/8” & 28 mm 23 1/4” & 6 mm 19,2) 59)
TX6-…7 7/8” & 22 mm 19 1-1/8” & 28 mm 23 1/4” & 6 mm

ALCO CONTROLS is not to be held responsible for erroneous literature for use by persons having the appropriate technical knowledge and
regarding capacities, dimensions, applications, etc. stated herein. skills, at their own discretion and risk. Since conditions of use are
Products, specifications and data in this literature are subject to change outside of ALCO'S control we can not assume any liability for results
without notice. The information given herein is based on technical data obtained or damages occurred due to improper application.
and tests which ALCO CONTROLS believes to be reliable and which This document replaces all earlier versions.
are in compliance with technical knowledge of today. It is intended only

Phone.: Fax:
Emerson Electric GmbH & Co. OHG Benelux +31 (0)773 240 234 +31 (0)773 240 235
ALCO CONTROLS Denmark & Finland +32 (0)87 305 565 +49 24 08 929 568
Heerstraße 111 Eastern Europe, Turkey & Iran +32 (0)87 305 061 +32 (0)87 305 506
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Germany Deutschland, Österreich, Schweiz +49 (0)6109 6059 0 +49 (0)6109 6059 40
Italia +39 02 961 78 1 +39 02 961 78 888
Phone ...49-(0)7151-509-0 Middle East & Africa +97 148 832 828 +97 148 832 848
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Russia & Cis +7 495 981 9811 +7 495 981 9816
www.eCopeland.com/alcoliterature.cfm España & Portugal +34 93 4 123 752 +34 93 4 124 215
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UK & Ireland +44 (0)1 189 838 000 +44 (0)1 189 838 001

TX6__35011_EN_R06.doc 12 / 12 17.03.2008
Instruction Sheet
PA-00211
August 2007 ASC, ASC2, AM, AH, DM, EB, EM, MM, RM Coils

ASC, ASC2, AM, AH, DM, EB, EM, MM, RM Coils

GENERAL INSTALLATION 6. Dual Voltage Wiring Diagram
1. Verify selection of proper coil type, coil voltage and
120-240 V. COIL 240-480 V. COIL
frequency. This information appears on coil nametag. BLACK BLACK
BLACK 240V. BLACK 480V.
120V. YELLOW 240V. YELLOW
YELLOW YELLOW
Emerson Climate COIL RED
COIL COIL RED
COIL
RED RED
Technologies 120V. 240V. 240V. 480V.
BLUE BLUE BLUE BLUE

COIL TYPE AM
VOLTS 24
WATTS 7 HZ 50-60 INSTALLATION OF ASC OR ASC2 COILS
1. Install coil so that electrical connections are closer to
the top of the enclosing tube.
2. Use metal snap cap X-13740-1 and press on until you
2. Always disconnect electrical power source. hear it click into place.
3. Attach electric connector (DIN PLUG) onto coil and
tighten screw until snug.

INSTALLATION OF RM COILS
1. Install coil on top of the enclosing tube.
3. Install the coil on the enclosing tube of the valve. 2. Attach lockwasher and screw to top and secure tightly.

WARNING
A. Caution: Failure to attach ground wire to grounding lug
violates certain electrical codes and creates the
possibility of shock hazard.
B. Caution: Omission of conduit cover locking screw
violates certain electrical codes and could cause cover
to come off exposing "live" (energized) wires with
resulting possibility of fire hazard and/or personal
injury.
4. Coil may be rotated 360° for easy wiring. It is recom-
mended that coil lead connections be soldered on D.C. REMOVE
and 24V/50-60 HZ. 1. Verify selection of proper coil type, coil voltage and
frequency.
360° 2. Before removing coil from valve, always disconnect
electrical power source. Failure to do so will cause a
good coil to burn out and possible personal injury or
property damage.
3. Remove old coil.

5. Press firmly to ensure coil is secured.

Warning: To avoid any damage to the enclosing tube, use

your hands to secure the coil, do not use a hammer or
other kind of tool.

CLICK

www.emersonclimate.com/flowcontrols

11911 Adie Road P.O. Box 411400 St. Louis MO 63141 USA CUSTOMER SERVICE (314) 569-4666
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves
Technical Data

ALCO Controls EX4 / EX5 / EX6 / EX7 / EX8 are stepper motor
driven valves for precise control of refrigerant mass flow in air
conditioning, refrigeration, heat pumps, close control, and
industrial process cooling applications.
The Control Valves can be used as thermo-expansion duty,
liquid injection duty, hot gas bypass, evaporator pressure
regulator, crankcase pressure regulator, head pressure
regulator, or liquid level control.
This data sheet describes only the performance of the valves.
Operation of required controllers, driver boards and sensors EX4 / EX5 / EX6 (Uni-flow/Bi-flow)
are part of other documentations (see page 29).
Features
• Multifunction as expansion valves, hot gas bypass, suction
gas throttling, head pressure, liquid level actuator etc.
• Fully hermetic design (no thread joints between valve body
and motor compartment)
• Stepper motor driven
• Very fast full stroke time (1.5 sec. for EX4/5/6, 3.2 sec. for
EX7 and 5.2 sec. for EX8)
• High resolution and excellent repeatability EX7 (Uni-flow/Bi-flow)
• Bi-flow versions for heat pump applications
• Positive shut-off function to eliminate the use of an
additional solenoid valve
• Linear flow capacity
• Extremely wide capacity range (10 … 100%)
• Continuous modulation of mass flow, no stress (liquid
hammering) in the refrigeration circuit
• Direct coupling of motor and valve for high reliability (no
gear mechanism)
• Ceramic slide and port for accurate flow and minimal wear
• Balanced force design
• Corrosion resistant stainless steel body
• Europe patent No. 0743476, USA patent No. 5735501, EX8 (Uni-flow)
Japan patent No. 28225789
• Compatible with all CFCs, HCFCs and HFCs
Selection table
Type Part Code Flow pattern Capacity range Inlet connection Outlet connection Electrical
Nr. connection
EX4-I21 800 615 3/8” ODF 5/8” ODF
EX4-M21 800 616 10 mm ODF 16 mm ODF
EX5-U21 800 618 5/8” (16 mm) ODF 7/8” (22 mm) ODF
M12 plug
EX6-I21 800 620 7/8” ODF 1-1/8” ODF
Uni-flow
EX6-M21 800 621 22 mm ODF 28 mm ODF
EX7-I21 800 624 1-1/8” (28 mm) ODF 1-3/8” (35 mm) ODF
EX7-M21 800 625 10 … 100% 1-1/8” (28 mm) ODF 1-3/8” (35 mm) ODF
EX8-M21 801 964 42 mm ODF 42 mm ODF DIN Plug
EX8-U21 801 970 1-3/8” (35 mm) ODF 1-3/8” (35 mm) ODF DIN Plug
EX4-U31 800 617 5/8” (16 mm) ODF 5/8” (16 mm) ODF
EX5-U31 800 619 Bi-flow 7/8” (22 mm) ODF 7/8” (22 mm) ODF
EX6-I31 800 622 (Heat pump) 1-1/8” ODF 1-1/8” ODF M12 plug
EX6-M31 800 623 28 mm ODF 28 mm ODF
EX7-U31 800 626 1-3/8” (35 mm) ODF 1-3/8” (35 mm) ODF
EX4/5/6/7 is delivered without cable/connector assembly (order separately). EX8 is delivered with electrical DIN plug.

EX48_35008_EN_R07.doc 1 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Cable and connector assembly for EX4 / EX5 / EX6 /EX7

Type Part Code Temperature Length Connector type to Connector type to driver board Illustration
Nr. Range valve or controller
EX5-N15 804 650 1.5 m
EX5-N30 804 651 -25 … +80°C 3.0 m M12 Loose wires for EXD-S / -U / -C
and EC3-33x
EX5-N60 804 652 6.0 m
EX5-L60 804 655 -50 …+80°C 6.0 m M12, low temp.
EX5-C15 804 656 1.5 m
-25 … +80°C M12 Phoenix type, crimp connection
EX5-C30 804 657 3.0 m
for Alco EC3 controller
EX5-C60 804 658 6.0 m

Introduction Guidelines for selection of electrical control valves

Thermostatic expansion valves and mechanical regulator valves The following guideline should be taken in to the consideration
have been used in the refrigeration and air conditioning industry in order to obtain full advantages of ECV:
to control superheat and refrigerant mass flow since its very - Published capacities are maximum. There are no reserve
beginning. As today’s systems require improved energy capacities.
efficiency, tighter temperature control, wider range of operating - Larger size of valve leads to shorter pull down period and
conditions and incorporate new features like remote monitoring shorter travel time i.e. faster respond. For example, EX7
and diagnostics, the application of electronically operated has maximum 3.2 seconds travel time. The valve has
valves becomes mandatory. Only they offer the controls approximately 1.6 seconds travel time at 50% capacity
performance necessary to meet these needs. operation.
As more new refrigerants appear on the market requiring an
ever increasing number of different charges and settings for ALCO Selection Tool
thermostatic expansion valves, electrical control valves can For easy and quick selection of Electrical Control Valves an
solve this problem too. Excel based selection tool can be ordered from the ALCO sales
ALCO electrical control valves are the solution for the offices, or use the quick selection tables mentioned in this
challenges above. The latest technology and more than 80 datasheet.
years of experience in design and production of flow controls Example:
®
including Thermo expansion valves have been incorporated in System with R407C having two different operating conditions:
the design of the EX4, EX5, EX6, EX7 and EX8.
A) 110 kW capacity at +4°C/+50°C with two stages compressor
Construction at 50%/100% capacity
EX4/EX5/EX6/EX7/EX8 consist of two main internal B) 137 kW at +4°C/+30°C with two stages compressor at
assemblies, the valve and the stepper motor. The stepper motor 50%/100% capacity
is connected directly to the slide and cage assembly of the EX6 with 126 kW covers condition A, however is not sufficient
valve. Similar to the technology used in compressors, the motor to cover condition B. It is recommended to select the larger
is exposed to refrigerant and lubricant and the materials used valve EX7 which offers 337 kW at condition A and 293 kW at
are identical. The housing of the motor and valve assembly is condition B.
fully hermetic, utilising exclusively brazing and welding
technologies and eliminating all gaskets. Condition A:
This design offers several technical advantages. The motor is
110
direct coupled to the valve assembly for easy and reliable Full load ratio = = 33%
movement of the valve slide, no need for any other seals and 337
eliminating the use of bellows and diaphragms which could be (110 / 2)
subject to lifetime limitations and leaks. Partial load ratio = = 16%
337
Four electrical pins connect the motor to the outside. These Condition B:
pins are applied to the housing using melting-glass process
technology. The EX4/5/6/7 pins require a M12 electrical 137
Full load ratio = = 47%
connector. EX8 is supplied with DIN electrical plug. 293
The complete housing of the ECVs is made from stainless steel. (137 / 2)
EX8 is equipped with rotalock connections. Partial load ratio = = 23%
293
Unlike to mechanical expansion valves, EX4/5/6/7/8 are The capacity ratios of system to valve are in all conditions
equipped with ceramic slide port. higher than 10%. It is recommended to use EX7 rather EX6.
Features:
- Wide range regulation (10 … 100%) with one slide orifice
for each valve
- Linear characteristic over entire capacity range
- Positive shut-off

EX48_35008_EN_R07.doc 2 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

EX4/EX5/EX6/EX7/EX8 nominal and extended capacities as expansion valves and liquid injection valves
Nominal Capacities (10% … 100%), kW
Valve Type R 407C R 22 R 134a R 404A R 410A R 23 R 124 R 744
EX4 2 ... 17.4 2 ... 16.5 1 ... 12.8 1 ... 11.5 2 ... 19.3 2 ... 17.8 1 ... 9.2 3 ... 33.5
EX5 5 ... 53 5 ... 50 4 ... 39 4 ... 35 6 ... 58 5 ... 54 3 ... 28 10 ... 102
EX6 15 ... 126 15 ... 120 10 ... 93 10 ... 84 15 ... 140 13 ... 130 7 ... 67 24 ... 244
EX7 35 ... 347 35 ... 330 25 ... 255 25 ... 230 40 ... 385 - - 70 ... 670
EX8 100 ... 925 90 ... 880 70 ... 680 60 ... 613 100 ... 1027 - - 180 ... 1789
The nominal capacity (Qn) is based on the following conditions:
Refrigerant Evaporating temperature Condensing temperature Subcooling
R 22, R 134a, R 404A, R 410A +4°C +38°C 1K
R 407C +4°C dew point +38°C bubble / +43°C dew point 1K
R 124 +20°C +80°C 1K
R 23 -60°C -25°C 1K
R 744 -40°C -10°C 1K
Overview of working pressure regardless of applied refrigerant type
Valve type Flow pattern Maximum working pressure PS Factory test pressure PT
EX4, EX5, EX6, EX7 Uni-flow/Bi-flow 45 bar 49.5 bar
EX8 Uni-flow 35 bar 38.5 bar

Capacity Diagrams (kW)

35
34
R744 (33.5 kW)
30 R410A (19.3 kW) EX4
R23 (17,8 kW)
25 R407C (17.4 kW)
R22 (16.5 kW)
20 19
R134a (12.8 kW)
Qn, kW

18
R404A (11.5 kW) 17
15 17
R124 (9.2 kW)
13
12
10
9

0 00
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Number of Steps

110
R744 (102 kW) 102
EX5
100
R410A (58 kW)
90
R23 (54 kW)
80
R407C (53 kW)
70 R22 (50 kW)
R134a (39 kW) 58
Qn, kW

60 53
R404A (35 kW) 54
50 50
R124 (28 kW)
40 39
35
30 28
20
10
0 00
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750

Number of Steps

EX48_35008_EN_R07.doc 3 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

250 244
R744 (244 kW)
R410A (140 kW)
200 R23 (130 kW) EX6
R407C (126 kW)
150 R22 (120 kW) 140
130
Qn, kW

R134a (93 kW) 126

120
R404A (84 kW)
100
R124 (67 kW) 93
84
67
50

0 0
0 50 100 150 200 250 300 350 400 450 500 550 600 650 700 750
Number of Steps

700
670
600 R744 (670 kW)
R410A (385 kW)
EX7
500 R407C (347 kW)
R22 (330 kW)
400 385
R134a (255 kW)
Qn, kW

347
R404A (230 kW) 330
300
255
230
200

100

0 0
0 200 400 600 800 1000 1200 1400 1600
Number of Steps

1200
1100
1000 R410A (1027 kW)
R407C (925 kW)
EX8 1027
925
900 880
800 R22 (880 kW)
700 R134a (680 kW) 680
Qn, kW

600 R404A (613 kW) 613

500
400
300
200
100
0 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600

Number of Steps

EX48_35008_EN_R07.doc 4 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing Extended capacity kW Valve
temperature R 410A Evaporating temperature °C Type
°C 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
17 17 18 18 18 18 18 18 18 18 17 17 17 EX4
51 52 53 54 54 54 54 54 53 53 52 51 50 EX5
60 123 126 129 130 131 131 131 130 129 127 125 123 120 EX6
339 348 354 358 360 361 360 358 354 350 344 338 331 EX7
- - - - - - - - - - - - - EX8
18 18 19 19 19 19 19 19 19 19 19 18 18 EX4
53 55 56 57 57 58 58 58 57 57 56 55 54 EX5
55 127 132 135 137 138 139 139 139 138 137 135 133 131 EX6
350 362 370 377 381 383 383 382 380 377 372 366 360 EX7
935 965 988 1005 1016 1021 1023 1020 1014 1005 992 978 961 EX8
18 18 19 19 20 20 20 20 20 20 20 19 19 EX4
53 55 57 58 59 60 60 60 60 59 59 58 57 EX5
50 128 133 137 140 142 144 145 145 144 143 142 140 138 EX6
351 366 377 386 392 396 398 398 397 394 391 386 380 EX7
936 975 1006 1029 1045 1056 1061 1062 1059 1052 1043 1030 1015 EX8
17 18 19 19 20 20 20 20 20 20 20 20 20 EX4
52 54 57 58 60 60 61 61 61 61 61 60 59 EX5
45 124 131 136 141 144 146 147 148 148 147 146 145 143 EX6
342 361 375 387 395 401 405 407 407 405 403 399 394 EX7
913 962 1001 1031 1054 1070 1080 1085 1085 1082 1075 1064 1052 EX8
16 17 18 19 20 20 20 21 21 21 21 20 20 EX4
49 52 55 57 59 60 61 62 62 62 62 61 61 EX5
40 118 126 133 138 142 145 147 149 149 149 149 148 146 EX6
324 348 366 381 392 400 406 409 411 411 409 406 402 EX7
864 927 977 1015 1045 1067 1082 1091 1095 1095 1091 1084 1073 EX8
15 16 18 18 19 20 20 20 21 21 21 20 20 EX4
45 49 53 55 58 59 60 61 62 62 62 62 61 EX5
35 108 118 127 134 139 143 146 148 149 149 149 149 148 EX6
296 326 349 368 382 393 401 406 409 411 410 409 406 EX7
789 869 932 981 1019 1048 1069 1083 1092 1095 1095 1090 1082 EX8
13 15 16 17 18 19 20 20 20 20 20 20 20 EX4
38 44 49 52 55 57 59 60 61 61 61 61 61 EX5
30 93 107 118 126 133 138 142 145 147 148 148 148 147 EX6
255 294 325 348 366 380 390 398 403 406 407 406 405 EX7
680 786 866 928 976 1013 1041 1061 1075 1083 1086 1084 1079 EX8
10 13 15 16 17 18 19 19 20 20 20 20 20 EX4
29 38 44 48 52 54 56 58 59 60 60 60 60 EX5
25 71 91 106 117 125 131 136 140 143 144 145 146 145 EX6
195 251 291 321 344 361 375 385 392 397 399 400 399 EX7
520 669 775 855 916 964 1000 1027 1046 1058 1065 1067 1065 EX8
4 9 12 14 16 17 18 18 19 19 19 20 20 EX4
13 28 37 43 47 51 53 55 57 58 58 59 59 EX5
20 31 68 89 103 114 122 129 133 137 139 141 142 142 EX6
84 188 244 284 314 337 354 367 377 383 388 390 390 EX7
225 501 652 758 837 898 944 979 1005 1023 1034 1040 1042 EX8
3 9 12 14 15 16 17 18 18 19 19 19 EX4
10 27 36 42 46 49 52 54 55 56 57 57 EX5
15 23 65 86 100 111 119 125 130 133 135 137 137 EX6
64 178 236 276 305 327 344 357 366 372 376 378 EX7
172 475 629 735 813 873 917 951 976 992 1003 1008 EX8
1 8 11 13 15 16 17 17 18 18 18 EX4
4 25 34 40 44 47 50 52 53 54 55 EX5
10 10 60 82 96 107 115 121 125 128 130 132 EX6
28 166 225 265 294 315 332 344 352 358 362 EX7
76 443 600 706 783 841 885 917 940 956 965 EX8

EX48_35008_EN_R07.doc 5 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing temperature Extended capacity kW Valve
Dew point Bubble point R 407C Evaporating temperature °C (Dew point) Type
°C °C 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
16 17 17 17 17 17 16 16 16 15 15 15 14 EX4
50 51 51 51 51 50 50 49 48 47 46 45 43 EX5
64 60 119 120 121 121 121 119 118 116 114 112 109 106 103 EX6
328 332 333 333 332 329 325 320 314 308 301 293 285 EX7
874 884 889 889 885 877 867 854 838 821 802 781 759 EX8
17 17 17 17 17 17 17 17 16 16 16 15 15 EX4
50 51 52 52 52 52 51 51 50 49 48 47 46 EX5
59 55 120 122 123 124 124 123 122 121 119 117 114 112 109 EX6
330 336 339 341 341 339 336 332 328 322 315 308 301 EX7
879 895 904 909 908 904 897 886 873 858 840 821 801 EX8
16 17 17 17 17 17 17 17 17 17 16 16 16 EX4
50 51 52 52 53 53 52 52 51 51 50 49 48 EX5
54 50 118 121 123 125 125 125 125 123 122 120 118 116 113 EX6
326 334 340 343 345 345 343 340 336 331 325 319 312 EX7
869 891 906 915 919 919 914 907 896 883 868 851 832 EX8
16 16 17 17 17 17 17 17 17 17 17 16 16 EX4
48 50 51 52 53 53 53 52 52 51 51 50 49 EX5
50 45 115 119 122 124 125 125 125 125 124 122 120 118 116 EX6
316 327 336 341 344 346 345 344 341 337 332 326 320 EX7
843 873 894 909 918 921 920 916 908 897 884 869 853 EX8
15 16 16 17 17 17 17 17 17 17 17 17 16 EX4
46 48 50 51 52 52 52 52 52 52 51 50 49 EX5
45 40 109 114 118 121 123 124 125 125 124 123 121 120 118 EX6
300 315 326 334 339 342 344 343 341 338 334 330 324 EX7
801 840 870 891 905 913 916 915 910 902 891 878 864 EX8
14 15 16 16 17 17 17 17 17 17 17 17 16 EX4
42 45 48 49 50 51 52 52 52 51 51 50 50 EX5
40 35 101 108 113 117 120 122 123 123 123 122 121 120 118 EX6
278 297 312 323 330 335 338 339 338 337 334 330 325 EX7
742 793 832 860 880 894 901 904 902 897 889 879 866 EX8
12 14 15 15 16 16 16 17 17 17 17 16 16 EX4
38 42 45 47 48 49 50 51 51 51 50 50 49 EX5
35 30 90 99 106 111 115 118 119 120 121 120 120 119 117 EX6
248 273 292 306 317 324 329 331 332 331 329 326 323 EX7
661 729 779 817 844 864 876 883 885 884 878 870 860 EX8
10 12 13 14 15 15 16 16 16 16 16 16 16 EX4
32 37 41 44 46 47 48 49 49 49 49 49 48 EX5
30 25 75 88 97 103 108 112 115 116 117 117 117 116 115 EX6
207 241 266 285 299 309 316 320 322 323 322 320 317 EX7
552 644 710 760 796 823 841 853 860 861 859 854 846 EX8
7 10 12 13 14 14 15 15 16 16 16 16 15 EX4
23 30 36 39 42 44 46 47 47 48 48 48 47 EX5
26 20 54 72 85 94 100 105 108 111 112 113 113 113 112 EX6
148 199 233 258 276 289 299 305 309 312 312 311 309 EX7
395 530 621 687 735 770 796 814 825 831 832 829 824 EX8
7 9 11 12 13 14 14 15 15 15 15 15 EX4
21 29 34 38 40 42 44 45 45 46 46 46 EX5
21 15 50 69 81 90 96 101 104 106 108 108 109 108 EX6
137 189 223 247 265 277 287 293 297 299 299 298 EX7
365 503 594 658 705 740 764 781 791 796 797 795 EX8
6 9 11 12 13 13 14 14 14 14 14 EX4
19 27 32 36 38 40 42 43 43 43 43 EX5
16 10 45 64 76 85 91 96 99 101 103 103 103 EX6
123 176 210 234 251 264 273 279 282 284 284 EX7
329 470 561 624 670 704 727 743 753 757 758 EX8

EX48_35008_EN_R07.doc 6 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing Extended capacity kW Valve
temperature R 22 Evaporating temperature °C Type
°C 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
17 17 18 18 18 18 18 18 18 17 17 17 17 EX4
51 52 53 54 54 54 54 54 53 53 52 52 51 EX5
60 123 126 128 129 130 130 130 129 128 127 126 124 122 EX6
337 345 351 355 357 358 357 356 353 350 345 340 335 EX7
900 921 936 946 952 954 953 948 941 932 921 908 893 EX8
16 17 17 18 18 18 18 18 18 18 17 17 17 EX4
50 51 52 53 54 54 54 54 54 53 53 52 52 EX5
55 119 123 126 128 129 130 130 130 129 128 127 126 124 EX6
328 339 346 352 355 357 358 357 356 353 350 345 340 EX7
876 903 923 938 948 953 955 953 949 941 932 921 908 EX8
16 16 17 17 18 18 18 18 18 18 18 17 17 EX4
48 50 51 52 53 54 54 54 54 54 53 53 52 EX5
50 114 119 123 125 127 129 129 129 129 128 127 126 125 EX6
314 327 337 345 350 354 355 356 355 353 351 347 343 EX7
838 873 899 919 933 943 948 949 947 942 935 925 914 EX8
15 16 16 17 17 17 17 18 18 18 17 17 17 EX4
45 47 49 51 52 52 53 53 53 53 53 52 52 EX5
45 107 113 118 121 124 126 127 128 128 127 127 126 124 EX6
295 311 324 334 341 346 349 351 351 350 348 346 342 EX7
787 830 864 890 909 923 932 936 937 934 929 922 912 EX8
13 15 15 16 16 17 17 17 17 17 17 17 17 EX4
41 44 46 48 50 51 52 52 52 52 52 52 51 EX5
40 98 106 111 116 119 122 124 125 125 125 125 124 123 EX6
270 290 306 319 328 335 340 343 345 345 344 342 339 EX7
719 774 817 850 875 894 907 915 919 919 916 911 903 EX8
12 13 14 15 16 16 16 17 17 17 17 17 17 EX4
36 40 43 45 47 49 50 50 51 51 51 51 50 EX5
35 86 96 103 109 113 117 119 121 122 122 122 122 121 EX6
237 264 284 300 312 321 327 332 335 336 336 335 333 EX7
632 703 757 799 831 856 873 885 893 896 896 893 888 EX8
10 11 13 14 15 15 16 16 16 16 16 16 16 EX4
29 35 39 42 44 46 47 48 49 49 49 49 49 EX5
30 70 83 93 100 106 110 113 116 117 118 118 118 118 EX6
194 229 256 276 291 303 312 318 322 325 326 326 324 EX7
516 611 682 735 776 808 831 848 859 866 869 868 865 EX8
7 9 11 12 13 14 15 15 15 16 16 16 16 EX4
20 28 33 37 40 43 44 46 46 47 47 48 48 EX5
25 47 67 80 90 97 102 106 109 112 113 114 114 114 EX6
130 184 220 246 266 281 292 301 307 311 313 314 314 EX7
347 491 587 656 709 749 779 802 818 829 835 837 836 EX8
6 9 10 12 13 13 14 14 15 15 15 15 EX4
18 26 32 36 39 41 42 44 45 45 45 46 EX5
20 43 63 76 85 93 98 102 105 107 108 109 109 EX6
117 173 209 235 254 269 280 288 294 298 300 300 EX7
312 461 557 627 678 718 747 768 784 793 799 801 EX8
5 8 10 11 12 13 13 14 14 14 14 EX4
15 24 30 34 37 39 40 42 42 43 43 EX5
15 37 58 71 81 88 93 97 100 102 103 104 EX6
101 160 196 222 241 256 266 274 279 283 285 EX7
269 426 524 593 644 682 710 731 745 754 759 EX8
4 7 9 10 11 12 13 13 13 13 EX4
12 22 28 31 34 36 38 39 40 40 EX5
10 29 53 66 76 82 87 91 94 96 97 EX6
80 145 182 208 227 241 251 258 263 267 EX7
214 386 485 554 604 642 669 689 702 711 EX8

EX48_35008_EN_R07.doc 7 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing Extended capacity kW Valve
temperature R 134a Evaporating temperature °C Type

°C 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45

13 13 13 13 13 13 12 12 12 12 11 11 11 EX4
39 39 39 39 39 39 38 37 36 35 34 33 32 EX5
60 93 94 94 94 93 92 90 89 87 84 82 79 77 EX6
255 257 258 257 255 252 248 243 237 231 224 217 210 EX7
679 686 688 686 680 672 661 648 633 616 598 580 560 EX8
12 13 13 13 13 13 13 12 12 12 12 11 11 EX4
38 39 39 39 39 39 38 38 37 36 35 34 33 EX5
55 91 92 93 94 93 93 92 90 88 86 84 82 80 EX6
249 253 256 257 256 254 251 247 242 237 231 225 218 EX7
663 676 683 685 683 678 670 659 647 632 616 599 582 EX8
12 12 13 13 13 13 13 12 12 12 12 12 11 EX4
36 38 38 39 39 39 38 38 37 37 36 35 34 EX5
50 87 90 91 92 93 92 92 91 89 88 86 84 81 EX6
238 246 250 253 254 253 251 249 245 240 235 229 223 EX7
636 655 668 675 677 676 671 663 653 640 627 611 595 EX8
11 12 12 12 12 13 12 12 12 12 12 12 11 EX4
34 36 37 38 38 38 38 38 37 37 36 35 35 EX5
45 81 85 88 90 91 91 91 90 89 88 86 84 82 EX6
223 234 241 246 248 249 249 247 244 240 236 231 226 EX7
595 623 642 655 662 664 663 658 651 641 629 616 602 EX8
10 11 11 12 12 12 12 12 12 12 12 12 11 EX4
31 33 35 36 37 37 37 37 37 36 36 35 34 EX5
40 74 79 83 85 87 88 89 88 88 87 85 84 82 EX6
202 217 227 234 239 242 243 242 240 238 234 230 225 EX7
539 578 606 625 638 645 647 646 641 634 625 614 601 EX8
9 10 10 11 11 12 12 12 12 12 12 11 11 EX4
27 30 32 34 35 35 36 36 36 36 35 35 34 EX5
35 63 71 76 80 83 84 85 86 85 85 84 83 81 EX6
173 194 209 219 226 231 234 235 234 232 230 227 223 EX7
463 517 556 584 604 616 623 625 624 620 613 604 594 EX8
7 8 9 10 11 11 11 11 11 11 11 11 11 EX4
20 25 28 30 32 33 34 34 34 34 34 34 33 EX5
30 49 60 67 73 76 79 81 82 82 82 81 80 79 EX6
133 164 184 199 210 217 221 224 225 224 223 221 217 EX7
356 436 492 531 559 578 590 597 600 599 595 588 580 EX8
3 6 8 9 9 10 10 11 11 11 11 11 11 EX4
10 18 23 26 29 30 31 32 33 33 33 32 32 EX5
25 23 44 55 63 69 72 75 77 78 78 78 77 76 EX6
63 121 152 173 188 198 206 210 213 214 213 212 210 EX7
169 322 406 462 501 529 548 560 567 570 569 565 559 EX8
2 5 7 8 9 9 10 10 10 10 10 10 EX4
5 16 21 25 27 28 29 30 31 31 31 31 EX5
20 12 38 51 58 64 68 70 72 73 73 73 73 EX6
34 105 139 160 175 186 193 197 200 201 201 199 EX7
90 281 370 427 467 495 514 526 533 536 535 532 EX8
4 6 7 8 9 9 9 9 9 9 EX4
13 19 22 25 26 27 28 28 29 29 EX5
15 32 45 53 59 62 65 67 68 68 68 EX6
87 123 145 161 171 178 183 186 187 187 EX7
231 328 388 428 456 475 488 495 498 498 EX8
3 5 6 7 8 8 8 9 9 EX4
9 16 20 22 24 25 26 26 26 EX5
10 22 38 47 52 56 59 61 62 62 EX6
61 104 128 144 155 162 167 170 171 EX7
162 277 341 384 413 432 445 452 455 EX8

EX48_35008_EN_R07.doc 8 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing Extended capacity kW Valve
temperature R 404A / R 507 Evaporating temperature °C Type

°C 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45

9 9 9 9 9 9 9 8 8 8 7 7 6 EX4
28 28 28 28 28 27 26 25 24 23 22 21 20 EX5
60 68 68 68 67 66 65 63 61 58 56 53 50 47 EX6
186 187 186 184 181 177 172 166 160 153 145 137 129 EX7
495 498 496 491 482 471 458 443 425 407 387 366 344 EX8
10 10 10 10 10 10 10 9 9 9 8 8 8 EX4
30 31 31 31 30 30 29 29 28 27 26 25 23 EX5
55 72 73 74 74 73 72 70 69 67 64 62 59 56 EX6
198 201 202 202 200 197 193 188 182 176 169 162 154 EX7
527 535 538 537 533 525 514 501 486 470 451 432 411 EX8
10 10 11 11 11 11 10 10 10 10 9 9 9 EX4
31 32 32 32 32 32 32 31 30 30 29 28 27 EX5
50 74 76 77 78 78 77 76 75 73 71 69 66 64 EX6
203 208 211 213 213 211 208 204 200 194 188 181 174 EX7
541 555 564 567 567 562 555 545 532 518 501 484 465 EX8
10 10 11 11 11 11 11 11 11 10 10 10 9 EX4
31 32 33 33 33 33 33 33 32 32 31 30 29 EX5
45 74 77 79 80 80 80 80 79 78 76 74 72 69 EX6
201 210 215 219 220 220 219 216 212 208 202 196 190 EX7
537 559 574 583 587 586 582 575 566 553 539 524 506 EX8
10 10 11 11 11 11 11 11 11 11 11 10 10 EX4
29 31 33 33 34 34 34 34 34 33 32 32 31 EX5
40 71 75 78 80 81 82 82 81 81 79 78 76 74 EX6
193 205 214 219 223 225 225 223 221 217 213 208 202 EX7
515 547 570 585 594 598 598 595 588 578 567 553 538 EX8
9 10 10 11 11 11 11 11 11 11 11 11 11 EX4
27 30 31 33 34 34 34 34 34 34 33 33 32 EX5
35 65 71 75 79 81 82 83 83 82 81 80 79 77 EX6
178 195 207 215 221 225 226 226 225 223 219 215 210 EX7
474 519 551 574 590 599 603 604 600 594 585 573 560 EX8
8 9 10 10 11 11 11 11 11 11 11 11 11 EX4
23 27 30 31 33 34 34 34 34 34 34 33 33 EX5
30 56 65 71 75 78 81 82 83 83 82 81 80 79 EX6
153 177 194 206 215 221 224 226 226 225 223 219 215 EX7
409 472 517 550 573 588 598 603 603 600 593 584 573 EX8
6 8 9 10 10 11 11 11 11 11 11 11 11 EX4
17 23 27 29 31 32 33 34 34 34 34 34 33 EX5
25 42 55 64 70 74 78 80 81 82 82 81 80 79 EX6
114 150 174 191 204 213 218 222 224 224 223 220 217 EX7
305 400 465 510 543 566 582 592 596 597 593 587 579 EX8
1 5 7 8 9 10 10 11 11 11 11 11 11 EX4
3 16 22 26 28 30 32 33 33 33 33 33 33 EX5
20 8 40 53 62 68 73 76 78 80 80 80 80 79 EX6
21 108 146 170 187 200 208 214 218 219 220 218 216 EX7
56 289 388 453 499 532 555 571 580 585 585 582 576 EX8
5 7 8 9 10 10 10 11 11 11 11 EX4
15 21 25 28 29 31 32 32 32 33 32 EX5
15 37 51 60 66 71 74 76 77 78 78 78 EX6
101 139 164 181 194 202 208 212 213 214 213 EX7
268 371 437 484 516 540 555 564 569 569 566 EX8
5 7 8 9 9 10 10 10 10 10 EX4
14 20 24 26 28 30 31 31 31 31 EX5
10 33 48 57 64 68 71 73 75 75 75 EX6
91 131 156 174 186 195 201 204 206 206 EX7
242 350 417 464 496 519 535 544 548 549 EX8

EX48_35008_EN_R07.doc 9 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing Extended capacity kW Valve
temperature R 23 Evaporating temperature °C Type
°C -45 -50 -55 -60 -65 -70 -75 -80 -85 -90 -95 -100
17 18 19 19 19 19 19 19 19 19 19 18 EX4
-10 53 55 56 57 58 58 58 58 58 57 57 56 EX5
127 132 135 138 139 140 140 140 139 138 137 135 EX6
16 17 18 18 19 19 19 19 19 19 18 18 EX4
-15 50 52 54 55 56 57 57 57 57 57 56 55 EX5
119 125 130 133 135 137 137 137 137 136 135 134 EX6
15 16 17 17 18 18 18 18 18 18 18 18 EX4
-20 45 48 51 53 54 55 55 55 55 55 55 54 EX5
109 117 122 127 130 132 133 134 133 133 132 131 EX6
13 14 15 16 17 17 17 18 18 18 18 17 EX4
-25 40 44 47 49 51 52 53 53 53 53 53 53 EX5
96 106 113 118 122 125 127 128 129 128 128 127 EX6
11 13 14 15 16 16 16 17 17 17 17 17 EX4
-30 33 38 42 45 47 49 50 51 51 51 51 51 EX5
78 92 101 108 114 117 120 122 122 123 123 122 EX6
7 10 12 13 14 15 15 16 16 16 16 16 EX4
-35 22 30 36 40 43 45 46 47 48 48 48 48 EX5
53 73 86 96 103 108 111 114 115 116 116 116 EX6
6 9 11 12 13 14 14 15 15 15 15 EX4
-40 19 28 33 37 40 42 43 44 45 45 45 EX5
46 67 80 90 96 101 104 106 108 108 108 EX6
5 8 10 11 12 13 13 13 14 14 EX4
-45 15 25 30 34 37 39 40 41 41 41 EX5
37 60 73 82 88 93 96 98 99 100 EX6

Condensing Extended capacity kW Valve

temperature R 124 Evaporating temperature °C Type
°C 30 25 20 15 10 5 0
7 7 7 6 6 6 5 EX4
100 22 21 20 19 18 17 16 EX5
53 51 49 47 44 42 39 EX6
8 8 7 7 7 7 6 EX4
95 24 23 23 22 21 20 19 EX5
57 56 54 52 50 47 45 EX6
8 8 8 8 7 7 7 EX4
90 25 25 24 24 23 22 21 EX5
61 59 58 56 54 52 50 EX6
9 9 8 8 8 8 7 EX4
85 26 26 25 25 24 23 23 EX5
63 62 61 60 58 56 54 EX6
9 9 9 8 8 8 8 EX4
80 27 27 26 26 25 25 24 EX5
64 63 63 62 61 59 57 EX6
9 9 9 9 9 8 8 EX4
75 27 27 27 26 26 25 25 EX5
64 64 64 63 62 61 60 EX6
9 9 9 9 9 9 8 EX4
70 26 26 27 27 26 26 25 EX5
62 63 64 63 63 62 61 EX6
8 8 9 9 9 9 8 EX4
65 25 26 26 26 26 26 26 EX5
60 61 62 63 63 62 62 EX6
8 8 8 8 8 8 8 EX4
60 23 24 25 26 26 26 26 EX5
56 58 60 61 62 62 61 EX6

EX48_35008_EN_R07.doc 10 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities as expansion and liquid injection valves

The following tables provide the capacity of valves at different conditions considering 1.5 bar pressure drop through liquid line:
Condensing Extended capacity kW Valve
temperature R 744 Evaporating temperature °C Type
°C 8 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 -50
5 12 18 22 26 29 31 33 34 35 36 37 38 EX4
15 36 55 68 79 87 94 99 104 108 110 113 114 EX5
10 36 86 132 164 189 208 225 238 249 257 264 269 273 EX6
99 237 362 450 518 572 617 653 683 707 726 740 750 EX7
- - - - - - - - - - - - - EX8
12 19 23 27 29 32 33 35 36 37 38 EX4
37 57 71 81 90 96 102 106 110 113 115 EX5
5 89 137 170 195 215 231 244 254 263 269 274 EX6
244 376 466 535 589 634 670 699 722 739 753 EX7
- - - - - - - - - - - EX8
12 19 24 27 30 32 34 35 36 37 EX4
38 58 72 83 91 98 103 107 111 113 EX5
0 90 139 173 198 218 234 247 257 265 271 EX6
247 383 475 544 598 642 677 705 727 744 EX7
659 1023 1267 1452 1598 1715 1809 1883 1942 1987 EX8
12 19 24 27 30 32 34 35 36 EX4
37 59 73 83 91 98 103 107 110 EX5
-5 89 140 174 199 219 234 247 257 264 EX6
245 385 477 547 601 644 678 705 725 EX7
654 1028 1275 1460 1604 1718 1809 1881 1937 EX8
12 19 24 27 30 32 34 35 EX4
36 58 72 83 91 97 102 106 EX5
-10 87 139 173 198 217 233 245 254 EX6
239 382 475 544 597 639 671 697 EX7
639 1021 1269 1452 1594 1705 1793 1861 EX8
11 19 23 27 29 31 33 EX4
35 57 71 82 89 96 100 EX5
-15 84 137 171 195 214 229 240 EX6
229 376 468 536 588 628 660 EX7
613 1003 1250 1431 1570 1677 1761 EX8
11 18 23 26 29 31 EX4
33 56 70 80 87 93 EX5
-20 79 133 166 191 209 223 EX6
216 365 457 523 574 613 EX7
576 974 1220 1398 1532 1636 EX8
10 18 22 25 28 EX4
30 53 67 77 85 EX5
-25 72 128 161 185 202 EX6
198 350 442 507 556 EX7
528 935 1179 1353 1483 EX8
9 17 21 24 EX4
27 51 64 74 EX5
-30 64 121 154 177 EX6
175 332 423 486 EX7
466 887 1129 1298 EX8
7 16 20 EX4
22 47 61 EX5
-35 53 113 146 EX6
145 310 400 EX7
386 828 1068 EX8
5 14 EX4
16 43 EX5
-40 37 103 EX6
103 284 EX7
275 759 EX8

EX48_35008_EN_R07.doc 11 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

EX4/EX5/EX6/EX7/EX8 Nominal and extended capacities as hot gas bypass regulator

Nominal Capacities, kW
Valve Type Kv, m3/h R 22/R 407C R 134a R 404A/R 507
EX4 0.21 4.9 3.4 4.6
EX5 0.68 16 11 15
EX6 1.57 37 26 35
EX7 5.58 131 92 126
EX8 16.95 399 278 382
Nominal capacities at +4°C, +38°C bubble point for all refrigerants (+43°C dew point for R407C).
Remarks: EX4, EX5, EX6, EX7 and EX8 must be installed with motor downward in hot gas line applications.
This insures the valve life expectancy.
Extended capacities, kW
Liquid / Condensing temperature R 22 / R 407C R 134a R 404A / R 507 Valve
°C type
7 4.9 5.8 EX4
23 16 19 EX5
60 bubble point for all refrigerants 54 38 45 EX6
(64 dew point for R407C) 191 135 161 EX7
581 411 488 EX8
6.1 4.3 5.5 EX4
20 14 18 EX5
50 bubble point for all refrigerants 46 32 41 EX6
(54 dew point for R407C) 163 115 147 EX7
495 348 447 EX8
4.9 3.7 4.9 EX4
16 12 16 EX5
40 bubble point for all refrigerants 38 27 36 EX6
(45 dew point for R407C) 136 95 130 EX7
414 289 394 EX8
4.3 2.8 4 EX4
14 9 13 EX5
30 bubble point for all refrigerants 32 22 31 EX6
(35 dew point for R407C) 112 78 111 EX7
340 236 336 EX8

EX6/EX7/EX8 Nominal and extended capacities as suction pressure regulator (evaporator or crankcase)
Nominal Capacities, kW
Valve Type Kv, m3/h R 407C R 22 R 134a R 404A
EX6 1.57 3.9 4.1 3.1 3.5
EX7 5.58 14 15 11 13
EX8 16.95 42 45 34 38
Nominal capacities at +4°C, +38°C bubble point for all refrigerants (+43°C dew point for R407C) and 0.15 bar pressure drop.
Remarks: EX4, EX5, EX6, EX7 and EX8 must be installed with motor downward in suction line applications.
This insures the valve life expectancy.

Multiply above nominal capacities by following factors to obtain capacities at different pressure drops:
∆P, bar 0.10 0.15 0.20 0.30
Correction factor 0.82 1.00 1.15 1.41
Example:
EX6 provides 3.5 kW at 0.15 bar pressure drop with R404A: 3.5*1.41 = 4.9 kW capacity at 0.3 bar pressure drop.

EX48_35008_EN_R07.doc 12 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities in kW, suction pressure regulator duty

Condensing Extended capacity kW Valve
temperature R 22 Evaporating temperature °C Type
°C 10 5 0 -10 -20 -30 -40
4 3 3 3 2 2 1 EX6
60 13 12 11 9 7 5 4 EX7
41 37 34 27 22 17 12 EX8
4 4 3 3 2 2 1 EX6
50 15 13 12 10 8 6 5 EX7
45 41 37 30 24 19 14 EX8
5 4 4 3 2 2 1 EX6
40 16 15 13 11 9 7 5 EX7
49 45 41 33 27 21 15 EX8
5 4 4 3 3 2 2 EX6
30 17 16 14 12 9 7 5 EX7
53 48 44 36 29 22 16 EX8
5 5 4 4 3 2 2 EX6
20 19 17 15 13 10 8 6 EX7
56 52 47 39 31 24 18 EX8

Condensing temperature Extended capacity kW Valve

Dew point Bubble point R 407C Evaporating temperature °C Type
°C °C 10 5 0 -10 -20
3 3 3 2 2 EX6
64 60 12 11 10 8 6 EX7
36 33 29 23 18 EX8
4 3 3 2 2 EX6
54 50 14 12 11 9 7 EX7
41 37 34 27 21 EX8
4 4 3 3 2 EX6
45 40 15 14 12 10 8 EX7
46 42 38 30 23 EX8
5 4 4 3 2 EX6
35 30 17 15 14 11 9 EX7
51 46 41 33 26 EX8
5 5 4 3 3 EX6
26 20 18 16 15 12 9 EX7
55 50 45 36 28 EX8

EX48_35008_EN_R07.doc 13 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities in kW, suction pressure regulator duty

Condensing Extended capacity kW Valve
temperature R 134a Evaporating temperature °C Type
°C 10 5 0 -10 -20
3 2 2 2 1 EX6
60 10 9 8 6 4 EX7
30 27 24 18 13 EX8
3 3 2 2 1 EX6
50 11 10 9 7 5 EX7
34 30 27 21 15 EX8
3 3 3 2 2 EX6
40 12 11 10 8 6 EX7
38 34 30 23 17 EX8
4 3 3 2 2 EX6
30 14 12 11 8 6 EX7
41 37 33 26 19 EX8
4 4 3 3 2 EX6
20 15 13 12 9 7 EX7
45 40 36 28 21 EX8

Condensing Extended capacity kW Valve

temperature R 404A / R507 Evaporating temperature °C Type
°C 10 5 0 -10 -20 -30 -40
3 2 2 2 1 1 1 EX6
60 9 8 8 6 4 3 2 EX7
29 26 23 18 13 10 7 EX8
3 3 3 2 2 1 1 EX6
50 12 11 9 7 6 4 3 EX7
36 32 29 23 18 13 9 EX8
4 3 3 3 2 1 1 EX6
40 14 12 11 9 7 5 4 EX7
42 38 34 27 21 16 12 EX8
4 4 4 3 2 2 1 EX6
30 16 14 13 10 8 6 5 EX7
48 43 39 31 25 19 14 EX8
5 4 4 3 3 2 1 EX6
20 17 16 14 12 9 7 5 EX7
53 48 44 35 28 21 16 EX8

EX48_35008_EN_R07.doc 14 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

EX5/EX6/EX7/EX8 Nominal and extended capacities as condensing pressure regulator and liquid duty
Nominal Capacities, kW
Valve Type Kv, m3/h R 407C R 22 R 134a R 404A
EX5 0.68 18 20 18 13
EX6 1.57 43 46 42 30
EX7 5.58 153 162 151 106
EX8 16.95 463 491 458 323
Nominal capacities at +4°C, +38°C bubble point for all refrigerants (+43°C dew point for R407C) and 0,35 bar pressure drop.
Multiply above nominal capacities by following factors to obtain capacities at different pressure drops.
∆P, bar 0.15 0.20 0.35
Correction factor 0.65 0.76 1.00
Extended capacities, kW
Condensing Extended capacity kW Valve
temperature R 22 Evaporating temperature °C Type
°C 10 0 -10 -20 -30 -40
15 15 15 14 14 13 EX5
60 36 35 34 33 32 30 EX6
128 124 120 116 112 108 EX7
387 377 365 353 341 328 EX8
17 17 16 17 16 15 EX5
50 41 40 36 39 36 35 EX6
144 141 129 137 129 124 EX7
439 428 391 416 391 377 EX8
19 19 19 18 17 17 EX5
40 45 44 43 42 41 39 EX6
161 157 153 149 145 140 EX7
488 477 465 453 439 426 EX8
21 21 20 20 19 19 EX5
30 50 49 48 46 45 44 EX6
177 173 169 165 160 156 EX7
536 525 513 500 486 472 EX8
23 23 22 22 21 21 EX5
20 54 53 52 51 49 48 EX6
192 188 184 180 175 171 EX7
584 572 560 547 533 519 EX8

Condensing Extended capacity kW Valve

temperature R 134a Evaporating temperature °C Type
°C 10 0 -10 -20 -30 -40
14 13 13 12 EX5
60 32 31 29 27 EX6
115 109 104 98 EX7
350 332 315 296 EX8
16 15 15 14 EX5
50 37 36 34 32 EX6
133 127 121 115 EX7
405 387 369 350 EX8
18 18 17 16 EX5
40 42 41 39 37 EX6
151 145 139 133 EX7
458 440 422 403 EX8
20 20 19 18 EX5
30 47 46 44 42 EX6
168 162 156 150 EX7
512 493 474 455 EX8
22 22 21 20 EX5
20 52 51 49 47 EX6
186 180 173 167 EX7
564 546 526 507 EX8

EX48_35008_EN_R07.doc 15 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities in kW, condensing pressure and liquid regulator

Condensing Extended capacity kW Valve
temperature R 404A/R 507 Evaporating temperature °C Type
°C 10 0 -10 -20 -30 -40
8 8 7 6 6 5 EX5
60 19 17 16 15 13 12 EX6
66 62 58 53 48 43 EX7
202 189 175 160 146 130 EX8
11 10 9 9 8 8 EX5
50 24 23 22 20 19 17 EX6
87 82 78 73 67 62 EX7
264 250 236 220 205 189 EX8
13 12 12 11 10 10 EX5
40 30 28 27 26 24 23 EX6
106 101 96 91 85 80 EX7
321 306 291 276 260 243 EX8
15 14 14 13 12 12 EX5
30 35 33 32 30 29 27 EX6
123 119 114 108 103 97 EX7
375 360 345 329 312 295 EX8
17 16 16 15 14 14 EX5
20 40 38 37 35 34 32 EX6
141 136 131 125 120 114 EX7
427 412 397 380 363 346 EX8

Condensing temperature Extended capacity kW Valve

Dew point Bubble point R 407C Evaporating temperature °C Type
°C °C 10 0 -10 -20
14 13 12 12 EX5
64 60 32 30 29 28 EX6
112 108 103 98 EX7
340 327 313 298 EX8
16 15 15 14 EX5
54 50 37 36 35 33 EX6
132 128 123 118 EX7
402 388 373 358 EX8
18 18 17 17 EX5
45 40 43 41 40 38 EX6
152 147 142 137 EX7
460 446 431 415 EX8
21 20 19 19 EX5
35 30 48 47 45 44 EX6
170 166 160 155 EX7
517 503 487 471 EX8
23 22 22 21 EX5
26 20 53 52 50 49 EX6
189 184 179 173 EX7
573 558 543 526 EX8

EX48_35008_EN_R07.doc 16 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

EX6/EX7/EX8 Nominal and extended capacities for hot gas flow such as heat reclaim application
Nominal Capacities, kW
Valve Type Kv, m3/h R 22 / R 407C R 134a R 404A/R 507 R 410A
EX6 1.57 11 9 10 13
EX7 5.58 39 33 36 47
EX8 16.95 119 101 108 144
Nominal capacities are at 0.5 bar pressure drops, +4°C evaporating temperature, +38°C bubble point for all refrigerants (+43°C dew
point for R407C) and 0.8 isentropic efficiency of compressor. For other conditions, page 17-20.
Remarks: EX6/EX7/EX8 must be installed with motor downward in hot gas line applications. This insures the valve life expectancy.

Extended capacities, kW
Condensing Pressure Extended capacity kW Valve
temperature drop R 404A Evaporating temperature °C Type
°C bar 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
4 4 4 4 4 3 3 3 3 3 3 2 2 EX6
0.1 15 14 14 13 13 12 11 11 10 10 9 8 8 EX7
45 43 42 40 38 36 35 33 31 29 27 25 23 EX8
9 9 8 8 8 7 7 7 6 6 6 5 5 EX6
60
0.5 32 31 30 29 28 26 25 24 22 21 20 18 17 EX7
99 95 92 88 84 80 76 72 68 64 60 56 52 EX8
13 12 12 11 11 10 10 9 9 8 8 7 7 EX6
1 45 44 42 40 39 37 35 33 31 29 27 26 24 EX7
137 132 127 122 117 112 106 101 95 89 84 78 72 EX8
5 4 4 4 4 4 4 4 3 3 3 3 3 EX6
0,1 16 16 15 15 14 14 13 13 12 11 11 10 10 EX7
49 47 46 44 43 41 40 38 36 35 33 31 30 EX8
10 10 9 9 9 8 8 8 7 7 7 6 6 EX6
50
0.5 35 34 33 32 31 30 29 28 26 25 24 23 22 EX7
107 104 101 98 95 91 88 84 80 77 73 69 65 EX8
14 13 13 13 12 12 11 11 10 10 9 9 8 EX6
1 49 48 46 45 43 42 40 38 37 35 33 32 30 EX7
149 145 141 136 131 127 122 117 112 107 102 96 91 EX8
5 4 4 4 4 4 4 4 4 3 3 3 3 EX6
0.1 16 16 16 15 15 14 14 13 13 12 12 11 11 EX7
50 49 47 46 45 43 42 40 39 37 36 34 33 EX8
10 10 10 9 9 9 9 8 8 8 7 7 7 EX6
40
0.5 36 35 34 33 32 31 30 29 28 27 26 25 24 EX7
109 107 104 101 98 95 92 89 86 83 79 76 73 EX8
14 14 13 13 13 12 12 11 11 11 10 10 9 EX6
1 50 49 48 46 45 44 42 41 39 38 36 35 33 EX7
152 148 144 140 136 132 128 124 119 115 110 105 101 EX8
5 4 4 4 4 4 4 4 4 4 3 3 3 EX6
0.1 16 16 15 15 15 14 14 13 13 13 12 12 11 EX7
49 48 47 46 45 43 42 41 40 38 37 36 34 EX8
10 10 10 9 9 9 9 8 8 8 8 7 7 EX6
30
0.5 35 35 34 33 32 31 31 30 29 28 27 26 25 EX7
108 105 103 101 98 95 93 90 87 84 81 78 76 EX8
14 13 13 13 13 12 12 12 11 11 10 10 10 EX6
1 49 48 47 46 45 43 42 41 40 38 37 36 34 EX7
149 146 142 139 135 132 128 124 120 117 113 109 104 EX8

EX48_35008_EN_R07.doc 17 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities kW, hot gas flow such as heat reclaim applications
Condensing Pressure Extended capacity kW Valve
temperature drop R 134a Evaporating temperature °C Type
°C bar 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
5 5 4 4 4 4 4 4 4 3 3 3 3 EX6
0.1 16 16 16 15 15 14 14 13 13 12 12 11 10 EX7
50 49 47 46 44 43 41 40 38 37 35 33 32 EX8
10 10 10 9 9 9 8 8 8 7 7 7 6 EX6
60
0.5 36 35 34 33 32 31 30 29 28 26 25 24 23 EX7
110 107 104 101 97 94 91 87 84 80 77 74 70 EX8
14 14 13 13 12 12 12 11 11 10 10 9 9 EX6
1 50 49 47 46 44 43 41 40 38 37 35 34 32 EX7
152 148 144 139 135 130 126 121 116 112 107 102 97 EX8
5 4 4 4 4 4 4 4 4 3 3 3 3 EX6
0,1 16 16 15 15 14 14 14 13 13 12 12 11 11 EX7
49 48 47 45 44 43 41 40 39 37 36 35 33 EX8
10 10 9 9 9 9 8 8 8 8 7 7 7 EX6
50
0.5 35 35 34 33 32 31 30 29 28 27 26 25 24 EX7
108 105 102 99 97 94 91 88 85 82 79 76 73 EX8
14 13 13 13 12 12 12 11 11 10 10 10 9 EX6
1 49 48 46 45 44 43 41 40 39 37 36 34 33 EX7
148 145 141 137 133 129 125 121 117 113 109 105 100 EX8
4 4 4 4 4 4 4 4 4 3 3 3 3 EX6
0.1 16 15 15 14 14 14 13 13 13 12 12 11 11 EX7
47 46 45 44 43 42 40 39 38 37 36 34 33 EX8
10 9 9 9 9 8 8 8 8 7 7 7 7 EX6
40
0.5 34 33 32 32 31 30 29 28 27 26 26 25 24 EX7
103 100 98 96 93 91 88 86 83 80 78 75 73 EX8
13 13 12 12 12 12 11 11 11 10 10 10 9 EX6
1 46 45 44 43 42 41 40 39 38 36 35 34 33 EX7
141 138 134 131 128 124 121 117 114 110 107 103 100 EX8
4 4 4 4 4 4 4 3 3 3 3 3 3 EX6
0.1 15 14 14 14 13 13 13 12 12 12 11 11 11 EX7
44 43 42 42 41 40 39 38 37 35 34 33 32 EX8
9 9 9 8 8 8 8 8 7 7 7 7 6 EX6
30
0.5 32 31 30 30 29 28 28 27 26 25 25 24 23 EX7
96 94 92 90 88 86 84 81 79 77 75 72 70 EX8
12 12 12 11 11 11 11 10 10 10 9 9 9 EX6
1 43 42 41 40 39 38 37 36 35 34 33 32 31 EX7
130 128 125 122 119 117 114 111 108 105 102 98 95 EX8

EX48_35008_EN_R07.doc 18 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities kW, hot gas flow such as heat reclaim applications
Condensing Pressure Extended capacity kW Valve
temperature drop R 22 / R 407C* Evaporating temperature °C Type
°C bar 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
6 5 5 5 5 5 5 5 4 4 4 4 4 EX6
0.1 20 19 19 18 18 17 17 16 16 15 15 14 14 EX7
59 58 57 55 54 53 51 50 48 47 45 44 42 EX8
12 12 12 11 11 11 10 10 10 10 9 9 9 EX6
60
0.5 43 42 41 40 39 38 37 36 35 34 33 32 31 EX7
131 129 126 123 119 116 113 110 107 103 100 97 94 EX8
17 17 16 16 15 15 15 14 14 13 13 13 12 EX6
1 60 59 58 56 55 53 52 51 49 48 46 45 43 EX7
183 179 175 171 167 162 158 154 149 145 140 135 131 EX8
5 5 5 5 5 5 5 5 4 4 4 4 4 EX6
0,1 19 19 18 18 17 17 17 16 16 15 15 14 14 EX7
58 57 56 54 53 52 51 49 48 47 45 44 42 EX8
12 12 11 11 11 11 10 10 10 10 9 9 9 EX6
50
0.5 42 41 40 40 39 38 37 36 35 34 33 32 31 EX7
128 126 123 120 117 115 112 109 106 103 100 97 94 EX8
17 16 16 15 15 15 14 14 14 13 13 13 12 EX6
1 59 57 56 55 54 52 51 50 49 47 46 44 43 EX7
178 175 171 167 163 159 155 151 147 143 139 135 131 EX8
5 5 5 5 5 5 5 4 4 4 4 4 4 EX6
0.1 18 18 18 17 17 16 16 16 15 15 15 14 14 EX7
56 55 54 52 51 50 49 48 47 45 44 43 42 EX8
11 11 11 11 10 10 10 10 9 9 9 9 8 EX6
40
0.5 40 40 39 38 37 36 35 35 34 33 32 31 30 EX7
123 120 118 115 113 110 108 105 103 100 97 94 92 EX8
16 15 15 15 14 14 14 14 13 13 12 12 12 EX6
1 56 55 54 53 52 50 49 48 47 46 44 43 42 EX7
170 167 163 160 157 153 149 146 142 139 135 131 127 EX8
5 5 5 5 4 4 4 4 4 4 4 4 4 EX6
0.1 17 17 17 16 16 16 15 15 15 14 14 14 13 EX7
53 52 51 50 49 48 46 45 44 43 42 41 40 EX8
11 10 10 10 10 10 9 9 9 9 9 8 8 EX6
30
0.5 38 37 37 36 35 34 34 33 32 31 30 30 29 EX7
115 113 111 109 107 104 102 100 97 95 93 90 88 EX8
15 14 14 14 14 13 13 13 12 12 12 12 11 EX6
1 52 51 50 49 48 47 46 45 44 43 42 41 40 EX7
159 156 153 150 147 144 141 138 134 131 128 124 121 EX8

*) Condensing temperatures R 407C:

The relation between bubble points and dew points is as follows:
Dew point Bubble point
°C °C
64 60
54 50
45 40
35 30

EX48_35008_EN_R07.doc 19 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Extended capacities kW, hot gas flow such as heat reclaim applications
Condensing Pressure Extended capacity kW Valve
temperature drop R 410A Evaporating temperature °C Type
°C bar 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45
6 6 6 6 5 5 5 5 5 5 4 4 4 EX6
0.1 21 21 20 20 19 19 18 18 17 16 16 15 15 EX7
64 63 62 60 58 57 55 53 52 50 48 46 44 EX8
13 13 13 12 12 12 11 11 11 10 10 10 9 EX6
60
0.5 47 46 45 44 43 41 40 39 38 36 35 34 32 EX7
143 140 137 133 130 126 122 118 115 111 107 103 99 EX8
19 18 18 17 17 16 16 15 15 14 14 13 13 EX6
1 66 64 63 61 60 58 56 55 53 51 49 47 46 EX7
200 196 191 186 182 177 171 166 161 155 150 144 138 EX8
6 6 6 6 6 6 5 5 5 5 5 5 4 EX6
0,1 22 22 21 21 20 20 19 19 18 18 17 17 16 EX7
67 66 65 63 62 60 59 57 55 54 52 50 48 EX8
14 14 13 13 13 12 12 12 11 11 11 10 10 EX6
50
0.5 49 48 47 46 45 44 43 42 40 39 38 37 35 EX7
149 146 143 140 137 133 130 126 123 119 115 111 108 EX8
19 19 19 18 18 17 17 16 16 15 15 14 14 EX6
1 69 67 66 64 63 61 60 58 57 55 53 51 50 EX7
209 204 200 196 191 186 182 177 172 167 161 156 151 EX8
6 6 6 6 6 6 5 5 5 5 5 5 5 EX6
0.1 22 22 21 21 20 20 19 19 18 18 17 17 16 EX7
67 66 65 63 62 60 59 58 56 54 53 51 50 EX8
14 13 13 13 13 12 12 12 11 11 11 11 10 EX6
40
0.5 49 48 47 46 45 44 43 42 41 40 39 37 36 EX7
148 146 143 140 137 134 131 127 124 121 117 114 110 EX8
19 19 18 18 18 17 17 16 16 16 15 15 14 EX6
1 68 67 66 64 63 61 60 59 57 55 54 52 51 EX7
207 203 199 195 191 187 182 178 173 168 164 159 154 EX8
6 6 6 6 6 5 5 5 5 5 5 5 5 EX6
0.1 21 21 21 20 20 19 19 19 18 18 17 17 16 EX7
65 64 63 61 60 59 58 56 55 53 52 51 49 EX8
13 13 13 13 12 12 12 12 11 11 11 10 10 EX6
30
0.5 47 46 45 45 44 43 42 41 40 39 38 37 36 EX7
143 141 138 135 133 130 127 124 121 118 115 112 109 EX8
18 18 18 17 17 17 16 16 16 15 15 14 14 EX6
1 65 64 63 62 61 60 58 57 56 54 53 51 50 EX7
199 195 192 188 185 181 177 173 169 165 160 156 152 EX8

EX48_35008_EN_R07.doc 20 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application of control valves in systems

The following schematics show the arrangement of integrated valves for different applications.

Legends:
TC
Pump
Thermo Expansion valve

Compressor
P Pressure transmitter

T Temperature sensor
Condenser/Evaporator
Flow direction

Check valve

Plate heat exchanger

Sight glass

Liquid Receiver

Solenoid valve
Suction accumulator

Four way reversing valve

Filter dryer

Overview applications: page

Application 1: Expansion valve in cooling system 22
Application 2: Bi-Flow expansion valve in heat pump (except EX8) 22
Application 3: Expansion valve in heat pump (one valve) 23
Application 4: Expansion valve in heat pump (two valves) 23
Application 5: Expansion valve as liquid injection valve for desuperheating 24
Application 6: Expansion valve as liquid injection valve for subcooling 24
Application 7: Capacity control by means of hot gas bypass 25
Application 8: Capacity control by means of suction pressure throttling 25
Application 9: Crankcase pressure control 26
Application 10: Head pressure control 26
Application 11: Liquid level control 27

EX48_35008_EN_R07.doc 21 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application 1: Expansion valve in cooling system

2
EC3-X33

(1) = Expansion Valve

(2) = Superheat controller EC3-X33

Application 2: Bi-Flow expansion valve in heat pump (except EX8)

2
EC3-X33
1

(1) = Bi-Flow Expansion Valve

(2) = Superheat controller EC3-X33

EX48_35008_EN_R07.doc 22 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application 3: Expansion valve in heat pump (one valve)

2
EC3-X33

(1) = Expansion Valve

(2) = Superheat controller EC3-X33
Application 4: Expansion valve in heat pump (two valves)

(1) = Expansion Valve, heating mode

(2) = Expansion Valve, cooling mode

EX48_35008_EN_R07.doc 23 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application 5: Expansion valve as liquid injection valve for desuperheating

4-20mA/0-10V 1 T
2

TC

(1) = Temperature Controller

(2) = Stepper motor driver EXD-U00
(3) = Electrical Control Valve

Application 6: Expansion valve as liquid injection valve for subcooling

4-20mA/0-10V
1
2

TC

(1) = Temperature Controller

(2) = Stepper motor driver EXD-U00
(3) = Electrical Control Valve
EX48_35008_EN_R07.doc 24 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application 7: Capacity control by means of hot gas bypass

3
4-20mA/0-10V
5

1
T

TC

4
Remarks:
(1) = Temperature Controller (3) = Hot gas bypass valve must be installed with motor
(2) = Check Valve: It is important to install a check valve just downward. This insures the valve life expectancy.
after T-connection as shown. Check valve will not allow return (4) = Liquid Distributor must be selected properly for hot gas
of liquid refrigerant from condenser through electrical control mass flow.
valve in to the evaporator during power interruption to system. (5) = Stepper motor driver EXD-U00

Application 8: Capacity control by means of suction pressure throttling

T 4-20mA/0-10V

TC

Remarks:
(1) = Temperature Controller (3) This application may require additional liquid injection to
(2) = Evaporator temperature regulator. EX6, EX7 and EX8 suction line for desuperheating of compressor by means of
must be installed with motor downward in suction line suction line superheat control or discharge line temperature
applications. This insures the valve life expectancy. control. Please consult Alco Controls for more details.
(4) = Stepper motor driver EXD-U00

EX48_35008_EN_R07.doc 25 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application 9: Crankcase pressure control

4-20mA/0-10V

3 P

TC

Remarks:
(1) = Pressure Controller (3) = Stepper motor driver EXD-U00
(2) = Crankcase pressure regulator. ECVs must be installed
with motor downward in suction line applications. This insures
the valve life expectancy.

Application 10: Head pressure control

P
2

3 4-20mA/0-10V

TC

(1) = Pressure Controller

(2) = Condensing pressure regulator
(3) = Stepper motor driver EXD-U00

EX48_35008_EN_R07.doc 26 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Application 11: Liquid level control

4-20mA/0-10V
1
3

4-20mA 2

4-20mA/0-10V
1
3

4-20mA 2

(1) = Level Controller

(2) = Liquid level sensor
(3) = Stepper motor driver EXD-U00
Note: ECVs are not released for use with ammonia.

EX48_35008_EN_R07.doc 27 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Driver and controller

In contrary to thermo-expansion and regulator valves, stepper EXD-U Universal driver is a stepper motor driver which uses
motor driven valves are not self operated actuators and require: an analogue input signal to define the valve opening. It enables
- a stepper motor driver which generates the digital pulse the operation of EX4/EX5/EX6/EX7/EX8 as:
sequence needed to move the stepper motor in clockwise • Electronic expansion valve
or counter clockwise direction • Capacity control by means of hot gas bypass or evaporating
- an algorithm which determines the opening of the valve as pressure regulator
a function of system parameters and conditions. • Crankcase pressure regulator
Alco Controls offers several solutions for this task: • Condenser pressure regulator
EC3-X33 Superheat controller as stand alone for all
• Liquid level actuator
applications and EC3-X32 Superheat controller for use in
TCP/IP networks. The modules contain all required algorithms • Liquid injection valve
for full operation of ALCO ECVs. For further details please refer The input signal for the driver module can be 4…20mA or
to EC3X33 or EC3X32 technical data sheet. 0…10V. The output pulses provide the proportional
EC3-33x Cold Room Controller is a digital temperature opening/closing of EX4/EX5/EX6/EX7/EX8 and consequently
controller primary for refrigeration applications such as cold the control of liquid or vapour refrigerant mass flow. The
rooms. It features temperature control, superheat control and universal driver module can be connected to any controller
defrost, compressor and fan management where applicable. which provides the analogue signal. This gives system
For further details please refer to EC33x technical data sheet. manufacturers the extreme flexibility to use any desired
controller in conjunction with the universal driver module to
achieve different functionality. For further details please refer to
EXD-U technical data sheet.
The patented valve control module VCM is a hybrid integrated
circuit, which provides the superheat algorithm and the stepper
motor driver to those customers, who want to integrate the
valve control into their own system controller. This solution is
mainly for OEMs having serial mass production systems.

The following information is for those customers who want 2) Valve

to develop their own driver/controller/algorithms: The gate type valve is optimised to provide a wide range of
capacity with a linear relation between flow and positioning of
Function
the valve (capacity vs. number of steps). Slide and ports are
1) Motor made from ceramic for precise flow characteristics, high
A 2-phase bipolar stepper motor drives the EX4/5/6/7/8. This resolution and infinite life.
motor follows the basic operating characteristics of any stepper The compliant slide eliminates undesirable horizontal forces
motor i.e. the motor will be held in position unless current caused by differential pressure (across the valve) to the cage
pulses from a driver board initiate rotation in either direction. assembly and shaft of stepper motor. The internal design of the
The direction of the rotation depends on the phase relationship EX4/5/6/7/8 is patented.
of the current pulses, the amount of rotation is dependent on
the number of pulses. One pulse will drive the motor one step Total valve travel is 750 full steps for EX4/5/6, 1600 steps for
EX7 and 2600 steps for EX8.
i.e. the rotor will move by α=1.8°. Successive pulses will lead to
continuous rotation. A mechanical stop in the fully closed position of the valve acts
as reference point. The controller is reset by driving the valve
The drive shaft of the rotor is connected to a spindle which
towards the fully closed position against the mechanical stop.
transforms the rotation into linear motion of the valve slide.
By overdriving the valve i.e. applying more than the full number
of steps, it can be assured that the reference point is correct.
0 1α 2α 3α

Pulse

1 2 3

M M
Time

Angular rotation (cross section of shaft) closed open

EX48_35008_EN_R07.doc 28 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

4 3) Driving of stepper motor

10 There are many different options to drive stepper motors like
8
the one used in the EX4/5/6/7/8. Alco Controls stepper motors
need a driver board with chopper drive function (constant
current), an interface and a controller.
Chopper drive (constant current)
9 The stepper motor of EX4/5/6/7/8 is a bipolar, 2-phase
7 1 permanent-magnet motor and operates with constant DC
6 current in each phase. A driver board with chopper drive
function feeds a DC current as indicated below to the windings
5 of the stepper motor.
Time in ms
0,5

Current in A
2

6
3 0,0
0 0,002 0,004 0,006 0,008 0,01 0,012 0,014 0,016 0,018 0,02

4 -0,5

7
8

4) Design of customised driver board

A suitable driver board must be selected according to the
electrical data of the stepper motor and based on the following
requirements:
• Electrical output (four-stage switching sequence, see next
9 page)
6 • The EX4/5/6/7/8 should be operated in full step mode.
• Stepping rate: 500Hz for EX4/5/6/7/8
• Chopper function, current:
10 1
Current EX4/5/6 EX7 EX8
5 Operating 500 mA 750 mA 800 mA
Holding 100 mA 250 mA 500 mA
6

6
2

1 Stainless steel body

2 Stepper motor
3 Electrical connector
4 Cage assembly
5 Shaft
6 Welding and/or brazing
7 Ceramic inlet port
8 Ceramic slide
9 Ceramic outlet port
10 Brass ball

EX48_35008_EN_R07.doc 29 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Sequence for driving of stepper motor and valve

Direction Reverse Number Identification code of pins for electrical connections to third party
direction of steps drivers/controllers
A B C D
Current direction
Valve Valve Step 1 + - + -
is is Step 2 - + + -
opening closing Step 3 - + - +
Step 4 + - - +
Remark The sequence is repeated from step 5 to 8 similar to step 1 to 4
Step 5 + - + -
Step 6 - + + -
Step 7 - + - +
Step 8 + - - +
Remark The sequence is repeated from step 9 to 12 similar to step 1 to 4
↓ ↓ ↓ ↓

EX4/EX5/EX6/EX7/EX8 DIN plug M12 plug and cable assembly (EX5-xxx)

identification code of pins for for
for EX8 EX4/EX5/EX6/EX7
electrical connection to
third party drivers/controllers

Plug terminal numbers Cable, wire colour

A 1 White
B 3 Black
C -/4 Blue
D 2 Brown

EX48_35008_EN_R07.doc 30 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Technical data
CE marking Protection accordance EX4/5/6/7: IP68 with Alco supplied
EX4/EX5: not required to IEC 529, DIN 40050 cable connector assembly
EX6/EX7/EX8: required, Cat I, Module A EX8: IP65 with DIN plug
Compatibility CFCs, HCFCs, HFCs, mineral Vibration for non-connec- 4g
(not released for use with and POE lubricants ted and fastened valve (0 to 1000 Hz, 1 octave /min.)
inflammable refrigerants)
MOPD (maximum operating EX4/EX5/EX6/EX7: 33 bar Shock 20g at 11 ms
pressure differential) EX8: 25 bar 80g at 1 ms
Max. working pressure, PS EX4/EX5/EX6/EX7: 45 bar Net weight (kg) 0.5 kg (EX4), 0.52 kg (EX5), 0.60 kg
EX8: 35 bar (EX6), 1.8 kg (EX7), 2.5 kg (EX8)
Temperature range: Accessories See table on page 2
Refrigerant TS: -50 to +100°C (at motor) Package and delivery EX4/5/6/7: without electrical connector
Ambient -40 to +55°C (individual)
Salt spray test non-corrosion stainless steel EX8: with DIN plug and a pair of
body rotalock connections
Humidity 5 to 95% r.H. External leakage ≤ 3 gram / year
Connections EX4/EX5/EX6/EX7: ODF Seat leakage Positive shut-off as solenoid valve
stainless steel fittings
EX8: Rotalock with ODF,
plated fittings

Electrical data
Stepper motor type Bi-polar, phase current Phase inductance EX4/EX5/EX6: 30 mH ± 25%
by chopper control (constant EX7: 20 mH ± 25%
current) EX8: 22 mH ± 25%
Electrical connection 4 pin terminal via plug Step mode 2 phase full step
Reccom. driver supply voltg. 24 VDC (nominal) Step angle 1.8° per step ± 8%
Driver supply voltage range 18 … 36 VDC Total number of steps EX4/EX5/EX6: 750 full steps
EX7: 1600 full steps
EX8: 2600 full steps
Phase current, operating EX4/EX5/EX6: 500mA max, Stepping rate 500Hz
-10%
EX7: 750mA ±10%
EX8: 800mA ±10%
Holding current EX4/EX5/EX6: 100mA Winding resistance per EX4/EX5/EX6: 13Ohm ±10%
EX7: 250mA phase EX7: 8Ohm ±10%
EX8: 500mA EX8: 6Ohm ±10%
Nominal input power per EX4/EX5/EX6: 3.5W Full travel time EX4/EX5/EX6: 1.5 seconds
phase EX7/EX8: 5W EX7: 3.2 seconds
EX8: 5.2 seconds
Reference position Mechanical stop at fully close position

EX48_35008_EN_R07.doc 31 / 32 27.09.2006
 EX4 / EX5 / EX6 / EX7 / EX8
Electrical Control Valves

Dimensions EX4 / EX5 / EX6 / EX7

Valve Type Ø A x Ø F (ODF) B C D E H1 H2

EX4-I21 3/8" x 5/8" 8 45 55 11 113 25
EX4-M21 10 x 16 mm 8 45 55 11 113 25
16 x 16 mm
EX4-U31 11 55 55 11 113 25
(5/8" x 5/8")
5/8" x 7/8"
EX5-U21 11 55 65 16 113 25
(16 x 22mm)
7/8" x 7/8"
EX5-U31 16 65 65 16 113 25
(22 x 22mm)
EX6-I21 7/8" x 1-1/8" 16 65 75 19 113 25
EX6-M21 22 x 28 mm 16 65 75 19 113 25
EX6-I31 1-1/8" x 1-1/8" 19 75 75 19 113 25
EX6-M31 28 x 28 mm 19 75 75 19 113 25
Dimensions EX8 EX7-I21 1-1/8" x 1-3/8" 20 77.5 82.5 23 157 42
EX7-M21 28 x 35 mm 20 77.5 82.5 23 157 42
1-3/8 x 1-3/8
EX7-U31 23 82.5 82.5 23 157 42
(35 x 35mm)
EX8-M21 42 x 42 25 119 117 25 78
1-3/8 x 1-3/8
EX8-U21 25 119 117 25 78
(35 x 35mm)

ALCO CONTROLS is not to be held responsible for erroneous literature for use by persons having the appropriate technical knowledge and
regarding capacities, dimensions, applications, etc. stated herein. skills, at their own discretion and risk. Since conditions of use are
Products, specifications and data in this literature are subject to change outside of ALCO'S control we can not assume any liability for results
without notice. The information given herein is based on technical data obtained or damages occurred due to improper application.
and tests which ALCO CONTROLS believes to be reliable and which This document replaces all earlier versions.
are in compliance with technical knowledge of today. It is intended only
Phone.: Fax:
Emerson Electric GmbH & Co. OHG Benelux +31 (0)773 240 234 +31 (0)773 240 235
ALCO CONTROLS Denmark & Finland +32 (0)87 305 565 +49 24 08 929 568
Heerstraße 111 Eastern Europe, Turkey & Iran +32 (0)87 305 061 +32 (0)87 305 506
D-71332 Waiblingen France, Greece, Maghreb +33 (0)478 668 570 +33 (0)478 668 571
Germany Deutschland, Österreich, Schweiz +49 (0)6109 6059 0 +49 (0)6109 6059 40
Italia +39 02 961 78 1 +39 02 961 78 888
Phone ...49-(0)7151-509-0 Middle East & Africa +97 148 832 828 +97 148 832 848
Fax ...49-(0)7151-509-200 Poland +48 (0)22 458 9205 +48 (0)22 458 9255
Russia & Cis +7 495 981 9811 +7 495 981 9816
www.eCopeland.com/alcoliterature.cfm España & Portugal +34 93 4 123 752 +34 93 4 124 215
Sweden & Norway +32 (0)87 305 565 +49 24 08 929 568
UK & Ireland +44 (0)1 189 838 000 +44 (0)1 189 838 001

EX48_35008_EN_R07.doc 32 / 32 27.09.2006
 EC3-D7x Digital Superheat Controller
EC3-D72 with TCP/IP communication capability GB
Operating Instructions
Description • Important: Keep controller and sensor wiring well separated from mains wiring.
EC3-D7x is the superheat controller with Minimum recommended distance 30mm.
TCP/IP connection for stepper motor driven Warning: Use a class II category transformer for 24VAC power supply. Do not
Alco Electrical Control Valves EX4...EX6 ground the 24VAC lines. We recommend using individual transformers for EC3
and is optimized to operate with the controller and for 3rd party controllers to avoid possible interference or grounding
Copeland Digital Scroll series utilising a 0- problems in the power supply. Connecting any EC3 inputs to mains voltage will
10V input from a third party controller. The permanently damage the EC3.
controller synchronises the PWM digital Digital input status is dependant to operation of compressor/0-10V input
compressor solenoid valve with the
System
superheat controlled by the electrical control valve; EX series. The EC3-D73 has 0-10V input from third party
Operating Digital Inputs
the same functionality but can only be set-up via the ECD-002 display. It has no controller
condition
external communication functionality.
Comp. 1 & “Cooling demand” ECV remains closed irrespective of
Note: This document contains short form instructions for experienced users.
Comp.2 in stop open (0V) voltage input value
mode “Comp 2 Running”
! Safety instructions: open (0V)
• Read installation instructions thoroughly. Failure to comply can result in ECV active
device failure, system damage or personal injury. Comp. 1 in run “Cooling demand” Input =0V: digital valve capacity at
• The product is intended for use by persons having the appropriate
& Comp.2 in closed (24V) / 10% default capacity.
knowledge and skills. stop mode) “Comp 2 Running” When the digital comp. is in by-pass
• Disconnect all voltages from system before installation.
open (0V) the ECV will:
• Do not operate system before all cable connections are completed.
Close when capacity is <70%
• Comply with local electrical regulations when wiring.
Be inhibited when the capacity is >70%
Note: The EC3-D7x series contains a lead, acid gel rechargeable battery. The Comp 1 & “Cooling demand” ECV active
battery must NOT be disposed of with other commercial waste. Instead, it is the Comp. 2 in run closed (24V) / The ECV will always modulate even
user’s responsibility to pass it to a designated collection point for the safe recycling mode “Comp 2 Running” when the digital compressor is in by-
of batteries (harmonised directive 98/101/EEC). For further information contact closed (24V) pass mode.
your local environmental recycling centre. Comp.1 in stop “Cooling demand” ECV remains closed irrespective of
and Comp. 2 in open (0V) / voltage input value
Technical data run mode starts “Comp 2 Running”
Power supply 24VAC ±10%; 50/60Hz; 1A closed (24V)
Digital comp. should always be regarded as base load; compressor 1
Power consumption 25VA max. including EX4 … EX6
Plug-in connector Removable screw terminals wire size 0,14 .. 1,5 mm2 Wiring
Grounding 6,3 mm spade earth connector
Protection class IP20
COM, TCP/IP connection RJ45 Ethernet
Connection to optional ECC-Nxx or CAT5 cable with RJ45 connectors
local ECD-002
Digital Input; Cooling 0/24VAC/DC for stop/start function. EX valve closes
demand during stop command. Typically thermostat or third
party controller.
Digital Input; Comp2 0/24VAC/DC typically connected to auxiliary
running connection. EX valve control loop remains active
when input is 24V and the digital scroll is idle.
NTC input; Coil-out Emerson temperature sensor ECN-N60 or ECN-P60
temperature sensor
4-20 mA Analog input Emerson PT4-07M / PT4-18M / PT4-30M
4-20 mA Analog output For connection to any 3rd party controller with
Deviation from input 12/24VDC power supply and appropriate burden
signal ±8% max
Output alarm relay SPDT contact 24V AC/DC, 2 Amp inductive load
(If L2 = 1) Activated: During normal operation (no alarm condition)
Deactivated: During alarm condition or power supply is OFF
Output pump down relay SPDT contact 24V AC/DC, 2 Amp inductive load
(If L2 = 1) Activated: During normal operation
Deactivated: All other conditions
! If the output relays are not utilized, the user must ensure appropriate safety
precautions are in place to protect the system against damage caused by a
power failure. A: White wire B: Black wire J: Transformer Class II, 24VAC
Output Digital Scroll t 24V or 230V AC output to activate PWM valve on C: Blue wire D: Brown wire secondary / 25VA min. Model
Triac Digital Scroll E: M12 Plug cable assembly EX5-Nxx ECT-323
for connection to EX4/EX5/EX6 K: Third party controller (can use the
Stepper motor output for Maximum current 0.6A with nominal 24VDC
F: 24V/230V Triac output to PWM suction pressure (4-20mA) analog
EX4…EX6 operating voltage
Digital Scroll valve output signal from EC3)
Ambient temperature 0 … 60°C G: Remote control panel, system L: Pump down relay, dry contact.
range 1 … 25°C (for best battery life time) controller Relay is energized during normal
> 35°C battery life time < 2 years H: Alarm relay, dry contact. Relay coil is operation.
! In order to provide system protection in the event of power loss, it is not energised at Alarm or power off M: Digital input 2: “Comp. 2 running”
recommended to change the battery annually. ! (0V/open = Comp2 stop;
The use of the relay is essential to
24V/closed = Comp2 running
Mounting protect the system in case of power
The EC3-D7x is designed to be mounted onto a standard DIN rail. failure if the communications interface N: Discharge Temp. Sensor
or the ECD-002 are not utilized.. O: 0-10V Digital Scroll capacity
Electrical installation I: Digital input 1: “Cooling demand” demand signal from system
• Refer to the electrical wiring diagram for electrical connections. (Digital compressor run: (0V/open = controller
• Do not apply voltage to the controller before completion of wiring. Stop; 24V/closed = Control Start;) P: ECN-N60 Coil out sensor
• Ground the metal housing with a 6.3mm spade connector.

EC3-D72_65141_EN_R02.doc Replacement for R01 1/4 PCN: 865 019 11.02.2009

 EC3-D7x Digital Superheat Controller
EC3-D72 with TCP/IP communication capability GB
Operating Instructions

Preparation for Start-up: After the parameters have been modified, the complete list of settings can be saved
• Vacuum the entire refrigeration circuit. to the memory of the computer and used later to upload into another controller.
Warning: Alco Electrical Control Valves EX4...EX6 are delivered at half open This can save a considerable amount of time when using multiple controllers and
position. Do not charge system before closure of valve. over a period of time, a library can be created containing the parameter lists for
• Apply supply voltage 24V to EC3 while the cooling demand digital input is 0V equipment for different applications.
(open). The valve will be driven to close position. It is also possible to display live graphical data from the controller. Superheat,
• After closure of valve, start to charge the system with refrigerant. evaporating pressure, coil-out temperature and evaporating temperature are
available on a 10 minutes rolling chart. Refer to the TCP/IP Controller-Readme file
for a complete description of the features available for the TCP/IP series of
Possibilities of connecting EC3-D72 to a network or PC controllers.
A TCP/IP Controller Readme file is available on the www.emersonclimate.eu Alternative procedure for parameter modification using ECD-002
website to provide detailed information about TCP/IP Ethernet connectivity. Please
Note: Some of the functions/parameters (manual control and TCP/IP
refer to this file if you need information beyond the contents of this instruction
configuration) cannot be modified when using ECD-002 comparing to a set-up by
sheet.
PC via TCP/IP. Warning: All alarms are disabled during manual control. We do
1) Connect the EC3-D72 using the optional ECC-Nxx cable assembly or a standard
not recommend unattended operation of system during manual control.
CAT5 network cable with RJ45 plugs assembly to a network or router that enables
The parameters can be accessed via the 4-button keypad. The configuration
the controller to receive a dynamic TCP/IP address or
parameters are protected by a numerical password. The default password is “12”.
2) Connect the EC3-D72 to a computer using a crossover cable plugged directly
To select the parameter configuration:
into the Ethernet port. In this case, the TCP/IP address of the computer must be
manually modified to be compatible with the default address of the controller. • Press the PRG button for more than 5 seconds
Refer to the TCP/IP Controller-Readme file for more details. A flashing 0 is displayed
• Press or until the password is displayed (default 12).
Setting and visualising Data: WebPages (recommended method) If the password was changed, select the new password
Important: Make sure that cooling demand input is 0V (open). Turn the power • Press SEL to confirm password
supply ON. • Press or to show the code of the parameter that has to be changed;
Four parameters i.e. refrigerant type (u0), pressure sensor type (uP), valve type (ut) • Press SEL to display the selected parameter value;
and control mode can be set only when cooling demand digital input is open (0V)
and the power supply is ON (24V). This feature is for added safety to prevent • Press or to increase or decrease the value;
accidental damage of compressors and other system components. All other • Press SEL to temporarily confirm the new value and display its code;
parameters can be modified at any time. Repeat the procedure from the beginning "press or to show..."
The EC3-D72 has a TCP/IP Ethernet communication interface enabling the To exit and save the new settings:
controller to be directly connected to a network or a PC via the standard Ethernet Press PRG to confirm the new values and exit the parameters modification
port. The EC3-D72 controller has embedded WebPages to enable the user to procedure.
visualise the parameter lists using real text labels. To exit without modifying any parameters:
To view WebPages on the PC, a standard WebBrowser like Internet Explorer® or Do not press any button for at least 60 seconds (TIME OUT).
Mozilla Firefox and JRE Java Runtime Environment is needed. JRE can be
downloaded at no charge from the www.java.com website. Special Functions:
Open the Internet browser program on the computer and, if EC3-D72 is connected The Special Functions can be activated by:
directly to PC with a crossover cable enter the default TCP/IP address of the • Press and together for more than 5 seconds.
controller (192.168.1.101) into the address line, or the dynamic address from the A flashing 0 is displayed.
DHCP server from network/Router. Refer to the TCP/IP Controller-Readme file if • Press or until the password is displayed (default = 12).
a specific port is required. If password was changed, select the new password.
It is possible to identify the dynamic TCP/IP address assigned by DHCP of the
• Press SEL to confirm password
Router or network, refer to the TCP/IP Controller-Readme file.
A 0 is displayed and the Special Function mode is activated.
After a few moments, the default monitoring page should be displayed. If the
browser does not open the default page or display active data, the user should • Press or to select the function. The number of special functions is dynamic
check the Internet browser “Option” configuration. Refer to the TCP/IP Controller- and controller dependent. See list below.
Readme file. 0: Reset controller to factory settings (this action is possible only when digital
input is 0V i.e. open)
1: Displays the current TCP/IP address
2: Assign temporary 192.168.1.101 as TCP/IP address if EC3-D72 has
different address
• Press SEL to activate the function without leaving the special function mode.
• Press PRG to activate the function and leave the special function mode.

ECD-002 display/keypad unit (LEDs and button functions)

Blinking: valve is opening
ON: valve is fully open

Blinking: valve is closing

Parameters setting/saving Next parameter/
ON: valve is fully close
value (higher)

ON: demand Not applicable

OFF: no demand for the EC3-D72
Blinking: pump
The Monitoring and Alarm WebPages are read only and therefore it is not down
necessary to enter a username or password. A username and password will be
requested upon the initial request to any of the other WebPages. The factory ON: alarm Next parameter/
OFF: no alarm Prg & Sel (5 sec) value (lower)
default settings are : Manual reset for
Username: “EmersonID” , Password: “12” Selecting/confirming
blinking alarm codes
The default settings may be modified on the Display configuration page.
Press the tabs at the top of the Monitoring page with a left click of the mouse
button to enter the respective Webpage.
The parameters will be visualised in real text together with the program code as
defined in the parameter list below.

EC3-D72_65141_EN_R02.doc Replacement for R01 2/4 PCN: 865 019 11.02.2009

 EC3-D7x Digital Superheat Controller
EC3-D72 with TCP/IP communication capability GB
Operating Instructions

List of parameters in scrolling sequence by pressing button

Code Parameter description and choices Min Max Factory Field
Code Parameter description and choices Min Max Factory Field
settings settings
setting setting
H5 Password 1 199 12 L2 Output logic 0 3 1
u0 System refrigerant 0 7 4 0: Alarm & pump down. = normal 1: Alarm = inverse, pump down. = normal
0 = R22; 1 = R134a; 2 = R507; 3 = R404A; 4 = R407C; 3: Alarm & pump down. = inverse 2: Alarm = normal, pump down. = inverse
5 = R410A; 6 = R124; 7 = R744 (subcritical application) b1 Battery error management, when battery 0 3 2
uP Installed pressure sensor type 0 2 0 is defective, see below:
0 = PT4-07M (for R22/R134a/R507/R404A/R407C/R124) Alarm display Reset possibility after
1 = PT4-18M (for R410A) value Alarm relay Valve recovery/replacement
2 = PT4-30M (for R744, subcritical) 0 - - Regulating -
ut Installed valve type 1 3 2 1 Ab - Regulating -
1 = EX4; 2 = EX5; 3 = EX6 2 Ab Signalling Fully close Auto
uu Start valve opening (%) 10 100 50 3 Ab (blinking) Signalling Fully close Manual
u9 Start opening duration (second) 1 30 5 ! When setting b1 to option 0 or 1, the user must ensure appropriate safety
uL Low superheat alarm function 0 2 1 precautions are in place to protect the system against damage caused by a
0 = disable (for flooded evaporator) power failure.
1 = enable auto reset 2 = enable manual reset /6 Show decimal point; 0=yes, 1 = no 0 1 0
Cut-out at 0.5K (if it maintains 1 min.); Cut-in immediately at 3K A6 Maximum discharge temperature; °C 100 140 130
u5 Superheat set-point (K) A7 Discharge temp. alarm delay; sec. 0 199 30
If uL enabled (auto or manual) 3 30 6 F2 Minimum capacity; % 10 100 10
If uL disabled 0.5 30 6 F3 Maximum capacity; % 10 100 100
u2 MOP function 0 1 1 F6 Scroll Valve, PWM cycle time; sec. 10 20 20
0 = disable 1 = enable t3 Monitor discharge temperature sensor 0 1 0
u3 MOP set-point (°C) saturation * * X 0 = no, 1 = Yes
temperature ru 0-10V input filtering; 0 = off, 1 = on 0 1
Factory setting is according to selected refrigerant (u0): *) Min. and Max. setting values are dependant to selected type of refrigerant.
+13°C for R22 +15°C for R134a +7°C for R507 Control (valve) start-up behaviour (Parameter uu and u9)
+7°C for R404A +15°C for R407C +15°C for R410A
%
+50°C for R124 -5°C for R744
┌┘5 Units conversion 0 1 0
0 = °C, K, bar 1 = °F, R, psig uu

EC3-X3 BA.cdr
(Psig values are divided by 10. Example: Display 12.5 is 125 psig) EX4/5/6 ≤ 1.5 seconds
┌┘1 Value to show 0 4 0
0 = Measured superheat (K) 1 = Measured evaporator pressure (bar)
2 = Valve opening (%) 3 = Measured coil-out temp. (°C) u9 Sec.
4 = Calculated evaporating temperature (°C) from the pressure
5 = Compressor capacity in % Pump down function (if P6=1 and L2=1)
u4 Superheat control mode 0 1 0 Cooling demand Alarm condition Pump down relay
0 = Standard, 1 = Slow status
uH High superheat alarm function 0 1 0 24V (ON) NO Activate
0 = disable, 1 = enable auto reset 0V (OFF) NO Deactivate when pressure drops below
uA High superheat alarm setpoint 16 40 30 P7 and after elapsed time P8
ud High superheat alarm delay, min. 1 15 3 0V or 24V YES Deactivate instantaneously
P2 Freeze protection cut-out, °C -40 40 0 Start-up
P3 Freeze protection cut-in, °C -37 43 3
Start the system and check the superheat and operating conditions. The EC3-D72 is
P4 Freeze protection alarm function 0 2 0 fully functional without connected PC or keypad/display unit. ECD-002.
0 = disable, 1 = enable auto-reset,
2 = enable manual reset Mounting of ECD-002
P5 Freeze protection alarm delay, sec. 5 199 30 ECD-002 can be installed at any time also during operation.
P6 Pump-down function 0 1 0 • ECD-002 can be mounted in panels with 71x29 mm

0 = disable, 1 = enable auto-reset cutout

• Push controller into panel cut-out.(1)
P7 Pump-down cut-out, barg -0,5 18 0.5
• Make sure that mounting lugs are flush with outside of
P8 Pump-down time delay, sec. 0 199 30
controller housing
P9 Low pressure alarm function 0 2 0
• Insert Allen key into front panel holes and turn
0 = disable, 1 = enable auto-reset,
clockwise. Mounting lugs will turn and gradually
2 = enable manual reset
move towards panel (2)
PA Low pressure alarm cut-out, barg -0,8 17,7 0
• Turn Allen key until mounting lug barely touches
Pb Low pressure alarm delay, sec. 5 199 5 panel. Then move other mounting lug to the same
Pd Low pressure alarm cut-in, barg -0,5 18 0.3 position (3)
• Tighten both sides very carefully until keypad is
secured. Do not over tighten as mounting lugs will
break easily.

Error/Alarm handling
Alarm Description Related Alarm Valve Requires manual reset
code parameter relay What to do? after resolving alarm
E0 Pressure transmitter error - Signalling Fully close Check wiring connection and measure the signal 4 to 20 mA No
E1 Coil-out temperature sensor - Signalling Fully close Check wiring connection and measure the resistance of sensor No
error 10,000ohms @ 25°C
E3 Discharge temp. sensor - Signalling Regulating Check wiring connections and measure the resistance of the
error sensor. Also check the status of the I/O configuration (t3)
AΠ EX4…EX6 electrical - Signalling - Check wiring connection and measure the resistance of winding No
connection error Refer to EX series datasheet: EX58e35008

EC3-D72_65141_EN_R02.doc Replacement for R01 3/4 PCN: 865 019 11.02.2009

 EC3-D7x Digital Superheat Controller
EC3-D72 with TCP/IP communication capability GB
Operating Instructions

Alarm Description Related Alarm Valve Requires manual reset

code parameter relay What to do? after resolving alarm
Ab b1: 1 - Regulating Battery potentially does not have enough charge to close valve -
in case of main power supply interruption. May occur
Ab Battery error b1: 2 Signalling Fully close temporarily with new controllers or after long storage but should -
disappear when battery is charged sufficiently (allow 10hrs). If
Ab blinking b1: 3 Signalling Fully close Ab remains active even when battery is charged, battery may be Yes
defective and should be replaced. (Replacement kit: 807 790).
AE blinking Pump down action P6: 1 Signalling Already Allocate the source, which does not let suction pressure drops Yes
can not accomplished closed by below desired set-point
Pumpdown
command
AF Freeze protection P4: 1 Fully close Check the system for cause of low pressure such as insufficient No
AF blinking P4: 2 Signalling Pumpdown load on evaporator Yes
deactivated
AL Low superheat uL: 1 Fully close Check wiring connection and operation of valve No
AL blinking (<0,5K) uL: 2 Signalling Pumpdown Yes
deactivated
AH High superheat uH: 1 Signalling Fully close Check the system No
Pumpdown
deactivated
AP Low pressure P9: 1 Fully close Check the system for cause of low pressure such as refrigerant No
AP blinking P9: 2 Signalling Pumpdown loss Yes
deactivated
dA High discharge temp. A6: alarm Signalling Fully close Check the system No
setpoint Pumpdown Fixed differential =
deactivated 10°C
Er Data error display – - - -
Data send to the display is out of range. Check temperature and No
out of range pressure sensor.
Note: When multiple alarms occur, the highest priority alarm is displayed until Message
being cleared, then the next highest alarm is displayed until all alarms are --- No data to display
cleared. Only then will parameters be shown again. The display will show an “---” at start up and when no data is send to ECD-002

Checking system operating conditions using local display/keypad ECD-002

The data to be permanently shown on the display can be selected by the user second the numerical identifier of the data (see ┌┘1 parameter) and then the selected data.
(parameter ┌┘1). It is possible to temporarily display these values. However this After 5 minutes, the display will return to the value selected by parameter ┌┘1.
function is not available in an alarm condition. The display will show for one

Service / Troubleshooting
Symptom Cause Action
Operating superheat is several degrees Incorrect signal from pressure or 1- Check the sensors
higher or lower than set-point temperature sensors 2- Make sure ECN-N60 temperature sensor is used
3- For optimum accuracy, please use:
PT4-07M for R22/R134a/R507/R404A/R407C/R124
PT4-18M for R410A
PT4-30M for R744
4- Make sure the sensor cables are not installed along with other high voltage cables
Operating superheat is too low i.e. 1- Incorrect wiring of ECV 1- Check the wiring
compressor wet running 2- Defective sensors 2- Check the sensor
Valve is not fully closed 1- The cooling demand digital 1- Valve is shut off only when the digital input is turned off (0V)
input is ON (24V)
2- Wrong ECV selected. 2- Check the setting of parameter ut
Unstable superheat (hunting) Evaporator is designed to operate Increase the superheat set-point to a higher value; if system is stable, start to
at higher superheat decreasing gradually checking each time for a stable control
Valve opens when EC3 commands to close Wrong wiring between EC3-D72 Check the wiring and obey the colour coding: white/black, blue/brown.
and vice versa and valve
Superheat set-point is shifting after several Stepper motor driven valves Do not apply permanent 24V digital input. Interrupt digital input once every week for
months of uninterrupted operation or require synchronization 5 seconds if compressor never stops. This has the effect of referencing the valve to the
permanent jumper of 24V digital input fully closed position.

Dimensions EC3-D72/D73 ECD-002

Revision applicable to EC3-D72 software release =>114, rev 6

Emerson Electric GmbH & Co OHG - Postfach 1251 - Heerstraße 111 - D-71332 Waiblingen - Germany - Phone .49-(0)7151-509-0 - Fax .49-(0)7151-509-200
www.emersonclimate.eu

EC3-D72_65141_EN_R02.doc Replacement for R01 4/4 PCN: 865 019 11.02.2009

 FANs 930, 930.5, 125, 121
Product/Technical Bulletin A350P
Issue Date 0899

System 350TM A350P Electronic Proportional Plus Integral

Temperature Control

The A350P is an electronic, proportional plus integral

temperature control with analog 0 to 10 VDC and
0 to 20 mA outputs. The control is equipped with
three user-selectable time integration constants and
an adjustable throttling range of 2 to 30F° (1 to 17C°).
Two models cover a setpoint range of -30 to 130°F
(-35 to 55°C) and 90 to 250°F (32 to 121°C).

As are all System 350™ products, the A350P control

is housed in a NEMA 1, high-impact plastic enclosure.
The modular design provides easy, plug-together
connections for quick installation and future
expandability.

Figure 1: A350P Electronic Proportional Plus

Integral Temperature Control

Features and Benefits

❑ Modular Design Enables stage, display, and power modules to
be purchased and installed as needed

❑ Plug-Together Connectors Eliminates wiring between modules, which

and 35 mm DIN Rail reduces installation costs
Mounting

❑ Two Models Cover a Wide Reduces inventory by encompassing

Setpoint Range of -30 to temperature ranges required to support the
250°F (-35 to 121°C) majority of Heating, Ventilation, Air Conditioning,
and Refrigeration (HVAC/R) applications

❑ Minimum Output Adjustable Tailors the output to the requirements of the

from 0 to 60% controlled device; can be used to set minimum
valve or damper position

❑ Adjustable Throttling Enables the user to tune the system for optimum
Range of 2 to 30F° (1 to 17C°) stable performance

❑ Field-selectable Reverse Works in heating or cooling applications

or Direct Acting Mode

❑ Three User-Selectable Provides selection of the integration constant for

Integration Time Constants applications requiring proportional plus integral
control

❑ Interchangeable Increase versatility and serviceability

Temperature Sensors

© 1999 Johnson Controls, Inc. 1

Part No. 24-7664-192, Rev. F www.johnsoncontrols.com
Code No. LIT-930020
A pplication O peration
The A350P Temperature Control can be used as a The A350P control operates on 24 VAC/VDC and
standalone device or in conjunction with plug-together provides two simultaneous analog outputs:
accessory modules. The addition of S350 Stage 0 to 10 VDC and 0 to 20 mA. A cover-mounted,
Modules allows for the control of multiple stage 10-segment Light-Emitting Diode (LED) bar graph
HVAC/R applications. Typical application for the indicates percentage of output.
A350P includes:
Features include:
• proportional heating control with staged direct
• adjustable setpoint
expansion cooling
• adjustable minimum output
• simple temperature control for air handling units
• adjustable throttling range (proportional band)
• modulating damper actuators for mixed air control
• selectable integration time constant
• simple proportional mixed air control
A typical System 350 Temperature Control setup • selectable Reverse Acting (RA) or Direct Acting
includes the following: (DA) mode of operation

• A350P Temperature Control IMPORTANT: All System 350 controls are

designed for use only as
• A99B Series Temperature Sensor operating controls. Where an
• Y350R Power Module (or 24 VAC Class 2 operating control failure would
transformer) result in personal injury and/or
loss of property, it is the
• S350 Stage Modules responsibility of the installer to
add devices (safety, limit controls)
• D350 Digital Temperature Display Module
or systems (alarm, supervisory
systems) that protect against, or
warn of, control failure.

Integration
Cover Screw Module DIP Switch
(One of Four) Connector
Fast
1 2 3 4

Medium
Slow
Setpoint Off
On
Dial

Throttling Range
Potentiometer THROT MIN Integration DIP switch is
RANGE OUTPUT
shown in proportional-only position.
Minimum Output
Potentiometer

Reverse
Acting (RA)
LED Indicator
VDC

24V

Direct
SN

(Percent of Output)
C
V

Acting (DA)
I

Operation Mode
Jumper Positions

V: 0-10 VDC Output 24V: 24 VAC (+)

I: 0-20 mA Output C: Common (-)
SN: Sensor Input VDC: +5 VDC (not used)

Figure 2: Interior View Showing A350P Control’s Features

2 System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin
Minimum Output Adjustment Throttling Range (Proportional Band)
The minimum output adjustment sets the minimum The throttling range is the range over which a control
voltage or milliampere output provided by the A350P is active. Throttling range for the A350P control can be
control. It can be adjusted from 0 to 60% (0 to 6 VDC adjusted from 2 to 30F° (1 to 17C°). Make the
or 0 to 12 mA) of the output range. adjustment at the throttling range potentiometer
marked THROT RANGE (see Figure 2).
Example:
A controlled device responding to a 4-20 mA output
would require the minimum output to be adjusted to Integration Function
20% or 4 mA. (See Figure 3.) The minimum output Proportional-only controls cannot hold a process at the
adjustment may also be used to set valves or dampers exact setpoint. A proportional offset is always present
to minimum positions. because the control output is 0% at setpoint. Any load
0% on the system will cause the control point to be offset
20% from the setpoint. The greater the load on the system,
20 50% the further the control point will be offset from the
setpoint. (This is commonly referred to as proportional
offset, and under maximum load this error will
Output 10 approach the throttling range.)
(mA)
4 Throttling Range Some proportional-only controls are designed with
0 their setpoint located midway through the proportional
2 4 6 8 10 12 14 16 18 20 band to help compensate for this offset. This results in
0
a plus/minus error from the setpoint rather than a
Deviation Above Setpoint (F°) single-ended error. Refer to Figure 4.

Figure 3: Output vs. Deviation from

Setpoint for: Minimum Output = 0, 20, and
50%, Throttling Range = 20°F (DA)

Make the adjustment at the minimum output

potentiometer marked as MIN OUTPUT.
(See Figure 2.) For each 10% increase in output, the
next bar on the LED indicator will light (only one bar is
lit at any time).
Note: Before setting the minimum output
potentiometer, verify that the control reads
zero output (that is, no LEDs are lit).

System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin 3
 Proportional Only Control
Temperature

System Load
Proportional
Offset Throttling
Load Change
Range
Control Point
Follows the Load
Setpoint

Time

Proportional Plus Integral Control

Temperature System Load

Proportional Load Change

Integration adjusts the
Offset = 0
proportional output to
bring the process to
Setpoint
setpoint regardless of load.

Time

Figure 4: Comparison Between Proportional Only and Proportional Plus Integral Control

The A350P control has an integration feature that The A350P control has three field-selectable
forces the control point to match the setpoint. Over integration constants and an off position. The
time, the A350P will control the heating/cooling integration DIP switch selects the integration constant.
equipment to balance the system load at the control (See Figure 2 for location.)
setpoint. (See Figure 4.)
The field-selectable integration constants include:
On traditional proportional plus integral controls, the
amount of correction will become too large if the • OFF: Switch 1 to On position, all others Off
system load exceeds the capacity of the equipment. provides proportional-only operation.
When the actuated device (valve or damper) is fully Note: In open-loop (without feedback) applications,
open or closed and the setpoint still cannot be select OFF (proportional-only) operation.
reached, the integration error continues to grow. The
result is called integral windup. • Slow (C3): Switch 2 to On position, all others
Off is the slowest integration constant (26 minute),
The A350P control avoids integral windup with a and is suitable for most proportional plus integral
patented circuit that puts a dynamic ceiling on the applications. Slow is the recommended initial
integrator. This resets the integration error when the setting.
sensor goes just above the setpoint plus the throttling
range (in DA mode) or just below the setpoint minus • Medium (C2): Switch 3 to On position, all
the throttling range (in RA mode). This allows the others Off selects a 13-minute integration
process to recover from an out-of-range condition constant. If the rate of system recovery to setpoint
without a large overshoot. is sluggish with the control set to slow, and if the
system has enough capacity to drive the process
to setpoint at a faster rate, the medium setting
may be used.
• Fast (C1): Switch 4 in On position, all
others Off is the fastest integration constant
(6.5 minutes). Use fast only in instances where the
rate of change at the sensor is extremely rapid
and system capacity can compensate for that
rapid change.

4 System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin
Reverse or Direct Acting Operation
With the operation jumpers in the Reverse Acting (RA) S350A On-Off Stage Modules
position, the analog output increases as the
temperature drops below setpoint. (See Figure 5.) S350A On-Off stage modules receive power, setpoint,
and sensor input from the A350P control. S350A stage
With the operation jumpers in the Direct Acting (DA) modules perform switching functions based on the
position, the analog output will increase as the control’s setpoint and sensor information, as well as
temperature rises above the setpoint. the offset and differential selected at the S350A stage
module.
Select the RA/DA mode by positioning the operation
jumpers vertically or horizontally. (See Figure 2.) For more information on these modules, refer to the
TM
Position the operation jumpers vertically for RA and System 350 S350 Temperature, S351 Humidity,
horizontally for DA. and S352 Pressure On/Off Stage Modules
Product/Technical Bulletin (LIT-930080).
The RA/DA operation jumpers are installed in the RA
mode at the factory.
S350C Slave Stage Module
Note: Dashed areas show throttling range possibilities
from minimum to maximum. S350C slave stage modules receive power and sensor
Reverse Acting Direct Acting
input from the A350P control. S350C slave stage
10 20 20 10 modules perform switching functions based upon the
VDC mA mA VDC control’s sensor information, as well as the setpoint
RA DA and differential selected at the S350C stage module.
10 10
For more information on these modules, refer to the
- + TM
0 0 0 0 System 350 S350C Temperature Slave Stage
30 25 20 15 10 5F° 5 10 15 20 25 30F° Module Product/Technical Bulletin (LIT-930084).
Setpoint Setpoint
Throttling Range Throttling Range
S350P Proportional Stage Modules
Figure 5: RA and DA Proportional Bands Shown in S350P proportional stage modules receive power,
Proportional-Only Mode setpoint, and sensor input from the A350P control. The
S350P stage module responds with an analog 0 to
A dd-on Modules 10 VDC and 0 to 20 mA output signal. This is based
upon the control’s setpoint and sensor information, as
well as the offset, throttling range, and minimum output
The maximum number of add-on modules is listed in
selected at the S350P stage module.
Table 1.
For more information on these modules, refer to the
TM
Table 1: Maximum Number of S350 Stage System 350 S350P Proportional Plus Integral
Modules per A350P Temperature Stage Module Product/Technical Bulletin
(LIT-930086).
Power Number Number of Number of
Source of S350A S350A or S350A or
or S350C S350C S350C
Stage Modules Modules
Modules (with (with
Allowed One S350P) Two S350Ps)
Allowed Allowed
Y350R 4 2 0
External 9 8 7
Class 2
Transformer

System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin 5
D imensions
Mounting Slots 3/16 (4)
for No. 6 Screws

1/2 (13)

5 (127)
2 15/16 A350P
(75)
4 (102)

1 9/16 DIN 2 3/8 (61)

(40) 7/16 (11) Rail Mount

1 3/16 (31)

Sensor 3 (76)
1/4 (6) 2 3/8 (61)

9 3/4 (248) 2 (50)

7/8 (22) Conduit 7/8
Hole (22)

Figure 6: A350P Control and Sensor Dimensions, in. (mm)

I nstallation and Wiring

The A350P Temperature Control is housed in a
Celsius Scale Conversion compact NEMA 1 plastic enclosure designed for
A Celsius scale throttling range decal is included with standard 35 mm DIN rail mounting. Four key-slot
the A350P control. If the Celsius scale is desired: mounting holes on the back of the control case are
provided should surface mounting be required. If a
1. Locate the throttling range and minimum output Y350R is used, it should be mounted immediately to
potentiometers on the main PC board. the right of the control. Any S350 modules would
(See Figure 2.) Carefully remove the knobs and follow on the right, with the D350 being the last module
the existing decal. mounted, also on the right.
2. Apply the Celsius scale decal in the same place as Note: When mounting any System 350 module to
the original decal. rigid conduit, attach the hub to the conduit
3. Rotate both knob stems completely before securing the hub to the control
counterclockwise (CCW). enclosure.

4. Reinstall the potentiometer knobs so the arrows

point to the minimum values. ! WARNING: Risk of Electrical Shock.
Disconnect power supply before
making electrical connections to
avoid possible electrical shock or
equipment damage.

6 System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin
Wiring Terminals Sensor Connection
Install all wiring to conform to the National Electrical Shielded cable is not generally required for sensor
Code and local regulations. For maximum electrical wiring on runs of less than 50 feet. When using
rating of control, refer to the label inside the control shielded cable, isolate and tape the shield at the
cover. Terminals will accept 12 to 26 AWG wire. Use sensor. Connect the shield to Terminal C on the
only copper conductors. A350P control.
1. Use a 1/8 in. (3 mm) flat-blade screwdriver to push Refer to Table 3 for the maximum recommended cable
the clamp arm down. lengths for particular sizes of wire.
2. Insert the appropriate wire into the opening. Table 3: Maximum Recommended
Refer to Table 2 for terminal designations. Sensor Cable Lengths
3. Release the clamp arm to secure the wire.
Wire Shielded Cable Length
See Figure 7.
Gauge Feet Meters
14 AWG 800 244
16 AWG 500 152
18 AWG 310 94
20 AWG 200 61
22 AWG 124 38

• Various A99B Series Temperature Sensors and

mounting hardware are available for use with
A350P Series controls.
The sensor must be connected to Terminals SN
V I SN VDC and C. (See Figure 2.) The sensors are not
polarity sensitive.
Figure 7: Cage Clamp Terminal Block • The sensor must be mounted so that it can
accurately sense the temperature of the controlled
Table 2: Terminal Designations medium.
Terminal Description Table 4: A350P Controls And Sensors
V 0 to 10 VDC output Control Sensor Included
I 0 to 20 mA output Sensor Lead Length is 9-3/4 in. (0.25 m)
SN Temperature sensor input A350PS-1C A99BB-25C; Range: -40 to 212°F
VDC 5 VDC power supply (not used) (-40 to 100°C)
C Common for power supply, A350PS-1CM A99BB-25C; Range: -40 to 212°F
temperature sensor, and outputs (-40 to 100°C)
24V 24 Volts AC A350PS-2C A99BC-25; Range: -40 to 248°F
(-40 to 120°C)
Note: Output signals from the A350P control vary
from 0 to 10 VDC and 0 to 20 mA. (Both A350PS-2CM A99BC-25; Range: -40 to 248°F
outputs can be used simultaneously.) (-40 to 120°C)
Connections can be made to both the V and A350PT-1C No Sensor Included
I terminals, allowing the control to drive A350BA-2C A99BC-25; Range: -40 to 248°F
two outputs from the same RA or DA ramp (-40 to 120°C)
simultaneously. This feature can be used to
drive motor actuators of different types in a • For more information regarding sensor options
single application. and installation, refer to the A99B Series
Temperature Sensors Product/Technical Bulletin
(LIT-125186).
System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin 7
A djustments
Follow this procedure to set up the A350P control for 5. Make sure the system is stable in the proportional
the types of operation desired. mode before selecting integration. Refer to the
Checkout Procedure section.
1. Remove its cover by loosening the four captive
cover screws. (See Figure 2.) 6. Reinstall the cover and secure in place with the
four captive cover screws.
2. Set the RA/DA operation jumpers to the desired
mode of operation. Position the operation jumpers 7. Adjust the setpoint dial to the desired setpoint.
vertically for RA (Reverse Acting) or horizontally
If using the D350 Display Module, press and hold
for DA (Direct Acting). (See Figure 2.)
the setpoint button on the D350 while rotating the
3. Adjust the throttling range potentiometer to desired setpoint dial.
setting. Rotate Clockwise (CW) to increase the
Note: The control’s setpoint is factory calibrated at
throttling range.
midscale to a tolerance of ±1F° (0.6C°). The
Notes: Included with the control is a Celsius scale setpoint tolerance at the extreme ends of the
throttling range decal. If the Celsius scale is setpoint scale may be ± 4F° (2.2C°). The
desired, refer to the Celsius Scale Conversion D350 Display Module is unaffected by this
section for decal installation instructions. tolerance shift. Use the D350 for the most
accurate setpoint selection.
If the A350P is to be used in proportional plus
integral control, the initial throttling range
adjustment is seldom set below 6F° (3C°). C heckout Procedure
A narrow proportional band used in Follow this procedure to verify the A350P control is
conjunction with the integration may result in connected and functioning properly.
unstable control.
1. Before applying power, make sure that the
4. If minimum output is required, set the minimum installation and wiring connections are according
output potentiometer (see Figure 2) to the desired to job specifications.
position. The 10-segment front LED panel or a
voltmeter can be used to read the minimum 2. Set up the system for proportional mode
output. (The minimum setting for the control is (Integration = OFF), and make any necessary
designated by the 0 on the decal.) adjustments to the setpoint, throttling range, and
minimum output. Then select Reverse or Direct
Notes: Before adjusting the minimum output Acting mode.
potentiometer, verify that the control reads
zero output (that is, no LEDs are lit). 3. After making adjustments and electrical
connections, apply power to the system, and
For each 10% increase in output, the next observe it for stable operation.
bar will light on the LED bar graph (only
one bar is lit at anytime). In a milliampere 4. If integration is required, select the fast (C1),
application, each bar equals 2 mA. In a medium (C2), or slow (C3) integration constant.
voltage application, each bar equals 1 VDC. Slow is the recommended initial setting. (Refer to
(Refer to Figure 3.) the Integration Function section.)
Example: 5. Put the system back into operation. If instability
occurs, consider increasing the throttling range.
To set the control for a minimum output of
4 mA, turn the minimum output potentiometer
clockwise until the second LED segment just
lights.

8 System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin
T roubleshooting
If the control system does not function properly, verify 2. Check sensor for proper resistance at a given
that the proper operation mode is selected on each temperature. (The resistance across the sensor
module (DA or RA), and perform the following changes with the temperature of the sensor.)
procedures to determine the cause of the problem:
a. Disconnect power from the A350P control.
1. Check for proper voltages on the A350P control.
b. Disconnect the sensor from the control and
a. Connect a digital voltmeter (DVM) between measure the resistance across sensor leads.
Terminals 24V (+) and C (-) located on the
c. When measuring the sensor’s resistance, use
A350P’s terminal block. (See Figure 2.)
an accurate thermometer to measure the
If an external transformer is used, select AC temperature at the sensor.
volts on the DVM. Verify that the voltage is
d. Refer to Figure 8 to determine the optimal
between 20 and 30 VAC.
resistance for the measured temperature.
If a Y350R Power Module is used, select DC
e. If the measured resistance varies substantially
volts on the DVM. Verify that the voltage is
from the optimal resistance for that
between 16 and 38 VDC.
temperature, the sensor or wiring must be
If an external DC power supply is used, select replaced.
DC volts on the DVM. Verify that the voltage is
f. If the sensor’s resistance conforms to the
between 22 and 29 VDC.
chart in Figure 8, reconnect the sensor to the
b. If the DVM reading is within the indicated control.
voltage range, select DC volts on the DVM
g. Reconnect power to the control.
(DVM must be accurate to +/-0.01 VDC), and
connect the (+) lead to Terminal VDC and the Note: The sensor reading indicated by the D350
(-) lead to Terminal C. may differ somewhat from thermometer
readings due to sensor tolerances, time
If the DVM voltage is between 4.9 and
constants, thermometer accuracy, and other
5.1 VDC, proceed to Step 2.
factors.
If the DVM voltage is above 5.1 VDC, replace
the A350P. °F Temperature °C
260
c. If the DVM voltage is below 4.9 VDC, check 240 120
the control using the following procedure. 220 100
200
180 80
Disconnect all loads from the A350P control. 160
(If in Direct Acting mode with power on, the 140 60
120
system will go to full output when the sensor is 100 40
disconnected. Thus, ensure that any loads are 80
20
disconnected before disconnecting the 60
40 0
temperature sensor.) 20
0 -20
Disconnect the temperature sensor -20
-40 -40
completely, and recheck the DVM voltage. 500 700 900 1100 1300 1500 1700 1900 2100
If the DVM voltage rises to a value between Resistance (Ohms)
4.9 and 5.1 VDC, replace the sensor.
Figure 8: Temperature vs. Resistance Chart for the
If the DVM voltage is still below 4.9 VDC, A99B Series Sensor
replace the A350P control.

System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin 9
3. Check the A350P control for proper operation. g. If the sensor voltage is above 1.1 VDC
on A350PS-1C or above 1.6 VDC on
Note: Perform Steps 1 and 2 first.
A350PS-2C, adjust the setpoint to match the
a. Reconnect the sensor to the control and actual temperature (Ts). The output Terminal
re-apply power. V should be less than 0.1 VDC, and all LEDs
b. Turn the throttling range and the minimum in the bar graph should be off.
output to minimum by turning both Note: Some tolerance error is present between the
potentiometers counterclockwise. setpoint scale and the setpoint knob pointer.
c. Switch off the integration. Refer to the Adjustments section.

d. Select the RA mode. 1. Make sure the A350P control is in RA

mode.
e. Connect the DVM (+) lead to the A350P
control’s Terminal SN and the (-) lead to 2. Increase the setpoint in increments of 2F°
Terminal C. (1C°).
If the sensor voltage is less than 1.8 VDC on 3. As the setpoint is increased, the control’s
model A350PS-1C or less than 2.3 VDC on Terminal V output voltage should go from
model A350PS-2C, go to Step 3g. 0 to 10 VDC, the Terminal I output current
should go from 0 to 20 mA, and the LEDs
f. If the voltage is greater than 1.8 VDC on should turn on, one at a time from left to
model A350PS 1C or greater than 2.3 VDC on right.
model A350PS-2C, adjust the setpoint to
120°F (49°C) on model A350PS-1C or 240°F 4. If the LEDs do not turn on and if the
(116°C) on model A350PS-2C. outputs of terminals V and I do not change
as described above, replace the control.
The output Terminal V should be less than
0.1 VDC, and all LEDs in the bar graph display h. Readjust the A350P control to the desired
should be off. If not, replace the A350P. control settings.
1. Adjust the minimum output to the
maximum by turning the potentiometer
R epairs and Replacement
CW. As the potentiometer is turned CW, Do not make field repairs or perform calibration.
the LEDs in the bar graph should turn on A99B Temperature Sensors and replacement controls
from left to right until the fifth or sixth bar is are available through the nearest Johnson Controls
on. If not, replace the A350P control. representative. (See Tables 5 and 6 for ordering
2. Adjust the minimum output to zero again, information.)
and select the DA mode.
3. If the right most LED in the bar graph is on
(Terminal V = 10 VDC, Terminal I = 20 mA),
go to Step 3h. If the LED is not on, replace
the A350P.

10 System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin
O rdering Information
Table 5: System 350 Products
Item Product Code Number Description
A350P Proportional Plus Integral A350PS-1C Range: -30 to 130°F (-35 to 55°C)
Temperature Controls Throttling Range: 2 to 30 F° (1 to 17C°)
(Includes the A99BC-25C Temperature Sensor)

A350PS-2C Range: 90 to 250°F (30 to 120°C)

Throttling Range: 2 to 30 F° (1 to 17C°)
(Includes the A99BC-25C Temperature Sensor)

A350PT-1C Range: -30 to 130°F (-35 to 55°C)

Throttling Range: 2 to 30F° (1 to 17C°)
(Sensor not included)
Display Modules D350AA-1C Digital Temperature Display Module (Fahrenheit Scale)
D350BA-1C Digital Temperature Display Module (Celsius Scale)
On/Off Stage Modules S350AA-1C Fahrenheit Scale
S350AB-1C Celsius Scale
Slave Stage Module S350CC-1C Dual Scale (°F and °C)
Proportional Stage Module S350PQ-1C Dual Scale (°F and °C)
Power Module Y350R-1C 120 or 240 VAC, 50/60 Hz Input, Rectified Class 2,
24 VAC Output

Table 6: System 350 Accessories

Item Product Code Number Description
Wall Mount Plate TE-6001-4 Includes sensor mounting clip
Cover T-4000-2644 For wall mount plate
Mounting Clip A99-CLP-1 Surface mounting clip for the A99B Temperature Sensor
Duct Mounting TE-6001-1 Duct-mounting hardware with handy box
Duct Mounting TE-6001-11 Duct-mounting hardware without handy box
Conduit Adaptor ADP11A-600R 1/2 in. snap-fit EMT conduit adaptor (box of 10)
Immersion Well WEL11A-601R For liquid sensing applications
Sun Shield SHL10A-603R For use with outside sensors in sunny locations
DIN Rail Sections BKT287-1R 12 in. (0.3 m) long
BKT287-2R 39-1/3 in. (1.0 m) long
DIN Rail End Clamp PLT344-1R Consists of two end clamps
Cables for Remote Mounting of WHA29A-600R* 3 ft (0.9 m)
D350 Display Module WHA29A-603R 25 ft (7.6 m)
WHA29A-604R 50 ft (15.2 m)
*WHA29A-600R may be used to daisy chain S350 modules together.

System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin 11
Specifications
Product A350P Proportional Plus Time Integral Temperature Control
Supply Voltage Y350R Power Module: Input: 120/240 VAC 50/60 Hz
Output: 24 VDC, unfiltered, 10 VA
External Source: 24 VAC, 50/60 Hz, Class 2 (20-30 VAC)
Note: Only one supply voltage source may be used.
Power Consumption 3.2 VA maximum
Ambient Temperature Operating: -30 to 150°F (-34 to 66°C)
Shipping: -40 to 185°F (-40 to 85°C)
Humidity (all modules) 0 to 95% RH non-condensing; maximum dew point 85°F (29°C)
Setpoint Adjustment Range A350PS-1C: -30 to 130°F (-35 to 55°C)
A350PS-2C: 90 to 250°F (30 to 120°C)
A350PT-1C: -30 to 130°F (-35 to 55°C)
Throttling Adjustment 2 to 30F° (1 to 17C°)
Range
Analog Outputs 0 to 10 VDC (550 ohm load minimum) and 0 to 20 mA (600 ohm load maximum)
Minimum Output Adjustable from 0 to 60% of the output
Output Indication A ten segment LED bar graph indicates percentage of output.
Control Action Direct or reverse action is jumper selectable.
Integration Constant Four selectable rates: fast, medium, slow, and off
Sensor Replaceable positive temperature coefficient sensor
Reference resistance 1035 ohms at 77°F (25°C)
Material Case and cover: NEMA 1 high-impact thermoplastic
Agency Listing UL Listed, CCN XAPX, File E27734
UL Listed for Canada, CCN XAPX7, File E27734
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications,
consult Johnson Controls Application Engineering at (414) 274-5535. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication
or misuse of its products.

Controls Group
507 E. Michigan Street
P.O. Box 423 Printed in U.S.A.
Milwaukee, WI 53201 www.johnsoncontrols.com

12 System 350 A350P Electronic Proportional Plus Integral Temperature Control Product/Technical Bulletin