Emerson ALCO CONTROLS OSB Manual De Instrucciones

G e n e r a l i n f o r m a t i o n :
The function of oil separator is the separation of oil from hot
gas of discharge line and returning it back to the
compressor or to the oil reservoir in systems with multiple
compressors.
S a f e t y i n s t r u c t i o n s :
• Read operating instructions thoroughly. Failure to
comply can result in device failure, system damage or
personal injury.
• This product is intended for use by qualified personnel
having the appropriate knowledge and skills like trained
according to EN 13313 or a specific training for
flammable refrigerants.
• Flammable refrigerants require special handling and
care due to its flammability. Sufficient ventilation is
required during service of the system. Contact with
rapidly expanding gases can cause frostbite and eye
damage. Proper protective equipment (gloves, eye
protection, etc.) has to be used.
• Ensure that the system is correctly labelled with applied
refrigerant type and a warning for explosion risk.
• In a severely contaminated system, avoid breathing acid
vapours and avoid contact with skin from contaminated
refrigerant / lubricants. Failure to do so could result in
injury.
• Before opening any system make sure pressure in
system is brought to and remains at atmospheric
pressure.
• Do not release any refrigerant into the atmosphere!
• Do not exceed the specified maximum ratings for
pressure and temperature.
• Observe and avoid mechanical damage of component
housing.
• Do not use any other fluid media without prior approval
of EMERSON. Use of fluids not listed could result in:
- Change of hazard category of product and
consequently change of conformity assessment
requirement for product in accordance with European
Pressure Equipment Directive 2014/68/EU.
• Ensure that design, installation and operation comply
with European and national standards/regulations.
• For flammable refrigerants only use accessories
approved for it!
M o u n t i n g l o c a t i o n :
The oil separator should be installed as close as possible
to the compressor(s) in the main discharge line (Fig. 1 & 2)
but after any installed muffler or vibration adsorber.
(1) Oil separator (5)
(2) Oil return line to (6)
compressor crankcase
or to oil reservoir
(3) Compressor (7)
(4) Condenser (8)
• WARNING: Prevent the migration of liquid
refrigerant back into the oil separator shell during off-
cycles by one of the following recommendations:
- Install the oil separator in a location where it is higher
than condenser.
- If the oil separator located slightly lower than
condenser, install the line from oil separator to the
condenser at higher level than the condenser and with
a downward slope into the condenser inlet connection.
- In systems which the condenser located higher than
the oil separator, it is recommended the use of a check
valve at outlet of oil separator.
I n s t a l l a t i o n :
• Before proceeding with the installation, the oil separator
must be charged with certain amount of oil in order to
actuate the float mechanism immediately after start-up.
Use the same type of oil as filled in the compressor
Emerson Climate Technologies GmbH
Pascalstrasse 65 I 52076 Aachen I Germany
O P E R A T I N G I N ST RU C T I O N S
Oil separators OSB / OSH / OST
crankcase.
• 0.5 Liter initial oil charge for OSH / OST-4xx(-L)
• 0.6 Liter initial oil charge for OSB / OSH-6xx
• The oil must be charged through outlet connection.
• The oil separator shell must be mounted securely in a
vertical position.
• WARNING: Protect the oil separator against
vibration and gas pulsation generated by compressor.
Install the vibration adsorber and muffler between
compressor and oil separator.
• The oil return line (minimum 3/8" or 10 mm tube) should
be connected to the compressor crankcase or to the oil
reservoir in the systems with multiple compressors.
B r a z i n g :
• Perform the brazing joint as per EN 14324.
• Before and after brazing clean tubing and brazing joints.
• Minimize vibrations in the piping lines by appropriate
solutions.
• To avoid oxidization, it is advised to purge the system
with an inert gas such as nitrogen while brazing.
• When brazing, direct flame away from shell. Use wet rags
or other suitable heat protection to prevent damage to the
paint surfaces adjacent the fittings.
• Do not exceed the max. surface temperature of +150 °C!
• WARNING: The oil separators OSB / OST with
flange cap are incorporated a gasket. If so, the gasket
can be destroyed, and it must be replaced. Keep the
flange cap cool.
P r e s s u r e T e s t :
After completion of installation, a pressure test must be
carried out as follows:
- according to EN 378 for systems which must comply with
European pressure equipment directive 2014/68/EU.
- to maximum working pressure of system for other
applications.
T i g h t n e s s T e s t :
Conduct a tightness test according to EN 378-2 with
appropriate equipment and method to identify leakages
from joints and products. The allowable leakage rate must
be according system manufacturer's specification.
WARNING:
• Failure to pressure test or tightness test as
described could result in loss of refrigerant, damage
to property and/or personal injury.
• The tests must be conducted by skilled personnel
with due respect regarding the danger related to
Oil level controller
pressure.
Connection line to
• In case of detection of leakage around flange of oil
suction line
separators OSB / OST, check the gasket and the
tightness of bolts with 35 Nm torque. A spare gasket is
Differential oil
supplied with each OSB / OST oil separator.
pressure switch
• After leakage test, the unused spare gasket should be
Oil reservoir
taped or hanged in a position near oil separator for use
when it is required.
O p e r a t i o n :
• After leakage test, start system. The oil level in
compressor crankcase and in oil reservoir must be
watched after start-up, the first hours of operation and
few days later. The new refrigerant will adsorb some oil.
It may a small portion of oil to be trapped in the system
somewhere in lines or heat exchangers.
• The oil separator removes the excess oil but this may not
be retained in compressor crankcase immediately.
• In normal operation, the oil return line to the compressor
crankcase or to the oil reservoir which will be alternatively
hot and cold. This is caused by opening and closing of
the needle valve via lifting and lowering of the float
mechanism.
• In outdoor installation at low ambient temperatures, the
oil separator may be needed to be protected against cold
www.climate.emerson.com/en-gb
stream of air in order to prevent the condensation of
refrigerant in the oil separator shell. The condensed
liquid refrigerant will be sent through oil return line into
the compressor crankcase, creating foam in the oil and
causing lubrication problem. Oil separators perform best
when operating at or near the compressor discharge
temperature. It is advisable to insulate the oil separator
shell.
WARNING: During operation of system, the shells
•
have a high surface temperature
S e r v i c e / M a i n t e n a n c e :
• Oil separator OSB and OST are equipped with flange and
can be opened for cleaning. Always use a new gasket
(Gasket set – Part No. 808800) and tight the bolts with
35 Nm torque.
• The external surface of shells is coated by epoxy powder
painting for optimum protection against corrosion. The
external surface of shell shall be checked as per EN 378
during routine/periodic inspection/service.
• Before any debrazing ensure that the flammable
refrigerant is pumped out of the system and the room
around the system is well vented so no refrigerant left.
• According to EN 378-4
maintenance, tightness tests shall be carried out at the
relevant part of the refrigerating system. This shall apply
where appropriate following any repair.
• When disposing or removing the component or part from
refrigeration system, ensure that no refrigerant remains
ed trapped inside of the part.
T e c h n i c a l D a t a :
Max. allowable
pressure PS 31 bar
Max. Test pressure PT
Cat. I 34.1 bar
Cat. II 44.3 bar
Temperature range TS -10...+150 °C
Initial required
Oil Charge
OS...-4...(-L): 0.5 l
OS...-6...: 0.6 l
Volume
OS...-4...(-L):
1.8 ... 3.8 l
OS...-6...:
6.5 ... 7.9 l
Hazard category / (PED 2014/68/EU)
Conformity Assessment
OS...-4... Cat. I / Modul A (A1)
OS...-6... Cat. II / Modul D1 (A1)
OS...-4...-L Cat. II / Modul D1 (A2L)
Refrigerants
Fluid Group II R134a, R404A, R407C,
OS...-4... R448A, R449A, R450A,
OS...-6...: R452A, R507, R513A,
R1234ze*
Fluid Group I R444B, R447A, R454A,
OS...-4...-L R454C, R455A,
R1234yf
NOTE: Fluid group according to PED 2014/68/EU.
*) A2L acc. to ASHARE
Date code on label Mxxxx (Made in Mexico)
Marking
OS...-4...:
OS...-6... /
OS...-4...-L
all types
Dimensions See Fig. 3
OI_OS_A1_A2L_EN_DE_FR_ES_IT_RU_Rev09_862958.docx
EN
during each periodic
,
0036, (pending)
, (pending)
Date: 12.01.2023