Air purger type CPAM EKA AIR C16 Controller data

sheet, installation, instruction and service manual

• Proven performance
• Suitable to work with NH3 plant from 250kW upto 3700 kW
• Standard 16 purge points
• Record of volume of purged out air
• Works with liquid pump systems, HP valve systems, gravity feed
systems
• Easy installation

The only air purger that works efficiently and remove air out of
NH3 systems
EKA-KOOL Air purger is suitable for NH3 plants capacity up to 3700kW at -42C. EKA AIR M3 Air purger EKA AIR M3. System Desciption
nominal condensing capacity 2kW Mk. 2 and i Description of (pos. no.) function and items

The heat exchanger in the air purger has a nominal design capacity of 3kW at 10°C differential pressure
10
/ temperature between suction pressure and condensing pressure on the system it is connected to. At
larger pressure/temperature differences the capacity increase to a maximum of 3kW. The low pressure
side connected to the air purger needs to be able to deliver this capacity. However the actual air (non
condensable gas) venting capacity is dependent on the amount of non condensables in the condenser. 6
On the high pressure side the air purger draws refrigerant gas and non condensables into the purger
with a minimum of 2kW’s capacity, ensuring that the purger vents as much non condensables as possible 3
during its operation. Due to its high capacity it is recommended that on small systems the purger is only
run for a relatively short period of time every day. Once the general level of non condensibles has been
brought down to a low level, one hour once or twice a day is often appropriate. In conjunction with this 4
we recommend that you compare the time the air purger is in operation with the time it vents. If the air
purger vents a majority of time in operation, it is likely possible to get more air out by increasing the time 9 1C
in operation. On the other hand, if the air purger only vents for a short period of time during operation, it 5 8
is recommended to shorten the time in operation and thereby saving the 2kW of heat load. Once the air
purger gains access to large pockets of air, its capacity will be very large and not limited to the condens- 1B
ing capacity of the coil as illustrated in below diagram.
1A
Purge flow by volume at condensing pressure. Liter/minute 2A

7 1
2

Installation:
If the CPAM air purger is installed with either pumped or high pressure liquid feed (standard installation,
see enclosed drawing), it does not need to be installed in any specific position in relation to the condens-
er, high pressure receiver etc. The CPAM can be installed anywhere convenient for your system. If the
CPAM is installed for gravity feed circulation (see enclosed drawing), it needs to be placed appropriately
in relation to the feed reservoir to enable a low pressure liquid flow into the air purger. The height differ-
ence requirement to secure this gravity circulation of the refrigerant is to place the CPAM a minimum of
0.5 m. below lowest liquid level in the low pressure liquid separator. Important: The foul gas (pos 1) line
from the condenser must be a minimum DN8 and all the valves in this line should be a minimum DN8
(solenoid valves, stop valves) to ensure the necessary capacity can be transported to the air purger while
it is purging. NOTE: Foul gas line must be connected to DN10 (3/8”) inlet on purger, but should be DN10
The table shows ratio air purging on condensing pressure temperature and equivalent to its present in until last possible moment.
the system under current operating pressure
Description of positions and function The following numbers refer to the position numbers in the en-
closed drawing.
1) Connection for liquid supply: DN 10 (3/8”). 5) Connection to “wet” suction line: DN 18 (3/4”) stainless steel. Function: Connects the air purger to the
Function: The Low pressure liquid fills the CPAM outer vessel to keep the inner vessel and coil cooled. low pressure liquid separator.
The liquid supply can be done in three different ways either by low pressure pumped liquid, gravity circu-
lation, or by high pressure liquid. 6) Safety valve according to local rules and regulations. Not included in delivery. For calculation of safety
• Pos. 1 A is the standard connection for the liquid supply to a low pressure pumped liquid line through valve for the EKA Air Controller C16, an outer surface of 0.45 M² can be used.
the included orifice Ø 1.2 mm (pos.1.A). Function: Securing the vessel against excessive pressure. A safety valve must be selected and mounted
• Pos 1.B If the CPAM is feed by high pressure liquid supply a Danfoss EVM + CVH (not included in by the user according to local rules and regulations.
delivery) + special orifice screw (Ø 0.5 mm included in delivery on request ) must be used. The spe-
cial orifice screw must be mounted in the EVM solenoid valve (pos. 1.B) and the EVM mounted in the
CVH housing. The EVM solenoid valve (pos. 1.B) must be opened when the air purger get “run” power
from the refrigeration system by the same power supply as the EVM in pos. 3 and the EKA-AIR C16
controller. The CPAM must be stopped when the refrigeration systems stops and / or when the liquid
separator it is connected to gives alarm / warning for high level. Otherwise there is a risk of overfilling 7A 7 7B
the low pressure liquid separator.
• Pos. 1.C is the connection type to be used if the CPAM is feed by gravity circulation. When using
gravity circulation the CPAM must be placed min. 0,5 m below lowest liquid level in the low pressure
liquid separator and the Ø 3,0 mm orifice must be removed.

2) Connection to fouled gas from purge points: DN 10 (3/8”) stainless steel. 7) Expansion plug with special built in orifice: , This expansion plug is with special expansion orifice
Function: Connects the internal coil with the purge points. Note: The connection from the coil to the mounted.
purge points must be min. DN 10 (3/8”) and the connection must never be closed during operation of Function: The special expansion orifice and the internal connection housing work as an expansion valve
the CPAM as this can result in an unintended refrigerant gas release from the air purger. for return of condensed liquid to the suction side of the refrigeration system. Once the system starts,
the condensed and sub cooled liquid in the CPAM separation chamber is drained back and expanded
2A) Stop valve: DN10. Not included in delivery. through the connection housing to the CPA’s external chamber. As the separation chamber is drained for
Function: Closing the fouled gas line from purge points during service. NOTE: This valve must never be condensed liquid, new refrigerant and non condensable gas is drawn into the CPAM for separation.
closed during operation of the air purger as it can result in an unintended release of refrigerant gas thru
the air purger vent line. 7A & 7B) Drain plugs of inner and outer vessels.
When cleaning and service is nescessary, these plugs can be lossen and liquid in air purger can be
3) Solenoid valve with special built in orifice: EVM pilot solenoid valve, with special orifice mounted in drained
CVH pilot valve housing.

Function: When the solenoid valve opens it allows for air purging. Regulation: The solenoid opens when
8) Capacitive liquid level probe: A HBLC-SW3 special level control rod with build in heating element and
the liquid level in the separation chamber is pressed below the lowest switch point of the special level
two factory calibrated preset switch points for correct function.
probe by the air (non condensable gas) above the liquid surface. The solenoid valve closes again when
there has been enough air purged allowing the liquid level to reach the upper factory preset switch point
Function: When the volume of air (non condensable gas) in the separation chamber increase it will dis-
of the level probe.
place the volume of condensed refrigerant in the separation chamber and the liquid level will drop. The
Note: A time counter is integrated in the EKA-AIRC16 control box, counting how many seconds the purge
level probe will open the air vent solenoid valve at low liquid level and close it again at high liquid level.
solenoid (pos3) has been open. This gives a fairly accurate measurement of how much air has been
Regulation: When the level drops below the lowest preset switch point on the level probe (pos. 8), the air
purged from the system. Please see the diagram and example on page 1.
purge solenoid (pos3) opens and the air (non condensable gas) purge at condensing pressure through
the purge solenoid with its special orifice (pos.3). When the liquid level reach the upper preset switch
Note: A time counter is integrated in the EKA-AIRC16 control box, counting how many seconds the purge
point on the level probe (pos.8) the air purger solenoid (pos3) closes.
solenoid (pos3) has been open. This gives a fairly accurate measurement of how much air has been
purged from the system. Please see the table on page 1.
9) Water filled reservoir. Not included in delivery.

4) Check valve: Parker stainless steel hydraulic check valve with max. 0.5 bars opening pressure or Function: Absorption of any ammonia gas that might be purged with the air (non condensable gas).
similar. Bubbles that pass through the water to the surface are air (non condensable gas), while bubbles that
Function: The check valve ensures that ambient air or water from a water reservoir/bubbler is not drawn disappear in the water will be ammonia gas. Note: The ammonia content in the purged air will depend
into the EKA Air Controller C16 in the event of a malfunction where the pressure in the EKA Air Controller on the difference between the saturated condensing and saturated evaporating temperatures respec-
C16 could drop below atmospheric pressure. tively. A large difference will result in a very low content of ammonia, while a low difference will result in
a somewhat higher content.
10) EKA-AIRC16 Control box: A complete control box for CPAM (and CPA 10-3) with connection for up to Safety
16 purge points
Function: Start delay: The control box will delay the possible opening of the air out blow valve in 05 to 60 • It is the customers/users responsibility to connect the air purger to a safety valve system in
minutes (adjustable) from the start of the air purger to ensure that the CPAM and the refrigeration accordance with local rules and regulations. For calculation of safety valves an outer surface of the air
system are in balance before it is allowed to vent air out. Recommended standard setting is 10 minutes. purger vessel of 0.45 m² can be used.
The delay time can be set longer on systems where it takes a long time for the starting compressors to • The customer/user must mount a quick closing drain valve on the oil drain in accordance with local
make normal differential pressure in the system. The delay time can be set shorter if the starting com- rules and regulations.
pressor makes normal system differential pressure very quickly. • The customer/user must ensure that the air purger cannot be activated without access to an open
purge point. If this requirement is not met it can result in refrigerant in the air purge line.
Liquid level indication: At normal operation the display on the EKA-AIRC16 Control box will show the liq- • It is not possible to get trapped liquid in the air purger as long as no service stop valves are closed
uid level in the separation chamber of the CPAM. By following the liquid level it can be seen if air is build- since solenoid valves can open backwards allowing trapped liquid to escape.
ing up in the separation chamber as the liquid level will slowly drop. When the level reaches the preset
low switch point the air vent valve is opened. The air vent is closed again when the liquid level reaches Note:
the preset upper level. This can be followed on the EKA-AIRC16 Control Box during operation.
It is recommended to check the refrigeration systems water content on the low pressure side, when air is
Air purging start and stop: The control box will allow the CPAM to vent air when the inner chamber is found in the system as the air brings moisture with it. Since air and water are pollutants in a refrigeration
filled with air (non condensable gas) and after the start up timer has run out. The air purging starts when system, the presence of them have serious consequences for the system’s capacity, power consumption,
liquid level reaches the lower preset switch point of the special HBLCSW3 liquid level sensor and stops efficiency and maintenance cost. If any water is found in ammonia refrigeration systems it is
again when the liquid level reaches the preset upper switch point. recommended to mount a CPW-15 to clean the system for water and other impurities.

Purge time counter: The control box has a build in purge time counter so the volume of air purged can be
calculated from the curves enclosed in the description material. The time counter counts the time the air
vent valve (pos.11) has been opened in hours, minutes and seconds. On the operation screen total purge
time can be seen. The total purge time is the total time the air vent valve (pos.11) has been open no
matter the control box has been switched off (or lost power etc.) as the time is stored in the memory of
the control box.

Purge points: The control box has connections for up to 16 purge points. When a time (05 to 30 minutes)
is set for a purge point the purge point will be active. If zero (0 minutes) is entered for the purge point the
purge point is not active.
Note: It is very important that only the purge points which are connected to the refrigeration system are
set to be active in the control box. Otherwise the air purger can be turned on with no open connection to
the fouled HP gas which can lead to an unintended release of refrigerant vapor.

Communication Port RS485

The communication port RS485 is enable and you can extract data from controller to your PLC. Data re-
trievable are 1)Liquid level, 2) Number of purge point, 3) Current active purge point, 4) Total purge time

CB
The circuit board is protected by an 10A CB.
Practical installation guidelines Purge Point Installation
Below are some typical systems which purge points should be correctly installed.
1. The CPAM should be installed at a position which is easy to access and conduct service.
2. All systems might not be clean and there is dirt, particles, foreign agents in the system and it will
block the expansion plug at the bottom of the CPAM. Cleaning will be needed.
3. The Controller should be installed near the CPAM and under the roof. Should you need to extend the
control cable provided by us, you must make sure the cable is of compatible screen type. Silver solder
the connection points. Control cable may not be ran together with high voltage cable to avoid elec-
trical noise/disturbances
4. There should be a main CB near the controller for easy setup and service
5. There should be filter on all solenoid valves at purge points.
6. If possible, you should have all purge pipes run down to lower level before joining the common pipe
go to the CPAM. The solenoid valves can be at one station for easy checking and replace the coil
when needed.
7. Make sure the liquid pipe from LP vessel is not from the lowest point of the vessel. There is a risk of
having decomposed oil from LP vessel enter the CPAM and the CPAM will not work properly.
8. Feed the liquid from LP vessel which should always be in operation mode. e.g. cold storage
9. All valves should be fully opened in operation mode (Only one solenoid valve at purge points should
be energized)
10. The vessel should be insulated

Trouble shooting:
Condition Possible cause/Solution
A little constant smell of ammonia • Electrical failure keeping the air vent solenoid valve (pos. 3)
from the air vent pipe and Arm- open when there is no air trapped in the air purger.
strong liquid trap (pos. 9) very cold • Air vent solenoid valve (pos. 3) is leaking.
at the bottom.
High concentration of ammonia • There is no open connection to at least one purge point. This
gas released when the air purger is could be caused by a broken coil or an electrical problem
purging air. where no solenoid valves at the purge points are open or a
closed service stop valve in the fouled gas line
• Liquid feed orifice clogged
The air purger does not seem to • The coil on the ON / OFF solenoid valve (pos.3) is broken.
have any condensing capacity. • The special built in orifice in the expansion plug (pos. 7) is
clogged and must be cleaned. (note the complete CPAM
must be emptied for liquid and high pressure refrigerant
through the drain plugs (pos. 7A and 7B) before the expan-
sion plug (pos. 7) can be dismantled.
The air vent never seems to open. • No air in the system
• Foul gas line mounted on the refrigeration system at a spot
where no air accumulates.
CPAM EKA AIR C16 Drawing

Technical Data:

Operating pressure -1/25bar

Design pressure 25bar
Test pressure 32bar
Operating temperture -40C / +50C
Design temperature +50C
Stress occassion I (100%) Acc. To AD-Blatt W10
Working fluid NH3
Testing fluid Air*
Volume 23 liter
Actual weight 30kg
Corrosion allowance 1.5mm
Vessel position Vertical
"Utilisation of calculating
tension allowed" 0.85
*: only in pressure testing room
EKA Air C16 Controller Dimenion EKA Air C16 Controller Setting
The EKA Air Controller C16 is easy to set up.
The factory setting default values are shown on table below

Start screen: EKA Air C16 Controller

The only parameter you need to key in is the number of

purge point (1-16)
Press Save
Press Next will lead you to operation screen.

Operation screen:

Total Purge Point: The number of purge point you have

on your system
Delay: Time delay before the EKA-AIR C16 start its purg-
ing process. The time delay is needed for stablising con-
densation process inside the purger. (default 10min.)
PP: The current active purge point 23
Communication Time: The remaining purge time of the current active
Port RS485 purger point
Air valve: Flashing when air valve open and air purging is
in action
Liquid level in percentage
Total purge Time: The total time of air valve open in min.
White
Brown
Black
Blue

Edit setting Parameters

Air Valve You can change value of parameter by touching the Edit
button on operation screen and confirm by
touching ok button
Level Controller Voltage: 200V-240V 50/60 Hz Pasword: 12345678

Delay Time: 5-60 min

Purge Time: 1-30 min
Press save to store changed value
You can reset all values to factory default values by
pressing the ok button

Note: Always restart system after editing

parameters value.
 Safety CB 10A

Air valve connection

RS 485

Voltage 200-240V
Level sensor 50/60 Hz

Unit
Supply voltage 200-240V AC. 1ph, 50/60Hz
Level sensor 24V DC
Level sensor signal 4-20mA
Number of purge point 16
Air valve 1
Total purge time min.

Parameters setting Min. Max. Default

Purge point 1 30 10
Delay time 5 60 10

Contact:
Eka-Kool Pte. Ltd. Home page: www.eka-kool.com
60 Tessensohn Road. #02-01A Club CSC @ Email: [email protected]
Tessensohn. Tel. +84903788664
Singapore 217664