Emerson FD113 - User Manual

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FD113 Oil Pressure Safety Control

Instruction Sheet

PA-00250

June 2013

THE FLEXIBLE CONTROL

• TheFD113OilPressureSafetyControlsensestheeffectiveoil

pressuredifferentialincompressorswithpositivedisplacementoil

pumps.Ifinadequateoilpressureexists,atimedelayisenergized.

Iftheoilpressuredoesnotrecovertosafelevelswithinthetime

delaysetting,thecompressorisshutdown.Thetimedelayallows

thecompressoradequatetimetoestablishoilpressureonstart–up

andavoidsnuisanceshutdownsonpressuredropofshortduration

duringtheruncycle.

• Maximumapplicationexibilityisassuredbyprovidingan

adjustabledifferentialpressureswitchwhichcanbeadjustedto

thecompressor’sminimumrequiredoilpressureneedsandan

adjustabletimedelaywhichallowsyoutoselectthelengthof

timethecompressorrunsbelowtheminimumpressurebefore

shutdown.Theminimumpressuresettingandtimedelayvalues

speciedbythecompressormanufacturershouldbeusedwhen

installingtheFD113control.

FEATURES

• PressureRangeadjustablefrom4to65PSID.

 Timerstartpressure–timerstoppressureis3PSIDabove

timerstartpressure.

• ASPDTswitchisusedinthepressureportionofthecontrol

whichallowstheadditionofa“safelight”ifdesired.

• TimerisTime–Adjustablefrom20to150seconds.

 Supplyvoltage–24to240VoltAC/DC.Timingunaffectedby

voltageorambienttemperaturevariations.

• ASPDTManualResetSwitchisusedintheTimerModule.

 Upontime-out,thecompressorisstoppedandanalarmcircuit

isenergized.Torestartthecompressorandde-energizethe

alarmcircuit,theresetbuttonispushed.

• AfactoryinstalledJumperallowstheFD113tobepoweredfrom

asinglepowersource.Shouldseparatecircuitsbedesiredfor

thetimerand“Lockout”switch,theJumpercanberemoved.

SAFETY INSTRUCTIONS

1. ReadallInstructionsthoroughly.Failuretocomplycanresult

incontrolfailure,systemdamageorpersonalinjury.

2. Donotusewithammoniaoronhazardousorcorrosiveuids.

3. DonotinstallinHazardousLocations.

4. Disconnectelectricalpowerbeforeinstallation.Donotreapply

poweruntilcontrolinstallationiscomplete,wiringconnections

securedandcoverisinplace.

5. Beforemakingpressurecontrolconnections,depressurize

systemandmakecertainlinesareatatmosphericpressure.

Pilot Duty Ratings: 120/240VAC

 U.L.B300 360VAMaximum

CONTROL RATINGS

INSTALLATION INSTRUCTIONS–GENERAL

1. Cover Removal—Loosencoverscrew,pullcoverforward.

2. Mounting—Mountthecontrolinaprotectedareaonthe

 mountingbracketoraatsurfacewithscrewsprovided.

 CAUTION:Ifotherscrewsareused,use8-32screwsthat

do notpenetrateintothecontrolmorethan1/8’’.

 OilPressureSafetyControlsshouldalwaysbemounted

 abovetheoillevelinthecompressorcrankcase.The

 capillarytubesorpressureconnectionsshouldberouted

 toallowthemtobefree–drainingtothecompressor

 crankcase.Thiswillpreventoillogginginthecapillary

 tubesduringlowambientconditions.

3. Capillary Tube Connections:Properinstallationof

 capillarytubesand/orpressurecontrollineswillinsure

 atrouble–freeinstallation.WARNING:Beforemakingany

 pressurecontrolconnections,depressurizesystem.Failure

 todosocancausesystemdamageorpersonalinjury.

 • Ifthecontrolismountedonthecompressor,alllines

  mustbesecuredtothecompressorsotheydonot

  vibrateindependentlyfromthecompressor.

 • Ifthecontrolismountedremotefromthecompressor

  anopencoiledvibrationloop,2to3coils,2to3’’

  diametershouldbeprovidedbetweenthecompressor

  baseandthemovingcompressor.Thelinescoming

  fromthecoilshouldbesecuredtothebaseand

  compressorsothecoiltakesallthevibration.Avoid

  any“violinstring”runsofcontrolcapillarytubes.

 • Sharpbendsorkinksmustbeavoidedinthecapillary

  orpressurelines.Donotallowthelinestoruband

  abradeagainstanymovingsurface.Avoidanyexcess-

  ivehandlingorreformingofthecopperlinesto

  minimizeworkhardeningofthecopper.

4. Electrical Connections—WARNING: Beforemakingany

 electricalconnections,disconnectallelectricalpower.

 Checkwithavoltmeterasmorethanonesourceofpower

 maybesupplied.Makecertaintheloadtoconnectedis

 withintheelectricalratingofthecontrol(seeTable1).

 • AllwiringshouldconformtoNationalElectricalCode

  and/orlocalcodes.Use14AWG or larger copper

conductors ONLY.

 • Theterminalsareofaclampdesign.Loosenthe

  terminalscrewswithasmallscrewdriver,insert

  approximately3/8’’strippedwireandsecurelytighten.

SPECIFICATIONS – FD113ZU/ZUK

Ambient Temperature Range –5°Fto+140°F

Pressure Range–PSID–Adjustable

Timer Energize:4to65PSIDneteffectiveoilpressureon

 pressuredrop.

Timer De-energize:3PSIabovetimerenergizesettingon

 pressurerise.

Timer

Voltage:24to240voltsACorDC

Timing:20to150seconds–Adjustable

Maximum Over Pressure:Duringinstallationandservice,the

control’spowerelementshouldnotbeexposedtopressures

exceeding330PSIG.

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.

SPECIFICATIONS – ENCLOSURE

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Summary

FD113 Oil Pressure Safety Control Overview

The Flexible Control

Explains the FD113 Oil Pressure Safety Control's function and adjustable features for compressor oil pressure monitoring.

Features of the FD113 Control

Details the adjustable pressure range, timer function, voltage compatibility, and manual reset switch.

Safety Instructions

Provides essential safety precautions to prevent system damage, failure, or personal injury during installation and use.

Control Ratings

Lists the pilot duty ratings (U.L. B300) and voltage/VA specifications for the control.

Enclosure Specifications

Specifies the NEMA CLASS I enclosure requirement for mounting the control body in protected areas.

General Installation Instructions

Outlines general steps for cover removal, mounting, and routing capillary tubes for proper installation.

FD113 ZU;ZUK Model Specifications

Details specific operating ranges, pressure settings, and timer specifications for the FD113ZU/ZUK models.

Effective Oil Pressure Definition

Effective Oil Pressure Explained

Defines effective net oil pressure as the difference between oil pump and crankcase pressure, with an example.

Control Calibration and Adjustment

Manufacturer Setting Specifications

Provides typical time delay and pressure settings for various compressor manufacturers like Copeland, Bitzer, and Carrier.

Checking and Adjusting Pressure

Details the procedure for checking and adjusting the pressure setting disc to achieve desired timer start pressure.

Checking and Adjusting Timer

Explains how to check and adjust the timer to achieve the desired trip-out time for compressor shutdown.

FD113 Installation and Wiring

Pressure Connections

Instructs on connecting the 'Oil' and 'Low' pressure elements to the compressor's oil pump and crankcase connections.

Electrical Wiring Cross-Reference

Provides a cross-reference for wiring when replacing other control brands and illustrates terminal connections.

Control Checkout Procedures

Timer Checkout Procedure

Details the procedure to test the timer function by energizing the circuit and observing the compressor shutdown time.

Pressure Checkout Procedure

Explains how to accurately check the operating pressure of the FD113 control after installation.

Wiring Diagrams and Configurations

New Copeland 3-Wire Wiring

Illustrates wiring for a new Copeland 3-wire setup, addressing nuisance trips from auxiliary devices.

3-Wire Separate Power Source Wiring

Details wiring for a 3-wire control using a separate power source, ensuring consistent voltage for all components.

4-Wire Common Power Wiring

Presents a 4-wire wiring configuration where the control power is common to the compressor, suitable for 208/240V systems.

Summary

FD113 Oil Pressure Safety Control Overview

The Flexible Control

Explains the FD113 Oil Pressure Safety Control's function and adjustable features for compressor oil pressure monitoring.

Features of the FD113 Control

Details the adjustable pressure range, timer function, voltage compatibility, and manual reset switch.

Safety Instructions

Provides essential safety precautions to prevent system damage, failure, or personal injury during installation and use.

Control Ratings

Lists the pilot duty ratings (U.L. B300) and voltage/VA specifications for the control.

Enclosure Specifications

Specifies the NEMA CLASS I enclosure requirement for mounting the control body in protected areas.

General Installation Instructions

Outlines general steps for cover removal, mounting, and routing capillary tubes for proper installation.

FD113 ZU;ZUK Model Specifications

Details specific operating ranges, pressure settings, and timer specifications for the FD113ZU/ZUK models.

Effective Oil Pressure Definition

Effective Oil Pressure Explained

Defines effective net oil pressure as the difference between oil pump and crankcase pressure, with an example.

Control Calibration and Adjustment

Manufacturer Setting Specifications

Provides typical time delay and pressure settings for various compressor manufacturers like Copeland, Bitzer, and Carrier.

Checking and Adjusting Pressure

Details the procedure for checking and adjusting the pressure setting disc to achieve desired timer start pressure.

Checking and Adjusting Timer

Explains how to check and adjust the timer to achieve the desired trip-out time for compressor shutdown.

FD113 Installation and Wiring

Pressure Connections

Instructs on connecting the 'Oil' and 'Low' pressure elements to the compressor's oil pump and crankcase connections.

Electrical Wiring Cross-Reference

Provides a cross-reference for wiring when replacing other control brands and illustrates terminal connections.

Control Checkout Procedures

Timer Checkout Procedure

Details the procedure to test the timer function by energizing the circuit and observing the compressor shutdown time.

Pressure Checkout Procedure

Explains how to accurately check the operating pressure of the FD113 control after installation.

Wiring Diagrams and Configurations

New Copeland 3-Wire Wiring

Illustrates wiring for a new Copeland 3-wire setup, addressing nuisance trips from auxiliary devices.

3-Wire Separate Power Source Wiring

Details wiring for a 3-wire control using a separate power source, ensuring consistent voltage for all components.

4-Wire Common Power Wiring

Presents a 4-wire wiring configuration where the control power is common to the compressor, suitable for 208/240V systems.

The FD113 Oil Pressure Safety Control is designed to monitor the effective oil pressure differential in compressors equipped with positive displacement oil pumps. Its primary function is to ensure adequate oil pressure for compressor operation and to prevent damage due to low oil pressure conditions. If the oil pressure drops below a safe level, a time delay is initiated. Should the oil pressure not recover within this set delay, the compressor is shut down. This mechanism allows for sufficient time for oil pressure to establish during start-up and prevents unnecessary shutdowns caused by brief pressure drops during normal operation.

Function Description:

The control features an adjustable differential pressure switch, allowing it to be tailored to the specific minimum oil pressure requirements of various compressors. An adjustable time delay further enhances flexibility, enabling users to set the duration the compressor can run below the minimum pressure before shutdown. The manufacturer's specified minimum pressure setting and time delay values should always be used during installation.

Important Technical Specifications:

Pressure Range: Adjustable from 4 to 65 PSID (Pounds per Square Inch Differential).
Timer Start Pressure: The timer energizes when the net effective oil pressure drops to a value between 4 and 65 PSID, depending on the setting.
Timer Stop Pressure: The timer de-energizes when the pressure rises to 3 PSID above the timer start pressure setting.
Switch Type: A SPDT (Single-Pole, Double-Throw) switch is integrated into the pressure portion of the control, allowing for the addition of a "safe light" if desired.
Timer Type: Adjustable from 20 to 150 seconds.
Supply Voltage: 24 to 240 Volt AC/DC. The timing function is unaffected by voltage or ambient temperature variations.
Manual Reset Switch: A SPDT Manual Reset Switch is included in the Timer Module. Upon time-out, the compressor is stopped, and an alarm circuit is energized. To restart the compressor and de-energize the alarm, the reset button must be pushed.
Power Source: A factory-installed jumper allows the FD113 to be powered from a single source. This jumper can be removed if separate circuits are desired for the timer and "Lockout" switch.
Pilot Duty Ratings: U.L. B300, 120/240 VAC, 360 VA Maximum.
Enclosure: NEMA CLASS I, designed for mounting in areas protected from weather, water, excessive moisture, dirt, dust, and corrosive or explosive atmospheres.
Ambient Temperature Range: -5°F to +140°F.
Maximum Over Pressure: The control's power element should not be exposed to pressures exceeding 330 PSIG during installation and service.

Usage Features:

Application Flexibility: The adjustable differential pressure switch and time delay allow for customization to various compressor models and operational needs.
Nuisance Shutdown Prevention: The time delay feature prevents unnecessary shutdowns due to momentary pressure drops, ensuring continuous operation during normal fluctuations.
Alarm Circuit: Upon shutdown, an alarm circuit is energized, providing immediate notification of a low oil pressure event.
Manual Reset: The manual reset button ensures that the system is not restarted without human intervention after a shutdown, allowing for inspection and resolution of the underlying issue.
Mounting: The control should be mounted in a protected area, either on a mounting bracket or a flat surface, using provided screws. It is crucial to mount the control above the oil level in the compressor crankcase.
Capillary Tube Connections: Proper installation of capillary tubes and pressure control lines is essential for trouble-free operation. Lines should be secured to prevent independent vibration, and an open coiled vibration loop (2-3 coils, 2-3" diameter) should be provided between the compressor base and the moving compressor when mounted remotely. Sharp bends, kinks, rubbing, and excessive handling of copper lines should be avoided.
Electrical Connections: All wiring must conform to National Electrical Code and/or local codes, using 14AWG or larger copper conductors. Terminals are of a clamp design, requiring a small screwdriver to loosen, insert approximately 3/8" stripped wire, and securely tighten.

Maintenance Features:

Calibration/Adjustment: The control is factory preset but can be adjusted. To change pressure settings, the control cover must be removed, and the notched pressure setting disc rotated (right to increase, left to decrease). The timer adjustment button allows for setting the desired trip-out time.
Bench Test: A "Pressure Check" procedure without voltage applied allows for verifying continuity across terminals 11 and 14 (safe light connection) and observing the energize/de-energize points of the continuity light as pressure is applied and depressurized.
Timer Checkout: A "Timer Checkout" procedure involves removing a jumper, connecting a continuity light, and applying voltage to verify the timer's trip-out time.
Tamper Prevention: After pressure and time settings are made and verified, a piece of tape should be placed over the pressure setting disc slot and timer adjustment button to prevent tampering.
Safety Precautions: Always read instructions thoroughly, disconnect electrical power before installation or maintenance, depressurize the system before making pressure control connections, and ensure all connections are secure before reapplying power. The control should not be used with ammonia or hazardous/corrosive fluids and should not be installed in hazardous locations.