OMEGA AIR EMD HP User manual

Please read the following instructions carefully before installing filter into service. Trouble
free and safe operating of the filter can only be guaranteed if recommendations and
conditions stated in this manual are respected.
Installation and operating
manual
(EMD HP)

2
Description
EMD HP is an electronically controlled condensed water drain, which is designed for use in
compressed air systems with pressure up to 50 bar. It discharges water trapped in the lowest
parts of compressed air installation out of the system. This water is a condensed water vapor
that is always present in the atmosphere. Because of laws of physics, some vapor always
condenses during compression of air.
The EMD HP consists of a water tank, valve assembly and electronics. The water tank should
be the lowest part of the compressed air system where condensed water collects. In the
tank, there is a water level sensor. This way, electronics could detect the tank is full. Then, it
operates the electromagnetic valve to discharge condensed water from compressed air
system. The bottom cover of water tank is designed as debris trap where solid parts are
intercepted. The bottom can be removed from EMD HP for cleaning.
In the condensed water leaving the EMD HP, there are still small particles of rust and
remains of compressor oil. Oil must be removed before the water is drained to sewage
system. To remove oil, water-oil separator WOS or WOSm device could be used.
Because of its construction, the EMD HP could be attached to the compressed air system
horizontally or vertically. Under the pressure vessel or under the refrigerator dryer, the
EMD HP is fixed horizontally whereas under filters, it is more convenient to fix it vertically.
The valve is operated by electronics. It opens the valve when a button on the electronics
cover is pressed or when water level in the tank reaches threshold. Occasionally, a timed
venting mode that combines water level triggered discharging and timed venting is desired.
By pressing the test button, we could see if EMD HP is operational. Besides, the test button
makes possible to discharge water that has collected in a system during maintenance
manually.
WOSm

3
The main mode of operation is a water level triggered discharging. The valve opens when
water level in EMD HP’s tank reaches threshold and it closes back before the tank is empty.
This way, only condensed water is discharged and no compressed air is lost.
In the timed venting mode, the valve is opened when water level reaches threshold, too.
Besides, when the valve is closed continuously for a predetermined period, it is opened
shortly although there is no water in the tank. During working day, water in EMD HP collects
rapidly so that venting period would never expire and there are no air losses. When
production rests, EMD HP is opening its valve. But since these discharges are short and
sparse, air losses are small. The timed venting mode should be used when there is a lot of
debris in condensed water and piping upward the EMD HP could not be inclined enough.
Such situation is quite common under pressure vessels. It may happen that air could not
escape from the tank upward the piping and while there is air around water level sensor, the
EMD HP would never open. In the timed venting mode, the valve is opened after the venting
period has expired and trapped air is allowed to escape through drainage. Now, condensed
water can reach water level sensor and EMD HP is opening its valve until all collected water
is discharged.
The timed venting mode is disabled initially since situations when this mode is needed are
rare. The mode could be enabled through the service network.
To service network, only types of EMD HP with communication electronics built in could be
connected. The service network is used for uploading data that are collected in EMD HP
during its operation. The data are elapsed hours, number of water discharging, current
water level in the tank and other data that could help to supervise and troubleshoot the
system. Through the service network, some operating parameters of EMD HP like venting
period in timed venting mode could be set. Additionally, valve could be operated remotely.
Features:
No loss drain
EMD HP could be fixed horizontally or vertically
Strainer integrated in the bottom cover of water tank
Optional time venting mode of operation
Optional Alarm/ Warning output and Service Network Protocol for remote
surveillance
Elapsed hour counter, valve operating counter and other data collection
Easy replacement of parts due to wear

4
Components
1
Electronic housing
2
Electronics
3
Communication electronics
4
Water tank with level sensor
5
Screw M3x16 DIN912
6
Washer 3.2 DIN125A
7
Cover
8
Sealing, O-Ring 100 x 1.5
9
Power Inlet gland
10
Sealing, O-Ring 12 x 2.0
11
Alarm inlet plug
12
Valve
13
Flow choke
14
Bracket
15
Washer 5.3 DIN125A
16
Screw M4x8 DIN912
17
Sealing, O-Ring 54 x 3.0
18
Back-up ring SRI PTFE 54x2.6
19
Strainer mesh
20
Bottom cover
21
Washer M8 DIN127A
22
Washer 8.4 DIN125A
23
Screw M8x50 DIN912
Remarks:
Do not disassemble Water tank with level sensor
(4).

5
Technical data
Type
EMD
HP
230V
EMD
HP A
230V
EMD
HP C
230V
EMD
HP
115V
EMD
HP A
115V
EMD
HP C
115V
EMD
HP
24Vac
EMD
HP A
24Vac
EMD
HP A
24Vdc
Service Network
Connection
No No Yes No No Yes No No No
Alarm output
No
Yes
Yes
No
Yes
Yes
No
Yes
Yes
Voltage
230V ac, 50 – 60Hz
115V ac, 50 – 60Hz
24V ac, 50 – 60Hz
24V dc
Fuse inside EMD12
5x20 1A T
5x20 1A T
2A
2A
Power
25VA
25VA
22W
Operating pressure
range
0 – 50 bar
0 – 725 psi
Drain capacity
Kv
30.4 l/h @ 50 bar, 0.018 cfm @ 725 psi
4.3 (l/h) / √bar
Operating
temperature range
1,5°C – 65°C
Protection class
IP 54
Inlet connection
G 1/2" (parallel thread)
Outlet connection
G 1/4" (parallel thread)
Mass
2.3 kg
Peak Compressor Capacity
System pressure
Northern Europe,
Canada, Central Asia
Rest of the world
Moist tropical and
subtropical regions
50 bar
29.5 m3/min
22.2 m3/min
12.9 m3/min
40 bar
26.4 m3/min
19.9 m3/min
11.5 m3/min
30 bar
22.9 m3/min
17.2 m3/min
10.0 m3/min
20 bar
18.7 m3/min
14.0 m3/min
8.1 m3/min

6
Safety instructions
Installation and maintenance work may only be carried out when the device is
not under pressure. To depressurize the device, close ball valve and press the
test button on device until pressure in it drops.
Installation and maintenance work may only be carried out by trained and
experienced personnel.
Installation and maintenance workers must use proper safety / protection
equipment (e.g. protection gloves, protection goggles, …)
Disconnect electrical power supply before opening the top cover of the
device.
Installation and maintenance work may only be carried out when electrical
power supply is disconnected.
Electrical work must always be carried out by qualified electrician.
Do not exceed maximal operating pressure or operating temperature range
(see data label).
Do not use the device in hazardous areas with potentially explosive
atmospheres.
Use original spare parts only.
Use the device for the appropriate purpose only.
Appropriate use
EMD series electronic condensate drain is intended exclusively for the following purpose:
Draining condensate from compressed air system (air compressors, air
receivers/pressure vessels, air dryers and air filters).
Any other form of use or one going beyond this shall be considered as inappropriate. We
shall have no liability whatsoever for any damage incurred as a result.

7
Installation guidelines
Keep to the safety rules when working with
pressure equipment.
The EMD HP should be connected to a pressure
system by ball valve. This way, it is not needed to
depressurize the whole system each time strainer
cleaning or other maintenance takes place.
The outlet of EMD HP’s valve is connected to
drainage system by suitable connection and pipe.
Pay attention that in case of clogged drainage,
pressure in it would rise up to the system level
pressure!
The EMD HP could be mounted horizontally (left) or vertically (right). But, it must not be rolled aside
more than ±15°. The horizontal position is preferred in case of a lot of debris in condensed water.
G 1/2"
Internal thread
G 1/4"
Internal thread

8
Do not connect several condensed water sources to one drain device because air would bypass filtering
(left). Instead, each spot where condensed water collects must have its own condensate drain device
(right).
Drainage piping must be built without traps that would trap air in the EMD HP and prevent condensed
water to enter it (left). Additional venting would not help because debriss collects in the lowest part of
drainge pipe and clogg it (right).
Horizontal drainage pipes must be inclined so that air could escape from EMD HP and that debriss is
flushed toward EMD HP (left). When horizontal drainge pipes are long, venting should be built (right).
Electrical wiring:

Fully disconnect power from EMD HP before opening the cover of electronic compartment.

Please ensure that the installation is carried out according to valid regulations.
Power Connection Cable
2 x 0,75mm2+ PE
Oil resistant insulation recomended
Wires should be equipped with appropriate
ferrules. Make sure, that all strands of a wire are
fitted inside the ferrule.
Make sure that all wires are fitted into terminals
firmly!
EMD12


EMD12
EMD12
EMD12




8 mm

9
EMD HP 230Vac, 115Vac
EMD HP A 230Vac, 115Vac
EMD HP C 230Vac, 115Vac
EMD HP 24Vac
EMD HP A 24Vac
EMD HP A 24Vdc
Power Connection
1
230Vac (115Vac) Neutral
2
230Vac (115Vac) Line
3
PE Conductor
Valve Connection
4
PE Conductor
5
Power line
6
Power line
Service Network (EMD HP C)
7
Alarm/W. (white X2.4 BE)
8
Transmit (blue X2.3 MO)
9
GND (brown X2.2 RJ)
10
Receive (black X.2.1 CR)
Connector pins' description:
Alarm output (EMD HP A)
7
Alarm/ Warning
9
GND
Umax (at high impedance): 39V
Imax (at low impedance): 200mA
Ureverse: -0,7V
Power Connection
1
24Vac (grounded line)
2
24Vac
3
PE Conductor
Valve Connection
4
PE Conductor
5
Power line
6
Power line
Alarm output (EMD HP A)
7
Alarm/ Warning
9
GND
Umax (at high impedance): 39V
Imax (at low impedance): 200mA
Ureverse: -0,7V
Power Connection
1
24Vdc positive pole
2
24Vdc negative pole
3
PE Conductor
Valve Connection
4
PE Conductor
5
Power line
6
Power line
Alarm output (EMD HP A)
7
Alarm/ Warning
8
GND
Relay contact: NO
Umax: 250Vac, 30Vdc
Imax: 8A
Touching electronics should be avoided, when cables are being connected!
Place the cover back immediately after the cables are connected!
GND
Transmit
Alarm
Receive
9
7
I
U
9
7
I
U
8
7
I
U
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
7,8

10
Provide means for full disconnection of electric
power from EMD HP.
Do not connect EMD HP after protection device of heavy inductive load like compressor motor (left).
Instead, heavy inductive load and EMD HP should be protected separately (right).
After installation or maintenance work, press the
test button to drain all condensed water which
has meanwhile collected in the compressed air
system.
L
N
PE
L
N
PE
M

L
N
PE
M


11
Operation
By pressing the test button, valve is opened.
Green LED indicator shows water level in tank.
Short green flashes show that water in tank is
under the threshold.
Long green flashes indicate that the tank is
almost full.
When the tank is full, the green is on
permanently.
Red LED indicator is on permanently during
alarm mode.
In normal mode, EMD measures condensed water level in its tank. When level reaches
threshold, the valve is opened and water is discharged. Period between successive
discharges is from 5s to 7s long. When there is so much water, that EMD HP is not able to
remove it in 90s, it enters overload mode. In this mode, EMD HP opens its valve longer and
more frequently and its capacity is doubled. When EMD HP is still not able to discharge all
the water in 5min, it enters alarm mode. In alarm mode, EMD HP opens its valve so that it
would discharge 50% of its nominal capacity. The capacity in alarm mode is limited to limit
air losses in case of drain malfunction. EMD HP returns from overload or alarm mode to
normal mode when the tank get empty.
Extreme amount of condensed water is possible after maintenance work. In front of
EMD HP, there is valve that is closed during maintenance. Behind this valve, condensed
water collects. After a while, there is so much water that EMD HP is not able to drain it
without entering alarm mode. To avoid entering alarm mode, test button should be pressed
after each maintenance work to discharge all condensed water manually.
Test button
LED indicator

12
Service Network and Alarm/ Warning output
EMD HP variants C, which are equipped with communication electronics and connector
could be connected to a Service Network. The Service Network is a communication protocol
used in EMD HP and other compressed air equipment that allow a remote supervision. Work
data could be regularly read out of the device with a network or they could be read by a data
logger. At the same time, the Service Network could also serve as display and keypad for
setting EMD HP’s parameters at commissioning.
The Service network consists of two devices. These are a slave device which is EMD HP and a
master device. The master device could be a Service Network Reader SN-10.200. It’s a
handheld device that allows user to send command messages manually. It also comprises a
display where answer to command are read. In the table in next page, command message
codes specific to EMD HP are described. There, we see which work data are collected, which
parameters could be set and which remote commands are available in EMD HP.
More detailed description of Service Network Protocol could be found in document
SN-02.000, Service Network Protocol.
An alarm/warning output is included in the service network. Nevertheless, it may be used to
signal alarm condition without being connected to service network. The alarm/warning
output is an open collector output and it shares its GND with serial communication of
Service Network. The output is in high impedance state during alarm. When EMD HP
operates normally, the output is in low impedance state.

13
Important Service Network command message codes and their meaning
Code
Description
0x80…0x9F
Device data
0x84
Device Name
Manufacturer, manufacturer’s address and other important data.
0xA0…0xBF
Device State
0xA4
Device condition – general
0xA8
Power on counter, Elapsed hours counter
0xAC
Valve operation counter, Timed venting counter
0xB0
Overload timer, Alarm timer
0xB4
Processor events: Brown out counter, Voltage error counter
0xB8
Processor events: Watch dog reset counter, Software reset counter
0xBC
Water level sensor adjustment data
0xC0
Current working parameters
0xE0…0xF0
Settings
0xE4
Timed Venting - valve opened period
Values: 0.6s, 0.8s, 1.2s, 1.7s, 2.4s, Timed venting off (default)
0xE8
Timed Venting - Period to first operating of valve:
Values: 60min, 40min (default), 20min, 10min, 5min
0xEC
Timed Venting - Period between subsequent operating of valve:
Values: 120min, 60min (default), 40min, 20min, 10min
0xF0
Overload duration:
Values: 2min, 5min (default), 10min
0xF4…0xFF
Control
0xFB
Remote triggering of condensed water purging from EMD HP
Alarm in 24Vdc version
Contrary to ac versions of EMD HP, a dc version of EMD HP has a built-in relay, which
provides a voltage free contact. It is of NO type and it is closed, when EMD HP operates
normally.

14
Maintenance
For EMD HP to work reliably, strainer mesh should be cleaned regularly. The mesh is part of
bottom cover. It intercepts larger solid particles that would clog valve. Cleanings period
depends on condition of compressed air system.
The valve is due to wear. When the valve is worn out, a complete valve assembly should be
replaced. The valve assembly could be ordered as spare part.
Strainer cleaning procedure
Keep to the safety rules when working with
pressure equipment.
First, close the valve. Then, press the test button
to depressurize EMD HP!
Detach the bottom cover with strainer mesh.
Then, clean strainer mesh.
At the same time,
check its integrity. Clean also O-ring sealing and
its gland thoroughly. Otherwise, strainer sealing
may start to leak.
Be careful while cleaning, because solid particles
in debris may be sharp.
Reattach bottom cover insert back to its
position and open valve slowly.
Replacement of valve assembly
1. First, close the valve in press the test button to depressurize EMD HP.
2. Than disconnect the unit from electrical power supply.
3. Detach valve connector and bracket 14. Unscrew the valve 12 and flow choke 13.
4. Clean remains of a treadlocker glue.
5. Install new valve with flow choke 13. To seal assembly, use threadlocker glue. Fix the valve
with bracket 14. Reattach valve connector.
6. Only after the glue is cured, pressurize EMD HP.
After maintenance work, press the test button
to drain all condensed water which has
meanwhile
collected in the compressed air
system.

15
Troubleshooting
After powering EMD, it enters overload mode and afterwards, it enters alarm mode.
During power down, large amount of condensed water has collected in compressed air system. Hold the
test button until all the water is drained.
EMD enters alarm mode occasionally. But, it gets back to normal mode immediately after all the water is
drained by holding the test button.
The reason might be extremely hot and moist day.
EMD is undersized and it should be replaced by bigger drain.
Pressing test button does not open the valve.
Check electric power and cable connections.
Check the fuse.
There is no LED signal although the valve could be opened by pressing test button.
The LED is not bright enough to be seen in daylight.
Fuse is blown.
Check integrity of electronics. Replace the fuse if there is no visible damage on electronics.
Air leaks through the drain pipe even when EMD is disconnected from power.
There might be debris in valve or valve may be damaged. Check integrity of strainer. The valve assembly
should be cleaned or replaced by authorized person.
Long flashes of green LED indicate full tank although the tank is empty.
Clean the water level sensor surface.
EMD is in alarm and there is no water drained, only air.
Clean the water level sensor surface.
EMD is in alarm and valve opens, but there is no water or air drained.
Path between EMD’s tank and valve is clogged. Clean the tank, strainer and valve assembly. Replace
strainer or valve assembly when they are damaged.
Condensed water is not drained automatically. Instead, it is drained only when test button is pressed.
If the amount of drained water is small, then the water in tank hasn’t reached the threshold, yet.
If water is drained during pressing the test button, then we should check the piping in front of EMD.
Pipe’s inclination is too small or there may be debris in the pipe so that air in the EMD’s tank is trapped.
When the test button is pressed, this air escapes through drainage and makes place for condensed
water. Solution: clean pipe, build venting. Switch timer function on.
Red LED is flashing.
EMD is in one of production modes or there is some other error. First, check supply voltage. Then,
contact supplier.

16
Auxiliary and spare parts
Service kit EMD HP 230V
Strainer mesh (19) and sealing elements (17), (18).
Valve 230V (12) and flow choke (13).
Service kit EMD HP 115V
Strainer mesh (19) and sealing elements (17), (18).
Valve 115V (12) and flow choke (13).
Service kit EMD HP 24Vac
Strainer mesh (19) and sealing elements (17), (18).
Valve 24Vac (12) and flow choke (13).
Service kit EMD HP 24Vdc
Strainer mesh (19) and sealing elements (17), (18).
Valve 24Vdc (12) and flow choke (13).
Pictures are illustrative only!
Warranty exclusion
The guarantee shall be void if:
The installation and operating manual was not followed with respect to
installation, initial commissioning and maintenance.
The unit was not operated properly and appropriately.
The unit was operated when it was clearly defective.
Non-original spare parts or replacement parts were used.
The unit was not operated within the permissible technical parameters.
Unauthorized constructional changes were made to the unit or if the unit has
been opened/disassembled by an unauthorized person.
OMEGA AIR d.o.o. Ljubljana
Cesta Dolomitskega odreda 10
SI-1000 Ljubljana, Slovenia
Tel.: [phone]
Fax.: [phone]
E-mail: [e-mail]
www.omega-air.si