Controller for temperature control - EKC 202A,B,C and EKC 302A,B Manual Introduction Application • The controller is used for temperature control refrigeration appliances and cold room in supermarkets • Control of defrost, fans, alarm and light • EKC 202 for front panel mounting • EKC 302 for DIN-rail mounting Principle The controller contains a temperature control where the signal can be received from one temperature sensor. The sensor is placed in the cold air flow after the evaporator or in the warm air flow just before the evaporator. The controller controls the defrost with either natural defrost or electric defrost. Renewed cutin after defrost can be accomplished based on time or temperature. A measurement of the defrost temperature can be obtained directly through the use of a defrost sensor. Two to four relays will cut the required functions in and out – the application determines which: • Refrigeration (compressor or solenoid valve) • Defrost • Fan • Alarm • Light The different applications are described on next page. Advantages • Integrated refrigeration-technical functions • Defrost on demand in 1:1 systems • Buttons and seal imbedded in the front (EKC 202) • IP65 density from the front panel (EKC 202) • Digital input for either: - Door contact function with alarm - Defrost start - Start/stop of regulation - Night operation - Change-over between two temperature reference - Case cleaning function • Instant programming via programming key • HACCP Factory calibration that will guarantee a better measuring accuracy than stated in the standard EN 441-13 without subsequent calibration (Pt 1000 ohm sensor) Extra module • The controller can afterwards be fitted with an insertion module if the application requires it. The controller has been prepared with plug, so the module simply has to be pushed in. Contents Introduction........................................................................................................ 2 Operation............................................................................................................. 5 Menu survey........................................................................................................ 6 Functions.............................................................................................................. 8 2 Override..............................................................................................................15 Connections......................................................................................................16 Ordering.............................................................................................................18 Technical data...................................................................................................19 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 EKC 202A / EKC 302A Controller with two relay outputs, two temperature sensors and digital input. Temperature control at start/stop of compressor / solenoid valve Defrost sensor Electrical defrost / gas defrost Alarm function If an alarm function is required, relay number two may be used for it. Defrost is performed here with circulation of the air as the fans are operating continuously. EKC 202B / EKC 302B Controller with three relay outputs, two temperature sensors and digital input. Temperature control at start/stop of compressor / solenoid valve Defrost sensor Electrical defrost / gas defrost Relay output 3 is used for control of fan. EKC 202C Controller with four relay outputs, two temperature sensors and digital input. Temperature control at start/stop of compressor / solenoid valve Defrost sensor Electrical defrost / gas defrost Control of fan Relay output 4 can be used for an alarm function or for a light function. EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 3 Start of defrost A defrost can be started in different ways Interval: Defrost is started at fixed time intervals, say, every eight hour Refrigeration time: Defrost is started at fixed refrigeration time inter- vals, in other words, a low need for refrigeration will ”postpone” the coming defrost Contact Defrost is started here with a pulse signal on a digital input. Manual: An extra defrost can be activated from the control- ler’s lower-most button S5-temp. In 1:1 systems the efficiency of the evaporator can be followed. Icing-up will start a defrost. Schedule Defrost here can be started at fixed times of the day and night. But max. six defrosts Network A defrost can be started via data communication All the mentioned methods can be used at random – if just one them is activated a defrost will be started. When the defrost starts the defrost timers are set at zero A pulse signal starts the defrost If you need coordinated defrost, this must be done via data communication. Digital input The digital input can be used for the following functions: - Door contact function with alarm if the door has been open for too long. - Defrost start - Start/stop of regulation - Change-over to night operation - Case cleaning - Change to another temperature reference - Inject on/off Case cleaning function This function makes it easy to steer the refrigeration appliance through a cleaning phase. Via three pushes on a switch you change from one phase to the next phase. The first push stops the refrigeration – the fans keep working ”Later”: The next push stops the fans ”Still later”: The next push restarts refrigeration The different situations can be followed on the display. - + + °C 1 ÷ + Fan There is no temperature monitoring during case cleaning. 2 ÷ ÷ Off 3 + + °C On the network a cleaning alarm is transmitted to the system unit. This alarm can be ”logged” so that proof of the sequence of events is provided. Defrost on demand 1 Based on refrigeration time When the aggregate refrigeration time has passed a fixed time, a defrost will be started. 2 Based on temperature The controller will constantly follow the temperature at S5. Between two defrosts the S5 temperature will become lower the more the evaporator ices up (the compressor operates for a longer time and pulls the S5 temperature further down). When the temperature passes a set allowed variation the defrost will be started. This function can only be used in 1:1 systems 4 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 Operation Display The values will be shown with three digits, and with a setting you can determine whether the temperature are to be shown in °C or in °F. Examples Set menu 1. Push the upper button until a parameter r01 is shown 2. Push the upper or the lower button and find that parameter you want to change 3. Push the middle button until the parameter value is shown 4. Push the upper or the lower button and select the new value 5. Push the middle button again to enter the value. Light-emitting diodes (LED) on front panel There are LED’s on the front panel which will light up when the belonging relay is activated. = Refrigeration = Defrost = Fan Cutout alarm relay / receipt alarm/see alarm code • Push briefly the upper button If there are several alarm codes they are found in a rolling stack. Push the uppermost or lowermost button to scan the rolling stack. The light-emitting diodes will flash when there is an alarm. In this situation you can download the error code to the display and cancel/sign for the alarm by giving the top button a brief push. Set temperature 1. Push the middle button until the temperature value is shown 2. Push the upper or the lower button and select the new value 3. Push the middle button to select the setting Defrost During defrost a –d– is shown in the display. This view will continue up till 15 min. after the cooling has resumed. However the view of –d– will be discontinued if: - The temperature is suitable within the 15 minutes - The regulation is stopped with “Main Switch” - A high temperature alarm appears Manuel start or stop of a defrost • Push the lower button for four seconds. See the temperature at the defrost sensor • Push briefly the lower button If no sensor has been mounted, ”non” will appear. The buttons When you want to change a setting, the upper and the lower buttons will give you a higher or lower value depending on the button you are pushing. But before you change the value, you must have access to the menu. You obtain this by pushing the upper button for a couple of seconds - you will then enter the column with parameter codes. Find the parameter code you want to change and push the middle buttons until value for the parameter is shown. When you have changed the value save the new value by once more pushing the middle button 100% tight The buttons and the seal are imbedded in the front. A special moulding technique unites the hard front plastic, the softer buttons and the seal, so that they become an integral part of the front panel. There are no openings that can receive moisture or dirt. EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 5 Menu survey EKC 202: SW = 1.3x EKC 302: SW = 1.0x Parameters Function Max.value Factory setting --- -50°C 50°C 2°C r01 r02 r03 r04 r05 r09 r12 r13 r39 r40 0,1 K -49°C -50°C -20 K °C -10 K -1 -10 K OFF -50 K 20 K 50°C 49°C 20 K °F 10 K 1 10 K on 50 K 2K 50°C -50°C 0.0 K °C 0K 1 0K OFF 0K A03 A04 A12 A13 A14 A27 A37 0 min 0 min 0 min -50°C -50°C 0 min 0°C 240 min 240 min 240 min 50°C 50°C 240 min 99°C 30 min 60 min 90 min 8°C -30°C 30 min 50°C c01 c02 c30 c70 0 min 0 min 0 / OFF OFF 30 min 30 min 1 / on On 0 min 0 min 0 / OFF On d01 d02 d03 d04 d05 d06 d07 d08 d09 no 0°C 0 hours 0 min 0 min 0 min 0 min -15°C 0 gas 25°C 48 hours 180 min 240 min 60 min 60 min 0°C 2 EL 6°C 8 hours 45 min 0 min 0 min 0 min -5°C 1 0 0 hours 0K 2 48 hours 20 K 0 0 hours 20 K no 0 min -50°C yes 30 min 50°C no 0 min 50°C 0 hours 23 hours 0 hours 0 min 59 min 0 min 0 hours 0 min 1 1 0 23 hours 59 min 31 12 99 0 hours 0 min 1 1 0 0s 0 600 s 11 5s 0 0 OFF 0 Pt no 0 min 1 240 ON 100 ntc yes 60 min 3 0 OFF 0 Pt no 20 1 OFF ON OFF 0: Stopped 1: Running 2: Running during pump down and defrost Defrost sensor (0=time, 1=S5, 2=Sair) d10 Max. aggregate refrigeration time between two defrosts d18 Defrost on demand - S5 temperature’s permitted variation during frost build-up. On d19 central plant choose 20 K (=off ) Fans Fan stop at cutout compressor F01 Delay of fan stop F02 Fan stop temperature (S5) F04 Real time clock Six start times for defrost. t01-t06 Setting of hours. 0=OFF Six start times for defrost. t11-t16 Setting of minutes. 0=OFF Clock - Setting of hours t07 Clock - Setting of minute t08 Clock - Setting of date t45 Clock - Setting of month t46 Clock - Setting of year t47 Miscellaneous Delay of output signals after start-up o01 Input signal on DI1. Function: o02 0=not used. 1=status on DI1. 2=door function with alarm when open. 3=door alarm when open. 4=defrost start (pulse-pressure). 5=ext.main switch. 6=night operation 7=change reference (r40 will be activated) 8=alarm function when closed. 9=alarm function when open. 10=case cleaning (pulse pressure). 11=Inject off when open. Network address o03 On/Off switch (Service Pin message) o04 Access code 1 (all settings) o05 Used sensor type (Pt /PTC/NTC) o06 Display step = 0.5 (normal 0.1 at Pt sensor) o15 Max hold time after coordinated defrost o16 Configuration of light function (relay 4) o38 1=ON during day operation. 2=ON / OFF via data communication. 3=ON follows the DIfunction, when DI is selected to door function or to door alarm Activation of light relay (only if o38=2) o39 6 Controller EKC EKC 202B 202C /302B Min.value Codes Normal operation Temperature (set point) Thermostat Differential Max. limitation of set point setting Min. limitation of set point setting Adjustment of temperature indication Temperature unit (°C/°F) Correction of the signal from Sair Manual service(-1), stop regulation(0), start regulation (1) Displacement of reference during night operation Activation of reference displacement r40 Value of reference displacement (activation by r39 or DI) Alarm Delay for temperature alarm Delay for door alarm Delay for temperature alarm after defrost High alarm limit Low alarm limit Alarm delay DI1 High alarm limit for condenser temperature (o70) Compressor Min. ON-time Min. OFF-time Compressor relay must cutin and out inversely (NC-function) External relays (Zero crossing control – only EKC 302) Must be 'ON' when connecting to external relays Defrost Defrost method (none/EL/gas) Defrost stop temperature Interval between defrost starts Max. defrost duration Displacement of time on cutin of defrost at start-up Drip off time Delay for fan start after defrost Fan start temperature Fan cutin during defrost EKC 202A / 302A Manual RS8DZ702 © Danfoss 03-2012 Actual setting EKC 202 / 302 Case cleaning. 0=no case cleaning. 1=Fans only. 2=All output Off. Access code 2 (partly access) EKC 202 only. Save the controllers present settings to the programming key. Select your own number. EKC 202 only. Load a set of settings from the programming key (previously saved via o65 function) Replace the controllers factory settings with the present settings Re alternative application for the S5 sensor (maintain the setting at 0 if it is used as defrost sensor, otherwise 1 = product sensor and 2 = condenser sensor with alarm) Select application for relay 4: 1=defrost/light, 2= alarm Service Temperature measured with S5 sensor Status on DI1 input. on/1=closed Status on night operation (on or off ) 1=closed Read the present regulation reference Status on relay for cooling (Can be controlled manually, but only when r12=-1) Status on relay for fans (Can be controlled manually, but only when r12=-1) Status on relay for defrost. (Can be controlled manually, but only when r12=-1) Temperature measured with Sair sensor Status on relay 4 (alarm, defrost, light). (Can be controlled manually, but only when r12=-1) Factory setting If you need to return to the factory-set values, it can be done in this way: - Cut out the supply voltage to the controller - Keep upper and lower button depressed at the same time as you reconnect the supply voltage Fault code display E1 Fault in controller E6 Change battery + check clock E 27 S5 sensor error E 29 Sair sensor error o46 o64 o65 0 0 0 2 100 25 0 0 0 o66 0 25 0 o67 o70 OFF 0 On 2 OFF 0 1 2 2 o72 defrost / Alarm Light / Alarm u09 u10 u13 u28 u58 u59 u60 u69 u71 Alarm code display A1 High temperature alarm A2 Low temperature alarm A4 Door alarm A5 Max. Hold time A 15 DI 1 alarm A 45 Standby mode A 59 Case cleaning A 61 Condenser alarm Status code display S0 Regulating S1 Waiting for end of the coordinated defrost S2 ON-time Compressor S3 OFF-time Compressor S4 Drip-off time S10 Refrigeration stopped by main switch S11 Refrigeration stopped by thermostat S14 Defrost sequence. Defrosting S15 Defrost sequence. Fan delay S16 Refrigeration stopped because of open DI input S17 Door open (open DI input) S20 Emergency cooling S25 Manual control of outputs S29 Case cleaning S32 Delay of output at start-up non The defrost temperature cannot be displayed. There is stop based on time -dDefrost in progress / First cooling after defrost PS Password required. Set password Start-up: Regulation starts when the voltage is on. 1 Go through the survey of factory settings. Make any necessary changes in the respective parameters. 2 For network. Set the address in o03 and then transmit it to the gateway/ system unit with setting o04. EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 7 Functions Here is a description of the individual functions. A controller only contains this part of the functions. Cf. the menu survey. Function Parameter Parameter by operation via data communication Normal display Normally the temperature value from thermostat sensor Sair is displayed. Display air (u69) Thermostat Thermostat control Set point Regulation is based on the set value plus a displacement, if applicable. The value is set via a push on the centre button. The set value can be locked or limited to a range with the settings in r02 and r03. The reference at any time can be seen in ”u28 Temp. ref” Differential When the temperature is higher than the reference + the set differential, the compressor relay will be cut in. It will cut out again when the temperature comes down to the set reference. Cutout °C r01 Differential To avoid a too high setting of the set point, the max. allowable reference value must be lowered. r02 Max cutout °C To avoid a too low setting of the set point, the min. allowable reference value must be increased. r03 Min cutout °C Correction of the display’s temperature showing If the temperature at the products and the temperature received by the controller are not identical, an offset adjustment of the shown display temperature can be carried out. Temperature unit Set here if the controller is to show temperature values in °C or in °F. r04 Disp. Adj. K r05 Temp. unit °C=0. / °F=1 (Only °C on AKM, whatever the setting) Correction of signal from Sair Compensation possibility through long sensor cable r09 Adjust Sair Start / stop of refrigeration With this setting refrigeration can be started, stopped or a manual override of the outputs can be allowed. Start / stop of refrigeration can also be accomplished with the external switch function connected to the DI input. Stopped refrigeration will give a ”Standby alarm”. Night setback value The thermostat’s reference will be the set point plus this value when the controller changes over to night operation. (Select a negative value if there is to be cold accumulation.) Activation of reference displacement When the function is changed to ON the thermostat differential will be increased by the value in r40. Activation can also take place via input DI (defined in o02). r12 Main Switch Value of reference displacement The thermostat reference and the alarm values are shifted the following number of degrees when the displacement is activated. Activation can take place via r39 or input DI Ref. Dif. Set point limitation The controller’s setting range for the set point may be narrowed down, so that much too high or much too low values are not set accidentally - with resulting damages. 1: Start 0: Stop -1: Manual control of outputs allowed r13 Night offset r39 Th. offset r40 Th. offset K Night setbck (start of night signal) 8 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 Alarm Alarm settings The controller can give alarm in different situations. When there is an alarm all the light-emitting diodes (LED) will flash on the controller front panel, and the alarm relay will cut in. A03 With data communication the importance of the individual alarms can be defined. Setting is carried out in the “Alarm destinations” menu. Alarm delay A04 DoorOpen del A12 Pulldown del A13 HighLim Air A14 LowLim Air A27 AI.Delay DI A37 Condtemp Al. Alarm delay (short alarm delay) If one of the two limit values is exceeded, a timer function will commence. The alarm will not become active until the set time delay has been passed. The time delay is set in minutes. Time delay for door alarm The time delay is set in minutes. The function is defined in o02. Time delay for cooling (long alarm delay) This time delay is used during start-up, during defrost, immediately after a defrost. There will be change-over to the normal time delay (A03) when the temperature has dropped below the set upper alarm limit. The time delay is set in minutes. Upper alarm limit Here you set when the alarm for high temperature is to start. The limit value is set in °C (absolute value). The limit value will be raised during night operation. The value is the same as the one set for night setback, but will only be raised if the value is positive. The limit value will also be raised in connection with reference displacement r39. Lower alarm limit Here you set when the alarm for low temperature is to start. The limit value is set in °C (absolute value). The limit value will also be raised in connection with reference displacement r39. Delay of a DI alarm A cut-out/cut-in input will result in alarm when the time delay is passed. The function is defined in o02. High alarm limit for condenser temperature If the S5 sensor is used for monitoring the condenser’s temperature you must set the value at which the alarm is to become activated. The value is set in °C. The definition of S5 as condenser sensor is accomplished in o70. The alarm is zeroset again 10 K below the set temperature. Reset alarm Compressor Compressor control The compressor relay works in conjunction with the thermostat. When the thermostat calls for refrigeration will the compressor relay be operated. Running times To prevent irregular operation, values can be set for the time the compressor is to run once it has been started. And for how long it at least has to be stopped. The running times are not observed when defrosts start. Min. ON-time (in minutes) c01 Min. On time Min. OFF-time (in minutes) c02 Min. Off time Reversed relay function for compressor relay 0: Normal function where the relay cuts in when refrigeration is demanded 1: Reversed function where the relay cuts out when refrigeration is demanded (this wiring produces the result that there will be refrigeration if the supply voltage to the controller fails). External relay (only EKC 302) Here it is possible to force the build in relays to connect in the voltage's zero crossing. The lifetime of the relays is increased, or the load can be increased. The function should not be activated if contactors are connected to one or more of the controller's relays. This will result in a reduction of the contactors lifetime. 0: The load is connected directly to the controller's relays (zero-crossing activated) Relay contact and controller supply must use same phase. 1: The controller's relay must draw a external contactor (zero-crossing cancelled) c30 Cmp relay NC c70 Ext. Relay EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 9 Defrost Defrost control The controller contains a timer function that is zeroset after each defrost start. The timer function will start a defrost if/when the interval time is passed. The timer function starts when voltage is connected to the controller, but it is displaced the first time by the setting in d05. If there is power failure the timer value will be saved and continue from here when the power returns. This timer function can be used as a simple way of starting defrosts, but it will always act as safety defrost if one of the subsequent defrost starts is not received. The controller also contains a real-time clock. By means of settings of this clock and times for the required defrost times, defrost can be started at fixed times of the day. If there is a risk of power failure for periods longer than four hours, a battery module should be mounted in the controller. (only possible in EKC 202) Defrost start can also be accomplished via data communication, via contact signals or manual start-up. All starting methods will function in the controller. The different functions have to be set, so that defrosts do not ”come tumbling” one after the other. Defrost can be accomplished with electricity, hot gas or brine. The actual defrost will be stopped based on time or temperature with a signal from a temperature sensor. Defrost method Here you set whether defrost is to be accomplished with electricity or "non". During defrost the defrost relay will be cut in. When gas defrosting the compressor relay will be cut in during defrost. Defrost stop temperature The defrost is stopped at a given temperature which is measured with a sensor (the sensor is defined in d10). The temperature value is set. d01 Def. method d02 Def. Stop Temp Interval between defrost starts The function is zeroset and will start the timer function at each defrost start. When the time has expired the function will start a defrost. The function is used as a simple defrost start, or it may be used as a safeguard if the normal signal fails to appear. If master/slave defrost without clock function or without data communication is used, the interval time will be used as max. time between defrosts. If a defrost start via data communication does not take place, the interval time will be used as max. time between defrosts. When there is defrost with clock function or data communication, the interval time must be set for a somewhat longer period of time than the planned one, as the interval time will otherwise start a defrost which a little later will be followed by the planned one. In connection with power failure the interval time will be maintained, and when the power returns the interval time will continue from the maintained value. The interval time is not active when set to 0. Max. defrost duration This setting is a safety time so that the defrost will be stopped if there has not already been a stop based on temperature or via coordinated defrost. (The setting will be the defrost time if d10 is selected to be 0) Time staggering for defrost cut ins during start-up The function is only relevant if you have several refrigeration appliances or groups where you want the defrost to be staggered in relation to one another. The function is furthermore only relevant if you have chosen defrost with interval start (d03). The function delays the interval time d03 by the set number of minutes, but it only does it once, and this at the very first defrost taking place when voltage is connected to the controller. The function will be active after each and every power failure. Drip-off time Here you set the time that is to elapse from a defrost and until the compressor is to start again. (The time when water drips off the evaporator). d03 Def Interval (0=off ) d04 Max Def. time d05 Time Stagg. d06 DripOff time Delay of fan start after defrost Here you set the time that is to elapse from compressor start after a defrost and until the fan may start again. (The time when water is “tied” to the evaporator). d07 FanStartDel Fan start temperature The fan may also be started a little earlier than mentioned under “Delay of fan start after defrost”, if the defrost sensor S5 registers another allowable value than the one set here. d08 FanStartTemp Fan cut in during defrost Here you can set whether fan is to operate during defrost. 0: Stopped (Runs during pump down) 1: Running (stopped during "fan delay") 2: Running during pump down and defrost. After that stopped Defrost sensor Here you define the defrost sensor. 0: None, defrost is based on time 1: S5 2: Sair d09 FanDuringDef d10 DefStopSens. 10 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 Defrost on demand – aggregate refrigeration time Set here is the refrigeration time allowed without defrosts. If the time is passed, a defrost will be started. With setting = 0 the function is cut out. Defrost on demand – S5 temperature The controller will follow the effectivity of the evaporator, and via internal calculations and measurements of the S5 temperature it will be able to start a defrost when the variation of the S5 temperature becomes larger than required. Here you set how large a slide of the S5 temperature can be allowed. When the value is passed, a defrost will start. The function can only be used in 1:1 systems when the evaporating temperature will become lower to ensure that the air temperature will be maintained. In central systems the function must be cut out. With setting = 20 the function is cut out d18 MaxTherRunT d19 CutoutS5Dif. If you wish to see the temperature at the S5 sensor, push the controller’s lowermost button. Defrost temp. If you wish to start an extra defrost, push the controller’s lowermost button for four seconds. You can stop an ongoing defrost in the same way Def Start Here you can start a manual defrost. Hold After Def Shows ON when the controller is operating with coordinated defrost. Defrost State Status on defrost 1= pump down / defrost Fan Fan control Fan stopped at cut-out compressor Here you can select whether the fan is to be stopped when the compressor is cut out F01 Fan stop CO (Yes = Fan stopped) Delay of fan stop when compressor is cut out If you have chosen to stop the fan when the compressor is cut out, you can delay the fan stop when the compressor has stopped. Here you can set the time delay. F02 Fan del. CO Fan stop temperature The function stops the fans in an error situation, so that they will not provide power to the appliance. If the defrost sensor registers a higher temperature than the one set here, the fans will be stopped. There will be re-start at 2 K below the setting. The function is not active during a defrost or start-up after a defrost. With setting +50°C the function is interrupted. F04 FanStopTemp. Real-time clock The controller (EKC 202) can accommodate one insertion module which may either be a data communication module or a battery module for the real-time clock. The battery module is used in conjunction with the real-time clock and will keep the clock going during lengthy power failures. Real-time clock You can set up to six individual times for defrost starts for each 24-hour period. There is also a date indication used for registration of temperature measurements. Defrost start, hour setting Defrost start, minute setting (1 and 11 belong together, etc.) When all t01 to t16 equal 0 the clock will not start defrosts. Clock: Hour setting (Times cannot be set via data communication. Settings are only relevant when there is no data communication). t01-t06 t11-t16 t07 Clock: Minute setting t08 Clock: Date setting t45 Clock: Month setting t46 Clock: Year setting t47 EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 11 Miscellaneous Miscellaneous Delay of output signal after start-up After start-up or a power failure the controller’s functions can be delayed so that overloading of the electricity supply network is avoided. Here you can set the time delay. o01 DelayOfOutp. Digital input signal - DI The controller has a digital input which can be used for one of the following functions: Off: The input is not used 1) Status display of a contact function 2) Door function. When the input is open it signals that the door is open. The refrigeration and the fans are stopped. When the time setting in “A04” is passed, an alarm will be given and refrigeration will be resumed. 3) Door alarm. When the input is open it signals that the door is open. When the time setting in “A04” is passed, there will be alarm. 4) Defrost. The function is started with a pulse pressure. The controller will register when the DI input is activated. The controller will then start a defrost cycle. If the signal is to be received by several controllers it is important that ALL connections are mounted the same way (DI to DI and GND to GND). 5) Main switch. Regulation is carried out when the input is short-circuited, and regulation is stopped when the input is put in pos. OFF. 6) Night operation. When the input is short-circuited, there will be regulation for night operation. 7) Reference displacement when DI1 is short-circuited. Displacement with “r40”. 8) Separate alarm function. Alarm will be given when the input is short-circuited. 9) Separate alarm function. Alarm will be given when the input is opened. (For 8 and 9 the time delay is set in A27) 10) Case cleaning. The function is started with a pulse pressure. Cf. also description on page 4. 11) Inject on/off. Off when DI is open. Address If the controller is built into a network with data communication, it must have an address, and the master gateway of the data communication must then know this address. o02 DI 1 Config. Definition takes place with the numerical value shown to the left. (0 = off ) The address is set between 1 and 240, gateway determined o03 The address is sent to the system manager when the menu o04 is set to 'ON', or when the system manager's scanning function is activated. (o04 is only to be used if the data communication is LON.) Access code 1 (Access to all settings) If the settings in the controller are to be protected with an access code you can set a numerical value between 0 and 100. If not, you can cancel the function with setting 0. (99 will always give you access). Sensor type Normally a Pt 1000 sensor with great signal accuracy is used. But you can also use a sensor with another signal accuracy. That may either be a PTC sensor (1000 ohm at 25°C) or an NTC sensor (5000 Ohm at 25°C). All the mounted sensors must be of the same type. Display step Yes: Gives steps of 0.5° No: Gives steps of 0.1° Max. standby time after coordinated defrost When a controller has completed a defrost it will wait for a signal which tells that the refrigeration may be resumed. If this signal fails to appear for one reason or another, the controller will itself start the refrigeration when this standby time has elapsed. Configuration of light function 1) The relay cuts in during day operation 2) The relay to be controlled via data communication 3) The relay to be controlled by the door switch defined in either o02 where the setting is selected to either 2 or 3. When the door is opened the relay will cut in. When the door is closed again there will be a time delay of two minutes before the light is switched off. Activation of light relay The light relay can be activated here (if 038=2) Case cleaning The status of the function can be followed here or the function can be started manually. 0 = Normal operation (no cleaning) 1 = Cleaning with fans operating. All other outputs are Off. 2 = Cleaning with stopped fans. All outputs are Off. If the function is controlled by a signal at the DI input, the relevant status can be seen here in the menu. Access code 2 (Access to adjustments) There is access to adjustments of values, but not to configuration settings. If the settings in the controller are to be protected with an access code you can set a numerical value between 0 and 100. If not, you can cancel the function with setting 0. If the function is used, access code 1 (o05) must also be used. o04 DI state (Measurement) The DI input’s present status is shown here. ON or OFF. After installation of data communication the controller can be operated on an equal footing with the other controllers in ADAPKOOL® refrigeration controls. The installation of the data communication cable has been mentioned in a separate document “RC8AC”. 12 Manual RS8DZ702 © Danfoss 03-2012 o05 - o06 SensorConfig Pt = 0 PTC = 1 NTC = 2 o15 Disp. Step = 0.5 o16 Max HoldTime o38 Light config o39 Light remote o46 Case clean o64 - EKC 202 / 302 Copy the controller’s present settings (EKC 202 only) With this function the controller’s settings can be transferred to a programming key. The key can contain up to 25 different sets. Select a number. All settings except for Address (o03) will be copied. When copying has started the display returns to o65. After two seconds you can move into the menu again and check whether the copying was satisfactory. Showing of a negative figure spells problems. See the significance in the Fault Message section. Copy from the programming key (EKC 202 only) This function downloads a set of settings earlier saved in the controller. Select the relevant number. All settings except for Address (o03) will be copied. When copying has started the display returns to o66. After two seconds you can move back into the menu again and check whether the copying was satisfactory. Showing of a negative figure spells problems. See the significance in the Fault Message section. Save as factory setting With this setting you save the controller’s actual settings as a new basic setting (the earlier factory settings are overwritten). Other application for S5 sensor Maintain the setting at 0 if the sensor has been defined as defrost sensor in D10. If D10 has been set at 0 or 2 the S5 input can be used as product sensor or condenser sensor. Here you define which: 0: Defrost sensor 1: Product sensor 2: Condenser sensor with alarm o65 - o66 - o67 - o70 S5 Config Relay 4 Here you define the application for relay 4: 1: Defrost (EKC 202A / 302A) or Light (EKC 202C) 2: Alarm o72 DO4 Config - - - Night Setback 0=Day 1=Night Service Service Temperature measured with S5 sensor u09 S5 temp. Status on DI input. on/1=closed u10 DI1 status Status on night operation (on or off ) 1=night operation u13 Night Cond. Read the present regulation reference u28 Temp. ref. * Status on relay for cooling u58 Comp1/LLSV * Status on relay for fan u59 Fan relay * Status on relay for defrost u60 Def. relay * Temperature measured with Sair sensor u69 Sair temp * Status on relay 4 (alarm, defrost or light function) u71 DO4 status *) Not all items will be shown. Only the function belonging to the selected application can be seen. EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 13 Fault message In an error situation the LED’s on the front will flash and the alarm relay will be activated. If you push the top button in this situation you can see the alarm report in the display. If there are further push again to see them. There are two kinds of error reports - it can either be an alarm occurring during the daily operation, or there may be a defect in the installation. A-alarms will not become visible until the set time delay has expired. E-alarms, on the other hand, will become visible the moment the error occurs. (An A alarm will not be visible as long as there is an active E alarm). Here are the messages that may appear: A1: High temperature alarm Alarms A2: Low temperature alarm Low t. alarm A4: Door alarm Door Alarm A5: Information. Parameter o16 is expired Max Hold Time A15: Alarm. Signal from DI input DI1 alarm A45: Standby position (stopped refrigeration via r12 or DI input) Standby mode A59: Case cleaning. Signal from DI input Case cleaning A61: Condenser alarm Cond. alarm E1: Faults in the controller EKC error E6: Fault in real-time clock. Check the battery / reset the clock. - E27: Sensor error on S5 S5 error E29: Sensor error on Sair Sair error 1 = alarm High t. alarm When copying settings to or from a copying key with functions o65 or o66, the following information may appear: 0: Copying concluded and OK 4: Copying key not correctly mounted 5: Copying was not correct. Repeat copying 6: Copying to EKC incorrect. Repeat copying 7: Copying to copying key incorrect. Repeat copying 8: Copying not possible. Order number or SW version do not match 9: Communication error and timeout 10: Copying still going on (The information can be found in o65 or o66 a couple of seconds after copying has been started). Alarm destinations The importance of the individual alarms can be defined with a setting (0, 1, 2 or 3) Warning ! Direct start of compressors * To prevent compressor breakdown parameter c01 and c02 should be set according to suppliers requirements or in general : Hermetic Compressors c02 min. 5 minutes Semihermetic Compressors c02 min. 8 minutes and c01 min. 2 to 5 minutes ( Motor from 5 to 15 KW ) * ) Direct activating of solenoid valves does not require settings different from factory (0) 14 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 Override The controller contains a number of functions that can be used together with the override function in the master gateway / System Manager. Function via data communication Functions to be used in the gateway’s override function Used parameter in EKC 202 and EKC 302 Start of defrosting Defrost control Time schedule - - - Def.start Coordinated defrost Defrost control - - - HoldAfterDef u60 Def.relay Night setback Day/night control Time schedule - - - Night setbck Light control Day/night control Time schedule o39 Light Remote EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 15 Connections EKC 202A EKC 202B EKC 202C or EKC 302A or EKC 302B or Digital On/Off signal A cut-in input will activate a function. The possible functions are described in menu o02. Power supply 230 V a.c. Sensors Sair is thermostat sensors. S5 is a defrost sensor and is used if defrost has to be stopped based on temperature. It may however also be used as product sensor or condenser sensor. 16 Relays The general connections are: Refrigeration. The contact will cut in when the controller demands refrigeration Defrost. Fan. Alarm. The relay is cut out during normal operation and cuts in in alarm situations and when the controller is dead (de-energised) Light. The contact will cut in when the controller demands light. Electric noise Cables for sensors, DI inputs and data communication must be kept separate from other electric cables: - Use separate cable trays - Keep a distance between cables of at least 10 cm - Long cables at the DI input should be avoided Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 Data communication If data communication is used, it is important that the installation of the data communication cable is performed correctly. See separate literature No. RC8AC.. Data communication EKC 202: MODBUS or LON-RS485 via insert cards. EKC 302: Fixed MODBUS or LON-RS485/MODBUS via insert card. See also below when using external display Extenal display on EKC 302 Only in standalone Do not connect anything other than a display on data communication. The distance to the display must not exceed 200 m. An address has to be set in o03 (0 can not be used). The display will self find the controller address. EKC 302 External display plus data communication EKC 302 + + EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 EKA 175 (LON RS485) EKA 178B (MODBUS) 17 Ordering Type Function Supply voltage Code no. EKC 202A Refrigeration controller EKC 202B Refrigeration controller with fan function EKC 202C Refrigeration controller for electric defrost 084B8523 EKA 178A Data communication module. MOD-bus 084B8564 EKA 179A Data communication module. RS 485- LON 084B8565 EKA 181A Battery and buzzer module that will protect the clock in case of lengthy power failure 084B8566 EKA 181C Battery module that will protect the clock in case of lengthy power failure EKA 182A Copy key EKC - EKC Type Function EKC 302A Refrigeration controller with MODBUS data communication EKC 302B Refrigeration controller r with fan function and MODBUS data communication 084B4163 EKA 175 Data communication module LON RS485 084B8579 EKA 178B Data communication module MODBUS 084B8571 EKA 163A External display option 084B8562 EKA 164A External operation option 084B8563 084B8521 230 V 084B8522 0848577 084B8567 Supply voltage Code no. 084B4162 230 V Temperature sensors: please refer to lit.no. RK0YG Type Funcion EKA 183A Programming key Code no. 084B8582 Copy tool for setting of EKC. For further details refer to Technical Brochure RD8BJ 18 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 Technical data Supply voltage 230 V a.c. +10/-15 %. 2.5 VA, 50/60 Hz Pt 1000 or Sensors 3 pcs off PTC (1000 ohm / 25°C) or either NTC-M2020 (5000 ohm / 25°C) Measuring -60 to +99°C range ±1 K below -35°C Accuracy Controller ±0.5 K between -35 to +25°C ±1 K above +25°C Pt 1000 ±0.3 K at 0°C sensor ±0.005 K per grad Display LED, 3-digits External display Digital inputs Electrical connection cable EKA 163A / EKA 164A Signal from contact functions Requirements to contacts: Gold plating Cable length must be max. 15 m Use auxiliary relays when the cable is longer Max.1,5 mm2 multi-core cable Max. 1 mm2 on sensors and DI inputs Weight = 200 g IEC60730 EKC 202 DO1 10 (6) A & (5 FLA, 30 LRA) DO2 DO3 10 (6) A & (5 FLA, 30 LRA) 6 (3) A & (3 FLA, 18 LRA) DO4** DO1 Relays* EKC 302 DO2 DO3 DO4** Data communication Environments Density 4 (1) A, Min. 100 mA** 10 (6) A & (5 FLA, 30 LRA) 1) 16 (8) A & (10 FLA, 60 LRA) 2) 6 (3) A & (3 FLA, 18 LRA) 1) 10 (6) A & (5 FLA, 30 LRA) 2) 6 (3) A & (3 FLA, 18 LRA) 1) 10 (6) A & (5 FLA, 30 LRA) 2) 4 (1)A Min. 100 mA** EKC 202: Via insert card EKC 302: Fixed MODBUS. Can be expanded with LON or MODBUS via insert card 0 to +55°C, During operations -40 to +70°C, During transport 20 - 80% Rh, not condensed No shock influence / vibrations EKC 202: IP 65 from front. Buttons and packing are imbedded in the front. EKC 302: IP 20 Escapement reserve for the clock 4 hours Approvals EU Low Voltage Directive and EMC demands re CEmarking complied with EKC 202: UL approval acc. UL 60730 LVD tested acc. EN 60730-1 and EN 60730-2-9, A1, A2 EMC tested acc. EN 61000-6-3 and EN 61000-6-2 * EKC 202: DO1 and DO2 are 16 A relays. DO3 and DO4 are 8 A relays. Above max. load must be kept. EKC 302: DO1 are 20 A relays. DO2 and DO3 are 16 A relays. DO4 are 10 A relays. The max. load listed above must be observed when connecting without zero-crossing control. When connecting with zero-crossing control, the load must be increased to the value indicated by 2) ** Gold plating ensures make function with small contact loads 1) With external relay (c70=ON) (zero-crossing control disabled) 2) Without external relay (c70=OFF) (zero-crossing control enabled) Relay contact and controller supply must use same phase and the load (compressor) must phase compensated to Cos ϕ = 1. EKC 202 / 302 Manual RS8DZ702 © Danfoss 03-2012 19 20 Manual RS8DZ702 © Danfoss 03-2012 EKC 202 / 302 ADAP-KOOL® Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alternations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property of the respecitve companies. 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