EC3-X33

Stand-alone Superheat Controller

Technical Data

EC3-X33 is a stand-alone universal superheat controller for air conditioning, refrigeration and industrial applications such as chillers, industrial process cooling, rooftops, heat pumps, package unit, close control, cold room, food process and air driers. The optional ECD-002 Display/keypad Unit is necessary for setup but not for operation of the controllers.

ECD-002 can be connected or disconnected to EC3-X33 at any time.

Features EC3-X33

Superheat control in conjunction with Emerson stepper motor driven Electrical Control Valves EX4 … EX8

Limitation of evaporating pressure (MOP)

Low superheat alarm

Feed through of 4…20mA signal from evaporator pressure sensor to analogue output. This may also be connected to pressure input of any other controller to avoid need for multiple pressure sensors

Monitoring of sensors and sensor wiring and detection of sensor and wiring failures

Intelligent alarm management in order to protect the compressor i.e fail safe operation

Integral rechargeable battery to close Electrical Control

Valve in case of power loss

Electrical connection via plug-in type screw terminals

Aluminum housing for DIN rail mounting

EC3-X33 with ECD-002

Features ECD-002

2½ digit LED display with automatic decimal point

Indicator LEDs for valve opening/closing, external demand and alarm

Connection to EC3 Series via ECC-Nxx or standard CAT5 patch cord with RJ45 connectors

Typical ordering package:

Description

Superheat Controller

Terminal kit

Temperature sensor

Type

EC3-X33

K03-X32

ECN-N60

Emerson PCN

097707

097709

097714

Electrical Control Valve

Pressure sensor

for R-22/R-124/R-134a/R-404A/R-407C/R-507C

for R-410A

for R-744

Plug and cable assembly for pressure sensor

EX4, EX5, EX6, EX7 or EX8 *

PT5-07M

PT5-18M

PT4-30M

PT4-M60

*

097748

097749

097728

097717

*For further details refer to: EX4, EX5, EX6, EX7, EX8 Electrical Control Valves datasheet FC-TD/ EX4-8

Part No.

807 783

807 644

804 497

*

802 350

802 851

802 334

804 805

Accessories (required for setting at start-up only):

Description Type

Optional display/keypad ECD-002

Cable connection between EC3-X33 and ECD-002 ECC-N30 or any standard Cat 5 patch cord with

RJ45 connectors

Replacement Battery for EC3

Emerson

PCN

Part No.

097712 807 657

097713 807 861

097693 807 790

Application

EC3-X33 as superheat controller can be applied for the following:

Superheat control of conventional evaporators such as shell and tube, plate heat exchanger, air coil etc.

Superheat control of subcoolers or economizers connected to suction pressure of compressor or intermediate pressure of screw/scroll compressors having vapor or liquid injection connection

Superheat control of intermediate gas in two stage compressors

Superheat control of suction gas in conjunction with hot gas bypass

Superheat control of flooded evaporators

FC-TD/ EC3-X33 1 / 6 July 2011

EC3-X33

Stand-alone Superheat Controller

Introduction

The EC3-X33 controls the opening of an electrical control valves according to desired superheat. As Emerson Electrical

Control Valves (ECV) are able to a provide positive shut-off function better than conventional solenoid valves, there will be no flow through Emerson ECV as long as the compressor is not running. In the event of cooling request and compressor startup, EC3-X33 needs to be informed. This can be achieved by a digital input. EC3-X33 will start to control the refrigerant mass flow stand alone by precise positioning of the ECV under different operating conditions such as compressor start-up, start of further compressor, high head pressure, low head pressure, high load, low load and partial load operation.

EC3-X33 is capable for diagnostics and alarm. The alarm can be received via relay output as well as optical LED/alarm code on ECD-002.

Algorithm

The superheat control algorithm is self-adapting, so that it automatically adjusts itself to the characteristics of the evaporator at regular intervals. This guarantees optimal superheat control performance for different types of evaporators, as well as when the operating conditions of the evaporator change over time.

Superheat Control function

By receiving two measured values from Emerson pressure sensor PT4 and Emerson temperature sensor ECN-N60, EC3-

X33 calculates the actual superheat and compares with preset superheat. EC3-X33 operates the Electrical Control Valve in order to keep superheat at desired setpoint under various operating conditions.

The superheat setpoint is adjustable between 6°F and 60°F. If low superheat alarm function is disabled, it is possible to adjust the superheat set point below 6°F down to 1°F for special applications such as flooded evaporators.

MOP function

To avoid overload of the compressor motor, the MOP function of the EC3-X33 limits the evaporating pressure to a predetermined value. This can be adjusted to match the safe operating envelope of the compressor. MOP setpoints are entered as saturation temperature values to match published safe operating data of compressor manufacturers and to avoid unnecessary manual conversions from temperature into pressure values. The MOP function may be totally disabled, when not needed.

Low superheat alarm

Liquid flooding may lead to serious damage of compressors and must be avoided. The built-in low superheat alarm function of the EC3-X33 detects low superheat conditions and deactivates the alarm relay. If the alarm relay is wired into the serial safety loop, the compressor will be switched off when a low superheat alarm occurs.

Digital input status

The digital input is the interface between EC3-X33 and system controller. The digital status depends on the system’s compressor/thermostat.

Commander Operating condition Digital input status

Compressor Compressor starts Closed / 24V (Start)

Compressor stops Open / 0V (Stop)

Thermostat Demand (compressor must be ON)

No demand

Closed / 24V (Start)

Open / 0V (Stop)

Shut-off function

When digital input is open (0V), the EC3-X33 will drive the electrical control valve to the closed position. Due to the positive shut-off capabilities of the EX4/5/6/7/8 valves a separate liquid line solenoid valve is not required. The shut-off function is guaranteed in case of power loss due to built-in internal battery.

Analogue output (4-20mA signal) function

EC3-X33 requires the outlet pressure level of the evaporator for superheat and MOP control. The output signal from PT4 is used by EC3-X33 and again provided as a 4...20mA signal

(galvanized) for the connection to any other third party controller, which can receive a 4...20mA signal. Please see the wiring diagram for more details. If the system controller does not have the capability of using this signal, the terminal will not be wired to any other device.

Pump down function

Emerson Electrical Control Valves can be driven to close position while the compressor is running for pump down function. There are two possibilities to achieve this function:

1) The valve will be driven to close position by interruption of the digital input. The compressor can be turned off by a pressure switch and / or a timer.

2) By using 4 to 20 mA analogue output connected to system controller.

In both cases, the initiation and termination of pump down is under the system controller functionality/responsibility.

Safety / internal battery function

In the event of a power failure to the entire system, a stepper motor driven valve would not be able to move. Due to the differential pressure between condenser and evaporator, the refrigerant would continue to flow through the valve if the valve is open. The compressor must be protected after power recovery against flood- back. The EC3-X33 contains an internal rechargeable battery and smart battery charge control.

Optimum battery life is achieved through temperature compensated charge cycles.

Alarm and maintenance functions

EC3-X33 provides several alarms to facilitate diagnosis as well as shut down of compressor/system if the alarm relay is wired into the serial safety loop. Built-in diagnostic routines constantly monitor battery health and sensors the Electrical Control Valve and the associated wiring for open and short circuits. When such errors are detected, the controller goes into an alarm condition and closes the valve.

In addition to hardware errors, the EC3-X33 will monitor the minimum operating superheat. If the superheat drops below

1°F for a continuous period of one minute, the low superheat alarm will occur. The low superheat alarm can be disabled for applications such as a flooded evaporator, where a lower operating superheat is required.

In the case of an alarm, the EC3-X33 will close the valve, and the alarm relay will be deactivated. Alarm codes such as alarm

LED will be available if the optional display/keypad, ECD-002, is connected to EC3-X33

All alarms are automatically cleared after correction. Battery alarm and low superheat alarm can be modified for manual reset.

Alarm relay function

Alarm relay contains a SPDT contact. If the relay is wired to the system controller, it is possible to stop the compressor/system.

The alarm relay is activated during normal operation and

FC-TD/ EC3-X33 2 / 6 July 2008

EC3-X33

Stand-alone Superheat Controller deactivated during alarm conditions such as supply power interruptions.

Start-up configuration function

Built-in valve opening (%) at start-up for a certain period of time helps the compressor’s start-up and prevents erratic low pressure cut-out for the following cases:

Operation of systems with air cooled condensers in low ambient temperatures

Compressor start-up after a long standby time in a low ambient environment

Start-up of very large single stage compressor capacity

Emerson Pressure Sensor PT4 function

The pressure sensor measures the saturation pressure at the outlet of the evaporator. The output signal is 4 to 20 mA corresponding to a pressure range. Based on the type of refrigerant and system, different types of pressure sensors are needed.

PT4-07M for evaporators operating with refrigerants R-

22/R-124/R-134a/R-404A/R-407C

PT4-18M for evaporators operating with R-410A

PT4-30M for evaporators operating with R744

Every type of pressure sensor is calibrated in a temperature range for the above specified applications. The feature set and performance of the PT4 Series is a perfect match for the EC3-

X33. Other pressure sensors are not released for use with

EC3-X33 and when applied, may lead to poor performance.

Emerson temperature sensor ECN-N60

The temperature sensor measures the refrigerant temperature at the outlet of the evaporator. It is important to use only this particular temperature sensor because the ECN-N60 has the right performance such as desired time constant and tolerance compensation within the specific working range. The use of other temperature sensors is not recommended. The sensor is hermetically sealed for high reliability and long lifetime and has metal housings for optimal thermal conductivity.

Optional ECD-002 display/keypad unit

The ECD-002 is required to set a parameter during start-up.

After completion of start-up, it may be left connected or removed from EC3-X33.

The display unit can be switched from K/bar/°C to R/psig/°F.

Indicator LEDs show the status of valve opening, valve closing, demand and alarm.

Blinking: Valve is opening

ON: Valve is fully open

Blinking: Valve is closing

ON: Valve is fully close

Parameters setting/saving

Next parameter/value (higher)

ON: Demand

OFF: No demand

ON: Alarm

OFF: No alarm

Next parameter/value (lower)

Wiring Diagram

A: White wire B: Black wire C: Blue wire D: Brown wire

E: Plug cable assembly EX5-Nxx for connection to

EX4/EX5/EX6/EX7/EX8

F: Remote control panel, system controller

G: Alarm relay, dry contact. Relay coil is not energized at alarm condition or power off

H: Digital input (0V/open = Stop; 24V/closed = Start)

I: Transformer Class II, 24VAC secondary / 28VA

J: Third party controller (can use the analog output signal from

EC3)

Note: The internal resistor of a third party controller must fulfill the following conditions:

Supply voltage 12VDC: R ≤ 200Ω

Supply voltage 24VDC: R ≤ 800Ω

Manual reset for blinking alarm codes

(press 5 sec together)

FC-TD/ EC3-X33

Selecting/confirming

3 / 6 July 2008

EC3-X33

Stand-alone Superheat Controller

Ordering, main parts

Description

Controller EC3-X33

Terminal Kit for EC3-X33

Pressure Sensors

Cable Assembly for PT4

-

11.6…101.5 psi

0…261.1 psi

0…435.1 psi

20 ft cable length

Type

EC3-X33

K03-X32

PT4-07M

PT4-18M

PT4-30M

PT4-M60

NTC Temperature sensors 20 ft cable length ECN-N60

Display/keypad unit (need for set-up only)

Connection cable EC3 to ECD-002 10 ft

ECD-002

ECC-N30

Ordering, accessories, spare part

Transformer Emerson PCN

Primary:120/208/240VAC 60 Hz

Secondary: 24V 40VA

097724

Type

T2

Part Code Nr.

807 783

807 644

802 332

802 333

802 334

804 805

804 497

807 657

807 861

Part Code Nr.

90-T40F3

Suitable valves for connection to EC3-X33

Valve Capacity range

Tons *

EX4

EX5

EX6

EX7

EX8

EX4

EX5

EX6

EX7

EX8

EX4

EX5

EX6

EX7

EX8

EX4

EX5

EX6

EX7

EX8

0.6 … 5.7

1.4 … 14.2

3.4 … 34.1

10 … 93.8

25.6 … 250.2

0.6 … 6

1.4 … 15.1

3.7 … 35.8

10 … 98.7

28.4 … 263

0.6 … 4.3

1.1 … 11.1

2.8 … 26.4

7.1 … 72.5

19.9 … 193.4

0.6 … 4

1.1 … 10

2.6 … 23.9

6.8 … 65.4

17.6 …174.3

Refrigerant

R-22

R-407C

R-134a

R-404A/

R-507

Capacity regulation

10-100%

Valve Capacity range

EX4

EX5

EX6

EX7

EX8**

EX4

EX5

EX6

EX7

EX8**

EX4

EX5

EX6

Tons*

0.9 … 6.5

1.7 … 16.5

4 … 39.8

11.4 … 109.5

28.4 … 292

1.1 … 11.7

2.8 … 29

7.1 … 69.4

19.9 … 190.8

51.2 … 508.7

0.3 … 3.1

0.9 … 8

1.7 … 19.1

*) Nominal rating conditions:

Refrigerant

R-22, R-134a, R-404A, R-407C,

R-410A

R-23

R-744

R-124

**) MWP: 508 psi

Refrigerant

R-410A

R-744

R-124

Evaporating

Temperature

+39.2°F

-76°F

-40°F

68°F

Capacity regulation

10 to 100%

Condensing

Temperature

+100.4°F

-13°F

14°F

176°F

FC-TD/ EC3-X33 4 / 6 July 2008

EC3-X33

Stand-alone Superheat Controller

Technical Data

EC3-X33

Supply voltage

Digital input

Marking

Protection class

Vibration

Temperatures

storage

operating

Humidity

Protection class

Weight

Mounting

24VAC ±10%, 50/60Hz

24V AC ±10%, 50-60HZ

24V DC ±10%

Power consumption 25VA max. including connected ECV and display/keyboard

ECD-002 Display Unit

Supply

LED indicators

From EC3 Series Controller via connecting cable

Valve opening, valve closing, alarm, demand

Display LED

Internal battery charging time

Approximately 2 hours if battery is fully empty

Plug-in connector size Removable screw version wire size 12-20 AWG

Ground connection

Applied directive

EMC

LVD

RoHS

1/4 in spade earth connector

EN 61326, EN 50081, EN 61000-6-2,

EN 61000-4-2, EN 61000-4-3, EN

61000-4-4, EN 61000-4-5, EN 61000-

4-6, EN 61000-4-11

Connecting cable

Temperature

storage

operating

Humidity

Protection class

CE

IP 20

4g, 10-1000Hz

-

4 … +149°F

+

32 … +140°F

0 … 80% r.h. non condensing

IP20

~28.2oz

DIN rail mounted

Weight

Mounting

Numeric segmental display, 2½digits, red, with automatic decimal point betw. ±19.9, switchable between

°C and °F

ECC-Nxx or standard CAT5 patch cord with RJ45 connectors

4 … +149°F

+

32 … +140°F

0 … 80% r.h. non condensing

IP 65 (front protection with gasket)

~ 1.8oz

Panel mount (2.8 x 1.1 in cutout)

Input and Output, EC3-X33 Controller

Description Specification

Temperature input

Pressure sensor input

Analog output (evaporating pressure fed-through signal)

Digital input

Output relay

Stepper motor output

Connection to ECD-002

ECN-N60

10k @ +77 °F, Range: -58

… +122 °F

PT4-07M/18M

24VDC, 4 … 20mA

4 20mA

Requires 12 or 24 VDC

0/24 VAC/DC

SPDT contacts, AgCdO , 24VAC/DC

Inductive 2Amp, Resistive 8 Amp

For EX4 … EX8 Electrical Control Valves

RJ45

List of adjustable parameters

Superheat set point

Low superheat function

MOP function and set point

Type of refrigerant and required pressure sensor

Type of Electrical Control Valve

Valve start opening and duration

Unit conversion

Value to display

Battery error management

Password

FC-TD/ EC3-X33 5 / 6 July 2008

Dimensions (in)

EC3-X33 Controller

EC3-X33

Stand-alone Superheat Controller

ECD-002 Display Unit

Emerson is not to be held responsible for erroneous literature regarding capacities, dimensions, applications, etc. stated herein. Products, specifications and data in this literature are subject to change without notice. The information given herein is based on technical data and tests which Emerson believes to be reliable and which are in compliance with technical knowledge of today. It is intended only for use www.emersonclimate.com/flowcontrols

11911 Adie Road P.O. Box 411400 St. Louis, MO 63141 USA

FC-TD/ EC3-X33 6 / 6 by persons having the appropriate technical knowledge and skills, at their own discretion and risk. Since conditions of use are outside of

Emerson control we can not assume any liability for results obtained or damages occurred due to improper application.

This document replaces all earlier versions.

CUSTOMER SERVICE (314)-569-4666

July 2008