Alco EX Driver Series Operating Instructions

Alco EX Driver Series Operating Instructions
EC3-X33 Superheat Controller and ECD-002 Keypad / Display Unit
Operating Instructions
Description
GB
Wiring
EC3-X33 is an universal superheat controller in conjunction with Alco Electrical
Control Valves EX4...EX8.
!
Safety instructions:
Read installation instructions thoroughly. Failure to comply can result in
device failure, system damage or personal injury.
• The product is intended for use by persons having the appropriate
knowledge and skills.
• Disconnect all voltages from system before installation.
• Do not operate system before all cable connections are completed.
• Comply with local electrical regulations when wiring.
Note: The EC3-X33 series contains a lead, acid gel rechargeable battery. The
battery must NOT be disposed of with other commercial waste. Instead, it is the
user’s responsibility to pass it to a designated collection point for the safe recycling
of batteries (harmonised directive 98/101/EEC). For further information contact
your local environmental recycling centre.
•
Technical data
Power supply
24VAC ±10%; 50/60Hz; 1A
Power consumption
Plug-in connector
25VA max. including EX4 … EX8
Removable screw terminals
wire size 0.14 … 1.5 mm2
Grounding
6.3 mm spade earth connector
Protection class
IP20
Connection to ECD-002
ECC-Nxx or CAT5 cable with RJ45 connectors
Digital Inputs
0/24VAC/DC for stop/start function
NTC input
Alco Controls temperature sensor ECN-N60
4-20 mA Analog input
Alco Controls PT4-07M / PT4-18M / PT4-30M
4-20 mA Analog output
For connection to any 3rd party controller with
12/24VDC power supply and appropriate burden
Output alarm relay
SPDT contacts 24V AC/DC, 2 Amp inductive load
Activated: During normal operation (no alarm condition)
Deactivated: During alarm condition or power supply is OFF
Stepper motor output for
Maximum current 0.8A with nominal 24VDC
EX4…EX8
operating voltage
Ambient temperature range 0 … 60°C
1 … 25°C (for best battery life time)
> 35°C battery life time < 2 years
Mounting
The EC3-X33 is designed to be mounted onto a standard DIN rail. Mounting
position: on vertical walls, with stepper motor connector on top side only.
Electrical installation
Refer to the electrical wiring diagram for electrical connections.
Do not apply voltage to the controller before completion of wiring.
• Ground the metal housing with a 6.3mm spade connector.
• Important: Keep controller and sensor wiring well separated from mains wiring.
Minimum recommended distance 30mm.
Warning: Use a class II category transformer for 24VAC power supply. Do not
ground the 24VAC lines. We recommend to use individual transformers for EC3
controller(s) and for 3rd party controllers to avoid possible interference or
grounding problems in the power supply. Connecting any EC3 inputs to mains
voltage will permanently damage the EC3.
Digital input status is dependant to operation of compressor/thermostat
Commander
Operating condition
Digital input (I)
Compressor
Compressor starts
Closed / 24V (Start)
Compressor stops
Open / 0V (Stop)
Thermostat
Demand (compressor must be ON) Closed / 24V (Start)
No demand
Open / 0V (Stop)
•
•
Document Nr.: EC3-X33_65126_EN_R06.doc
Replacement for R05
A:
E:
F:
G:
H:
I:
J:
K:
White wire
B: Black wire C: Blue wire
D: Brown wire
Plug cable assembly EX5-Nxx for connection to EX4/EX5/EX6/EX7/EX8
PG/DIN plug for connection to EX8 (prior to March 2008 production)
Remote control panel, system controller
Alarm relay, dry contact. Relay coil is not energised at Alarm or power off
Digital input (0V/open = Stop; 24V/closed = Start)
Transformer Class II, 24VAC secondary / 25VA
Third party controller (can use the analog output signal from EC3)
Preparation for Start-up:
•
•
•
•
Vacuum the entire refrigeration circuit.
Warning: Alco Electrical Control Valves EX4...EX8 are delivered at half open
position. Do not charge system before closure of valve.
Apply supply voltage 24V to EC3 while the digital input is 0V. The valve will be
driven to close position.
After closure of valve, start to charge the system with refrigerant.
Warning: EC3 needs to be setup prior to start-up. Do not apply 24V digital
input to EC3 before completion of main parameters setting.
Connect ECD-002 to EC3 as shown in wiring diagram with ECC-Nxx cable or
with any standard straight Cat5 cable with two RJ45 plugs.
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12.11.2008
EC3-X33 Superheat Controller and ECD-002 Keypad / Display Unit
GB
Operating Instructions
ECD-002 display/keypad unit (LEDs and button functions)
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
Prg & Sel (5 sec)
Manual reset for
blinking alarm codes
value (lower)
Selecting/confirming
• Make sure that digital input is 0V (open). Turn the power supply ON.
Important: Three main parameters i.e. refrigerant type (u0), pressure sensor type
(uP) and valve type (ut) can be set only when digital input is open (0V) while the
power supply is ON (24V). This feature is for added safety to prevent accidental
damage of compressors and other system components.
• For easy setting of main parameters, follow the pictorial procedure of “Quick
start-up” on the attached individual paper.
Once the main parameters have been selected/saved the EC3 is ready for
startup. All other parameters can be modified at any time during operation or
standby if it is necessary.
Start-up
Start the system and check the superheat and operating conditions.
The EC3-X33 is fully functional without keypad/display unit. ECD-002 may be
removed or connected at any time.
Procedure for parameters modification using ECD-002
The parameters can be accessed via the 4-button keypad. The configuration
parameters are protected by a numerical password. The default password is “12”.
To select the parameter configuration:
Press the PRG button for more than 5 seconds
A flashing 0 is displayed
Press or until 12 is displayed; (password)
Press SEL to confirm password
Press or to show the code of the parameter that has to be changed;
Press SEL to display the selected parameter value;
Press or to increase or decrease the value;
Press SEL to temporarily confirm the new value and display its code;
Repeat the procedure from the beginning "press
or to show..."
To exit and save the new settings:
Press PRG to confirm the new values and exit the parameters modification
procedure.
To exit without modifying any parameters:
Do not press any button for at least 60 seconds (TIME OUT).
Reset all parameters to factory setting:
•
•
•
•
•
•
•
Min Max Factory Field
setting setting
H5 Password
1
199
12
u0 System refrigerant
0
7
1
0 = R22
1 = R134a 2 = R507
3 = R404A
4 = R407C
5 = R410A 6 = R124
7 = R744 (subcritical application)
uP Installed pressure sensor type
0
1
0
0 = PT4-07M (for R22/R134a/R507/R404A/R407C/R124)
1 = PT4-18M (for R410A)
2 = PT4-30M (for R744, subcritical)
ut Installed valve type
1
5
5
1 = EX4
2 = EX5
3 = EX6
4 = EX7
5 = EX8
Optional parameters
Next parameter/ (recommended factory setting for majority of applications)
Setup of main parameters (need to be checked/modified before
start-up) using ECD-002
•
Main parameters (must be checked and modified if necessary)
Code Parameter description and choices
Blinking: valve is opening
ON: valve is fully open
Mounting of ECD-002
Make shure that digital input is 0V (open).
Press and together for more than 5 seconds.
A flashing 0 is displayed.
Press or until the password is displayed (Factory setting = 12).
If password was changed, select the new password.
Press SEL to confirm password
“0” is displayed.
Press SEL to reset all parameters to factory setting
Press PRG to activate the function and leave the special function mode.
Control (valve) start-up behaviour (Parameter uu and u9)
EX4/5/6 ≤ 1.5 seconds uu
EX7
≤ 3.2 seconds
EX8
≤ 5.2 seconds
Document Nr.: EC3-X33_65126_EN_R06.doc
Sec.
EC3-X3 BA.cdr
%
u9
uu Start valve opening (%)
10
100
50
u9 Start opening duration (second)
1
30
5
uL Low superheat alarm function
0
2
1
0 = disable (for flooded evaporator)
1 = enable auto reset
2 = enable manual reset
Cut-out at 0.5K (if it maintains 1 min.); Cut-in immediately at 3K
u5 Superheat set-point (K)
If uL enabled (auto or manual)
3
30
6
If uL disabled
0.5
30
6
u2 MOP function
0
1
1
0 = disable 1 = enable
u3 MOP set-point (°C) saturation temperature
*
*
X
Factory setting is according to selected refrigerant (u0):
+13°C for R22
+15°C for R134a
+7°C for R507
+7°C for R404A +15°C for R407C
+15°C for R410A
+50°C for R124
-5°C for R744
┌┘5 Units conversion (only for u3, u5, ┌┘1)
0
1
0
0 = °C, K, bar
1 = °F, R, psig
(Psig values are divided by 10. Example: Display 12.5 is 125 psig)
┌┘1 Value to show
0
4
0
0 = Measured superheat (K) 1 = Measured evaporating pressure, (bar);
2 = Valve opening (%)
3 = Measured coil-out temperature (°C)
4 = Calculated evaporating temperature (°C) from the pressure
u4 Superheat control mode
0
1
0
0 = Standard, 1 = Slow
b1 Battery error management, when battery is
0
3
2
defective, see below:
Alarm
Reset possibility
value display Alarm relay
Valve
after
recovery/replace
ment
0
Regulating
1
Ab
Regulating
2
Ab
Signalling
Fully close
Auto
3
Ab
Signalling
Fully close
Manual
(blinking)
*) Min. and Max. setting values are dependant to selected type of refrigerant.
Replacement for R05
ECD-002 can be installed at any time also during operation.
• ECD-002 can be mounted in panels with 71x29
mm cutout
• Push controller into panel cut-out.(1)
• Make sure that mounting lugs are flush with
outside of controller housing
• Insert Allen key into front panel holes and turn
clockwise. Mounting lugs will turn and gradually
move towards panel (2)
• Turn Allen key until mounting lug barely touches
panel. Then move other mounting lug to the same
position (3)
• Tighten both sides very carefully until keypad is
secured. Do not over tighten as mounting lugs will
break easily.
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12.11.2008
EC3-X33 Superheat Controller and ECD-002 Keypad / Display Unit
GB
Operating Instructions
Error/Alarm handling
Alarm
code
E0
Description
Pressure transmitter
error
Temperature sensor
E1
error
EX4…EX8 electrical
AΠ
connection error
Low superheat
AL
AL blinking (<0,5K)
Ab
Related
Alarm
parameter
relay
Signalling
-
Signalling
-
Signalling
uL: 1
uL: 2
b1: 1
Signalling
Signalling
-
Valve
Fully close Check wiring connection and measure the signal 4 to 20 mA
Requires manual reset
after resolving alarm
No
Fully close Check wiring connection and measure the resistance of sensor
No
-
What to do?
Check wiring connection and measure the resistance of winding
No
Fully close Check wiring connection and operation of valve
No
Fully close
Yes
Regulating Battery potentially does not have enough charge to close valve in case of main power supply interruption. May occur temporarily
Battery error
b1: 2
Signalling Fully close with new controllers or after long storage but should disappear
Ab
when battery is charged sufficiently. If Ab remains active even
b1: 3
Signalling Fully close when battery is charged, battery may be defective and should be
Yes
Ab blinking
replaced. (Replacement kit: 807 790).
Data error display Data send to the display is out of range. Check temperature and
No
Er
out of range
pressure sensor.
Note: When multiple alarms occur, the highest priority alarm is displayed until being
Message
cleared, then the next highest alarm is displayed until all alarms are cleared. Only then
--- No data to display
will parameters be shown again.
The display will show an “---” at start up and when no data is send to ECD-002
Checking system operating conditions
The data to be permanently shown on the display can be selected by the user
(parameter ┌┘1). It is possible to temporarily display other values. However this
function is not available in an alarm condition. The display will show for one
second the numerical identifier of the data (see ┌┘1 parameter) and then the selected data.
After 5 minutes, the display will return to the value selected by parameter ┌┘1.
Service / Troubleshooting
Symptom
Operating superheat is several degrees higher or lower than
set-point
Cause
Incorrect signal from pressure or
temperature sensors
Operating superheat is too low i.e. compressor wet running
Action
1- Check the sensors
2- Make sure ECN-N60 temperature sensor is used
3- For optimum accuracy, please use:
PT4-07M for R22/R134a/R507/R404A/R407C/R124
PT4-18M for R410A
PT4-30M for R744
4- Make sure the sensor cables are not installed along with other
high voltage cables
1- Check the wiring
2- Check the sensor
1- Valve is shut off only when the digital input is turned off (0V)
2- Check the setting of parameter ut
Increase the superheat set-point
1- Incorrect wiring of ECVs
2- Defective sensors
Valve is not fully closed
1- The digital input is ON (24V)
2- Wrong setting of parameter ut.
Instable superheat (hunting)
Evaporator is designed to operate at
higher superheat
Valve opens when EC3 commands to close and vice versa
Wrong wiring between EC3-X33 and Correct the wiring
valve
EX8 is not able to open at high differential pressure
Wrong setting of parameter ut
Check the parameter ut. (Larger valve requires higher torque and
higher current)
Superheat set-point is shifting after several months of
Stepper motor driven valves require
Do not apply permanent 24V digital input. Interrupt digital input
uninterrupted operation or permanent jumper of 24V digital synchronization
once every week for 5 seconds if compressor never stops.
input
Dimensions
EC3-X33
ECD-002
Emerson Electric GmbH & Co OHG - Postfach 1251 - Heerstraße 111 - D-71332 Waiblingen - Germany - Phone .49-(0)7151-509-0 - Fax .49-(0)7151-509-200
www.emersonclimate.eu
Document Nr.: EC3-X33_65126_EN_R06.doc
Replacement for R05
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12.11.2008
Quick Start Up
EC3-X33 & ECD-002
0
EC3-X33
2
4
2a
4a
2b
4b
0V
24 V AC
1
5 sec.
1a
0 = R22
1 = R134a
2 = R507
3 = R404A
4 = R407C
5 = R410A
6 = R124
7 = R744
12x
1b
2
1c
3
1 = EX4
2 = EX5
3 = EX6
4 = EX7
5 = EX8
R 410A
EX7
4c
4d
1-199
1d
88
4e
EC3-X33
3a
24 V
3b
24 V AC
1e
0 = PT4-07M
(R22/R134a/R507/R404A/R407C/R124)
1 = PT4-18M (R410A)
2 = PT4-30M (R744)
PT4
3c
Display of Data:
Po (barg)
Vo (%)
Ts (°C)
100%
0%
Po => To
Ts
R22
EX4, EX5
EX6, EX7
EX8
To (°C)
EC3X_65130.cdr
SH = Ts - To (K)
Emerson Electric GmbH & Co OHG - Postfach 1251 - Heerstraße 111 - D-71332 Waiblingen - Germany - Phone .49-(0)7151-509-0 - Fax .49-(0)7151-509-200
www.emersonclimate.eu
Document Nr.: EC3-X33_65126_EN_R06.doc
Replacement for R05
4/4
12.11.2008
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