EC3-X32 Technical Data

EC3-X32 Technical Data
EC3-X32
Stand-alone Superheat Controller
Technical Data
EC3-X32 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. EC3-X32 offers remote access with built-in TCP/IP
Ethernet communications and WebServer functionality. Any
®
standard WebBrowser (e.g. Internet Explorer 5.0 or higher or
Mozilla Firefox) can be used for monitoring or parameter
setting.
Features EC3-X32
Superheat control in conjunction with Emerson stepper
motor driven Electrical Control Valves (EX4 … EX8)
Limitation of evaporating pressure (MOP)
Low and high superheat alarm
Low pressure switch function/alarm
Freeze protection function/alarm
Pump down function
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
Support of TCP/IP Ethernet technology with WebServer
functionality allows monitoring and configuration of
controllers through a standard WebBrowser (e.g. Internet
®
Explorer or Mozilla Firefox)
Electrical connection via plug-in type screw terminal
Aluminum housing for DIN rail mounting
EC3-X32
Typical ordering package:
Description
Type
Superheat Controller
EC3-X32
Terminal kit
K03-X32
Temperature sensor
ECN-N60
Electrical Control Valve
EX4, EX5, EX6, EX7 or EX8 *
Pressure sensor
- for R-22/R-124/R-134a/R-404A/R-407C/R-507C PT5-07M
- for R-410A
PT5-18M
- for R-744 (transcritical)
PT4-30M
Plug and cable assembly for pressure sensor
PT4-M60
Replacement Battery for EC3
*For further details refer to: EX4, EX5, EX6, EX7, EX8 Electrical Control Valves datasheet
Emerson
PCN
097708
097709
097714
*
Part No.
807 782
807 644
804 497
*
097748
802 350
097749
802 851
097728
802 334
097717
804 805
097693
807 790
FC-TD/ EX4-8
Application
EC3-X32 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-X32
1/9
July 2011
EC3-X32
Stand-alone Superheat Controller
Description of performance
The EC3-X32 controls the opening of an electrical control valve
according to desired superheat. As Emerson Electrical Control
Valves (ECV) are able to provide a 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-X32 needs to be informed. This can be achieved by a
digital input. EC3-X32 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-X32 is capable for diagnostics and alarm. The alarm can
be received via relay output, via TCP/IP network 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, EC3X32 calculates the actual superheat and compares to preset
superheat. EC3-X32 operates the Electrical Control Valve in
order to keep superheat at desired setpoint under various
operating conditions.
The superheat set point 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-X32 limits the evaporating pressure to a predetermined value. That 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.
Digital input status (factory setting)
The digital input is the interface between EC3-X32 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 Closed / 24V (Start)
must be ON)
No demand
Open / 0V (Stop)
Shut-off function
When digital input is open (0V), the EC3-X32 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-X32 requires the outlet pressure level of the evaporator for
superheat and MOP control. The output signal from PT4 is
used by EC3-X32 and again provided as 4 to 20mA signal
(galvanized) for connection to any other third party controller,
which can receive a 4 to 20 mA signal. Please see the wiring
diagram for more details. If the system controller does not have
capability of using this signal, the terminal will not be wired to
any other device.
Pump down function
When the pump-down function is active, the electrical control
valve will close in event of no demand i.e. the digital is 0V
(open), but the compressor will keep running to perform a
pump down of the refrigeration system until the pump-down
threshold pressure (adjustable) is reached and after a time
delay (adjustable), the output pump down relay trips to stop the
compressor. This relay must be wired into the compressor
control wiring.
Low pressure switch function/alarm
The use of a low-pressure switch is very common to prevent
the compressor from running in event of a refrigerant charge
loss and alarm. When the low pressure function is active, a
software routine detects excessively low pressure level
(adjustable) and after a time delay (adjustable) output alarm
relay trips.
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-X32 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.
Freeze protection function/alarm
This feature permits the elimination of a separate freeze
protection thermostat, in a water chiller application. When the
freeze protection function is activated, the evaporating
temperature is constantly monitored. If it drops below the
freeze protection threshold, the freeze protection alarm triggers
the alarm relay.
High superheat alarm
If this function is enabled, it detects longer lasting high
superheat conditions (adjustable) and triggers the high
superheat alarm.
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-X32 contains an internal
rechargeable battery and smart battery charge control.
Optimum battery life is achieved through temperature
compensated charge cycles.
FC-TD/ EC3-X32
2/9
July 2011
EC3-X32
Stand-alone Superheat Controller
Alarm and maintenance functions
EC3-X32 provides several alarms to facilitate diagnosis as well
as shut down of compressor/system if alarm relay is wired into
the serial safety loop. Built-in diagnostic routines constantly
monitor the 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-X32 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.
There are several other alarms such as a low pressure alarm,
freeze protection alarm and high superheat alarm if they are
enabled.
In the case of an alarm, EC3-X32 will close the valve and the
alarm relay will be deactivated. All alarms are automatically
cleared after correction. Battery alarm, low superheat alarm,
freeze protection alarm and low pressure alarm can be
modified for manual reset.
Emerson temperature sensor ECN-N60 function
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/released. The
sensor is hermetically sealed for high reliability and long life.
The sensor has metal housings for optimal thermal
conductivity.
Alarm relay function (factory setting)
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
deactivated during alarm conditions such as supply power
interruption.
List of adjustable parameters
Superheat set point and mode
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
User name (only via web page)
Low pressure alarm: cut-out/cut-in and time delay
Freeze protection alarm: cut-out/cut-in and time delay
High superheat alarm: Cut-out and time delay
Pump down cut-out and duration
Manual control of valve (only via web page)
TCP/IP configuration (only via web page)
Others
Start-up configuration function
Built-in valve opening (%) at start-up for 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 condenser in low
ambient temperatures
Compressor start-up after long period standby time in 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 R-22/R-124/R134a/R-404A/R-407C refrigerants
PT4-18M for evaporators operating with R-410A refrigerant
PT4-30M for evaporators operating with R-744 refrigerant
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 EC3X32. Other pressure sensors are not released for use with
EC3-X32 and when applied, may lead to poor performance.
FC-TD/ EC3-X32
Setting and visualizing Data via WebPages
The EC3-X32 has a TCP/IP Ethernet communication interface
enabling the controller to be directly connected to a network or
a PC via the standard Ethernet port. The EC3-X32 controller
has embedded WebPages to enable the user to visualize the
parameter lists using real text labels.
To view WebPages on the PC, a standard WebBrowser like
Internet Explorer® or Mozilla Firefox and JRE Java Runtime
Environment is needed. JRE can be downloaded at no charge
from the Emerson website.
WebServer function of the EC3-X32 with TCP/IP Ethernet
networking capabilities
All relevant parameters and modes are visible on a single
WebPage simultaneously. For more details on the setup and
maintenance click on the screen tab that correlates to the
specific task. The next page shows the homepage of an EC3X32 with the monitoring WebPage of the controller. EC3-X32
features multi-language WebPages. Two languages are always
available in the controller. English is the default language.
3/9
July 2008
EC3-X32
Stand-alone Superheat Controller
Examples for Webpages:
The top fields indicate the status of the controller. When alarms
occur, they will be shown in red. The fields below show
temperature and pressure of all sensors attached to the
controller as well as the superheat setpoint, the measured
superheat and the valve opening. The evaporator status field
on the right hand side shows the operating modes. The active
mode is shown in blue.
All WebPages that allow the change of controller parameters
are password protected. Below is the example for the
superheat configuration WebPage of an EC3-X32 Controller.
The setpoints for superheat, low and high super-heat alarms as
well as the refrigerant and the Electrical Control Valve selected
can be easily reviewed and modified if needed:
F
F
F
sec.
F
FC-TD/ EC3-X32
4/9
July 2008
EC3-X32
Stand-alone Superheat Controller
Alarms
The monitoring WebPage shows all alarms in text form. All
possible alarm messages are visible, active alarms are
highlighted red, see below:
Service Functions
Particularly useful facilities are the service functions, which
enable the engineer to manually control the system during
commissioning. They include manual operation of the Electrical
Control Valve, clearing alarms which require a manual reset
and resetting the controller to factory default settings.
A logfile can be stored on the PC. The file format of the datalog
is text with semicolon (;) separated fields. On the picture below
is a sample log file from an EC3-X32 imported in Microsoft
®
Excel :
Optional ECD-002 display/keypad unit
The ECD-002 can be used as optional for service purposes.
ECD-002 may be connected or removed from EC3-X32 at any
time. 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.
A rolling graph with superheat, evaporating pressure,
evaporating temperature, valve opening and coil out
temperature data over a period of approximately 10 minutes
can be displayed:
FC-TD/ EC3-X32
5/9
July 2008
EC3-X32
Stand-alone Superheat Controller
Wiring Diagram
Permanent
Temporary for set-up, start-up and service
Direct connection via
cross over cable
Connection via Router
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
FC-TD/ EC3-X32
J: Third party controller (can use the analog output signal from
EC3)
Note: The internal resistor of third party controller must fulfill
the following conditions:
R ≤ 200 Ω if the supply voltage is 12VDC
R ≤ 800 Ω if the supply voltage is 24VDC
6/9
July 2008
EC3-X32
Stand-alone Superheat Controller
Ordering
Description
Controller EC3-X32
Terminal Kit for EC3-X32
Pressure Sensors
-11.6…101.5 psi
0 … 261.1psi
0 … 435.1 psi
20 ft cable length
20 ft cable length
Cable Assembly for PT4
NTC Temperature sensors
Display/keypad unit (opt.)
Connection cable EC3 to ECD-002
10 ft
Emerson
PCN
097708
097709
097715
097716
097728
097717
097714
097712
097713
Type
EC3-X32
K03-X32
PT4-07M
PT4-18M
PT4-30M
PT4-M60
ECN-N60
ECD-002
ECC-N30
Part Code
Nr.
807 782
807 644
802 332
802 333
802 334
804 805
804 497
807 657
807 861
Ordering, accessories, spare part
Transformer
Primary:120/208/240VAC 60HZ
Secondary: 24V 40VA
Emerson PCN
097724
Type Part Code Nr.
T2
90-T40F3
Suitable valves for connection to EC3-X32
Valve
Capacity range
Tons *
EX4
EX5
EX6
EX7
EX8
0.6 … 5.7
1.4 … 14.2
3.4 … 34.1
10 … 93.8
25.6 … 250.2
EX4
EX5
EX6
EX7
EX8
0.6 … 6
1.4 … 15.1
3.7 … 35.8
10 … 98.7
28.4 … 263
EX4
EX5
EX6
EX7
EX8
0.6 … 4.3
1.1 … 11.1
2.8 … 26.4
7.1 … 72.5
19.9 … 193.4
EX4
EX5
EX6
EX7
EX8
0.6 … 4
1.1 … 10
2.6 … 23.9
6.8 … 65.4
17.6 … 174.3
FC-TD/ EC3-X32
Valve
Capacity range
Tons *
R-22
EX4
EX5
EX6
EX7
EX8**
0.9 … 6.5
1.7 … 16.5
4 … 39.8
11.4 … 109.5
28.4 … 292
R-407C
EX4
EX5
EX6
EX7
EX8**
1.1 … 11.7
2.8… 29
7.1… 69.4
19.9 … 109.8
51.2 … 508.7
EX4
EX5
EX6
0.3 … 3.1
0.9 … 8
1.7 … 19.1
Refrigerant
Capacity
regulation
10-100%
R-134a
*) Nominal rating conditions:
Refrigerant
R-404A/
R-507
R-22, R-134a, R-404A, R-407C,
R-410A
R-23
R-124
**) MWP: 508 psi
7/9
Refrigerant
Capacity
regulation
R-410A
R-744
10 to 100%
R-124
Evaporating
temperature
Condensing
temperature
+39.2°F
+100.4°F
-76°F
+68°F
-13°F
+176°F
July 2008
EC3-X32
Stand-alone Superheat Controller
Technical Data
EC3-X32
ECD-002 Display Unit
Supply voltage
24VAC ±10%, 50/60Hz
Supply
From EC3 Series Controller via
connecting cable
Digital input
24 V AC ±10%, 50-60HZ
24 V DC ±10%
LED indicators
Valve opening, valve closing, alarm,
demand
Power consumption
25VA max. including connected ECV
and display/keyboard
Display LED
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
Internal battery
Approximately 2 hours if battery is fully
charging time
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
Connecting cable
Temperature
storage
operating
Humidity
-4 … +149°F
+32 … +140°F
0 … 80% r.h. non condensing
Protection class
IP 65 (front protection with gasket)
Marking
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 610004-6, EN 61000-4-11
CE
Weight
~1.8 oz
Protection class
IP 20
Mounting
Panel mount (2.8 x 1.1 in cutout)
Vibration
4g, 10-1000Hz
Temperature
storage
operating
Humidity
-4 … +149°F
+32 … +140°F
0 … 80% r.h. non condensing
Weight
~ 28.2 oz
Mounting
DIN rail mounted
Input and Output, EC3-X32 Controller
Description
Temperature input
Pressure sensor input
Analog output (evaporating
pressure feed-through signal)
Digital input
Output relay
Stepper motor output
Connection to ECD-002
TCP/IP connection
FC-TD/ EC3-X32
Specification
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
RJ45
8/9
July 2008
EC3-X32
Stand-alone Superheat Controller
Physical Dimensions Drawings (in)
EC3-X32 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 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.
www.emersonclimate.com/flowcontrols
11911 Adie Road P.O. Box 411400 St. Louis, MO 63141 USA
FC-TD/ EC3-X32
CUSTOMER SERVICE (314)-569-4666
9/9
July 2008
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