D A T A ... EC3 Series Coldroom Controllers

D   A   T   A ...  EC3  Series Coldroom Controllers
EC3 Series
Coldroom Controllers
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The EC3-33x Series form a new generation of electronic
controllers for refrigeration and air conditioning.
The controllers feature a DIN rail mounted housing and a
separate optional display unit in the small industry standard
housing form factor. They offer maximum functionality such as
superheat, temperature and defrost controller with built-in
TCP/IP
Ethernet
communications
and
WebServer
functionality. Any standard WebBrowser (e.g. Internet
Explorer® or Mozilla Firefox) can be used for monitoring or
parameter setting.
The version with Echelon LON® network interface is for use in
more complex systems, where different controllers must
communicate with each other.
Features
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Superheat control with self-adapting algorithm and driver
circuit for stepper motor driven Electrical Control Valves
EX4 … EX8
Air temperature control
Defrost and fan management
Limitation of evaporating pressure (MOP)
Feed-through of 4 … 20mA signal of evaporating pressure
transmitter to analogue output to operate multiple
controllers with a common pressure transmitter
2 digital inputs for compressor safety loop and coldroom
door contact
4 relay outputs for compressor, fan, defrost and alarm
Support of two network technologies:
TCP/IP Ethernet with WebServer functionality allows
monitoring and configuration of controllers through a
®
standard WebBrowser (e.g. Internet Explorer or Mozilla
Firefox)
or Echelon FTT10 LON® technology for monitoring and
configuration through a supervisory system such as the
ALCO Monitoring Server EMS
Alarm messaging by email (EC3-332)
Integral backup 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
Features ECD-001 Display Unit
•
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•
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Front panel mounted human interface for parameter and
status read-out and controller setup via keypad
2½ digit LED display with automatic decimal point
Indicator LEDs for compressor, fan, heater and alarm
Connection to EC3 Series via ECC-N10 or standard CAT5
patch cord with RJ45 connectors.
Standard 71 x 29 mm cut-out dimensions
IP65 protection class when mounted in front panel
EC3 Series Coldroom Controller
with ECD-001 Display Unit
Typical ordering package:
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EC3-332 Coldroom Controller with K03-330 Terminal Kit
EX5-U21 Electrical Control Valve with EX5-N30 Cable
ECD-001 Display Unit with ECC-N10 Cable
ECT-323 Transformer
PT5-07M Pressure Transmitter with PT4-M30 Cable
ECN-N30 Air Temperature Sensor
ECN-P30 Pipe Temperature Sensor
ECN-F60 Fin Temperature Sensor
Selection Table Coldroom Controller
Description
Coldroom Controller ECV Stepper Motor Drive
TCP/IP Ethernet
Type
Part No.
Part No.
single unit
Kit*
807 632
808 013
EC3-332
Type
®
LON FTT
Part No.
single unit
Part No.
Kit*
EC3-331
807 631
808 012
*) Kit contains terminal kit, pressure transmitter PT5-07M with cable assembly, transformer 25VA, NTC sensors 6m fin, pipe and single insulated version
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Introduction
The EC3-33x series Controllers are for use in commercial
refrigeration systems, primarily to control the refrigeration circuit
of coldrooms. This includes the control of the refrigerant flow to
optimize superheat, maintain air temperature and the defrost
management. Alco Controls EX4…EX8 Electrical Control
Valves must be used in conjunction with the EC3-33x units to
modulate refrigerant flow.
Two separate control loops are coordinated in the device: one
senses evaporating pressure and temperature to maintain
optimum superheat, while the other loop controls air temperature.
Other functions include the management of defrost schedules
and sequences, data monitoring and alarm handling. Though
EC3 Controllers can operate as stand alone devices, they are
best suited to networked solutions, which take advantage of the
monitoring capabilities.
The EC3-33x Controllers are members of the range of EC2 and
EC3 devices, which can be easily assembled into complete
control systems for commercial refrigeration. They all share the
benefits of remote access and data communication. Please
refer to specific datasheets for details.
Application
The functions of the EC3-33x Controllers are described in the
functional diagram below:
… 8 valves a separate liquid line solenoid valve is not required.
Superheat Control
The EC3 Series controls evaporator superheat by varying the
mass flow through the Electrical Control Valve (ECV). The
controller automatically calculates the number of steps required
for the correct valve opening by measuring pressure and
temperature at the evaporator output. PT4-07M pressure
transmitters and ECN-Pxx pipe type temperature sensors from
EMERSON must be used.
The controller works in two operating modes: fixed superheat
and adaptive superheat. In the “fixed” mode, the superheat
set-point is fixed to a user-defined value. In the “adaptive” mode
the controller varies superheat set-points in the range between
3K and 15K depending on system conditions to maintain stable
operation. The pressure drop through a distributor or the glide
associated with certain refrigerants (e.g. R407C) can be
compensated in the controller.
Temperature Control
The ECN-Sxx air sensor is used for temperature control of the
coldroom. The dead band control function is described in the
diagram below:
The horizontal axis represents the temperature, with St the setpoint for day operation and rd the difference at day, while r6 is
the set-point for night operation and r7 the difference at night.
The vertical axis represents cooling operation (1 = cooling, 0 =
no cooling).
A control parameter allows to switch off the evaporator fan
during “no cooling”.
A more precise temperature control can be achieved by using
the modulating temperature mode as shown below:
With coil out temperature (1) and evaporating pressure (4) the
superheat is calculated to define the opening of the Electrical
Control Valve (11). Superheat can be set to a fixed value or an
adaptive mode may be used. Temperature sensor (2) is part of
the temperature control loop. The defrost heater (8) can be
activated locally by fixed timing intervals or remotely through the
communications port. For defrost end termination the
temperature sensor (3) can be used. Fan (10) and compressor
(7) are controlled as well. One digital input is allocated to the
compressor safety loop (5). Another digital input monitors the
door switch (6), which will activate an alarm if the door is not
closed within a specified time. The analog output (12) feeds the
evaporating pressure transmitter signal to a 2nd EC3-33x or
other Controller on the same suction line thus eliminating the
need for a second pressure transmitter.
In case of power loss a battery built in the EC3-33x will close
the Electrical Control Valve (11) and avoid flooding of the
compressor. Due to the positive shut-off capabilities of the EX4
EC3-3_35041_EN_R12.doc
The horizontal axis represents the temperature, the vertical axis
the superheat setting. At high temperatures, the controller works
with minimum superheat. St is the set-point for day operation, at
which the superheat is already increased. rd specifies the
proportional band in which the superheat is modulated.
Equivalent is r6, the set-point for the night operation and r7 the
width of the proportional band at night. At a temperature of St
minus ½*rd (day) or r6 minus ½*r7 (night) the valve is closed.
In case the controller should be used in a heat pump for
heating, the function of the temperature controller can be
inversed:
When used with a standard condensing unit, the compressor
relay can be used to switch the coil of power contactor. The
compressor relay is not used in a refrigeration system with a
rack controller. In this application, the electrical control valve
closes when the thermostat set-point has been reached and the
rack will automatically pump down if there is insufficient demand
from the rest of the refrigeration system.
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Defrost
EC3-33x Series controllers allow local defrost management
through the built-in defrost timer but also permit remote defrost
scheduling through the networking connection. For remote
defrost details please consult the operating instructions.
Two basic defrost modes are possible:
Electrical / hot gas defrost
All timing parameters can be selected to cover specific defrost
modes, see the diagrams below for the function of defrost
output and fan output at defrost:
Fan
Defrost
Defrost can be activated after power up (d4 flag) and the delay
(d5). Delay (d6) allows for pump down. The defrost will end
either when the defrost termination temperature (dt) has been
exceeded or after the maximum defrost duration (dP). Other
delays take care for synchronization of multiple evaporators in
the same system (dU), for drain (d7) and for injection (d8). The
next defrost will occur after the specified defrost interval (dI).
Fans can be switched off at defrost (F3 flag) and switched on
after defrost and drip time delay (Fd).
End of defrost is detected by the dedicated defrost temperature
sensor ECN-F60.
Natural Defrost
Though natural defrost is possible with the EC3-33x Series, it is
unlikely that such a defrost method is used in a coldroom. Since
the EC3-33x Series is also applicable for other refrigeration
applications, natural defrost may well be applicable there.
Sensors
Low cost NTC sensors are available with different cable lengths
to meet specific customer's requirements for optimal positioning
of the sensors. All sensors are hermetically sealed for high
reliability and long life. Air sensors have a plastic housing, pipe
and fin sensors have metal housings for optimal thermal
conductivity and the fin sensor has an additional mounting clip.
Operation and Commissioning
Operating and commissioning of an EC3-33x Controller may be
performed by using one of the following options:
- Locally or remote with a PC connected to the TCP/IP Ethernet
port of the EC3-332.
- Remotely via the AMS Server connected to the LON® port of
an EC3-331.
- Locally through the 4-button keypad of an optional ECD-001.
For initial commissioning of a new installation depending on the
networking technology of the EC3-33x the first two options are
the most appropriate. Commissioning is done via dedicated
menus with meaningful default values, which make
commissioning an EC3-33x a plug-and-play type of job.
Anybody who is familiar with Microsoft Windows® based
programs and WebBrowsers should find it very intuitive without
the need for special training.
EC3-3_35041_EN_R12.doc
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Optional ECD-001 Display Unit
The ECD-001 may be attached to the EC3 Series Controller to
provide a local display of system parameters, most commonly
temperatures. With the 2½ digit display temperatures within
±199°C can be shown with a resolution of 1°C. The resolution
improves to 0.1°C within a range of ±19.9°C. The display unit
can be switched from °C to °F. When displaying °F the same
resolution as above applies.
Indicator LEDs show the status of compressor, fan, defrost and
alarm. A blinking LED indicates that the EC3 Controller is trying
to fulfill a task but is prevented from doing so by another
restraint in the system. An example of this would be the
minimum compressor run time.
WebServer function of the EC3-332 with TCP/IP Ethernet
networking capabilities
Though the actual status of the controllers can be viewed on the
optional ECD-001 Display Unit, it is much more convenient to
do the viewing on a PC. All relevant parameters and modes are
visible on a single WebPage simultaneously. For even more
details and for setup and maintenance a click on one of the
screen tabs calls up a WebPage dedicated to specific task. All
of this can be done with a standard WebBrowser like the
Internet Explorer®, the Mozilla Firefox or others. The picture on
page 4 shows the homepage of an EC3-332 with the monitoring
WebPage of the controller.
Echelon LON® Networking Capabilities of the EC3-331
The remote access, viewing and monitoring features of the
LON® version EC3 Series Controllers match and exceed the
capabilities of their TCP/IP counterparts. Though remote access
requires the use of the EMS Monitoring Server or special third
party LON® compliant hardware and software, many more
additional functions and features are available.
The EC3-331 Controllers are equipped with LON-FTT10 (free
topology) transceiver types. This offers the installer greatest
flexibility in the way the controllers are connected to the LON®
network in addition to offering higher communication
transmission rates.
When connected to the LON® network, the individual EC3
Series controllers may be bound together through peer-to-peer
communication to form self-contained control loops for
applications such as synchronised defrosting.
Retrieval and download of setups and data is very comfortable
and easily achievable in LON® systems.
Refer to the "Alco Networking Application" sheets for further
details.
Where to apply TCP/IP Ethernet vs. LON® Controllers
In general TCP/IP Ethernet controllers are more applicable for
smaller refrigeration systems with only a few pieces of
refrigeration equipment. No special hardware or special
software is needed and whoever can set up a small PC network
has all the necessary know-how to set up and operate EC2 and
EC3 TCP/IP Ethernet controllers.
In larger installations LON® has its merits. Network wiring is
easier and less costly. Peer-to-peer communication is another
benefit of LON® and data retrieval and storage are very easily
achievable. These advantages come at a price however: a
monitoring and server device like the EMERSON EMS is
needed along with some special know-how in LON®
technology. The associated cost therefore makes LON®
technology primarily applicable in large refrigeration plants with
many pieces of refrigeration equipment like Supermarkets or
large cold storage facilities.
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Coldroom Controllers
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The top fields indicate the status of compressor, defrost heater,
fan and alarm output relay (left) and the status of compressor
alarm loop and door switch inputs (right). The fields below show
temperatures and pressure of all sensors attached to the
controller as well as the setpoints for air temperature and
superheat. The coil-in temperature is calculated from the
saturation pressure of the used refrigerant. All status messages
(thermostat, defrost and evaporator) are displayed in the lower
section with normal font, all active messages are in bold letters.
A rolling graph with air temperature and superheat data over a
period of approximately 10 minutes can be displayed:
EC3-3_35041_EN_R12.doc
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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 EC3-332 imported in Microsoft
Excel®:
All WebPages, which allow the change of controller parameters
are password protected. Below is the example for the
thermostat configuration WebPage of an EC3-332 Controller.
The setpoints of day and night operation, as well as the settings
which will initiate an alarm can be easily reviewed and modified
if needed:
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Alarm and Maintenance Functions
EC3-33x provides many alarm codes to facilitate diagnosis.
Limit violation alarms are associated with temperature and
pressure set point (high alarm, low alarm, sensor failure).
The serial alarm loop of the compressor can be connected to a
digital input. It will monitor compressor operation and signal
shutdown in case the serial alarm loop is open due to high
motor temperature or excessive pressure etc.
Alarm management includes the issuing of an alarm message
through the network and to show the alarm code on the
controllers display. The priorities and subsequent actions can
be individually defined for each alarm when connected to a PC
or an AMS monitoring server.
The EC3-332 has the capability to send alarm messages
directly by email.
While the attached Display Unit ECD-001 indicates alarms as
blinking symbols only, the monitoring WebPage shows all
alarms in text form. All possible alarm messages are visible,
active alarms are highlighted bold, see below:
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Safe operating modes allow the system to continue to operate
safely even when the signal is lost from a defective or
disconnected sensor.
Particularly useful facilities are the service functions, which
enable the engineer to manually control the system during
commissioning. They include manual operation of compressor,
fan and Electrical Control Valve, or special operating modes of
system for cleaning, permanent night operation, manual defrost
or others, see below:
In event of power failure to the entire system, the stepper motor
driven valve would not be able to move. Due to the differential
pressure between condenser and evaporator, the refrigerant
could continue to flow through the valve if the valve is open. The
compressor must be protected after power recovery against wet
running. EC3-33x contains an internal rechargeable battery and
smart battery charge control to automatically close the valve in
case of power failure. Whilst the battery is maintenance free,
the life expectancy will depend upon the working ambient; as
the temperature increases the life expectancy reduces.
It is recommended to replace the battery annually to maintain
the system in optimum operating condition.
Safety Functions
Various safety functions are available for use particularly when
the EC3-33x is controlling the compressor directly. These safety
features are used to prevent compressor damage and include:
Limitation of maximum evaporating pressure (MOP), delay of
compressor start after control reset, minimum time between two
starts, minimum compressor off time, minimum compressor run
time.
! If the alarm relay is not utilized, the user must ensure
appropriate safety precautions are in place to protect the
system against damage caused by a power failure.
Wiring Diagram
EC3-33x Coldroom Controller for Electrical Control Valves EX4 … EX8
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Accessories
Terminal Kits for EC3 Series:
Terminal Kit for EC3-33x series
Type
K03-331
PCN.
807 648
ECD-001
ECC-N10
ECC-N30
ECC-N50
807 641
807 860
807 861
807 862
K03-331
ECD Series Display Unit:
Display for EC3-33x
Connection cable EC3 to ECD
1.0 m
3.0 m
5.0 m
ECD-001
Electrical Control Valves with Stepper Motor Drive*
1 … 11,5kW
EX4-I21
800 615
1 … 11,5kW
EX4-M21
4 ... 35kW
EX5-U21
800 618
10 ... 84kW
EX6-I21
800 620
10 … 84kW
EX6-M21
800 621
25 … 230kW
EX7-I21
800 624
25 … 230kW
EX7-M21
800 625
*) see datasheet EX48_35008.pdf
for details
60 … 613kW
EX8-M21
801 964
60 … 613kW
Cable and connector
assembly for
EX4 / EX5 / EX6 / EX7
low temp.
Länge: 1.5m
Länge: 3.0m
Länge: 6.0m
Länge: 6.0m
EX8-U21
EX5-N15
EX5-N30
EX5-N60
EX5-L60
801 970
804 650
804 651
804 652
804 655
1,5m cable length
3m cable length
ECN-S15
ECN-S30
804 304
804 305
6m cable length
3m cable length
6m cable length
ECN-S60
ECN-P30
ECN-P60
804 284
804 280
804 281
8m cable length
ECN-P80
804 282
6m cable length
ECN-F60
804 283
-0.8…7bar
0…18bar
1.5m cable length
3.0m cable length
6.0m cable length
PT5-07M
PT5-18M
802 350
802 351
PT4-M15
PT4-M30
PT4-M60
804 803
804 804
804 805
25VA
60VA (EX8 only)
ECT-323
ECT-623
804 424
804 421
Nominal capacity R404A
NTC Sensors (Air type)
(10 kΩ at 25°C)
NTC Sensors (Pipe type)
(10 kΩ at 25°C)
NTC Sensors (Fin type)
(10 kΩ at 25°C)
Pressure Transmitter
Cable Assembly for PT5
Transformer
Din rail mounting, Class II
230VAC Input, 24V Output
800 616
EX5
ECN-Sxx
ECN-Pxx
ECN-Fxx
PT5-07M with PT4-Mxx
ECT-623
EC3-3_35041_EN_R12.doc
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Technical Data
EC3 Series Controller
Supply voltage
ECD-001 Display Unit
24VAC ±10%, 50/60Hz Class II only
6.3mm spade earth connector
Power consumption
25VA max. including EX4 … EX7
28VA max. including EX8
Plug-in connector size Removable screw version
wire size 0.14 … 1.5mm2
Communication
Temperature
storage
operating
TCP/IP Ethernet
®
LON FTT-10
(EC3-332)
(EC3-331)
-20 … +65°C
0 … +60°C
1….+25°C for optimum battery life
Supply
From EC3 Series Controller via
connecting cable
LED indicators
Compressor, Fan, Defrost, Alarm,
LON-Service pin, IR status
Display LED
Numeric segmental display, 2½-digits,
red, with automatic decimal point
betw. ±19.9, switchable between °C
and °F
ECC-Nxx cables or standard CAT5
patch cord with RJ45 connectors
Connecting cable
Temperature
storage
operating
-20 … +65°C
0 … +60°C
Humidity
0 … 80% r.h. non condensing
Humidity
0 … 80% r.h. non condensing
Protection class
IP20
Protection class
IP 65 (front protection with gasket)
Weight
~ 800g
Weight
~ 52g
Mounting
DIN rail mounted
Mounting
Panel mount (71 x 29 mm cutout)
Input and Output Configuration EC3-33x Controller
Description
Temperature inputs (3)
Pressure transmitter input
Analog output (evaporating
pressure feed-through signal)
Deviation from input signal
Digital inputs (2)
Output relays (4)
Stepper motor output
Communications
EC3-3_35041_EN_R12.doc
I/O Specification
Coil out temperature, Air temperature,
Defrost termination
10kΩ @ 25 °C,
-50 … 50 °C
24VDC, 4 … 20mA
4 … 20mA
Requires 12 or 24 VDC
±8% max
Evaporating pressure
Evaporating pressure
24VAC/DC
SPDT contacts, AgNi
Inductive (AC15) 250V / 2A,
Resistive (AC1) 250V / 8A
SPST contacts, AgNi
Inductive (AC15) 250V / 2A,
Resistive (AC1) 250V / 6A
For EX4 … EX8 Electrical Control Valves
®
RJ45 10MBit/sec. Ethernet or LON FTT10
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Compressor Safety, Door contact
Compressor
Alarm
Heater
Fan
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Physical Dimensions Drawings (mm)
EC3-Series Controller
ECD-001 Display Unit
ECT-323 Transformator
ECT-623 Transformator
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. Our products are designed and adapted
for fixed locations. For mobile applications failures may occur. The
suitability for this has to be assured from the plant manufacturer which
may include making appropriate tests.
This document replaces all earlier versions.
Emerson Electric GmbH & Co. OHG
ALCO CONTROLS
Heerstraße 111
D-71332 Waiblingen
Germany
Phone ...49-(0)7151-509-0
Fax
...49-(0)7151-509-200
www.emersonclimate.eu
EC3-3_35041_EN_R12.doc
Benelux
Denmark & Finland
Eastern Europe, Turkey & Iran
France, Greece, Maghreb
Deutschland, Österreich, Schweiz
Italia
Middle East & Africa
Poland
Russia & Cis
España & Portugal
Sweden & Norway
UK & Ireland
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Phone:
+31 (0)773 240 234
+32 (0)87 305 565
+32 (0)87 305 061
+33 (0)478 668 570
+49 (0)6109 6059 0
+39 02 961 78 1
+97 148 832 828
+48 (0)22 458 9205
+7 495 981 9811
+34 93 4 123 752
+32 (0)87 305 565
+44 (0)1 189 838 000
Fax:
+31 (0)773 240 235
+49 24 08 929 568
+32 (0)87 305 506
+33 (0)478 668 571
+49 (0)6109 6059 40
+39 02 961 78 888
+97 148 832 848
+48 (0)22 458 9255
+7 495 981 9816
+34 93 4 124 215
+49 24 08 929 568
+44 (0)1 189 838 001
21.12.2009
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