D A T A ... EC3-D72 / EC3-D73 Superheat & Digital Scroll Controller

D   A   T   A ...  EC3-D72 / EC3-D73 Superheat & Digital Scroll Controller
EC3-D72 / EC3-D73
Superheat & Digital Scroll Controller
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The EC3-D7x series is a stand-alone universal superheat
controller with a built-in synchronization control for the
Copeland Digital Scroll. It is suitable 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 EC3D72 offers remote access with built-in TCP/IP Ethernet
communications and WebServer functionality. Any standard
Webbrowser (e.g. Microsoft Internet Explorer® or Mozilla
Firefox) can be used for monitoring or parameter setting. The
EC3-D73 is exactly the same in its functionality but has no
external communications. It is only possible to program the
parameters using the optional ECD-002 display unit.
Features EC3-D72
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Superheat control in conjunction with Alco Controls stepper
motor driven Electrical Control Valves (EX4...EX6)
Synchronization of the PWM solenoid valve used for
variable capacity control of the Copeland Scroll Digital
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 the 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 the 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)
Multiple language support
Electrical connection via plug-in type screw terminal
Aluminum housing for DIN rail mounting
EC3-D72/D73
Typical ordering package: refer to page 7 for details
Description
Type
PCN
807 805
807 648
804 497
*
Digital Superheat Controller with TCP/IP communication
EC3-D72
Terminal Kit
K03-331
Temperature sensor
ECN-N60
Electrical Control Valve
EX4, EX5, EX6
Pressure sensor
- for R22/R124/R134a/R404A/R407C/R507C
PT5-07M
802 350
- for R410A & intermediate pressure applications
PT5-18M
802 351
- for R744
PT5-30M
802 352
Plug and cable assembly for pressure sensor
PT4-M60
804 805
*For further details refer to: EX4, EX5, EX6 Electrical Control Valves datasheet EX48_35008.pdf
EC3-D7_35063_EN_R04.doc
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Application
The EC3-D7x series can be applied into a number of different
superheat applications in conjunction with either a single
Copeland Digital ScrollTM or a tandem unit consisting of one
fixed and one Copeland Digital Scroll:
• Superheat control of conventional evaporators such as shell
and tube, plate heat exchanger, air coil etc.
• Superheat control of sub-coolers or economizers connected
to suction pressure of compressor or intermediate pressure
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-D7x detects low superheat conditions and deactivates
the alarm relay. If the alarm relay is wired into the serial safety
loop of the system controller, the compressor will be switched
off when a low superheat alarm occurs and the ECV will close.
Description of performance
High superheat alarm
If this function is enabled, it detects longer lasting high
superheat conditions (adjustable) and triggers the high
superheat alarm and the ECV will close.
EC3-D7x series controls the opening of electrical control valve
according to desired superheat. As the Emerson Electrical
Control Valves (ECV) are able to provide a better positive shutoff function than conventional solenoid valves, there will be no
flow through Emerson ECV when the compressor(s) are not
running. In the event of a cooling demand request from a third
party controller and the Copeland Digital Scroll compressor
starts-up, the EC3-D7x needs to be informed through a digital
cooling demand input. In addition, upon receiving a capacity
demand signal through the 0-10V input, the Digital Scroll will
initially run at minimum capacity and will subsequently start to
vary the capacity of the compressor. The EC3-D7x will start to
control the refrigerant mass flow by precise positioning of the
ECV under different operating conditions such as compressor
start-up, start of second compressor, high head pressure, low
head pressure, high load, low load and partial load operation.
EC3-D7x is capable of alarm handling and diagnostics. 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
and even when the operating conditions of the evaporator
change over time.
Superheat Control function
By receiving two measured values from Emerson pressure
sensor PT5 and temperature sensor ECN-N60, the EC3-D7x
calculates the actual superheat and compares to preset
superheat. The EC3-D7x operates the Electrical Control Valve
in order to keep superheat at desired setpoint under various
operating conditions.
The superheat set point is adjustable in the range between 3K
and 30K. If low superheat alarm function is disabled, it is
possible to adjust the superheat set point below 3K down to
0.5K for special applications such as flooded evaporators.
MOP function
To avoid overload of the compressor motor, the MOP function
of the EC3-D7x limits the evaporating pressure to a predetermined value, which 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 manufacturer and to avoid
unnecessary manual conversions from temperature into
pressure values. The MOP function may be totally disabled,
when not needed.
EC3-D7_35063_EN_R04.doc
Digital input status (factory setting)
The digital input is the interface between EC3-D7x and system
controller. The digital status is dependant on the operation of
system’s compressor/thermostat. The Copeland Digital Scroll
should always be regarded as the base load; compressor 1.
System
Operating
condition
Digital Inputs
0-10V input from third party
controller
Comp. 1 &
Comp.2 in
stop mode
“Cooling
demand” open
(0V) “Comp 2
Running” open
(0V)
ECV remains closed
irrespective of voltage input
value
Comp. 1 in
run &
Comp.2 in
stop mode)
“Cooling
demand”
closed (24V) /
“Comp 2
Running” open
(0V)
ECV active
Input =0V: digital valve
capacity at 10% default
capacity.
When the digital comp. is in
by-pass the ECV will:
Close when capacity is <70%
Be inhibited when the capacity
is >70%
Comp 1 &
Comp. 2 in
run mode
“Cooling
demand”
closed (24V) /
“Comp 2
Running”
closed (24V)
ECV active
The ECV will always modulate
even
when
the
digital
compressor is in by-pass
mode.
Comp.1 in
stop and
Comp. 2 in
run mode
starts
“Cooling
demand” open
(0V) / “Comp 2
Running”
closed (24V)
ECV
remains
closed
irrespective of voltage input
value
Shut-off function
When the cooling demand digital input is open (0V), the EC3D7x will drive the electrical control valve to closed position. Due
to the positive shut-off capabilities of the EX4/5/6 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.
!
If this function is disabled, the user must ensure
appropriate safety precautions are in place to protect the
system against damage caused by a power failure. Refer to
operating instructions
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Analogue output (4-20mA signal) function
EC3-D72 requires the outlet pressure level of evaporator for
superheat and MOP control. The output signal from the PT5 is
used by EC3-D7x 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 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 input is 0V
(open), but the Digital Scroll compressor will keep running to
perform a pump down of the refrigeration system until the
pump-down threshold pressure (adjustable) is reached. If after a
time delay (adjustable) the pump-down setpoint is not reached,
the output pump-down relay trips to stop the compressor and an
alarm is indicated. This relay must be wired into the Digital
Scroll compressor control wiring.
Low pressure switch function/alarm
The use of low-pressure switch is very common for preventing
of compressor running in event of refrigerant charge loss and
alarming. 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 and the
ECV will close.
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 and if it drops below the
freeze protection threshold, the freeze protection alarm triggers
the alarm relay and the ECV will close.
Safety / internal battery function
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-X32 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.
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If the output relays are not utilized, the user must ensure
appropriate safety precautions are in place to protect the
system against damage caused by a power failure
Alarm and maintenance functions
EC3-D7x 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 diagnostics routines constantly
monitor the battery health, 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.
EC3-D7_35063_EN_R04.doc
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Additional to hardware errors also EC3-D7x will monitor the
minimum operating superheat. If the superheat drops below
0.5K for continuous period of one minute, the low superheat
alarm will occur. The low superheat alarm can be disabled for
applications such as flooded evaporator, which lower operating
superheat is required.
There are several other alarms such as low pressure alarm,
freeze protection alarm and high superheat alarm if they are
enabled.
In case of alarm, EC3-D7x 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.
Alarm relay function (factory setting)
Alarm relay contains a SPDT contact. If the relay is wired to
system controller, it is possible to stop compressor/system. The
alarm relay is activated during normal operation and deactivated
during alarm conditions as well as supply power interruption.
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 PT5 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 type of refrigerant
and system, different types of pressure sensor are needed.
• PT5-07M for evaporators operating with
R22/R124/R134a/R404A/R407C refrigerants
• PT5-18M for evaporators operating with R410A refrigerant
• PT5-30M for evaporators operating with R744
Every type of pressure sensor is calibrated in temperature
range for the above specified applications. The feature set and
performance of the PT5 Series is a perfect match for the EC3D7x. Other pressure sensors are not released for use with EC3D7x and when applied, may lead to poor performance.
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
dedicated 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.
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Setting and visualising Data via WebPages
The EC3-D72 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-D72 controller has
embedded WebPages to enable the user to visualise 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; www.emersonclimate.eu
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)
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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
WebServer function of the EC3-D72 with TCP/IP Ethernet
networking capabilities
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. The next page shows the
homepage of an EC3-D72 with the monitoring WebPage of the
controller.
EC3-D72 features multi-language WebPages. Two languages
are always available in the controller. English is the default
language and is permanently stored. When delivered from the
factory, the second language is German. Customers who desire
to use an alternative second language can download language
files for the most common European languages from the
www.emersonclimate.eu website and upload one of them into
the EC3-D72. This action will overwrite the German language
with the customers’ language choice.
Examples 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
EC3-D7_35063_EN_R04.doc
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.
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All WebPages, which allow the change of controller parameters
are password protected. Below is the example for the superheat
configuration WebPage of an EC3-D72 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:
Alarms
The monitoring WebPage shows all alarms in text form. All
possible alarm messages are visible, active alarms are
highlighted red, see below:
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:
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-D72 imported in Microsoft
Excel®:
EC3-D7_35063_EN_R04.doc
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Optional ECD-002 display/keypad unit
The ECD-002 can be used as an option for service purposes for
the EC3-D72 but is the only means of visualizing the
parameters for the EC3-D73. ECD-002 may be connected or
removed from EC3-D72 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.
Wiring Diagram
Temporary for set-up, start-up and service
Permanent
Direct connection via
cross over cable
Connection via Router
I:
A: White wire B: Black wire C: Blue wire D: Brown wire
E: Plug cable assembly EXV-Mxx for connection to
EX4/EX5/EX6
F: Output for Copeland Digital Scroll solenoid valve
G: Remote control panel, system controller
H: Alarm relay, dry contact. Relay coil is not energized at alarm
condition or power off
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The use of the relay is essential to protect the system in
case of power failure if the communications interface or the
ECD-002 are not utilized
EC3-D7_35063_EN_R04.doc
Digital input 1: “Cooling demand”; Digital Scroll compressor
is running: 0V/open = Stop; 24V/closed = Start)
J: Transformer Class II, 24VAC secondary / 25VA
K: 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
L: Pump down relay, dry contact. Relay is energized during
normal operation
M: Digital input 2: “Comp. 2 running”;
0V/open = Comp2 stop; 24V/closed = Comp2 running.
N: Discharge Temp. Sensor
O: 0-10V Digital Scroll capacity demand signal from system
controller
P: ECN-N60 Coil out sensor
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Ordering
Description
Digital Superheat Controller with communication;
Complete kit for 7bar applications
Digital Superheat Controller without communication;
Complete kit for 7bar applications
Type
Part No.
EC3-D72
808 042
EC3-D73
808 041
Kit consists of: Controller, Terminal kit, Pressure transmitter inc. 6.0m cable, 6.0m
Temp. sensor, 60VA transformer
Description
Type
EC3-D72
EC3-D73
K03-331
PT5-07M
PT5-18M
PT5-30M
PT5-50M
PT4-M15
PT4-M30
PT4-M60
ECN-N30
ECN-N60
ECN-N99
ECD-002
Part No.
807 805
807 804
807 648
ECC-N10
ECC-N30
ECC-N50
807 860
807 861
807 862
Transformer 230VAC Input, 24V output, Din rail mounting
For one set of controller and valve
25VA
ECT-323
For two sets of controllers and valves
60VA
ECT-623
804 424
804 421
Replacement battery kit
807 790
Digital Superheat Controller EC3-D72
Digital Superheat Controller EC3-D73
Terminal Kit for EC3-X32
-0.8…7bar
Pressure Sensors
0…18bar
0…30bar
0…50bar
1.5m cable length
Cable Assembly for PT5
3.0m cable length
6.0m cable length
NTC Temperature sensors 3m cable length
6m cable length
12m cable length
Display/keypad unit (opt.)
1,0 m
Connection cable EC3 to ECD-002
3,0 m
5,0 m
802 350
802 351
802 352
802 353
804 803
804 804
804 805
804 496
804 497
804 499
807 657
ECT-323
Suitable valves for connection to EC3-D7x series
Valve
Capacity range
kW *
Refrigerant
EX4
EX5
EX6
2 ... 20
5 ... 50
12 ... 120
R 22
EX4
EX5
EX6
2 ... 21
5 ... 53
13 ... 126
R 407C
EX4
EX5
EX6
2 ... 15
4 ... 39
10 ... 93
R 134a
EX4
EX5
EX6
2 ... 14
4 ... 35
9 ... 84
EC3-D7_35063_EN_R04.doc
Capacity
regulation
Valve
10 -100%
R 404A/
R507
Capacity range
kW *
EX4
EX5
EX6
3 ... 23
6 ... 58
14 ... 140
EX4
EX5
EX6
EX4
EX5
EX6
1 ... 11
3 ... 28
6 ... 67
3 ... 33.5
10 ... 102
24 ... 244
*) Nominal rating conditions:
Refrigerant
R22, R134a, R404A, R507C,
R407C, R410A
R744
R124
..
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Refrigerant
Capacity
regulation
R 410A
R 124
10 - 100%
R 744
Evaporating
temperature
+4°C
Condensing
temperature
+38°C
-40°C
+20°C
-10°C
+80°C
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Technical Data
EC3-D7x series
ECD-002 Display Unit
Supply voltage
24V AC ±10%, 50/60Hz, 1A
Supply
From EC3 Series Controller via
connecting cable
Digital input
24V AC ±10%, 50-60HZ
24V 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, 2½-digits,
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 0.14 … 1.5mm2
Ground connection
6.3mm spade earth connector
Connecting cable
Applied directive
EMC
LVD
RoHS
Temperature
storage
operating
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 61000-46, EN 61000-4-11
CE
Protection class
IP 20
Vibration
4g, 10-1000Hz
Temperature
storage
operating
Humidity
-20 … +65°C
0 … +60°C
1….+25°C for optimum battery life
0 … 80% r.h. non condensing
Weight
~ 800g
Mounting
DIN rail mounted
Protection class
IP 65 (front protection with gasket)
Humidity
0 … 80% r.h. non condensing
-20 … +65°C
0 … +60°C
Weight
~ 52g
Mounting
Panel mount (71 x 29 mm cutout)
Input and Output, EC3-D7x series Controller
Description
Temperature input
Specification
ECN-Nxx: 10kΩ @ 25 °C, Range: -50 … 50 °C
PT5-07M/18M/30M: 24VDC, 4 … 20mA
0-10VDC with maximum load current 2mA.
Absolute maximum voltages: -0.7V min / 10.7V max
Pressure sensor input
Analog input
Digital Scroll capacity demand from
system controller
Analog output (evaporating pressure 4 20mA
fed-through signal)
Requires 12 or 24 VDC
Deviation from input signal
±8% max
Digital input
Cooling demand
0/24 VAC/DC
Comp.2 running
Output relay Alarm/Pumpdown
SPDT contacts, AgCdO,
Max. rating: Inductive 2Amp,
Resistive 8 Amp @ 250V
Digital Scroll solenoid Solid state relay, Max rating 1Amp @ 240VAC with 1.6
voltage drop. Minimum switching current 22mA
Maximum off state leakage current 1.5mA
Spare relay
SPST: not used
Stepper motor output
For EX4 … EX6 Electrical Control Valves
Connection to ECD-002
RJ45
TCP/IP connection
RJ45
EC3-D7_35063_EN_R04.doc
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Physical Dimensions Drawings (mm)
EC3-D72 Controller
ECT-623 Transformer
ECT-323
58
73
4354 76
ECD-002 Display Unit
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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
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-D7_35063_EN_R04.doc
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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.
Benelux
Denmark & Finland
Eastern Europe, Turkey & Iran
France, Greece, Maghreb
Deutschland, Österreich, Schweiz
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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
29.06.2010
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