GB EC3-X32 Superheat Controller with TCP/IP communication capability Description

GB EC3-X32 Superheat Controller with TCP/IP communication capability Description
EC3-X32 Superheat Controller with TCP/IP communication capability
Operating Instructions
Description
EC3-X32 is the superheat controller
with TCP/IP connection for stepper
motor driven Alco Electrical Control
Valves EX4...EX8.
Note: This document contains short
form instructions for experienced
users.
!
GB
Digital input status is dependant to operation of compressor/thermostat
Commander
Operating condition
Digital input
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)
Wiring
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-X32 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 (harmonized 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
Grounding
Protection class
COM, TCP/IP
connection
Connection to optional
local ECD-002
25VA max. including EX4 … EX8
Removable screw terminals wire size 0,14 .. 1,5 mm2
6,3 mm spade earth connector
IP20
RJ45 Ethernet
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
Deviation from input
±8% max
signal
Output alarm relay
SPDT contact 24V AC/DC, 2 Amp inductive load
(If L2 = 1) Activated: During normal operation (no alarm condition)
Deactivated: During alarm condition or power supply is OFF
Output pump down relay SPDT contact 24V AC/DC, 2 Amp inductive load
(If L2 = 1)
Activated During normal operation
Deactivated All other conditions
! 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.
Stepper motor output for Maximum current 0.8A with nominal 24VDC
EX4…EX8
operating voltage
Ambient temperature
0 … 60°C
range
1 … 25°C (for best battery life time)
> 35°C battery life time < 2 years
In
order
to
provide
system
protection in the event of power loss, it is
!
recommended to change the battery annually.
A: White wire
B: Black wire C: Blue wire
D: Brown wire
E: M12 Plug cable assembly EX5-Nxx for connection to
EX4/EX5/EX6/EX7/EX8(new)
F: PG/DIN plug for connection to EX8 (prior to March 2008 production)
G: Remote control panel, system controller
H: Alarm relay, dry contact. Relay coil is not energized at Alarm or power off
!
•
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..
I: Digital input (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)
L: Pump down relay, dry contact. Relay is energized during normal
operation.
•
Preparation for Start-up:
Mounting
The EC3-X32 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 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.
Document Nr.: EC3-X32_65127_EN_R06.doc Replacement for R05
• 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 (open). The
valve will be driven to close position.
• After closure of valve, start to charge the system with refrigerant.
1/4
PCN 865008 09.02.2009
EC3-X32 Superheat Controller with TCP/IP communication capability
Operating Instructions
Possibilities of connecting EC3-X32 to a network or PC
A TCP/IP Controller Readme file is available on the www.emersonclimate.eu
website to provide detailed information about TCP/IP Ethernet connectivity.
Please refer to this file if you need information beyond the contents of this
instruction sheet.
1) Connect the EC3-X32 using the optional ECC-Nxx cable assembly or a
standard CAT5 network cable with RJ45 plugs assembly to a network or router
that enables the controller to receive a dynamic TCP/IP address or
2) Connect the EC3-X32 to a computer using a crossover cable plugged
directly into the Ethernet port. In this case, the TCP/IP address of the computer
must be manually modified to be compatible with the default address of the
controller. Refer to the TCP/IP Controller-Readme file for more details.
Setting and
method)
visualising
Data:
WebPages
(recommended
Important: Make sure that digital input is 0V (open). Turn the power supply
ON.
Four parameters i.e. refrigerant type (u0), pressure sensor type (uP), valve type
(ut) and control mode 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. All other
parameters can be modified at any time.
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 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 www.java.com website.
Open the Internet browser program on the computer and, if EC3-X32 is
connected directly to PC with a crossover cable enter the default TCP/IP
address of the controller (192.168.1.101) into the address line, or the dynamic
address from the DHCP server from network/Router. Refer to the TCP/IP
Controller-Readme file if a specific port is required.
It is possible to identify the dynamic TCP/IP address assigned by DHCP of the
Router or network, refer to the TCP/IP Controller-Readme file.
After a few moments, the default monitoring page should be displayed. If the
browser does not open the default page or display active data, the user should
check the Internet browser “Option” configuration. Refer to the TCP/IP
Controller-Readme file.
GB
controller. This can save a considerable amount of time when using multiple
controllers and over a period of time, a library can be created containing the
parameter lists for equipment for different applications.
It is also possible to display live graphical data from the controller. Superheat,
evaporating pressure, coil-out temperature and evaporating temperature are
available on a 15 minutes rolling chart. Refer to the TCP/IP Controller-Readme
file for a complete description of the features available for the TCP/IP series of
controllers.
Alternative procedure for parameter modification using ECD-002
Note: Some of the functions/parameters (manual control and TCP/IP
configuration) can not be modified when using ECD-002 comparing to a set-up
by PC via TCP/IP. Warning: All alarms are disabled during manual control.
We do not recommend unattended operation of system during manual control.
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).
Special Functions:
The Special Functions can be activated by:
• Press and together for more than 5 seconds, a flashing “0” is displayed.
• Press or until the password is displayed (default = “12”).
If password was changed, select the new password.
• Press SEL to confirm password
A “0” is displayed and the Special Function mode is activated.
• Press
or
to select the function. The number of special functions is
dynamic and controller dependent. See list below.
0: Reset controller to factory settings (this action is possible only when
digital input is 0V i.e. open)
1: Displays the current TCP/IP address
2: Assign temporary 192.168.1.101 as TCP/IP address if EC3-X32 has
different address
• Press SEL to activate the function without leaving the special function mode.
• Press PRG to activate the function and leave the special function mode.
ECD-002 display/keypad unit (LEDs and button functions)
Blinking: valve is opening
ON: valve is fully open
Blinking: valve is closing
ON: valve is fully close
The Monitoring and Alarm WebPages are read only and therefore it is not
necessary to enter a username or password. A username and password will be
requested upon the initial request to any of the other WebPages. The factory
default settings are :
Username: “EmersonID” , Password: “12”
The default settings may be modified on the Display configuration page.
Press the tabs at the top of the Monitoring page with a left click of the mouse
button to enter the respective Webpage.
The parameters will be visualised in real text together with the program code as
defined in the parameter list below.
After the parameters have been modified, the complete list of settings can be
saved to the memory of the computer and used later to upload into another
Document Nr.: EC3-X32_65127_EN_R06.doc Replacement for R05
Parameters setting/saving
Next parameter/
value (higher)
ON: demand
OFF: no demand
Blinking: pump
down
ON: alarm
OFF: no alarm
2/4
Prg & Sel (5 sec)
Manual reset for
blinking alarm codes
Next parameter/
value (lower)
Selecting/confirming
PCN 865008 09.02.2009
EC3-X32 Superheat Controller with TCP/IP communication capability
GB
Operating Instructions
button
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
2
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
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
*
*
X
temperature
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
┌┘1 Value to show
0
4
0
0 = Measured superheat (K) 1 = Measured evaporator pressure (bar)
2 = Valve opening (%)
3 = Measured coil-out temp. (°C)
4 = Calculated evaporating temperature (°C) from the pressure
┌┘5 Units conversion
0
1
0
0 = °C, K, bar
1 = °F, R, psig
(Psig values are divided by 10. Example: Display 12.5 is 125 psig)
u4 Superheat control mode
0
1
0
0 = Standard, 1 = Slow
uH High superheat alarm function
0
1
0
0 = disable, 1 = enable auto reset
uA High superheat alarm setpoint
16 40
30
ud High superheat alarm delay, min.
1
15
3
P2 Freeze protection cut-out, °C
-40 40
0
P3 Freeze protection cut-in, °C
-37 43
3
P4 Freeze protection alarm function
0
2
0
(0 = disable, 1 = enable auto-reset, 2 = enable manual reset)
P5 Freeze protection alarm delay, sec.
5 199
30
P6 Pump-down function
0
1
0
(0 = disable, 1 = enable auto-reset)
P7 Pump-down cut-out, barg
-0,5 18
0.5
P8 Pump-down time delay, sec.
0 199
30
P9 Low pressure alarm function
0
2
0
(0 = disable, 1 = enable auto-reset,
2 = enable manual reset)
PA Low pressure alarm cut-out, barg
-0,8 17,7
0
Pb Low pressure alarm delay, sec.
5 199
5
Pd Low pressure alarm cut-in, barg
-0,5 18
0.3
b1 Battery error management, when battery is 0
3
2
defective, see below:
Alarm
Reset possibility after
value display Alarm relay
Valve
recovery/replacement
0
Regulating
1
Ab
Regulating
2
Ab
Signalling Fully close
Auto
3
Ab
Signalling Fully close
Manual
(blinking)
! When setting b1 to option 0 or 1, the user must ensure appropriate
safety precautions are in place to protect the system against damage
caused by a power failure.
L2 Output logic
0
3
1
0: Alarm = normal, pump down. = normal
1: Alarm = inverse, pump down. = normal
2: Alarm = normal, pump down. = inverse
3: Alarm = inverse, pump down. = inverse
*) Min. and Max. setting values are dependant to selected type of refrigerant.
Control (valve) start-up behaviour (Parameter uu and u9)
%
Code Parameter description and choices
Document Nr.: EC3-X32_65127_EN_R06.doc Replacement for R05
EX4/5/6 ≤ 1.5 seconds
EX7
≤ 3.2 seconds
EX8
≤ 5.2 seconds
uu
Sec.
u9
EC3-X3 BA.cdr
List of parameters in scrolling sequence by pressing
Pump down function (if P6=1 and L2=1)
Digital input
status
24V (ON)
0V (OFF)
Alarm
condition
NO
NO
0V or 24V
YES
Pump down relay
Activate
Deactivate when pressure drops
below P7 and after elapsed time P8
Deactivate
Start-up
Start the system and check the superheat and operating conditions.
The EC3-X32 is fully functional without connected PC or keypad/display unit
ECD-002.
Mounting of ECD-002
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.
3/4
PCN 865008 09.02.2009
EC3-X32 Superheat Controller with TCP/IP communication capability
Operating Instructions
GB
Error/Alarm handling
Alarm
code
E0
E1
AΠ
Description
Related
Alarm
parameter
relay
Pressure transmitter error
Signalling
Temperature sensor error
Signalling
EX4…EX8 electrical
Signalling
connection error
b1: 1
-
Valve
Requires manual reset
after resolving alarm
Fully close Check wiring connection and measure the signal 4 to 20 mA
No
Fully close Check wiring connection and measure the resistance of sensor No
Check wiring connection and measure the resistance of winding No
What to do?
Regulating Battery potentially does not have enough charge to close valve in case of main power supply interruption. May occur
Battery error
b1: 2
Signalling Fully close temporarily with new controllers or after long storage but should Ab
disappear when battery is charged sufficiently. If Ab remains
b1: 3
Signalling Fully close active even when battery is charged, battery may be defective
Yes
Ab blinking
and should be replaced. (Replacement kit: 807 790).
P6: 1
Signalling Allocate the source, which does not let suction pressure drops
Yes
AE blinking Pump down action
can not accomplished
below desired set-point
P4: 1
Signalling Fully close Check the system for cause of low pressure such as insufficient No
Freeze protection
AF
P4: 2
Signalling Fully close load on evaporator
Yes
AF blinking
uL: 1
Signalling Fully close Check wiring connection and operation of valve
No
Low superheat
AL
uL: 2
Signalling Fully close
Yes
AL blinking (<0,5K)
High superheat
uH: 1
Signalling Fully close Check the system
No
AH
P9: 1
Signalling Fully close Check the system for cause of low pressure such as refrigerant No
Low pressure
AP
P9: 2
Signalling Fully close loss
Yes
AP blinking
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
Message
until being cleared, then the next highest alarm is displayed until all alarms
--- No data to display
are cleared. Only then will parameters be shown again.
The display will show an “---” at start up and when no data is send to ECD-002
Ab
Checking system operating conditions using local display/keypad ECD-002
The data to be permanently shown on the display can be selected by the user
(parameter ┌┘1). It is possible to temporarily display these 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
┌┘1.
parameter
Service / Troubleshooting
Symptom
Operating superheat is several degrees higher or lower
than set-point
Operating superheat is too low i.e. compressor wet
running
Valve is not fully closed
Instable superheat (hunting)
Valve opens when EC3 commands to close and vice
versa
EX8 is not able to open at high differential pressure
Superheat set-point is shifting after several months of
uninterrupted operation or permanent jumper of 24V
digital input
Cause
Incorrect signal from pressure or
temperature sensors
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- Incorrect wiring of ECVs
1- Check the wiring
2- Defective sensors
2- Check the sensor
1- The digital input is ON (24V)
1- Valve is shut off only when the digital input is turned off (0V)
2- Wrong setting of parameter ut.
2- Check the setting of parameter ut
Evaporator is designed to operate at Increase the superheat set-point
higher superheat
Wrong wiring between EC3-X32
Correct the wiring
and valve
Wrong setting of parameter ut
Check the parameter ut. (Larger valve requires higher torque and
higher current)
Stepper motor driven valves require Do not apply permanent 24V digital input. Interrupt digital input
synchronization
once every week for 5 seconds if compressor never stops.
Dimensions
EC3-X32
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-X32_65127_EN_R06.doc Replacement for R05
4/4
PCN 865008 09.02.2009
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