EC3-X33 Superheat Controller and ECD-002 Keypad / Display Unit Operating Instructions GB Wiring Description EC3-X33 is a 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 6.3 mm spade earth connector IP20 Grounding Protection class Connection to ECD-002 Digital Inputs NTC input 4-20 mA Analog input 4-20 mA Analog output ECC-Nxx or CAT5 cable with RJ45 connectors 0/24VAC/DC for stop/start function Alco Controls temperature sensor ECN-N60 Alco Controls PT4-07M / PT4-18M / PT4-30M For connection to any 3rd party controller with 12/24VDC power supply and appropriate burden Deviation from input signal ±8% max 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 If the output 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. 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 In order to provide system protection in the event of power loss, it is ! recommended to change the battery annually. 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_R07.doc Replacement for R06 A: E: F: G: H: 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 ! 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) 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. 1/4 12.02.2009 EC3-X33 Superheat Controller and ECD-002 Keypad / Display Unit Operating Instructions ECD-002 display/keypad unit (LEDs and button functions) Main parameters (must be checked and modified if necessary) Code Parameter description and choices Blinking: valve is opening ON: valve is fully open Blinking: valve is closing ON: valve is fully close GB Parameters setting/saving Next parameter/ value (higher) ON: demand OFF: no demand 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) Prg & Sel (5 sec) uu Start valve opening (%) 10 100 50 value (lower) Manual reset for u9 Start opening duration (second) 1 30 5 Selecting/confirming blinking alarm codes uL Low superheat alarm function 0 2 1 Setup of main parameters (need to be checked/modified before 0 = disable (for flooded evaporator) 1 = enable auto reset 2 = enable manual reset start-up) using ECD-002 Cut-out at 0.5K (if it maintains 1 min.); Cut-in immediately at 3K • Make sure that digital input is 0V (open). Turn the power supply ON. u5 Superheat set-point (K) Important: Three main parameters i.e. refrigerant type (u0), pressure sensor type If uL enabled (auto or manual) 3 30 6 (uP) and valve type (ut) can be set only when digital input is open (0V) while the If uL disabled 0.5 30 6 power supply is ON (24V). This feature is for added safety to prevent accidental damage of compressors and other system components. u2 MOP function 0 1 1 • For easy setting of main parameters, follow the pictorial procedure of “Quick 0 = disable 1 = enable start-up” on the attached individual paper. u3 MOP set-point (°C) saturation temperature * * X Once the main parameters have been selected/saved the EC3 is ready for Factory setting is according to selected refrigerant (u0): startup. All other parameters can be modified at any time during operation or +13°C for R22 +15°C for R134a +7°C for R507 standby if it is necessary. +7°C for R404A +15°C for R407C +15°C for R410A +50°C for R124 -5°C for R744 Start-up ┌┘5 Units conversion (only for u3, u5, ┌┘1) 0 1 0 Start the system and check the superheat and operating conditions. 0 = °C, K, bar 1 = °F, R, psig The EC3-X33 is fully functional without keypad/display unit. ECD-002 may be (Psig values are divided by 10. Example: Display 12.5 is 125 psig) removed or connected at any time. ┌┘1 Value to show 0 4 0 Procedure for parameters modification using ECD-002 0 = Measured superheat (K) 1 = Measured evaporating pressure, (bar); The parameters can be accessed via the 4-button keypad. The configuration 2 = Valve opening (%) 3 = Measured coil-out temperature (°C) parameters are protected by a numerical password. The default password is “12”. 4 = Calculated evaporating temperature (°C) from the pressure To select the parameter configuration: u4 Superheat control mode 0 1 0 Press the PRG button for more than 5 seconds 0 = Standard, 1 = Slow A flashing 0 is displayed b1 Battery error management, when battery is 0 3 2 Press or until 12 is displayed; (password) defective, see below: Press SEL to confirm password Alarm Reset possibility after value display Alarm relay Valve recovery/replacement Press or to show the code of the parameter that has to be changed; 0 Regulating Press SEL to display the selected parameter value; 1 Ab Regulating Press or to increase or decrease the value; 2 Ab Signalling Fully close Auto Press SEL to temporarily confirm the new value and display its code; 3 Ab Signalling Fully close Manual or to show..." Repeat the procedure from the beginning "press (blinking) To exit and save the new settings: ! When setting b1 to option 0 or 1, the user must ensure appropriate safety Press PRG to confirm the new values and exit the parameters modification precautions are in place to protect the system against damage caused by a procedure. power failure. To exit without modifying any parameters: *) Min. and Max. setting values are dependant to selected type of refrigerant. Do not press any button for at least 60 seconds (TIME OUT). ON: alarm OFF: no alarm Reset all parameters to factory setting: • • • • • • • • 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 u9 Document Nr.: EC3-X33_65126_EN_R07.doc Sec. EC3-X3 BA.cdr % Replacement for R06 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. 2/4 12.02.2009 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_R07.doc Replacement for R06 3/4 12.02.2009 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_R07.doc Replacement for R06 4/4 12.02.2009
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