D A T A ... EC3-X33 Stand-alone Superheat Controller

D   A   T   A ...  EC3-X33 Stand-alone Superheat Controller
EC3-X33
Stand-alone Superheat Controller
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EC3-X33 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. The optional ECD-002 Display/keypad Unit is
necessary for setup but not for operation of the controllers.
ECD-002 can be connected or disconnected to EC3-X33 at any
time.
Features EC3-X33
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Superheat control in conjunction with EMERSON stepper
motor driven Electrical Control Valves EX4 … EX8
Limitation of evaporating pressure (MOP)
Low superheat alarm
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
Electrical connection via plug-in type screw terminals
Aluminum housing for DIN rail mounting
EC3-X33 with ECD-002
Features ECD-002
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2½ digit LED display with automatic decimal point
Indicator LEDs for valve opening/closing, external demand
and alarm
Connection to EC3 Series via ECC-Nxx or standard CAT5
patch cord with RJ45 connectors
Typical ordering package:
Description
Type
Superheat Controller
EC3-X33
Terminal kit
K03-X33
Temperature sensor
ECN-N60
Electrical Control Valve
EX4, EX5, EX6, EX7 or EX8 *
Pressure sensor
PT5-07M
• for R22/R124/R134a/R40A/R407C/R507C
PT5-18M
• for R410A
PT5-30M
• for R744
PT5-18M
• for intermediate pressure applications
Plug and cable assembly for pressure sensor
PT4-M60
*For further details refer to: EX4, EX5, EX6, EX7, EX8 Electrical Control Valves datasheet EX48_35008.pdf
PCN
807 783
807 645
804 497
*
802 350
802 351
802 352
802 351
804 805
Accessories (required for setting at start-up only):
Description
Optional display/keypad
Cable connection between EC3-X33 and ECD-002
Type
ECD-002
ECC-N50 or any standard Cat 5 patch cord with RJ45
connectors
PCN
807 657
807 862
Application
EC3-X33 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 vapour 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
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EC3-X33
Stand-alone Superheat Controller
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Introduction
EC3-X33 controls the opening of electrical control valves
according to desired superheat. As electrical control valves EX4
… EX8 are able to provide positive shut-off function better than
conventional solenoid valves, there will be no flow through the
valve as long as the compressor is not running. In the event of
cooling request and compressor start-up, EC3-X33 needs to be
informed. This can be achieved by a digital input. EC3-X33 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-X33 is capable for diagnostics and alarm. The alarm can
be received via relay output 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, EC3-X33
calculates the actual superheat and compares with preset
superheat. EC3-X33 operates the Electrical Control Valve in
order to keep superheat at desired setpoint under various
operating conditions.
The superheat setpoint 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-X33 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 manufacturers and to avoid
unnecessary manual conversions from temperature into
pressure values. The MOP function may be totally disabled,
when not needed.
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-X33 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.
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Digital input status
The digital input is the interface between EC3-X33 and system
controller. The digital status is dependant to operation of
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-X33 will drive the
electrical control valve to close 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.
!
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.
Analogue output (4-20mA signal) function
EC3-X33 requires the outlet pressure level of the evaporator for
superheat and MOP control. The output signal from PT5 is used
by EC3-X33 and again provided as a 4...20mA signal
(galvanized) for the connection to any other third party
controller, which can receive a 4...20mA signal. Please see the
wiring diagram for more details. If the system controller does not
have the capability of using this signal, the terminal will not be
wired to any other device.
Pump down function
EMERSON Electrical Control Valves can be driven to close
position while the compressor is running for pump down
function. There are two possibilities to achieve this function:
1) The valve will be driven to close position by interruption of the
digital input. The compressor can be turned off by a pressure
switch and / or a timer.
2) By using 4 to 20 mA analogue output connected to system
controller.
In both cases, the initiation and termination of pump down is
under the system controller functionality/responsibility.
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.
! 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
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Stand-alone Superheat Controller
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Alarm and maintenance functions
EC3-X33 provides several alarms to facilitate diagnosis as well
as shut down of compressor/system if the alarm relay is wired
into the serial safety loop. Built-in diagnostic routines constantly
monitor 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.
Additional to hardware errors also EC3-X33 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. It can be disabled for applications such as
flooded evaporator, which lower operating superheat is required.
In case of alarm, EC3-X33 will close the valve, alarm relay will
be deactivated and alarm codes as well as alarm LED will be
available if the optional display/keypad ECD-002 is connected
to EC3-X33.
All alarms are automatically cleared after correction. Battery
alarm and low superheat alarm can be modified for manual reset.
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Optional ECD-002 display/keypad unit
ECD-002 is required to set parameter during start-up and may
be left connected or removed from EC3-X33 afterwards.
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.
Alarm relay function
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 a 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 condensers in low
ambient temperatures
• Compressor start-up after a long standby time in a low
ambient environment
• Start-up of very large single stage compressor capacity
Blinking: Valve is opening
ON: Valve is fully open
Parameters setting/saving
Blinking: Valve is closing
ON: Valve is fully close
Next parameter/value (higher)
ON: Demand
OFF: No demand
ON: Alarm
OFF: No alarm
Manual reset for
blinking alarm codes
(press 5 sec together)
Next parameter/value (lower)
Selecting/confirming
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 refrigerant and
system, different types of pressure sensors are needed.
• PT5-07M for evaporators operating with refrigerants
R22/R124/R134a/R404A/R407C
• PT5-18M for evaporators operating with R410A
• PT5-30M for evaporators operating with R744
• PT5-18M for evap. as economizers, subcoolers, which the
outlet of evaporator connected to intermediate pressure of
screw/scroll compressors or two stage compressors.
Every type of pressure sensor is calibrated in temperature
range for above specified applications. The feature set and
performance of the PT5 Series is a perfect match for the EC3X33. Other pressure sensors are not released for use with EC3X33 and when applied, may lead to poor performance.
EMERSON temperature sensor ECN-N60
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. The sensor is
hermetically sealed for high reliability and long lifetime and has
metal housings for optimal thermal conductivity.
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EC3-X33
Stand-alone Superheat Controller
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Wiring Diagram
A:
E:
G:
H:
!
I:
White wire B: Black wire C: Blue wire D: Brown wire
Plug cable assembly EXV-Mxx for connection to EX4 .. EX8
Remote control panel, system controller
Alarm relay, dry contact. Relay coil is not energized at alarm
condition or power off
J: Transformer Class II, 24VAC secondary / 25VA
K: Third party controller (can use analog output signal of EC3)
Note: The internal resistor of a third party controller must fulfill the
following conditions:
Supply voltage 12VDC: R ≤ 200Ω
Supply voltage 24VDC: R ≤ 800Ω
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
Digital input (0V/open = Stop; 24V/closed = Start)
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EC3-X33
Stand-alone Superheat Controller
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Ordering, main parts
Description
Controller EC3-X33
Terminal Kit for EC3-X33
Pressure Sensors
-0.8…7bar
0…18bar
0…30bar
1.5m
cable
length
Cable Assembly for PT5
3.0m cable length
6.0m cable length
3m cable length
NTC Temperature sensors
6m cable length
12m cable length
Display/keypad unit (need for set-up only)
1,0 m
Connection cable EC3 to ECD-002
3,0 m
5,0 m
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Type
EC3-X33
K03-X33
PT5-07M
PT5-18M
PT5-30M
PT4-M15
PT4-M30
PT4-M60
ECN-N30
ECN-N60
ECN-N99
ECD-002
Part Code Nr.
807 783
807 645
802 350
802 351
802 352
804 803
804 804
804 805
804 496
804 497
804 499
807 657
ECC-N10
ECC-N30
ECC-N50
807 860
807 861
807 862
Type
Part Code Nr.
ECT-323
ECT-623
804 424
804 421
807 790
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Ordering, accessories, spare part
Transformer
230VAC Input, 24V output, Din rail mounting
For one set of controller and valve
25VA
For two sets of controllers and valves
60VA
Replacement battery kit EC3
Suitable valves for connection to EC3-X33
Valve
Capacity range
kW *
EX4
EX5
EX6
EX7
EX8
2 ... 20
5 ... 50
12 ... 120
35 ... 330
90 ... 880
EX4
EX5
EX6
EX7
EX8
2 ... 21
5 ... 53
13 ... 126
35 ... 347
100 ... 925
EX4
EX5
EX6
EX7
EX8
2 ... 15
4 ... 39
10 ... 93
25 ... 255
70 ... 680
EX4
EX5
EX6
EX7
EX8
2 ... 14
4 ... 35
9 ... 84
24 ... 230
62 ... 613
EC3-X33_35060_EN_R05.doc
Refrigerant
Valve
Capacity
regulation
Capacity range
kW *
Refrigerant
R22
EX4
EX5
EX6
EX7
EX8**
3 ... 23
6 ... 58
14 ... 140
40 ... 385
100 ... 1027
R 410A
R407C
EX4
EX5
EX6
EX7
EX8**
4 ... 41
10 ... 102
25 ... 244
70 ... 671
180 ... 1789
R 744
1 ... 11
3 ... 28
6 ... 67
R124
10-100%
EX4
EX5
EX6
R134a
*) Nominal rating conditions:
Refrigerant
R22, R134a, R404A, R407C, R410A
R23
R744
R124
**) PS:35bar
R404A/
R507
5/8
Evaporating
temperature
+4°C
-60°C
-40°C
+20°C
Capacity
regulation
10 to
100%
Condensing
temperature
+38°C
-25°C
-10°C
+80°C
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EC3-X33
Stand-alone Superheat Controller
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Technical Data
EC3-X33
Supply voltage
Digital input
Power consumption
ECD-002 Display Unit
Supply
From EC3 Series Controller via
connecting cable
LED indicators
Valve opening, valve closing, alarm,
demand
24VAC ±10%, 50/60Hz
24 V AC ±10%, 50-60HZ
24 V DC ±10%
25VA max. including connected ECV
and display/keyboard
Display LED
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
Applied directive
EMC
LVD
RoHS
Marking
Protection class
Vibration
Temperatures
storage
operating
Humidity
Protection class
Weight
Mounting
6.3mm spade earth connector
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
IP 20
4g, 10-1000Hz
Connecting cable
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
Temperature
storage
operating
Humidity
Protection class
-20 … +65°C
0 … +60°C
0 … 80% r.h. non condensing
IP 65 (front protection with gasket)
Weight
Mounting
~ 52g
Panel mount (71 x 29 mm cutout)
-20 … +65°C
0 … +60°C
1… +25°C for optimum battery life
0 … 80% r.h. non condensing
IP20
~ 800g
DIN rail mounted
Input and Output, EC3-X33 Controller
Description
Temperature input
Pressure sensor input
Analog output (evaporating
pressure fed-through signal)
Deviation from input signal
Digital input
Output relay
Stepper motor output
Connection to ECD-002
Specification
ECN-Nxx
10kΩ @ 25 °C, Range: -50 … 50 °C
PT5-07M/18M/30M
24VDC, 4 … 20mA
4 … 20mA
Requires 12 or 24 VDC
±8% max
0/24 VAC/DC
SPDT contacts, AgCdO , 24VAC/DC
Inductive 2Amp, Resistive 8 Amp
For EX4 … EX8 Electrical Control Valves
RJ45
List of Adjustable Parameters
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Superheat set point
Low superheat function
MOP function and set point
Type of refrigerant and required pressure sensor
Type of Electrical Control Valve
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Valve start opening and duration
Unit conversion
Value to display
Battery error management
Password
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EC3-X33
Stand-alone Superheat Controller
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Dimensions (mm)
EC3-X33 Controller
ECT-623 Transformer
ECT-323 Transformer
58
73
4354 76
ECD-002 Display Unit
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EC3-X33
Stand-alone Superheat Controller
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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-X33_35060_EN_R05.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.
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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
22.12.2010
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