EC2-7xx Series Condenser Controllers Technical Data EC27e35034.doc Rev.: 00 1 / 8 12.05.2005 The EC2-Series form a new generation of electronic controllers for refrigeration and air conditioning. The controllers combine in the small industry standard housing maximum functionality like variable fan speed control with 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. Several versions are available: EC2-74x Series Condenser Controllers with analogue 0…10V output for variable fan speed control EC2-71x Series Condenser Controllers with fan cycling Features EC2-7xx Series Condenser Controllers EC2-74x features • Variable fan speed control with Alco Controls FSP Series Fan Speed Power Modules • Proportional control of condensing pressure • 2 Relay outputs for split circuit condenser and adiabative or evaporative condensing control • 1 Temperature input for condensing pressure setpoint shifting EC2-71x features • Cycling of up to 4 fans/stages with 4 relay outputs • Dead band control of condensing pressure • Monitoring of fan motor condition with 4 digital inputs Common features • 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 AMS. • Alarm messaging by email (EC2-xx2) • Electrical connection via plug-in type screw terminals • 2½ digit LED display with automatic decimal point • Indicator LEDs for fan and alarm status • Standard 71 x 29 mm cut-out dimensions • IP 65 protection class when mounted in front panel EC2-7xx Series Condenser Controller Typical ordering package (EC2-742) • EC2-742 Condenser Controller with K02-540 Terminal Kit • ECT-523 Transformer • ECX-N60 Ethernet Cable • PT4-30S Pressure Transmitter with PT4-L15 Cable • FSP-180 Fan Speed Power Module with FSP-L15 Cable Selection Table TCP/IP Ethernet LON ® FTT-10 Description Type Order Nr. Type Order Nr. Condenser Controller Variable Fan Speed Control with FSP Fan Speed Power Module EC2-742 807 762 EC2-741 807 761 Condenser Controller Fan cycling of up to 4 fans/stages EC2-712 807 752 EC2-711 807 751
Transcript
EC2-7xx Series
Condenser Controllers Technical Data
EC27e35034.doc Rev.: 00 1 / 8 12.05.2005
The EC2-Series form a new generation of electronic controllers for refrigeration and air conditioning. The controllers combine in the small industry standard housing maximum functionality like variable fan speed control with TCP/IP Ethernetcommunications 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. Several versions are available:
EC2-74x Series Condenser Controllers with analogue 0…10V output for variable fan speed control EC2-71x Series Condenser Controllers with fan cycling
Features EC2-7xx Series Condenser Controllers EC2-74x features • Variable fan speed control with Alco Controls FSP Series
Fan Speed Power Modules • Proportional control of condensing pressure • 2 Relay outputs for split circuit condenser and adiabative or
evaporative condensing control • 1 Temperature input for condensing pressure setpoint
shifting EC2-71x features • Cycling of up to 4 fans/stages with 4 relay outputs • Dead band control of condensing pressure • Monitoring of fan motor condition with 4 digital inputs Common features • 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 AMS.
• Alarm messaging by email (EC2-xx2) • Electrical connection via plug-in type screw terminals • 2½ digit LED display with automatic decimal point • Indicator LEDs for fan and alarm status • Standard 71 x 29 mm cut-out dimensions • IP 65 protection class when mounted in front panel
EC2-7xx Series
Condenser Controller
Typical ordering package (EC2-742) • EC2-742 Condenser Controller with K02-540 Terminal Kit • ECT-523 Transformer • ECX-N60 Ethernet Cable • PT4-30S Pressure Transmitter with PT4-L15 Cable • FSP-180 Fan Speed Power Module with FSP-L15 Cable
Selection Table TCP/IP Ethernet LON® FTT-10
Description Type Order Nr. Type Order Nr.
Condenser Controller Variable Fan Speed Control with FSP Fan Speed Power Module EC2-742 807 762 EC2-741 807 761
Condenser Controller Fan cycling of up to 4 fans/stages EC2-712 807 752 EC2-711 807 751
EC2 -7xx Series
Condenser Controllers
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Introduction The EC2-7xx Series Controllers are for use in commercial refrigeration systems, primarily to control the condensing pressure of air cooled condensers. For energy efficiency reasons condensing pressure should be kept as low as possible, however there are low end limits which must not be exceeded: Minimum condensing pressures are specified by compressor manufacturers for safe and reliable compressor operation. In order to function properly, expansion valves need solid liquid refrigerant and a certain minimum pressure at the valve inlet. This is particularly true for Thermo® Expansion Valves whilst electronically controlled expansion valves are more forgiving. Normally condensing pressure is controlled by varying the air flow through the condenser. This can be achieved by cycling individual fixed speed fans (EC2-71x) or by varying fan motor speed (EC2-74x). Other functions include split circuit condenser control, adiabative or evaporative condensing control, data monitoring and alarm handling. Though EC2 Controllers can operate as stand alone devices, they are best suited to networked solutions, which take advantage of the monitoring capabilities. The EC2 Series Condenser 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 EC2-74x The application of the EC2-74x Controllers are described in the functional diagram below:
The condensing pressure is measured with an Alco Controls PT4 Series Pressure Transmitter (1) to define the needed air flow. Air flow is modulated by phase chopping the supply voltage of the fan motors in the FSP Fan Speed Power Module (3). The FSP is capable of reducing fan motor speed down to approximately 25% of nominal speed. With respect to air flow the modulation range is between approximately 20% and 100% of nominal air flow. When the demand for air flow is below the lower end of the modulation range, the FSP will shut the fan motors off. The ambient air temperature sensor (2) may be used for shifting of the condensing pressure setpoint. On split circuit condensers, one circuit may be completely isolated by closing the solenoid valve (5) when capacity demand is very low or in low ambient temperature conditions. Adiabate or evaporative condensing may be used to increase condenser capacity temporarily in extremely high ambient conditions. When needed, the solenoid valve (4) activates the flow of water to the sprinklers.
Condensing Pressure Control EC2-74x P1 is the proportional band around the condensing pressure setpoint P0. Ideally the variation of fan motor speed (respectively air flow) maintains condensing pressure within the proportional band P1.
SolenoidValve (4)
Solenoid Valve (5)
Motor Speed & Air Flow
If ambient temperatures and/or condenser load increase and fans are running at 100%, condensing pressure will continue to rise. When P8 is reached, the sprinkler control for adiabate or evaporative condensing is activated (where applicable). The sprinkler control is a dead band control with setpoint P8 and control band P9. On split circuit condensers, when falling condensing pressure reaches P3, the split circuit condenser control loop is activated (where applicable). It is a dead band control for one circuit with setpoint P3 and control band P2. A setpoint floating feature is available when an ambient temperature sensor is connected. Depending on ambient temperature, the condensing pressure setpoint may be lowered in a controlled way for improved energy efficiency of the overall system.
Application EC2-71x The application of the EC2-71x Controllers are described in the functional diagram below:
As with the EC2-74x, the needed air flow is derived from the actual condensing pressure with an Alco Controls PT4 Series Pressure Transmitter (5). The air flow is modulated by switching on and off up to 4 fans or 4 groups of fans. The EC2-71x features 4 volt free digital inputs to connect the serial safety loop of fan motors back to the controller. This permits remote monitoring of the motor health.
EC2 -7xx Series
Condenser Controllers
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Condensing Pressure Control EC2-71x The condensing pressure control loop in the EC2-71x is a dead band control with setpoint P0 and control band P1. excess dead band demand
setpoint condensing pressure When condensing pressure increases beyond P0 + ½ P1, an extra fan motor is turned on. Similarly a fan motor is turned off, when condensing pressure decreases beyond P0 – ½ P1. To smooth condensing pressure variations and cut out short pressure peaks fan motor on/off switching may be delayed. Delay times are adjustable. In base load mode, one of the condenser fans becomes a dedicated baseload fan. This fan is then always switched on first and switched off last as lead and ambient conditions vary. The configurable FIFO (First In First Out) logic balances fan motor run times. As an option, this mode can be set to FILO (First In Last Out). A fast recovery procedure is available to switch off all fan motors when the condensing pressure falls below a pre-defined limit or to switch on all fan motors when the condensing pressure exceeds a pre-defined limit.
Sensors Low cost NTC sensors are available with different cable lengths to meet specific customer's requirements for optimal positioning of the sensors. Air sensors have a hermetically sealed plastic housing. The use of Alco Controls PT4 Series Pressure Transmitters is highly recommended. They are dedicated for refrigeration applications and feature pre-fabricated plug and cable assemblies with different cable lengths as well as waterproof electrical connectors for easy installations. Their electrical characteristics match the requirements of the EC2 Series and guarantee proper function of the built-in sensor detection and self-test feature.
Display and Keypad With the 2½ digit display pressures within ±199 bar can be shown with a resolution of 1 bar. The resolution improves to 0.1 bar within a range of ±19.9 bar. The same principle applies to the display of temperatures in °C to °F. The display unit can be switched from °C to °F. Indicator LEDs show the status of the condenser. A blinking LED indicates that the EC2 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 condensing pressure above upper limit.
Operation and Commissioning Setup and commissioning of an EC2 Series 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 EC2. - Remotely via the AMS Server connected to the LON® port
of an EC2. - Locally through the 4-button keypad. - Locally with the infrared remote control.
For initial commissioning of a new installation depending on the networking technology of the EC2 the first two options are the most appropriate. Commissioning is done via dedicated menus with meaningful default values, which make commissioning an EC2 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.
WebServer function of the EC2 with TCP/IP Ethernet networking capabilities Though the actual status of the controllers can be viewed on the local display, 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 EC2-712 with the monitoring WebPage of the controller.
Echelon LON® Networking Capabilities of the EC2 The remote access, viewing and monitoring features of the LON® version EC2 Series Controllers match and exceed the capabilities of their TCP/IP counterparts. Though remote access requires the use of the Alco Controls AMS Monitoring Server or special third party LON® compliant hardware and software, many more additional functions and features are available. The LON® version EC2 Controllers are equipped with 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 EC2 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 small and medium 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 Alco Controls AMS 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.
EC2 -7xx Series
Condenser Controllers
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The fields on the upper left side show actual pressure, pressure setpoint and condensing temperature. On the upper right side, fan motor health is displayed. All status messages (operating modes and relay outputs) are displayed in the lower section with normal font, all active messages are in bold letters. A rolling graph with the pressure and temperature data over a period of approximately 10 minutes can be displayed:
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 EC2-742, imported in Microsoft Excel®:
All WebPages, which allow the change of controller parameters, are password protected. Below is the example for the setpoint configuration WebPage of an EC2-742 Controller. All setpoints can be easily reviewed and modified if needed:
EC2 -7xx Series
Condenser Controllers
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Alarm / maintenance functions EC2 Series Controllers provide many alarm codes to facilitate diagnosis. Limit violation alarms are associated with temperature and pressure setpoint (high-, low alarm, sensor failure). 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 TCP/IP Ethernet versions EC2 Controllers have the capability to send alarm messages directly by email. While the display 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:
The Maintenance WebPage of an EC2-712 for example shows the fan motor operating hours. The timers can be reset individually when fan motors are replaced during maintenance:
Safety Functions Various safety functions are available for use to insure the proper operation of the refrigeration system and to avoid damage of system components. These safety features include a rapid recovery mode: When the condensing pressure exceeds the control band of the EC2-71x Condenser Controller by a user-defined pressure value, all available fan motors are immediately switched on without any delay to protect the compressors and avoid tripping of the high pressure safety limiter. Low pressure rapid recovery operates in a similar matter
when a low pressure threshold is reached: All running fan motors are switched off immediately. The adiabative/evaporative condensing feature of the EC2-74x Condenser Controller will prevent excessive condensing pressures and thus contribute to the safety and reliability of the refrigeration system Safe operating modes will 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 individual fan motors (EC2-71x) or manual fan motor speed control (EC2-74x) or others, see below:
Electrical Connection For electrical connection removable screw connectors can be used. This allows the electrical wiring to be completed at the display case manufacturer and the controller is simply plugged-in on site when necessary. The terminal Kit K02-540 (K02-211 for EC2-712) must be ordered separately For TCP/IP controllers an Ethernet cable must be used. The assembled cable ECX-N60 comes with RJ45 connector on one side and the 4-pin screw connector at the other.
Screw Connector Kit EC2-742, K02-540 Rear side
EC2 -7xx Series
Condenser Controllers
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Accessories Terminal Kits and Cables for EC2 Series Type Order Nr. Terminal Kit for EC2-74x K02-540 800 070 Terminal Kit for EC2-71x K02-211 807 647 Ethernet Cable (TCP/IP) 6,0 m cable length ECX-N60 804 422
Fan Speed Power Modules 3-phase 4A max 1-phase 8A max
FSP-340 FSP-180
800 376 800 373
1-phase 5A max FSP-150 800 370 Cable Assembly for FSP 1.5 m cable length
3.0 m cable length 6.0 m cable length
FSP-L15 FSP-L30 FSP-L60
804 693 804 694 804 695
NTC Sensors (Air type) 1,5 m cable length ECN-S15 804 304 (10 kΩ at 25°C) 3 m cable length ECN-S30 804 305 6 m cable length ECN-S60 804 284
Pressure Transmitters 0…30 bar PT4-30S 802 324 0…50 bar PT4-50S 802 326 Cable Assembly for PT4 1.5 m cable length
3.0 m cable length 6.0 m cable length
PT4-L15 PT4-L30 PT4-L60
804 593 804 594 804 595
Transformer Class II
230 VAC Input, 24 V output, 20VA
ECT-523
804 332
Infrared Remote Control English EC2-IRE 804 345 German EC2-IRD 804 346 Language French EC2-IRF 804 347 Spanish EC2-IRS 804 348 Italian EC2-IRI 804 349
Technical Data Input and Output Configuration Power supply 24 VAC ± 10% 50/60 Hz Class II EC2- 71x 74x Power consumption 4 VA max Pressure transmitter inputs Plug-in connector size Removable screw version 24 V DC, 4 … 20 mA 1 1 wire size 0.14 … 1.5 mm2 Temperature inputs Communication TCP/IP Ethernet (EC2-xx2) 10 kΩ @ 25 °C, -50 … 50 °C 1 LON® FTT-10 (EC2-xx1) Digital inputs Display 2½ digits red LED Volt free contact 4 -199 to +199 with decimal point 5 V/0,1 mA Switchable between bar, °C & °F Output relays 4 indicator LEDs Inductive (AC15) 250 V/2 A Temperature Resistive (AC1) 250 V/8 A 2 storage -20 … +65°C Resistive (AC1) 250 V/6 A 4 operating 0 … +60°C Analogue output Humidity 0 … 80% r.h. non condensing 0…10VDC 3mA max 1 Protection class IP65 (front protection with gasket) Communication Weight ~ 150 g TCP/IP Ethernet 10 Mbit/sec Mounting Panel mount (71 x 29 mm cutout) LON® FTT10
EC2 -7xx Series
Condenser Controllers
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Wiring Diagrams
Physical dimensions, drawings
EC2-7xx Series controller housing
Transformers
ECT-523
73
4354 76
58
ALCO CONTROLS 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 ALCO CONTROLS 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. Since conditions of use are outside of ALCO'S control we can not assume any liability for results obtained or damages occurred due to improper application. This document replaces all former versions.
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