ec2-5x2 series condensing unit controllers d a t a s h e e t · pdf fileec2-5x2 series...

EC2-5x2 Series Condensing Unit Controllers

D A T A S H E E T

EC2-5_35056_EN_R03.doc 1 / 8 21.12.2009

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 such as step less compressor modulation and 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.

Features EC2-552 • Suction pressure control for up to 2 compressors;

1 Copeland Digital Scroll compressor and 1 single stage compressor

• Variable fan speed condensing pressure control with EMERSON FSP Series Fan Speed Power Modules

EC2-512 • Suction pressure control for up to 2 single stage

compressors • Condensing pressure control with fan cycling of up to 2

fixed speed condenser fans • Separate inputs for compressor serial control loops,

common input for fan motor control loop Common Features • Multiple control options: Dead band control, base load

control • Compressor and fan motor rotation with run-time

equalisation • Fast recovery of suction and condensing pressure • Sensor failure management with emergency operating

procedures • Relay outputs with 230 VAC SPDT contacts for

compressor crankcase heater control • Support of TCP/IP Ethernet networking technology with

WebServer functionality allows monitoring and configuration of controllers through a standard WebBrowser (e.g. Internet Explorer® or Mozilla Firefox)

• Alarm messaging by email • Electrical connection via plug-in type screw terminals • 2½ digit LED display with automatic decimal point • Indicator LEDs for compressor, fan, press./°C and alarm • Standard 71 x 29 mm cut-out dimensions • IP 65 protection class when mounted in front panel

EC2-5x2 Series

Typical ordering package • EC2-552 Condensing Unit Controller with K02-540

Terminal Kit • FSP-150 Fan Speed Power Module with FSP-L15 Cable • ECT-523 Transformer • ECX-N60 Ethernet Cable • PT5-07M Suction Pressure Transmitter • PT5-30M Condensing Pressure Transmitter • 2 x PT4-M15 cable for PT5 Pressure Transmitters

Selection Table TCP/IP Ethernet Description Type Part No.

Condensing Unit Controller 1 Digital Scroll Compressor, 1 Single Stage Compressor, Variable Fan Speed Control with FSP

EC2-552 807 738

Condensing Unit Controller 2 Single Stage Compressors, 2 Fixed Speed Fans

EC2-512 807 732


D A T A S H E E T

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Introduction The EC2-5x2 Series Condensing Units Controllers are for use in commercial refrigeration systems to control suction pressure and condensing pressure of a refrigeration circuit by modulating compressors and fan motors of a condensing unit. Though the controllers are designed to handle tandem compressors, they are also perfectly suited for single compressor applications. When compared with more traditional condensing unit control methods, which utilise mechanical pressostats for compressor modulation and fan cycling, or which may have no fan control at all, the EC2-5x2 Series Controllers greatly enhance system efficiency, reliability and operating conditions. The built-in communications capabilities permit remote access to the condensing units for monitoring, remote maintenance and retrieval of operational data. Though remote access through a network to individual equipment controllers has been available before for display case, coldroom and rack controllers, it is a new feature for condensing unit controllers. It is now possible to access the entire refrigeration system remotely and not only a part of it. The EC2 Series Condensing Unit 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. The EC2-552 has been exclusively designed to control single compressor or tandem compressor condensing units with a Copeland Digital Scroll compressor. It features a 0…10 VDC output to connect to an EMERSON FSP Fan Speed Power Module for variable fan speed control. Alternatively this output may be used to control fan motor speed with an inverter or to connect to ECM type fan motors directly. The EC2-512 is also capable of controlling 1 or 2 single stage compressors. 1 or 2 fan motors can be controlled by on – off cycling. When compared to on – off cycling of fan motors, variable fan speed control offers two distinctive advantages: A proportional control loop keeps condensing pressure constant and minimizes fan motor noise. By keeping condensing pressure as low as possible, major energy savings can be achieved.

Application The functions of the EC2 Series Condensing Unit Controllers are described in the functional diagrams below:

EC2-552

The Emerson PT5 pressure transmitter (1) senses suction pressure. The Digital Scroll Compressor (6) operates as the base load compressor. Capacity modulation is achieved by temporarily unloading the compressors scroll sets with the Pulse Width Modulated (PWM) signal (11) which controls the compressor unloading valve (12). In tandem compressor condensing units, the single stage compressor (7) will only be turned on when demand exceeds the refrigeration capacity of the Digital Scroll Compressor. The discharge temperature thermistor of the Digital Scroll Compressor should be connected to the Disch. Temp. input (5) of the controller and the volt-free digital inputs (3) and (4) should be connected to the serial alarm loops of both compressors for feedback of compressor tripping.

Suction Pressure Control EC2-552 2 control loops with the same suction pressure setpoint P0 modulate the compressors. StandardScroll

Digital Scroll

Suction Pressure The dead band control loop with dead band P1 switches the single stage compressor on or off, whereas a PI control loop modulates the Digital Scroll base load compressor between approximately 10% and 100% capacity. Being the base load compressor, the Digital Scroll Compressor will never be switched off while the single stage compressor remains on.

Condensing Pressure Control EC2-552 The PT5 pressure transmitter (2) senses condensing pressure and feeds the signal into a control loop which generates a 0…10V output signal (10) to modulate condenser fan motor speed by using the EMERSON FSP Fan Speed Power Module. The control algorithm for condensing pressure is generating a proportional transfer characteristic:

P1

0%

100%

P0 Condensing Pressure P0 is the condensing pressure setpoint for the fan. P1 is the proportional pressure band within the fan speed is controlled proportional.


D A T A S H E E T

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Application EC2-512

The suction pressure control algorithm and the compressor control features of the EC2-512 are identical to the ones as described above in the EC2-552. As above, the PT5 pressure transmitter (2) senses condensing pressure and feeds the signal into a condensing pressure dead band control loop, which is similar to the dead band compressor control loop as described in the EC2-552. Condensing pressure is modulated by turning fan motors on and off. excess dead band demand

setpoint condensing pressure No change occurs as long as the condensing pressure remains within the dead band around the condensing pressure setpoint. The controller will add/remove fan capacity when the condensing pressure goes beyond the limits of the condensing pressure dead band. For stable condenser operation, adjustable time delays for fan motor on and off are available. To avoid premature wear of individual fan motors, run time equalization is built into the controller.

Sensors The use of Emerson PT5 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 connec-tors 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 ±199bar can be shown with a resolution of 1bar. The resolution improves to 0.1bar within a range of ±19.9bar. The same principle applies to the display of temperatures, which can be switched from °C to °F. Indicator LEDs show the status of the compressors and the fan motors. 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 a request to remove a compressor, which is temporarily inhibited by the minimum compressor run time requirement.

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. • Locally through the 4-button keypad. For initial commissioning of a new installation depending on the networking technology of the EC2 the first option is 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. Englisch and german are the standard languages, others are also available. 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 EC2-552 with the monitoring WebPage.


D A T A S H E E T

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The top center field indicates the status of compressors and fan(s). The top left field shows suction pressure setpoint and actual suction data. The top right field shows the equivalent condensing pressure data. The fields below show controller status, active compressors and compressor and fan motor modulation. All active messages are in bold letters in blue colour. 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. In the picture below is a sample log file from an EC2-552, imported in Microsoft Excel®:


D A T A S H E E T

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All WebPages, which allow the change of controller parameters, are password protected. Below is the example for the setpoint configuration WebPage of an EC2-552 Controller. All setpoints can be easily reviewed and modified if needed:

Alarm / maintenance functions EC2 Series Condensing Unit Controllers provide many alarm codes to facilitate diagnosis. Limit violation alarms are associated with temperature and pressure set point (high-, low alarm, sensor failure). Maintenance alarms are based on compressor/fan runtimes. When a defined runtime is exceeded the maintenance alarm is triggered. Compressor and fan motor feedback alarms occur when the serial control loop opens due to excessive temperature, pressure, motor overload etc. Alarm management includes the issuing of an alarm message and to show the alarm code on the controllers display. 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 in red colour, see below:

Safety Functions Safe operating modes allow the system to continue to operate safely even when the signal is lost from a defective or disconnected sensor or when one of the serial control loops open. Particularly useful facilities are the service functions, which enable the engineer to manually control the system during commissioning. They include manual operation of compressors and fans. Service intervals for compressors and fans can be preset and cause an alarm when the preset run time has been exceeded.

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 EC2-512) 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 EC2-552, K02-540 Rear side


D A T A S H E E T

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Accessories Terminal Kits and Cables for EC2 Series Type PCN Terminal Kit for EC2-552 K02-540 800 070 Terminal Kit for EC2-512 K02-211 807 647 Ethernet Cable (TCP/IP) 6,0m 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 1.5m cable length

3.0m cable length FSP-L15 FSP-L30

804 693 804 694

Pressure Transmitter -0.8…7bar 0…18bar

PT5-07M PT5-18M

802 350 802 351

0…30bar PT5-30M 802 352 0…50bar PT5-50M 802 353

Cable Assembly for PT5 1.5m cable length 3.0m cable length 6.0m cable length

PT4-M15 PT4-M30 PT4-M60

804 803 804 804 804 805

Transformers Class II

230VAC Input, 24V output, 25VA, DIN

ECT-323 804 442

115-230VAC Input, 12/24V output, 20VA

ECT-523 804 332

K02-540 Rückseite

Klemmensatz

FSP-150 FSP-340 Fan Speed Control Module

PT5-07M Pressure Transmitter with Cable Plug Assembly PT4-Mxx

ECT-323 ECT-523


D A T A S H E E T

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Technical Data Input and Output Configuration Power supply 24VAC ± 10% 50/60Hz Class II EC2- 512 552 Power consumption EC2-512 4VA max Pressure transmitter inputs

EC2-552 20VA max 24VDC, 4…20mA 2 2 Plug-in connector size Removable screw version Digital inputs

wire size 0.14 … 1.5mm2 Volt free contact 3 2 Communication TCP/IP Ethernet (EC2-xx2) 5V / 0,1mA Display 2½ digits red LED Discharge temperature

-199 to +199 with decimal point thermistor 1 Switchable between bar, °C & °F Output relays 4 indicator LEDs Inductive (AC15) 250V / 2A

Temperature Resistive (AC1) 250V / 8A 2 storage -20 … +65°C Resistive (AC1) 250V / 6A 4 operating 0 … +60°C Output Triacs

Humidity 0 … 80% r.h. non condensing 24VAC 0,1…1A 1 Protection class IP 65 (front protection with gasket) Analogue output Weight ~ 150g 0…10VDC 3mA max 1

Mounting Panel mount (71 x 29mm cutout) Communication Ethernet 10Mbit/sec.

Marking

Wiring Diagrams

EC2-552

EC2-512


D A T A S H E E T

EC2-5_35056_EN_R03.doc 8 / 8 21.12.2009

Physical Dimensions

EC2-5x2 Controllers

Transformers

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 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.

Emerson Electric GmbH & Co OHG ALCO CONTROLS Postfach 1251 Heerstraße 111 D-71332 Waiblingen Germany Phone ...49-7151-509-0 Fax ...49-7151-509-200 www.emersonclimate.eu

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