Installation and Owner Man u al

T H R E E P H A S E Evaporator Fan Control System Installation and Owner Man u al

WARNING The installation of this device should be done only by competent personnel, experienced in electrical wiring, and familiar with electrical codes. Contact with lethal voltages is possible during installation. 2 Frigitek Three Phase Evaporator Fan Control System

Contents Overview... 4 Features... 4 Configuration... 5 The Controller Module... 5 The Power Unit... 6 The Speed Control Module... 6 The Signal Sensing Tee... 7 System Diagram... 8 Installation... 9 Power Wiring... 9 Power Unit Connection Diagram... 10 Speed Control Module Connections... 11 Interconnection Wiring... 11 Daisy-Chain Wiring... 11 Daisy-Chain Wiring Diagram... 12 Signal Wiring... 13 Tee Signal Sensor Installation... 13 Ice Sensors... 14 Operating the Frigitek... 15 Circulation Enhancement... 16 Testing the Frigitek... 16 Observing Frigitek Operation... 17 Evaporator Fans... 17 Frigitek Options... 17 Troubleshooting... 18 Evaporator Fans Run Backwards... 18 Indicator Light Matrix... 18 Scotchlok Connectors... 19 ScotchLok Crimp-on Connector Diagram... 20 Specifications... 21 Three Phase System... 21 Signal Sensing Tee... 21 Frigitek Limited Warranty... 22 Installation and Owner Man u al 3

Overview The Frigitek is the embodiment of a simple concept. It senses the status of the refrigeration system (cooling or idle), and adjusts the speed of the evaporator fans accordingly. If the refrigeration system is actively cooling, the fans are operated at their normal high speed. If the system is idle, the fans are slowed to approximately 20% of high speed. This saves energy used to operate the fan motors and reduces the amount of heat the motors inject into the cooled space. The net effect is a dramatic reduction in the cost of operating the refrigerator. The Frigitek concept is patented, and the method of reducing the speed of three-phase motors is patent pending (03/04). The concept is applicable to both refrigerators and freezers, but, for readability, in the rest of this manual, we will only refer to refrigerators. Features The Three-Phase Frigitek has a number of design features which are mostly invisible in operation, but may be of interest to technical personnel. Soft-Start: When power is first applied to the system, the Frigitek starts the fan motors in low speed mode, providing a soft-start of the motors. Soft-starting the fan motors reduces the stress of the start-up surge which normally occurs when motors are powered on. See also Phase Fault Sensing. Low Power Line Pollution: The method of slowing the motors is unique to the Frigitek (and is patent-pending as of March, 2004). This method results in very low sine-wave distortion, and virtually zero high-frequency pulses on the power line. Because of the low power line noise, no special filters are needed between the Frigitek and the power line. Low Motor Stress: The speed-control method used in the Frigitek is very motor-friendly, and causes no extra stress on motor windings. Standard-duty motors may be used with the Frigitek. There is no need to use special motors, as is the case with many Variable Speed or Variable Frequency Drives. 4 Frigitek Three Phase Evaporator Fan Control System

Phase Fault Sensing: If one phase of the three-phase input power is dropped, the Frigitek will immediately disconnect the fan motors from the power source. This will prevent the motors from burning up because of a dropped phase. When the dropped phase is restored, the Frigitek will automatically re-start the motors in low speed mode. Configuration The Three-Phase Frigitek consists of four components: The Controller Module The Controller Module contains the circuitry to sense the status of the refrigeration system, and command the Frigitek into high or low speed. It also has indicators which reflect the status of the Frigitek. On the top is a switch which sets the Frigitek system to Operate or Bypass mode. On the left side is a recessed pushbutton which turns on the Circulation Enhancement feature, which is described later. The controller is typically mounted low on a wall of the refrigerator in some convenient location where it is easily visible and connected to the Power Unit(s) by a 5-wire low-voltage cable. The Controller Module Installation and Owner Man u al 5

The Power Unit The Power Unit contains the power switching components which operate the fans at high or low speed. It also has circuitry to sense evaporator coil icing and a dropped phase. Power units may be daisy-chained to allow one Controller module to control and monitor multiple evaporator coils with multiple Power Units. The Power Unit is typically mounted on the wall of the refrigerator, near the evaporator coil The Power Unit which it controls. The original fan power wiring is re-connected so that it routes through the Power Unit. Associated with the Power Unit is the Speed Control Module, described next. The Speed Control Module The Speed Control Module contains the elements which are used to reduce the speed of the fan motors. Each Speed Control Module is specifically sized for the horsepower of the motors connected to its associated Power Unit. The module is a sealed unit, and cannot be opened or modified. It is connected to the Power Unit by means of six wires. Having the Speed Control module as a separate unit allows very flexible installation of the power components of the Frigitek. As mentioned before, the Power Unit and the Speed Control Module are associated together, and mounted near each other in some convenient The Speed Control Module 6 Frigitek Three Phase Evaporator Fan Control System

manner. Typically, a length of flexible electrical conduit is used to bring the wires from the Speed Control Module to the Power Unit. The Signal Sensing Tee The Tee unit is used to sense the status of the refrigeration system (cooling or idle). It is wired into a circuit which is carrying current when the refrigerator is cooling, and which is de-energized when the system is idle. Typically, this is the thermostat/solenoid circuit which gates the refrigerant into the evaporator, but other sensing points may be used as well. The Tee is connected to the Controller, and the Controller uses the Tee signal to command the Power Unit(s) into high or low speed. Tees are available in two models: Standard and High Current. The Standard Tee, which is normally supplied with a Frigitek, is designed to sense currents between 0.02 A and 2.0 A, at 120 or 240 VAC. A special High Current Tee is available for situations where the current to be sensed exceeds 2.0 A. The High Current Tee is designed for 0.5 A to 20 A, 120 or 240 VAC, and must be specially ordered from ECE. The Tee and a solenoid valve Installation and Owner Man u al 7

System Diagram Existing Thermostat Tee Sensor Controller Module Controller Cable Three Phase Power from Breakers Power Unit 1 Daisy- Chain Cable Power Unit 2 To more Power Units Speed Control Module 1 Speed Control Module 2 Fan Motors Ice Sensor Fan Motors Ice Sensor Solenoid Valve Evaporator 1 Solenoid Valve Evaporator 2 To more Evaporators 8 Frigitek Three Phase Evaporator Fan Control System

Installation IMPORTANT Turn off the cooling system power and check to see that no voltage is present before beginning work! Select the locations where the Controller, Power Unit and Speed Control Module will be mounted. Typically, the Controller will be mounted at or above eye level, near a door, where it can be easily observed. The Power Unit and Speed Control Module will be mounted near or on the evaporator which they will be controlling. If installation on the evaporator case is not convenient, you may want to consider a wall-mounting location. Pay attention to the need for some flexible conduit to carry the three-phase power wiring to the Power Unit, and from the Power Unit to the evaporator fans. Fasten the units to the selected locations. Power Wiring The Power Unit is wired into the power lines which feed the fan motors. Typically there will be a fan power disconnect switch on or near the evaporator coil which will be controlled by the Power Unit. The connections from the bottom of the disconnect box will now be wired to the input terminals (1-2-3) inside the Power Unit. The three wires which connect to the fans, and were originally connected to the disconnect box, are wired to the output terminals (1-2-3) inside the Power Unit. Flexible conduit should be used to convey the wires to and from the Power Unit. There is a wiring chart inside the door of the Power Unit which indicates the correct power connections. This diagram is also shown on page 10. Installation and Owner Man u al 9

Power Unit Connection Diagram 10 Frigitek Three Phase Evaporator Fan Control System

Speed Control Module Connections The Speed Control Module may be mounted wherever convenient near the Power Unit. It is connected to the Power Unit by means of six wires, which should be run through flexible conduit. The wires are connected inside the Power Unit, to the A-B-C terminals. Be sure that the same color wires connect to each pair of corresponding terminals for example, the two red wires connect to the two A terminals. It will be necessary for the installer to attach crimp-on terminals (provided with the unit) to the wires before attaching the wires inside the Power Unit. This allows the installer to adjust the length of the wires as necessary for the installation. Interconnection Wiring The Power Unit(s) and the Controller are connected by a fivewire low voltage cable. The cable is to be attached to the block labeled Controller inside the Power Unit in accordance with the chart inside the Power Unit door. At the Controller, the cable is spliced to the 5-wire pigtail which is permanently attached to the Controller, using the Scotchlok crimp-on connectors supplied with the system. It is not necessary to strip the individual wires in order to use the crimp-on connectors. Insert the two same color wires into one connector, and crimp it tightly closed. Daisy-Chain Wiring Multiple Power Units may be connected into the system, so that one Controller is operating multiple evaporator fan units. Typically, in a large refrigerator, one thermostat will control some number of evaporators. The Frigitek system is designed so that the Controller, which is sensing one thermostat, can also control the same multiple evaporators which the thermostat controls. Multiple Power Units are connected via the Daisy-Chain terminals inside the Power Units, using a low-voltage cable similar to the one which is used between the Power Unit and the Controller (although only four wires are used). The following chart shows the daisy-chain wiring sequence. Installation and Owner Man u al 11

Daisy-Chain Wiring Diagram Controller Module Controller Connector Power Unit First Power Unit Must have the Ice-In and Fault-In jumpers removed Daisy-Out Connector Daisy-In Connector Controller Connector Power Unit Intermediate Power Unit(s) Must have the Ice-In and Fault-In jumpers removed Daisy-Out Connector Daisy-In Connector Controller Connector Power Unit Last Power Unit Must have the Ice-In and Fault-In jumpers installed Daisy-Out Connector Daisy-In Connector 12 Frigitek Three Phase Evaporator Fan Control System

Signal Wiring The following two sections describe installation of the signal sensor Tee, and the Ice Sensor(s). The Tee and the Ice Sensor wires should be secured so they are protected from damage and from moisture. Clips are provided to attach the wires to the lip of the evaporator pan. The lip of the pan which is away from the fan blades is recommended for routing of the wires. Tees are available in two models: Standard and High Current. The Standard Tee, which is normally supplied with a Frigitek, is designed to sense currents between 0.02 A and 2.0 A, at 120 or 240 VAC. A special High Current Tee is available for situations where the current to be sensed exceeds 2.0 A. The High Current Tee is designed for 0.5A to 20 A, 120 or 240 VAC, and must be specially ordered from ECE. Tee Signal Sensor Installation The Tee is usually installed on the solenoid which gates the refrigerant into the evaporator coils. There is often a spare knockout hole on the side of the solenoid cover into which the Tee can be installed. If that is inconvenient, the Tee can be installed into the same knockout hole which is already being used for the solenoid wiring, and the original wiring rerouted through the third leg of the Tee. In some installations, the Tee must be installed in a circuit which carries more than two Amperes of current, such as a compressor wire. In this case, the High Current Tee must be used. This Tee must be specially ordered from ECE. For installation in the solenoid circuit, remove one of the wire nuts connecting the solenoid wires, separate the wires and re-connect each of the two wires to one of the Tee wires, thus putting the Tee in series with the solenoid wiring. IMPORTANT DO NOT wire the Tee in parallel with the solenoid. To do so will destroy the Tee, and could cause an electrical short circuit. The Tee and a solenoid valve Installation and Owner Man u al 13

WARNING The power for the solenoid may not come from the same circuit breaker which supplies the evaporator fans! Check to be sure the solenoid power is off before connecting the wires. Insert the two-pin connector on the cable labeled Signal Sensor into the mating connector on the Tee. Run this cable to the Controller module. IMPORTANT Do not run the sensor cable in conduit with any power wires. Connect the sensor cable to the two-wire cable coming out of the back of the Controller, using two of the Scotchlok connectors supplied. Be sure to crimp the Scotchlok connectors tightly closed. See the Scotchlok information presented later in this manual. If the third leg of the Tee is used for wiring, remove the hole plug and screw in the cable clamp supplied. Ice Sensors The Power Unit has special circuitry inside to detect icing of the evaporator coils. Each Power Unit can have two Ice Sensors attached, to monitor two different coils (if the Power Unit is handling two evaporators), or two locations on the same coil. Each Power Unit comes with one Ice Sensor in the box. If a second Sensor is needed, please contact ECE. The Ice Sensor is a standard feature, of the Frigitek, and should only be installed in systems where the thermostat setting is above freezing (32 F), and where there is no defrost system. It should never be used in freezers. Ice Sensors are installed by inserting the black Sensor tip between the evaporator coil fins, from the air inlet side of the coil. The location should be near the center of the coil in the area where frost will normally first begin to accumulate. The other end of the Ice Sensor cable is connected to the Ice Sensor connection inside the Power Unit. Either Ice Sensor connection may be used. Run the cable into the Power Unit through one of the gray cable feed-through fittings near the top of the Power Unit case. Connect the two Ice Sensor wires to terminals A and C on the three-terminal Ice Sensor connector. These wires are not 14 Frigitek Three Phase Evaporator Fan Control System

polarity sensitive, and may be connected either way. Remove the adjacent two-pin jumper to enable the sensor circuitry to operate normally. Note that the Ice Sensor is shipped from the factory with a ten foot cable attached. If this cable needs to be longer, you may use any good quality, waterproof cable to extend it. If the Ice Sensor detects frost, the Power Unit will keep the fans at high-speed, and leave them at high speed, regardless of the status of the cooling system, until the evaporator coil temperature is sensed to be higher than 32 F. Use of the Ice Sensor can somewhat reduce the amount of savings which the Frigitek can provide, if the evaporator coils regularly frost up. For maximum savings, keeping the evaporator coils clean of blockage by dust or debris, or raising the box thermostat temperature a degree or two can prevent frosting up, and let the Frigitek control the fans normally. When the Power Unit is in high speed because of frost, the Ice Light on the front of the unit will be illuminated, as well as the Ice Light on the Controller. Ice detected by one Power Unit will only cause that unit to operate at high speed, even if more Power Units are daisy-chained together. Operating the Frigitek The Controller has a bypass switch on the top, near the left side. This switch turns the Frigitek ON (right position) or OFF (left position). If the Frigitek is off, the evaporator fans are returned to full-time operation at their original, high speed. When the Controller is connected to a Power Unit, and the Power Unit has power applied, the Power Light will always be illuminated. The controller draws its power (20 VDC) from the Power unit to which it is attached. The Hi Speed Light will be illuminated when the Frigitek senses that the refrigeration system is in cooling mode, and has switched the fans to high speed, and will be off when the fans are at low speed. The Ice Light will be illuminated if any of the Power Units connected to the Controller are operating at high speed because of evaporator icing. The Fault Light indicates a fault condition somewhere in the system. Maintenance personnel should be notified if this light is on. Installation and Owner Man u al 15

The Bypass Light is on whenever the switch on the top of the Controller is set to the OFF position. All Power Units will switch to high speed if the Controller is in Bypass Mode. Each Power Unit has a panel of LEDs and switches to allow local monitoring and control of the Power Unit. The Power light will be on anytime power is applied to the Unit. The High Speed light will be on any time the Unit is in High Speed mode, whether under Controller command, or because the attached Ice Sensor is sensing a temperature below 33 F. The Ice Light will also be on if the Ice Sensor is sensing a temperature below 33 F. The Bypass switch allows local switching of the Power Unit to high speed, without affecting other units in the system. If the Unit is set to bypass locally, the Fault light on the Controller will blink, to indicate that the Unit is out of normal service. Circulation Enhancement On the left side of the Controller, there is a small silver cap, which may be removed with fingernails or a small screwdriver. With the silver cap removed, a red button will be visible inside the Controller. This button is used to activate the Circulation Enhancement feature. The Circulation Enhancement feature may be activated if some extra stirring of the air is desired while the system is in low speed mode. With this feature turned on, the evaporator fans will be operated at high speed for approximately one minute every ten minutes, while the Frigitek is in low speed mode. With Circulation Enhancement activated, the Hi Speed Light on the front of the Controller will blink, even while the fans are at high speed because of Circulation Enhancement. However, when the system switches to normal high speed, because of the Tee signal, the Hi Speed Light will be continuously on, as normal. Testing the Frigitek To test a newly-installed Frigitek, first pull the ice sensor(s) out of the coil(s). Warm the thermostat (do not re-adjust it!) to put the refrigeration system in cooling mode. The Frigitek should switch the fans to high speed. Then unplug the two-pin connector at the Tee. After about 60 seconds the Frigitek should switch to low speed. Next, put the Ice Sensor(s) back into the coil(s). The Frigitek should 16 Frigitek Three Phase Evaporator Fan Control System

again switch to high speed as the Ice Sensor detects that the coil is below 33 F. Re-connect the Tee cable, and the Frigitek will be ready for normal operation. Observing Frigitek Operation In most refrigerators, it is normally difficult to observe when the refrigeration system is cooling, and when it is idle. The Frigitek makes this cycling visible, because of its control of the evaporator fan speed. When the thermostat calls for cooling, the Frigitek will switch the fans to high speed, and continue to run them at high speed as long as cooling is called for. The green Hi Speed Light on the Controller is on during this period. When the thermostat switches the cooling system to idle mode, the Frigitek will continue to run the fans at high speed for approximately an additional 60 seconds, then switch to low speed. This delay allows the system to purge refrigerant from the evaporator coils, and helps prevent icing. If a problem is detected in the system, the Fault Light on the Controller will be illuminated, and the fans will be switched to high speed. If an Ice Sensor on a Power Unit detects that the coils are below 33 F, the fans on that Power Unit will operate at high speed, but the Controller Hi Speed Light will be off. Evaporator Fans In some refrigerators, after the fans switch to low speed with the Frigitek installed, the evaporator fans may run slower than expected This is an indication that the supply voltage may be too low for the Frigitek model supplied. Frigitek Options An optional System Monitor connection is available for the three-phase Frigitek. The Monitor allows the facilities monitoring system to monitor the operation of the Frigitek, and record statistics on its cycling. This feature must be factory installed. Installation and Owner Man u al 17

Troubleshooting The ECE web site (www.frigitek.com) provides a list of problems which others have encountered, and offers solutions and explanations for them. This list is an on-going effort, and your participation in helping to keep it up-to-date is appreciated. If you encounter a problem not described on the web site, please call our toll-free number for assistance: 877-522-6924. Evaporator Fans Run Backwards A common problem encountered after installation of the Frigitek is that the evaporator fans run backwards. If this happens, it is because two of the three-phase wires are swapped. Simply swap any two of the three-phase power wires. This may be done at the input or the output terminals of the Frigitek, or at the disconnect box on the evaporator fan unit. Indicator Light Matrix The following sections describe the meanings of the indicator lights on the Controller Module and on the Power Unit. Controller Power light ON Five-wire cable not connected, or improperly connected. Fuse in first Power Unit blown. First Power Unit not connected to 3-phase power, or power not turned on. High Speed light ON Tee signal present, system in high speed mode. High Speed light OFF No Tee signal, system in low speed mode. High Speed light BLINKING Circulation Enhancement Mode turned on. Ice light ON One or more Power Units are sensing ice. Fault light ON One or more Power Units are in bypass mode, or has a fault condition. Bypass Light ON The switch on top of the Controller is in bypass mode, and all Power Units are operating at high speed. 18 Frigitek Three Phase Evaporator Fan Control System

Power Unit Power light OFF Unit not connected to 3-phase power, or power not turned on. High Speed light ON Controller has commanded high speed, or Power Unit has sensed ice. High Speed light OFF Controller has commanded Unit to low speed mode, and the Unit is not sensing ice. Controller cable is disconnected, or improperly connected. Ice light ON The Power Unit is sensing ice, and has switched to high speed. Fault light ON The Power Unit is in bypass mode, or has a fault condition. Scotchlok Connectors Scotchlok connectors make the connecting or extending of the signal cables used between various Frigitek modules very easy. There is no need to strip the wires before crimping them in the connector. Just push the two wires into the two sides of the connector, and evenly crimp the top tightly down using pliers. Two metal blades inside the connector pierce the wires insulation, and make an electrical bridge between the wires. At the same time, a special sealant covers the contact points, to keep out any moisture. The Scotchlok connectors are made by 3M company, and Scotchlok is a registered trademark of 3M. Installation and Owner Man u al 19

ScotchLok Crimp-on Connector Diagram ScotchLok Crimp-on Connector Insert wires fully. DO NOT strip wires. Crimp cap completely closed, all the way around. Connector Diagram Black Wires Brown Wires White Wires Control Cable To Controller Control Cable To Power Unit Red Wires Green Wires 20 Frigitek Three Phase Evaporator Fan Control System

Specifications Three Phase System Input Voltage: 208 VAC, 240 VAC, 460 VAC Voltage Type: Three phase, 60 Hz, Wye or Delta Maximum Operating Current: 20 A Signal Sensing Tee Standard: 02 A 2.0 A, 120/240 VAC High Current: 0.5 A 20 A, 120/240 VAC Installation and Owner Man u al 21

Frigitek Limited Warranty The Frigitek Three-Phase Evaporator Fan Controller is warranted for five (5) years from the date of purchase against defects in materials and workmanship. Under this warranty, Energy Control Equipment, Inc. (Manufacturer) will repair or replace failed modules, at its option, and at no charge, with new or refurbished units, if a module is found to be defective during the limited warranty period specified above. All replaced parts become the property of Manufacturer and must be returned to Manufacturer. Replacement parts assume the remaining original warranty, or ninety (90) days, whichever is longer. Manufacturer authorized representatives must perform all warranty service, unless otherwise authorized by Manufacturer. To obtain warranty service, purchaser must first contact Manufacturer for problem determination and service procedures. This warranty is subject to the following conditions and exclusions: Coverage This limited warranty covers manufacturing defects in materials and workmanship encountered in normal use of this equipment and, as determined by Manufacturer, shall not apply to the following, including, but not limited to: damage which occurs in shipment; applications or uses for which this equipment was not intended; failures or problems which are caused by products or equipment not supplied by Manufacturer; accidents; misuse; abuse; neglect; faulty or improper application or installation; fire; water; lightning or other acts of nature; alteration of the equipment; improper voltage supply or load; electrical fluctuations or surges; damage caused by unauthorized installation, improper installation, or improper removal and reinstallation of the equipment; damage caused by failure to follow instructions; improper or unauthorized repair; cosmetic damage or equipment with altered serial numbers; use of non-manufacturer or unauthorized parts, consumables, accessories or equipment which damage the equipment or result in service problems; failures or problems due to incompatibility with other equipment. 22 Frigitek Three Phase Evaporator Fan Control System

Limits and Exclusions There are no express warranties other than those listed and described above, and no warranties whether express or implied, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose, shall apply after expiration of the express warranty period stated above. No other warranty or guaranty given by any person, whether an employee or representative of Manufacturer or not, shall be binding upon Manufacturer. Manufacturer shall not be responsible for incidental or consequential damages or loss of revenue or profits resulting from the use of this product, any failure of this product, misuse or inability to use this product, failure to achieve expected savings or other benefits, or arising out of any breach of this Warranty, even if Manufacturer has been advised of the possibility of such damages, losses or failures. No recovery of any kind against Manufacturer shall be in an amount greater than the purchase price of the equipment alleged to be responsible for claimed damage, sold by the manufacturer. Without limiting the foregoing, purchaser assumes all risk and liability for loss, damage or injury to purchaser, purchaser s goods and property, and to others and their property, arising out of the use, misuse or inability to use this equipment sold by Manufacturer, said loss, damage or injury not caused directly by negligence of Manufacturer. This limited warranty shall not extend to anyone other than the original purchaser of the equipment, is not transferable, and states the purchaser s exclusive remedy. Note: Because some states do not allow the exclusion of limitation of liability for consequential or incidental damages, the above stated liability limitations may not apply to the purchaser. In such states, Manufacturer s liability is limited to the greatest extent permitted by law. Installation and Owner Man u al 23

316 Locust Street Watsonville, CA 95076 TOLL FREE 877.522.6924 PHONE 831.768.8848 FAX 831.768.8818 www.frigitek.com Copyright, May, 2004, ECE., Inc.