Technical Data 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. Three Condensing Unit Controller versions are available: EC2-552: For Copeland Digital Scroll compressors EC2-542: 2 compressors with variable fan speed control EC2-512: 2 compressors with fan cycling of 2 fans Features EC2 Series EC2-552 Features 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 Alco Controls FSP Series Fan Speed Power Modules EC2-542 Features Suction pressure control for up to 2 single stage compressors Variable fan speed condensing pressure control with Alco Controls FSP Series Fan Speed Power Modules EC2-512 Features Suction pressure control for up to 2 single stage compressors Condensing pressure control with fan cycling of up to 2 fixed speed condenser fans 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 Separate inputs for compressor serial control loops, common input for fan motor control loop, except EC2-552 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 EC2-5x2 Series Condensing Unit Controller 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 Typical ordering package (EC2-542) EC2-542 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 PT4-07S Suction Pressure Transmitter PT4-30S Condensing Pressure Transmitter 2 x PT4-L15 cable for PT4 Pressure Transmitters Selection Table TCP/IP Ethernet Description Type Order Nr. Condensing Unit Controller 1 Digital Scroll Compressor, 1 Single Stage Compressor, Variable Fan Speed Control with FSP Condensing Unit Controller 2 Single Stage Compressors, Variable Fan Speed Control with FSP Fan Speed Power Module Condensing Unit Controller 2 Single Stage Compressors, 2 Fixed Speed Fans EC2-552 807 738 EC2-542 807 735 EC2-512 807 732 EC25e35056.doc Rev.: 00 1 / 8 Date: 27.01.2006
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 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 Alco Controls 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 EC2-542 can control 1 or 2 single stage compressors and features variable fan speed control as described above in the EC2-552. 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 are described in the functional diagrams below: EC2-552 The Alco Controls PT4 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. Standard Scroll 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 PT4 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 Alco Controls FSP Fan Speed Power Module. The control algorithm for condensing pressure is generating a proportional transfer characteristic: P1 100% 0% 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. EC25e35056.doc Rev.: 00 2 / 8 Date: 27.01.2006
EC2-542 control loop as described in the EC2-542. Condensing pressure is modulated by turning fan motors on and off. excess dead band demand The application of the EC2-542 is very similar to the EC2-552, but without the continuous modulation capabilities of the Copeland Digital Scroll compressor. A dead band control loop controls suction pressure by turning compressors on and off. excess dead band demand setpoint suction pressure No change occurs as long as the suction pressure remains within the dead band around the suction pressure setpoint. The controller will add/remove compressor capacity when the suction pressure goes beyond the limits of the suction pressure dead band. To minimize compressor wear, minimum compressor run times and minimum compressor off times as specified by compressor manufacturers should be applied. Both can be set in the EC2 Series. Another feature of the EC2 is the default compressor run time equalization. However, if desired, run time equalization may be disabled and a base load compressor can be allocated or the FILO mode (First In Last Out) may be applied. 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 EC2-542. As above, the PT4 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 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 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 ±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 in C to F. The display unit 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. - Locally with the infrared remote control. 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. 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 of the controller. EC25e35056.doc Rev.: 00 3 / 8 Date: 27.01.2006
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. A rolling graph with the pressure and temperature data over a period of approximately 10 minutes can be displayed: All WebPages, which allow the change of controller parameters, are password protected. Below is the example for the setpoint configuration WebPage of an EC2-542 Controller. All setpoints can be easily reviewed and modified if needed: 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 EC2-542, imported in Microsoft Excel : Alarm / maintenance functions EC2 Series 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. EC25e35056.doc Rev.: 00 4 / 8 Date: 27.01.2006
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: 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 pluggedin 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 EC2-542, K02-540 Rear side Accessories Terminal Kits and Cables for EC2 Series Type Order Nr. Terminal Kit for EC2-552 and EC2-542 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 6.0m cable length FSP-L15 FSP-L30 FSP-L60 804 693 804 694 804 695 FSP-150 FSP-340 Fan Speed Control Module Pressure Transmitter Cable Assembly for PT4-0.8 7bar 0 18bar PT4-07S PT4-18S 802 320 802 322 0 30bar PT4-30S 802 324 0 50bar PT4-50S 802 326 1.5m cable length 3.0m cable length 6.0m cable length PT4-L15 PT4-L30 PT4-L60 804 593 804 594 804 595 PT4-07S Pressure Transmitter with Cable Plug Assembly PT4-Lxx EC25e35056.doc Rev.: 00 5 / 8 Date: 27.01.2006
Accessories (cont'd) Transformer Class II 230VAC Input, 24V 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 EC2-IRE Remote Control Transformer ECT-523 Technical Data Input and Output Configuration Power supply 24VAC ± 10% 50/60Hz Class II EC2-512 542 552 Power consumption EC2-512 & 542 4VA max Pressure transmitter inputs EC2-552 20A max 24VDC, 4 20mA 2 2 2 Plug-in connector size Removable screw version Digital inputs wire size 0.14 1.5mm 2 Volt free contact 3 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 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 1 Mounting Panel mount (71 x 29mm cutout) Communication Ethernet 10Mbit/sec. EC25e35056.doc Rev.: 00 6 / 8 Date: 27.01.2006
Wiring Diagrams EC2-552 EC2-542 EC2-512 EC25e35056.doc Rev.: 00 7 / 8 Date: 27.01.2006
Physical Dimensions EC2-5x2 Controllers Transformers ECT-523 73 58 4354 76 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 cannot assume any liability for results obtained or damages occurred due to improper application. This document replaces all former 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.ecopeland.com/alcoliterature.cfm Benelux Denmark & Finland Eastern Europe Français Deutschland Italia Middle East & Africa Poland Russia & Cis España & Portugal Sweden & Norway UK & Ireland Phone: +31 (0)77 324 0 234 +44 (0) 1635 876 161 +32 (0)87 305 061 +33 (0)4 78 66 85 70 +49 (0)6109 6059-0 +39 02 961 781 +97 148 832 828 +48 (0)22 458 9205 +7 095 981 9811 +34 93 41 23 752 +44 (0) 1635 876 161 +44 (0) 1635 876 161 Fax: +31 (0)77 324 0 235 +44 (0) 1635 877 111 +32 (0)87 305 506 +33 (0)4 78 66 85 71 +49 (0)6109 6059 40 +39 02 961 788 888 +97 148 832 848 +48 (0)22 458 9255 +7 095 981 9816 +34 93 41 24 215 +44 (0) 1635 877 111 +44 (0) 1635 877 111 EC25e35056.doc Rev.: 00 8 / 8 Date: 27.01.2006