User Guide
Controller for
temperature control
EKC 202D1
ADAP-KOOL® Refrigeration control systems
Introduction
Application
•The controller is used for temperature control refrigeration appliances in supermarkets
•With many predefined applications one unit will offer you several options. Flexibility has been planned both for new installations and for service in the refrigeration trade
Principle
The controller contains a temperature control where the signal can be received from one or two temperature sensors.
The thermostat sensors are either placed in the cold air flow after the evaporator, in the warm air flow just before the evaporator, or both. A setting will determine how great an influence the two signals are to have on the control.
A measurement of the defrost temperature can be obtained directly through the use of an S5 sensor or indirectly through the use of the S4 measurement. Four relays will cut the required functions in and out – the application determines which. The options are the following:
•Refrigeration (compressor or relay)
•Fan
•Defrost
•Rail heat
•Alarm
•Light
The different applications are described on page 7.
Advantages
•Several applications in the same unit
•The controller has integrated refrigeration-technical functions, so that it can replace a whole collection of thermostats and timers
•Buttons and seal imbedded in the front
•Easy to remount data communication
•Quick set-up
•Two temperature references
•Digital inputs for various functions
•Clock function with super cap backup
Contents |
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Introduction........................................................................................................ |
2 |
Operation............................................................................................................. |
3 |
Applications........................................................................................................ |
7 |
Survey of functions.......................................................................................... |
8 |
Operation........................................................................................................... |
17 |
Menu survey..................................................................................................... |
18 |
Ordering............................................................................................................. |
21 |
Connections...................................................................................................... |
22 |
Data...................................................................................................................... |
23 |
2 |
Manual RS8FL402 © Danfoss 2015-12 |
EKC 202D1 |
Operation
Sensors
Up to two thermostat sensors can be connected to the controller. The relevant application determines how.
A sensor in the air before the evaporator: S3
This connection is primarily used when control is based on area.
A sensor in the air after the evaporator: S4
This connection is primarily used when refrigeration is controlled and there is a risk of a too low temperature near the products.
A sensor before and after the evaporator: S3 + S4
This connection offers you the possibility of adapting the thermostat, the alarm thermostat and the display to the relevant application. The signal to the thermostat, the alarm thermostat and the display is set as a weighted value between the two temperatures, and 50% will for example give the same value from both sensors.
The signal to the thermostat, the alarm thermostat and the display can be set independently of one another.
Defrost sensor: S5
The best signal concerning the evaporator’s temperature is obtained from a defrost sensor mounted directly on the
evaporator. Here the signal may be used by the defrost function, so that the shortest and most energy-saving defrost can take place.
If 2 (x) S5 sensors are required, an S5B sensor can be mounted on the DI1 input. Defrosting will stop when both temperature sensors record a temperature higher than the set defrost stop temperature.
If a defrost sensor is not required, defrost can be stopped based on time, or S4 can be selected.
Change of temperature reference
In an impulse appliance, for example, used for various product groups. Here the temperature reference is changed easily with a contact signal on a digital input. The signal raises the normal thermostat value by a predefined amount. At the same time the alarm limits with the same value are displaced accordingly.
EKC 202D1 |
Manual RS8FL402 © Danfoss 2015-12 |
3 |
Digital inputs
There are two digital inputs both of which can be used for the following functions:
-Case cleaning
-Door contact function with alarm
-Starting a defrost
-Coordinated defrost
-Change-over between two temperature reference
-Retransmission of a contact’s position via data communication
-The DI1 input can receive a signal from an S5B temperature sensor.
Case cleaning function
This function makes it easy to steer the refrigeration appliance through a cleaning phase. Via three pushes on a switch you change from one phase to the next phase.
The first push stops the refrigeration – the fans keep working ”Later”: The next push stops the fans
”Still later”: The next push restarts refrigeration
The different situations can be followed on the display.
On the network a cleaning alarm is transmitted to the system unit. This alarm can be ”logged” so that proof of the sequence of events is provided.
Door contact function
In cold rooms and frost rooms the door switch can switch the light on and off, start and stop the refrigeration and give alarm if the door has remained open for too long.
Overriding of light diagram
(Only for use with circuit diagram 2 in which relay 4 is used to control the light)
By holding the middle button in for four seconds, the light relay will change over to the opposite position. An “-L-” will appear in the display as a conformation.
The override will only apply to the current On or Off period. The next change will follow the planned diagram.
If the light function is set to follow the door function, the override will not be possible and the door function will be followed.
An override cannot be performed if the regulation is stopped by the “Main switch” or “Appliance cleaning function”, or if it is awaiting the "Power up delay”.
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+ |
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°C |
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1 |
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÷ |
+ |
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Fan |
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2 |
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÷ |
÷ |
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Off |
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3 |
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+ |
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°C |
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The middle button is |
The middle button is |
activated here |
activated here |
Planned change via diagram
Position of light relay
4 |
Manual RS8FL402 © Danfoss 2015-12 |
EKC 202D1 |
Defrost
Depending on the application you may choose between the following defrost methods:
Natural: |
Here the fans are kept operating during the defrost |
Electric: |
The heating element is activated |
Brine: |
The valve is kept open so that the brine can flow |
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through the evaporator |
Gas |
Simple defrost |
Start of defrost
A defrost can be started in different ways
Interval: |
Defrost is started at fixed time intervals, say, every |
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eight hour |
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Refrigeration time: |
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Defrost is started at fixed refrigeration time inter- |
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vals, in other words, a low need for |
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refrigeration will ”postpone” the coming defrost |
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Schedule: |
Here defrost can be started at fixed times of the |
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day and night. However, max. 6 times |
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Contact: |
Defrost is started with a contact signal on a digital |
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input |
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Network: |
The signal for defrost is received from a system unit |
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via the data communication |
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S5 temp |
In 1:1 systems the efficiency of the evaporator can |
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be followed. Icing-up will start a defrost. |
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Manual: |
An extra defrost can be activated from the control- |
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ler’s lower-most button |
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All the mentioned methods can be used at random – if just one them is activated a defrost will be started.
Coordinated defrost
There are two ways in which coordinated defrost can be arranged. Either with wire connections between the controllers or via data communication
Wire connections
One of the controllers is defined to be the controlling unit and a battery module may be fitted in it so that the clock is ensured backup.
The controlling unit is the controller with a defrost diagram installed in t1-t6, t11-t16. This is indicated when the “HACCP” symbol lights up in the front.
When a defrost is started all the other controllers will follow suit and likewise start a defrost. After the defrost the individual
controllers will move into waiting position. When all are in waiting position there will be a change-over to refrigeration.
(If just one in the group demands defrost, the others will follow suit. A manual start of the defrost function will only apply to the current controller.).
Defrost via data communication
All controllers are fitted with a data communication module, and via the override function from a gateway/system manager the defrost can be coordinated.
Defrost on demand
1 Based on refrigeration time
When the aggregate refrigeration time has passed a fixed time, a defrost will be started.
2 Based on temperature
The controller will constantly follow the temperature at S5. Between two defrosts the S5 temperature will become lower the more the evaporator ices up (the compressor operates for a longer time and pulls the S5 temperature further down). When the temperature passes a set allowed variation the defrost will be started.
This function can only work in 1:1 systems
If both an S5 and an S5B sensor are used, defrosting will be initiated by the sensor, which detects the lowest temperature.
EKC 202D1 |
Manual RS8FL402 © Danfoss 2015-12 |
Max. 15
5
Night time cover function
The controller has a function that automatically detects when a night time cover has been placed over the refrigeration appliance. This function requires the use of both an S3 and S4 sensor.
When the night time cover is placed over the appliance, heat intake and thus the need for increased cooling are reduced. The temperature difference between S3 and S4 will be reduced, and the controller will change to night operation mode once this difference becomes less than the set difference (night time cover difference).
Example
During day operation there is a temperature difference of e.g. 8K between S3 and S4.
During operating with a night time cover the difference drops to e.g. 3 K.
r75 Cover diff must be set to a value between the two values. In this case, 5.5 k.
This function is not active during the following operating situations:
Interrupted regulation Appliance cleaning Defrosting
Pull-down sequence
If the controller registers a negative difference, it will “see” this as an inversion of the two sensors. It will therefore send the alarm, “S3/S4 inverted”.
This function has no influence on the light function.
Night time cover |
Night |
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placed over |
Night |
time cover |
Removal of |
appliance |
removed |
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time cover |
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night time |
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detected |
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cover detected |
Example of temperature sequence |
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Example of settings: r15 Ther S4% = 100%
r61 Ther S4% Night = 0%
r13 Night setback = 3 K
r75 Cover dif = 5 K
Extra module
•The controller can afterwards be fitted with an insertion module if the application requires it.
The controller has been prepared with plug, so the module simply has to be pushed in
-Battery module
The module guarantees voltage to the controller if the supply voltage should drop out for more than four hours. The clock function can thus be protected during a power failure.
-Data communication
If you require operation from a PC, a data communication module has to be placed in the controller.
•External display
If it is necessary to indicate the temperature on the front of refrigeration appliance, a display can be mounted. The extra display will show the same information as the controller's display, but does not incorporate buttons for operation.
6 |
Manual RS8FL402 © Danfoss 2015-12 |
EKC 202D1 |
Applications
Here is a survey of the controller’s field of application.
A setting will define the relay outputs so that the controller’s interface will be targeted to the chosen application.
On page 18 you can see the relevant settings for the respective wiring diagrams.
S3 and S4 are temperature sensors. The application will determine whether either one or the other or both sensors are to be used. S3 is placed in the air flow before the evaporator. S4 after the evaporator.
A percentage setting will determine according to what the control is to be based. S5 is a defrost sensor and is placed on the evaporator.
DI1 and DI2 are contact functions that can be used for one of the following functions: door function, alarm function, defrost start, external main switch, night operation, change of thermostat reference, appliance cleaning, forced refrigeration or coordinated defrost. See the functions in settings o02 and o37.
Refrigeration control with one compressor |
1 |
The functions are adapted to small refrigeration systems which |
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either may be refrigeration appliances or cold rooms. |
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The three relays can control the refrigeration, the defrost and the |
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fans, and the fourth relay can be used for either alarm function, |
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light control or rail heat control |
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•The alarm function can be linked up with a contact function from a door switch. If the door remains open longer than allowed there will be an alarm.
•The light control can also be linked up with a contact function from a door switch. An open door will switch on the light and it will remain lit for two minutes after the door has been closed again.
•The rail heat function can be used in refrigeration or freezing appliances or on the door’s heating element for frost rooms.
The fans can be stopped during defrost and they may also follow a door switch’s open/close situation.
2
There are several other functions for the alarm function as well as the light control, rail heat control and fans. Please refer to the respective settings.
The connections shown in applications 1, 2 and 3 are the recommended connections if an extra display is not installed.
If an extra display (type EKA 163A) is connected, terminal 21 must be used for the display, and solely for the display.
The remaining connections can be made as follows:
3
S5B
If a defrost sensor is connected to the DI1 input, the sensor must be mounted on terminals 18 and 19.
EKC 202D1 |
Manual RS8FL402 © Danfoss 2015-12 |
7 |
Survey of functions
Function |
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Para- |
Parameter by operation via data |
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meter |
communication |
Normal display |
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Normally the temperature value from one of the two thermostat sensors S3 or S4 or a |
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Display air (u56) |
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mixture of the two measurements is displayed. |
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In o17 the ratio is determined. |
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Thermostat |
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Thermostat control |
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Set point |
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Cutout °C |
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Regulation is based on the set value plus a displacement, if applicable. The value is set |
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via a push on the centre button. |
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The set value can be locked or limited to a range with the settings in r02 and r 03. |
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The reference at any time can be seen in ”u28 Temp. ref” |
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Differential |
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r01 |
Differential |
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When the temperature is higher than the reference + the set differential, the com- |
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pressor relay will be cut in. It will cut out again when the temperature comes down to |
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the set reference. |
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Ref. |
Dif. |
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Setpoint limitation |
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The controller’s setting range for the setpoint may be narrowed down, so that much |
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too high or much too low values are not set accidentally - with resulting damages. |
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To avoid a too high setting of the setpoint, the max. allowable reference value must |
r02 |
Max cutout °C |
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be lowered. |
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To avoid a too low setting of the setpoint, the min. allowable reference value must be |
r03 |
Min cutout °C |
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increased. |
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Correction of the display’s temperature showing |
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r04 |
Disp. Adj. K |
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If the temperature at the products and the temperature received by the controller are |
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not identical, an offset adjustment of the shown display temperature can be carried |
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out. |
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Temperature unit |
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r05 |
Temp. unit |
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Set here if the controller is to show temperature values in °C or in °F. |
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°C=0. / °F=1 |
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(Only °C on AKM, whatever the set- |
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ting) |
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Correction of signal from S4 |
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r09 |
Adjust S4 |
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Compensation possibility through long sensor cable |
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Correction of signal from S3 |
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r10 |
Adjust S3 |
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Compensation possibility through long sensor cable |
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Start / stop of refrigeration |
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r12 |
Main Switch |
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With this setting refrigeration can be started, stopped or a manual override of the |
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outputs can be allowed. |
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1: Start |
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Start / stop of refrigeration can also be accomplished with the external switch func- |
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0: Stop |
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tion connected to a DI input. |
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-1: Manual control of outputs allowed |
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Stopped refrigeration will give a ”Standby alarm”. |
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Night setback value |
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r13 |
Night offset |
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The thermostat’s reference will be the setpoint plus this value when the controller |
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changes over to night operation. (Select a negative value if there is to be cold ac- |
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cumulation.) |
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Selection of thermostat sensor |
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r15 |
Ther. S4 % |
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Here you define the sensor the thermostat is to use for its control function. S3, S4, or a |
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combination of them. With the setting 0%, only S3 is used (Sin). With 100%, only S4. |
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Activation of reference displacement |
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r39 |
Th. offset |
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When the function is changed to ON the thermostat differential will be increased by |
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the value in r40. Activation can also take place via input DI1 or DI2 (defined in o02 or |
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o37). |
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Value of reference displacement |
r40 Th. offset K |
The thermostat reference and the alarm values are shifted the following number of |
|
degrees when the displacement is activated. Activation can take place via r39 or input |
|
DI |
|
8 |
Manual RS8FL402 © Danfoss 2015-12 |
EKC 202D1 |
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