Emerson EC3 Series, EC3-812 Operating Instructions Manual

EC3-812 Dual Circuit Rack Controller

Note: This document contains short form instructions for experienced users. Use last column in List of Parameters to document your individual settlings. More detailed information can be found in the User Manual.

The EC3-812 dual circuit rack controller is a digital controller for racks in commercial refrigeration applications. The controller is designed for split suction systems with a common discharge side. Typically the suction side consists of the combination of a Low Temperature (LT) rack and a Medium Temperature (MT) rack. The LT rack can consist of up to 3 single stage compressors and the MT rack of up to 4 single stage compressors. For the two controllers, the control target is to maintain the suction pressure at a defined value by varying the available compressor capacity. For the measurement of the two suction pressures, two PT4 pressure sensors with 4 – 20 mA interface can be connected to the controller. The rack controller has seven relays outputs to activate the compressors. Eight digital inputs for 24V AC/DC or 230V AC and four digital inputs for 24V AC/DC are available, seven for compressor serial alarm, two for low pressure alarm, one for high pressure alarm, one for oil level alarm and one for refrigerant level alarm. To control the discharge end temperature of compressor from LT rack, three temperature inputs are available. Two analogue outputs 0 to 10 V are available to control the first compressor of MT and LT rack with an inverter. The optional display can show values with a decimal point in the range between -19.9 and +19.9 otherwise without decimal point. An IR receiver for the optional IR remote control unit is build in. The supply voltage is 24 VAC. Transformers for 230V or 110V mains supply are available as options.

Safety instructions:

• Read installation instructions thoroughly. Failure to comply can result in

device failure, system damage or personal injury.

• The product is intended for use by persons having the appropriate

knowledge and skills.

• Ensure electrical ratings per technical data are not exceeded.

• Disconnect all voltages from system before installation.

• Keep temperatures within nominal limits.

• Comply with local electrical regulations when wiring

•

Operating Instructions

Technical Data

EC3 Series Controller

Power supply 24VAC ±10%; 0.5A; 50/60Hz; Class II

Power consumption 20VA max.

Communication TCP/IP Ethernet 10MBit/s

Plug-in connector size Removable screw terminals

Temperatures:

storage

operating Humidity 0…80% r.h. non condensing Protection class IP20 Inputs Feedback failure contact for compressor B1 to B3 and

Switch

Temperature sensor inputs

Pressure transmitter inputs

Outputs

ECD-000 Display Unit

Power Supply From EC3 via connecting cable

Display 2½-digit red LED with decimal point

LED indicators Controller 1, Controller 2, p bar, Alarm, IR status

Temp. & Humidity Identical to EC3 specifications above

Protection class IP65 (front protection with gasket)

Connecting cable ECC-N10 (1m), ECC-N30 (3m), ECC-N50 (5m) or

6.3mm spade earth connector

wire size 0.14 … 1.5 mm

-20 … +65°C 0 … +60°C

A1 to A4, low-pressure alarm contact A, low-pressure alarm contact B, high-pressure alarm contact, oil level alarm contact and refrigerant level alarm contact 8 x 24V AC / DC or 230V AC

4 x 24V AC/DC NTC ( 1M at 25°C for temperature input 1 to 4:

discharge temperature; 10K at 25°C for temperature input 5 and 6)

2 x 24VDC, 4...20mA

8 x Relays SPDT

= 8A res (2A), VAC max = 250V :

max

Compressor relays B1 to B3, A1 to A4

reversible between °C and °F

CAT5 cable with RJ45 connectors

Mounting

The EC3 can be mounted onto a standard DIN rail.

The ECD-000 can be mounted in panels with a 71x29 mm cutout. See dimensional drawing below for space requirements including rear connectors. Push controller into panel cutout. (1) Make sure that mounting lugs are flush with outside of controller housing Insert allen key into front panel holes and turn clockwise. Mounting lugs will turn and gradually move towards panel (2) Turn allen key until mounting lug barely touches panel. Then move other mounting lug to the same position (3) Tighten both sides very carefully until display is secured. Do not over tighten as mounting lugs will break easily.

EC3-812_65118_EN_R00.doc Replacement for R- 1 / 5 PCN: 864916 18.03.2009

EC3-812 Dual Circuit Rack Controller

Electrical Installation

Refer to the electrical wiring diagram (below) for electrical connections. A copy of this diagram is labeled on the controller. Use connection wires/cables suitable for 90°C operation (EN 60730-1). Ground the metal housing with a 6.3mm spade connector. Important: Keep controller and sensor wiring well separated from mains wiring. Minimum recommended distance 30mm.. Warning: Use a class II category transformer for 24VAC power supply (EN 60742). Do not ground the 24VAC lines. We recommend to use one transformer per EC3 controller and to use separate transformers for 3 controllers, to avoid possible interference or grounding problems in the power supply. Connecting any EC3 inputs to mains voltage will permanently damage the EC3.

Setup and Parameter Modification Using the Keypad of the ECD-000

For convenience, an infrared receiver for the optional IR remote control unit is build-in, enabling quick and easy modification of the system parameters when a computer interface is not available. Alternatively, the parameters can be accessed via the 4-button keypad. The configuration parameters are protected by a numerical password. The default password is “12”. To select the parameter configuration:

• Press the PRG button for more than 5 seconds

A flashing “0” is displayed

• Press or until 12 is displayed; (password)

• Press SEL to confirm password

The first modifiable parameter code is displayed (/1). To modify parameters see Parameters modification below.

Parameter Modification: Procedure

• Press or to show the code of the parameter that has to be changed;

• Press SEL to display the selected parameter value;

• Press or to increase or decrease the value;

• Press SEL to temporarily confirm the new value and display its code;

• Repeat the procedure from the beginning "press or to show..."

To exit and save the new settings:

• Press PRG to confirm the new values and exit the parameters modification

procedure.

To exit without modifying any parameter:

• Do not press any button for at least 60 seconds (TIME OUT).

• Press “ESC” on IR remote control.

Wiring Diagram (controller label)

Operating Instructions

party

Special Functions:

The Clear Alarm function has been replaced by the Special Functions mode. The Special Functions can be activated by:

Press

and together for more than 5 seconds.

A flashing “0” is displayed.

or until the password is displayed (default = 12). If password was

Press changed, select the new password. Press SEL to confirm password A “0” is displayed and the Special Function mode is activated.

or to select the function. The number of special functions is dynamic

Press and controller dependent. See list below. Press SEL to activate the function without leaving the special function mode. Press PRG to activate the function and leave the special function mode. Most of the Special Functions work in a toggle mode, the first call activates the function, and the second call deactivates the function. The indication of the function can only be displayed after exiting the special function mode.

• 0: Display test function

• 1: Displays the current TCP/IP address

• 2: Set the controller's TCP/IP address to 192.168.1.101 (default value). This

change is only temporary. A power down will reset the previous address.

• 3: Resets all parameters to the factory default setting. The controller will

indicate “oF” during the reset.

Display of Data:

The data to be permanently shown on the display can be selected by the user (parameter /1). In case of an alarm, the alarm code is displayed alternately with the selected data. The user can inhibit the alarm code. It is possible to temporarily display these values. This is a useful feature when initially setting-up the system without the aid of the LON interface. Press the SEL button to scroll through all possible displayable data. The display will show for one second the numerical identifier of the data (see /1 parameter) and then the selected data. After two minutes the display will return to the by parameter /1 selected data. This action is only valid when parameter H2 = 3.

Controller 1 LED IR LED Compressor A4 on

Service LED

Controller 2 LED

Pressure LED

Alarm LED

Compressor B3 on Compressor A1 on

Compressor B2 on Compressor A2 on

Compressor B1 on Compressor A3 on

EC3-812_65118_EN_R00.doc Replacement for R00 2 / 5 PCN: 864916 18.03.2009

EC3-812 Dual Circuit Rack Controller

Operating Instructions

List of Parameters

/ DISPLAY PARAMETERS

/1 Value to show 0 4 - 0

0 = compressors states (controller 1 and controller 2)

1 = suction pressure 1 (bar) 2 = saturation temperature from suction pressure 1 (°C) 3 = suction pressure 2 (bar) 4 = saturation temperature from suction pressure 2 (°C)

CONTROLLER C1 (LT) SET-POINT PARAMETERS (C1)

Suction setpoint -1 50.0 bar 3.0

P0 P1 Suction band 0.0 50.0 bar 2.0 P3 Suction recovery min -9.9 50 bar -9.9 P4 Suction shift (0=disabled, 1=enabled) 0 1 - 0 P5 Suction shift max 0.0 3.0 bar 3.0 P8 Discharge recovery max -9.9 50.0 bar 50.0 P9 Discharge recovery step 0.0 5.0 bar 1.0

t TIME PARAMETERS (C1)

t0 Integration time 300 990 10 sec* 600 t1 Suction request on time 0 990 10 sec* 30 t2 Suction request off time 0 990 10 sec* 30 t3 Compressor min on time 0 990 10 sec* 180 t4 Compressor min off time 0 990 10 sec* 420 t5 Compressor cycle rate

(0=number of switching unrestricted)

A ALARM-PARAMETERS (C1)

A0 Alarm delay LP 0 990 10 sec* 0 A1 Alam delay HP 0 990 10 sec* 0 A2 Suction warning min -1.0 50.0 bar 1.0 A3 Suction warning max -1.0 50.0 bar 6.0 A4 Warning delay suction min 0 990 10 sec* 0 A5 Warning delay suction max 0 990 10 sec* 0 A6 Maximum discharge end temperature 50 150 °C 120 A7 Discharge end temp. alarm delay 0 990 10 sec* 30 A8 Alarm delay serial alarm 0 990 10 sec* 0 A9 Compressor service interval 0 990

u STEP ENABLE PARAMETERS (C1)

u0 Comp service interval reset 0 5 - 0

0 = do nothing

1 = reset operating time compr. 1

2 = reset operating time compr. 2 u1 Compr.1 enable (0=disable, 1=enable) 0 1 flag 1 u2 Compr.2 enable (0=disable, 1=enable) 0 1 flag 1 u3 Compr.3 enable (0=disable, 1=enable) 0 1 flag 1

APPLICATION PARAMETERS (C1)

c1 Number of compressors 1 3 - 3 c3 Control mode 0 3 - 2

(0 = P mode, 1 = PI mode, 2 = dead band mode, 3 = binary mode)

c4 Compressor 1 control mode 0 2 - 0

0 = in standard control loop,

1 = act as base load compressor, c5 Compressor rotation 0 1 flag 0

0 = FILO logic (First In, Last Out) 1 = FIFO logic (First In, First Out)

c6 Sensor fail (number of compressors in

case of sensor failure) h0 Discharge pressure

0 = not available; 1 = available

r SENSOR PARAMETERS (C1)

r0 Suction sensor 1 0% -1.0 50.0 bar -0.8 r1 Suction sensor 1 100% -1.0 50.0 bar 7 r2 Suction sensor 1 offset -1.0 1.0 bar 0.0 r3 Refrigerant 0 7 - 3

0 = R 22

1 = R 134a

2 = R 507

* Unit on ECD-000 data entry. EMS allows data entry in sec. ** Unit on ECD-000 data entry. EMS allows data entry in 1000hr *** Unit on ECD-000 data entry. EMS allows data entry in hr

EC3-812_65118_EN_R00.doc Replacement for R00 3 / 5 PCN: 864916 18.03.2009

3 = R 404A 4 = R 407C 5 = R 410A

6 = R 124 7 = R 744

Min Max Unit Def. Custom

0 199 1/hr 199

10 000

hr**

3 = reset operating time compr. 3 5 = reset operating time all

compressors

2 = act as modulating capacity; 0…10V for inverter command

0 3 - 0

0 1 flag 1

F MODULATING PARAM. (C2)

F0 Compressor INV setpoint -1.0 50.0 bar 3.0

valid only for dead band control (c3 = 2),

not valid for P (c3 = 0) and PI control (c3 = 1); with P/PI control the modulating set-point is the P0 parameter

F1 Compressor INV band 0.0 50.0 bar 2.0

valid only for dead band control (c3 = 2),

not valid for P (c3 = 0) and PI control (c3 = 1);

with P/PI control the modulating pressure band is the P1 parameter F2 Compressor INV min speed 0.0 100.0 % 0.0 F3 Compressor INV max speed 0.0 100.0 % 100

Min Max Unit Def. Custom

CONTROLLER C2 (MT)

SET-POINT PARAMETERS (C2)

P0 Suction setpoint -1 50.0 bar 3.0 P1 Suction band 0.0 50.0 bar 2.0 P3 Suction recovery min -9.9 50 bar -9.9 P4 Suction shift (0=disabled, 1=enabled) 0 1 - 0 P5 Suction shift max 0.0 3.0 bar 3.0 P8 Discharge recovery max -9.9 50.0 bar 50.0 P9 Discharge recovery step 0.0 5.0 bar 1.0

t TIME PARAMETERS (C2)

A ALARM-PARAMETERS (C2)

A0 Alarm delay LP 0 990 10 sec* 0 A1 Alarm delay HP 0 990 10 sec* 0 A2 Suction warning min -1.0 50.0 bar 1.0 A3 Suction warning max -1.0 50.0 bar 6.0 A4 Warning delay suction min 0 990 10 sec* 0 A5 Warning delay suction max 0 990 10 sec* 0 A8 Alarm delay serial alarm 0 990 10 sec* 0 A9 Compressor service interval 0 990

10 000 hr**

u STEP ENABLE PARAMETERS (C2)

u0 Comp service interval reset 0 5 - 0 u1 Compr.1 enable (0=disable, 1=enable) 0 1 flag 1 u2 Compr.2 enable (0=disable, 1=enable) 0 1 flag 1 u3 Compr.3 enable (0=disable, 1=enable) 0 1 flag 1 u4 Compr.4 enable (0=disable, 1=enable) 0 1 flag 1

APPLICATION PARAMETERS (C2)

c1 Number of compressors 1 4 - 4 c3 Control mode 0 3 - 2 c4 Compressor 1 control mode 0 2 - 0 c5 Compressor rotation 0 1 flag 0 c6 Sensor fail 0 3 - 0 h0 Discharge pressure 0 1 flag 1

r SENSOR PARAMETERS (C2)

r0 Suction sensor 1 0% -1.0 50.0 bar -0.8 r1 Suction sensor 1 100% -1.0 50.0 bar 7 r2 Suction sensor 1 offset -1.0 1.0 bar 0.0 r3 Refrigerant 0 5 - 4

F MODULATING PARAMETERS (C2)

F0 Compressor INV setpoint -1.0 50.0 bar 3.0 F1 Compressor INV band 0.0 50.0 bar 2.0 F2 Compressor INV min speed 0.0 100.0 % 0.0 F3 Compressor INV max speed 0.0 100.0 % 100

H OTHER PARAMETERS

H2 ECD Display access 0 3 - 3

0 = all disabled (Caution, access to

controller only via TCP/IP network

possible)

H3 IR access code 0 199 - 0 H5 Password 0 199 - 12 Note: Concerning the indicated parameters, it is recommended to check, before

installing, if the factory value is suitable for the required use

1= Keyboard enabled 2= IR remote control enabled 3= Keyboard and IR control enabled

Alarm Codes

HP General alarm HP

Controller 1 + 2: High pressure signal from digital input

LP General alarm LP

Controller 1 + 2: Low pressure signal from digital input

hP Limit violation suction side

Controller 1 + 2: Suction pressure higher than the maximum limit

lP Limit violation suction side

Controller 1 + 2: Suction pressure lower than the minimum limit

EP Sensor failure suction side

Controller 1: Suction pressure sensor 1 failure Controller 2: Suction pressure sensor 2 failure

Ed Sensor failure condenser

Controller 1 + 2: Discharge pressure sensor failure

Fr Fast recovery suction low

Controller 1 + 2: Fast recovery from low suction pressure

hr Fast recovery condensing

Controller 1 + 2: High discharge pressure recovery

d1 Discharge temperature alarm 1

Controller 1: discharge end temperature associated with compressor B 1 is to high

d2 Discharge temperature alarm 2

Controller 1: discharge end temperature associated with compressor B 2 is to high

d3 Discharge temperature alarm 3

E1 Feedback alarm 1

E2 Feedback alarm 2

E3 Feedback alarm 3

E4 Feedback alarm 4

n1 Service alarm compressor 1

n2 Service alarm compressor 2

n3 Service alarm compressor 3

n4 Service alarm compressor 4

oL Oil receiver level alarm

rL Refrigerant level alarm

Er Data error - out of range

Controller 1: discharge end temperature associated with compressor B 3 is to high

Controller 1: Digital input associated with compressor B1 has changed into alarm state (safety chain) Controller 2: Digital input associated with compressor A1 has changed into alarm state (safety chain)

Controller 1: Digital input associated with compressor B2 has changed into alarm state (safety chain) Controller 2: Digital input associated with compressor A2 has changed into alarm state (safety chain)

Controller 1: Digital input associated with compressor B3 has changed into alarm state (safety chain) Controller 2: Digital input associated with compressor A3 has changed into alarm state (safety chain)

Controller 2: Digital input associated with compressor A4 has changed into alarm state (safety chain)

Controller 1: Compressor B1 operating time higher than run limit Controller 2: Compressor A1 operating time higher than run limit

Controller 1: Compressor B2 operating time higher than run limit Controller 2: Compressor A2 operating time higher than run limit

Controller 1: Compressor B3 operating time higher than run limit Controller 2: Compressor A3 operating time higher than run limit

Controller 2: Compressor A4 operating time higher than run limit

Controller 1: Oil level detection from digital input

Controller 1: Refrigerant level detection from digital input

Data send to the display is out of range

EC3-812 Dual Circuit Rack Controller

Operating Instructions

Messages

--- No data

The display will show an “---” at node start up, when no data is send to the display or when the display is disabled.

In Configuration data initialization

The display will show an “In” when the configuration data are initialized with the factory default values.

Id Wink request received

The display will show a flashing “Id” when the wink request was received. The node will receive the flashing “Id” will be shown on the display until the service button will be pressed, or a 30 min delay timer will expire or a second wink request.

oF Offline

The node is offline: no application is running. This is the result of a network management command an will happen

- -- --- Controller disabled, waiting for restart After a major change of the configuration parameter, the rack controller 1 and 2 are disabled for 20 seconds. After this delay the controllers restart automatically. The rack controller 1 and 2 are disabled (with object status or with the network variable nviContEnable[0] and nviContEnable[1]).

EC3-812_65118_EN_R00.doc Replacement for R00 4 / 5 PCN: 864916 18.03.2009

EC3-812 Dual Circuit Rack Controller

Visualising Data: WebPages

A TCP/IP Controller-Readme file is available on the www.emersonclimate.eu website to provide detailed information about TCP/IP Ethernet connectivity. Please refer to this file if you need information beyond the contents of this instruction sheet. The EC3-812 has a TCP/IP Ethernet communication interface enabling the controller to be directly connected to a PC or network via the standard Ethernet port. The EC3-812 controller has embedded WebPages to enable the user to easily visualise the parameter lists using real text labels. No special software or hardware is required. Connect the EC3-812 using the optional ECX-N60 cable assembly to a network or hub that enables the controller to receive a dynamic TCP/IP address. If a DHCP server is not available, the controller can be connected to a computer using a crossover cable plugged directly into the Ethernet port. In this case, the TCP/IP address of the computer must be manually modified to be compatible with the default address of the controller. Refer to the TCP/IP Controller-Readme file for more details. Open the Internet browser program on the computer and enter the default TCP/IP address of the controller into the address line of the Internet browser:

192.168.1.101 or the dynamic address from the DHCP server. Refer to the TCP/IP Controller-Readme file if a specific port is required.

After a few moments, the default monitoring page should be displayed. If the browser does not open the default page or display active data, the user should check the Internet browser “Option” configuration. Refer to the TCP/IP Controller-Readme file.

Operating Instructions

The Monitoring and Alarm WebPages are read only and therefore it is not necessary to enter a username or password. A username and password will be requested upon the initial request to any of the other WebPages.

The factory default settings are :

Username: EmersonID Password : 12

The default settings may be modified in the Display configuration page. Press the tabs at the top of the Monitoring page with a left click of the mouse button to enter the respective Webpage. The parameters will be visualised in real text together with the program code as defined in the parameter list below. After the parameters have been modified, the complete list of settings can be saved to the memory of the computer and used later to upload into another controller. This can save a considerable amount of time when using multiple controllers and over a period of time, a library can be created containing the parameter lists for equipment for different applications. It is also possible to display live graphical data from the controller. In addition, a permanent 30 days log file containing the control temperature at 15 minutes intervals is stored in the non-volatile memory to be later transferred using FTP to the computer. The log file can be imported into a standard spreadsheet program such as Excel. Refer to the TCP/IP Controller-Readme file for a complete description of the features available for the TCP/IP series of controllers

Die in dieser Dokumentation enthaltenen Informationen basieren auf technischen Daten und Versuchen, die EMERSON als zuverlässig ansieht und die den Regeln der heutigen Technik entsprechen. Da die genauen Umstände der Anwendung EMERSON nicht bekannt sind, können wir für Ergebnisse bzw. Schäden, die auf unsachgemäße Anwendung zurückzuführen sind, keine Verantwortung

übernehmen. Bei allen Leistungs- und Maßangaben ist Irrtum ausdrücklich vorbehalten. Typen-, Modell-, Maß- und Konstruktionsänderungen können ohne Vorankündigung erfolgen. Dieses Dokument ersetzt alle Vorgängerversionen.

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

EC3-812_65118_EN_R00.doc Replacement for R00 5 / 5 PCN: 864916 18.03.2009

Emerson EC3 Series, EC3-812 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual