Russell Surveillant Installation Manual
HT-SUI-0313A
Surveillant
Demand Defrost
Evaporator Control
Installation and Operations Manual
Page 2
EvaporatorControl
Installation Instructions
Introduction
The Surveillant Evaporator Control is an electronically operated
evaporator controller engineered to save energy in refrigeration
systems through precise control of superheat, space temperature, fan cycling, reducing compressor runtime, and implementing demand defrosts. Surveillant was designed to be used in
Surveillant - Controls and Communicates
CONTROLS: COMMUNICATES:
TEV/EEV
Surveillant Evap. Control
single and multiple evaporator installations, with a payback
period of two years*, and a life expectancy that matches that of
the system. Once the controller pays for itself, it continues to pay
dividends for the life of the system.
*based on utility rate of $.09/kWh
Locally on site
or
Remotely via the Internet
Room
Temperature
Evaporator
Fans
Compressor/
Liquid Line
Solenoid
Defrost
Heaters
Multiple
Alarms
ENTER
Table of Contents
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
Installation & Wiring . . . . . . . . . . . . . . . . . . . Page 3 - 9
Figure1: Installation Locations . . . . . . . . . . . . . . Page 3
Figure 2: Return Air Sensor Placement . . . . . . . . . Page 3
Figure 3: Proper Sensor Location . . . . . . . . . . . . . Page 4
Figure 4: Sensor Positioned to Touch Circuit Tubes . Page 4
Figure 5: Proper Sensor Positioning . . . . . . . . . . . Page 4
Figure 6: Evaporator E ciency Diagram . . . . . . . . Page 6
Figure 8: Wiring Schematic - New Install . . . . . . . . .Page7
Figure 9: Wiring Schematic - with Contactor Box . . . Page 8
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . Page 9
Figure 10: Dimensions . . . . . . . . . . . . . . . . . . . Page 9
Mounting the Controller . . . . . . . . . . . . . . . . . Page 10
Controller Setup . . . . . . . . . . . . . . . . . . . . . . Page 10
Table 1: Introduction Mode . . . . . . . . . . . . . . . Page 10
Adjusting Controller Parameters . . . . . . . . . . Page 10-15
Table 2: Navigation Through Controller Parameters Page 11
Table 3: Controller Menus and Menu Parameters Pgs. 12-14
Variables Menu . . . . . . . . . . . . . . . . . . . Page 12
Alarm Status Menu . . . . . . . . . . . . . . . . . Page 12
Manual Menu . . . . . . . . . . . . . . . . . . . . Page 12
Setpoint Menu . . . . . . . . . . . . . . . . . Page 14 & 15
Table 4: Defrost Defaults . . . . . . . . . . . . . . . . . Page 13
Communication . . . . . . . . . . . . . . . . . . . . . . . Page 13
Table 5: Ethernet Speci cations Summary . . . . . . Page 13
Speci cations . . . . . . . . . . . . . . . . . . . . . . . . Page 13
2 5
Smart Gate
RB201 1UAS-2HND-IN
POE GIGABIT ETHERNET
USB
SFP
ETH1 ETH5ETH3 ETH4ETH2 ETH6 ETH10ETH8 ETH9ETH7
ABC Contracting
MODIFY
(888)555-3358
Room Temp
Coil Temp
Cool
BACK
-8.5 F
Defrost
Dig Input 1
Dig Input 2
Off
Closed
Superheat
Suct Pressure
Suct Temp
0.0 F
96.2 F
FAST ETHERNET
1 2 3 4 5
6 7 8 9 10
STATUS
CompressorOnSystem Mode
Evaporator Fan
All Clear
Off
15.4 F
Dig Input 3
Aux Temp
Dis
Dis
Dis
Sat Temp
Valve Position
46.0 F
Manual
87.7 F
PC
Smart Phone
Internet
ABC Contracting
MODIFY
(888)555-3358
Room Temp
Coil Temp
Cool
-8.5 F
15.4 F
Defrost
Dig Input 1
Dig Input 2
Off
Closed
Dis
Superheat
Suct Pressure
Suct Temp
0.0 F
96.2 F
87.7 F
Tablet
STATUS
CompressorOnSystem Mode
Evaporator Fan
All Clear
Off
Dig Input 3
Aux Temp
Dis
Dis
Sat Temp
Valve Position
46.0 F
Manual
EvaporatorControl
Installation Instructions
Page 3
Location
Surveillant Evaporator Control was developed with ease of installation in mind. The controller is supplied in an enclosure,
with encapsulated electronics to protect the circuitry from
moisture damage. This extra level of protection allows the controller to be installed in the refrigerated space.
When installing the controller, it may either be mounted on
an interior/exterior wall or on the evaporator. Many evaporators have su cient space to install the controller on the face of
evaporator or on its housing. Locating the controller as close to
the evaporator as possible reduces the amount of wiring when
converting existing systems, as well as when it is applied on new
applications.
Alternatively, users may nd it bene cial to install the controller
in a location providing easy access -- on the wall or near the entrance. This enables the user to easily view the display, and eliminates the need to use a ladder or lift to modify the setpoints or
check alarms.
If viewing the temperature outside the walk-in or refrigerated
room is desirable, Surveillant may be used as a digital thermostat. The controller is then installed near the door of the space
Figure 1. Installation Locations
On the evaporator
2
2
ENTER
BACK
On the wall
2
2
ENTER
BACK
for easy viewing of the room temperature and/or system status.
See Figure 1 for locations.
If installing the controller on the face of the evaporator, preexisting knockouts on the evaporator should be used for installing
the high voltage wiring. If knockouts do not preexist, hole(s)
may be carefully cut into an unobstructed area of the evaporator case. If modifying the face of the evaporator is not feasible
or desired, the controller’s conduit knockouts may be used with
½ inch conduit.
The bottom side of the controller includes a cutout with cable
tie slots providing a strain relief for the low voltage and sensor
wires. Additional knockouts are available on either side if conduit is preferred.
Installation & Wiring
The Surveillant Evaporator Control is supplied with pluggable
connectors for all connections. Pluggable connectors permit
the controller to be placed in a safe location while the wiring is
installed. They also simplify the wiring, allowing the wires to be
fastened to the screw terminals in the open air. Once all wiring
is completed using accepted wiring practices, it is plugged into
the controller prior to nal mounting.
Although there is one pressure transducer and four temperature sensor inputs, when used with mechanical valves (TEVs),
Surveillant only requires the (3) sensors supplied with the kit.
One sensor reads the return air temperature and the other two
measure the coil temperature. NOTE! Sensor location is critical
to the proper operation of the controller.
Return Air Temperature Sensor - The air temperature sensor is
installed in the return air of the evaporator using the included
sensor mount. Most applications allow the sensor mount to
be installed using an existing screw. On evaporators where using an existing screw is not possible, the included self-tapping
screw may be used to secure the sensor mount to the evaporator. Note: Be careful to avoid damage to an evaporator tube
or causing a leak in the drip pan. When installing, it is important to prevent the air sensor from coming into contact with the
mounting bracket, cable ties, or any other solid material. Figure
2 shows an example of how to mount the sensor. The sensor
must be a minimum of 6 inches from the coil surface.
Figure 2 - Return Air Sensor Placement
At the entrance
>6”
Air
Sensor
2
ENTER
BACK
Return Air
Page 4
e
EvaporatorControl
Installation Instructions
After the sensor is installed, route the wire back to the controller location. When routing sensor wire, it is important to avoid
interference from high voltage lines. If sensor wire is run parallel
to the high voltage, there is a potential for inductance to a ect
the sensor reading. This is of particular concern with long wire
runs. When extending sensors, use the 18 gage, shielded twisted pair. Sensor wires can be run beyond 100 feet when using 18
gage twisted shielded pair. After the wire has been successfully
routed, it may be connected to the pluggable terminal on the
controller.
Coil Temperature Sensor - A
ler, it is essential the sensor is located at the coldest point on
the evaporator coil for optimal operation. The coil sensor is an
integral part of the control algorithm used to determine coil ef ciency, to initialize defrosts, and to terminate defrosts.
s a critical input to the control-
Determine the coil sensor location
To determine the most appropriate sensor location, when
arriving on site, put the system into defrost. The location
where frost is last to disappear is where the coil sensor
should be placed. Monitor both the air entering side, as well as
the air exiting side, of the evaporator coil. Don’t be surprised if
the last place for frost to disappear is on the air exiting side. It is
usually near the right or left end of the coil.
Steps to Ensure Proper Coil Sensor Location
For more robust installations, it is recommended that two coil
sensors are used, located as described above. Typically the coldest spot is on the side of the suction header/expansion valve
side of the evaporator. Select two places that are the last to defrost, preferably at each end of the evaporator.
Figure 3 - Proper Sensor Location
Locate sensor approx.
ocat
1-1/2” from end, in the
bottom third of coil
Figure 4 - Sensor Positioned to Touch Two Circuit Tubes
More often than not on coils, the location of the sensor is a short
distance from the end, approximately 1 to 1-1/2” away from the
right and left edges of the active coil surface. The ice tends to
grow from these edges towards the center. Therefore, the sensor location is best situated approximately 1 to 1-1/2” from the
outer edges and typically near the bottom 1/3rd portion of the
evaporator. The sensor needs to be as far away from the defrost
heat sources as possible. See Figure 3.
Locating the sensor too close to the elements will cause false
defrost termination temperatures. It is important to note, the
most active portion of the sensor is the rst 1/2” of the 1-1/2”
long stainless steel probe. As a result, it is important to touch
two circuit tubes. When inserting the sensor into the coil, the tip
should touch one of the circuit tubes. This location is appropriate for the sensor. Figure 4 shows the proper sensor position.
When choosing the location, the sensor should not be located
adjacent to the electric heating elements. The sensor should be
approximately half the distance between the heaters if possible.
Insert the probe into the ns approximately 1/16” deeper than
the stainless shielding of the probe. Pinch the two ns gently
together to secure the sensor in place. This provides the thermal
ballast to ensure a complete defrost every time. See Figure 5.
Figure 5 - Proper Sensor Positioning
EvaporatorControl
Installation Instructions
Page 5
It is important to verify all heating elements are working
properly.
Due to the many factors in uencing the evaporator performance, it is impossible to provide the proper location of every
installation. However, the coil sensor is an integral part of the
control algorithm used to determine coil e ciency to initiate, as
well as, terminate defrosts. The coldest point in the coil can be
identi ed from existing system knowledge or by monitoring the
normal operation.
Controller Power - The high voltage wiring is protected by a
metal shield fastened to the back side of the controller. The
shield should be removed to gain access to the wiring connections, making note of the location of the fasteners. The screws in
the upper corners are coarse thread screws, while the screw in
the middle is a 4-40 machine screw.
The controller accepts either 120V or 208/240V incoming power.
The controller includes metal oxide varistors (MOVs), providing
protection from voltage spikes. MOVs use the same technology
commonly applied to protect consumer electronics. They function by ltering out voltages high enough to damage the board.
When the voltage exceeds the allowed amount, the MOVs short
to ground, protecting the circuitry. For additional protection,
the board has a replaceable BK/MDL-1/4 fuse in line. The grey
plug is accessible without removing the metal shield in the fuse
holder. Depress slightly and turn 1/4 turn counterclockwise to
remove. Replace by depressing slightly and turning 1/4 turn
clockwise. Do not overtighten.
The board uses a pluggable screw terminal connector to connect incoming power. The terminal is located in the top right
corner of the controller when the terminals are facing the user.
See Figure 6.
Fan and Defrost Relays - There are 2 larger relays on the controller with spade connectors. These are used for the evaporator
fans and defrost heaters. Due to the spacing of the enclosure
the spades require a 90 degree terminal. Spade connectors (4)
are included to assist in wiring the relays.
Compressor/Liquid Line Solenoid Relay - The compressor relay is rated at 3A inductive at 240V. This relay uses the 3-position
pluggable screw terminal to make the connection to the board.
The relay is not intended to control the compressor directly. It is
designed to be used to control the liquid line solenoid or as a pilot to the compressor contactor. One leg of the incoming power
supply (L1) should be connected to COM terminal of the compressor relay, the upper of the two smaller relays. The remaining
leg, (L2), should be connected to one lead on the solenoid/compressor contactor. The remaining lead, should be connected to
the normally open (NO) position on the terminal.
Auxiliary Relay - The auxiliary relay is rated at 3A inductive at
240V. This relay uses the 3-position pluggable screw terminal
to make the connection to the board. The relay may be connected to a variety of devices. One leg of the incoming power
supply (L1) should be connected to COM terminal of the auxiliary relay, the lower of the two smaller relays. The remaining leg,
(L2), should be attached to one lead on the connected device.
The remaining alarm lead, should be connected to the normally
open (NO) position on the terminal.
After all high voltage wiring is completed the metal shield
must be replaced and screws tightened.
Additional Inputs
Suction Temperature Sensor (T1 Auxiliary) - The suction tem-
perature sensor is required when applying the controller with
an electronic expansion valve. The sensor’s proximity to the
evaporator outlet di ers slightly for electronically controlled
valves from the placement of a TEV bulb. Due to the more re ned control from an electronically controlled valve, the sensor must be placed as close to the outlet of the coil as feasible.
Although the distance from the outlet is di erent, the nature
of the refrigerant’s ow through the tube remains unchanged,
thus the orientation of the sensor remains at the 4 or 8 o’clock
position. The sensor should be secured to the suction line using
the included wire ties designed for low ambient operation. In
addition to being con gured as a suction sensor, the T1 input
may also be con gured like the auxiliary sensor.
Evaporator Fan Relay - The fan relay is rated 10A inductive at
240V. One leg of the incoming power (L1) for the fans should
be connected to the COM terminal of the fan relay, the upper
of the two larger relays. The remaining leg, (L2) should be connected to one lead of the fan. The remaining fan lead should be
connected to the NO (Normally Open) terminal on the fan relay.
See Figure 8.
Defrost Heater Relay - The heater relay is rated 20A resistive
at 240V. One leg of the incoming power (L1) for the heaters
should be connected to the COM terminal of the heater relay,
the lower of the two larger relays. The remaining leg, (L2) should
be connected to one lead of the heater. The remaining heater
lead should be connected to the NO (Normally Open) terminal
on the heater relay.
Pressure Transducer - In addition to the suction temperature
sensor, a pressure transducer is also required for superheat
measurement when applying a Hybrid Stepper Valve (HSV). The
pressure tap should be mounted on the top of a horizontal section of tube. It should be located near the suction sensor, approximately 3 inches downstream from the position of the temperature sensor.
Auxiliary Temperature Sensor -The auxiliary temperature sensor provides exibility and may be used for any purpose desired
by the user. The placement of the sensor is dependent on the
requirements of the user’s intended application. The Auxiliary
Temperature sensor must be supplied by HTPG.
Digital Inputs - The controller includes (3) digital inputs. See
Table 3 for con guration options.
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