Zero Zone Kelvin II Installation Manual

SD-324

Sporlan Kelvin II
Refrigeration Controller

User’s Manual, November 2009

Page 1

1

24 VAC

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

19

36

35

34

33

32

31

30

29

28

27

26

25

24

23

22

21

20

24 VAC

N/C

N/C

N/C

N/C

N/C

Ground

RS-485 A+

RS-485 B-

N/C

N/C

N/C

Load

Line

N/C

N/C

N/C

N/C

N/C

N/C

T3-

T3+

T2-

T2+

T1-

T1+

PWR

Room

Tout

RS485

Valve

LL Sol

N/C

Pressure

Aux

SER, SEI, SEH ESX

Red Black

Green Red

White Yellow

Black Orange

N/C Gray

Black

Green

White

+5VDC

Ground

Sense

Description

The Kelvin II is a standalone superheat controller. The Kelvin
II may be connected with a MODBUS master or a Network
Master to give remote access to pressure and temperature
readings in addition to viewing and editing the controller’s
setpoints. The user can also take advantage of the easy to use
local display or a Remote Display to accomplish the same
tasks.

1. Kelvin II Configuration

Specifications

n Input Voltage: 24 VAC (± 10%), 40 VA minimum to board

with external transformer

n Operating ambient temperature: -40°F to 120°F
n LED: One Power LED
n Communications: 1 RS485 Port, 1 USB port

(Not operational)

n 4 Digit 7 segment display
n Inputs:

– Optical Encoder (Knob)
– One Pressure Input
– Three Temperature inputs

n Valve Control of all Sporlan Electric Expansion Valves

“EEV”

n 3 amp Solid State Relay for Liquid Line Solenoid Kelvin II

w/o Local Display

n 1 amp Solid State Relay for Liquid Line Solenoid Kelvin II

w/Local Display

2. Kelvin II Connections

The Kelvin II has screw terminals on the each side of the
controller. The controller should be wired as follows and as
shown in Figure 1.

Figure 1

Item Wire (line)

Power

Valve

RS-485

Liquid Line Solenoid

Auxiliary Temperature Sensor
(Displayed menu item: S-3)

Room Temperature Sensor
(Displayed menu item: CtP)

Coil Out Temperature Sensor
(Display option: tout)

Pressure Transducer
(Displayed menu item: SucP)

24VAC 1
24 VAC 2
SEI, SER, SEH ESX —
N/C Gray 4
Black Orange 5
White Yellow 6
Green Red 7
Red Black 8
Ground 13
A+ 14
B- 15
Line 19
Load 20

T3

T2

T1

Sense (WHITE) 33
Ground (GREEN) 34
+5 VDC (BLACK) 35

Kelvin II

connect point

27
28
29
30
31
32

3. Kelvin II Display

Upon the rst power-up from Sporlan, the Kelvin II will en­ter the setup menu. This menu allows the user to set some
critical setpoint values, seen in Table 1, before the controller
will operate. These critical values can be set via the local or
remote displays, MODBUS, or Network Master. (Note: Only
the Valve Type and Refrigerant have to be set via MODBUS
or Network Master for the controller to operate) Once these
values are entered the Kelvin II will then begin its control. If
the setup menu is displayed on the local or remote displays

Page 2

and the user sets these values via MODBUS then the Kelvin
II will automatically leave the setup menu.

Table 1 Setup Menu

Displayed Menu Item Description Selections

StEP

rEFr

PtYP

un_T

un_P

Valve Type 1596, 3192, 2500, 6384, 400

Refrigerant

Pressure Sensor Type gAUg, AbSL

Temperature Units FAHR, CELS

Pressure Units PSI, BAR

r22, 134A, 402A, 404A,
407A, 407C, 410A, 417A,
r507, 422d, r744, 245F

After setup, the Kelvin II defaults to showing the Superheat
value. The user can then turn the knob to view the other pro­cess values of their system. The screen will alternate between
the process values identity and value alternating every 3 sec­onds. For ease of use, the value that is displayed for a process
value may come in the form of text to eliminate the need of
‘looking up the meaning’. The menu text and meanings for
process values are described in Table 2.

The user may also view/edit the setpoints by pressing the knob
and holding it down for 5 seconds. The user is then prompted
for a password to verify his credentials. The knob should be
rotated up to ‘111’ for the password. If the password is cor­rect the user may change the setpoints to the value he desires
in order to obtain optimum system performance. The menu
text and meanings for setpoint values are described in Table 3.
Setpoints are saved to the controller when the user leaves the
Setpoint menu by pressing the knob when “ESC” is shown.
The setpoint menu has a timeout of 60 seconds for inactiv­ity. When this timeout is reached the controller goes back to
showing the process values and does not save any setpoints
that might have been changed. If the user is in the Manual
Valve Position setpoint then this timeout length is 60 minutes.
As long as the controller does not time out the 60 minutes,
Setpoints are saved to the controller when the user leaves the
Setpoint menu by pressing the knob when “ESC” is shown.

All process values and setpoints are accessible1 through the
local and remote displays.

Table 2 Process Value Menus

Displayed Menu Item Description Range

SuPH
SucP
tSAt
tout
CtP
PoSn
S-3
rELA

StAt

ALS

Superheat 0 to 165°F, 0 to 91.6°C
Suction Pressure
Saturation Temperature -60 to 150°F, -51.1 to 65.6°C
Suction Temperature -60 to 150°F, -51.1 to 65.6°C
System Temperature -60 to 150°F, -51.1 to 65.6°C
Valve Position 0 to 100% Open
Auxiliary Temperature
Solenoid Status dEng, Eng

System Cycle Status

Alarm Status

4

0 to 150 PSI, 0 to 10.34 Bar

2

-60 to 150°F, -51.1 to 65.6°C

Current cycle and manual

3

valve position state
noAL or all active alarms

Table 3 Setpoint Menu

Displayed

Menu

Item

ESC

SHSP

rEFr

d_On
dOFF

d_St

CtSP

H_oP

C_in

Cout

HiCP
SUPS

-P-

-I-

-d-

StEP

SPoS

nEt

Addr

un_P
un_T

PtYP

CaLP

CLt1

CLt2

CLt3

CAdr

Description Range

Escape and save
settings

Superheat Setpoint 0 to 45°F, 0 to 25°C 8

Refrigerant

Delay On 0 to 60 seconds 0
Delay Off 0 to 60 seconds 0
Delay Percent Open

of Valve
Cut-out Suction

Pressure
Maximum Operating

Pressure

Cut-in Temperature

Cut-out Temperature

Max Valve Capacity 20 to 100% 100
Supermarket Setting OFF, ON OFF
Proportional

Coefficient
Integral Coefficient 0 to 100 25
Derivative

Coefficient

Valve Type

Manual Valve
Position

Network Type
(MODBUS or
Network Master)

MODBUS/Network
Master Address

Pressure Units PSI, BAR PSI
Temperature Units FAHR, CELS FAHR
Pressure Sensor

Type
Pressure Sensor

calibration value
Tout calibration

value

Ctp calibration value

S-3 calibration value

Controller Display
Address

— —

r22, 134A, 402A,
404A, 407A, 407C,
410A, 417A, r507,
422d, r744, 245F

0 to 100 percent 0

4

PSI,

0 to 150

4

4

4

Bar

PSI,

Bar

0 to 10.3
0 to 150

0 to 10.3

-60 to 125°F,

-51.1 to 51.6°C

-60 to 124°F,

-51.1 to 51.1°C

0 to 100 40

0 to 100 5

1596, 3192, 2500,
6384, 400

0 to 100% Open

nbUS (MODBUS)
or ProP (Network
Master)

1 to 255 1

AbSL, gAUg gAUg

-5 to 5 PSI,

-0.34 to 0.34 Bar

-5 to 5°F, -2.7 to

2.7°C

-5 to 5°F, -2.7 to

2.7°C

-5 to 5°F, -2.7 to

2.7°C

0 to 99

Default
Setting

404A

0

150

-59

-60

1596

Present
Position

nbUS

0

0

0

0

0 or 1
for local
display

User

Setpoints

4. Kelvin II MODBUS

The Kelvin II can communicate with a MODBUS master.
The Kelvin II will transfer process values and setpoints via
MODBUS.

1 Setpoints can only be viewed and edited when the proper password is entered.
2 The Auxiliary Temperature sensor input has a special Pumpdown feature. If a “short” or switch closure is placed across these terminals, the valve will

shut for pumpdown. The full details of this feature are described in Section 5.

3 The Alarm Status process value is described in Section 6.
4 The maximum value varies based on which refrigerant is selected. (R-410A is 300 PSI, R-744 is 500 PSI and all others are 150 PSI).

Page 3

The Kelvin II only supports the RTU transmission mode. The
serial settings are as follows:

n 9600 baud
n 8 data bits
n 1 stop bit
n Even parity

The Kelvin II supports the ‘Read Input Registers’, ‘Read
Holding Register’, ‘Write Single Register’, ‘Read Multiple
Coils’ and ‘Write Single Coil’ function codes. Any other re­quest will result in an exception response. The Kelvin II will
allow a full and partial block read of the Input and Holding
registers and Coils.

4.1. Scaling

In order to preserve precision, scaling was implemented when
using Bar or Celsius for units. PSI and Fahrenheit units are
both in whole numbers and have no scaling. The tables of the

MODBUS memory map below reect this implementation.

The Celsius values that are transferred via MODBUS are 10X.
For example, if Celsius is chosen for the temperature units
then 45°C is transferred for the Superheat. The actual Super­heat is 4.5°C. If the user desired to change a setpoint they
should keep this in mind when they enter a value.

The Bar values that are transferred via MODBUS are 100X.
For example, if Bar is chosen for the pressure units then 1034
Bar is transferred for the Maximum Operating Pressure. The
actual Maximum Operating Pressure is 10.34 Bar. If the user
desired to change a setpoint they should keep this in mind
when they enter a value.

4.2. MODBUS Memory Map

Table 4 Memory Map

MODBUS

Function

Code

Read Coils

(0x01)

Read Holding

Register

(0x03)

Mapped

Data

Manual

Valve

Control

Setpoints

Data Map Range

Bit 0 = Manual Valve
Enabled Flag
Bit 1 = Manual Valve
Duration Enabled
Flag

0. Superheat
Setpoint

1. Refrigerant Type

2. Delay On Relay 0 to 60 seconds

3. Delay Off Relay 0 to 60 seconds

4. Delay Steps 0 to 100 % Open

5. Cut-out Suction
Pressure

0 = Disabled,
1 = Enabled.

0 to 45°F, 0 to 250°C
(0.0 to 25.0°C)

0 = r22 1 = 134A
2 = 402A 3 = 404A
4 = 407A 5 = 407C
6 = 410A 7 = 417A
8 = 422A 9 = 422d
10 = r507 11 = r744
12= 245F

5

PSI, 0 to 1034

0 to 150
Bar (0 to 10.34 Bar)

MODBUS

Function

Code

Read Holding

Register

(0x03)

Read Input

Registers

(0x04)

Mapped

Data

Setpoints

Process

Variables

Data Map Range

6. Max Operation
Pressure

7. Temperature
Cut-in

8. Temperature
Cut-out

9. Valve Maximum 20 to 100 %

10. Supermarket
Mode

11. P 0 to 100

12. I 0 to 100

13. D 0 to 100

14. Valve Type

15. Manual Valve
Position

16. Network Type

17. Unit Address 1 to 255

18. Pressure Units 0 = PSI, 1 = BAR

19. Temperature
Units

20. Pressure Sensor
Type

21. Pressure
Calibration Offset

22. Suction
Temperature
Calibration Offset

23. Room
Temperature
Calibration Offset

24. Auxiliary
Temperature
Calibration Offset

0. Superheat

1. Suction
Pressure

2. Saturation
Temperature

3. Suction
Temperature

4. Room
Temperature

5. Valve Capacity

6. Auxiliary
Temperature

7. Relay Status

6

6

0 to 150
Bar (0 to 10.34 Bar)

-60 to 125°F,

-511 to 516 °C
(-51.1 to 51.6 °C)

-60 to 124°F,

-511 to 511 °C
(-51.1 to 51.1 °C)

0 = OFF 1 = ON

0 = 1596 1 = 3192
2 = 2500 3 = 6384
4 = 400

0 to 100 % Open

0 = MODBUS
1 = Network Master

0 = FAHR, 1 = CELS

0 = GauG, 1 = ABSL

-5 to 5°F,

-34 to 34 Bar
(-0.34 to 0.34 Bar)

-5 to 5°F,

-27 to 27°C
(-2.7 to 2.7°C)

-5 to 5°F,

-27 to 27°C
(-2.7 to 2.7°C)

-5 to 5°F,

-27 to 27°C
(-2.7 to 2.7°C)

0 to 165°F,
0 to 916°C
(0 to 91.6°C)

0 to 150 PSI,
0 to 1034 Bar
(0 to 10.34 Bar)

-60 to 150°F,

-511 to 656°C
(-51.1 to 65.6°C)

-60 to 125°F,

-511 to 656°C
(-51.1 to 65.6°C)

-60 to 125°F,

-511 to 656°C
(-51.1 to 65.6°C)

0.0 to 100.0% Open
(0.0 to 100.0)

-60 to 125°F,

-511 to 656°C
(-51.1 to 65.6°C)

0 = Deenergized,
1 = Energized

PSI, 0 to 1034

5 The maximum value varies based on which refrigerant is selected. (410A is 300 PSI, r744 is 500 PSI and all others are 150 PSI).
6 The maximum value varies based on which refrigerant is selected. (410A is 300 PSI, r744 is 500 PSI and all others are 150 PSI).

Page 4

MODBUS

Function

Code

Read Input

Registers

(0x04)

Write Single
Coil (0x05)

Write Single
Register
(0x06)

Mapped

Data

Process

Variables

Manual
Valve
Control

Setpoints Same as above.

Data Map Range

8. Alarm Status

9. System Cycle
Status

Bit 0 = Manual Valve
Enabled Flag

If Bit set then alarm is
active:
Bit 0 = Suction
Transducer Failure
Bit 1 = Tout Sensor
Failure
Bit 2 = High Superheat
Bit 3 = Low Superheat

If Bit set then mode is
active:
Bit 1 = Setup Mode
Bit 2 = Off Cycle
Bit 3 = Cooling Cycle
Bit 4 = Pump-down Cycle
Bit 5 = Manual Valve
Override Mode

0 = Disabled,
1 = Enabled.
The Manual Valve
duration Bit is read-only.

The max number of
registers written at a
time is

1. The limits can be
seen above in the
‘Read Holding
Register’ definition.

5. Kelvin II Features

5.1. Pumpdown Feature

The Kelvin II will initiate a pumpdown when Auxiliary Tem­perature sensor terminals are shorted. If desired, this temper­ature connection could be set up as a dry contact. When a
pumpdown is desired the contact should be closed. The pump­down will be ended when the short is removed provided that
there are no sensor alarms.

Normally, on the process value screens, the process value
text alternates with its value. When an alarm is activated the
alarm status “-AL-“screen is added to the rotation to make the
user aware that an alarm has been activated. The Alarm Status
menu display item ALS, will show the active alarms shown
in Table 5.

7. Kelvin II Display Networking

The Kelvin II displays can be set up to access other Kelvin II
controllers on the network. The controller’s current ‘CAdr’
value can be determined by pressing down the button on the
display while viewing a process value. To enable the display
network the ‘CAdr’ setting MUST be set to a unique nonzero
value with the RJ-45 connector on the side of the controller
DISCONNECTED.

After ‘CAdr’ has been set, an ‘End’ screen is added just be­fore the ‘SuPH’ process value. Pressing the button on the
display while viewing the ‘End’ screen brings up a menu al­lowing the selection of other Kelvin II controllers connected
to the display network. Turning the knob allows the selec­tion of other Kelvin II controllers based on their appropriate
‘CAdr’ address. The local controller is listed as ‘LocL’ by a
local display. Note: the remote display always includes the
‘End’ screen since it must be able to view any controller on the
display network.

8. Kelvin II Factory Reset

A factory reset can be performed by holding the button down
on the local or remote displays for 5 seconds when power is

rst applied. If using a local display the display will show

‘FrSt’ while the factory reset is being performed and then
automatically connect to the local controller.

5.2. Manual Valve Position Feature

The Kelvin II has the ability to manually control the valve.
To enable this manual control via the local or remote displays
simply open the setpoint menu and edit the ‘SPoS’ setpoint.
When the value is displayed for this setpoint the user is manu­ally controlling the valve. The valve position can be changed
by rotating the knob clockwise or counterclockwise. There is
an inactivity timer of 60 minutes while in manual control. The
timer is reset each time the user moves the valve. The manual
control of the valve is ended when the user presses the knob to
go back to displaying ‘SPoS’ or a timeout has been reached.

6. Kelvin II Alarms

The Kelvin II has 4 alarms. The following table lists the
possible alarms and the text that is seen on the controller.
The controller’s alarm status can be viewed via MODBUS,
Network Master, and local and remote displays.

Table 5 Alarms

Alarm Text Meaning

NoAL
PSAL
TSAL
HSAL
LSAL

No Alarms active
Pressure Sensor alarm
Tout Sensor alarm
High Superheat alarm
Low Superheat alarm

If using a remote display the display will show ‘FrSt’ and
switch to a menu that allows the selection of the controller
to reset. To perform a factory reset, select the controller with
the appropriate ‘CAdr’ value. The display should show ‘----‘
while the reset is being performed. When nished perform­ing factory resets turn the knob counterclockwise until ‘ESC’
is shown on the display. Pressing the button while ‘ESC’ is
shown on the display exits the factory reset menu and should
automatically connect to a controller on the display network.

Table 6 Replacement Parts

Part Number Description

952560 Kelvin II without display
952561 Kelvin II with local display
952562 Kelvin II Remote panel display
952662 Temperature Sensor Assembly
952795 Well Sensor Kit
953091 Pressure Transducer 150 psig with cable
952995 Pressure Transducer 150 psia with cable

952740

952504

Pressure Transducer 300 psig with cable for
R-410A applications only

Pressure Transducer 500 psig with cable for
R-477 applications only

Parker Hannifin Corporation

Sporlan Division

206 Lange Drive • Washington, MO 63090 USA
phone [phone] • fax [phone]
www.sporlan.com

112009 / SD-324