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R E F R I G E R A T I O N A N D A I R C O N D I T I O N I N G

Controller for control of industrial evaporator- EKC 315A

Manual

Refrigeration and Air Conditioning Controls

ADAP-KOOL®

Refrigeration control systems

2 Manual RS.8C.S2.02 © Danfoss 12-2002 EKC 315A

Introduction

ApplicationThe controller and valve can be used where there arerequirements to accurate control fo superheat and tempera-ture in connection with refrigeration.E.g.:• Cold store (air coolers)• Processing plant (water chillers)• A/C plant

Advantages• The evaporator is charged optimally – even when there are

great variations of load and suction pressure• Energy savings – the adaptive regulation of the refrigerant

injection ensures optimum utilisation of the evaporator andhence a high suction pressure

• Exact temperature control – the combination of adaptiveevaporator and temperature control ensures great tem-perature accuracy for the media

• The superheating is regulated to the lowest possible valueat the same time as the media temperature is controlled bythe thermostat function

Functions• Regulation of superheat• Temperature control• MOP function• ON/OFF input for start/stop of regulation• Input signal that can displace the superheat reference or

the temperature reference• Alarm if the set alarm limits are exceeded• Relay output for solenoid valve• PID regulation• Output signal following the temperature showing in the

display

SystemThe superheat in the evaporator is controlled by one pres-sure transmitter P and one temperature sensor S2.The valve can be one of the following types:• TQ (PHTQ, TEAQ)• AKV (AKVA)TQ is a modulating valve, and when this is used a solenoidvalve must also be used in the liquid line.AKV is a pulsating valve.Where the AKV valve is used it also functions as solenoidvalve.Temperature control is performed based on a signal fromtemperature sensor S3 which is placed in the air currentbefore the evaporator. Temperature control is in the shape ofan ON/OFF thermostat that shuts off the liquid flow in theliquid line, either via the solenoid valve in TQ applications ordirectly when AKV is used.

EKC 315A Manual RS.8C.S2.02 © Danfoss 12-2002 3

Operation

Superheat functionYou may choose between two kinds of superheat, either:• Adaptive superheat or• Load-defined superheat

MOPThe MOP function limits the valve’s opening degree as longas the evaporating pressure is higher than the set MOPvalue.

Override functionVia the analog input a displacement can be made of thetemperature reference or of the superheat reference. Thesignal can either be a 0-20 mA signal or a 4-20 mA signal.The reference can be dsplaced in positive or negativedirection.

External start/stop of regulationThe controller can be started and stopped externally via acontact function connected to input terminals 1 and 2.Regulation is stopped when the connection is interrupted.The function must be used when the compressor is stopped.The controller then closes the solenoid valve so that theevaporator is not charged with refrigerant.

RelaysThe relay for the solenoid valve will operate when refrigera-tion is required. The relay for the alarm function works insuch a way thatr the contact is cut in in alarm situations andwhen the controller is de-energised.

Modulating/pulsating expansion valveIn 1:1 systems (one evaporator, one compressor and onecondenser) with small refrigerant charge TQ is recom-mended.

In a system with an AKV valve the capacity can be distributedby up to three valves if slave modules are mounted. Thecontroller will displace the opening time of the AKV valves,so that they will not pulsate at the same time.Used as slave module is a controller of the type EKC 347.

Analog outputThe controller is provided with an analog current outputwhich can be set to either 0-20 mA or 4-20 mA. The signalwill either follow the superheat, opening degree of the valveor the air temperature.

PC operationThe controller can be provided with data communication sothat it can be connected to other products in the range ofADAP-KOOL® refrigeration controls. In this way operation,monitoring and data collection can be performed from onePC – either on the spot or in a service company.See also page 14.


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Light-emitting diodes (LED) on front panelThere are LED’s on the front panel which will light up whenthe belonging relay is activated.The upper LED will indicate the valve’s opening degree. Ashort pulse indicates a small liquid flow and a long pulse aheavy liquid flow. The other LED will indicate when thecontroller calls for refrigeration.The three lowermost LED’s will flash, if there is an error in theregulation.In this situation you can upload the error code on the displayand cancel the alarm by giving the uppermost button a briefpush.

DisplayThe values will be shown with three digits, and with a settingyou can determine whether the temperature are to be shownin °C or in °F.

Operation Menu survey

The buttonsWhen you want to change a setting, the two buttons will giveyou a higher or lower value depending on the button you arepushing. But before you change the value, you must haveaccess to the menu. You obtain this by pushing the upperbutton for a couple of seconds - you will then enter thecolumn with parameter codes. Find the parameter code youwant to change and push the two buttons simultaneously.When you have changed the value, save the new value byonce more pushing the two buttons simultaneously.

Gives access to the menu (or cutout an alarm)

Gives access to changes

Saves a change

Examples of operations

Set set-point1. Push the two buttons simultaneously2. Push one of the buttons and select the new value3. Push both buttons again to conclude the setting

Set one of the other menus1. Push the upper button until a parameter is shown2. Push one of the buttons and find the parameter you want

to change3. Push both buttons simultaneously until the parameter

value is shown4. Push one of the buttons and select the new value5. Push both buttons again to conclude the setting

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Factory settingIf you need to return to the factory-set values, it can be done in this way:- Cut out the supply voltage to the controller- Keep both buttons depressed at the same time as you reconnect the supply

voltage

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Data

Ordering

Data communication

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Temperature sensor Pt 1000 ohm / Pressure transmitter type AKS33 / TQ Valves / AKV valves: ............. Kindly refer to catalogueRK.0Y.G...

Necessary connectionsTerminals:25-26 Supply voltage 24 V a.c.23-24 Supply to actuator17-18 Only at TQ actuator: Signal from actuator20-21 Pt 1000 sensor at evaporator outlet (S2)14-15 Pressure transmitter type AKS 339-10 Relay switch for start/stop of solenoid valve1-2 Switch function for start/stop of regulation. If a switch

is not connected, terminals 1 and 2 must beshortcircuited.

Application dependent connectionsTerminal:21-22 Pt 1000 sensor for measuring air temperature (S3)12-13 Alarm relay

There is connection between 12 and 13 in alarmsituations and when the controller is dead

18-19 Current signal from other regulation (Ext.Ref.)2-5 Current output for showing superheat or air tempera-

ture. Or for signal to a slave module3-4 Data communication

Mount only, if a data communication module hasbeen mounted.It is important that the installation of the data commu-nication cable be done correctly. Cf. separate litera-ture No. RC.8A.C...

Connections

Wire length TQ:See appendix 2


Installation considerationsAccidental damage, poor installation, or site conditions, cangive rise to malfunctions of the control system, and ultimatelylead to a plant breakdown.Every possible safeguard is incorporated into our products toprevent this. However, a wrong installation, for example,could still present problems. Electronic controls are nosubstitute for normal, good engineering practice.

Danfoss wil not be responsible for any goods, or plantcomponents, damaged as a result of the above defects. It isthe installer's responsibility to check the installation thor-oughly, and to fit the necessary safety devices.Particular attention is drawn to the need for a “force closing”signal to controllers in the event of compressor stoppage,and to the requirement for suction line accumulators.

Your local Danfoss agent will be pleased to assist withfurther advice, etc.

Appendix 1

Interaction between internal and external start/stop func-tions and active functions.

Appendix 2

Cable length for the TQ actuatorThe actuator must be supplied with 24 V a.c. ± 10%.To avoid excessive voltage loss in the cable to the actuator,use a thicker cable for large distances.

Wire cross section

Cable length

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Appendix 3

If the flow of refrigerant is to be distributed to severalexpansion valves, this can be accomplished by using AKVvalves and EKC controllers as slave modules.

Remember to open the functions in:- EKC 315A's menu o09- EKC 347's menu o09

Appendix 4

If there are two evaporators sharing the same suction line,the signal from the pressure transmitter can be used by twocontrollers.


Appendix 5

Standby temperatures for TQ valves.

TQ valveThe valve’s actuator temperature is limited, both whenregulation is stopped and when the valve is right out at theopening point and closing point.(The opening and closing points may fluctuate a couple ofdegrees up or down, depending on pressures and toler-ances).

n26The setting is based on the TQ valve’s closing curve. With aplus value the valve can be kept slightly open. With a minusvalue the valve can be closed completely. If the minusvalue is high you can be sure that the valve will close, butthen it will also react slowly when it has to open again.

n27This setting defines the number of degrees the actuator hasto be warmer when the valve is completely open. If thevalue is high you can be sure that the valve is completelyopen, but then it will also react slowly when it has to closeagain.

Appendix 6

The two types of regulation for superheat are, as follows:

Adaptive superheat

Regulation is here based on the evaporator’s load bymeans of MSS search (MSS = lowest permissible super-heat).(The superheat reference is lowered to the exact pointwhere instability sets in).The superheat is limited by the settings for min.andmax.superheat.

Load-defined superheat

The reference follows a defined curve.This curve is definedby three values: the closing value, the min. value and themax. value. These three values must be selected in such away that the curve is situated between the MSS curve andthe curve for average temperature difference ∆Tm (tem-perature difference between media temperature andevaporating temperature.Setting example = 4, 6 and 10 K).


Start of controller

When the electric wires have been connected to the control-ler, the following points have to be attended to before theregulation starts:1. Switch off the external ON/OFF switch that starts and stops

the regulation.2. Follow the menu survey on page 8, and set the various

parameters to the required values.3. Switch on the external switch, and regulation will start.

If the superheating fluctuates

When the refrigerating system has been made to worksteadily, the controller’s factory-set control parameters shouldin most cases provide a stable and relatively fast regulatingsystem.If the system however fluctuates this may be due to the factthat too low superheat parameters have been selected:

If adaptive superheat has been selected:Adjust: n09, n10 and n18.

If load-defined superheat has been selected:Adjust: n09, n10 and n22.

Alternatively it may be due to the fact that the set regulationparameters are not optimal.

If the time of oscillation is longer than the integration time:(Tp > Tn , (Tn is, say, 240 seconds))1. Increase Tn to 1.2 times Tp

2. Wait until the system is in balance again3. If there is still oscillation, reduce Kp by, say, 20%4. Wait until the system is in balance5. If it continues to oscillate, repeat 3 and 4

If the time of oscillation is shorter than the integration time:(Tp < Tn , (Tn is, say, 240 seconds))1. Reduce Kp by, say, 20% of the scale reading2. Wait until the system is in balance3. If it continues to oscillate, repeat 1 and 2.

4. Follow the actual room temperature or superheat on thedisplay.(On terminals 2 and 5 a current signal can be transmittedwhich represents the display view. Connect a datacollection unit, if applicable, so that the temperatureperformance can be followed).

If the superheat has excessive underswingduring start-up

If you regulate with valve type AKV:Adjust n22 a little bit up and/or n04 a little bit down.

If you regulate with valve type TQ:Adjust n26 a littlle bit down


Data communication

Example

Example of menu display

If you want to know more about operation of controllers viaPC, you may order additional literature.

This page contains a description of a few of the possibilitiesyou will have when the controller is provided with datacommunication.

Each controller is pro-vided with a plug-inmodule.

The controllers are thenconnected to a two-corecable.

Up to 60 controllers maybe connected to onecable.

This cable is also connectedto a gateway type AKA 243.

This gateway will nowcontrol the communicationto and from the controllers.

It will collect temperaturevalues and it will receivealarms. When there is analarm the alarm relay will beactivated for two minutes.

The gateway can now beconnected to a modem.

When an alarm occurs fromone of the controllers, thegateway will - via themodem - make a phone callto the service company.

At the service company amodem, gateway and PCwith system software typeAKM have been installed.

All the controllers’ functionscan now be operated fromthe various menu displays.

The programme will forexample upload all thecollected temperaturevalues once a day.

• Measurements are shownat one side and settings atthe other.

• You will also be able to seethe parameter names ofthe functions on page 4-6.

• With a simple change-overthe values can also beshown in a trend diagram.

• If you wish to check earliertemperature measure-ments, you can see themin the log collection.

AlarmsIf the controller is extendedwith data communication, itwill be possible to define theimportance of the transmit-ted alarms.The importance is definedwith the setting: 1, 2, 3 or 0.When the alarm then arisesat some time, it will result inone of the following activi-ties:

1 = AlarmThe alarm message is sentoff with alarm status 1. Thismeans that the gateway thatis the master in the systemwill have its alarm relayoutput activated for twominutes. Later, when thealarm ceases, the alarm textwill be retransmitted, butnow with status value 0.

2 = MessageThe alarm text is transmittedwith status value 2. Later,when the “message” lapses,the alarm text isretransmitted, but now withstatus value 0.

3 = AlarmAs “1”, but the mastergateway’s relay output is notactivated.

0 = Suppressed informationThe alarm text is stopped atthe controller. It is transmittednowhere.



RC

-ET

List of literature

Instructions RI.8G.T. (extract from this manual).Here you can see how controllers are mounted and programmed.

Installation guide for extended operation RC.8A.CHere you can see how a data communication connection to ADAP-KOOL® Refrigeration control systems can beestablished.

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to productsalready on order provided that such alternations can be made without subsequential changes being necessary in specifications already agreed.All trademarks in this material are property of the respecitve companies. Danfoss and Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

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Manualdocumentatii-tehnice.ro/webcontent/uploads/documentatii/... · 2013. 3. 26. · Manual Refrigeration and Air Conditioning Controls ... nn19 Kp Mi Amplification factor for the