EC2-5x2 Series
Condensing Unit Controllers
Technical Data
The EC2-Series form a new generation of electronic
controllers for refrigeration and air conditioning. The
controllers combine in the small industry standard housing
maximum functionality such as step less compressor
modulation and variable fan speed control with TCP/IP
Ethernet communications and WebServer functionality. Any
®
standard WebBrowser (e.g. Internet Explorer or Mozilla
Firefox) can be used for monitoring or parameter setting.
Three Condensing Unit Controller versions are available:
EC2-552: For Copeland Digital Scroll compressors
EC2-542: 2 compressors with variable fan speed control
EC2-512: 2 compressors with fan cycling of 2 fans
Features EC2 Series Condensing Unit Controllers
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EC2-552 Features
Suction pressure control for up to 2 compressors; 1
Copeland Digital Scroll compressor and 1 single stage
compressor
Variable fan speed condensing pressure control with Alco
Controls FSP Series Fan Speed Power Modules
EC2-542 Features
Suction pressure control for up to 2 single stage
compressors
Variable fan speed condensing pressure control with Alco
Controls FSP Series Fan Speed Power Modules
EC2-512 Features
Suction pressure control for up to 2 single stage
compressors
Condensing pressure control with fan cycling of up to 2
fixed speed condenser fans
Common Features
Multiple control options: Dead band control, base load
control
Compressor and fan motor rotation with run-time
equalisation
Fast recovery of suction and condensing pressure
Separate inputs for compressor serial control loops,
common input for fan motor control loop, except EC2-552
Sensor failure management with emergency operating
procedures
Relay outputs with 230 VAC SPDT contacts for
compressor crankcase heater control
Support of TCP/IP Ethernet networking technology with
WebServer functionality allows monitoring and
configuration of controllers through a standard
WebBrowser (e.g. Internet Explorer® or Mozilla Firefox)
Alarm messaging by email
EC2-5x2 Series
Condensing Unit Controller
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Electrical connection via plug-in type screw terminals
2½ digit LED display with automatic decimal point
Indicator LEDs for compressor, fan, press./°C and alarm
Standard 71 x 29 mm cut-out dimensions
IP 65 protection class when mounted in front panel
Typical ordering package (EC2-542)
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EC2-542 Condensing Unit Controller with K02-540
Terminal Kit
FSP-150 Fan Speed Power Module with FSP-L15 Cable
ECT-523 Transformer
ECX-N60 Ethernet Cable
PT4-07S Suction Pressure Transmitter
PT4-30S Condensing Pressure Transmitter
2 x PT4-L15 cable for PT4 Pressure Transmitters
Selection Table
TCP/IP Ethernet
Type
Order Nr.
Description
Condensing Unit Controller
1 Digital Scroll Compressor, 1 Single Stage Compressor, Variable Fan Speed Control with FSP
EC2-552
807 738
Condensing Unit Controller
2 Single Stage Compressors, Variable Fan Speed Control with FSP Fan Speed Power Module
EC2-542
807 735
Condensing Unit Controller
2 Single Stage Compressors, 2 Fixed Speed Fans
EC2-512
807 732
EC25e35056.doc Rev.: 00
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Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
Introduction
The EC2-5x2 Series Condensing Units Controllers are for use
in commercial refrigeration systems to control suction pressure
and condensing pressure of a refrigeration circuit by modulating
compressors and fan motors of a condensing unit.
Though the controllers are designed to handle tandem
compressors, they are also perfectly suited for single
compressor applications.
When compared with more traditional condensing unit control
methods, which utilise mechanical pressostats for compressor
modulation and fan cycling, or which may have no fan control at
all, the EC2-5x2 Series Controllers greatly enhance system
efficiency, reliability and operating conditions. The built-in
communications capabilities permit remote access to the
condensing units for monitoring, remote maintenance and
retrieval of operational data. Though remote access through a
network to individual equipment controllers has been available
before for display case, coldroom and rack controllers, it is a
new feature for condensing unit controllers. It is now possible to
access the entire refrigeration system remotely and not only a
part of it.
The EC2 Series Condensing Unit Controllers are members of
the range of EC2 and EC3 devices, which can be easily
assembled into complete control systems for commercial
refrigeration. They all share the benefits of remote access and
data communication. Please refer to specific datasheets for
details.
The EC2-552 has been exclusively designed to control single
compressor or tandem compressor condensing units with a
Copeland Digital Scroll compressor. It features a 0…10 VDC
output to connect to an Alco Controls FSP Fan Speed Power
Module for variable fan speed control. Alternatively this output
may be used to control fan motor speed with an inverter or to
connect to ECM type fan motors directly.
The EC2-542 can control 1 or 2 single stage compressors and
features variable fan speed control as described above in the
EC2-552.
The EC2-512 is also capable of controlling 1 or 2 single stage
compressors. 1 or 2 fan motors can be controlled by on – off
cycling.
When compared to on – off cycling of fan motors, variable fan
speed control offers two distinctive advantages: A proportional
control loop keeps condensing pressure constant and minimizes
fan motor noise. By keeping condensing pressure as low as
possible, major energy savings can be achieved.
The Alco Controls PT4 pressure transmitter (1) senses suction
pressure. The Digital Scroll Compressor (6) operates as the
base load compressor. Capacity modulation is achieved by
temporarily unloading the compressors scroll sets with the
Pulse Width Modulated (PWM) signal (11) which controls the
compressor unloading valve (12). In tandem compressor
condensing units, the single stage compressor (7) will only be
turned on when demand exceeds the refrigeration capacity of
the Digital Scroll Compressor. The discharge temperature
thermistor of the Digital Scroll Compressor should be connected
to the Disch. Temp. input (5) of the controller and the volt-free
digital inputs (3) and (4) should be connected to the serial alarm
loops of both compressors for feedback of compressor tripping.
Suction Pressure Control EC2-552
2 control loops with the same suction pressure setpoint P0
modulate the compressors.
Standard
Scroll
Digital
Scroll
Suction Pressure
The dead band control loop with dead band P1 switches the
single stage compressor on or off, whereas a PI control loop
modulates the Digital Scroll base load compressor between
approximately 10% and 100% capacity. Being the base load
compressor, the Digital Scroll Compressor will never be
switched off while the single stage compressor remains on.
Condensing Pressure Control EC2-552
The PT4 pressure transmitter (2) senses condensing pressure
and feeds the signal into a control loop which generates a
0…10V output signal (10) to modulate condenser fan motor
speed by using the Alco Controls FSP Fan Speed Power
Module.
The control algorithm for condensing pressure is generating a
proportional transfer characteristic:
P1
100%
Application
The functions of the EC2 Series Condensing Unit Controllers
are described in the functional diagrams below:
EC2-552
EC25e35056.doc Rev.: 00
0%
P0
Condensing Pressure
P0 is the condensing pressure setpoint for the fan. P1 is the
proportional pressure band within the fan speed is controlled
proportional.
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Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
control loop as described in the EC2-542. Condensing pressure
is modulated by turning fan motors on and off.
excess
dead band
demand
EC2-542
setpoint
condensing pressure
No change occurs as long as the condensing pressure remains
within the dead band around the condensing pressure setpoint.
The controller will add/remove fan capacity when the
condensing pressure goes beyond the limits of the condensing
pressure dead band. For stable condenser operation, adjustable
time delays for fan motor on and off are available.
To avoid premature wear of individual fan motors, run time
equalization is built into the controller.
The application of the EC2-542 is very similar to the EC2-552,
but without the continuous modulation capabilities of the
Copeland Digital Scroll compressor.
A dead band control loop controls suction pressure by turning
compressors on and off.
excess
dead band
demand
setpoint
suction pressure
No change occurs as long as the suction pressure remains
within the dead band around the suction pressure setpoint. The
controller will add/remove compressor capacity when the
suction pressure goes beyond the limits of the suction pressure
dead band.
To minimize compressor wear, minimum compressor run times
and minimum compressor off times as specified by compressor
manufacturers should be applied. Both can be set in the EC2
Series Condensing Unit Controllers. Another feature of the EC2
is the default compressor run time equalization. However, if
desired, run time equalization may be disabled and a base load
compressor can be allocated or the FILO mode (First In Last
Out) may be applied.
Sensors
The use of Alco Controls PT4 Series Pressure Transmitters is
highly recommended. They are dedicated for refrigeration
applications and feature pre-fabricated plug and cable
assemblies with different cable lengths as well as waterproof
electrical connectors for easy installations. Their electrical
characteristics match the requirements of the EC2 Series and
guarantee proper function of the built-in sensor detection and
self-test feature.
Display and Keypad
With the 2½-digit display pressures within ±199bar can be
shown with a resolution of 1bar. The resolution improves to
0.1bar within a range of ±19.9bar. The same principle applies to
the display of temperatures in °C to °F. The display unit can be
switched from °C to °F.
Indicator LEDs show the status of the compressors and the fan
motors. A blinking LED indicates that the EC2 Controller is
trying to fulfill a task but is prevented from doing so by another
restraint in the system. An example of this would be a request to
remove a compressor, which is temporarily inhibited by the
minimum compressor run time requirement.
Operation and Commissioning
Setup and commissioning of an EC2 Series Controller may be
performed by using one of the following options:
Locally or remote with a PC connected to the TCP/IP
Ethernet port of the EC2.
Locally through the 4-button keypad.
Locally with the infrared remote control.
For initial commissioning of a new installation depending on the
networking technology of the EC2 the first option is the most
appropriate. Commissioning is done via dedicated menus with
meaningful default values, which make commissioning an EC2
a plug-and-play type of job. Anybody who is familiar with
Microsoft Windows® based programs and WebBrowsers should
find it very intuitive without the need for special training.
EC2-512
WebServer function of the EC2 with TCP/IP Ethernet
networking capabilities
The suction pressure control algorithm and the compressor
control features of the EC2-512 are identical to the ones as
described above in the EC2-542.
As above, the PT4 pressure transmitter (2) senses condensing
pressure and feeds the signal into a condensing pressure dead
band control loop, which is similar to the dead band compressor
EC25e35056.doc Rev.: 00
Though the actual status of the controllers can be viewed on the
local display, it is much more convenient to do the viewing on a
PC. All relevant parameters and modes are visible on a single
WebPage simultaneously. For even more details and for setup
and maintenance a click on one of the screen tabs calls up a
WebPage dedicated to specific task. All of this can be done with
a standard WebBrowser like the Internet Explorer®, the Mozilla
Firefox or others. The picture on page 4 shows the homepage
of an EC2-552 with the monitoring WebPage of the controller.
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Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
The top center field indicates the status of compressors and
fan(s). The top left field shows suction pressure setpoint and
actual suction data. The top right field shows the equivalent
condensing pressure data. The fields below show controller
status, active compressors and compressor and fan motor
modulation. All active messages are in bold letters.
A rolling graph with the pressure and temperature data over a
period of approximately 10 minutes can be displayed:
All WebPages, which allow the change of controller parameters,
are password protected. Below is the example for the setpoint
configuration WebPage of an EC2-542 Controller. All setpoints
can be easily reviewed and modified if needed:
Alarm / maintenance functions
A logfile can be stored on the PC. The file format of the datalog
is text with semicolon (;)separated fields. In the picture below is
a sample log file from an EC2-542, imported in Microsoft
Excel®:
EC25e35056.doc Rev.: 00
EC2 Series Condensing Unit Controllers provide many alarm
codes to facilitate diagnosis.
Limit violation alarms are associated with temperature and
pressure set point (high-, low alarm, sensor failure).
Maintenance alarms are based on compressor/fan runtimes.
When a defined runtime is exceeded the maintenance alarm is
triggered.
Compressor and fan motor feedback alarms occur when the
serial control loop opens due to excessive temperature,
pressure, motor overload etc.
Alarm management includes the issuing of an alarm message
and to show the alarm code on the controllers display.
The TCP/IP Ethernet versions EC2 Controllers have the
capability to send alarm messages directly by email.
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Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
While the display indicates alarms as blinking symbols only, the
monitoring WebPage shows all alarms in text form. All possible
alarm messages are visible, active alarms are highlighted bold,
see below:
Electrical Connection
For electrical connection removable screw connectors can be
used. This allows the electrical wiring to be completed at the
display case manufacturer and the controller is simply pluggedin on site when necessary. The terminal Kit K02-540 (K02-211
for EC2-512) must be ordered separately
For TCP/IP controllers an Ethernet cable must be used. The
assembled cable ECX-N60 comes with RJ45 connector on one
side and the 4-pin screw connector at the other.
Safety Functions
Safe operating modes allow the system to continue to operate
safely even when the signal is lost from a defective or
disconnected sensor or when one of the serial control loops
open.
Particularly useful facilities are the service functions, which
enable the engineer to manually control the system during
commissioning. They include manual operation of compressors
and fans. Service intervals for compressors and fans can be
preset and cause an alarm when the preset run time has been
exceeded.
Screw Connector Kit
K02-540
EC2-542,
Rear side
Accessories
Terminal Kits and Cables for EC2 Series
Terminal Kit for EC2-552 and EC2-542
Terminal Kit for EC2-512
Ethernet Cable (TCP/IP)
6,0m cable length
Type
K02-540
K02-211
ECX-N60
Order Nr.
800 070
807 647
804 422
Fan Speed Power Modules 3-phase 4A max
1-phase 8A max
1-phase 5A max
1.5m cable length
Cable Assembly for FSP
3.0m cable length
6.0m cable length
FSP-340
FSP-180
FSP-150
FSP-L15
FSP-L30
FSP-L60
800 376
800 373
800 370
804 693
804 694
804 695
-0.8…7bar
0…18bar
0…30bar
0…50bar
1.5m cable length
3.0m cable length
6.0m cable length
PT4-07S
PT4-18S
PT4-30S
PT4-50S
PT4-L15
PT4-L30
PT4-L60
802 320
802 322
802 324
802 326
804 593
804 594
804 595
Pressure Transmitter
Cable Assembly for PT4
FSP-150
FSP-340
Fan Speed Control Module
PT4-07S Pressure Transmitter with Cable
Plug Assembly PT4-Lxx
EC25e35056.doc Rev.: 00
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Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
Accessories (cont'd)
Transformer
Class II
230VAC Input,
24V output, 20VA
ECT-523
804 332
Infrared Remote Control
English
German
French
Spanish
Italian
EC2-IRE
EC2-IRD
EC2-IRF
EC2-IRS
EC2-IRI
804 345
804 346
804 347
804 348
804 349
Language
EC2-IRE Remote Control
Transformer ECT-523
Technical Data
Power supply
Power consumption
Plug-in connector size
Communication
Display
Temperature
storage
operating
Humidity
Protection class
Weight
Mounting
EC25e35056.doc Rev.: 00
Input and Output Configuration
24VAC ± 10% 50/60Hz Class II
EC2-512 & 542 4VA max
EC2-552
20A max
Removable screw version
wire size 0.14 … 1.5mm2
TCP/IP Ethernet
(EC2-xx2)
2½ digits red LED
-199 to +199 with decimal point
Switchable between bar, °C & °F
4 indicator LEDs
EC2Pressure transmitter inputs
24VDC, 4…20mA
Digital inputs
Volt free contact
5V / 0,1mA
Discharge temperature
thermistor
Output relays
Inductive (AC15) 250V / 2A
Resistive (AC1) 250V / 8A
Resistive (AC1) 250V / 6A
Output Triacs
24VAC 0,1…1A
Analogue output
0…10VDC 3mA max
Communication
-20 … +65°C
0 … +60°C
0 … 80% r.h. non condensing
IP 65 (front protection with gasket)
~ 150g
Panel mount (71 x 29mm cutout)
6/8
512
542
552
2
2
2
3
3
2
1
2
2
4
1
1
1
Ethernet 10Mbit/sec.
Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
Wiring Diagrams
EC2-552
EC2-542
EC2-512
EC25e35056.doc Rev.: 00
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Date: 27.01.2006
EC2-5x2 Series
Condensing Unit Controllers
Physical Dimensions
EC2-5x2 Controllers
Transformers
ECT-523
58
73
43 54 76
ALCO CONTROLS is not to be held responsible for erroneous literature
regarding capacities, dimensions, applications, etc. stated herein.
Products, specifications and data in this literature are subject to change
without notice. The information given herein is based on technical data
and tests, which ALCO CONTROLS believes to be reliable and which
are in compliance with technical knowledge of today. It is intended only
Emerson Electric GmbH & Co. OHG
ALCO CONTROLS
Postfach 1251
Heerstraße 111
D-71332 Waiblingen
Germany
Phone ...49-7151-509-0
Fax ...49-7151-509-200
www.eCopeland.com/alcoliterature.cfm
EC25e35056.doc Rev.: 00
for use by persons having the appropriate technical knowledge and
skills, at their own discretion and risk. Since conditions of use are
outside of ALCO'S control we cannot assume any liability for results
obtained or damages occurred due to improper application.
This document replaces all former versions.
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Date: 27.01.2006