Danfoss Type EKE 1C PV05 Electronic Superheat Controller Installation Guide

Danfoss Type EKE 1C PV05 Electronic Superheat Controller

Introduction

• Superheat controller EKE 1C is for use where superheat must be accurately controlled, typically in commercial air conditioning, Commercial and industrial heat pumps, Commercial refrigeration, food retailing and industrial applications.
• Compatible valves: Danfoss ETS 6, ETS 8M (Bipolar) / ETS / ETS Colibri® / ETS L, KVS / KVS Colibri® and CCM / CCMT / CCMT L / CTR valves.
• Reference: For details please see EKE data sheet.

Applications

1. Superheat controller: standalone / network
2. Valve driver

Dimensions

Dimensions EKE 1C

• Weight: 190 gram

TECHNICAL SPECIFICATIONS

POWER SUPPLY

• EKE has galvanic isolation by switch-mode power supply.
• 24 V AC ± 20 %, 50/60 Hz. Maximum power consumption: 18 VA.
• Input voltage rating (DC): 24 V DC ± 20%, 15 W.

Do not connect voltage sources to unpowered units without limiting the current to analog inputs (overall 80 mA).

Open circuit HW diagnostics available for voltage input on: AI3 and AI4

Voltage| 2| AI3, AI4

0 – 5 V, 0 – 5 V ratiometric, 0 – 10 V

Current| AI3, AI4

0 – 20 mA

NTC| 3| AI1 (S3/S4), AI2 (S2), AI5 (S3/S4)

NTC temperature probes, 10 k0 at 25 °C

Pt 1000| AI1 (S3/S4), AI2 (S2)

Accuracy: ≤ 0.5 K Resolution: 0.1 K.

Range: 723 0 to 1684 0

Auxiliary Supplies| 1| 5 V +

Sensor supply: 5 VDC / 50 mA, overload protection approximately 150 mA

1| 15 V +

Sensor supply: 15 VDC / 30 mA, overload protection approximately 200 mA

Digital inputs| Voltage free contacts| 2| DI1 , DI2

Steady current minimum 1mA Cleaning current 100mA at 15 V DC On: RIL < = 300 0

Off: RIH > = 3.5 k 0

Digital output| Relay| 1| C1-NO1

Normally Open: 3 A General purpose, 250 V AC, 100 k cycle Normally Open: 3 A Inductive (AC-15), 250 V AC, 100 k cycle Normally Closed: 2 A General purpose, 250 V AC, 100 k cycle

---|---|---|---
Stepper motor| Bipolar| 1| Stepper valves: A1, A2, A3, A4

Bipolar stepper motor output:

– Danfoss ETS 8M (Bipolar) / ETS C / ETS L / KVS / KVS C / CCMT 2 – CCMT 42 / CCMT L / CTR Valves

Other Valves:

– speed 10 – 400 pps

– drive mode 1/8 microstep

– max. peak phase current: 1.2 A (848 mA RMS)

– max. drive voltage 40 V

– max. output power 12 W

Battery backup| | 1| VBATT : 18 – 24 V DC (24 V DC recommended):

–   max. battery current: 850 mA at 18 V

–   battery alarm will be activated below 16 V DC and above 27 V DC

Communi- cation| RS-485 RTU| 1| RS485

Galvanic isolation.

No Built-in termination.

CAN| 1| CAN – RJ

RJ connector to directly connect and supply a MMI.

GENERAL FEATURES AND WARNINGS

PLASTIC HOUSING FEATURES

• DIN rail mounting complying with EN 50022
• Self-extinguishing V0 according to IEC 60695-11-10 and glowing/hot wire test at 960 °C according to IEC 60695-2-12
• Ball test: 125 °C according to IEC 60730-1. Leakage current: ≥250 V according to IEC 60112

OTHER FEATURES

• Operating conditions CE: -20T60, 90% RH non-condensing
• Storage conditions: -30T80, 90% RH non-condensing
• To be integrated in Class I and/or II appliances
• Index of protection: IP 20 on the product and IP40 only on the front cover
• Period of electric stress across insulating parts: long
• Suitable for use in a normal polluted environment
• Category of resistance to heat and fire: D
• Immunity against voltage surges: Category II
• Software class and structure: class A

CE COMPLIANCE
This product is designed to comply with the following EU standards:

• Low voltage guideline: 2014/35/EU
• Electromagnetic compatibility EMC: 2014/30/EU and with the following norms:
• EN61000-6-1, EN61000-6-3 (immunity for residential, commercial and light-industrial environments)
• EN61000-6-2, EN61000-6-4 (immunity and emission standard for industrial environments)
• EN60730 (Automatic electrical controls for household and similar use)

GENERAL WARNINGS

• Every use that is not described in this manual is considered incorrect and is not authorized by the manufacturer
• Verify that the installation and operating conditions of the device respect those specified in the manual, especially concerning the supply voltage and environmental conditions
• This device contains live electrical components. All service and maintenance operations must therefore be performed by qualified personnel
• The device must not be used as a safety device
• Liability for injury or damage caused by the incorrect use of the device lies solely with the user

INSTALLATION WARNINGS

• Recommended mounting position: vertical
• Installation must comply with local standards and legislation
• This product is not subject to the UK PSTI regulation, as it is for supply to and use only by professionals with the necessary expertise and qualifications.
• Any misuse or improper handling may result in unintended consequences. By purchasing or using this product, you acknowledge and accept the professional-use-only nature of its application. Danfoss does not assume any liability for damages, injuries, or adverse consequences (“damage”) resulting from the incorrect or improper use of the product and you agree to indemnify Danfoss for any such damage resulting from your incorrect or improper use of the product.
• Before working on the electrical connections, disconnect the device from the main power supply
• Before carrying out any maintenance operations on the device, disconnect all electrical connections
• For safety reasons, the appliance must be fitted inside an electrical panel with no live parts accessible
• Do not expose the device to continuous water sprays or to a relative humidity greater than 90%.
• Avoid exposure to corrosive or pollutant gases, natural elements, environments where explosives or mixes of flammable gases are present, dust, strong vibrations or shock, large and rapid fluctuations in ambient temperature that might cause condensation in combination with high humidity, strong magnetic and/or radio interference (e.g. transmitting antennae)
• When connecting loads be aware of the maximum current for each relay and connector
• Use cable ends suitable for the corresponding connectors. After tightening the connector screws, tug the cables gently to check their tightness
• Use appropriate data communication cables. Refer to the EKE data sheet for the kind of cable to be used and setup recommendations
• Minimize the length of probe and digital input cables as much as possible, and avoid spiral routes around power devices. Separate from inductive loads and power cables to avoid possible electromagnetic noises
• Avoid touching or nearly touching the electronic components fitted on the board to avoid electrostatic discharges

PRODUCT WARNINGS

• Use a class II category transformer for 24 V AC power supply.
• Connecting any EKE inputs to the mains voltage will permanently damage the controller.
• Battery Backup terminals do not generate power to recharge a device connected.
• Battery backup – the voltage will close the stepper motor valves if the controller loses its supply voltage.
• Do not connect an external power supply to the digital input DI terminals to avoid damaging the controller.

DIN rail mounting/demounting
The unit can be mounted onto a 35 mm DIN rail simply by snapping it into place and securing it with a stopper to prevent sliding. It is demounted by gently pulling the stirrup located in the base of the housing.

Connection overview

Connection overview: EKE 1C

Sensor mounting

Sensor mounting: Temperature sensor

Important Note

• Mount the sensor on a clean paint-free surface.
• Remember to use heat conducting paste and insulate the sensor.
• For precise measurements, mount the sensor max. 5 cm from the outlet of the evaporator.

Pressure transmitter

• Installation of the pressure transmitter is less critical. However, the pressure transmitter should be closer to the temperature sensor, right after the evaporator and with its head upright. It is a good practice to select a pressure transmitter with an average load of 40 – 60% of full scale.
• Pressure transmitter values can be shared with multiple EKE 1C via CANbus.

Power supply

• Power sharing is allowed in EKE controller.
• It is a good practice not to reverse the polarity of the power connection cables. Selection of the common power supply depends on the total number of sharings and the valve in use.

Relay Outputs
EKE 1C has 1 relay output:

• Type SPDT relay. Digital Output can be used to connect either a solenoid valve or an alarm.
• The relays cannot be used for the direct connection of capacitive loads such as LEDs and ON/OFF control of EC motors. All loads with a switch-mode power supply must be connected with a suitable contactor or similar.

Cable length
EKE controller supports the following max. cable length.

| Cable length| Wire size min. / max.
---|---|---
[m]| [mm2]
Analog inputs (Voltage)| max. 10| 0.14 / 1.5
Temperature sensor| max. 10 *)| –
Stepper valve connection| max. 30| 0.14 / 1.5
Power supply| max. 5| 0.2 / 2.5
Digital input| max. 10| 0.14 / 1.5
Digital output| –| 0.2 / 2.5
Digital MMI| max. 3 over CAN RJ| –
Communication bus| max. 1000| 0.14 / 1.5

*Cable and wiring )**

• The max. cable distance between the controller and the valve depends on many factors like shielded/unshielded cable, the wire size used in the cable, the output power for the controller and EMC.
• Keep controller and sensor wiring well separated from mains wiring.
• Connecting sensors by wires more than the specified length may decrease the accuracy of measured values.

Warning
Separate the sensor and digital input cables as much as possible (at least 10 cm) from the power cables to the loads to avoid possible electromagnetic disturbance. Never lay power cables and probe cables in the same conduits (including those in the electrical panels).

Connecting Modbus

• For the MODbus cable, it is best to use 24 AWG shielded twisted-pair cable with a shunt capacitance of 16 pF/ft and 100Ω impedance.

• The controller provides an insulated RS485 communication interface which is connected to the RS485 terminals (see connection overview).

• The max. permissible number of devices simultaneously connected to the RS485 cable output is 32.

• The RS485 cable is of impedance 120Ω with a maximum length of 1000 m.

• Terminal resistors 120Ω for terminal devices are recommended at both ends.

• The EKE communication frequency (baud rate) can be one of the following: 9600, 19200 or 38400 baud, default 19200 8 E 1.

• The default unit address is 1, which can be changed using the parameter “G001 Controller adr. ”.

• For a detailed explanation of Modbus installation and setting software parameters, see:

• Datasheet for “EKE Superheat Controller” and “EKD EIM Data Communication Modbus RS485 RTU”.

Stepper Motor Output

• All valves are driven in a bipolar mode with a 24V supply chopped to control the current (Current driver).
• The stepper motor is connected to the “Stepper Valve” terminals (see terminal assignment) with a standard M12 connection cable.
• To configure stepper motor valves other than Danfoss stepper motor valves, the correct valve parameters must be set as described in the Valve configuration section (see manual for details).
• The default valve setting in EKE 1C is: none.
• The correct valve must be defined in “Valve configuration”, i.e. parameter I067. An overview of valve types is given in the “Parameter identification” section.

Valve Cable Connection

Stepper valve connector

| ETS/KVS/CCM/ CCMT/CTR/ CCMT L

(Using Danfoss M12 Cable)

| ****

ETS 8M Bipolar

| ****

ETS 6

---|---|---|---
A1| White| Orange| Orange
A2| Black| Yellow| Yellow
B1| Red| Red| Red
B2| Green| Black| Black
Not connected| –| –| Grey

• All valves are driven in a bipolar mode with a 24 V supply chopped to control the current (Current driver).
• The stepper motor is connected to the “Stepper Valve” terminals (see terminal assignment) with a standard M12 connection cable.
• To configure stepper motor valves other than Danfoss stepper motor valves, the correct valve parameters must be set as described in the Valve configuration section by selecting user user-defined valve.

Guideline for long M12 cables on Danfoss stepper motor valves

• Long cables will lead to degradation of performance.
• You can overcome this degradation by changing the settings for the valve driver. This guideline is based on the cable type being the same type as the standard Danfoss stepper motor cable.

Recommended wire size and cable distance between EKE controller and stepper motor valve

LED indication

(A) Two status LEDs to indicate operational status

• Steady green = power ON
• Flashing green = data transmission/initialization
• Flashing red = alarm/error condition

(B) Two status LEDs to indicate valve operation

• Flashing red = valve closing
• Steady red = valve fully closed
• Flashing green = valve opening
• Steady green = valve fully open
• Both green and red flashing = valve-related alarm

USER INTERFACE
EKE 1C can be set using one of the following user interfaces:

1. Danfoss KoolProg software
2. Danfoss MMIGRS external display.
3. Communication bus: Modbus RS485 RTU

KoolProg

• KoolProg is a software tool for quickly and easily configuring EKE controllers. It enables you to make online changes to parameter configuration, copy settings to multiple controllers, monitor the live status of input/outputs, and quickly analyze controller behavior and program patterns with a graphical trending tool.
• KoolProg Software is available for download free of charge at http://koolprog.danfoss.com.
• KoolProg requires a Gateway (code 080G9711) to connect to the PC.
• Always use the latest KoolProg version and the User must check the software version of EKE and create a duration fle in KoolProg for that version. Configuration made with the different software version should not be copied to the controller.

Important note!
To guarantee a reliable USB connection to a host device (e.g. industrial PC), you must:

• Connect terminals R and H on MMIMYK CAN port using a termination wire.
• Place cable holder close to MMIMYK to keep USB connector firmly in place.
• Keep USB cable length < 1 m.
• Place MMIMYK and route USB cable far from noise sources (inverter, motors, contactors, etc.)

Danfoss MMIGRS2 display

Connecting external MMIGRS2 display
MMIGRS2 display can be used to set up EKE 1C. The display can be used not only for setting up the necessary parameters but also as an external display during operation to show important parameters, e.g. degree of opening of valve, superheat, etc.

Important note

• Max. distance between the controller and display is 3 m over CAN RJ.
• CANbus requires termination in both ends of the cable by a 120 Ohm resistor to ensure reliable communication.
• On EKE 1C and MMI, the termination must be included by shorting CAN R and CAN H with a wire.
• No external power supply for MMIGRS2 is needed while using the CAN RJ connector.

MMIGRS2 (Back view)

MMIGRS2 (Front view)

Note: Setup and service menu requires login with the default password 100 ( daily use), 200 (service use) or 300 (commissioning use). Long press the Enter key to access the login menu.

Setup wizard via MMIGRS2 display
When all connections to the controller have been made after the power is switched on, the Danfoss logo will appear for 5 seconds, then the Home screen will be displayed.
To access the Wizard: press and hold enter to access the Login screen, the commissioning password is 300, scroll down the Setup and Service menu and select “Setup wizard

The Wizard workflow is: a. Language selection; b. Application selection; c. Input configuration; and d. Output configuration.
When using the Setup Wizard, repeat the following sequence for all parameter settings:

• From the Setup wizard, select relevant parameters.
• Press ENTER to highlight 1st option
• Scroll with UP / DOWN to your desired option
• If the selected default value is acceptable, press DOWN to get to the next settings. Otherwise, press ENTER to set your choice
• Scroll with DOWN to the next parameter (repeat sequence a. to e.)

Note

• If you do not have sufficient information to complete the Wizard, leave settings on their default values. To generate the requested info, you can use Danfoss Coolselector2 software to calculate operating conditions and valve OD for the same operating point.
• Setup Wizard only covers the most important parameters. If other features are to be enabled (e.g. Alarm settings, MOP/LOP, etc.), they must be configured separately once the Setup Wizard is done.
• Setup Wizard is also available in the KoolProg PC tool.
• The workflow process is the same as that described above for the MMIGRS2 display.
• For details, please refer to the EKE data sheet.

Quick guide for parameter selection

• Apart from wizard setup, users can also use the following section which describes quick parameter settings for general applications.

EKE 1C – Commonly used parameter identification
PNU – equivalent to the Modbus register no. (Modbus address +1).
Actual value are read/written as 16-bit integer values without decimals. This is the default value as read via Modbus.

For a detailed parameter list and explanation, please check the EKE data sheet.

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