NeoCharge Evaporator Control Panel
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Product Specifications
| Temperature range ambient | -4 to +104 °F (-20 to +40 °C) |
| Communication protocol | Modbus RTU for PLC integration, CANbus for front door display communication |
| User interface | Danfoss SM-800 interoperable Controller LCD setup wizard |
| Maximum Current | 5 A |
| UL/cUL listed | Yes |
| Type | Type 4 rated |
| Dimensions (inches) | 20 x 16 x 8 (508 x 406 x 203) |
| Color | Painted ANSI 61 Gray outside, Painted white inside |
Product Usage Instructions
Mounting the NeoCharge Sensor
The NeoCharge sensor should be mounted on one of the individual
tubes out of a fin and tube evaporator, before the outlet manifold.
Use the NeoCharge sensor clamp for proper positioning as shown in
Figure 5.
Function of the NeoCharge Sensor
The heating element of the sensor adds heat to the evaporator
tube. The measured temperature varies depending on the amount of
liquid inside the tube. This temperature signal is crucial for
monitoring the refrigerant.
Application Principles
The NeoCharge Retrofit Control Panel offers different
application choices for existing Industrial Refrigeration systems.
Assign control applications to each liquid feeding solenoid or
motorized valve as needed. Control possibilities include Direct
Expansion (WDX) and Controlled Circulation Rate (CCR) options.
Frequently Asked Questions (FAQ)
Q: What is the purpose of the NeoCharge sensor?
A: The NeoCharge sensor provides temperature signals that depend
on the amount of liquid in the evaporator tube, aiding in
monitoring the refrigerant.
Q: Can different control applications be assigned to each
valve?
A: Yes, the NeoCharge Retrofit Control Panel allows assigning
different control applications to each liquid feeding solenoid or
motorized valve based on requirements.
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Data Sheet
NeoCharge Evaporator control panel CCR and WDX low-charge Ammonia and CO2 Retrofit Control Panel
The Danfoss Retrofit Control Panel is a control solution for NeoCharge (low-charge ammonia and CO2) existing industrial refrigeration systems
The NeoCharge Standard Retrofit Control Panel are distributed control logic panels designed specifically for low-charge ammonia and CO2 industrial refrigeration existing control applications. Application-specific, energy-efficient control algorithms in each panel, achieve low charge ammonia goals for safe, efficient, trouble-free operation. For customized panels please contact your Danfoss Sales representative for more details. Required system components for compatibility: – ICM Motorized Valve with ICAD-B Actuator – Pressure Transmitter – Temperature Sensor
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Features
· Designed ready-to-mount-and-connect supply power, sensors and actuator wiring needed for existing low-charge industrial refrigeration control applications
· High quality standardized panel electrical components · Rigorously tested control sequences and algorithms · Well laid-out Type 4 rated panels (Type 1 when front door display used) · Modbus RTU communication · Standardized documentation
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
NeoCharge sensor
The Danfoss NeoCharge sensor consists of a heating element and a PT1000 temperature sensor build together into one sensor. The NeoCharge sensor is designed to be mounted on one of the individual tubes out of a fin and tube evaporator, before the outlet manifold. Figure 1: NeoCharge sensor mounted on one of the evaporator outlet tubes
Mounting the sensor on one of the evaporator tubes has several advantages: · The sensor will always be placed horizontally. Placing the sensor after the manifold would sometimes mean that it
would be placed on a vertical pipe where the flow patterns are completely different · There is much less variation in flow velocity and tube diameter. The variation in tube sizes for different sizes of
heat exchanges is not large a larger heat exchanger normally means increasing tube length and the number of parallel runs · One size sensor can be used for many sizes of evaporators Further advantages of the NeoCharge sensor, is that it is mounted outside on the evaporator tube, making it much easier to install and service the sensor (no welding or refrigerant evacuation is required). Outside mounting also means that the sensor does not disturb the flow regime or introduce a pressure drop. The heating element of the NeoCharge sensor is adding heat to the evaporator tube and depending on the amount of liquid inside the tube, the measured temperature varies.
Function of the NeoCharge sensor
The heating element of the NeoCharge sensor is adding heat to the evaporator tube and depending on the amount of liquid inside the tube, the measured temperature varies. Figure 2: NeoCharge sensor on an evaporator tube
The mounting of the NeoCharge sensor on an evaporator tube is shown in Figure 2. The NeoCharge sensor is providing a temperature signal, which is depending on the overall heat transfer coefficient from the temperature sensor to the refrigerant inside the pipe.
Tests and simulations have shown that the temperature signal from the NeoCharge sensor temperature sensor depends on the amount of liquid in the tube as shown in Figure 3:
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Figure 3: NeoCharge sensor superheat signal depending on amount of liquid in the tube
NOTE: That it is the NeoCharge sensor superheat that is shown in Figure 2 measured as the difference between the NeoCharge sensor temperature and the evaporation temperature. If there is only gas in the tube where the NeoCharge sensor is mounted, then the temperature will increase dramatically, and when the amount of liquid increases considerably, the temperature will be constant, giving no signal to control the injection valve by. But in between “only gas” and “more liquid”, there is an area where the amount of liquid out of the evaporator can be controlled this is the area indicated by the green circle in Figure 7. The superheat response of the NeoCharge sensor depends on several properties, the most important being: 1. The power to the heating element 2. The dimension and material of the evaporator tubes 3. The evaporator capacity 4. The evaporating temperature Tests and simulations have shown that variations in the dimensions and material of the evaporator tubes can be compensated by adjusting the power to the heating element and that differences in evaporator capacity can be handled by selecting a proper setpoint for the NeoCharge sensor superheat. Selecting the right power and setpoint for the NeoCharge sensor is done by the EKE 450 controller in an automatic adjustment process.
Mounting the NeoCharge sensor
Mounting the NeoCharge sensor on an evaporator requires that: 1. The NeoCharge sensor is mounted in the correct angle from vertical on the tube 2. The right tube for mounting the NeoCharge sensor is identified Mounting in the correct angle is relatively uncomplicated especially if the clamp provided by Danfoss is used. Figure 4 and Figure 5 below, shows the NeoCharge sensor position on an evaporator tube. Figure 4 shows the angle of the NeoCharge sensor from vertical, and Figure 5 shows that the mounting automatically complies with this angle if the NeoCharge sensor clamp is used and the arrows on the clamp are pointing vertically upwards. Figure 4: NeoCharge sensor position on evaporator tube. Either 30° left or 30° right
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel Figure 5: NeoCharge sensor position using the NeoCharge sensor clamp
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Application Application principles: General
The NeoCharge Standard Retrofit Control Panel has different application choices available that are designed for existing Industrial Refrigeration applications. It is possible to assign different control applications to each of the only controlling liquid feeding solenoid or motorized valve, if required. Some of the control possibilities offered are as follows: Figure 6: Direct expansion (WDX) Motorized Valve
Figure 7: Controlled Circulation Rate (CCR) through PMW Valve
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Product specification
Technical data and dimension
Table 1: Technical data
Standards Class of protection Short circuit current rating Ue Supply voltage Ue Control voltage Frequency Dimensions (Height x Width x Depth) Panel color Painted steel
Temperature range ambient
Communication protocol
User interface Maximum Current
UL/cUL listed Type 4 rated 10 kA 1 x 120 + N + PE 120 60 20 x 16 x 8 (508 x 406 x 203) Painted ANSI 61 Gray outside. Painted white inside -4 to +104 (-20 to +40) Modbus RTU for PLC integration CANbus for front door display communication Danfoss SM-800 interoperable Controller LCD setup wizard 5 A
Units
kA V AC V AC Hz inches (mm)
°F (°C)
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Ordering
Table 2:
Type
NeoCharge Retrofit panel
Description
NeoCharge function only, includes NeoCharge sensor and adaptor. Neo Sensor Evaporator Tubing Compatibility with 3/8″, 1/2″, 5/8″ or 10, 12, 16 mm
NeoCharge function only, includes NeoCharge sensor and adaptor. Neo Sensor Evaporator Tubing Compatibility with 3/4″, 7/8″, 1″ or 20, 22, 27 mm
Code Number 128S0030 128S0031
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
NeoCharge Evaporator Control Panel Mounting Instructions Mounting Procedure
Wall/column mounting Retrofit Control Panel must be mount securely on a wall or sturdy steel channels. There are four mounting holes in the frame which are provided to support the unit. See image below.
CAUTION: Maximum distance between Neosensor and Control Panel must not exceed 32 ft (10 meters). If distance is over 32 ft, please, contact Danfoss representative.
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel Figure 8: NeoCharge Evaporator Control Panel
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
NeoCharge Control Panel Component layout
For comprehensive wiring details please refer to the detailed wiring diagram that is delivered complete with NeoCharge Control Panel. Figure 9: wiring diagram
Table 3: Detailed wiring diagram
Part No. Description 1 Customer wireway 2 Miniature circuit breaker 3 Configurable controller 4 Power supply 5 DI terminals 6 #26 – #12 AWG 120 V contact relays (DI) 7 DO dry contacts for customer connections 8 Customer wireway 9 #26 – #12 AWG Modbus terminals 10 #26 – #12 AWG 24VDC terminals 11 Fuses 12 #26 – #12 AWG AI terminals 13 #26 – #12 AWG AO terminals
Table 4: Overview For Field Wiring for Low Charge ammonia Evaporator
Terminal
Description
Comment
CB1
Power supply: 120 V AC/60 HZ/1-PH Source
H & N. Ground terminal
CR1-DI1(2)
Danfoss Default Jumper 1-2 (Main Swith Optimization)
120 V AC relay
CR2-DI2
It might be used for Cooling ON-OFF signal
120 V AC relay
CR3-DI3
Customer configurable DI to application needs
120 V AC relay
CR4-DI4
Customer configurable DI to application needs
120 V AC relay
CR5-DI5(1)
Customer configurable DI to application needs
CR6-DI6(1)
Customer configurable DI to application needs.
CR7-DI7(1)
Customer configurable DI to application needs
CR8-DI8(1)
Customer configurable DI to application needs
DO1
Liquid Solenoid Valve Must be field wired
N.O. contact 10 A 250 V AC for resistive load 3.5 A 230 V AC for inductive load
DO2(1)
Customer configurable DO to application needs
N.O. contact 10 A 250 V AC for resistive load 3.5 A 230 V AC for inductive load
DO3(1)
Customer configurable DO to application needs
Changeover contact 6 A 250 V AC for resistive load 4 A 230 V AC for inductive load
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Terminal DO4(1)
Description Customer configurable DO to application needs
DO5
DO6 DO7(1)
DO8(1)
AI1
AI2 AI3 AI4 AI5(1) AI6(1) AI7(1) AI8(1) AO1 AO2(1) AO3(1) AO4(1)
NeoSensor Must be field wired
PWM Liquid Expansion Valve
Customer configurable DO to application needs
Customer configurable DO to application needs
Motorized Valve ICAD Actuator Feedback Must be field wired
NeoSensor Must be field wired Suction Temperature Sensor PT1000 Must be field wired Suction Pressure Sensor AKS33 Must be field wired
NOT USE FOR Neocharge application Customer configurable AI to application needs Must be field wired
Motorized Valve ICAD Actuator Must be field wired
NOT USE FOR Neocharge application Customer configurable AO to application needs Must be field wired
Comment Changeover contact 6 A 250 V AC for resistive load 4 A 230 V AC for inductive load Solid state relay for NeoSensor AC only. Imax = 0.5 A. Imin = 50 mA Red Wires from Heating element must be wired to Solid State Relay: 24 V DC (+) to Relay Terminal (11) Heating element to Relay Terminal (14) Heating element to 24 V DC (-) Solid state relay for PWM valve AC only. Imax = 0.5 A. Imin = 50 mA Changeover contact 6 A 250 V AC for resistive load 4 A 230 V AC for inductive load Changeover contact 6 A 250 V AC for resistive load 4 A 230 V AC for inductive load
420 mA signal Blue Cable (+): 420 mA Brown Cable (-): COMMON (GND)
PT1000 (White wires)
PT1000 RTD
420 mA signal
Example Ratiometric pressure transmitter 15 V pressure transmitter 020 mA/420 mA pressure transmitter PT1000 temperature sensor NTC temperature sensor ICM Motorized Valve ICAD-B Actuator Yellow Cable (+): 420 mA Orange Cable (-): COMMON (GND)
010 V signal output (optional 420 mA signal output on request)
(1) NOT used for Neocharge application (2) Please note: Optimization periodicity is based on specific application and system conditions. Everytime optimization occurs, unit might take
up to one hour to start Neocharge Control.
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Wiring Procedure
Figure 10: Wiring Procedure
1. Field wiring per local codes or NEC/Regulations 2. Use best wiring practice to enter bottom or sides of enclosure. avoid any penetrations on top of enclosure. seal
any entrances that may allow for condensing water within enclosure 3. Before drilling into panel, protect all devices inside the panel from metal filings 4. All intended field additions & conduit fittings must be of the same environmental type as enclosure to maintain
enclosure rating 5. All field control wiring to be #14AWG minimum unless otherwise specified by local codes 6. Field installed conductors should be copper rated 75 °C minimum unless otherwise designated 7. Consult manufacturer’s wiring recommendation for type, size and termination requirement as related to the
application 8. Before energizing panel clean out all metal filings and wire clippings 9. Check all terminals for tightness prior to energizing 10. Disconnect main power to panel when service is required 11. Disconnect power before removing any fuse guards. fuse guards must be reinstalled before turning power back
on 12. Replacement fuses must be of the same type, size, amperage and voltage rating 13. Motor starter wiring will vary. Refer to starter manufacturer’s diagram for actual wiring 14. To maintain overcurrent, short circuit, and ground fault protection, the manufacturer’s instructions for selection
of overload and short circuit protection must be followed to reduce the risk of fire and electrical shock 15. Tripping of the instantaneous trip circuit breaker is an indication that a fault current has been interrupted 16. Current carrying components of the magnetic motor controller should be examined and replaced if damaged to
reduce the risk of fire and electrical shock 17. All grounding/bonding conductors and lugs must terminate on bare metal and not painted surfaces
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Retrofit Neocharge evaporator Control Panel Wiring Diagram DO and DI
Figure 11:
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Wiring Diagram AO and AI
Figure 12:
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Retrofit Control Panel Application Examples
Application example WDX
Direct Expansion (DX) system evaporator with Motorized Valve liquid line control and hot gas defrost. Extra DI from PLC. Figure 13: Application example WDX
Table 5: Panel terminal description
Panel terminal
Description
DI1
Main switch signal from PLC
DI2
Liquid feed solenoid
DI3
Forced cooling on/off switch input from PLC/external
DI4
Forced close on/off switch input from PLC/external
DO5
NeoSensor on/off
AI1
Motorized Valve (ICM) feedback
AI2
NeoSensor
AI3
Suction Temperature Sensor
AI4
Suction Pressure Sensor
AO1
Motorized Valve (ICM)Modulating Opening Degree
Application example CCR
Direct Expansion (DX) system evaporator with PWM Valve liquid line control and hot gas defrost. Extra DI from PLC.
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel Figure 14: Application example CCR
Table 6: Panel terminal description
Panel terminal
Description
DI1
Main switch signal from PLC
DI2
Liquid feed solenoid
DI3
Forced cooling on/off switch input from PLC/external
DI4
Forced close on/off switch input from PLC/external
DO5
NeoSensor on/off
DO6
PWM modulation Valve AKV
AI2
NeoSensor
AI3
Suction Temperature Sensor
AI4
Suction Pressure Sensor
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NeoCharge (low-charge Ammonia and CO2) evaporator retrofit control panel
Standard Evaporator Control Panel: External wiring considerations: Signal wiring and Fieldbus
· The wiring of Modbus RTU (RS485) must be carried out in accordance with the standard ANSI/TIA/EIA-485-A-1998. Galvanic separation shall be provided for segments crossing buildings. Common ground shall be used for all devices on the same network inclusive router, gateways etc. All bus connections in the cables are made with twisted pair wires. The recommended cable type for this is AWG 22/0.32 mm2
· If the cable length exceeds 1200 meters (1312 yards) a repeater must be inserted. One repeater must be added for every 32 controllers
· If the data communication cable runs through an electrically noisy environment which impairs the data signal, one or more repeaters must be added to stabilize the signal
· When configuring Modbus devices on the control bus, the highest device address that can be used is 120 (max 120 Modbus control devices in total)
· The wires are looped from device to device and must observe polarity. A is connected to A and B is connected to B · The shield must be connected and complete a path from the device, all controllers, and any repeaters. The shield
must not be connected to earth ground · Remember to terminate the RS485 network following the last physical device
Figure 15: Signal wiring and Fieldbus
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Documents / Resources
 | Danfoss NeoCharge Evaporator Control Panel [pdf] Installation Guide AI515528325000en-000101, NeoCharge Evaporator Control Panel, NeoCharge, Evaporator Control Panel, Control Panel, Panel |