Danfoss EKE 110 1V Injection Controller
Installation guide
Introduction
The Injection Controller EKE 110 1V is designed for two primary modes of operation:
- Vapor or Wet Injection mode (VI/WI): The controller manages a stepper motor valve to inject superheated vapor into the compressor injection port. It automatically switches to wet injection to prevent high discharge gas temperature (DGT) under specific running conditions, thereby improving compressor performance over an extended operating range.
- Liquid Injection mode (LI): The controller manages a stepper motor valve for liquid injection to prevent excessively high discharge gas temperature (DGT). This ensures safe compressor operation within an extended running envelope. This mode is commonly used in light commercial, commercial, and industrial low ambient heat pump applications.
Compatible valves include: ETS 6 / ETS 5M Bipolar / ETS 8M Bipolar / ETS Colibri / ETS 175-500L / CCMT L / CCMT / CCM / CTR.
Basic Application Diagrams
Liquid Injection mode (LI):
A schematic diagram illustrates the Liquid Injection mode, showing a refrigeration cycle with key components: Condenser, Expansion valve, Evaporator, Injection valve, and a Discharge Gas Temperature (DGT) sensor. The controller manages the Injection valve.
Wet and Vapor Injection mode (VI/WI):
Two diagrams depict the Wet and Vapor Injection mode, separated into 'Upstream' and 'Downstream' sections. Each section shows a refrigeration cycle with a Condenser, Expansion valve, Evaporator, and Injection valve. Additional sensors and components shown include Discharge Gas Temperature (DGT), Pressure signal for economizer (PeA), and S2A sensors, along with an Economizer connection.
Technical Specification
| Specification | Value |
|---|---|
| Supply Voltage | 24 V AC/DC* 50/60 Hz, SELV ** |
| Battery backup Input (Danfoss recommends EKE 2U) | 24V DC |
| Number of valve outputs | 1 stepper motor valve |
| Valve type | Bipolar stepper valve |
| Modbus RS485 RTU | Yes (Isolated) |
| Baud rate (default setting) | 19200 |
| Mode (default setting) | 8E1 |
| No of temperature sensors | 2 (S2A, DGT) |
| Type of temperature sensors | S2A-PT1000/NTC10K, DGT-PT1000 |
| No of Pressure sensors | 1 (PeA) |
| Type of pressure transmitter*** | Ratiometric 0-5-5 V DC, 0-10V, Current 4-20mA |
| No of digital input | 1 (DI1) |
| Use of digital input**** | Start/Stop regulation |
| Digital output***** | 1 output: D0 (open collector), max sink current 10 mA |
| PC suite | Koolprog |
| Service tool | EKA 200 + EKE 100 service cable |
| Mounting | 35mm Din rail |
| Storage temperature | -30 – 80 °C / -22 – 176 °F |
| Operating temperature | -20 – 70 °C / -4 – 158 °F |
| Humidity | <90% RH, non-condensing |
| Enclosure | IP20 |
| Display | No |
Notes:
- The unit is suitable for use on a circuit capable of delivering not more than 50A RMS symmetrical Amperes.
- For US and Canada, use class 2 power supply.
- Pressure transmitter output supply voltage up to 18V/50mA.
- If not using DI for start/stop function then physically short the terminal with COM.
- By default, DO is configured for communicating alarm for compressor stop. It can be used for other alarms if activated in the configuration.
Connection Overview
The EKE 110 controller features various ports for connection:
| Port | Description |
|---|---|
| -/~ and +/~ | Power supply |
| +5V/18V | Voltage for pressure probe** |
| +5V/18V | Not used |
| Ext-GND | Not used |
| GND | Ground / Comm for I/O signals |
| DO | Digital Output |
| PeA | Pressure signal for economizer |
| S2A | Temperature signal for economizer |
| DI1* | Digital Input |
| DGT | Signal for Discharge gas temperature |
| BAT- and BAT+ | Battery backup inputs (EKE 2U) |
| Valve A | Connection for injection valve |
| MODBUS (B-, A+, GND) | Modbus RS485 port |
Notes:
- DI is software configurable; if not used with an external signal, short circuit it or configure it as not used in software.
- By default, the power supply for the pressure transmitter is set to 0V. Supply changes to 5V if the pressure transmitter is selected as ratiometric, and 18V if selected as current type. Supply can be changed manually via parameter P014 in advanced I/O configuration.
- To avoid potential malfunctions or damage to the EKE 110, connect all peripheral components only to the designated ports. Connecting components to unassigned ports may lead to operational issues.
Dimensions
The controller has dimensions of 70 mm width, 110 mm height, and 49 mm depth.
Mounting/Demounting
Mounting:
The unit mounts onto a 35 mm DIN rail by snapping it into place and securing it with a stopper to prevent sliding.
- Align the unit with the DIN rail.
- Push the unit onto the rail until it clicks into place.
- The unit is now secured.
Demounting:
- Step 1: Unplug the male connector from the unit.
- Step 2: Pull the stirrup located at the base of the housing using a screwdriver to release the unit from the rail.
Modbus Installation
- For Modbus cabling, use 24 AWG shielded twisted-pair cable with a shunt capacitance of 16 pF/ft and 100Ω impedance.
- The controller offers an insulated RS485 communication interface connected to the RS485 terminals.
- A maximum of 32 devices can be simultaneously connected to the RS485 cable output.
- The RS485 cable should have 120Ω impedance and a maximum length of 1000 m.
- Terminal resistors of 120Ω are recommended at both ends for terminal devices.
- EKE communication frequency (baud rate) can be 9600, 19200, or 38400 baud (default is 19200 8E1).
- The default unit address is 1.
- Refer to EKE 110 manuals for detailed information on Modbus PNU.
A diagram shows the Modbus cable connections with wires for A+, B-, and GND, with 'Not in use' indicated for another wire.
Manual Resetting Modbus Address:
- Ensure pressure transmitter settings are configured to the ratiometric type.
- Remove supply power from the EKE 110.
- Connect terminal BAT+ to +5 V / 18 V (ensure step 1 is observed).
- Connect the EKE 110 to power.
- Modbus communication options will now reset to factory defaults: Address 1, 19200 baud, mode 8E1.
Signal Sharing:
- Power and backup supply sharing: 1 EKE 110 and 1 EKE 2U can share power supply (AC or DC). 2 EKE 110 and 1 EKE 2U can share power supply only with DC.
- Pressure transmitter sharing: Physical sharing is not allowed. Modbus sharing is allowed with more than 1 controller.
- Temperature sensor sharing: Physical sharing is not allowed. Modbus sharing is allowed with more than 1 controller.
Cabling
Stepper Valve Connector Assignments:
| 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 operate in bipolar mode with a 24 V supply controlled by a current driver. The stepper motor connects to the 'Stepper Valve' terminals using a standard M12 cable. For non-Danfoss stepper motor valves, correct parameters must be set in the Valve configuration section.
Cable Length and Wire Size:
| Connection Type | Cable length | Wire size min/max (mm²) |
|---|---|---|
| Power supply and Battery input | Max 5m | AWG 24-12 (0.34-2.5 mm²) Torque (0.5-0.56 Nm) |
| Analog inputs | Max 10m | AWG 24-16 (0.14-1.5 mm²) |
| Sensor | Max 10m | AWG 24-16 (0.14-1.5 mm²) |
| Stepper valve | Max 30m | AWG 24-16 (0.14-1.5 mm²) Torque (0.22-0.25 Nm) |
| Digital input | Max 10m | AWG 24-16 (0.14-1.5 mm²) |
| Digital output | Max 10m | AWG 24-16 (0.14-1.5 mm²) |
Maximum cable distance depends on factors like shielding, wire size, controller output power, and EMC. Keep controller and sensor wiring separate from mains wiring. Exceeding specified sensor wire length may reduce accuracy. Separate sensor and digital input cables from power cables by at least 10cm to avoid electromagnetic disturbances. Avoid running power and probe cables in the same conduit.
LED Alarm and Warning
The controller uses LED indications for status monitoring:
Alarm/Warning LED Indication:
A table shows patterns for 'No Alarm/Warning A' and 'Alarm/Warning A' over 2, 1, and 0-second intervals, related to Power status.
Valve position by LED indication (Normal valve operation):
A table displays LED patterns for different valve states: Valve closed, Valve closing, Valve idle on target (two entries), Valve opening, and Valve open, across 2, 1, and 0-second intervals.
Valve open circuit or valve driver heat problem:
A table shows LED patterns indicating a valve open circuit or driver heat issue.
Valve type not defined:
A table shows LED patterns indicating an undefined valve type.
General features and warning:
- Plastic housing features: DIN rail mounting compliant with EN 60715. Self-extinguishing V0 according to IEC 60695-11-10 and glowing/hot wire test at 960 °C according to IEC 60695-2-12.
- Other features: Suitable for integration into Class I and/or II appliances. Index of protection: IP00 or IP20 (depending on sales number). Designed for long periods of electric stress across insulating parts, suitable for normal pollution environments. Category of resistance to heat and fire: D. Immunity against voltage surges: category II. Software class and structure: class A.
CE Compliance
- Operating conditions: -20 to +70 °C, 90% RH non-condensing.
- Storage conditions: -30 to +80 °C, 90% RH non-condensing.
- Complies with Low voltage guideline: 2014/35/EU.
- Electromagnetic compatibility (EMC): 2014/30/EU and norms EN61000-6-1, EN61000-6-2, EN61000-6-4, and EN60730.
General Warnings
- Any use not described in this manual is considered incorrect and unauthorized.
- Verify installation and operating conditions match manual specifications, especially regarding supply voltage and environment.
- Service and maintenance must be performed by qualified personnel.
- The device must not be used as a safety device.
- Liability for injury or damage from incorrect use lies solely with the user.
Installation Warnings
- Recommended mounting position: vertical.
- Installation must comply with local standards and legislation.
- Disconnect the device from the main power supply before working on electrical connections or performing maintenance.
- For safety, the appliance must be fitted inside an electrical panel with no live parts accessible.
- Do not expose the device to continuous water sprays or relative humidity greater than 90%.
- Avoid exposure to corrosive gases, dust, strong vibrations, shock, rapid temperature fluctuations causing condensation, strong magnetic/radio interference.
- Use appropriate cable ends and tug cables gently to check tightness. Minimize probe and digital input cable length and avoid spiral routes around power devices. Separate from inductive loads and power cables to avoid electromagnetic noise. Avoid touching electronic components to prevent electrostatic discharge.
- Use appropriate data communication cables; refer to the EKE data sheet for recommendations.
- Minimize probe and digital input cable length and avoid spiral routes around power devices. Separate from inductive loads and power cables to avoid electromagnetic noise. Avoid touching electronic components to prevent electrostatic discharge.
Product Warnings
- Use a class II power supply.
- Connecting any EKE inputs to mains voltage will permanently damage the controller.
- Battery Backup terminals do not generate power to recharge a connected device.
- Battery backup 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.
Danfoss Related Products
Danfoss offers a range of related products:
Powersupply:
- AK-PS STEP3 ACCTRD: Input 230 V AC, 50–60 Hz. Output 24 V AC, available with 12 VA, 22 VA, and 35 VA.
Temperature sensor:
- PT 1000: AKS is a high-precision temp. sensor. AKS 11 (preferred), AKS 12, AKS 21, ACCPBT PT1000.
- NTC sensors: EKS 221 (NTC-10 Kohm), MBT 153 ACCPBT, NTC Temp probe (IP 67/68).
Pressure transducer:
- DST/AKS Pressure Transducer: Available with ratiometric and 4–20 mA.
- NSK: Ratiometric pressure probe.
- XSK: Pressure probe 4–20 mA.
Stepper motor valves:
EKE is compatible with Danfoss stepper motor valves such as ETS 6, ETS, KVS, ETS Colibri®, KVS colibri®, CTR, CCMT, ETS 8M, CCMT L, ETS L.
M12 cable:
M12 Angle cable to connect Danfoss stepper motor valve and EKE controller.
Backup power module:
EKE 2U energy storage device for emergency valve shutdown during power outage.
Accessories:
- EKA 200 Koolkey: Used as a service/copy key for EKE 100 controller.
- EKE 100 service cable: Used to connect EKE 100/110 controller to EKA 200 Koolkey.
