EKE Type EKE 100 Installation Guide

Introduction

The Superheat controller EKE 100 is designed for applications where superheat must be accurately controlled or as a driver for stepper motor valves. It is typically used in air conditioning, heat pumps, commercial refrigeration, food retailing, and industrial applications.

Compatible valves include: ETS 6, ETS 8M (Bipolar coil), ETS C, KVS C, ETS L, ETS 500-800P, CCMT L, CCMT, CCM, and CTR.

Basic Application

Diagrams illustrate two basic application scenarios: 'EKE 100 1Valve SH control' and 'EKE 100 2Valve SH control'. These diagrams show the EKE controller connected to stepper motor valves (e.g., ETS Colibri), temperature sensors (S2A), pressure sensors (PeA), and utilizing RS485 communication. The diagrams also show power connections.

Note: For driver function, connect an analog signal to the pressure port (PeA/PeB).

Dimensions

The physical dimensions of the EKE 100 units are presented. The EKE 100 1V model measures 70 mm in width, 110 mm in height, and 44 mm in depth. The EKE 100 2V model measures 70 mm in width, 110 mm in height, and 49 mm in depth. A variant, possibly the EKE 100 2V with display, measures 70 mm in width, 110 mm in height, and 49.5 mm in depth. Terminal blocks for Valve A, Valve B, and MODBUS are visible on the 2V models.

Technical Specification

Connection Overview

Diagrams illustrate the terminal connections for the EKE 100 1V and EKE 100 2V units. The tables below detail the function of each port.

Mounting/Demounting

The unit can be mounted onto a 35 mm DIN rail by simply 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.

Mounting:

1. Slide the unit onto the 35 mm DIN rail.
2. Push until it clicks into place and is secured by the stopper.

Demounting:

1. Step 1: Unplug the male connector.
2. Step 2: Pull the stirrup using a screwdriver and remove the EKE from the rail.

Sensor Installation

Sensor mounting: Temperature sensor

Diagrams show the process of mounting a temperature sensor onto an evaporator outlet. This involves applying conductive paste to a clean, paint-free surface and mounting the sensor approximately 5 cm from the outlet. The diagrams also indicate recommended pipe diameters (OD) for sensor installation: 1/2 - 5/8 in. (12-16 mm), 3/4 - 7/8 in. (18-22 mm), 1 - 1 3/8 in. (25-35 mm), and 1 3/8 in. and higher (35 mm and higher).

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.

Modbus Installation

For Modbus communication, it is recommended to use a 24 AWG shielded twisted-pair cable with a shunt capacitance of 16 pF/ft and 100 Ω impedance. The controller provides an insulated RS485 communication interface connected to the RS485 terminals. The maximum number of devices that can be simultaneously connected to the RS485 cable output is 32. The RS485 cable should have an impedance of 120 Ω and a maximum length of 1000 m. Terminal resistors of 120 Ω are recommended at both ends for terminal devices.

The EKE communication frequency (baud rate) can be 9600, 19200, or 38400 baud, with 19200 8E1 as the default. The default unit address is 1. For detailed information on Modbus PNU, refer to the EKE 100 Datasheet.

A diagram shows the Modbus connection terminals: A+, B-, GND, and a terminal labeled 'Not in use'.

Manual resetting Modbus address:

1. Remove Supply power from EKE 100.
2. Connect terminal BAT+ to +5V.
3. Connect EKE 100 to power.
4. Modbus communication options will reset to factory default (Address 1, 19200 baud, mode 8E1).

Signal Sharing

Power and backup supply sharing

• 1 EKE 100 and 1 EKE 2U can share power supply (AC or DC).
• 2 EKE 100 and 1 EKE 2U can share power supply only with DC.

Pressure sensor sharing

• Physical sharing is allowed if used within the same controller and not allowed if 2 or more controllers are used for sharing.
• Modbus sharing is allowed with more than 1 controller.
• Software sharing is allowed within one controller by selecting option Common.

Temperature sensor sharing

• Physical sharing is not allowed.
• Modbus sharing is allowed with more than 1 controller.
• Software sharing is allowed within one controller by selecting option Common.

Cabling

The table below shows the stepper valve connector pin assignments and corresponding wire colors for different valve types.

Note: All valves are driven in a bipolar mode with a 24 V supply chopped to control the current (Current driver).

[Warning] The stepper motor is connected to the “Stepper Valve” terminals 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 defined valve.

The table below specifies cable length and wire size requirements for various connections.

Wiring Considerations

• The maximum cable distance between the controller and the valve depends on factors such as shielded/unshielded cable, wire size, controller output power, and EMC.
• Keep controller and sensor wiring well separated from mains wiring.
• Connecting sensor wires longer than the specified length may decrease the accuracy of measured values.
• Separate sensor and digital input cables from power cables (at least 10cm) to avoid possible electromagnetic disturbances. Never lay power cables and probe cables in the same conduit, including within electrical panels.

LED Alarm and Warning

The controller features LED indicators for alarm, warning, and valve status. The 'Alarm/Warning LED indication' shows states such as 'No Alarm/Warning A/&B', 'Alarm/Warning A or B', and '5 Sec initial boot'. The 'Valve position by LED indication' displays normal valve operation states including 'Valve closed', 'Valve closing', 'Valve idle on target', 'Valve opening', and 'Valve open'. Fault conditions like 'Valve open circuit or valve driver heat problem' and 'Valve type not defined' are also indicated.

General Features and Warning

Plastic housing features

• DIN rail mounting complies with EN 60715.
• The housing is self-extinguishing V0 according to IEC 60695-11-10 and passes a glowing/hot wire test at 960 °C according to IEC 60695-2-12.

Other features

• Designed for integration into Class I and/or II appliances.
• Index of protection is IP00 or IP20, depending on the sales number.
• Suitable for use in a normal pollution environment, with a long period of electric stress across insulating parts.
• 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°C to 70°C, 90% RH non-condensing.
• Storage conditions: -30°C to 80°C, 90% RH non-condensing.
• Complies with the Low voltage guideline: 2014/35/EU.
• Electromagnetic compatibility (EMC): Complies with 2014/30/EU and the following norms: EN61000-6-1 (Immunity for residential, commercial, light-industrial), EN61000-6-2 (Immunity for industrial), EN61000-6-4 (emission), and EN60730 (Automatic electrical controls for household and similar use).

General Warnings

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

Installation Warnings

• Recommended mounting position: vertical.
• Installation must comply with local standards and legislation.
• Before working on electrical connections, disconnect the device from the main power supply.
• Before carrying out any maintenance operations, 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 with explosives or flammable gases, dust, strong vibrations or shock, large and rapid fluctuations in ambient temperature that might cause condensation with high humidity, or strong magnetic and/or radio interference (e.g., transmitting antenna).
• Use cable ends suitable for the corresponding connectors. After tightening connector screws, tug the cables gently to check their tightness. Minimize the length of probe and digital input cables and avoid spiral routes around power devices. Separate from inductive loads and power cables to avoid possible electromagnetic noises. Avoid touching or nearly touching electronic components on the board to prevent electrostatic discharges.
• Use appropriate data communication cables. Refer to the EKE data sheet for cable type and setup recommendations.
• Minimize the length of probe and digital input cables and avoid spiral routes around power devices. Separate from inductive loads and power cables to avoid possible electromagnetic noises. Avoid touching or nearly touching electronic components on the board to prevent electrostatic discharges.

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 device connected.
• 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.

Related Products

Power Supply

• AK-PS: Input 100-240 V AC, 45-65 Hz; Output 24 V DC (available with 18 VA, 36 VA, and 60 VA).
• 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: High precision temperature 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 output.
• NSK: Ratiometric pressure probe.
• XSK: Pressure probe 4-20 mA.

Stepper Motor Valves

• The EKE is compatible with Danfoss stepper motor valves, including Danfoss ETS 6, ETS, KVS, ETS Colibri®, KVS colibri®, CTR, CCMT, ETS 8M, CCMT L, and 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.