Emerson Control Link ACC Service manual

technical bulletin
Document Part # 026-4703 Rev 8 10-JUN-2009 Page 1 of 18
©2009 Emerson Climate Technologies Retail Solutions, Inc. This document may be photocopied for personal use.
Visit our website at http://www.emersonretailsolutions.com/ for the latest technical documentation and updates.
Installation Instructions: Control Link ACC Anti-Condensate
Controller System
Overview
The Control Link ACC Anti-Condensate Controller System is a stand-alone controller for anti-sweat
heaters in glass door cases. The Control Link ACC varies anti-sweat heat based on dewpoint and temp-
erature around the door frame, providing effective control of door sweat with the maximum amount of
energy savings.
Components
Control Link ACC (P/N 810-6101)
The Control Link ACC (Figure 1) handles all aspects
of anti-sweat heater control. The on-board processor
calculates the required heater ON time based on the
dewpoint and door temperature readings, and controls
an on-board Triac to activate and deactivate the heaters.
The controller is designed to mount in the mullion
between glass doors or in any other suitable electrical
enclosure, such as a raceway or on the top of the case.
The door frame temperature sensor and dewpoint sen-
sor are mounted remotely and connect to this controller
with cable harnesses.
Four LEDs can be viewed on the front of the plastic
enclosure. They indicate the general status, heater ON/
OFF state, MODBUS network transmit, and MODBUS
network receive.
Dewpoint Sensor (P/N 809-6112)
The Control Link ACC uses an external dewpoint sensor
(Figure 2) to measure the dewpoint of the outside air next
to the case doors. This sensor is typically mounted directly
above or to the side of the case doors.
The Dewpoint Sensor is supplied in a mountable enclosure
with a12-foot jacketed cable with a four-wire pigtail con-
nects the Control Link ACC to the dewpoint sensor.
Figure 1 - Control Link ACC
Figure 2 - Dewpoint Sensor (6112)

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
When Control Link ACC controllers are networked
together via MODBUS, a single dewpoint sensor con-
nected to one Control Link ACC may be shared by
multiple Control Link ACC controllers.
Door Temperature Sensor (P/N 201-6008)
In addition to the indoor air dewpoint, the Control
Link ACC also factors in the value of the temperature
of the case door frame using an externally mounted
temperature sensor. This small thermistor mounts to
the coldest surface of the door frame.
The door temperature sensor is supplied with an
8-foot two-wire cable with Molex connector, which
plugs into the Control Link ACC.
Mounting the Control Link ACC
The Control Link ACC enclosure is
designed to be mounted in a case mul-
lion, but may also be mounted in the
raceway or in a metal electrical enclosure
on the top of the case. Figure 4 shows
examples of where the Control Link
ACC may be mounted.
Use the two mounting tabs at the top and
bottom of the enclosure to screw the
enclosure to the case wall, raceway, or
enclosure.
The tab at the top end of the Control Link ACC (the end nearest the CPC logo) must be securely
mounted against a large heat-conductive surface. This tab has a metal backing which acts as a
heat sink, dissipating heat from the Triac that controls the heater. The metal tab must be
mounted against a conductive metal surface of at least 64 square inches so heat can be con-
ducted out of the controller. Failure to secure the top tab against the case mullion may cause con-
troller overheating and shutdown.
Use 9/64” drill holes for mounting, and secure the Control Link ACC to the metal surface using
#8-32 thread trilobular thread forming screws, Taptite II or equivalent (Ref. Ty-Bolts
#SCHWSZ08043-TR). Mounting screws are not included with the Control Link ACC.
Figure 3 - Dewpoint Sensor (6111)
(Discontinued)
Figure 4 - Control Link ACC Mounting
ACC
ACC
ACC

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
Wiring The Control Link ACC
Power And Heater Element Wiring
The four leads on the top end of the Control Link ACC
enclosure are where the connections to supply voltage
and the case door heater element(s) are made.
Connect the WHITE wire to the NEUTRAL side, and the
BLACK wire to the HOT side of 120-230VAC, 50/60Hz
line voltage.
The RED lead carries supply voltage when the door
heater Triac relay is ON (closed). Connect the RED and
WHITE leads to the case door heater elements. All
heater elements in the door frame and all doors of that
frame should be connected in parallel to the Control
Link ACC.
Connect the GREEN lead on the controller to ground.
Ratings and Current Protection
The Control Link ACC’s Triac is fused for 20A, 250V on the heater circuit, with a separate 1A
fuse on the control components so that communication can continue even if the Triac’s fuse
blows. Neither fuse is field-replaceable; if a fuse on the Control Link ACC blows, the controller
should be replaced. The maximum heater load is UL approved up to 13A.
WARNING! DO NOT CONNECT THE
POWER TO THE DEWPOINT SENSOR
LEADS AT THE BOTTOM OF THE ENCLO-
SURE. The small-gauge leads at the bottom
are the same colors, but they are for the dewpoint sen-
sor. Connecting power to these leads will damage the
board.
Figure 5 - Power/Heater Wiring
ACC

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
Mounting and Wiring the Sensors
The Dewpoint Sensor
Placement
In order for the Control Link ACC to
function properly, the dewpoint sensor
must be placed where it can measure
the dewpoint of the air outside the
case. Mount the sensor underneath the
top side of the case in the area just
above the top of the doors (see
Figure 6). If the sensor cannot be
placed there, mount the sensor on top
of the case.
Do NOT mount the dewpoint sensor
near the bottom of the case or any
place where cold air from the case can
affect the sensor reading. Avoid
mounting the sensor in an area with
excessive water spray or moisture, extremely dirty environments, near heat sources, or in the
direct path of HVAC returns.
Note About Using RTV Sealants
Placing the dewpoint sensor in either of these locations may require a hole to be drilled in the case
to run the wire from the sensor to the Control Link ACC. Use caution when sealing this hole with
RTV sealants — the sensor element is sensitive to high concentrations of RTV. Do not let any
RTV sealants touch the sensor element, and keep the sensor element as far as possible from where
the hole is sealed.
Dewpoint Sensor Mounting Dimensions
The Dewpoint Sensor is provided with a pair of
mounting holes with 2.75” spacing. Choose a
location as close to the case doors as possible,
preferably directly over the doors or (if necessary)
on top of the case. Secure the sensor to the mount-
ing location with two screws (not supplied —rec-
ommended size #6 x ¼” long with sheet metal
threads). Hex head is recommended, but a slotted
head can be used. Note that the enclosure allows
clearance for a nut driver on the screw head.
Figure 7 shows the mounting dimensions.
Figure 6 - Sensor Placement
Figure 7 - Dewpoint Sensor Dimensions

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
It may be necessary to cut a 0.25”x0.25” notch in the edge of the metal frame behind the sensor
for the wires to pass through.
Dewpoint Sensor Wiring
For wiring, the Dewpoint Sensor is pro-
vided with a 12-foot cable with a four-wire
pigtail at the end (P/N 335-3200). Connect
the cable to the dewpoint sensor leads at the
bottom of the Control Link ACC enclo-
sure, matching wire colors as shown in
Figure 8. Retail Solutions strongly recom-
mends Dolphin Super B Wire Connectors
(P/N 110-1000) for all crimp connections.
If the Control Link ACC will not have a
dewpoint sensor connected to it, it is recommended you insulate the ends of the Control Link
ACC’s dewpoint sensor leads by capping them with Dolphin Super B Wire Connectors.
Dewpoint Sensor Storage
Prior to installation, dewpoint sensors should be stored separately from the cables. Do not store
cables and sensors together for a long period of time in a closed box or bag. The sensor should be
separated from the cables when a shipment is received and stored apart, preferably exposed to
room air. The sensors can become contaminated by outgassing from the cable insulation if kept in
a closed up box or bag with the cable. Contamination can be reversed with exposure to room air
over a period of weeks or in a temperature/humidity chamber over a period of three days.
The Door Temperature Sensor
Placement
The Door Temperature Sensor should be placed in an area where it can measure the temperature
of the door frame in the location on the door frame that stays the coldest. The coldest spot on a
door frame is usually the bottom horizontal section of the stationary frame, under the center door
(for cases with even-numbered doors), or near the center mullion (for cases with odd-numbered
doors). Cooler doors may also be coldest at the top center of the frame. Figure 6 on page 4 shows
an example of placement in a case with even-numbered doors — the sensor is placed under the
door just to the left of the center mullion where the Control Link ACC is installed. Do not mount
the sensor inside the case mullion or anywhere outside the case.
Mount the case door temperature sensor along the door frame inside the frame. Secure the sensor
in place by screwing it to the door frame using the mounting hole.
NOTE: To replace the dewpoint sensor for recalibration pur-
poses, replace the entire assembly (keep the existing cable).
Figure 8 - Dewpoint Sensor Wiring
ACC

Document Part # 026-4703 Rev 8 10-JUN-2009 Page 6 of 18
©2009 Emerson Climate Technologies Retail Solutions, Inc. This document may be photocopied for personal use.
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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
The sensor is supplied with an 8-foot cable, with a Molex connector. Plug the connector into the
matching socket at the bottom of the Control Link ACC enclosure.
Network Wiring and Configuration
If each Control Link ACC will be configured with its own dewpoint sensor, it is not necessary to
network the Control Link ACC together. However, when networked, multiple Control Link ACC
controllers may use a single dewpoint sensor. Furthermore, because the Control Link ACC is a
MODBUS-compliant device, a site controller can be programmed to communicate with the Con-
trol Link ACC controllers via MODBUS, supporting remote configuration and data acquisition.
The E2 controller supports networking of up to 63 Control Link ACC controllers.
Network Connection to E2
Connecting a Control Link ACC to an
E2 unit requires the E2 to be version
2.71 or above. Contact Retail Solutions
for upgrade information if the controller
is a version before 2.71.
An E2 has up to three COM ports that
can be assigned for MODBUS commu-
nication (COM2, an RS485 port on the
E2 power interface board, and COM4
and COM6, which are optional ports
requiring expansion cards). COM ports
can only be used for one function; in
other words, if COM2 is set up as the
I/O network, you cannot connect MOD-
BUS devices to COM2. Ensure your E2
is equipped with an RS485 COM Card
(P/N 637-4890) and configured in E2
General Services (I, Serial
tab) to enable COM4 or an E2 Expansion COM Card (P/N 637-4871) to enable COM6.
Connect the MODBUS network cable to the three-terminal connector on the COM port you wish
to assign as MODBUS. Like other Control Link connections, wire RS485+ to RS485+, RS485- to
RS485-, and the shield cable to the middle terminal. If the E2 will be the first device in the daisy-
chain, set the port’s termination jumpers to the TERMINATED & BIASED position (all three
jumpers UP); otherwise, set all jumpers DOWN if not the first device.
COM1
COM4
COM6
COM2
Serial Device
RS485 COM Port
(2 Connectors)
RS485 COM Card
(2 Connectors) Serial Device
RS232 Port
POWER INTERFACE BOARD
(PIB)
E2 Modem/Expansion
COM Card Mounted
Above PIB
Plug-In
Modem
Card
COM3
E2 Enclosure (Right Side)
RS485
RS232
Figure 9 - Location of E2 COM Ports

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
E2 Setup of Control Link ACC Devices
Set Up Network Ports
Before setting up a Control Link ACC, the port on the E2 that has the MODBUS cable connected
must be set up as a MODBUS port.
1. Log in to the E2 with Level 4 access.
2. Press I followed by  - General Controller Info.
3. Press 4+ to open the Serial tab of the General Controller Info setup screens:
4. This screen will have a “Connection” field for all COM ports on the E2. Highlight the COM
port connection field that will be used for Control Link, and press D - LOOK UP. From
the list of network types, select MODBUS.
5. Four fields will become visible underneath the COM port connection field, which pertain to
the way the device communicates:
•Baud - Default setting is 19.2k. The baud rate setting should be set to match the baud rate dip switch settings
of all Control Link devices. (All devices connected to the same COM port should be set to the same baud
rate.)
•Data Size - Leave this field at the default value (8).
•Parity - Leave this field at the default value (None).
•Stop Bits - Leave this field at the default value (1).
6. Press J to save changes and exit.
Add and Connect Control ACCs
To enable communications between E2 and the Control Link units, the devices must be added and
addressed in E2.
1. Log in to the E2 with Level 4 access.
2. Press I - Connected I/O Boards and Controllers.
Figure 10 - Serial Communications Manager Screen

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
3. In the Connected I/O screen, in a box labeled ECT Devices. Enter the number of ACC devices in the
CtrlLink ACC number field.
4. Press J to return to the Network Setup menu, then select  - Controller Setup.
5. Locate the CtrlLink ACC units you added to the network list (press 8 and 7 to scroll through the list). The
default name for a Control Link ACC begins with a two-letter designator of the model type (AC for anti-con-
densate). If desired, enter a new name for each device in the Name field.
6. By default, each CtrlLink ACC in the network list has a board number of 0. To set the address and begin
communication, press D and select  - Select Address. In the list of MODBUS devices, choose the
address number corresponding to the Control Links ACC’s dip switch/jumper setting, and press > to
select it. If a network ID has already been selected, its name will be shown next to the network ID in this list.
If the network ID you are trying to assign has already been used, you must set the network ID dip switch/
jumper on this device to a different number that is not being used.
Figure 11 - Connected I/O Screen
Figure 12 - Controller Setup Screen

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
technical bulletin
7. Repeat Steps 5 and 6 until each Control Link ACC device has a name and address.
8. When finished, press J to return to the Network Setup menu, then press  - Online Status (Figure 14).
Locate the Control Link ACCs you set up, and look at each device’s status in the Status field. You will see
one of the following messages:
•Online - The Control Link ACC is communicating normally.
•Offline - The Control Link ACC is not communicating, has not been commissioned, is not functional, or is not powered up. Ver-
ify the Control Link ACC is powered up, wired correctly, and has the proper network address, baud rate, and parity (see
“Troubleshooting Control Link ACCs and the ECT MODBUS Network” on page 18).
•Unknown - The Control Link ACC is not communicating or has not been commissioned. Verify the Control Link ACC is pow-
ered up, wired correctly, and has the proper network address, baud rate, and parity (see “Troubleshooting Control Link
ACCs and the ECT MODBUS Network” on page 18).
•No Port - No port is set up in the E2 Serial Configuration Manager to be a MODBUS port. Follow the instructions in “Set Up
Network Ports,” page 7.
•Wrong FW Rev - This message is likely caused by the Control Link ACC having a firmware version older than the minimum
revision required by E2 for communication. Replace the Control Link ACC with a new controller that has the latest version
of firmware on it.
Figure 13 - List of MODBUS Devices

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Installation Instructions: Control Link ACC Anti-Condensate Controller System
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Wiring Types
Retail Solutions specifies Belden #8761 shielded twisted pair cables for use as MODBUS wiring (or Belden
#82761 and Belden #88761 for plenum installations).
If the recommended cable is not available in your area, be sure the wiring meets or exceeds the following specs:
Shielded? Yes
Conductor Type Twisted Pair
Gauge 18 - 24 AWG
Capacitance between
signal wires 31 pF/ft or less
Capacitance between
signal and shield 59 pF/ft or less
Maximum Length 4000 ft/18 to 22 AWG
2500 ft/24 AWG
Nominal Impedance 120Ω±50Ω
Figure 14 - Online Status Screen