Ke2 therm solutions Evaporator efficiency User manual

Parts List

The following parts are included in the

KE2 Evaporator Eciency (KE2 Evap) controller kits:

Kit # 20178 with 120/208-240 VAC controller

- OR -

Kit #20222* with Beacon® I or II replacement controller

(4) 3-position screw down terminals (for power in, transducer

and 3A relays)

(1) 120 Voltage jumper

(1) 208-240V Voltage jumper (already on back of KE2 Evap)

(1) 5-position screw down terminal (for EEV)

(8) 2-position screw down terminals (for sensors and digital

input, analog output)

(1) High voltage safety shield

(1) Warranty card

(1) Air sensor mount

(4) wire ties (rated for low temp)

(5) Self-tapping screws

(4) 90 degree quick disconnects

(1) ne thread machine screw with lock washer

(2) course thread screws

(3) temperature sensors

(2) 1/2” plastic knockout plugs

* Beacon® kit includes an extra temperature sensor, pressure transducer and cable.

Q.1.3

September 2012

KE2 EvaporatorEfciency

Installation Manual

Supplies List

The KE2 Evap is supplied with all of the accessories required for the

controller to work, however, standard truck stock items will also be

required to install the controller. To simplify the installation, a list of

items has been provided.

Conduit to go between the controller and the evaporator

(2) Conduit connectors (straight or elbow as required)

(11) High voltage wires matched to the load of the heat-

ers, fans, liquid line solenoid, alarm (if used), and the

controller.

(8) Spade Connectors matched to the gauge of high volt-

age wires

Wire labeling (numbers, colors, etc.)

Additional wire ties

18 gauge twisted shielded pair (if extending sensor wires)

Foam insulation if running wires outside the space.

Silicone (for sealing any box penetrations)

B C D

This reference should remain on site with the installed KE2 Evaporator Eciency controller.

Q.1.3 September 2012

Page 2

KE2 EvaporatorEfciency

Quick Start Guide

for low temperature applications and 8-10 degrees for medium

temperature.

Subcooling - There should be a solid column of liquid at the inlet of

the valve. This can be veried by looking at the sight glass, however,

the proper method is to measure the subcooling of the liquid enter-

ing the valve.

Verify Temperature Dierence

A typical Temperature Dierence (TD) between the coil temperature

and the air temperature is between 5 and 15°F. An insucient TD,

between the coil and air temperature, indicates a system issue that

needs to be addressed before installing the KE2 Evap Eciency.

Understanding Frost

The air exiting side of the evaporator is often the coldest spot on the

coil due to the load eecting the temperature. As air travels through

the ns of the evaporator, the Relative Humidity will reach 100%.

Moisture will begin to drop out of the air and deposit on the coil

surfaces to form frost. Although frost typically has a negative con-

notation when discussed in refrigeration, initial frost formation has

a positive eect. Some may even say “frost is our friend.” It is not un-

common to see a small amount of frost on the coils that have KE2

Evaporator Eciency (KE2 Evap) controllers installed. The KE2 Evap

is continually measuring, monitoring, and managing the frost to as-

sist in maximum energy eciency. When the eciency of the coil is

reduced due to excessive frost, the KE2 Evap will initiate a defrost.

Liquid/Vapor Mix

Restrictor,

TEV or EEV

Warm Liquid

Cold Vapor

Hot Vapor

Warm Air

Cold Air

Evaporator

Compressor

Condenser

Saturation Temp °F

(from receiver pressure)

Liquid Temp at Valve °F

Subcooling °

Suction Pressure PSI

Suction Temp °F

(evaporator outlet)

Saturation Temp °F

(calculated from Suct. Pressure)

Superheat °

Temp Dierence (TD) °F

(return air minus coil temp)

Coldest point in evap °F

AMPS

Trouble Shooting Diagram

Discharge Pressure PSI

Refrigerant

Arriving at the Jobsite

When arriving at any jobsite, it is good practice to verify the correct

operation of the system. Even systems running for a considerable

amount of time without requiring a service call may not be running

properly.

Inspect the coil to see the current frost pattern. If the unit has not

recently performed a defrost, look for the heaviest area of frost. This

will be used to locate the coil sensor.

Installers should account for a full system diagnostic in the installa-

tion estimate for the controller.

Although it may seem unnecessary, identifying system issues before

the controller is installed will save time overall. It will also allow the

controller to provide the highest energy savings.

Verify the system is running correctly. Taking several measurements

will help determine the current health of the system. Using the dia-

gram below, ll in the necessary information.

Two of the most critical indicators of system health are the super-

heat and subcooling.

Superheat - Superheat is the most overlooked ineciency in exist-

ing systems. Typically the superheat on a TEV is set when there is not

product in the controlled space, if it is set at all.

When applying the controller to an existing system with a mechani-

cal expansion valve, the superheat should be between 6-8 degrees

Q.1.3 September 2012

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KE2 EvaporatorEfciency

Quick Start Guide

IMPORTANT Preliminary Steps

Determine the coil sensor location

To determine the most appropriate sensor location, when arriving on

site, put the system into defrost.

The location where frost is last to disappear is where the coil sensor

should be placed. Monitor both the air entering side, as well as the air

exiting side, of the evaporator coil. Don’t be surprised if the last place

for frost to disappear is on the air exiting side. It is usually near the

right or left end of the coil.

It is important to verify all heating elements are working properly.

Steps to Ensure Proper Coil Sensor Location

On larger evaporators (>864 in2), and in process facilities, KE2 Therm

recommends using two coil sensors, located as described above.

Typically the coldest spot is on the side of the suction header/expan-

sion valve side of the evaporator. Select two places that are the last to

defrost, preferably at each end of the evaporator.

More often than not on coils, the location of the sensor is a short

distance from the end, approximately 1 to 1-1/2”away from the right

and left edges of the active coil surface. The ice tends to grow from

these edges towards the center. Therefore, the sensor location is best

situated approximately 1 to 1-1/2”from the outer edges and typically

near the bottom 1/3rd portion of the evaporator. The sensor needs to

be as far away from the defrost heat sources as possible.

Note: Insert plug (Item O from parts list) into coil housing when

mounting sensor wire to prevent damage to the sensor from

sharp edges. Two plugs are provided. One plug should be inserted

into the inner housing to access the coil, and the other into the outer

housing to exit the coil. Installer must puncture plug to insert sensor.

DMake note of the locations you have determined for placement

of the coil sensors.

Typically last spots to defrost

Locate sensor approx.

1-1/2”from end, in the

bottom third of coil

Item O from Parts List on page 1

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KE2 EvaporatorEfciency

Quick Start Guide

KE2EvaporatorEfficiency

thermsolutions

ENTER

BACK

KE2EvaporatorEfficiency

thermsolutions

ENTER

BACK

KE2EvaporatorEfficiency

thermsolutions

ENTER

BACK

At the entrance

On the wall

On the evaporator

11 Determining Location

The controller is designed to be as versatile as possible. The loca-

tion should be discussed with the end users to determine if they have

a preference. It is designed so it can be installed inside or outside the

controlled space.

The controller can also be located at the condenser, but should not

be installed outdoors without an enclosure to protect it from sun-

light and moisture (must be within operating range -40°F to 140°F)

KE2 EvaporatorEfficiency

thermsolutions

ENTER

BACK

Evaporator

Cut a length of conduit to go from the controller to the evaporator

Measure the distance between the controller and evaporator to ac-

count for the extra length necessary to properly route conduit.

Determine the number of wires to go to the controller.

Controller power (3 wires)

Fan control (2 wires)

Defrost (heater) control (2 wires)

Liquid line solenoid (2 wires)

Alarm relay (2 wires)

Note: Install in accordance with local wiring codes. KE2 Therm

does not accept responsibility for incorrect or unsafe wiring.

Cut wires to length

Once the number of wire is determined, cut the wires to length.

The wire should be long enough to account for the necessary con-

nections in the controller and evaporator.

Using dierent colored wires, (blue - fan, orange - heaters, yellow

- solenoid, purple - alarm) will simplify the installation and trouble-

shooting. If only a single color is available, both ends of the wires

should be labeled with a matching number. This will save time when

wiring the evaporator.

Q.1.3 September 2012

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KE2 EvaporatorEfciency

Quick Start Guide

Determine the current draw of the unit.

Using the nameplate to determine the Amp rating of the unit. This

information should be used to select the proper sized wire. It should

also be used to verify the unit does not exceed the relay rating on the

KE2 Evaporator Eciency controller.

4 4

Preparing conduit

Feed the wires through the conduit.

The conduit connectors can be added at this time. Determine if a

straight or 90 degree connector is most appropriate for the installa-

tion, and attach to the conduit.

Securely connect one end of the conduit to the controller.

5 5

120V 208-240V

Wiring the controller

Locate the second Voltage Jumper in the accessory kit.

It is a 2 position plug with red jumper already installed.

Plug 1 jumper on the center 2 pins for 208-240V power and 2 jump-

ers on the outer 2 pins for 120V power.

Power is not connected to Voltage selector, it is a selector only.

Power for the controller is connected to the Power In location us-

ing a 3 position connector.

The controller will still illuminate the display when 120V is ap-

plied with 208-240V selected, however the controller will not

function properly.

6 6

Controller Power

Strip the end of the wires used to provide power to the controller

Locate a 3 position terminal in the accessories kit.

Fasten to the 3 position pluggable connector*.

Plug into the board as indicated in Wiring Schematic.

*All terminal screws should be tightened to 5 ft-lbs.

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KE2 EvaporatorEfciency

Quick Start Guide

Fan Relay

Strip the end of the 2 wires used for fan control.

Locate 2 female spade connectors in the accessories kit.

Crimp on the female spade connectors.

Plug the connectors to the COM and NO positions of the Fan Relay.

Conrm combined fan motor load is not over 10 amps

Defrost (Heater) Relay

Strip the end of the 2 wires used for the defrost control.

Locate the remaining 2 female spade connectors in the accessories

kit.

Crimp on the female connectors.

Plug the connectors to the COM and NO positions of the Defrost

Relay.

Conrm combined heater load is not over 20 amps.

9 9

Liquid line solenoid /Compressor Relay

Strip approximately 1/4”of wire insulation on the end of the 2 wires

the will be used for the liquid line solenoid

Locate a 3 position connector from the accessories kit.

Fasten the wires to the screw terminals.

Plug into the location as indicated in Wiring Schematic.

Max relay rating is 3A

10 10

Auxiliary Relay

Strip approximately 1/4”of wire insulation on the end of the 2 wires

to be used for the alarm

Locate a 3 position connector from the accessories kit.

Fasten the wires to the screw terminals.

Plug into the location as indicated in Wiring Schematic.

Max relay rating is 3A

11 11

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KE2 EvaporatorEfciency

Quick Start Guide

Preparing the Evaporator

The evaporator wiring will require access to the high voltage termi-

nal block on the coil.

Turn o power to the system.

Verify power is no longer present using a multimeter.

Note: Before installing the safety cover, plug in any remaining connec-

tors to store for future use.

Install Safety cover

Once all of the high voltage wiring is complete, install the metal

cover on the controller.

Locate the cover and 3 small screws from the accessories kit.

Position the cover over the 3 mounting posts.

Using the 2 course threaded screws attach the controller to the

plastic posts.

Use the ne threaded machine screw with lock washer to fasten the

controller to the metal post.

Set the controller in a safe place.

12 12

13 13

Evaporator wiring

Now that the conduit is prepared, it can be connected to the

evaporator.

Locate the proper sized knockout and carefully remove knockout.

Connect conduit to the evaporator

1414

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KE2 EvaporatorEfciency

Quick Start Guide

Study the existing wiring.

Determine the location of the following: incoming power, fan

leads, heater leads, defrost termination leads, and fan delay leads.

15 15

Evaporator wiring – Controller

Strip the end of the wires used to power the controller.

Attach to the line power to provide continuous power to the

controller.

Attach ground wire.

Note: Ground is required for the internal safeties to operate properly.

Evaporator wiring – Fans

Strip the ends of the wires (connected to the KE2 Evap) used to

control the evaporator fans.

The fan wires can be attached to the terminal block using either

screw down terminals or spade connectors.

Attach one of wires to the L1/Line. This wire will be connected to

COM of fan relay on the controller.

Attach the wire connected to the NO terminal on the Fan Relay to

one of the fan leads.

Connect L2/Neutral to remaining fan lead.

Evaporator wiring – Heater

Strip the ends of the wires being used for heater control.

The heater wires can be attached to the terminal block using either

screw down terminals or spade connectors.

Evaporator wiring – Liquid Line Solenoid /Compressor

Strip the ends selected to control the liquid line solenoid.

Attach the wire from the NO terminal on the L.L. Solenoid/

Compressor relay to one of the solenoid leads. Attach the wire

from the COM on the L.L. Solenoid/Compressor relay to the L1/Line

Voltage.

Connect L2/Neutral to the remaining L.L. Solenoid/Compressor

lead.

Remove defrost termination (Klixon®) from circuitry

Attach one of wires to the L1/Line. This wire will be connected to

COM of defrost relay on the controller.

Attach the wire connected to the NO terminal on the Defrost Relay

to one of the defrost leads.

Connect L2/Neutral to the remaining defrost lead.

The defrost safety should not be removed from the circuit. Its purpose

is to prevent the heaters from over heating and causing damage.

Q.1.3 September 2012

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KE2 EvaporatorEfciency

Quick Start Guide

Legend

EFM - Evaporator Fan Motor

DH - Defrost Header

LLS - Liquid Line Solenoid

AUX - Auxiliary

PT - Pressure Transducer

TSUCTION - Suction Temperature

TAIR - Return Air Temperature

TCOIL - Evaporator Coil Temperature

TAUX - Auxiliary Temperature

EEV - Electric Expansion Valve

ECM - Electronically Commutated Motor

D1 - Digital Input 1

D2 - Digital Input 2

D3 - Digital Input 3

- - - By others

All eld wiring must conform to local codes

Wiring Schematic -

Controller New Installation

Q.1.3 September 2012

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KE2 EvaporatorEfciency

Quick Start Guide

P/N: 20217 - 50A

20218 - 65A

20219 - 80A

Legend

EFM - Evaporator Fan Motor

DH - Defrost Header

LLS - Liquid Line Solenoid

AUX -Auxiliary

PT - Pressure Transducer

TSUCTION - Suction Temperature

TAIR - Return Air Temperature

TCOIL - Evaporator Coil Temperature

TAUX - Auxiliary Temperature

EEV - Electric Expansion Valve

ECM - Electronically Commutated Motor

D1 - Digital Input 1

D2 - Digital Input 2

D3 - Digital Input 3

- - - By others

All eld wiring must conform to local codes

Contactor ratings per UL508 CSA 22.2

Evaporator Fan Motors

Con1 Max HP & Amp Ratings (Total All Fans)

Voltage Max HP Max AMPS

230 3e 15 42

460 3e 30 40

575 3e 30 32

Existing Defrost Heaters Con2 Max Current Ratings

(Amps are Total All Heaters)

Relay Box P/N 230V 3Ø 460V 3Ø 575V 3Ø

20217 54 Amps 52 Amps 52 Amps

20218 68 Amps 65 Amps 62 Amps

20219 80 Amps 77 Amps 62 Amps

Wiring Schematic -

Controller with Contactor Box

Q.1.3 September 2012

Page 11

Evaporator wiring – Auxiliary

The auxiliary relay is optional and wiring will vary depending on the

auxiliary relay method selected.

Depending on auxiliary relay location, an additional conduit may

be required.

Strip the ends selected to control the auxiliary component.

Break the hot leg of the auxiliary component.

Attach the wire from the NO terminal on the auxiliary relay to one

of the auxiliary component leads. Attach the wire from the COM on

the auxiliary component relay to the L1/Line Voltage.

Connect L2/Neutral to the remaining auxiliary component lead.

Route and secure the conduit to the location the controller is to be

installed.

Wiring must follow local wiring codes.

22 22

Installing the sensors

Although not required, sensors should be labeled with their func-

tion. This will eliminate confusion when connecting the sensors to

the controller.

Air Sensor Bracket

Install the Air Temperature Sensor using the Stainless Steel self-

piercing screw and bracket from the accessory kit.

The end with the single loop is designed to be mounted with the

screw included.

The end with multiple loops is designed to hold the sensor.

Locate the best place to install the sensor.

The sensor should be located between 6 and 12 inches away from

the face of the evaporator. This distance prevents the sensor from

sensing heat from the heating elements during the defrost cycle, but

close enough to accurately sense the return air temperature.

The sensor bracket may be bent as necessary to locate the sensor

in the proper position.

WARNING!

Do not allow the metal portion of the air sensor to touch any-

thing other than air. It should not touch the bracket, nylon cable

tie, or any other solid surface.

23 23

KE2 EvaporatorEfciency

Quick Start Guide

KE2 EvaporatorEfciency

Quick Start Guide

Q.1.3 September 2012

Page 12

Coil Sensor

The coil sensor location is of the utmost importance for the

proper operation of the controller. It is essential that the sen-

sor is in the coldest location on the coil at the end of the defrost

cycle, to ensure a complete defrost. See preliminary steps A-D on

page 3 to determine the coldest location on the coil.

Once you have determined the proper sensor location as described

in preliminary steps A-D on page 3, the sensor can be installed.

Insert the probe into the ns approximately 1/16” deeper than the

stainless shielding of the probe. Pinch the two ns gently together to

secure the sensor in place. This provides the thermal ballast to ensure

a complete defrost every time.

Extending sensor wires

After the sensors are mounted, they are routed back to the control-

ler. If the sensors are mounted within 10 feet of the controller, the

included wiring may be used without modication. If the installation

requires more than 10 feet, the wires must be extended using 18

gauge twisted shielded pair. Maximum length for 18 gauge: 100ft.

When running the wires back to the controller care must be tak-

en to avoid interference being introduced into the sensor wires.

Interference can be introduced when sensor wires are located

near high voltage lines. High voltage is dened by Underwriter’s

Laboratories as being above 30V. The higher the voltage the more

likely it is to introduce interference and the more important to avoid.

If crossing a high voltage line is necessary, the sensor wiring should

be run at right angles to prevent noise.

Sensor mounted on same side of coil as distributor tube entry.

1.5”

Thermistor

Epoxy

.5”

Installing the Sensor Properly

It is important to note, the most active portion of the sensor is the

rst 1/2” of the 1-1/2”long stainless steel probe.

As a result, it is important to touch two circuit tubes. When inserting

the sensor into the coil, the tip should touch one of the circuit tubes.

This location provides an appropriate location for the sensor.

Q.1.3 September 2012

Page 13

Connecting sensor wires to controller

The temperature sensors are designed to be attached to the con-

troller using 2 position screw terminals. Using a connector from the

accessory kit, attach the sensor to the screw terminal. The sensors are

not polarized, so wire location does not eect sensor performance.

Connect all sensors to a screw terminal.

Once connected, the sensors should be plugged into the proper lo-

cation on the controller. The location can be determined from the la-

bel on the interior wall of the enclosure or from the Wiring Schematic.

Strain relief

The enclosure has been designed with a strain relief bar to pre-

vent the sensor wires from becoming unplugged from inadvertent

contact.

Before securing the sensor wires, create a service loop as shown in

Figure 27.

Using a cable tie from the accessory kit, securely fasten the sensor

wires to the strain relief bar.

Note: Unused connectors should be placed (installed) in their re-

spective location for future use.

27 27

Controller Mounting

Locate the 4 stainless steel screws in the accessories kit

Install the 4 screws

Place the controller on the mounting screws and tighten down the

screws.

28 28

Final Step

Leave the installation instructions onsite in a convenient location,

where it can be easily located, for future service.

KE2 EvaporatorEfciency

Quick Start Guide

KE2 EvaporatorEfciency

Quick Start Guide

Q.1.3 September 2012

Page 14

208-240

120

Temperature Sensors Pressure

Transducer

TSuctTAux TAirTCoil

line /L1

ground

neutral /L2

NO NC

COM

Power In

green

red

black

Transformer

3A Relay

COM

COM NC

18V

DI 1

DI 3

DI 2

Electric Valve*

Temperature Sensors (4) Pressure Transducer

RJ45 Ethernet Connection

ECM Fan

Fuse

ground

red

green

white

black

Alarm Relay

Fan Relay

(10 amp)

ground

signal +5

Defrost (Heater) Relay

(20 amp)

Bk/MDL-1/4

Time Delay

Liquid Line Solenoid

Power In

(compressor)

door switch

pumpdown

dual temp setting

external alarm

light switch

camera switch

Digital Inputs

Pressure Transducer

Wiring Detail

black

red

green

Voltage

Selector

120V - Jumpers

1&2 3&4

208-240V Jumper

2&3 only

1 2 3 4

yellow

blue

red

white

black

brown

green

white

yellow

*Beacon® I

*Beacon® II

blue

red

white

black

*Beacon® II

Table 1 - Specications

Controller

Input Voltage: 120V or 208-240V

Ambient Temp: -40° to 140°F

Operating Temp: -40° to 140°F

Display: 4 digit alphanumeric LED

IP Rating: IP65

Inputs: 4 temperature sensors (KE2 SKU 20200)

1 pressure transducer (KE2 SKU 20204)

Valve Types: unipolar and bipolar stepper motors (12V); (Beacon®II is 21V)

Relays: 20A resistive (defrost); 10A inductive (evaporator fan)

2–3A inductive rated cycles

Digital Input 1 & 2: door contact, use 2nd air temp setpoint, disabled, system o,

external alarm notication

Digital Input 3 door contact, use 2nd air temp setpoint, disabled, system o,

external alarm notication, lights, camera

Communication: Standard TCP/IP

Pressure Transducer

Pressure Range: 0 to 150 psia

Proof Pressure: 450 psi

Burst Pressure: 1500 psi

Operating Temp: -40° to 275°F

Temperature Sensor

Sensor Specs: -60° to 150°F moisture resistant package

Q.1.3 September 2012

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KE2 EvaporatorEfciency

Quick Start Guide

Table 1 - Controller Navigation - Menu Structure

Parameters:

MANUAL CONTROL

MANUAL VALVE

CLEAR ALARMS

MANUAL COMPRESSOR RELAY

MANUAL DEFROST RELAY

MANUAL FAN RELAY

DHCP

FACTORY RESET

Menus: Variables Manual

(view only)

Non-adjustable

NO ALARM

PRESSURE SENSOR

SUCTION TEMP SENSOR

AIR TEMP SENSOR

COIL TEMP SENSOR

AUX TEMP SENSOR

HIGH SUPERHEAT

LOW SUPERHEAT

HIGH AIR TEMP

LOW AIR TEMP

EXCESS DEFROST

DEFR TERM ON TIME

DOOR SWITCH

COMMUNICATION ERROR

EXT ALARM

Alarms

(view only)

ENTER

Left Arrow and Right Arrow

Use to move between Menus

Up Arrow and Down Arrow

Scroll through Menu Parameters

ENTER

Press and hold ENTER for 3 seconds, when display

begins blinking changes can be made

BACK

Press BACK to return to the previous view.

ENTER

Press and hold ENTER for 3 seconds to save change

To change settings:

To save setting changes:

To move through

controller menus:

To return to Main Menu:

Indicator lights Red light - critical alarm (system o)

Yellow light - non-critical alarm (system running)

Green light - compressor on

Green ashing - compressor waiting on timer to start/stop

KE2 EvaporatorEfficiency

thermsolutions

ENTER

BACK

ROOM TEMP

DEFROST TYPE

VALVE TYPE

MOTOR TYPE

MOTOR STEP RATE

MAX VALVE STEPS

SUPERHEAT

MAX OPERATING PRES

REFRIGERANT

AUX TEMP MODE

AUX RELAY MODE

MIN COMP RUN TIME

MIN COMP OFF TIME

REFRIG FAN MODE

DEFROST MODE

DEFROSTS / DAY

1ST DEFROST DELAY

DEFROST FAN STATE

DEFROST TERM TEMP

DEFROST PARAMETER

DRAIN TIME

COMP RUN TIME

ELEC DEFROST MODE

FAN DELAY TEMP

MAX FAN DELAY TIME

PUMP DOWN TIME

MULTI AIR TEMP CTRL

MULTI EVAP COOL

MULTI EVAP DEFROST

MULTI EVAP SENSOR

HIGH TEMP ALARM OFFSET

HIGH TEMP ALARM DELAY

LOW TEMP ALARM OFFSET

LOW TEMP ALARM DELAY

DOOR ALARM DELAY

DIG IN 1 MODE

DIG IN 1 STATE

DIG IN 2 MODE

DIG IN 2 STATE

DIG IN 3 MODE

DIG IN 3 STATE

2ND ROOM TEMP

SUCT PRES OFFSET

SUCT TEMP OFFSET

AIR TEMP OFFSET

COIL TEMP OFFSET

AUX TEMP OFFSET

TEMP UNITS

AIR TEMP DIFF

EXTREME TEMP DIFF

Setpoints*

* The Setpoint paramenters shown

in BOLD (Valve Type, Room Temp

Setpoint and Defrost Mode) need to

be set by the user prior to start up.

The other Setpoint Parameters can

also be adjusted, however the

factory setpoints are generally

correct for most applications.

The Setpoint parameters shown in

ITALIC are only displayed when an

EEV is used.

The Setpoint parameters shown in

BOLD ITALIC are displayed for

bonded controllers only.

ROOM TEMP

COIL TEMP

SYSTEM MODE

SUPERHEAT

SUCTION PRESSURE

SUCTION TEMP

SATURATION TEMP

VALVE % OPEN

AUX TEMP

COMPRESSOR RELAY

DEFROST RELAY

FAN RELAY

DIG 1 STATUS

DIG 2 STATUS

DIG 3 STATUS

IP OCTET 1

IP OCTET 2

IP OCTET 3

IP OCTET 4

SUBNET MASK OCTET 1

SUBNET MASK OCTET 2

SUBNET MASK OCTET 3

SUBNET MASK OCTET 4

FIRMWARE VERSION

Variables

for DIG IN Mode

DIG IN MODE = DISABLED

DIG IN MODE = 2ND (ROOM) TEMP

DIG IN MODE = DOOR SWITCH

DIG IN MODE = EXT ALARM

DIG IN MODE = SYSTEM OFF

DIG IN MODE = LIGHT SWITCH

DIG IN MODE = CAMERA SWITCH

Q.1.3 September 2012

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KE2 EvaporatorEfciency

Quick Start Guide

User Interface

The KE2 Evap’s onboard user interface uses a familiar 6-button ar-

rangement to simplify navigation through the controller’s menus.

The menu has been grouped by category to provide an easy to pro-

gram structure. By grouping the menu by each functional area, the

user is not required to scroll though unrelated setpoints to access the

desired functionality.

The left and right arrows move between the categories. When

pressed while in a menu, the left and right arrows will move to the

main screen or the adjacent menu.

The up and down arrows move the user through the available op-

tions for each group. All users are allowed access to the variable

alarms. All other information is password protected to prevent unau-

thorized access to the controller’s functionality.

The ENTER button is used to save an input option when it has been

changed. The enter button must be held for 3 seconds to prevent

accidental changes. Changes may be discarded by waiting, to allow

the controller to timeout and return to default screen, or hitting the

BACK button.

The BACK button is used to return to the previous screen. Pressing

the BACK button twice at any time will return the user to the default

view. See Table 1.

Controller Setup

Upon initially applying power to the controller, the controller will ini-

tialize, then automatically enter the Quick Start Menu. The Quick

Start Menu consists of as little as 3 setpoints that must be congured

for KE2 Evap to begin controlling the system. See Table 2.

The rst setpoint the user is asked to enter is the desired ROOM

TEMP. This is followed by the DEFROST TYPE. The controller is de-

signed to work with electric, hot gas, and o time defrosts. The last

setpoint is the VALVE TYPE. The controller is defaulted to be used

with a mechanical valve, but may be used with a variety of EEVs, in-

cluding a customer dened valve.

These are the only setpoints required to begin controlling the system,

when applied on a single evaporator with a mechanical valve.

If using a standard/predened EEV, the user will also be prompted to

specify the REFRIGERANT. The KE2 Evap may also be applied to user

dened EEVs. When this option is selected, the user will be prompted

to select MOTOR TYPE, MOTOR STEP RATE, and MAX VALVE STEPS.

Once these have been set, the KE2 Evap will begin controlling EEV

and the system.

Adjusting Controller Parameters

The controller has the ability to access an abundance of informa-

tion from the 4-digit alphanumeric display. However, the controller

requires a password, adding a degree of protection from unwanted

modications. The controller will prompt the user for a password

PASSWORD when the user attempts to access setpoints they do not

have permission to change.

Table 1 shows the menu structure of the controller. The default

display of the controller always displays the actual room tempera-

ture. Pressing the ENTER button will display room temp ROOM

TEMP. Pressing the up and down arrows moves the display through

the VARIABLES menu. See Controller Navigation on page 15. By de-

fault, the controller only allows access to the room temperature. The

VARIABLES menu consists of the current sensor readings and the

relays’ state. The User Password (1111) only provides access to the

ROOM TEMP setpoint.

For the protection of the system, access to the SETPOINT and

MANUAL control requires an Installer Password (2222). Pressing

the right or left arrow will move from the Variables menu to the next

menu, shown in the Controller Navigation on page 15, a complete

list of parameters is shown in Table 3.

Pressing the BACK key at any time will return the user to next level

up the menu. A second press will either return to the Main Menu or

to the room temperature reading.

Table 2 - Quick Start Menu

Mechanical Valve

TEV

3 steps

Dened EEV

4 steps

Custom EEV

7 steps

Room Temp Room Temp Room Temp

Defrost Type Defrost Type Defrost Type

Valve Type Valve Type Valve Type

Refrigerant Refrigerant

Motor Type (Unipolar/Bipolar)

Motor Step Rate

Max Valve Steps

Q.1.3 September 2012

Page 17

Parameter Name Description Range Default

MANUAL CONTROL Force the controller into the next operating mode COOL, OFF, DEFROST, DRIP TIME, FAN DELAY

MANUAL VALVE Manually open or close the electronic expanion valve in percentage increments 1% increment

CLEAR ALARMS Clear all active alarms

MANUAL COMPRESSOR RELAY Manually energize or de-energize liquid line solenoid /compressor relay AUTO ON/OFF, MANUAL OFF, MANUAL ON AUTO

MANUAL DEFROST RELAY Manually energize or de-energize defrost relay AUTO ON/OFF, MANUAL OFF, MANUAL ON AUTO

MANUAL FAN RELAY Manually energize or de-energize evaporator fan relay AUTO ON/OFF, MANUAL OFF, MANUAL ON AUTO

DHCP ADVANCED TOPIC, SEE USER GUIDE: Selects appropriate DHCP mode OFF, CLIENT, SERVER OFF

FACTORY RESET Reset the controller to the factory default setpoints RESET

Parameter Name Description

ROOM TEMP Room temperature as measured by the controller

COIL TEMP Coil temperature as measured by the controller

SYSTEM MODE Current operating status

SUPERHEAT Superheat as calculated by the controller (requires suction pressure transducer and suction temperature sensor)

SUCTION PRESSURE Suction pressure as measured by the controller

SUCTION TEMP Suction temperature as measured by the controller

SATURATION TEMP Saturation temperature as calculated by the controller

VALVE % OPEN Percentage the EEV is open

AUX TEMP Auxiliary Temperature (Taux) sensor reading as measured by the controller

COMPRESSOR RELAY Current state of liquid line solenoid/compressor relay

DEFROST RELAY Current state of the defrost relay

FAN RELAY Current state of the evaporator fan relay

DIG 1 STATUS Current status of the Digital Input #1

DIG 2 STATUS Current status of the Digital Input #2

DIG 3 STATUS Current status of the Digital Input #3

IP OCTET 1 The rst three digits of the IP address

IP OCTET 2 The second three digits of the IP address

IP OCTET 3 The third three digits of the IP address

IP OCTET 4 The fourth three digits of the IP address

SUBNET MASK OCTET 1 The rst three digits of the subnet mask address

SUBNET MASK OCTET 2 The second three digits of the subnet mask address

SUBNET MASK OCTET 3 The third three digits of the subnet mask address

SUBNET MASK OCTET 4 The fourth three digits of the subnet mask address

FIRMWARE VERSION Current version of the rmware on the controller

Variables Menu - Non Adjustable (view only)

Parameter Name Description

NO ALARM No alarms active, everthing is running correctly

PRESSURE SENSOR Suction pressure sensor is shorted, open or pressure out of range

SUCTION TEMP SENSOR Suction temperature sensor is shorted or open

AIR TEMP SENSOR Return air temperature sensor is shorted or open

COIL TEMP SENSOR Coil temperature sensor is shorted or open

AUX TEMP SENSOR Auxiliary temperature sensor is shorted or open

HIGH SUPERHEAT Superheat above upper limit

LOW SUPERHEAT Superheat below lower limit

HIGH AIR TEMP Room temperature is above ROOM TEMP + AIR TEMP DIFF + HIGH TEMP ALARM OFFSET for longer than HIGH TEMP ALARM DELAY

LOW AIR TEMP Room temperature is below ROOM TEMP - LOW TEMP ALARM OFFSET for longer than LOW TEMP ALARM DELAY

EXCESS DEFROST Three consecutive defrosts with less than a one hour interval between each defrost

DEFR TERM ON TIME Defrost terminated on time instead of temperature for two consecutive cycles

DOOR SWITCH If door is open and room temperature is 5 degrees above ROOM TEMP + AIR TEMP DIFF for DOOR ALARM DELAY time

COMMUNICATION ERROR ONLY FOR BONDED CONTROLLERS: No communication between controllers for one minute or more

EXT ALARM If DIG IN (1, 2 and/or 3) MODE = EXT ALARM: The digital input is in an active state

Alarms Status Menu Non Adjustable (view only)

Manual Menu

DIG IN Setting Status Displayed on Controller

DIG IN MODE = DISABLED DISABLED

DIG IN MODE = 2ND ROOM TEMP inactive = 2ND ROOM TEMP OFF; active = 2ND ROOM TEMP ON

DIG IN MODE = DOOR SWITCH inactive = DOOR CLOSED; active = DOOR OPEN

DIG IN MODE = EXT ALARM inactive = NO ALARM; active = EXT ALARM (x)

DIG IN MODE = SYSTEM OFF inactive = SYSTEM ON; active = SYSTEM OFF

DIG IN MODE = LIGHT SWITCH inactive = LIGHTS OFF; active = LIGHTS ON

DIG IN MODE = CAMERA SWITCH inactive = CAMERA OFF; active = CAMERA ON

Variables Menu Options for DIG IN MODE

Table 3 - Controller Menus and Menu Parameters

KE2 EvaporatorEfciency

Quick Start Guide

KE2 EvaporatorEfciency

Quick Start Guide

Q.1.3 September 2012

Page 18

Parameter Name Description Range Default Current

ROOM TEMP Room temperature to be maintained -50°F to 90°F -10°F

DEFROST TYPE Method of defrost used on the evaporator coil: Electric, Air, Hot Gas with Liquid Line Solenoid/Compressor relay o, Hot Gas with Liquid Line Solenoid/compressor relay on ELEC, AIR, HOT GAS COMP ON, HOT GAS COMP OFF ELEC

VALVE TYPE Type of valve used on the system: mechanical, pre-congured electric, custom EEV conguration MECHANICAL, KE2, SER/SEI 1 TO 20, SER B TO L, SEI 30, SEI 50, SEH, ETS12 TO 50, ETS100,

ETS250/400, KV, CAREL, CUSTOM; MECHANICAL

Custom

EEV Only

MOTOR TYPE If VALVE TYPE = CUSTOM: The motor type used in the valve BIPOLAR, UNIPOLAR BIPOLAR

MOTOR STEP RATE If VALVE TYPE = CUSTOM: The motor speed setting in number of steps per second 30 to 400 steps/second 200 steps

MAX VALVE STEPS If VALVE TYPE = CUSTOM: The total number of steps required to move the valve from closed to fully open 200 to 6400 steps 1600 steps

SUPERHEAT The superheat value that the controller will maintain, (not applicable if VALVE TYPE = MECHANICAL) 5°F to 30°F 8°F

MAX OPERATING PRES The maximum allowable suction pressure, (not applicable if VALVE TYPE = MECHANICAL) 10 to 150 psig 150 psig

REFRIGERANT The type of refrigerant used in the refrigeration system 404A, R507, 407A, 407C, 422A, 422D, 134A, R22, R717, 438A, 408A, 409A, 410A, R744 404A

AUX TEMP MODE Conguration mode of the auxiliary temperature sensor DISABLED, MONITOR, 2ND AIR TEMP, 2ND COIL TEMP DISABLED

AUX RELAY MODE Conguration mode of the auxiliary relay. ALARM RELAY, 2 SPEED FAN CTL, 2ND COMP RELAY, 2ND FAN RELAY, 2ND DEFR RELAY,

LIGHT RELAY, CAMERA RELAY ALARM RELAY

MIN COMP RUN TIME Minimum amount of time the liquid line solenoid/compressor relay must remain on after it is energized 0 to 15 minutes 2 minutes

MIN COMP OFF TIME Minimum amount of time the liquid line solenoid/compressor relay must remain o before it can be energized again. 0 to 15 minutes 5 minutes

REFRIG FAN MODE Fan operation while in refrigeration mode ON WITH COMPRESSOR, PERMANENT, CYCLE ON WITH COMPRESSOR

DEFROST MODE The method the controller uses to determine when to initiate a defrost. DEMAND, SCHEDULED, RUN TIME DEMAND

DEFROSTS / DAY If DEFROST MODE = SCHEDULED: The number of evenly spaced defrosts per day the controller will initiate. 0 to 8 5

1ST DEFROST DELAY If DEFROST MODE = SCHEDULED: The amount of time from controller power up until the rst defrost is initiated. 0 to 240 minutes 120 minutes

DEFROST FAN STATE Whether or not to run the evaporator fans during defrost ON/OFF OFF if DEFROST TYPE = ELEC, HOT GAS COMP ON, HOT GAS COMP OFF

ON if DEFROST TYPE = AIR

DEFROST TERM TEMP The temperature the coil sensor(s) must exceed in order to terminate defrost. The defrost relay is de-energized at this point. 35°F to 90°F 50°F if DEFROST TYPE = ELEC, HOT GAS COMP ON, HOT GAS COMP OFF

40°F if DEFROST TYPE = AIR

DEFROST PARAMETER The maximum amount of time the defrost relay will be energized. 0 to 90 minutes 25 minutes if DEFROST TYPE = ELEC

10 minutes if DEFROST TYPE = HOT GAS COMP ON, HOT GAS COMP OFF

40 minutes if DEFROST TYPE = AIR

DRAIN TIME Time to be in drain mode (drip time) 0 to 15 minutes 2 minutes

COMP RUN TIME If DEFROST MODE = RUN TIME: The amount of time liquid line solenoid/compressor relay is energized before the next defrost is initiated. 0 to 24 hours 6 hours

ELEC DEFROST MODE If DEFROST TYPE = ELEC: Whether to leave the defrost relay energized during the defrost cycle or to utilize advanced defrost algorithm. PULSE, PERMANENT PULSE

FAN DELAY TEMP After defrost, the coil sensor reading must fall below this temperature set point in order for the controller to resume normal fan operation. -40°F to 35°F 20°F

MAX FAN DELAY TIME Maximum amount of time after defrost to resume normal fan operation. 0 to 20 minutes 2 minutes

PUMP DOWN TIME Minimum amount of time between de-energizing the liquid line solenoid/compressor relay and energizing the defrost relay. 0 to 10 minutes 0 minutes

MULTI AIR TEMP CTRL Select control method to use with multiple room temperature sensors AVERAGE, WARMEST WARMEST

Bonded

Control-

lers Only

MULTI EVAP COOL Select type of multi evaporator control - options are synchronous or independent SYNC, INDEPENDENT SYNC

MULTI EVAP DEFROST Select whether to have all bonded controllers initiate defrost mode at the same time or independently. SYNC, INDEPENDENT SYNC

MULTI EVAP SENSOR Select whether or not to share room temperature, coil temperature and suction pressure sensor data with bonded controllers. SHARED, NOT SHARED SHARED

HIGH TEMP ALARM OFFSET The number of degrees above ROOM TEMP for a HIGH TEMP ALARM condition. 0°F to 99.9°F 10°F

HIGH TEMP ALARM DELAY The amount of time, in minutes, the room temperature must remain above ROOM TEMP + HIGH TEMP ALARM OFFSET before issuing a HIGH TEMP ALARM 0 to 120 minutes 60 minutes

LOW TEMP ALARM OFFSET The number of degrees below ROOM TEMP for a LOW TEMP ALARM condition. 0°F to 20°F 4°F

LOW TEMP ALARM DELAY The amount of time, in minutes, the room temperature must remain below ROOM TEMP - LOW TEMP ALARM OFFSET before issuing a LOW TEMP ALARM 0 to 30 minutes 10 minutes

DOOR ALARM DELAY If DIG IN (1, 2 and/or 3) MODE = DOOR SWITCH: The amount of time, in minutes, before an alarm condition is initiated if door is open and room temperature is 5 degrees

above ROOM TEMP + AIR TEMP DIFF 0 to 180 minutes 30 minutes

DIG IN 1 MODE Sets the function of the digital input DISABLED, 2ND ROOM TEMP, DOOR SWITCH, EXT ALARM, SYSTEM OFF DOOR

DIG IN 1 STATE Sets whether the switch activates when opened or closed OPEN, CLOSED CLOSED

DIG IN 2 MODE Sets the function of the digital input DISABLED, 2ND ROOM TEMP, DOOR SWITCH, EXT ALARM, SYSTEM OFF DISABLED

DIG IN 2 STATE Sets whether the switch activates when opened or closed OPEN, CLOSED CLOSED

DIG IN 3 MODE Sets the function of the digital input DISABLED, 2ND ROOM TEMP, DOOR SWITCH, EXT ALARM, SYSTEM OFF, LIGHT SWITCH,

CAMERA SWITCH DISABLED

DIG IN 3 STATE Sets whether the switch activates when opened or closed OPEN, CLOSED CLOSED

2ND ROOM TEMP If DIG IN (1, 2 and/or 3)MODE = 2ND ROOM TEMP: This value becomes the ROOM TEMP setpoint when the digital input is active -50°F to 90°F -50°F

SUCT PRES OFFSET An oset added or subtracted from the suction line pressure transducer reading to calibrate, if needed -5.0 to 5.0 psig 0.0 psig

SUCT TEMP OFFSET An oset added or subtracted from the suction temperature sensor reading to calibrate, if needed -5.0°F to 5.0°F 0.0°F

AIR TEMP OFFSET An oset added or subtracted from the room temperature sensor reading to calibrate, if needed -5.0°F to 5.0°F 0.0°F

COIL TEMP OFFSET An oset added or subtracted from the coil temperature sensor reading to calibrate, if needed -5.0°F to 5.0°F 0.0°F

AUX TEMP OFFSET An oset added or subtracted from the auxiliary temperature sensor reading to calibrate, if needed -5.0°F to 5.0°F 0.0°F

TEMP UNITS Units for temperature’s display in °F or °C FAHRENHEIT/CELSIUS FAHRENHEIT

AIR TEMP DIFF The number of degrees above ROOM TEMP before the controller will go into REFRIGERATION mode 0°F to 25°F 1°F

EXTREME TEMP DIFF ADVANCED TOPIC: Call KE2 Therm for assistance

Setpoints Menu - STPT

Q.1.3 September 2012

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