KE2 AdaptiveControl User manual

Parts List
The following parts are included in the KE2 Adaptive Control
controller kits:
Kit # 21177 with 120/208-240 VAC controller
(1) KE2 Adaptive Control controller
(1) high voltage safety shield
(1) 3-pack of colored 15’temperature sensors
(6) 90°spade connectors
(2) straight spade connectors
(5) self-tapping screws
(2) 1/2” plastic knockout plug
(1) air sensor mount
(3) course thread screws
(1) KE2 Terminal Board*
(1) Warranty card (not shown)
© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Q.1.35
January 2016
KE2 AdaptiveControl (pn 21177)
Quick Start Guide
Supplies List
The KE2 Adaptive Control is supplied with all of the accessories re-
quired for the controller to work, however, standard truck stock items
will also be required to install the controller. To simplify the installa-
tion, a list of items has been provided.
Conduit to go between the controller and the evaporator
(2) Conduit connectors (straight or elbow as required)
(8) High voltage wires matched to the load of the heaters,
fans, liquid line solenoid, and the controller.
(8) Spade Connectors matched to the gauge of high volt-
age wires
Wire labeling (numbers, colors, etc.)
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)
Accessories to Aid in Installation
The following parts are available separately:
10’Wire Harness pn 20736, 25’Wire Harness pn 20670, or 40’Wire
Harness pn 20737
Further information on the Wire Harness can be found in literature
Q.1.21.
* When used with the KE2 Adaptive Control controller, the fuses must be sized to
match the application (i.e. Replace existing fuses with 30 Amp Time Delay fuses
for fans and compressor)
D E F
G
H
BC
A
I
J
This reference should remain on site with the installed KE2 Adaptive Control controller.
A
C
D
E
F
G
H
I
B
J

© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Q.1.35 January 2016
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KE2 AdaptiveControl
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 requires measuring the subcooling of the liquid
entering 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 Adaptive Control.
Understanding Frost
The air exiting side of the evaporator is often the coldest spot on
the coil. 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 typi-
cally has a negative connotation when discussed in refrigeration,
initial frost formation has a positive eect. Some may even say “frost
is our friend.” It is not uncommon to see a small amount of frost on
the coils that have KE2 Adaptive Control controllers installed. The KE2
Adaptive Control is continually measuring, monitoring, and manag-
ing the frost to assist in maximum energy eciency. When the ef-
ciency of the coil is reduced due to excessive frost, the KE2 Adaptive
Control 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.1.35 January 2016
Page 3
© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
A
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.
B
C
Steps to Ensure Proper Coil Sensor Location
KE2 Therm recommends locating the coil sensor 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 G from parts list) into coil housing when
mounting sensor wire to prevent damage to the sensor from
sharp edges. The plug provided should be inserted into the inner
housing to access the coil. Installer must puncture plug to insert
sensor.
DMake note of the location you have determined for placement of
the coil sensors.
Typically last spots to defrost
B
Locate sensor approx.
1-1/2” from end, in the
bottom third of coil
Item G from Parts List on page 1
C
KE2 AdaptiveControl
Quick Start Guide

© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Q.1.35 January 2016
Page 4
thermsolutions
EnergySaving Refrigeration Controller
Adaptive
Control
.
thermsolutions
EnergySaving Refrigeration Controller
Adaptive
Control
.
thermsolutions
EnergySaving Refrigeration Controller
Adaptive
Control
.
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 120°F)
Evaporator
?
thermsolutions
Energy Saving Refrigeration Controller
Adaptive
Control
.
Cut a length of conduit to go from the controller to the evaporator
Measure the distance between the controller and evaporator to
account for the extra length necessary to properly route conduit.
Determine the number of wires to go to the controller.
Controller power (2 wires)
Fan control (2 wires)
Defrost (heater) control (2 wires)
Liquid line solenoid (2 wires)
Note: Install in accordance with local wiring codes. KE2 Therm
does not accept responsibility for incorrect or unsafe wiring.
22
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.
Use the optional KE2Wire Harness, or select dierent colored wires,
(blue - fan, orange - heaters, yellow - solenoid, purple - alarm). This
will simplify the installation and troubleshooting. 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.
33
Walk-in
Under Counter
Commercial
Reach-In
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Quick Start Guide

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© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Determine the current draw of the unit.
Use the nameplate to determine the Amp rating of the unit.This in-
formation 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 Adaptive Control controller.
44
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 instal-
lation, and attach to the conduit.
Securely connect one end of the conduit to the controller.
55
115V 208-240V
Wiring the controller
Locate the Voltage Selector Switch.
It is a 2 position switch with red indicator.
The selected voltage will be displayed on the face of the switch.
The controller will still illuminate the display when 115V is ap-
plied with 208-240V selected, however the controller may not
function properly. If 208-240V is applied with 115V selected the
controller’s display will cycle.
66
Controller Power
Strip the end of the wires used to provide power to the controller
(If using the KE2 Wire Harness the wires are pre-stripped)
Crimp on female spade connectors (Item E from list on page 1)
Plug into the board as indicated in Wiring Schematic.
Note: All terminals should be crimped to withstand 30 lb pull test.
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Quick Start Guide

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© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
88
9
Defrost (Heater) Relay
Strip the end of the 2 wires used for the defrost control.
Locate (2) 90° 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.
Defrost (Heater) Relay Using the KE2 Wire Harness
The orange wires are used for the heater control.
Locate the orange with black stripe, and black with orange stripe.
Plug the black with orange stripe to the COM terminal.
Plug the orange w. black stripe to the NO position of Defrost Relay.
Conrm combined heater load is not over 30 amps.
9
10
Liquid Line Solenoid /Compressor Relay
Strip the end of the 2 wires used for the liquid line solenoid.
Locate 2 90° female spade connectors in the accessories kit.
Crimp on the female connectors.
Plug the connectors to the COM and NO positions of the Liquid
Line Solenoid /Compressor Relay
Liquid Line Solenoid (LLS)/Comp. Relay Using KE2 Wire Harness
The yellow wires are used for Liquid Line Solenoid control.
Locate a 3-position connector from the accessories kit.
Fasten the black with yellow stripe to the fused lead.
Fasten yellow w. black stripe from the LLS to NO terminal position.
Plug into the location as indicated in Wiring Schematic.
Conrm compressor load is not over 30 FLA.
Fan Relay
Strip the end of the 2 wires used for fan control.
Locate 2 90° 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.
Fan Relay Using the KE2 Wire Harness
The blue wires are used for fan control.
They are blue with a black stripe, and the black with a blue stripe.
Plug the black with a blue stripe to the COM terminal.
Plug the blue with a black stripe to the NO position of the Fan
Relay
Conrm combined fan motor load is not over 30 FLA.
10
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Quick Start Guide

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© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Preparing the Evaporator
The evaporator wiring will require access to the high voltage ter-
minal block on the coil.
Turn o power to the system.
Verify power is no longer present using a multimeter.
Install Safety cover
Once all of the high voltage wiring is complete, install the plastic
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 3 small coursely threaded screws attach the controller to
the plastic posts.
Connecting sensor wires to controller
The temperature sensors are designed to be attached to the con-
troller using 2 position screw terminals. The terminals are located
on the controller’s lid, on the bottom side of the display.
Connect all sensors to the appropriate locations, which can be de-
termined from the label on the circuit board or from the Wiring
Schematic.
The sensors are not polarized, so wire location does not eect sen-
sor performance.
Set the controller in a safe place.
11
11
12
12
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
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Quick Start Guide

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© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Existing wiring.
Start by removing all of the exist-
ing wires from the terminal strip.
Determine the location of the fol-
lowing: incoming power, fan leads,
heater leads, defrost termination
leads, and fan delay leads.
14
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.
15
Evaporator wiring – Fans
Strip the ends of the wires (con-
nected to the KE2 Adaptive
Control) used to control the evapo-
rator fans.
The fan wires from the controller
can be attached to the terminal
block using either screw down ter-
minals or spade connectors.
Attach the black wire with blue
stripes to the L1/Line. This wire
will be connected to COM of fan
relay on the controller.
Attach blue wire with black
stripes to the NO terminal on
the Fan Relay to one set of the fan
leads. This wire will be connected
to the NO of the fan relay on the
controller.
Connect L2/Neutral to remaining
fan leads.
16
15
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Quick Start Guide

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Page 9
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.
17
Remove defrost termination
(Klixon®) from circuitry
Attach the black wire with orange
stripe to the L1/Line. This wire will
be connected to COM of defrost re-
lay on the controller.
Attach the orange wire with the
black stripe to the NO terminal
on the Defrost Relay to one of each
of the defrost leads.
Connect L2/Neutral to the remain-
ing defrost leads.
The defrost safety should not be re-
moved from the circuit. Its purpose
is to prevent the heaters from over
heating and causing damage.
18
© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Evaporator wiring – Liquid Line
Solenoid /Compressor
Strip the ends selected to control
the liquid line solenoid.
Attach the black wire with the yel-
low stripe to the L1. This wire will
be connected to the COM of the
L.L. Solenoid/Compressor.
Attach the yellow wire with
black stripe connects to the NO
terminal on the L.L. Solenoid/
Compressor relay to a solenoid
lead
Connect L2/Neutral to the remain-
ing L.L. Solenoid/Compressor lead.
19 19
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Quick Start Guide

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© Copyright 2016 KE2 Therm Solutions, Inc., Washington, Missouri 63090
Figure 8 - Wiring Schematic - Ladder Diagram
Figure 8 - Wiring Schematic - Using KE2 Terminal Board
KE2 AdaptiveControl
Quick Start Guide