EXD-U00 Universal Driver Module

Technical Data

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EXD-U00 universal driver module enables the operation of ALCO stepper motor driven valves EX4/EX5/EX6/EX7/EX8 as • Solenoid valve • Electrical expansion valve • Capacity control by means of hot gas bypass or evaporating

pressure regulator • Crankcase pressure regulator • Hot gas bypass regulator • Heat reclaim regulator • Liquid level regulator Features • 4…20mA or 0…10V analogue input signal • Plug and run, no parameter setting i.e. automatic operation • Easy configurable by Dip-switches • DIN rail mounted with aluminium housing • Easy wiring • Fully tested and ready for operation • CE marked

EXD-U00

Selection table Description Type Order Nr. Universal driver module EXD-U00 804 557 Electrical terminal kit for EXD-U00 K09-U00 804 559 Universal driver module with electrical terminal kit

808 038

Uninterruptible power supply ECP-024 804 558 Electrical terminal kit for ECP-024 K09-P00 804 560 Transformer 230V / 24V AC, 25VA ECT-323 804 424 Transformer 230V / 24V AC, 60VA ECT-623 804 421

K09-U00 ECP-024 K09-P00 ECT-323

Introduction Although the main structure for refrigeration and air conditioning systems (HVAC) has remained unchanged for many years, there has been a continuous trend of system improvements in order to increase the capability, reliability and reduction of energy consumption in HVAC systems. The improvements can be made by modification of the components, i.e. compressors, heat exchangers, system design and with the application of electronic controls. ALCO Controls, manufacturer of flow, temperature and pressure controls, has been working for several years on a new system control solution. This will assist system manufacturers to optimise and improve their systems. The electronic control solution concept stands for reduction of energy consumption whilst providing better and tighter control of all operating parameters.

Function The driver module requires an analogue input signal of 4…20mA or 0…10V. The output is the closing/opening of EX4/EX5/EX6/EX7/EX8 and consequently the control of refrigerant liquid or vapour mass flow in accordance with the analogue input. The universal driver module can be connected to any controller which can provide a 4…20mA or 0…10V analogue signal. This gives extreme flexibility to system manufacturers to use any desired controller and achieve different functionalities. The objective of design was the simplicity of the driver module and real plug and play.

The universal driver module keeps the valve at fully close position when the input signal is 4mA or 0V. The valve will be fully open at 20mA or 10V. EXD-U00 module needs a digital input command in order to operate the valve only when it is required.

Analogue input

Valve Opening

20mA

4mA

0% 100%

Analogue input

Valve Opening

10V

0V

0% 100%

EXD-U00

Universal Driver Module

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Shut-off and Start/Stop command ALCO stepper motor driven control valves provide positive shut-off when they are driven to close position. An external digital input allows the driver module start to regulate the valve. The valve remains at close position as long as the external digital input is off regardless of analogue input.

Pump down ALCO electronic valves can be driven to close position while the compressor is running for pump down function. The initiation and termination of pump down is within the system controller. For more information, please consult ALCO CONTROLS.

Start Mode There is the possibility to set the start mode: • With start mode: after start command (24V at digital

input), valve opens to 1/3 immediately and after that regulate the mass flow according to external analogue input signal (see figure below, right).

• Without start mode: after start command (24V at digital input), valve starts to regulate the mass flow according to analogue input signal (see figure below left).

Without Start Mode With Start Mode

Optional uninterruptible power supply ECP-024 In event of power failure to the entire system, stepper motor driven valve would not be able to move. Due to the differential pressure between condenser and evaporator, the refrigerant would continue to flow through the electronic valve if the valve is open. It is recommended to close the valve for protecting compressor against wet running.

ECP-024

With ECP-024, ALCO CONTROLS offers a very simple and reliable solution, which is able to close the electronic valve in event of power failure. To bridge the power loss ECP-024 contains rechargeable batteries and a smart charge control. Optimum battery lifetime is achieved through temperature compensated charge cycles. One ECP-024 is able to power up to two Alco drivers

Setting Universal driver needs no setting except configuration with dip-switches for the application of different valve, different analogue input signal and type of start mode.

Function Dip Switch Number 1 2 3 4 5 6 7 8 EX4/EX5/EX6 operation 0 1 1 0 1 0 - - EX7 operation 1 0 0 1 0 1 - - EX8 operation 1 1 0 1 1 1 - - 4-20 mA analogue input signal - - - - - - - 0 0-10V analogue input signal - - - - - - - 1 With start mode (Fig.3b) - - - - - - 1 - Without start mode (Fig.3a) - - - - - - 0 -

EXD-U00

Universal Driver Module

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Nominal Capacity Tables for Different Functions

EX4/EX5/EX6/EX7/EX8 Nominal capacities as expansion valves and liquid injection valves Nominal Capacities (10% … 100%), kW

Valve Type R 407C R 22 R 134a R 404A R 410A R 23 R 124 R 744 EX4 2 ... 17.4 2 ... 16.5 1 ... 12.8 1 ... 11.5 2 ... 19.3 2 ... 17.8 1 ... 9.2 3 ... 33.5 EX5 5 ... 53 5 ... 50 4 ... 39 4 ... 35 6 ... 58 5 ... 54 3 ... 28 10 ... 102 EX6 15 ... 126 15 ... 120 10 ... 93 10 ... 84 15 ... 140 13 ... 130 7 ... 67 24 ... 244 EX7 35 ... 347 35 ... 330 25 ... 255 25 ... 230 40 ... 385 - - 70 ... 670 EX8 100 ... 925 90 ... 880 70 ... 680 60 ... 613 100 ... 1027 - - 180 ... 1789

The nominal capacity (Qn) is based on the following conditions: Refrigerant Evaporating temperature Condensing temperature Subcooling

R 22, R 134a, R 404A, R 410A +4°C +38°C 1K R 407C +4°C dew point +38°C bubble / +43°C dew point 1K R 124 +20°C +80°C 1K R 23 -60°C -25°C 1K R 744 -40°C -10°C 1K

EX4/EX5/EX6/EX7/EX8 Nominal capacities as hot gas bypass regulator, kW Valve Type Kv, m3/h R 22/R 407C R 134a R 404A/R 507 EX4 0.21 4.9 3.4 4.6 EX5 0.68 16 11 15 EX6 1.57 37 26 35 EX7 5.58 131 92 126 EX8 16.95 399 278 382

Nominal capacities at +4°C, +38°C bubble point for all refrigerants (+43°C dew point for R407C). Remarks: EX4, EX5, EX6, EX7 and EX8 must be installed with motor downward in hot gas line applications. This insures the valve life expectancy.

EX6/EX7/EX8 Nominal capacities as suction pressure regulator (evaporator or crankcase), kW Valve Type Kv, m3/h R 407C R 22 R 134a R 404A EX6 1.57 3.9 4.1 3.1 3.5 EX7 5.58 14 15 11 13 EX8 16.95 42 45 34 38

Nominal capacities at +4°C, +38°C bubble point for all refrigerants (+43°C dew point for R407C) and 0.15 bar pressure drop. Remarks: EX4, EX5, EX6, EX7 and EX8 must be installed with motor downward in suction line applications. This insures the valve life expectancy. Multiply above nominal capacities by following factors to obtain capacities at different pressure drops:

∆P, bar 0.10 0.15 0.20 0.30 Correction factor 0.82 1.00 1.15 1.41

Example: EX6 provides 3.5 kW at 0.15 bar pressure drop with R404A: 3.5*1.41 = 4.9 kW capacity at 0.3 bar pressure drop.

EX5/EX6/EX7/EX8 Nominal capacities as condensing pressure regulator and liquid duty, kW Valve Type Kv, m3/h R 407C R 22 R 134a R 404A EX5 0.68 18 20 18 13 EX6 1.57 43 46 42 30 EX7 5.58 153 162 151 106 EX8 16.95 463 491 458 323

Nominal capacities at +4°C, +38°C bubble point for all refrigerants (+43°C dew point for R407C) and 0,35 bar pressure drop. Multiply above nominal capacities by following factors to obtain capacities at different pressure drops.

∆P, bar 0.15 0.20 0.35 Correction factor 0.65 0.76 1.00

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Universal Driver Module

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EX6/EX7/EX8 Nominal capacities for hot gas flow such as heat reclaim application, kW Valve Type Kv, m3/h R 22 / R 407C R 134a R 404A/R 507 R 410A EX6 1.57 11 9 10 13 EX7 5.58 39 33 36 47 EX8 16.95 119 101 108 144

Nominal capacities are at 0.5 bar pressure drops, +4°C evaporating temperature, +38°C bubble point for all refrigerants (+43°C dew point for R407C) and 0.8 isentropic efficiency of compressor. Remarks: EX6/EX7/EX8 must be installed with motor downward in hot gas line applications. This insures the valve life expectancy. Wiring diagram

(1) = Power supply (2) = Transformer (3) = Fuse (4) = DIN plug for connection to EX8 and EX7(prior to May 2006 production) (5) = Plug cable assembly EX5-Nxx for connection to EX4/EX5/EX6 and EX7(new) (6) = Controller supplies 4 … 20mA or 0 … 10V (7) = Digital input signal (0V = OFF; 24V = ON) (8) = Analogue input signal (4 … 20mA or 0 … 10V) (9) = Optional Uninterruptible Power Supply insures the closure of valve during power failures in systems, where a valve with positive shut-off function is needed

Cable color code WH = White BK = Black BL = Blue BN = Brown

EXD-U00

Universal Driver Module

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Application: Expansion valve

(1) = Electrical control valve (2) = Universal Driver Module EXD-U00 (3) = Superheat Controller

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Universal Driver Module

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Application: Liquid injection

(1) = Temperature Controller (2) = Universal Driver Module EXD-U00 (3) = Electrical control valve

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Universal Driver Module

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Application: Expansion valve in heat pumps (one EXV)

(1) = Electrical control valve (2) = Universal Driver Module EXD-U00 (3) = Superheat controller

EXD-U00

Universal Driver Module

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Application: Expansion valves in heat pumps (two EXVs)

(1) = Expansion valve heating mode (2) = Expansion valve cooling mode (3) = Cooling/heating mode change over (4) = Universal Driver Module EXD-U00 for heating mode (5) = Universal Driver Module EXD-U00 for cooling mode (6) = Superheat controller

EXD-U00

Universal Driver Module

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Application: Liquid level control

(1) = Level controller (2) = Liquid level sensor (3) = Universal Driver Module EXD-U00 Note: EXVs are not released for use with ammonia.

EXD-U00

Universal Driver Module

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Application: Capacity control / discharge air temperature control by means of hot gas bypass

(1) = Temperature Controller (2) = Check Valve: It is important to install a check valve just after T-connection as shown. Check valve will not allow return of liquid refrigerant from condenser through electrical control valve in to the evaporator during power interruption to system. (3) = Hot gas bypass valve must be installed with motor downward. This insures the valve life expectancy. (4) = Liquid Distributor must be selected properly for hot gas mass flow. (5) = Universal Driver Module EXD-U00

EXD-U00

Universal Driver Module

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Application: Capacity control / discharge air temperature control by means of evaporating pressure regulation

(1) = Temperature Controller (2) = Evaporator temperature regulator. EX6, EX7 and EX8 must be installed with motor downward in suction line applications. This insures the valve life expectancy. (3) This application may require additional liquid injection to suction line for desuperheating of compressor by means of suction line superheat control or discharge line temperature control. Please consult Alco Controls for more details. (4) = Universal Driver Module EXD-U00

EXD-U00

Universal Driver Module

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Application: Head pressure regulator

(1) = Pressure Controller (2) = Condensing pressure regulator (3) = Universal Driver Module EXD-U00

EXD-U00

Universal Driver Module

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Application: Crankcase pressure regulator

Remarks: (1) = Pressure Controller (2) = Crankcase pressure regulator. ECVs must be installed with motor downward in suction line applications. This insures the valve life expectancy. (3) = Universal Driver Module EXD-U00

EXD-U00

Universal Driver Module

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Technical Data

Universal Driver Module EXD-U00 Supply voltage 24V AC ±10%, 50-60HZ

24V DC ±10% Input analogue signal

Burden 4-20mA 364 Ω

Supply current to be protected by a 0.8 A external fuse Input analogue signal 0-10 V Power consumption 10VA in conjunction with EXV Impedance 27 kΩ Temperature: storage operating

-20 … +65°C 0 … +60°C

Digital input 24V AC ±10%, 50-60Hz 24V DC ±10%

Connection to EX4/EX5/EX6/EX7/EX8

via 4 wires cable, maximum 6m length AWG20/22

Humidity < 90% r.H. non condensing Connector Screw terminals for wire size 0.5-2.5 mm2

Protection class IP20 Mounting DIN rail mounted Approvals EMC EN 61326-1, EN50081, EN50082 Housing Aluminum Marking CE

Uninterruptible Power Supply ECP-024 Backup battery type Rechargeable lead battery Temperature: Number of backup batteries

2, each 12VDC, 0.8Ah storage operating

-20 … +65°C -10 … +60°C

Supply voltage 24VAC ±10%, 50-60Hz Humidity < 90% r.H. non condensing Output voltage, UB 18VDC Connection Screw terminals

for wire size 0.5-2.5 mm2 Number of outputs to drivers

2 Mounting Din rail mounted

Battery recharge time approximately 2 hours Protection class IP20 Approvals EMC EN 61326-1, EN50081, EN50082 Housing Aluminum Marking CE

EXD-U00

Universal Driver Module

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Dimensions

Universal Driver Modul EXD-U00

Uninterruptible Power Supply ECP-024

Transformer ECT-623 Transformer ECT-323 7562

50 62 71

82

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Universal Driver Module

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ALCO CONTROLS is not to be held responsible for erroneous literature regarding capacities, dimensions, applications, etc. stated herein. Products, specifications and data in this literature are subject to change without notice. The information given herein is based on technical data and tests which ALCO CONTROLS believes to be reliable and which are in compliance with technical knowledge of today. It is intended only

for use by persons having the appropriate technical knowledge and skills, at their own discretion and risk. Since conditions of use are outside of ALCO'S control we can not assume any liability for results obtained or damages occurred due to improper application. This document replaces all earlier versions.

Emerson Electric GmbH & Co. OHG ALCO CONTROLS Heerstraße 111 D-71332 Waiblingen Germany Phone ...49-(0)7151-509-0 Fax ...49-(0)7151-509-200 www.eCopeland.com/alcoliterature.cfm

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