ECH 400F

Four Steps Chiller Heat Pump Controller

with Water Free Cooling Function

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1 CONTENTS

1 Contents .................................................................................................................................................................... 2
2 Use of Manual ......................................................................................................................................................... 3
3 Free Cooling ............................................................................................................................................................. 4
3.1 FREE COOLING ADDENDUM.......................................................................................................................................................... 4
3.1.1 Reference manuals............................................................................................................................................................................................................................. 4
3.2 (WATER) FREE COOLING................................................................................................................................................................. 4
3.3 OPERATION OF THE FREE COOLING MODE............................................................................................................................... 4
3.4 FREE COOLING FANS ....................................................................................................................................................................... 5
3.5 ANTI-FREEZE PRE-ALARM FUNCTION........................................................................................................................................ 6
3.6 4÷20MA SIGNAL OF THE mA3 OUTPUT .................................................................................................................................... 6
3.6.1 Heating mode forcing in Defrosting mode .................................................................................................................................................................................. 7
3.6.2 Forcing of the mA3 signal during the defrosting, with single defrosting............................................................................................................................. 7
3.7 DESCRIPTION OF PARAMETERS.................................................................................................................................................... 8
3.8 TABLE OF PARAMETERS.................................................................................................................................................................. 8
3.9 I/O CONFIGURATION ...................................................................................................................................................................... 9
3.9.1 Analogue Inputs ................................................................................................................................................................................................................................. 9
3.9.2 Digital Inputs....................................................................................................................................................................................................................................... 9
3.9.3 Digital Outputs ................................................................................................................................................................................................................................... 9
3.10 USER INTERFACE............................................................................................................................................................................. 10
3.11 RESPONSIBILITY AND RESIDUAL RISKS ..................................................................................................................................... 11
3.12 DISCLAIMER ..................................................................................................................................................................................... 11
 2 USE OF MANUAL
This manual is designed to permit quick, easy reference with the following features:

References References column:

A column to the left of the text contains references to subjects discussed in the text to help you locate the information you
need quickly and easily.

Cross references Cross references:

All words written in italics are referenced in the subject index to help you find the page containing details on this subject;
supposing you read the following text:
”when the alarm is triggered, the compressors will be shut down”
The italics mean that you will find a reference to the page on the topic of compressors listed under the item compressors
in the index.
If you are consulting the manual “on-line” (using a computer), words which appear in italics are hyperlinks: just click on a
word in italics with the mouse to go directly to the part of the manual that discusses this topic.

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Warning! : information which is essential for preventing negative consequences for the system or a hazard to
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personnel, instruments, data, etc., and which users MUST read with care.
 3 FREE COOLING

3.1 FREE COOLING ADDENDUM

This document must be considered an Addendum to the User’s Manuals of Energy 400/ECH 400.

3.1.1 Reference manuals

Manual Code
ITA ENG GER FRE SPA RUS
ECH 400 8MA00103 8MA10103
Energy 400 8MA50102 8MA50102 8MA30102 8MAA0102

Please refer to these manuals for a complete description of the functions, parameters and diagrams not specifically
described in this document.

PLEASE NOTE: Analogue inputs/probes are indicated in this document with AI1. AI2, etc label while in related user
manuals ECH400/Energy 400 they could be indicated as ST1, ST2, etc.
Other labels could have the same discrepancy.

3.2 (WATER) FREE COOLING

DESCRIPTION OF The Water Free Cooling function allows for reduction of the temperature of the processed water, if applicable, by using
THE FUNCTION the external air temperature.
Water is cooled by circulating the water returned by the user’s plant through a bundled coil with fins (free cooling coil)
before it is conveyed to the evaporation exchangers.
If the Free Cooling mode is on, compressors are disabled, continue to follow the same rules and are started and stopped
using the default set points.
During the Free Cooling phase, the temperature of the water is controlled both by the compressors (if required) and by
modulating the fans used to circulate water through the free cooling coil. This can be done using the condensation fans
(internal free cooling (L01=3)) or the fans provided for this purpose (external free cooling (L01=2)).

INTERNAL Free The free cooling coil is situated next to the condensation coils. The same fans that control the air flow to cool the water
Cooling and regulate the condensation pressure of compressors.
EXTERNAL Free The free cooling coil is separated from the condensation coils and has an independent fan.
Cooling

3.3 OPERATION OF THE FREE COOLING MODE

OPERATION OF Free cooling means deviating the water flow returned from the user’s plant towards the free cooling coil before it is
THE FREE injected into the evaporation exchanger. The Free Cooling mode starts only if the temperature of the external air is below
COOLING MODE a specific value (this is dynamically controlled by the cooling set point of the unit). This ensures that the water output by
the free cooling coil is already cooled. The degree of cooling varies according to the temperature of the external air and
the air flow of the fans. The cooled water is then injected into the evaporation exchangers and the resulting temperature is
measured on temperature probe AI1. Compressor is dependent on temperature, as in the Free Cooling mode.
During the Free Cooling phase, the temperature of water is regulated by adjusting the air flow. The degree of variation is
dependent on the evaporator input temperature.

Diagram
SET

L02 L03
FCActive

FCNot Active
AI4

ECH 400 Free Cooling

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 The Free Cooling mode is started if:
- The external temperature (AI4) is below the value resulting from:
AI4 ≤ Current set point +L02
- The digital input that enables the Free Cooling mode is NOT ENABLED.
- The lowest evaporator water output temperature is above the anti-freeze alarm threshold (L04) plus 1°C.
The Free Cooling mode stops if:
- The external temperature (AI4) is above the value resulting from:
AI4 > (Current set point +L02) + L03
- The digital input that enables the Free Cooling mode is ENABLED.
- The lowest evaporator water output temperature (AI2, AI4) is below the anti-freeze alarm threshold (L04)
(applicable only if the compressors have already been stopped).

When the Free Cooling mode is ON:

- Relay RL6 is energized.
(for L01=1 and - The free cooling fans are running according to the evaporator water input temperature (AI1) (for L01=1 and
L01=2 only). L01=2 only).
L01=3 - Control is differentiated if the compressors are ON (fans regulated by the condensation probes) or OFF
(fans regulated by the water input temperature).

3.4 FREE COOLING FANS

FREE COOLING The following diagram shows the behavior of the temperature controller when the Free Cooling mode is on.
FANS For simplicity purposes, the example assumes that the unit has two compressor steps only.

Velocità
%
Set Point Cooling

Max

0
Temperatura acqua
Pa F11 Pa L05
evaporatore
Pa L06

Pa L07

IT GB
Velocità Speed
Temperatura Acqua Evaporator Water
evaporatore Temperature

ECH 400 Free Cooling

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 The chart above shows the curve of the proportional fan control outputs.
The function that controls the behavior of these outputs is the following:

⎡ (MAX − MIN ) ⎤
Ventilazione = MIN + ⎢
L05 ⎥ ⋅ [TemperaturaAcqua − (SetAttuale + L06 )]
⎣ ⎦

IT GB
Ventilazione Fan control
Temperatura Acqua Water Temperature
Set Attuale Current Set Point

MIN and MAX are the minimum and maximum voltage values that can be applied to the fan.

Fans are stopped when the evaporator water input temperature (AI1) is below the value resulting from: current set point +
L07 (Free Cooling cut-off temperature delta). The fans are restarted when the evaporator water input temperature rises to
the minimum Free Cooling value (AI1> Set Cooling + L07 + F11).

Note: L06 and L07 generally correspond to negative values.

3.5 ANTI-FREEZE PRE-ALARM FUNCTION

ANTI-FREEZE PRE- This function is mainly used to prevent the water output temperature*** from falling to excessively low values when the
ALARM FUNCTION Free Cooling mode is on. This condition would in fact stop the unit due an anti-freeze alarm.
Parameter FC4 contains a temperature value that must be added to the anti-freeze set point value to calculate the pre-
alarm threshold.
This function can be enabled in two different ways:

1) If the compressors are on and one of the output temperatures*** is equal to or below the pre-alarm threshold at
the end of the scan time (L07), one of the active compressors is switched off. If the temperature continues to be
below the pre-threshold alarm after the new scan, another compressor is switched off. These compressors can be
restarted (one at a time and at the end of the scan) by the temperature controller only, provided that the output
temperature exceeds the threshold by at least 1°C.
2) If the compressors are off and the output temperature*** is below the pre-alarm threshold at the end of the scan
time, the Free Cooling mode is disabled. The Free Cooling mode can be restarted only at the end of the scan time,
provided that the output temperature exceeds the threshold value by at least 1°C and that all the enabling conditions
are met.
*** output temperature read by AI2 or AI5 if configured as water output temperature

WARNING: THE ANTI-FREEZE ALARM, WHICH IMMEDIATELY STOPS THE MACHINE WHEN THE SET POINT IS
REACHED, IS ALWAYS ON.

Unit with internal Free Cooling coil

L01=1 In this configuration (Parameter L01=1), when the Free Cooling mode is on (the RL output enables and the water flow is
conveyed to the Free Cooling coil) the fans are no longer controlled by the condensation pressure and their cooling circuit.
The speed of rotation is instead controlled by the evaporator water input temperature. Consequently all fans are
controlled in synchronism regardless of their cooling circuit.
L01=3 In this configuration (Parameter L01=3), fans are controlled on the basis of the status of compressors:
a. If the compressors are ON, fans are controlled using the evaporator water output temperature.
b. If the compressors are OFF, fans are controlled by the input temperature.

3.6 4÷20MA SIGNAL OF THE mA3 OUTPUT

Unit with external Free Cooling coil

L01=2 In this configuration (Parameter L01=2), when the Free Cooling mode is on (the RL output enables and the water flow is
conveyed to the Free Cooling coil), the mA3 (4-20mA) output enables and starts controlling the Free Cooling fans using
the function described above.
The condensation fans will be controlled normally using the condensation pressure function.

L01≠ 2 In this configuration (Parameter L01≠2), i.e. for units without an external FC, the mA3 signal is adapted so that it contains
the information that has to be transmitted to the control modules it manages.

ECH 400 Free Cooling

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The operating mode or status is defined according to the mA signal value:
1. If the value of the signal is below 4mA, the unit is OFF or in Standby.
2. If the value of the signal ranges between 4mA and 11mA, the unit starts the Heating mode.
3. If the value of the signal is equivalent to 13mA, the unit starts the Cooling mode.

The following also applies to units in Heating mode:

• 4mA means that the temperature difference between the regulated temperature and the winter set point is
equivalent or greater than –6°C.
• 11mA means that the temperature difference between the regulated temperature and the winter set point is
equivalent or greater than + 6°C.
• If MA3 acquires intermediate values, the temperature differences range from –6°C to +6°C, as specified by the
following relation:

AN 3 = 4 + 0,5833 ⋅ (Treg − SetInvernale + 6)

IT GB
SetInvernale Winter Set Point

If the unit is shut down due to the following alarms (see also related user manuals- Diagnostic chapter):
• Compressor thermal switch
• Fan thermal switch
• High pressure (signaled by pressure switch and transducer)
• Low pressure (signaled by pressure switch and transducer)
• Alarm of probe AI3 or AI5 or AI4 (for the Heating mode only)
Signal mA3 will maintain the default value, in accordance with the rules defined above.

If the unit is shut down due to other alarms, the mA3 signal will have to be set to a value below 4mA.

3.6.1 Heating mode forcing in Defrosting mode

• If parameter F22 (Separate or single anti-freeze) is set to 1 (single anti-freeze), the mA3 signal will be forced to 4.1
mA in the interval of time between the enabling of the defrosting and the end of the safety timing, once the
defrosting cycle is complete.
• If parameter F22 (separate or single defrosting) is set to 0 (separate defrosting), the mA3 signal will be in the 4 -
11mA range. Thus, the exact value will be determined by the temperature difference measured.

3.6.2 Forcing of the mA3 signal during the defrosting, with single defrosting

11mA
Segnale AN3
4mA
On
Valvola 4V
Off
On
Compressore
Off Tempo

Tempo sicurezza
Inizio sbrinamento Fine sbrinamento

IT GB
Segnale AN3 AN3 Signal
Tvalvola 4V Valve 4V (4 ways
valve)
Compressore Compressor
Inizio Sbrinamento Start of Defrost
Fine Sbrinamento End of Defrost
Tempo Sicurezza Security Interval
Tempo Time

ECH 400 Free Cooling

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 3.7 DESCRIPTION OF PARAMETERS
Parameters can be set so that the Energy 400 is fully configurable.
Parameters can be changed from the:
• Device keyboard
• PC (if the required connection and "Param manager" software are available)
The following chapter describes in detail all the parameters of the Water Cooling category.
Free Cooling
Parameters If one or more parameters of this category is changed, it is necessary to turn the regulator on and off to ensure a correct
operation.

Pa L01
Water Free Cooling enabling
0 = Disabled
1 = Free cooling with internal coil
2 = Free cooling with external coil
3= Free Cooling C (internal coil and fan depending on condensing regulator)

Pa L02
Free cooling input delta
Temperature value expressed as temperature DELTA referred to the summer set point value.

Pa L03
Free Cooling output hysteresis

Pa L04
Anti-freeze pre-threshold
Temperature value expressed as temperature delta referred to the anti-freeze set point value.

Pa L05
Proportional band in Free Cooling mode

Pa L06
Minimum temperature delta in Free Cooling
Temperature value expressed as temperature DELTA referred to the summer set point value.

PA L07
Cut-off temperature delta in Free Cooling mode
Temperature value expressed as temperature DELTA referred to the summer set point value.

Pa L08
Scan time for anti-freeze pre-alarm threshold control

3.8 TABLE OF PARAMETERS

Free Cooling The following table summarizes all the parameters of “Energy 400” related to the Free Cooling mode.
Parameters
Free Cooling Parameters
Par Description of parameter Limits UM Default
L01 Water Free Cooling enabling 0÷2 num 0
0 = Disabled
1 = Free cooling with internal coil
2 = Free cooling with external coil
3 = Free Cooling C (internal coil and fan depending on
condensing regulator)
L02 Free cooling input delta -10.0 ÷ 10.0 °C -2
Temperature value expressed as temperature DELTA referred
to the summer set point value.
L03 Free Cooling output hysteresis 0.0 ÷ 10.0 °C 2

L04 Anti-freeze pre-threshold -10.0 ÷ 10.0 °C 2

Temperature value expressed as temperature delta referred
to the anti-freeze set point value.
L05 Proportional band in Free Cooling mode 0.0 ÷ 10.0 °C 1
L06 Minimum temperature delta in Free Cooling -10.0 ÷ 10.0 °C -1
Temperature value expressed as temperature DELTA referred
to the summer set point value.
L07 Cut-off temperature delta in Free Cooling mode -10.0 ÷ 10.0 °C -1
Temperature value expressed as temperature DELTA referred
to the summer set point value.
L08 Scan time for anti-freeze pre-alarm threshold control 0 - 999 sec 180

ECH 400 Free Cooling

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 3.9 I/O CONFIGURATION

3.9.1 Analogue Inputs

AI4 – NTC external air temperature probe; reading range: -30°C ÷ 90°C
AI4 MUST be configured as external air temperature (H14=3) --> see related user manuals ECH400/Energy 400

Analogue inputs: The resolution of the NTC analogue inputs is equal to the tenth Kelvin degree.
resolution and The precision is 0.8°C within the range 0÷35°C and variable within a range of 0.8°C ÷ 3°C over the rest of the scale.
precision
3.9.2 Digital Inputs
All digital inputs can be configured and can acquire the status described below if parameters from H23 to H34 and from
N02 to N05 are set.

Digital inputs: Parameter Description

Configuration value
table 0 Disabled input
1 Flow switch
2 Remote OFF
3 Remote Heat/Cool
4 Thermal switch of compressor 1
5 Thermal switch of compressor 2
6 Thermal switch of compressor 3
7 Thermal switch of compressor 4
8 Thermal switch of fan circuit 1
9 Thermal switch of fan circuit 2
10 High pressure on circuit 1
11 High pressure on circuit 2
12 Low pressure circuit 1
13 Low pressure circuit 2
14 High pressure on compressor 1
15 High pressure on compressor 2
16 High pressure on compressor 3
17 High pressure on compressor 4
18 End of defrosting of circuit 1
19 End of defrosting of circuit 2
20 Second power step request
21 Third power step request
22 Fourth power step request
23 Free Cooling

If several inputs are configured with the same value, the functions associated to the input perform a logical OR between
the inputs.

3.9.3 Digital Outputs

Configurable outputs can acquire the following statuses if parameters from H35 to H40 and from N06 to N07 are set.

Outputs Parameter Description

Configuration 0 Disabled
table 1 Reverse valve for circuit 1
2 Reverse valve for circuit 2
3 Condensation fan of circuit 1
4 Condensation fan of circuit 2
5 Resistance 1
6 Resistance 2
7 Pump
8 Evaporator fan
9 Step 2 power
10 Step 3 power
11 Step 4 power
12 Free Cooling

ECH 400 Free Cooling

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Menu tree 3.10 USER INTERFACE
diagram

Level 0 Level 1 Level 2 Level 3 Level 4

Control Probe
Set point SEt Label set cooling Coo Set Cooling Value
Current Alarm

Label set heating HEA Set Heating Value

Analogue Inputs tP Input Label t01...t04 Analogue Input Value

Alarms Err Current Alarms Label E00

Digital Inputs id Input Label i01-i11 Digital Input Status

Parameters PAr Configuration Parameters CnF Parameter Label H01... Parameter Value

Compressor Parameters CP Parameter Label C01... Parameter Value

Free Cooling Parameters SPL Parameter Labe L01... Parameter Value

Fan Parameters FAn Parameter Label F01... Parameter Value

Alarm Parameters ALL Parameter Label A01... Parameter Value

Pump Parameters PUP Parameter Label P01... Parameter Value

Parameters Folders
Antifrost Parameters Fro Parameter Label r01... Parameter Value

Defrost Parameters dFr Parameter Label d01... Parameter Value

Expansion Parameters ESP Parameter Label n01... Parameter Value

Password PSS Password Value

Operating hours 0Hr Compressor Op. Hours 0H1-0H4 Compressor Op. Hours Parameter

Pump Op. Hours 0PH Pump Op. Hours Parameter

ECH 400 Free Cooling

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3.11 RESPONSIBILITY AND RESIDUAL RISKS
Eliwell & Controlli s.r.l. shall not be liable for any damages deriving from:
• Installation/use other than that prescribed, which does not comply with the safety standards specified in the
regulations and/or those given herein.
• Use on equipment that does not guarantee adequate protection against electric shock, water or dust when
assembled.
• Use on equipment that allows dangerous parts to be accessed without the use of tools.
• Installation/use on equipment that is not compliant with the standards and regulations in force.

3.12 DISCLAIMER
This document is exclusive property of Eliwell & Controlli s.r.l. and cannot be reproduced and circulated unless expressly
authorized by Eliwell & Controlli s.r.l.
Although Eliwell & Controlli s.r.l. has taken all possible measures to guarantee the accuracy of this document, it declines
any responsibility for damages arising out from its use.
This applies also to all people or businesses involved in the preparation of this manual. Eliwell & Controlli s.r.l reserves the
right to apply, at any time, all the required aesthetic or functional changes without prior warning.
 4 ANALITIC INDEX
( FREE COOLING ADDENDUM.......................................... 4
(for L01=1 and L01=2 only). .....................................................5 FREE COOLING FANS....................................................... 5
(WATER) FREE COOLING .......................................................4 Free Cooling Parameters ................................................ 8
4 H
4(20MA SIGNAL OF THE mA3 OUTPUT .................6 Heating mode forcing in Defrosting mode................. 7
A I
Analogue inputs I/O CONFIGURATION ...................................................... 9
resolution and precision.............................................9 Icons for emphasis............................................................ 3
Analogue Inputs .............................................................9 INTERNAL Free Cooling ........................................................... 4
ANTI-FREEZE PRE-ALARM FUNCTION ........................6 L
C L01( 2................................................................................... 6
Configuration table ...............................................................9 L01=1 ..................................................................................... 6
CONTENTS..........................................................................2 L01=2 ..................................................................................... 6
Cross references .................................................................3 L01=3.............................................................................. 5; 6
D M
DESCRIPTION OF PARAMETERS ....................................8 Menu tree diagram ........................................................10
DESCRIPTION OF THE FUNCTION .............................................4 O
Diagram.................................................................................4 OPERATION OF THE FREE COOLING MODE............... 4
Digital Inputs .....................................................................9 Outputs ............................................................................... 9
Digital inputs: ....................................................................9 R
Digital Outputs..................................................................9 Reference manuals........................................................ 4
DISCLAIMER..................................................................... 11 References........................................................................... 3
E RESPONSIBILITY AND RESIDUAL RISKS .....................11
EXTERNAL Free Cooling............................................................4 T
F TABLE OF PARAMETERS.................................................. 8
Forcing of the mA3 signal during the defrosting, U
with single defrosting ..................................................7 USE OF MANUAL .............................................................. 3
FREE COOLING...................................................................4 USER INTERFACE.............................................................10

Eliwell & Controlli s.r.l.

Via dell’Industria, 15 Zona Industriale Paludi
32010 Pieve d’Alpago (BL) ITALY
Telephone +39 0437 986111
Facsimile +39 0437 989066
Internet http://www.eliwell.it

Technical Customer Support:

Telephone +39 0437 986300
Email: techsuppeliwell@invensys.com
ECH 400 Free Cooling
2005/4/
Invensys Controls Europe
An Invensys Company Cod: Addendum