The Elstat ems100 Nexo controller is an intelligent refrigeration solution designed for beverage coolers, including single-door, double-door, and vending machines. It aims to optimize energy savings without compromising drink serving temperature and provides consumer insights from field data.
Function Description:
The ems100 Nexo controller manages various aspects of a cooler's operation. It features a 3-digit, 7-segment LED display for user and diagnostic information, showing product temperature, defrost status, and alarm conditions. Push buttons allow end-users to cancel alarms and service technicians to run test routines. The controller measures the air temperature of the refrigeration compartment using an appliance sensor to manage product temperature. An optional condenser sensor monitors the refrigeration system's temperature to alert to issues like blocked condensers. Motion detection, either integrated or remote, senses activity in front of the cooler, while a door switch detects door openings. The controller switches the compressor to manage refrigeration temperature, controls the evaporator fan, and manages cooler lights for energy saving.
Important Technical Specifications:
- Relay Ratings:
- Compressor: 10 (10) A, p.f. 0.6 (IEC); 16 FLA, 96 LRA (UL @ 120VAC)
- Lights: 4 (4) A, p.f. 0.6 (IEC); 250W ballast (UL)
- Evaporator fan: 4 (4) A, p.f. 0.6 (IEC); 4.4 FLA, 13.1 LRA (UL)
- Temperature Input Ranges:
- Appliance sensor: -15°C to 50°C +/- 0.5°C (5°F to 122°F +/- 1°F)
- Condenser sensor: 50°C to 125°C +/- 5.0°C (122°F to 257°F +/- 10°F)
- Evaporator sensor: -15°C to 50°C +/- 0.5°C (5°F to 122°F +/- 1°F)
- NTC thermistor rating: -35°C to 125°C (-31°F to 257°F)
- Environmental Ratings:
- IP (Ingress Protection) Rating: IP45 Front Fascia, IP24 All Over
- Maximum operating temperature: 55°C (131°F)
- Minimum operating temperature: 0°C (32°F)
- Housing material: Black polycarbonate, Food grade
- Overall Dimensions: 120 mm (height) x 103 mm (width) x 41 mm (depth) for the main body, with a fascia of 142 mm x 127.8 mm.
- Power Supply: The controller is powered via a transformer, available in 120VAC/50-60Hz - 12VAC or 230VAC/50-60Hz - 12VAC options.
- Sensor Circuit: Designed for Safety Extra Low Voltage (SELV).
- Door Switch: Head: countersunk, max diameter 5.0mm (0.24in); Thread: max diameter 3.0mm (0.16in). Max torque for screws: 0.5Nm (0.37lb ft).
- Motion Sensor (for non-flush mounting): Ø55 mm (overall), Ø30 mm (aperture), 15 mm (behind panel). Head: countersunk, max diameter 6.0mm (0.24in); Thread: max diameter 4.0mm (0.16in). Max torque for screws: 0.5Nm (0.37lb ft).
- Parameter Ranges (examples):
- Differential (dIF): 0.0 to 9.9°C (0 to 18°F)
- Calibration 1 (CA1): -4.0 to 4.0°C (-7 to 7°F)
- Compressor rest time (rt): 1 to 30 minutes
- Delay to saving (dS): 0 to 120 minutes (in multiples of 30 minutes)
- Lights delay (Ld): 0 to 120 minutes
- Saving restart period (Sr): 0 to 240 minutes (in multiples of 30 minutes)
- Refrigeration system failure (Ct): 00 to 100 hours
- Celsius or Fahrenheit (CF): 00 (°C) or 01 (°F)
- Saving differential (Sd): 0.0 to 9.9°C (0 to 18°F)
- Saving set point (SSP): 0.0 to 9.9°C (32 to 50°F)
- Uninterrupted pull down (IPd): 0.0 to 60°C (32 to 140°F)
- Freeze-up protection (dtt): -10 to 10°C (14 to 50°F)
- Defrost interval (dE): 0 to 199 hours
- Defrost duration (dd): 1 to 199 minutes
- Fan cycle on (FCO): 1 to 30 minutes
- Fan cycle off (FCF): 0 to 30 minutes
- Alarm delay (Ad): 00 to 30 minutes
- Buzzer duration (b1): 1 to 254 seconds
- Motion sensor enable (Sn): 00 (disabled) or 01 (enabled)
- Display stability (d2): 1 to 254
- Low voltage (LO): 0 (disabled)
- High voltage (HI): 0 (disabled)
- Defrost termination temperature (dtd): 1 to 30°C (34 to 86°F)
- Activity frequency (AF): 00 (low frequency)
- Fan set point (FSP): 0 to 60°C (34 to 140°F)
- Buzzer enable (b0): 00 (disabled) or 01 (enabled)
- Saving temperature disable (PEr): 00 (off) or 01 (on)
- Learning period (LP): 00 (1 day) or 01 (7 days)
- Display (dIS): 00 (USE) or 01 (temperature)
- Marketing mode (Ar): 00 (off) or 01 (on)
- Shelf data enable (ShF): 0 (disabled) to 1 (enabled)
Usage Features:
- User Interface: Available with integrated or remote motion detection. The integrated variant should be installed externally where it can "see" activity, while the remote variant allows internal controller installation with the sensor placed to detect activity.
- LED Indicators: Compressor (Green), Evaporator fan (Green), Saving temperature disable (Red), Motion (Red, flashes continuously if faulty).
- Push Buttons:
- Set: Accepts/forwards menu options and parameters.
- Defrost: Activates a manual defrost (if temperature is below termination temp).
- Up: Scrolls up menus, increases parameter values.
- Down: Scrolls down menus, decreases parameter values, cancels rSF, d0, and Ht alarms.
- Display Codes:
USE or temperature: Ready mode, cooler lights on.---: Saving mode, cooler lights off (unless Ld parameter or marketing mode (Ar) keeps them on).dEF: Defrost mode, compressor off, evaporator fan on.d0: Door open.888: Freeze-up protection.-SF: Refrigeration system failure (rSF).Ht: Condenser high temperature.PF1: Appliance sensor failure.PF2: Condenser sensor failure.
- Firmware Menus (GDC):
PS (Parameter list): Displays parameters and values.tSt (Test routine): Tests relays, temperature sensors, door switch, and motion sensor.FLt (Faults): Displays the last three faults.Hr (Half reset): Clears the self-learning matrix.Fr (Full reset): Resets parameters to global defaults, clears self-learning matrix and statistics (Elstat use only).ddP (Data dump): Downloads data to a computer (Elstat use only).
- Menu Access: A specific button sequence (Set x3, Down x1, Up x2, Defrost x4) is required to access the main menu.
- Test Routines: Allows testing of all load relays, analogue inputs (temperature sensors, door switch), and motion sensor. Individual tests can be selected.
- Viewing Faults: Users can view the last three cooler faults to understand problems.
- Half Reset: Clears the self-learning matrix to allow the controller to re-learn outlet opening/closing times, useful if the cooler has been moved or if the motion sensor was obstructed.
- Viewing Statistics: Pressing Up and Down simultaneously displays statistics such as activity frequency, compressor cycles, compressor runtime, door openings, highest temperature, lowest temperature, motion counts, and saving temperature disable status.
Maintenance Features:
- Sensor Installation:
- Appliance sensor: Measures return air temperature, secured with a P-clip, head at right-angle to airflow. Avoid cable ties.
- Condenser sensor: Measures refrigeration system temperature, mounted on the liquid pipe of the condenser using a metal pipe clip or foil tape. Avoid cable ties and contact with hot pipes.
- Evaporator sensor: Placed in immediate proximity of the evaporator, securely mounted inside cooling fins. For defrost heaters, place away from the heating element. Avoid cable ties.
- Wiring Diagram: Detailed diagram for electrical connections, recommending right-angle insulated 6.3mm tab connectors for terminals 1-4 to prevent damage.
- Programming Port Cover: Rubber cover should be removed and left hanging on its strap to prevent misplacement. Replaced by inserting the left edge first, then securing other edges clockwise.
- Mounting: Designed for panel mounting with four countersunk self-tapping screws. Vertical mounting may lead to water ingress or ineffective motion sensing. Drip loops must be formed in all wiring immediately prior to connection to prevent water tracing.
- Troubleshooting: The manual provides flowcharts and descriptions for common issues like "Not cooling problems," "Door open alarms," "Temperature sensor alarms," "Freeze-up protection (888)," "Refrigeration system failure (rSF) alarms," and "Condenser high temperature (Ht) alarms."
- 'Limp Home' Functionality: The controller enters a 'limp home' mode during certain faults (e.g., door open for too long, refrigeration system failure) to allow continued operation with limited disruption while a service engineer visit is scheduled. This prevents damage to major components.
- Parameter Validation: The controller validates parameter values and displays warnings for clashing parameters.
- Full Reset: Resets all parameters to global default values and clears all statistics, intended for Elstat personnel only.
- Data Dump: Allows downloading of controller data for analysis, intended for Elstat use only.
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