MultiFlex ESR Installation and Operation Manual
Contents
1. Figure 5 2 Baud Rate Settings 6 Software Overview The MultiFlex ESR board is intended to inter face closely with E2 s Standard Circuit applica tion Once a valve on the MultiFlex ESR board has been associated with a Standard Circuit the Standard Circuit assumes control of the valve s position The Standard Circuit must be specifi cally configured to control a MultiFlex ESR 5 MultiFlex ESR I amp O Manual valve so that the advanced capabilities provided with the MultiFlex ESR will be enabled Valve Rescaling The Standard Circuit has an enhanced control strategy when it is configured to control a Multi Flex ESR valve As with previous ESR control a PID algorithm is used to position the valve during refrigeration mode in order to maintain the circuit temperature setpoint In addition a minimum and maximum valve percentage may be specified When this is used the PID output 0 100 is rescaled to a control range between the minimum and maximum valve percentage parameters This may be useful in situations where the valve is slightly oversized and tends to continuously overshoot the temperature setpoint Pulldown Mode A new Standard Circuit control state named Pulldown has been added The Pulldown state is optional and is by default disabled When enabled the Standard Circuit will go into Pull down following a defrost cycle or a case wash Also if a door switch is configured and refri2. Figure 1 2 MultiFlex ESR Molex Connector Board Layout Discontinued P N 810 3198 2 Installation The MultiFlex ESR control board is designed to be located in a central location preferably near the valves it is driving Figure 2 1 shows the mounting dimensions of the MultiFlex ESR board MULTIFLEX ESR BOARD WEIGHT 9 4 OZ Figure 2 1 MultiFlex ESR Board Dimensions 2 1 Panel Mounting and Heat Dis sipation The MultiFlex ESR can generate a substantial amount of heat when it draws up to a maximum of 80 VA during operation The MultiFlex ESR 1s rated for a maximum ambient temperature of 65 C 150 F therefore depending on the size of the enclosure and what other devices are in MultiFlex ESR Molex Connector Board Discontinued that enclosure with the MultiFlex ESR you may need to ventilate the enclosure by installing air circulation fans or other devices to aid in heat dissipation 2 2 Snap Track Installation Boards not supplied with an enclosure are sup plied with a snap track for easy installation The insulation sheet and I O board must be removed from the track before the track is mounted The snap track is mounted using the 0 1875 mount ing slots Figure 2 2 shows this installation pro cedure 1 REMOVE THE BOARD AND THE INSULATOR FROM THE SNAP TRACK 2 MOUNT THE SNAP TRACK USING THE 1875 SLOTS PROVIDED OPERATION OF THE BOARD TENPORL RENO
3. 1 1 Molex Connectors Board P N 810 1398 1 LA Hand Held Terminal e AINE DIE NN 1 UN IET DIT AAA te EIE ep he eR 1 1 2 MULTIFLEX ESR MOLEX CONNECTOR BOARD DISCONTINUED eese enhn nnne nennen neret rene enne nn 2 22 hy VS B AAA 2 2 1 PANEL MOUNTING AND HEAT DISSIPATION cccccscesesesessseseseeccceecececccecseececeececesesesseeeauausesussssacesseseeceseseeeesesenenseeseraes 2 2 2 SNAP IRACK INSTALELATION 4 222 22 22 22 2 En ES A Wate bettas bebe es 2 SI ON 2 DOEI DNA E r AOA ee mee br RT MEA RAO o 2 3 2 w VATE Bo WARING csc RE ed nse 3 3 2 1 Molex Connector Discontinued Board Wiring eese sees eese eene tnter en nennen enne tenent enne 3 4 SETTING THE TERMINATING RESISTANCE JUMPERS eee eee ee ee eee eee reete to netten se ease seen aet ene 4 5 SETTING THE NETWORK ADDRESS AND BAUD RATE 22200000000002200000020000000000000000000 000000000000 eese enne 4 6 SOFTWARE OVERVIEW voro tasaava osos aa ee era essen esae eeu po eu eS ee Pee Sepe esu npa as ege Fo dua eoe ee e Vae ep Foe epe a Ce PY UU UNE 5 6 1 PROGRAMMING E2 VERSION 2 21 AND ABOVE cccccccccccscssscecesssescesceessssesescsssssssccesesssssececeseesececesseesseccesseussssceesesesess 6 6 2 STEPS ADD AMUETIBEE
4. O Network The MultiFlex ESR communicates with the E2 directly over the RS 485 I O network unlike the previous version of the board which communi cated with the controller over the Echelon net work 1 1 Center Tapped Transformer For power a Class 2 SOVA 24VAC center tapped transformer is required for each Multi Flex ESR board Previous board versions did not require a center tapped power source Molex Connectors Board P N 810 1398 The discontinued MultiFlex ESR board s valve outputs are four contact molex connectors instead of the screw terminals Valve cables hav ing a four contact molex connector are plugged directly into the board This board has been dis continued and replaced with the new MultiFlex ESR board version P N 810 3199 Hand Held Terminal HHT Set configuration parameters setpoints and fail safe conditions of each valve with the HHT By using the HHT each valve output can be set sep arately with a valve step rate and the total num ber of steps from closed to fully open Snap Track Mounting The MultiFlex ESR board fits into the standard CPC 4 I O board snap track for mounting 026 1720 Rev 4 06 APR 2010 MultiFlex ESR Molex Connec tor Board Discontinued 1 2 LEGEND Valve Connectors 8 6 Termination Jumpers 24VAC CT 75 VAC Power Input HHT Jack General Status LED Network Address Switches Network Input Open LED 8 TX and RX LEDs Close LED 8
5. number of keystrokes The HHT can be used to fully open the valve override to 100 for brazing during the valve installation process or evacuation of the system 8 2 8 2 1 The HHT will display the following home or main screen Screens Main Screen MULTIFLEX ESR 810 3198 VER 1 11F01 PRESS Y D Figure 8 1 Main Screen eves NOTES Press F1 at any time to return to the 4 Home screen Use arrows to select fields and scroll Possible internal failures or communication bus problem messages FAIL FLASH CLK Either the flash executable code has changed or the hardware clock is not func tioning properly FAIL I O NET Unable to communicate with the Network FAIL USER CFG The MultiFlex ESR board set 13 MultiFlex ESR I amp O Manual points have not been configured the MultiFlex ESR board is using factory defaults for valve configura tions 8 2 2 Output Status Screens The third and fourth screens will show the state of all valves Valves 1 4 are seen on one screen and continue with 5 8 on the next These screens will allow an override to be placed on the valve s position 48 gt 0V 100 98 OV 5 NA 48 Figure 8 2 Output Status Screen Also shown are status indicators e Valve is idle O Valve is opening C Valve is closing A Alarm OV and its value will not appear unless the valve has been overridden Once the HHT has been remo
6. 026 1720 Rev 4 06 APR 2010 MultiFlex ESR Installation and Operation Manual EMERSON es EMERSON 3240 Town Point Drive NW Suite 100 Kennesaw GA 30144 USA Phone 770 425 2724 Fax 770 425 9319 ALL RIGHTS RESERVED The information contained in this manual has been carefully checked and is believed to be accurate However Computer Process Controls Inc assumes no responsibility for any inaccuracies that may be contained herein In no event will Computer Process Controls Inc be liable for any direct indirect special incidental or consequential damages resulting from any defect or omission in this manual even if advised of the possibility of such damages In the interest of continued product development Com puter Process Controls Inc reserves the right to make improvements to this manual and the products described herein at any time without notice or obligation FCC COMPLIANCE NOTICE This device complies with Class B of Part 15 of the FCC Rules Table of Contents I INTRODUCTION airoso tet reet totes pep et os toi eod ie us fee ev aae eet aaa ue eu da a AAA AAA AAA AAA A sn Lev deae eue uen 1 1 1 MULTIFLEX ESR AND ESR 8 BOARD DIFFERENCES ccssesscceceesssscescecsessesescsesssssescsesesseccsessesseescesseessessessssesseeses 1 1 1 RS 483 PLORA TI c 1 Ld Center Tapped Transformer eic aee o skin debil 1
7. 100 0 100 0 100 8 100 0 100 0 100 0 100 0 100 0 MFLEX ESR863 100 0 100 0 100 0 100 0 100 0 100 0 100 0 100 0 MFLEX ESR805 NONE NONE NONE NONE NONE NONE NONE NONE Figure 6 7 MultiFlex ESR Summary Screen 4 If more than one MultiFlex ESR is listed choose the one you wish to edit and press Enter 5 From the status screen press SET UP NOTE Use the F1 and F2 keys to scroll 4 between screens A General Setup Screen The General Setup screen is where general prop erties of the MultiFlex ESR application are spec ified The only field on this screen you will edit is the Name field If you wish to assign a name to this MultiFlex ESR application enter it in this field otherwise move to the Valves Setup screen Software Overview 10 61 85 66 RX 488 Unit 2 Use Ctrl X to Select Tabs SETUP C4 Valves cS Alarms Multiflex ESR MFLEX ESR661 General Value ESR801 Watchdog En No Update Rate 0 00 15 F1 PREU TAB F2 NEXT TAB F3 EDIT Fu STATUS Figure 6 8 General Properties Screen B Valves Setup Screen The Valves Setup screen C4 tab allows you to specify the type of valve connected to each out put on the MultiFlex ESR board 61 65 66 RX 488 Unit 2 Use Ctrl X to Select CX Tabs SETUP C1 General cS Alarms Multiflex ESR MFLEX ESR661 Step Rate MaxStep OvurClose Valve Mfg 5 ECT Flow 800 888 Other 888 Other 888 Other 888 Other 888 Other 800
8. MARY SIDE AC 2avac Center Tapped IGND Three conductor non shielded cables are the recommended wire for connecting between the center tapped transformer and I O boards SECONDARY SIDE Earth ground the GND center tapped terminal of each board Figure 3 1 Power Wiring Center Tapped Transformer 3 2 Valve Wiring The stepper valves are wired to the board by connecting the stepper valve harness to one of the eight screw terminal connectors along the top of the board Figure 3 3 and matching the wire colors to the legend on the connectors Use 3 MultiFlex ESR 180 Manual the cable and cable harnesses that are supplied with the valves Wire Color Legend on Each Valve Connector 8 R BLU BLK W Figure 3 2 Valve Connector Wire Color Indicator Stepper Valve Harness Match wire colors to silk screen legend on board terminals MultiFlex ESR Board w Eight Screw Terminal Connectors P N 810 3199 ECT Flow Stepper Valve Figure 3 3 ECT Flow Valve and New Board Wiring Diagram For Sporlan valves match all wire colors except the green wire Instead connect the green wire to the silk screen blue wire legend Figure 3 2 3 2 1 Molex Connector Discontinued Board Wiring The stepper valves are wired to the board by connecting the stepper valve molex connector to one of the eight molex connectors along the top of the board Figure 3 4 Use th
9. MultiFlex ESR board RS485 I O NET JP2 JP3 JP4 JP2 JP3 JP4 TERMINATION Jumpers in the NO TERMINATION Jumpers in the UP position DOWN position DAISY CHAIN CONFIGURATION SET TERMINATING JUMPERS Figure 4 1 Daisy Chain Termination Jumper Settings For more information about network configura tion and termination see the I O Network wiring section in your site controller s user manual located on the far right side of the board opposite the Termination jumpers set to the Normal position or the board will not operate correctly 5 Setting the Network Address and Baud Rate CAUTION Always have the JP1 jumper Set the network address on the first five rockers of the dip switch labeled S1 on the MultiFlex ESR board Set the network baud rate using rockers 6 and 7 Setting the Terminating Resistance Jumpers 4 Set the network address using the first 5 rockers of dip switch S1 Valid address range 1 31 ADDRESS 191 BOARD Bon BOA BOA a BOA BOR 2 T D BOARD 3 RI RD RD RD 18 RD Er i n 9600 baud I 19200 baud i
10. Other F1 PREU TAB F2 NEXT TAB F3 EDIT F4 LOOK UP Figure 6 9 Valves Setup Screen Enter specifics about the valves that are connected to the MultiFlex ESR All valves on this screen are listed in eight rows numbered one 1 through eight 8 The number on each row corresponds to the similarly numbered point on the MultiFlex ESR For each MultiFlex ESR point that has a valve attached to 11 MultiFlex ESR I amp O Manual F5 CANCEL F5 CANCEL jJ it define the following fields OvrClose The Over Close Percentage is the percentage of the MaxStep parameter that the valve will attempt to close past its 0 limit for defrost This will ensure the valve is fully closed when the circuit associated with the valve goes into defrost For example when a valve with an Over Close Percentage of 5 and a Maximum Steps value of 800 is called upon to over close i e defrost the valve will travel to the step that it counts as 0 and then attempt to close 40 more steps By doing this any error that may cause the valve to be slightly open at 0 will be eliminated It is recommended that this value be set to 5 for all Emerson Flow Control valves For more information refer to the Valve Specifications tables at the end of this manual Step Rate The Step Rate field corresponds to the valve manufacturer s recommended step rate in steps per second The default 50 steps per second is the correct step rate for the ES
11. R 12 and ESR 20 valves If using different types of valves refer to the Valve Specifications tables at the end of this manual and enter the rate listed for your valve type MaxStep The MaxStep field is where you must enter the total number of steps the valve travels between fully closed 0 and fully open 100 This is a physical property of the valve Refer to the Valve Specifications tables at the end of this manual to determine the total number of valve steps 026 1720 Rev 4 06 APR 2010 Valve Mfg If you have already associated the valve and circuit select the valve type in the appropriate field Press the F4 button to choose the type of valve used If this field is set to ECT Flow the following options will be available e Stuck Valve alarm the valve is not moving in response to commands Based on characteristics for this valve type this feature offers a high probability that 1f the valve becomes stuck a Stuck Valve alarm will be generated e Open Wire alarm at least one drive winding of the valve is disconnected or has an open coil no current flow was detected e Over Current alarm available if the Valve Mfg field is either set to ECT Flow or Other the valve driver is reporting an over current condition possibly caused by a shorted driver winding NOTE alarms attempt to auto reset con 4 tinuously every 10 minutes after the alarm was first detected 7 Valve Zeroing During the ins
12. TATUS F5 CANCEL Figure 6 6 More Tab Additional MultiFlex ESR Setup Screen Temp Fail EEPR Failsafe setting that is used exclusively when the valve type Valve Mfg under the MultiFlex ESR Valves Setup screen is set to Other The value set in this field will be the position the valve goes to if the case temperature sensor fails or the MultiFlex ESR board goes offline This failsafe setting is always available Comm FailDefrost If set to ENABLE default the scheduled defrost will occur if the board is in comm failure offline If set to DIS ABLE the circuit will disable any scheduled defrost if the MultiFlex ESR board containing the valve for this circuit is in comm failure off fline An advisory will be logged if a scheduled defrost is disabled due to a MultiFlex ESR 9 MultiFlex ESR I amp O Manual comm failure When CommFailDefrost is set to DISABLE the advisory priority and type can be configured The following two advisory parame ters will appear e AdvPrior lets the user set the priority of the Notice or Alarm logged if a defrost is disabled due to a MultiFlex ESR comm fail ure e AdvTyp lets the user select between Notice or Alarm to be logged for the event described above NOTE There are multiple screens under the 4 CO MORE tab Use F1 and F2 to toggle between available screens under this tab Standard Circuit Valve Parameters Min Valve Description The minimum percenta
13. VE 3 REINSTALL THE INSULATOR IN THE SNAP TRACK espero MAY CAUSE SEROUS DAMAGE TO THE BOARD 4 REINSTALL THE BOARD IN THE SLOTS IN THE SNAP TRACK 26501040 Figure 2 2 MultiFlex ESR Snap Track Installation 3 Wiring 3 1 Each MultiFlex ESR board requires a Class 2 80VA 24VAC center tapped transformer for power The power connector labeled J12 is located in the top left corner of the board Power Installation 2 CPC transformer P N 640 0080 is a multi tapped primary transformer that may be used with the MultiFlex ESR board Refer to Figure 3 1 and follow the instructions below for transformer power wiring 1 Connect the three wires from the secondary side of the transformer to the power connec tor The AC should be run with a minimum of 18 AWG wire up to 10 feet 16 AWG up to 20 feet or 14 AWG up to 30 feet 2 Connect 24VAC to ACI and AC2 3 Connect the center tap CT of the transform er to the GND center terminal of the power connector 4 Attach an additional 14 AWG or larger wire from the center GND terminal to solid earth ground Keep the wire as short as possible 6 or less is preferred and should be completed for each board Use 24VAC Center Tapped Transformer WIRING FOR 640 0080 80VA Transformer Power Wiring Types 14 AWG Be 9495 18AWG Belden 9493 120 208 240 VAC HOT N o E NEUTRAL 240 208 PRI
14. X ESR A da Ae ed aeo c eet 6 6 3 STEP2 ADD A SSTANDABD es tra eee cete deese dee doce ters 7 6 4 STEP 3 ASSOCIATE THE MULTIBLEX ls Mee 7 6 5 STEP 4 SET UP THE STANDARD CIRCUIT ccccccccessssscccsesssssceccscssessesescsesssssescsesessescsesssssesecessessssscesssesseccecessessesseessesees 8 6 6 STEP StSET UP THE MULTIFEREXESR 4 24 5 22 20 tee tete e ee ni tei tee te E ee Stes 10 IAN A a 12 PR ERE CERE 12 1 2 STEP Zn an a eei ie 12 8 HAND HELD TERMINUL i eee eee vo hte erra Eee Pee eaae ep PE ee auge es ev cae o Pe PE oses pass 12 SL TOVERVIEW EE EE TTE 12 8 2 SCREENS de A che Sock endo NA 13 0 215 Main Screen fo eei t ce P cud eL o Ee DE ero rores eei eoe siete etae De e Ee e io 13 8 2 2 Output Status Screens oda d e be de sii 13 922535 ein ita 13 6 24 Main Select SCFreeni css liec tla a 14 6 2 5 Valve Configuration Screens u seien obti err UR UR EP REI CE Ot teritur eap 14 0 2 0 7 Network Screen eite tte o gettin I D Oi esiti quein ticdu 14 VALVE SPECIFICATIONS TABLES terno eee ao Fei vale toan esos e Pa Pene pose Dose bep Va keel Poe ea 15 EMERSON FLOW CONTROLS STEPPER VALVES ccccccccssssssccccecsssscsscecesssesseccesssessescecsessssesesesssssecesessssssccsessassssceesse
15. ard Circuit application in E2 to control case circuit temperature Each Standard Circuit application should be programmed as docu mented in the E2 s installation guide or the E2 s user manual and or online help To specify that the case circuit is going to be controlled by a valve on a MultiFlex ESR board there are three important screens in the Standard Circuit application that you will need to alter To edit a Standard Circuit application 1 Press lt a gt 2 Press CIRCUITS 3 If more than one circuit has been added the Circuits Summary page will open displaying all circuits in the E2 Use the arrow keys to E the circuit you wish to edit and press 4 From that circuit s Status screen press SETUP armen NOTE Use the FI and F2 keys to scroll between screens Step 4 Set Up the Standard Circuit A General Setup Screen RX 366 Unit 2 10 29 19 SETUP FULL ALARM C5 Defr Times MORE Value STANDARD CKT62 Long Name Case Type SDIC SglDk Ice Cream 1 Num Case Sensrs Num Prod Sensrs 8 Dual Temp Enab N lo INE UP HFLEXESR DEF lo Using CaseDisp N Fan During Defr Fan During Idle ON Fan ON Delay H 6 66 Cleaning Switch NONE Door Sw Mode None Fi PREU TAB F2 NEXT TAB F3 EDIT F4 LOOK UP F5 CANCEL Figure 6 4 General Setup Screen Under the General Setup screen C1 tab the Temp Ctrl Strat field tells the E2 what method of cont
16. cations Tables TYPE ESR 12 ESR 20 ESVB ESVB 4 ESV 4 10 20 Ton 1 4 Ton Voltage 12 VDC 12 VDC 12 VDC 12 VDC 12 VDC 24 VDC 24 VDC 24 VDC 24 VDC 24 VDC Control Suction Suction Liquid Liquid Liquid Step Rate 50 50 50 50 30 ok 30 Max Steps 500 800 1 800 800 384 360 2 OverClose 5 5 5 5 5 Total Watts 10 10 10 3 4 12 8 Phase 3 29 ohms 29 ohms 29 ohms 84 ohms 23 5 ohms Resistance 115 ohms 115 ohms 116 ohms 336 ohms 95 ohms Hysteresis 0 0 0 0 0 Motor Bipolar Bipolar Bipolar Bipolar Unipolar at ESR CC100 ESR CC100 CC100 CC100 CC100 maw CCB CCB CCB CCB CCB products Notes 1 500 steps for valves manufactured before year 2001 Identify using date code before 0100 e g 0052 9902 9848 or brass body size 2 vs 2 1 4 for 800 steps 2 DO NOT exceed max steps of 384 for this valve 3 Shown for 12V and 24V motors 10 at 75 F 4 For ESV replacement with ESVB 1 Swap the Flow Control colors RED and BLUE 2 Cap off the YELLOW wire Sporlan Parker Stepper Valves TYPE CDS 8 CDS 16 SEI EEV CDS 9 CDS 17 Voltage 12 VDC 12 VDC 12 VDC 12 VDC Control Suction Suction Suction Suction Step Rate 200 200 200 200 Max Steps 3064 6386 1596 3193 6386 OverClose 5 10 10 10 Total Watts 10 4 5 7 4 Phase 3 75 ohms 75 ohms 72 ohms 75 ohms Resistance Hysteresis 0 0 0 0 Motor Bipolar Bipolar Bipolar B
17. e cable and cable harnesses that are supplied with the valves NOTE A valve cable harness may not be lon 4 ger than 150 feet 026 1720 Rev 4 06 APR 2010 Stepper valve harness with molex connector Discontinued Type MultiFlex ESR Board w Molex Connectors P N 810 3198 Figure 3 4 ECT Flow Valve and Old Board Wiring For retrofits or stepper valve harnesses without a mating molex connector use the MultiFlex ESR adapter cable P N 335 3275 Crimp type waterproof splices should be used to make the connections For Sporlan valves used with these discontinued boards match all wire colors except the blue wire Instead connect the blue wire to the Spor lan green wire 4 Setting the Terminat ing Resistance Jumpers All MultiFlex ESR boards have a set of termi nating resistance jumpers one jumper for each wire lead These jumpers are labeled JP2 JP3 and JP4 on the MultiFlex ESR board Set the termination jumpers UP JP2 JP3 JP4 if at either end of a daisy chain Otherwise set jumpers DOWN The purpose of the jumpers is to indicate the two ends or termination points of the segment On a daisy chain one device at the beginning and one device on the end must be terminated by placing all three termination jumpers in the UP position All other devices on the daisy chain must be set to the DOWN position Figure 4 1 shows the Valve Wiring proper terminating resistance jumper settings for the
18. e on the MultiFlex ESR board is associated with a circuit the two are automati 7 MultiFlex ESR I amp O Manual cally connected and can communicate This auto hookup of circuit valve control and alarm parameters between the circuit and the Multi Flex ESR application minimizes the set up of standard circuit s for MultiFlex ESR Step 4 To access the MultiFlex ESR Association screen from the Home screen 1 Press 2 Press 3 Use the arrow keys to id the circuit you wish to edit and press RX 488 Unit 2 ESR ASSOCIATIONS Circuit lt gt Multiflex ESR Association Circuit Mflex ESR Appl STANDARD 1 STANDARD CKT62 STANDARD CKT63 MFLEX ESR881 MFLEX ESR881 MFLEX ESR661 MFLEX 001 MFLEX ESR661 MFLEX ESR661 MFLEX ESR661 enoanzun STANDARD CKT68 Figure 6 3 Associations Screen The Circuit column displays all configured stan dard circuits in the E2 The MFlex ESR Appl column displays a list of all MultiFlex ESR applications in the E2 press F4 to choose which MultiFlex ESR board to associate with the cir cuit The Valve column selectable between 1 and 8 for the valve number displays the valve number the circuit is connected to NOTE A valve may be associated to only 4 circuit Multiple valves cannot be assigned to a single circuit 026 1720 Rev 4 06 APR 2010 6 5 Step 4 Set Up the Standard Circuit The MultiFlex ESR works in conjunction with a Stand
19. en the valve type is set to ECT Flow If enabled default the scheduled defrost will occur if the board is of fline comm fail If disabled and the MultiFlex ESR board containing the valve associated with this circuit is in Temp Fail Use Avg Comm Fail EEPR Comm Fail Use Avg CommFailDefrost comm fail the standard circuit will skip any scheduled defrost and an ad visory will be generated Additional ly two configurable advisory parameters will appear Table 6 1 MultiFlex ESR Valve Parameters E2 More Tab 6 6 Step 5 Set Up the MultiFlex ESR Before setting up the MultiFlex ESR evaporator stepper regulator you must have completed steps 1 4 so that the MultiFlex ESR boards are added and configured correctly in your Standard Circuit applications In this step you must spec ify the type of valves being used and if neces sary the specifics of the valve such as step rate and maximum number of steps To edit a MultiFlex ESR application 1 Press lt a gt 2 Press WEB Configured Applications 3 Use the arrow keys to highlight MultiFlex Step 5 Set Up the MultiFlex ESR ESR and press EH or simply enter the number next to it The MultiFlex ESR Sum mary screen will open 61 65 66 RX 488 Unit 2 SUMMARY 15 46 36 ALARN Summary For Multiflex ESR Multiflex ESR Valve1 1 2 Valve3 Valve4 Value5 1 Valve Values 590 0 58 8 58 8 50 0 50 0 50 0 50 0 50 0 HFLEX ESR82
20. ersion 2 21 and Above 3 Associate MultiFlex ESR Assign the Multi Flex ESR to standard circuit s so the valve on the board is associated or mapped to a circuit which will enable valve control The association creates auto hookup of circuit valve control and alarm parameters between the circuit and the MultiFlex ESR application This association should be completed prior to Step 4 Standard Circuit Setup to minimize the set up of standard circuit s for MultiFlex ESR 4 Standard Circuit Setup A Standard Circuit application must be set up as normal with all case types setpoints and other parameters defined except the Temperature Control Strat egy the Temperature Control Strategy must be set up as LINE UP MFLEXESR DEF 5 MultiFlex ESR Setup Physical properties of the valves connected to the MultiFlex ESR will need to be specified in the MultiFlex ESR appli cation in the E2 software 6 2 Step 1 Add a MultiFlex ESR A Add Number of Boards A MultiFlex ESR board must be added to the E2 in the same manner that an SRO or a 16AI is added in the network setup of the controller This is done from the Connected I O screen of the E2 Figure 6 1 61 65 66 RX 488 Unit 2 CONNECTED 1 0 THIS 82 1 Unit Name 15 35 49 2 Unit Number 1 0 Net Devices Num Ctrl Type Ctrl Type Num Ctrl Type 6 16AI DFHC 8 WTPK 6 8RO WCC 8 WPK 6 8 0 CUB 8 PAK IRLDS Multiflex ESR ECT Devices Num Ctrl Type 8 1SD 1 8 T
21. ge the valve can go to during refrigeration con trol The valve will go to 0 fully closed during defrost regardless of what the minimum valve has been set to Max Valve The maximum percentage the valve can open during refrigeration con trol Pulldown The percentage the valve will be open during the pulldown period af ter defrost Max Pulldown Tm The maximum amount of time the valve will remain in pulldown fol lowing a defrost If exceeded the valve will resume PID control Pull down will terminate earlier than the max pulldown time if the case tem perature reaches setpoint Table 6 1 MultiFlex ESR Valve Parameters E2 More Tab 026 1720 Rev 4 06 APR 2010 Standard Circuit Valve Parameters Temp Fail EEPR Description The MultiFlex ESR uses the value set in this field if the case temperature sensor fails This feature is always available If an ECT Flow valve has been se lected the MultiFlex ESR will have the option to use the daily average valve if the case temperature sen sor fails This option is only available when valve type is set to ECT Flow The MultiFlex ESR uses the value set in this field if a communication fail ure with the board occurs This fea ture is always available If an ECT Flow valve has been se lected the MultiFlex ESR will have the option to use the Daily Average Valve if a communication failure with the board occurs This option is only available wh
22. ger ation mode is temporarily suspended due to the door opening such as with a walk in box a Pulldown will be initiated when the door closes The Pulldown mode simply forces the valve to a fixed position as specified with the Pulldown Percent parameter The circuit will stay in Pull down until the case temperature reaches the set point or the maximum time allowed in Pulldown has been exceeded The maximum time in Pull down defaults to zero which disables the Pull down mode By setting this to a valid time up to 2 hours Pulldown mode will be enabled Valve Failsafe The Standard Circuit has additional valve fail safe capability If a control failure occurs such as a loss of the control temperature sensor the valve will be instructed to go to a failsafe posi tion As with previous ESR control the valve may be configured to go to a fixed position as specified by the Temp Fail EEPR parameter However a new Valve Daily Average Position is now being calculated for MultiFlex ESR and 026 1720 Rev 4 06 APR 2010 ECT Flow valves The valve may be configured to go to this position during periods of control failure The Valve Daily Average Position is determined by averaging the position of the valve only during the refrigeration state While in Defrost or other circuit states the average position will not be updated At midnight of each new day the Valve Daily Average Position is updated to reflect the average position calcula
23. he up and down arrows to select the desired valve 1 8 Use the right arrow to select the de sired fields Valve 1 can be set to Other or ECT Flow Max Steps can be set from 1 10000 De fault is 800 Rate can be set from 20 500 Default is 50 OvrCls can be set from 0 20 Default is 5 Fail can be set from 0 100 Default is 100 Screens For Valve choose the type of valve being used Set to ECT Flow for ECT valve types or Other for any other type of valve Max Steps is the total number of steps the valve travels between fully closed 0 and fully open 100 Rate corresponds to the step rate of the valve in steps per second The default 50 steps per sec ond is the correct step rate for the ESR 12 and ESR 20 valves OvrCls is the Over Close percentage that will be used when setting a valve to 0 for defrost Fail is the failsafe output percentage to use if communications are lost with the E2 8 2 6 Network Screen The Option 2 screen will show the network set tings for the MultiFlex ESR controller There are no editable fields on this screen This display is a reflection of the dip switch settings DIP Settings Address 1 9600 Baud Figure 8 6 DIP Switch Settings Screen NOTE This Network screen can also be 4 accessed by pressing the down arrow key once from the Home screen Hand Held Terminal 14 Emerson Flow Controls Stepper Valves Valve Specifi
24. hird Party Devices ES Te Echelon Devices Num Ctrl Type Ctrl Type DataLink TD3 Case Display Echelon 16A1 Echelon 8R0 Num Ctrl Type 8 EC2 29x Control 8 EC2 39x Control 6 CC188 Liquid 8 CS188 Ckt Suction 8 CC188 Suction 8 ESR8 Line Up Figure 6 1 Connected I O Screen 1 Press c Software Overview 6 2 Press 3 Press the down arrow key until the MultiFlex ESR field is highlighted 4 Enter the number of MultiFlex ESRs con Enter nected to the E2 and press 5 Press e to save changes and exit the Screen 6 3 Step 2 Add a Standard Circuit Before a standard circuit can be set up and asso ciated with the board you must first add the cir cuit in the E2 from the Add Application screen 1 Press 2 Press 3 Choose Standard Circuit from the list Press F4 for look up and use the arrow keys to move to the How Many field Enter the number of circuits you wish to add and press Enter RX 408 Unit 3 ADD APPLICATION 15 38 57 ALARM Add Application Select an application type to add then enter the number to add and press Enter Type Standard Circuit How many Note Only applications that can he added will be displayed Figure 6 2 Add Application Screen 6 4 Step 3 Associate the MultiFlex ESR Each standard circuit controls a single valve In this step you must associate or map the valve on the MultiFlex ESR board to a particular cir cuit When a valv
25. ipolar a ESR CC100 ESR CC100 CC100 ESR CC100 a CCB CCB CCB CCB products 15 MultiFlex ESR I amp O Manual 026 1720 Rev 4 06 APR 2010
26. onfiguration of Step Rate and Max Step parameters for the valve disconnect the power plug from the MultiFlex ESR board then reconnect the power plug to reapply power to the MultiFlex ESR board When power has been reapplied to the board all valves will begin to close and the Close LED located on the right side under the valve connector on the MultiFlex ESR board will illuminate After the valve closes the Max Step parameter number of steps the valve will begin to open and the Open LED located on the left side under the valve connec tor on the MultiFlex ESR board will illuminate The moment any Open LED illuminates dis connect power from the board Then reconnect the power plug to reapply power to the Multi Flex ESR board 8 Hand Held Terminal 8 1 The hand held terminal HHT connector is located on the lower left side of the board and is Overview Valve Zeroing 12 labeled as J2 The HHT allows each valve output to be set separately with a valve step rate and the total number of steps from closed to fully open The HHT is able to indicate the position status of each valve The failsafe condition of each valve can be set with the HHT However once the HHT is removed the settings will go back to the values programmed at the E2 if online Valves may be manually positioned with the HHT which overrides control from the E2 con troller Fully closing and fully opening any valve can be accomplished with a minimal
27. rol will be used This field should be set to LINE UP MFLEXESR DEF to indicate a MultiFlex ESR will control temperature NOTE To see all available options view screens in the Full Options mode Press A E2 to turn Full Options mode ON B Setpoints Setup Screen TMV LT I BATT 1 to Select CX Tabs SETUP C3 Setpoints C6 Inputs C7 Outputs C9 Notices Circuits Standard STANDARD CKT 1 400 Unit 3 F2 NEXT TAB F3 EDIT F4 STATUS F5 CANCEL Figure 6 5 Setpoints Setup Screen Software Overview 8 Under the Setpoints Setup screen C3 tab the TR field sets the throttling range of the Multi Flex ESR temperature control The throttling range is the number of degrees between a 0 and 100 valve aperture in the Proportional mode of PID control In most cases the default value 10 F is sufficient If a different TR is desired enter it here C Additional Setup Screen MultiFlex ESR Under the More Setup screen CO tab set the following parameters described in Table 6 1 64 61 66 RX 388 Unit 1 14 00 04 Use Ctrl X to Select CX Tabs SETUP FULL ALARM CS Defr Times E C1 General C2 C3 Setpoints Ch Defrost C6 Inputs C7 Outputs C8 Alarms C9 Notices Circuits Standard STANDARD CKT61 Min Valve Max Valve Pulldown Max PulldounTm Temp Fail EEPR Comm Fail EEPRZ ConnFailDefrost AduPrior AduType Fi PREU TAB NEXT TAB F3 EDIT Fh S
28. sssssecsenees 15 SPORLAN PARKER STEPPER VALVES n tie idiota 15 MultiFlex ESR I amp O Manual Table of Contents v 1 Introduction The MultiFlex ESR Valve Regulator board P N 810 3199 shown in Figure 1 1 is an RS 485 I O Network electronic stepper valve regulator capable of driving up to eight stepper motor valves which are typically used to control tem perature LEGEND Valve Connectors 8 6 Termination Jumpers 24VAC CT 75 VAC Power Input HHT Jack General Status LED 8 Network Address Switches Network Input 9 Open LED 8 TX and RX LEDs 10 Close LED 8 Figure 1 1 MultiFlex ESR Board Layout When controlling ECT Flow valves the Multi Flex ESR will detect overcurrent open wire stuck valve situations and generate the appropri ate alarms For non ECT Flow valves the Multi Flex ESR will only detect overcurrent situations and generate an alarm See Section 8 2 3 Alarm Status Screens for details on alarm descriptions The MultiFlex ESR uses suction side variable position evaporator regulators ESRs to vary evaporator pressure for an entire circuit and is an alternative to mechanical EPR control The MultiFlex ESR receives input data from a CPC E2 controller via the I O Network and then regulates the stepper valves according to the data from the E2 1 MultiFlex ESR I amp O Manual MultiFlex ESR and ESR 8 Board Differences RS 485 I
29. tallation process of the valves or when a valve is replaced the valve s must be zeroed before the MultiFlex ESR board can begin controlling The zeroing process closes the valve twice the number of Max Steps and should sufficiently zero ECT valves For Sporlan and other valve manufacturers that have a full travel much greater than Max Steps this process may need to be repeated one or two more times to fully zero the valve Once the valve has been zeroed the process will not need to be repeated unless the valve has been replaced or driven open beyond its control range by a device other than the Mul tiFlex ESR board Note that if the valve manu Step 1 facturer Valve Mfg is set to Other and the valve harness becomes disconnected while the MultiFlex ESR board is attempting to control zero the valve after the disconnect is resolved 7 1 Step 1 To zero the valve first configure the Step Rate and Max Step parameters for the valve type The configuration can be done with either the E2 controller or CPC s hand held terminal HHT For the parameters to be configured with the E2 the HHT must be unplugged and disconnected from the MultiFlex ESR board The Max Step parameter is the total number of control steps for the valve from 0 100 but the physical valve may have a step range that is sub stantially larger than the Max Step parameter This is why the valve must be zeroed at initial start up 7 2 Step 2 After the c
30. ted throughout the previous day In addition if a communication failure occurs the valve will be instructed to go to a different failsafe position Comm Fail EEPR or for ECT Flow valves the Valve Daily Average Position may be used Lead Circuit When a MultiFlex ESR circuit is defined as the lead circuit in its associated Suction Group and suction float has been enabled the Standard Cir cuit will suspend normal PID control of the valve while in the refrigeration state Instead the Standard Circuit will force the valve to full open By doing this the associated Suction Group will be able to float the suction setpoint to the highest possible value while still maintaining the circuit temperature setpoint Valve Alarms When a Standard Circuit is associated with a MultiFlex ESR valve it also processes alarms associated with that valve including Stuck Valve Fault Wire and Fault Overload Stuck Valve and Fault Wire are only ECT Flow valve alarms 6 1 Programming E2 Version 2 21 and Above Successful installation of a MultiFlex ESR requires you to perform five main programming steps in the E2 software 1 Add MultiFlex ESR Board s The E2 refriger ation controller must be programmed to commu nicate and utilize the MultiFlex ESR board s on the network 2 Add Standard Circuit s The circuit must first be added in the E2 before a circuit can be set up and associated with the MultiFlex ESR board Programming E2 V
31. ved all overrides will be erased 8 2 3 Alarm Status Screens The alarm screens provide information about alarms that have been generated during opera tion of the valve Figure 8 3 Alarm Status Screen Possible alarm states VALVE OK Normal valve operation Valve is ready for commands FAULT STUCK The valve is not moving or re sponding to commands Based on characteristics for this valve type this feature offers a high probability that if the valve becomes stuck a Stuck Valve alarm 026 1720 Rev 4 06 APR 2010 will be generated FAULT WIRE At least one drive winding is dis connected or has an open coil no current flow was detected e FAULT OVLD The valve driver is reporting a shorted driver winding 8 2 4 Main Select Screen The seventh screen or accessed by pressing F2 on the HHT will allow the user to select what sub system should be accessed Defaults to 1 SELECT 1 1 VALVE CONFIG 2 NET CONFIG Figure 8 4 Main Select Configuration Screen 8 2 5 Valve Configuration Screens The Option 1 screen will enable the user to view valve configurations and to make temporary changes to the settings However once the HHT is removed the settings will go back to the val ues programmed at the E2 if online Defaults are Flow Control s ESR 12 and ESR 20 valves VALVE 1 Other MAX STEPS 800 OvrCls 100 5 RATE 50 Fail Figure 8 5 Valve Configuration Screens Use t
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