Emerson MultiFlex ESR User manual

026-1720 Rev 4 06-APR-2010

MultiFlex ESR Installation and

Operation Manual

Computer Process Controls, Inc.

1640 Airport Road Suite #104

Kennesaw, GA 31044

Phone 770-425-2724

Fax 770-425-9319

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.

MultiFlex ESR I&O Manual Table of Contents • v

Table of Contents

1 INTRODUCTION.......................................................................................................................................................... 1

1.1. MULTIFLEX ESR AND ESR-8 BOARD DIFFERENCES................................................................................................... 1

1.1. RS-485 I/O Network................................................................................................................................................. 1

1.1. Center-Tapped Transformer.................................................................................................................................... 1

1.1. Molex Connectors (Board P/N 810-1398)............................................................................................................... 1

1.1. Hand-Held Terminal (HHT) .................................................................................................................................... 1

1.1. Snap-Track Mounting .............................................................................................................................................. 1

1.2. MULTIFLEX ESR MOLEX CONNECTOR BOARD (DISCONTINUED)............................................................................... 2

2 INSTALLATION........................................................................................................................................................... 2

2.1. PANEL MOUNTING AND HEAT DISSIPATION ................................................................................................................ 2

2.2. SNAP-TRACK INSTALLATION........................................................................................................................................ 2

3 WIRING.......................................................................................................................................................................... 2

3.1. POWER.......................................................................................................................................................................... 2

3.2. VALVE WIRING............................................................................................................................................................. 3

3.2.1. Molex Connector (Discontinued) Board Wiring................................................................................................... 3

4 SETTING THE TERMINATING RESISTANCE JUMPERS ................................................................................. 4

5 SETTING THE NETWORK ADDRESS AND BAUD RATE .................................................................................. 4

6 SOFTWARE OVERVIEW........................................................................................................................................... 5

6.1. PROGRAMMING E2 VERSION 2.21 AND ABOVE ........................................................................................................... 6

6.2. STEP 1: ADD AMULTIFLEX ESR................................................................................................................................. 6

6.3. STEP 2: ADD ASTANDARD CIRCUIT............................................................................................................................. 7

6.4. STEP 3: ASSOCIATE THE MULTIFLEX ESR................................................................................................................... 7

6.5. STEP 4: SET UPTHE STANDARD CIRCUIT .................................................................................................................... 8

6.6. STEP 5: SET UPTHE MULTIFLEX ESR....................................................................................................................... 10

7 VALVE ZEROING...................................................................................................................................................... 12

7.1. STEP 1......................................................................................................................................................................... 12

7.2. STEP 2......................................................................................................................................................................... 12

8 HAND-HELD TERMINAL ........................................................................................................................................ 12

8.1. OVERVIEW .................................................................................................................................................................. 12

8.2. SCREENS ..................................................................................................................................................................... 13

8.2.1. Main Screen ........................................................................................................................................................ 13

8.2.2. Output Status Screens ......................................................................................................................................... 13

8.2.3. Alarm Status Screens .......................................................................................................................................... 13

8.2.4. Main Select Screen.............................................................................................................................................. 14

8.2.5. Valve Configuration Screens .............................................................................................................................. 14

8.2.6. Network Screen................................................................................................................................................... 14

VALVE SPECIFICATIONS TABLES............................................................................................................................15

EMERSON FLOW CONTROLS STEPPER VALVES...................................................................................................................15

SPORLAN (PARKER) STEPPER VALVES................................................................................................................................15

1 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010

1Introduction

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.

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.

1.1. MultiFlex ESR and ESR-8 Board

Differences

RS-485 I/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.

Center-Tapped Transformer

For power, a Class 2, 80VA 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.

Figure 1-1 - MultiFlex ESR Board Layout

24VAC CT 75 VAC Power Input

Valve Connectors (8)

I/O Network Input

Termination Jumpers

Network Address Switches

General Status LED

HHT Jack

TX and RX LEDs

Open LED (8)

Close LED (8)

MultiFlex ESR Molex Connector Board (Discontinued) Installation • 2

1.2. MultiFlex ESR Molex Connec-

tor Board (Discontinued)

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:

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

is 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

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:

3 Wiring

3.1. Power

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.

Figure 1-2 - MultiFlex ESR Molex Connector Board Layout -

Discontinued (P/N 810-3198)

Figure 2-1 - MultiFlex ESR Board Dimensions

24VAC CT 75 VAC Power Input

Valve Connectors (8)

I/O Network Input

Termination Jumpers

Network Address Switches

General Status LED

HHT Jack

TX and RX LEDs

Open LED (8)

Close LED (8)

3.5”

4.00”

10.00"

4.75”

TYP 2 PL

MULTIFLEX ESR BOARD

WEIGHT: 9.4 OZ.

O 0.220”

TYP 6 PL

9.5”

Figure 2-2 - MultiFlex ESR Snap-Track Installation

3 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010

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 AC1 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.

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

the cable and cable harnesses that are supplied

with the valves.

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 the cable and

cable harnesses that are supplied with the valves.

Figure 3-1 - Power Wiring - Center-Tapped Transformer

WIRING FOR 640-0080, 80VA Transformer

SECONDARY SIDE

Use 24VAC Center-Tapped Transformer

PRIMARY SIDE

240 208 C

120

(NEUTRAL)

(HOT)

120/208/240 VAC

L2 L1

Three-conductor non-shielded cables

are the recommended wire

for connecting between the

center-tapped transformer

and I/O boards.

Power Wiring Types:

14 AWG Belden 9495

18 AWG Belden 9493

24V CT 24V

AC1

GND

AC2

AC1

AC2

24VAC Center-Tapped

Earth ground the

GND (center-tapped)

terminal of each board

GND

Figure 3-2 - Valve Connector Wire Color Indicator

Figure 3-3 - ECT Flow Valve and New Board Wiring Diagram

NOTE: A valve cable harness may not be lon-

ger than 150 feet.

BLU

RBLK W

Wire Color Legend on

Each Valve Connector (8)

ECT Flow

Stepper Valve

MultiFlex ESR Board w/ Eight

Screw Terminal Connectors

(P/N 810-3199)

Stepper Valve

Harness

WHITE

BLACK

RED

BLUE

Match wire colors to

silk screen legend on

board terminals

Valve Wiring Setting the Terminating Resistance Jumpers • 4

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

proper terminating resistance jumper settings for

the MultiFlex ESR board.

For more information about network configura-

tion and termination, see the I/O Network wiring

section in your site controller’s user manual.

5 Setting the Network

Address and Baud Rate

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.

Figure 3-4 - ECT Flow Valve and Old Board Wiring

Figure 4-1 - Daisy Chain Termination Jumper Settings

CAUTION: Always have the JP1 jumper

(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.

RS485 I/O NET

NO TERMINATION

(Jumpers in the

DOWN position)

JP2 JP3 JP4

TERMINATION

(Jumpers in the

UP position)

JP2 JP3 JP4

5 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010

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

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 refriger-

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

Figure 5-1 - Network Address Settings

Figure 5-2 - Baud Rate Settings

Set the network address

using the first 5 rockers

of dip switch S1.

Valid address range 1-31.

2345678

BOARD 1 BOARD 2 BOARD 3 BOARD 4

2345678

23456 78

2345678

BOARD 5 BOARD 6 BOARD 7 BOARD 8

2345678

BOARD 9 BOARD 10 BOARD 11 BOARD 12

2345678

23456 78

2345678

BOARD 13 BOARD 14 BOARD 15 BOARD 16

2345678

23456 78

2345678

BOARD 17 BOARD 18 BOARD 19 BOARD 20

2345678

23456 78

2345678

BOARD 21 BOARD 22 BOARD 23

2345678

BOARD 24

2345678

23456 78

2345678

BOARD 25 BOARD 26 BOARD 27 BOARD 28

2345678

BOARD 29

2345678

23456 78

BOARD 30 BOARD 31

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