026-1731 Rev 0 01-DEC-2014
High Pressure CO2 Controller Installation
and Operation Manual
Emerson Climate Technologies Retail Solutions
1065 Big Shanty Road NW, Suite 100
Kennesaw, GA 30144
Phone: 770-425-2724
Fax: 770-425-9319
Table of Contents
1 OVERVIEW ................................................................................................................................................................... 1
1.1 THE HIGH PRESSURE CO2 CONTROLLER I/O POINTS ................................................................................................... 1
1.2 INDEPENDENT SYSTEM CONTROL.................................................................................................................................. 2
2 HARDWARE SETUP.................................................................................................................................................... 3
2.1 CONNECTIONS............................................................................................................................................................... 3
2.2 INPUTS AND OUTPUTS .................................................................................................................................................. 4
2.3 TECHNICAL SPECIFICATIONS ........................................................................................................................................ 6
2.3.1 Analog Inputs ........................................................................................................................................................ 6
2.3.2 Digital Inputs ........................................................................................................................................................ 6
2.3.3 Analog Outputs ..................................................................................................................................................... 7
2.3.4 Digital Outputs...................................................................................................................................................... 7
2.3.5 Dimensions............................................................................................................................................................. 8
2.3.6 Wiring Diagrams.................................................................................................................................................... 9
2.3.7 Electrical Specifications ..................................................................................................................................... 10
2.3.8 Plastic Enclosure ................................................................................................................................................ 10
2.3.9 USB-Ethernet Adapter ........................................................................................................................................ 10
2.4 POWERING THE HIGH PRESSURE CO2 CONTROLLER .................................................................................................. 10
2.4.1 Choosing Transformer Sizes ................................................................................................................................ 10
2.4.2. Wire Types and Maximum Distances................................................................................................................. 11
3 THE MODBUS NETWORK ...................................................................................................................................... 12
3.1. WIRING TYPES ............................................................................................................................................................ 12
3.1.1. Daisy Chains ....................................................................................................................................................... 12
3.1.2. Network Addressing - Visograph ........................................................................................................................ 14
3.1.2.1.
3.1.2.2.
3.1.2.3.
3.1.2.4
Connecting the Visograph................................................................................................................................................. 14
Visograph Navigation ....................................................................................................................................................... 15
Setting the MODBUS Address ......................................................................................................................................... 15
Versions ............................................................................................................................................................................. 16
3.2 MODBUS TERMINATION ............................................................................................................................................ 16
4 INPUTS AND OUTPUTS SETUP.............................................................................................................................. 17
4.1 INPUTS SETUP ..............................................................................................................................................................
4.1.1 Wiring Analog and Digital Inputs........................................................................................................................
4.2 OUTPUTS SETUP ..........................................................................................................................................................
4.2.1 Wiring Relay and Analog Outputs .......................................................................................................................
17
17
20
20
5 HIGH PRESSURE CO2 CONTROLLER STATUS LED....................................................................................... 21
5.1 POWER ON (PWR ON) LED ....................................................................................................................................... 22
5.2 LED1 NETWORK STATUS ............................................................................................................................................ 22
6 SOFTWARE OVERVIEW ......................................................................................................................................... 22
6.1 HIGH PRESSURE VALVE CONTROL ..............................................................................................................................
6.1.1 HPV Subcritical Mode (Normal) .........................................................................................................................
6.1.2 HPV Transcritical Mode (Normal) ......................................................................................................................
6.1.3 HPV Heat Reclaim ...............................................................................................................................................
6.2 BYPASS GAS VALVE CONTROL ...................................................................................................................................
22
23
24
25
26
7 SAFETY OPERATION PARAMETERS FOR HIGH PRESSURE AND BYPASS GAS VALVES .................. 28
Table of Contents • v
7.1 LOW PRESSURE OPERATION ........................................................................................................................................ 28
7.1.1 Normal Operation ................................................................................................................................................ 28
7.2 HIGH PRESSURE OPERATION ....................................................................................................................................... 28
7.2.1 Normal Operation ................................................................................................................................................ 28
7.3 SENSOR FAILURE ......................................................................................................................................................... 29
7.4 EMERGENCY SHUTDOWN ENABLE INPUT .................................................................................................................... 29
8 VALVE CALIBRATION FEATURE ........................................................................................................................ 30
9 ALARMS....................................................................................................................................................................... 31
10 VISOGRAPH.............................................................................................................................................................. 32
10.1 STATUS SCREEN ......................................................................................................................................................... 32
10.1.1 Main Menu and Status Screens .......................................................................................................................... 32
10.2 CONFIGURATION SETUP SCREEN ............................................................................................................................... 33
10.2.1 Main Menu to Configuration Screens ................................................................................................................ 33
10.2.2 General Configuration Screens.......................................................................................................................... 34
10.2.3 Valve Configuration Screens.............................................................................................................................. 34
10.2.4 I/O Configuration Screens ................................................................................................................................. 35
10.2.5 XEV20D Configuration Screens......................................................................................................................... 37
10.3 OVERRIDE SCREEN .................................................................................................................................................... 37
11 HIGH PRESSURE CO2 CONTROLLER RANGES AND DEFAULT SETPOINT PARAMETERS ............. 39
12 XEV20D SETUP AND NETWORK CONNECTION ............................................................................................ 41
13 STEPPER VALVE ACTUATOR QUICK REFERENCE GUIDE XEV20D ...................................................... 42
13.1. GENERAL WARNINGS ............................................................................................................................................... 42
13.2 GENERAL DESCRIPTION ............................................................................................................................................. 43
13.3 ABSOLUTE MAXIMUM POWER ................................................................................................................................... 43
13.4 WIRING DIAGRAMS.................................................................................................................................................... 44
13.4.1 One Valve Configuration ................................................................................................................................... 44
13.4.2 Two Valve Configuration ................................................................................................................................... 44
13.5 VALVE CONNECTIONS ............................................................................................................................................... 44
13.6 SERIAL LINE - LAN BUS ........................................................................................................................................... 45
13.7 LED DESCRIPTIONS ................................................................................................................................................... 47
13.8 XEV20D TECHNICAL SPECIFICATIONS ..................................................................................................................... 47
vi • Name of Manual
026-1731 Rev 0 01-DEC-2014
1
Overview
The High Pressure CO2 controller (P/N 818-9010)
application is a standalone controller that operates the
High Pressure Valve (HPV) and the Bypass Gas
Valve (BGV) in a Booster Transcritical CO2 system.
The controller has a heat reclaim feature, safety parameter operation for the flash gas receiver tank and
calibration feature for the HPV and BGV.
CAUTION! GND is Common, not earth
ground. Do not earth ground this device.
1.1
The High Pressure
CO2 Controller I/O
Points
The board has 6 analog inputs and 11 digital inputs, with default configurations pre-loaded for quick
connection to for gas cooler pressure outlet, gas cooler temperature, flash gas receiver pressure and enable
digital input. Its 8 relay outputs, rated 2.0 amps max,
are used for activating and deactivating alarms. Its 4
analog outputs may be used for a 0-10 volt signal for
external valve driver for either the HPV or BGV.
Figure 1-1 - High Pressure CO2 Controller
The High Pressure CO2 controller supports local
physical inputs and outputs and communicates with
the E2 controller (version 3.00 and higher) via the
RS485 MODBUS network.
•1
1.2
Independent System
Control
The High Pressure CO2 controller can control the
HPV and BGV in a refrigeration Booster Transcritical
CO2 System. However, the High Pressure CO2 controller is designed to interface with an E2. Networking the High Pressure CO2 controller to a central
controller also allows you to view status on E2 and
UltraSite32 Site Manager status screens, report
alarms, and log point values.
The High Pressure CO2 controller configuration
can be programmed through the E2 front panel.
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2
Hardware Setup
Figure 2-1 - High Pressure CO2 Controller
2.1
Connections
Connector
Description
Connector for 24VAC/DC power supply
Analog inputs (Pb1 - Pb6, PbC)
Additional power: +5VDC, +12VDC, Common (-)
Analog outputs (Out1 - Out4, Common)
24VAC/DC digital inputs: DI1 - DI11, Common (-)
Connector for remote terminal (VISOGRAPH), maximum 1 terminal
per controller.
RS485 Slave connector
Serial port connector (LAN or RS485)
USB port for downloads (BIOS, ISaGRAF® application, maps of
parameters, remote display applications, network configuration, and
Web site) and uploads (log files).
Connection with the computer via a USB-ETH converter
Table 2-1 - Connections and Descriptions
•3
Connector
Description
Digital relay outputs
4 NO relays, 2 common
Digital relay outputs
4 NO relays, 2 common
Table 2-1 - Connections and Descriptions
2.2
Inputs and Outputs
Input
Number
Type of
Input
Description
1
Supply
Reference “-“/Common power (24VAC or 24VDC)
2
Pb1
Configurable analog input 1 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
3
Pb2
Configurable analog input 2 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
4
Pb3
Configurable analog input 3 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
5
+12V
Additional power +12VDC
6
+5V
Additional power +5VDC
7
Out1
Analog output 1, 0 - 10V, 4 - 20mA, Relay
8
Out2
Analog output 2, 0 - 10V, 4 - 20mA, Relay
9
Supply
10
Pb4
Configurable analog input 4 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
11
Pb5
Configurable analog input 5 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
12
Pb6
Configurable analog input 6 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
13
PbC
Common analog inputs (NTC, PTC, DI)
14
Voltage
Common
(-)
15
Out3
Analog output 3, 0 - 10V, 4 - 20mA, Relay
16
Out4
Analog output 4, 0 - 10V, 4 - 20mA, Relay
20
DI1
Digital input 1, 24VAC/DC
28 DI9 29 DI10 30 DI11
21
DI2
Digital input 2, 24VAC/DC
Reference “+” power supply (24VAC or 24VDC)
Additional power reference 5VDC and 12VDC, analog inputs
(0 - 20mA, 4 - 20mA, 0 -10V, 0- 1V, 0 - 5V), analog outputs
Table 2-2 - Description of the Inputs and Outputs
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Input
Number
Type of
Input
22
DI3
Digital input 3, 24VAC/DC
23
DI4
Digital input 4, 24VAC/DC
24
DI5
Digital input 5, 24VAC/DC
25
DI6
Digital input 6, 24VAC/DC
26
DI7
Digital input 7, 24VAC/DC
27
DI8
Digital input 8, 24VAC/DC
28
DI9
Digital input 9, 24VAC/DC
29
DI10
Digital input 10, 24VAC/DC
30
DI11
Digital input 11, 24VAC/DC
31
Digital
Common
(-)
40
C
Common relays 1, 2, 3 and 4
41
C
Common relays 1, 2, 3 and 4
42
RL1
Relay 1 normally open contact
43
RL2
Relay 2 normally open contact
44
RL3
Relay 3 normally open contact
45
RL4
Relay 4 normally open contact
46
RL5
Relay 5 normally open contact
47
C
Common relays 5, 6, 7 and 8
48
C
Common relays 5, 6, 7 and 8
49
RL6
Relay 6 normally open contact
50
RL7
Relay 7 normally open contact
51
RL8
Relay 8 normally open contact
60
Remote
Display
Connection for VISOGRAPH remote terminal (Vnr)
61
Remote
Display
Connection for VISOGRAPH remote terminal (+)
62
Remote
Display
Connection for VISOGRAPH remote terminal (-)
63
RS485
Slave
RS485 Slave connection (-)
Description
Reference “-” for digital inputs from1 to 11 (if version with dry contacts, this input has to
be used only as common for the digital inputs)
Table 2-2 - Description of the Inputs and Outputs
•5
Input
Number
Type of
Input
64
RS485
Slave
65
LAN
LAN Connection (-)
66
LAN
LAN Connection (+)
Description
RS485 Slave connection (+)
Table 2-2 - Description of the Inputs and Outputs
2.3
Technical Specifications
2.3.1
Analog Inputs
Analog
conversion type:
10-bit A/D converter
Number of
Inputs:
6
Type of analog
input:
(configurable
via software
parameter)
NTC Emerson Retail Solutions
(-50T110°C; 10KΩ±1% at 25°C)
PTC Emerson Retail Solutions
(-55T115°C; 990Ω±1% at 25°C)
Digital input (potential free
contact)
Voltage: 0 - V, 0 - 5V, 0 - 10V
(input resistance 3.7KΩ)
Current: 0 - 20mA, 4 - 20mA
(input resistance 100Ω)
Accuracy:
NTC, PTC: ±1
0-1V: ±20mV
0-5V: ±100mV
0-10V:±200mV
2-20mA, 4-20mA: ±0.30mA
Additional
power:
+12V: 200mA in total (between
+12V and analog outputs)
+5V: 100mA
2.3.2
Digital Inputs
Type:
(configurable
via software
parameter)
Opto-insulated live contact
(24VAC/DC)
External power 24VAC/DC ±20%
Number of
Inputs:
11
Digital input
status variation
detection time:
100ms (in any case it depends on
the cycle time set by the user in
the given application)
Table 2-4 - Digital Inputs
CAUTION! Use another transformer (do
not use the same secondary of the controller’s power) in order to prevent the inputs
from malfunctioning or being damaged.
Table 2-3 - Analog Inputs
CAUTION! Any inputs that are powered
with a voltage that differs from that supplied
by the device (+12V or +5V) must be powered separately with another transformer (do not use
the same secondary of the controller’s power) in order to prevent the inputs from malfunctioning or being damaged.
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2.3.3
Analog Outputs
2.3.4
Digital Outputs
Type:
Non opto-insulated internal power
Type:
Relays with NO contacts
Number of
Outputs:
4
Number of
Outputs:
8
Type of analog
output:
(configurable
via software
parameter)
4 configurable outputs 0-10VDC
4-20mA (Out1 - Out4)
Type of analog
output:
(configurable
via software
parameter)
Relays with normally open
contact
Maximum load:
40mA (Out1 - Out4) max with
configured outputs 0-10VDC
400Ω max with configured
outputs 4-20mA
22Ω per live analog output
Maximum
load:
5A(250VAC) SPST 5(2)A
Accuracy:
Out1 - Out4: ±2% full scale
Resolution:
8-bit
Table 2-5 - Analog Outputs
Table 2-6 - Digital Outputs
CAUTION! Verify the capacity of the output
used. There is double insulation between the
digital outputs and the low voltage of the rest
of the circuit. Do not use different voltages for the
various groups of relays or within each group.
CAUTION! The electrical devices controlled by these analog outputs must be powered separately with another transformer
(do not use the same secondary of the controller’s
power) in order to prevent the outputs from malfunctioning or being damaged.
•7
2.3.5
Dimensions
Figure 2-2 - Dimensions
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2.3.6
Wiring Diagrams
Figure 2-3 - Wiring Diagrams
NOTE: To ensure control in case of a power failure, it is recommended that a UPS be used on the High
Pressure CO2 controller.
•9
2.3.7
Electrical Specifications
Power Supply:
24VAC +10/-15%, 50/60Hz, 20 36VDC
Consumption:
From 30VA (VAC), From 25W
(VDC)
Connectors:
Molex connectors with low
voltage wiring (for IPS100D and
IPS400D)
Phoenix quick coupling
connectors for low voltage (for
IPS200D)
STELVIO 90° screw connectors
for digital outputs (250VAC, 6A
max)
Microprocessor:
AT91SAM9260 32-bit 200Mhz
Permanent
FLASH
memory:
16Mb, in 8-bit chunks
RAM:
2x128Kb, in 16-bit chunks
Internal clock:
Standard
Table 2-7 - Electrical Specifications
2.3.8
Plastic Enclosure
Mount:
On a DIN rail (EN 50022, DIN
43880)
Fastened with screws via the
removable plastic flaps.
Material:
PC-ABS Thermoplastic
Selfextinguishing:
V0 (UL94)
Comparative
Tracking
Index (CTI):
300V
Color:
Black or White, depending on the
model
2.3.9
USB-Ethernet Adapter
The IPS range of programmable controllers can be
connected to a computer via an external adapter. This
adapter must be used in the processing environment
for the application download in the controller. This
adapter is not set up for fixed or continuous connection. If the adapter should be kept connected continuously, the room temperature must not exceed 50°C
(122°F).
Figure 2-4 - USB-Ethernet Adapter
2.4
Powering the High
Pressure CO2
Controller
Retail Solutions supplies a wide variety of 24VAC
transformers with varying sizes without center taps.
(Table 2-9) shows the transformer sizes and are noncenter-tapped.
2.4.1
Choosing Transformer Sizes
The transformer used to power the High Pressure
CO2 controller should have at least a 30VA rating.
The High Pressure CO2 controller should not share a
transformer with any other devices. Figure 2-5 shows
how to wire the transformer to the High Pressure CO2
controller.
Table 2-8 - Enclosure Specifications
Transformer P/N
VA Rating
Primary
Voltage
640-0041
50 VA
110 VAC
640-0042
50 VA
220 VAC
Table 2-9 - Compatible Transformers with CO2 Controller
10 • High Pressure CO2 Controller Installation and Operation Manual
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Neither side of the secondary should be connected
to ground. Also, do not connect the center tap (if provided on the transformer) to ground. The entire secondary of the transformer should be isolated from any
ground.
2.4.2. Wire Types and Maximum
Distances
For powering I/O boards, use only the listed wire
types in Table 2-10. Two-conductor non-shielded
cables are the recommended wire for connecting the
transformer to the High Pressure CO2 controller.
Shielded cable should not be used for power wiring.
The center tap should be left disconnected if present
on the transformer.
Power Wiring Types
14 AWG
Belden 9495
18 AWG
Belden 9495
Table 2-10 - Power Wiring Types
The wire length from the transformer determines
the type wire gauge used. In most cases, the distance
between the High Pressure CO2 controller and the
transformer that supplies power to it is not enough to
be of concern; however, it is very important NOT to
exceed this maximum wire length or the controller
will not operate correctly.
Use these formulas to determine if the wire gauge
you are using fits within specification:
14 AWG:
Feet = 1920/VA
18 AWG:
Feet = 739/VA
(VA is the total VA rating of the controller)
For example, if you had an 80 VA load:
14 AWG: 24 ft.
18 AWG: 9 ft. (rounded down)
Figure 2-5 - Non-Center Tapped Transformer Wiring
Table 2-11 - Power Wire Lengths
Sensors requiring 24VAC should not be powered
from the same transformer that is powering the input
board. Any devices that will be connected to the High
Pressure CO2 controller inputs or outputs must be
powered with a separate 24VAC transformer.
• 11
3
The MODBUS Network
Although the High Pressure CO2 controller can
operate as a stand-alone controller, it relies on an E2
unit for advanced features such as remote dial-in/dialout, logging, and alarm control. The High Pressure
CO2 controller uses an RS485 network connection to
communicate with E2 site controllers.
3.1. Wiring Types
Retail Solutions specs Belden #8761 shielded
twisted pair cables for use as MODBUS wiring (or
Belden #82761 and Belden #88761 for plenum
installations).
If the recommended cable is not available in your
area, be sure the wiring meets or exceeds the
following specs:
Yes
Shielded?
Conductor Type
Twisted Pair
Gauge
18 - 24 AWG
Capacitance between
signal wires
31 pF/ft or less
(9.45 m) or less
Capacitance between
signal and shield
59 pF/ft or less
(17.98 m) or less
Nominal Impedance
12050
3.1.1. Daisy Chains
Connect the MODBUS network cable to the threeterminal connector on the E2 COM port you wish to
assign as MODBUS. Reverse the polarity of +/- on
the RS485 cable between the E2 and the High Pressure CO2 controller.
12 • High Pressure CO2 Controller Installation and Operation Manual
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Figure 3-1 - MODBUS Networking
• 13
3.1.2. Network Addressing - Visograph
The network address makes a board unique from other boards on the network of the same type. This allows
the site controller to find it and communicate with it easily.
The network address of the High Pressure CO2 controller is set using add-on devices called visographs
(P/N 818-9002).
3.1.2.1.
Connecting the Visograph
The visograph is connected with a 3-wire connection on pins 60, 61, and 62.
Figure 3-2 - Network ID Settings
CAUTION: The High Pressure CO2 controller
may be damaged if the wires are crossed when
connecting the visograph, especially if pin 60
(Vnr) is accidentally connected to + or –
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3.1.2.2.
Visograph Navigation
• Four status menu items are available to choose from
within the status menu.
• Press corresponding button along the bottom
(T1-T8) to navigate to desired item.
Figure 3-5 - Configuration Screen
Figure 3-3 - Visograph Menu
3.1.2.3.
Highlight General Config and press the ENTER
key (T3).
Setting the MODBUS Address
To setup the MODBUS settings, you will have to
enter the configuration menu from the main menu.
The configuration menu is password protected.
Figure 3-6 - General Config Screen
Press T8 to arrow over to the next screen.
Figure 3-4 - Main Menu
From main menu, press the T1+ T3 +T8 buttons
together and hold until you see the Configuration
screen.
Figure 3-7 - General Config Screen
Using the UP and DOWN arrows (T3 and
T5), highlight the field and press T4 to change the
address to the desired value.
• 15
Press ENTER to save new address.The address
field should stop blinking.
Press T1 (MENU) to go back to the previous
menu.
NOTE: When the MODBUS address is
changed, the High Pressure CO2 controller
needs to be rebooted.
3.1.2.4
Versions
The High Pressure CO2 controller and Visograph versions are also shown on the Controller Info screen.
To see the High Pressure CO2 controller version,
please see the Visograph Section of the Status screen.
3.2
MODBUS Termination
If the High Pressure CO2 controller is located at the
physical end of the MODBUS network, install the MODBUS termination block (P/N 537-2711).
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4
Inputs and
Outputs Setup
4.1
Inputs Setup
The High Pressure CO2 application has the ability to assign all inputs to be any of the possible options for
an analog input in the application. The analog inputs will have offsets available while the digital inputs will have
a polarity option. All input will use physical local input and have a network input from the E2 for backup if available. The default input configuration is:
Inputs
Description
Local
Network
Sensor Type
Pb1
Temperature-Outlet Gas Cooler (T1)
Yes
Yes
NTC
Pb2
Pressure-Outlet Gas Cooler (P1)
Yes
Yes
0-5V Only
Pb3
Pressure-Receiver (P2)
Yes
Yes
0-5V Only
TBD
Temperature-Bypass Outlet Gas Cooler (T2)
Yes
Yes
NTC
DI1
Reclaim Setpoint Shift (Digital Input) (HTR)
Yes
Yes
24VAC/DC
DI2
Enable Application/Emergency Shutdown (Digital Input
(Enable)
Yes
Yes
24VAC/DC
DI3
Control Temp Selector (Digital Input) (CTS)
Yes
Yes
24VAC/DC
Table 4-1 - High Pressure CO2 Controller Inputs
The application can use a local or E2 network value if online, but the local value will have priority over the
network value. However, if any sensor is in failure mode, its corresponding network value will be used. If no
network value is available, refer to Section 7.3, Sensor Failure.
The input assignment will be available from the Visograph local display and the E2.
4.1.1
Wiring Analog and Digital
Inputs
The analog inputs are located on the same connector
terminal as the controller power supply. Pay attention to
the input commons as they are share on terminal 13 (PbC)
for temperature probe and terminal 14: Voltage Common
(-) for pressure transducer.
CAUTION: Terminal 14 is labeled
Voltage Common (-) for use as common and
should NOT be earth chassis grounded.
• 17
Figure 4-1 - Analog Input Connectors
CAUTION: Any inputs that are powered
with a voltage that differs from that supplied
by the High Pressure CO2 controller (+12V
or +5V) must be powered separately with another
transformer in order to prevent the inputs from malfunctioning or being damaged. Do not use the same
secondary of the controller's power to power the sensors.
Terminal Number on
Connector
Name
1
24VAC Supply (-)
2
Probe Input 1 (default set as T1-Outlet Gas Cooler
Temp)
3
Probe Input 2 (default set as P1-Outlet Gas Cooler
Pressure)
4
Probe Input 3 (default set as P2-Flash Tank Receiver
Pressure)
5
+12VDC
6
+5VDC
7
Analog Output 1 (default set as HPV Stepper Valve 1)
8
Analog Output 2 (default set as BGV Stepper Valve 2)
9
24VAC Supply (+)
10
Probe Input 4
11
Probe Input 5
Table 4-2 - Analog Input Connector Terminals
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Terminal Number on
Connector
Name
12
Probe Input 6
13
Temperature Common
14
Transducer/Analog Output Common
15
Analog Output 3
16
Analog Output 4
Table 4-2 - Analog Input Connector Terminals
The digital inputs are located on the corresponding connector terminal below. Pay attention to the input commons as
they are share on terminal 31: Digital Common (-) and the digital inputs are voltage input that can handle 24VAC/DC.
CAUTION: Terminal 31 is labeled
Digital Common (-) for use as common and
should NOT be earth chassis grounded.
Figure 4-2 - Digital Inputs Connectors
Terminal Number on Connector
Name
20
Digital Input 1(default set as HTR-Relcaim Setpoint
Shift)
21
Digital Input 2(default set as ENABLE/SHUTDOWN)
22
Digital Input 3(default set as CTS-Control Temp
Selector)
23
Digital Input 4
24
Digital Input 5
25
Digital Input 6
Table 4-3 - Digital Input Connector Terminals
• 19
Terminal Number on Connector
Name
26
Digital Input 7
27
Digital Input 8
28
Digital Input 9
29
Digital Input 10
30
Digital Input 11
31
Digital Common
Table 4-3 - Digital Input Connector Terminals
4.2
Outputs Setup
The High Pressure CO2 application can assign any output to one of the available relay outputs, which have both delays
and polarity configuration definable by a user from the local display and E2. The default relay configuration is:
Rly Out
Description
Local
Network
RL1
General Alarm
Yes
Yes
RL2
Low Pressure Alarm
Yes
Yes
RL3
High Pressure Alarm
Yes
Yes
RL4
Shutdown
Yes
Yes
Table 4-4 - High Pressure CO2 Controller Inputs
The High Pressure CO2 application has the ability to assign all analog outputs to be any of the possible options for an
analog output in the application. It will also have connectivity to an XEV20 (Dual Valve), which will drive two steppers
valves using it for a high pressure valve and bypass gas valve. The default configuration is:
Anlg Out
Description
Local
Network
LAN
Out1
Stepper Valve 1
Yes
Yes
Yes
Out2
Stepper Valve 2
Yes
Yes
Yes
Table 4-5 - Analog Outputs
The relay outputs, analog outputs, and the XEV20 setup or assignment will be available from the local display and the
E2. The XEV20 will also provide online status on the Visograph and E2.
4.2.1
Wiring Relay and Analog
Outputs
The relay outputs are located on corresponding connector terminal below. There are 2 input relay commons on termi-
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nal 40 and 41 (C) for relay 1 through 4.
Figure 4-3 - Relay Output Connectors
The analog outputs are located on the same connector terminal as the controller power supply. Pay attention
to the analog outputs commons as they are shared on terminal 14: Voltage Common (-).
Figure 4-4 - Analog Output Connectors
• 21
5
High Pressure
CO2 Controller
Status LED
When a High Pressure CO2 controller board is powered up, the operating status of the board can be determined by
observing its status LEDs.
Figure 5-1 - LED Locations
5.1
Power On (PWR ON)
LED
second (blink twice as fast). When the High Pressure CO2
controller is offline, you can edit the setpoint from the
Visograph display.
The PWR ON LED stays on continuously to show that
the board is powered and operational. If this light is dark,
the board has likely lost power.
5.2
LED1 Network Status
The amber colored LED1 indicates whether the High
Pressure CO2 controller is online or offline with the E2.
When the High Pressure CO2 controller is online, the
LED1 will turn on for one second and off for one second.
However, if the High Pressure CO2 controller is offline,
the LED1 will turn on for half a second and off for half a
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6
Software
Overview
6.1
The High Pressure CO2 controller application
controls the operation of the high pressure valve and
the bypass gas valve in a Booster Transcritical CO2
system. The controller will modulate both valves to
maintain a setpoint.
Both the HPV and the BGV have safety modes.
The safety control point in both valves is the receiver
pressure. If the receiver pressure is higher than the
high pressure setpoint, the HPV closes and the BGV
opens. On the other hand, if the receiver pressure is
too low, the HPV opens and the BGV closes.
6.1.1
High Pressure Valve
Control
The high pressure valve (HPV) operates in two
normal-control modes, in Subcritical and Transcritical modes. The mode is defined by the control temperature. In the Subcritical mode, the valve will
modulate to maintain a subcool setpoint using pressure and temperature control values being read from
the gas cooler outlet to calculate subcool. In transcritical mode, the HPV starts modulating to maintain a
setpoint defined by an equation to achieve a virtual
subcooling using only the pressure input as a control
point.
HPV Subcritical Mode (Normal)
In Subcritical mode, when the control temperature (T1 or T2 is determined by digital input CTS) is below
the HPV Mode setpoint minus Hysteresis, will control the HPV using PID and the calculated subcool value from
the pressure and control temperature from the outlet of the gas cooler. The Subcritical inputs, outputs, setpoint
and PID parameters are listed below.
Inputs
Description
Type
Temperature - 1(T1)
Active Outlet Gas Cooler
Temperature
NTC Temperature
Temperature - 2 (T1)
Active Bypass Gas Cooler
Temperature
NTC Temperature
Pressure - 1 (P1)
Active Outlet Gas Cooler Pressure
0-5VDC only
Control Temp Selector (CTS)
Enables T2 as Active Gas Cooler
Temperature if present
Digital Input
Table 6-1 - Subcritical Inputs
• 23
Subcritical Parameter
Description
Default Value
HPV Mode Setpoint
Setpoint for Subcritical and Transcritical mode
31 DC
(87 DF)
HPV Mode Hysteresis
Control Temperature Hysteresis
3 DDC
(5 DDF)
HPV Subcool Setpoint
Subcool Setpoint in Subcritical Mode
2 DDC
(3 DDF)
Subcritical proportional band offset
0 DDC
Subcritical proportional band
16.7 DC
(30DF)
Integral sampling time
140 Sec
HPV RS-Temp
HPV PB-Temp (P)
HPV INC (I)
HPV DDER (D)
HPV Max Valve %
Derivative time
0 Sec
Maximum valve % opening
100%
Table 6-2 - Subcritical Parameters
Outputs
Valve % Output
Description
Valve Percentage Output
Type
0-10VDC
Only or
LAN to
XEV20D
Table 6-3 - Outputs
6.1.2
HPV Transcritical Mode
(Normal)
estimation of what the setpoint will be for the given control temperature readings.
In a booster Transcritical system, when the temperature exceeds a certain value, there is no longer an accurate
temperature to pressure relation. Because of this, the control temperature of T1 or T2 (defined by digital CTS), will
be the deciding factor of when the application will
switches modes from subcritical to transcritical. If the control temperature is above the HPV Mode setpoint, the
application will be in transcritical mode. Once the control
temperature is below the HPV Mode setpoint minus HPV
Mode Hysteresis, the system reverts to subcritical mode.
In transcritical mode, the application will stop maintaining a subcool setpoint and start maintaining a setpoint
value from an equation to achieve a virtual subcooling
using only the pressure input as a control point. The control temperature (T1 or T2) will still be used to as a reference to calculate the setpoint equation. Below is an
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In Transcritical mode, there is a separate PID running.
To ensure there is a smooth transition between the subcritical PID and the Transcritical PID, there is a linear-ratio
transition algorithm between the two PID's output. This
linear-ratio algorithm transition will keep the valve open
and allow the Transcritical PID to ramp up and take over.
The transition time is adjustable by the parameter
"Trans_Time" if the valve tends to modulate too fast
during the transition. By increasing the "Trans_Time"
parameter, this will slow the transitions and allow less
modulation. The same function will happen when transitioning from Transcritical mode to Subcritical mode as
well.
Figure 6-1 - Setpoint Estimates for Temp Readings
The Transcritical inputs, outputs, setpoint and PID parameters are listed below.
Inputs
Description
Type
Temperature - 1(T1)
Active Outlet Gas Cooler
Temperature
NTC Temperature
Temperature - 2 (T1)
Active Bypass Gas Cooler
Temperature
NTC Temperature
Pressure - 1 (P1)
Active Outlet Gas Cooler Pressure
0-5VDC only
Control Temp Selector (CTS)
Enables T2 as Active Gas Cooler
Temperature if present
Digital Input
Table 6-4 - Transcritical Inputs
• 25
Transcritical Parameter
Description
Default Value
HPV Mode Setpoint
Setpoint for Subcritical and Transcritical mode
31 DC (87 DF)
Control Temperature Hysteresis
3 DDC (5 DDF)
Setpoint During Transcritical Mode
From Equation
HPV Mode Hysteresis
HPV Trans Setpoint
HPV RS-Press
HPV PB-Press (P)
HPV INC (I)
HPV DDER (D)
HPV Max Valve %
Trans_Time
Transcritical proportional band offset
Transcritical proportional band
Integral sampling time
0 DDC
22 BAR (330 PSI)
140 Sec
Derivative time
0 Sec
Maximum valve % opening
100%
Transition Time of the Sub and Trans PID
180 Sec
Table 6-5 - HPV Inputs
Note: The HVP INC, HPV DER, and HPV DDER values are shared in the PID settings for Subcritical and Transcritical PID control.
Outputs
Valve % Output
Description
Valve Percentage Output
Type
0-10VDC Only or
LAN to XEV20D
Table 6-6 - Analog Outputs
6.1.3
HPV Heat Reclaim
The local Reclaim Setpoint Shift (HTR) or network (HTR) digital input determines if the application is in Heat
Reclaim. The priority of the input source will be determined as described in Section 4.1, Inputs Setup. If the Reclaim
Setpoint Shift (HTR) digital input is true, the HTR S Set (Setpoint Shift-Subcritical) or HTR T Set (Setpoint Shift-Transcritical) value will be added to the corresponding setpoint mode for the High Pressure Valve (HPV). The input and
parameters for setpoint added is listed below.
Inputs
Reclaim (HTR)
Description
Reclaim Setpoint Added
Type
24VAC/DC
Table 6-7 - Heat Reclaim Digital Inputs
CAUTION! A separate 24V power supply
must be used. Do not use the same power
supply that is used to power the controller.
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Heat Reclaim Parameter
Reclaim_Sub
Reclaim_Trans
Description
Type
Reclaim Setpoint Shift HPV Subcritical
Added
Reclaim Setpoint Shift HPV Transcritical
Added
0 DDC
0 DBAR
Table 6-8 - Analog Outputs
The Control Temp Selector (CTS) digital input is normally use if there is a gas cooler temperature sensor after a
bypass valve to bypass the gas cooler if needed during heat reclaim. If the digital input is True, the subcool calculation for
mode switching and Transcritical table being used by Temperature-1 (T1) will be switched to Temperature-2 (T2) as Control temperature.
Inputs
Control Temp Selector
(CTS)
Description
Type
Enables T2 as Active Gas Cooler
Temperature if Present
24 VAC/DC
Table 6-9 - Analog Outputs
CAUTION! A separate 24V power supply
must be used. Do not use the same power
supply that is used to power the controller.
6.2
Bypass Gas Valve
Control
The bypass gas valve (BGV) only operates in one normal-control mode, which is to modulate the valve accordingly to maintain a pressure setpoint. The control reading
is from the flash gas liquid receiver tank. If the BGV
enters a safety mode, the PID will reset to begin safety
operation.
Inputs
Pressure 2 - P2
Description
Flash Gas Tank Liquid Receiver
Type
0-5VDC only
Table 6-10 - BGV Input
• 27
BGV Parameter
Description
Default Value
BGV Setpoint
Setpoint for Subcritical and Transcritical mode
35 BAR (510 PSI)
Control Temperature Hysteresis
1.4 BAR (20 PSI)
BGV PB (P)
Subcool Setpoint in Subcritical Mode
2.75 BAR (40 PSI)
BGV INC (I)
Subcritical proportional band offset
BGV RS
BGV DDER (D)
Subcritical proportional band
100 Sec
0 Sec
Table 6-11 - BGV Parameters
Outputs
Valve % Output
Description
Valve Percentage Output
Type
0-10VDC Only or
LAN to XEV20D
Table 6-12 - BGV Output
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7
Safety Operation Parameters for High
Pressure and Bypass Gas Valves
Refer to Section 7.3, Sensor Failure.
Input
Description
Pressure 2
Receiver Pressure
Hi PSI Set
High Pressure Receiver Safety Setpoint
Hi Hy
High Pressure Receiver Safety Setpoint Hysteresis
Lo PSI Set
Low Pressure Receiver Safety Setpoint
Lo Hy
Low Pressure Receiver Safety Setpoint Hysteresis
Close Rate
Rate at which valve will close in failure mode
BGV % Open Fail
% Open During P2 High Pressure sensor failure
HPV % Open Fail-SC
% Open During P1 and Temp failure in subcritical mode
HPV % Open Fail-TC
% Open During P1 failure in Transcritical mode
HPV % Fail Lo
% Minimum Opening During Low Pressure alarm
Enable
Close valves and disable application during emergency
shutdown
Table 7-1 - Input Safety Operation
7.1
Low Pressure
Operation
The application determines Low Pressure mode if the
receiver pressure is below the Low Pressure setpoint.
In Low Pressure mode, the application will open the
HPV to a minimum user-defined percentage set by the
HPV Fail Lo parameter and close the BGV.
7.1.1
Normal Operation
Once the receiver pressure rises above the Low Pressure valve setpoint plus Hysteresis, the operation will be in
normal mode.
7.2
High Pressure
Operation
The application will determine High Pressure mode if
the receiver pressure is above the High Pressure setpoint.
In High Pressure mode, the application will close the
HPV and opens the BGV, the BGV will open to a user
definable percentage set by the BGV % Open Fail parameter.
7.2.1
Normal Operation
Once the pressure falls below the high pressure valve
setpoint minus Hysteresis, the operation will be in normal
mode.
In normal operation, both HPV and BGV will run off
PID.
• 29
7.3
Sensor Failure
Control
Temp.
T
Condensing
Control
Temp.
T
Condensing
3
11
15
23
4
12
16
24
5
13
17
25
6
14
18
26
7
15
19
27
8
16
20
28
If a failure occurs on the pressure (P1) at the outlet of
the gas cooler, the application:
• Uses the back pressure from E2 (Section 4.1,
High Pressure Controller Inputs).
• If no network backup pressure is available, set
the HPV to a fixed opening according to the
mode it is in (subcritical or transcritical). Parameters for P1 failure (% Open Fail-SC and %
Open Fail-TC) are in (Table 7-2).
If a failure occurs on the temperature (T1) at the outlet
of the gas cooler, the application:
• Uses the back temperature from E2 (Section 4.1,
Inputs Setup).
• In subcritical mode, if T1 fails, use T2 for control. If T2 fails, switch to the failsafe % using
close rate to adjust valve to HPV% Open FailSC.
• In transcritical mode, if T1 fails, use T2 for control. If T2 fails, switch to the failsafe % using
close rate to adjust valve to HPV% Open FailTC.
• If CTS is true in subcritical mode and T2 fails,
switch to the failsafe % using close rate to adjust valve to HPV% Open Fail-SC.
• If CTS is true in transcritical mode and T2 fails,
switch to the failsafe % using close rate to adjust valve to HPV% Open Fail-TC.
Control
Temp.
T
Condensing
Control
Temp.
T
Condensing
°C
°C
°C
°C
-3
5
9
17
-2
6
10
18
-1
7
11
19
0
8
12
20
1
9
13
21
2
10
14
22
Table 7-2 - Condensing and Control Temperature Chart
If a failure occurs on the pressure at the receiver
(P2), the application:
• Uses the back network pressure from E2, refer
to Section 4.1, Inputs Setup.
• If no network backup pressure is available, set
a user definable backup opening valve BGV %
Open Fail.
7.4
Emergency
Shutdown Enable
Input
This input is used for emergency safety shutdown. If
enable input signal is low, the application will close both
the HPV and BGV first before disabling the application
and generating an alarm. For normal operation, this digital input has to be high for the application to be enabled.
If the High Pressure CO2 controller is online with E2, both
the physical digital input and the E2 network enable signal
has to be high for the application to be enabled.
Table 7-2 - Condensing and Control Temperature Chart
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8
Valve
Calibration
Feature
The calibration mode feature allows the user to set a
time schedule to calibrate the HPV and/or BGV fully open
100 % or 0% closed to keep valve position accuracy
during long period runtime. The calibration mode feature
also has a monitoring parameter set by user to track when
to initiate calibration if valve position is within a percentage range to reduce system disruption.
In calibration mode, the High Pressure CO2 controller will send a signal of 100% to the XEV20D drive and a
10 volt analog output to calibrate open or a 0% to the
XEV20D drive and a 0 volt analog output to either of the
HPV and/or BGV. There is also a status display on both
the Visograph and E2 to show if the calibration mode is
initiated.
There are two parameters that will enable the valve
calibration mode feature. The calibration parameters are:
1. Cal Time - is the hour of day the calibration mode
will be initiated.
2. Cal Day - is the interval days of when the calibration
mode will be initiated.
3. Cal T Frame - is the time period to monitor and wait
for when the PID sets the valve percentage equal to or
exceed the Cal Min Valve % before initiating calibration
mode to minimized system disruption.
4. Cal Min Valve % - is the value for when the valve
percentage has to equal to or exceed before executing calibration mode IF Cal T Frame value is greater than 0.
5. Direct - is the direction the calibration mode will be
initialize the valve fully open or closed.
Cal Time and Cal Day values have to be greater than 0
to enable calibration mode.
Examples:
HPV Cal Time
22
HPV Cal T Frame
1
HPV Cal Min Valve %
20
HPV Direct
Closed
Table 8-1 - Cal Time and Day Values
For my HPV valve, the calibration mode will take
place every day because HPV CAL Day = 1 and it will
start at 10:00PM since HPV CAL Time = 22. The calibration mode then looks at the HPV Cal T Frame and since it
is 1, the calibration mode will wait 1 hour for the valve
percentage to equal HPV CAL Min Valve % = 20 or below
to initiate the valve closed. If the valve percentage does
not equal HPV CAL Min Valve % = 20 or below in 1 hour,
then the calibration mode will initiate. If HPV CAL Min
Valve % = 0, the calibration mode will skip this parameter
and initiate every day at 10:00PM closed.
Figure 8-1 - Valve Calibration Parameters
• 31
9
Alarms
The local display and the E2 have the ability to read
and display each alarm. Any sensor failure alarms will
turn on the relay designated as the General Alarm. For the
Shutdown alarm, this is true/active if the enable input is
not high from either the physical digital input and/or E2
network if online with E2.
Alarm
Local
Network
Low Pressure
Yes
Yes
High Pressure
Yes
Yes
Sensor 1 Bad
Yes
Yes
Sensor 2 Bad
Yes
Yes
Sensor 3 Bad
Yes
Yes
Sensor 4 Bad
Yes
Yes
Sensor 5 Bad
Yes
Yes
Sensor 6 Bad
Yes
Yes
Enable/shutdown
Yes
Yes
Table 9-1 - Alarm Designations
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10
Visograph
A Visograph is used as the local display. The screens
provide access for setting up and assigning all inputs, and
outputs. In addition to the entire parameters’ configuration, the user can change the time and date, MODBUS
address, baud rate (9600 or 19200), and update the Visograph with new screens if needed.
Note: Once the High Pressure CO2 controller is online
with E2, you will only be able to make changes through E2
only. For some preference settings, please make changes
on the Visograph before bringing the device online with
E2.
10.1
Figure 10-2 - Main Menu Screen
Highlight Status to enter the Status screen.
Status Screen
In the status screen, users will have visibility into the
operation of both HPV and BGV with their corresponding
control values and parameters. This includes the HPV dual
and failure/alarm operation modes. The status screen also
provides values to show valve modulation. In addition, the
application version is available on the first status screen.
10.1.1 Main Menu and Status
Screens
Bootup Screen:
Figure 10-3 - Status Screen
From the Status screen, you can select to view the
General Status, HPV Status, BGV Status and Alarms
screens. This screen also has the application version software. Highlight the status screen to view and press the T4
button for ENTER.
General Status Screen:
Figure 10-1 - Bootup Screen
Main Menu Screen:
Figure 10-4 - General Status Screen
This screen gives you a general overview of the inputs
and online status. To go back to the Status screen, press the
• 33
T1 button for EXIT.
HPV Status Screen:
alarm is true/active or false/not active. To return to the
main Status screen, press the T1 button for EXIT.
10.2
Figure 10-5 - HPV Status Screen
This screen gives you the HPV status of performance,
setpoints, and control input values. To return to the Status
screen, press the T1 button for EXIT.
BGV Status Screen:
Figure 10-6 - BGV Status Screen
This screen gives you the BGV status of performance,
setpoints, and control input values. To return to the Status
screen, press the T1 button for EXIT.
Alarm Status Screen:
Figure 10-7 - Alarm Status Screen
This screen gives you the alarm status values if the
Configuration Setup
Screen
The Configuration setup screens are password protected. In the Configuration screens, the user will have a
menu listing of setting up the control valve configuration
parameters, XEV20D valve settings, input + output configuration, and general configuration.
Under general configuration, it will have a menu with
the MODBUS address, baud rate, screens update, time and
date, Sensor type (Emerson Retail Solutions or Dixell),
engineering units, pressure transducer settings, shutdown
delay and the factory default reset. Note: Before connecting the High Pressure CO2 controller to E2, please make
these preference changes since it will not be available
through E2 once the device is online and configuration
can only be made via the E2 once online.
The valve configuration screen will have all of the setpoints parameters, PID settings, safeties, and calibration
feature for the valves (HPV/BGV).
The input and output configuration screen will define
the type of sensor function and the polarities of the digital
inputs and outputs. It will also provide the inputs offset.
The XEV20D configuration screen is for setting up the
valve specification if the XEV20D is chosen to drive the
HPV valve and/or BGV valve.
10.2.1 Main Menu to Configuration
Screens
To enter the Configuration Screens, you will need to be
on the Main Menu to enter the password.
Figure 10-8 - Main Menu Screen
Main Menu screen. To enter the Configuration screen,
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press T1 + T3 + T8 button together and hold it until you
see the Configuration screen.
Configuration Screen:
Figure 10-9 - Configuration Screen
From this screen, you can select to configure the General Config, Valve Config, IO Config and XEV20D Config. Highlight the status screen to view and press T4 for
ENTER.
10.2.2 General Configuration
Screens
From the Configuration Screens, the user will have the
ability to configure the MODBUS address, baud rate,
screens up- date, time and date, temp Sensor type (Emerson Retail Solutions or Dixell), engineering units, pressure
transducer settings, shutdown delay and the factory default
reset. Note: Before connecting the High Pressure CO2
Controller to E2, please make these preference changes
since it will not be available through E2 once the device is
online and configuration can only be made via E2 once
online.
The General Config Screen:
Figure 10-10 - General Config Screen 1
Press T5 button (down arrow) to highlight the parameter you wish to change. Press T4 SET to edit the value.
Once the parameter is flashing, press the T3 button or T5
button to change value and press T4 SET again to submit
the change. To see additional parameters in the General
Config screen, press the T8 button (right arrow).
General Configuration Additional Screen:
Figure 10-11 - General Config Additional Screen
Press the T5 button (down arrow) to highlight the
parameter you wish to change. Press T4 SET to edit the
value. Once the parameter is flashing, press the T3 button
or T5 button to change the value and press T4 SET again
to submit the change. To go back to the other General
Config screen, press the T3 button (left arrow) or press T1
button EXIT to exit back to the main Configuration
screen.
10.2.3 Valve Configuration Screens
From the Configuration Screens, the user will have the
ability to configure the setpoints, PID settings, safety settings, and the calibration feature for the HPV and BGV.
Valve Configuration Screen:
Figure 10-12 - Valve Config Screen
Press the T5 button (down arrow) to high the parameter you wish to change. Press T4 SET to edit the value.
Once the parameter is flashing, press the T3 button or T5
button to change value and press T4 SET again to submit
change. To see additional parameters in the Valve Config
screen, press T8 button (right arrow). Once in the addi-
• 35
tional Valve Config screen, you can press the T3 button
(left arrow) to go back a screen or press the T1 button
EXIT to exit back to the main Configuration screen.
Valve Configuration Additional Screen:
Figure 10-16 - Valve Config Additional Screen
Figure 10-13 - Valve Config Additional Screen
Valve Configuration Additional Screen:
Figure 10-17 - Valve Config Additional Screen
Figure 10-14 - Valve Config Additional Screen
Figure 10-18 - Valve Config Additional Screen
Figure 10-15 - Valve Config Additional Screen
10.2.4 I/O Configuration Screens
From the Configuration Screens, the user will have the
ability to configure the input and output, defined of the
type of sensor function and the polarities of the digital
inputs and outputs. It will also provide the inputs offset.
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IO Config Screen:
Figure 10-19 - IO Config Screen
Figure 10-21 - IO Config Additional Screen
Press the T5 button (down arrow) to highlight the
parameter you wish to change. Press T4 SET to edit the
value. Once the parameter is flashing, press the T3 button
or T5 button to change the value and press T4 SET again
to submit change. To see additional parameters in the IO
Config screen, press the T8 button (right arrow). Once in
the additional Valve Config screen, you can press the T3
button (left arrow) to go back a screen or press the T1 button EXIT to exit back to the main Configuration screen.
IO Configuration Additional Screen:
Figure 10-22 - IO Config Additional Screen
Figure 10-20 - IO Config Additional Screen
Figure 10-23 - IO Config Additional Screen
• 37
Figure 10-24 - IO Config Additional Screen
Figure 10-27 - XEV20D Config Screen
Press the T5 button (down arrow) to high the parameter you wish to change. Press T4 SET to edit the value.
Once the parameter is flashing, press the T3 button or T5
button to change value and press T4 SET again to submit
change. To see additional parameters in the IO Config
screen, press the T8 button (right arrow). Once in the additional Valve Config screen, you can press the T3 button
(left arrow) to go back a screen or press the T1 button
EXIT to exit back to the main Configuration screen.
Figure 10-25 - IO Config Additional Screen
Figure 10-28 - XEV20D Config Additional Screen
10.3
Figure 10-26 - IO Config Additional Screen
Override Screen
In the Override screen, users will have ability to override the operation of both HPV and BGV to a fix percentage with a timer.
10.2.5 XEV20D Configuration
Screens
From the Configuration Screens, the user will have the
ability to configure the valve specification if the XEV20D
is chosen to drive the HPV valve and/or BGV valve.
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Figure 10-29 - Override Screen
• 39
11
High Pressure CO2 Controller Ranges
and Default Setpoint Parameters
Setpoints
Description
Default
Range
Unit
HPV Mode Setpoint
Setpoint for Subcritical and Transcritical mode switch
31
-3 to 42
DC
HPV Mode Hysteresis
Control Temperature Hysteresis
2.8
0 to 20
DDC
HPV Subcool Setpoint
Setpoint in Subcritical Mode
1.7
0 to 100
DDC
HTR S Set
Reclaim Setpoint Shift-High Pressure Valve-Subcritical
0
0 to 30
DDC
HPV RS-Temp
Subcritical band offset
0
0 to 100
DC
HPV PB-Temp
Subcritical proportional band
16.7
0 to 100
DC
HPV Transcritical
Setpoint
Setpoint During Transcritical Mode
From
Table
-39.2 to
111
BAR
HTR T Set
Reclaim Setpoint Shift-High Pressure ValveTranscritical
0
0 to 30
DBAR
HPV RS-Press
Transcritical band offset
0
0 to 500
BAR
HPV PB-Press
Transcritical proportional band
12
0 to 500
BAR
HPV INC
Integral sampling time
140
0 to 1000
Seconds
HPV DER
Derivative sampling time
0
0 to 1000
Seconds
HPV DDER
Derivative time
0
0 to 1000
Seconds
HPV Max %
Maximum valve % open
100
0 to 100
%
BGV Setpoint
Receiver pressure setpoint
34
0 to 500
BAR
BGV_PB
BGV proportional band
2.75
0 to 500
BAR
BGV_RS
BGV band offset
1.4
0 to 500
BAR
BGV_INC
BGV integral sampling time
100
0 to 1000
Seconds
BGV_DER
BGV derivative sampling time
0
0 to 1000
Seconds
BGV_DDER
BGV derivative time
0
0 to 1000
Seconds
Hi PSI Set
High pressure setpoint
43
0 to 1000
BAR
Hi Hy
High pressure hysteresis
1
0 to 500
DBAR
Lo PSI Set
Low pressure setpoint
30
0 to 500
BAR
Lo Hy
Low Hysteresis
1
0 to 500
DBAR
Table 11-1 - High Pressure CO2 Controller Ranges and Default Setpoint Parameters
40 • High Pressure CO2 Controller Installation and Operation Manual
026-1731 Rev 0 01-DEC-2014
Setpoints
Description
Default
Range
Unit
Close Rate
Rate at which the HPV will close in safety mode
30
0 to 600
Seconds
HPV% Open Fail-SC
Valve % open during Subcritical with sensor failure
0
0 to 100
%
HPV% Open Fail-TC
Valve% open during Transcritical with sensor failure
0
0 to 100
%
HPV% Open Fail-Lo
Valve% minimum opening during low pressure safety
mode
15
0 to 100
%
BGV% Open Fail
Valve% open during high pressure safety mode
0
0 to 100
%
TransMaxTime
Transition time of the two Sub and Trans PID
180
30 to 600
Seconds
Table 11-1 - High Pressure CO2 Controller Ranges and Default Setpoint Parameters
• 41
12
XEV20D Setup and Network
Connection
The XEV20D is a stepper valve driver that can drive a bipolar stepper valve or unipolar stepper valve. It is a dummy
voltage chopper constant current driver that will be controlled by the High Pressure CO2 controller through a LAN communication network. It can control the High Pressure Valve function and/or the Bypass Gas Valve function. The user has
the option to use this driver or use the 0-10 voltage output from the High Pressure CO2 controller to another driver for
controlling the valve. If this driver is preferred, please check the manufacturer valve technical specifications for the current ratings and verify if the XEV20D is capable of driving the valve. The XEV20D address will have to be set to 1 to
communicate with the High Pressure CO2 controller.
CAUTION! GND is Common (-), not earth
ground. Do not earth ground this device.
Figure 12-1- High Pressure CO2 Device Wiring and Network Connection
42 • High Pressure CO2 Controller Installation and Operation Manual
026-1731 Rev 0 01-DEC-2014
Figure 12-2 - High Pressure CO2 Device Wiring and Network Connection
• 43
13
Stepper Valve
Actuator Quick
Reference Guide
XEV20D
13.1. General Warnings
Please read the following safety precautions and
warnings before using the instructions in this section:
CAUTION!
• This section is part of the product and should
be kept near the controller for easy and quick
reference.
• The controller should not be used for purposes
different from those described in this manual. It cannot be used as a safety device.
• Check the application limits before proceeding.
SAFETY PRECAUTIONS AND
WARNINGS!
• Check that the supply voltage is correct
before connecting the controller.
• Do not expose to water or moisture: use the controller only within the operating limits and avoid sudden temperature changes with high atmospheric
humidity to prevent condensation from forming.
• Warning! Disconnect all electrical connections
before performing any kind of maintenance.
• Fit the probe where it is not accessible by the end
user. The controller must not be opened.
• In case of failure or faulty operation, send the
controller back to the distributor with a detailed
description of the fault.
• Verify the maximum current that can be applied
to each relay (see Section 13.8, XEV20D Technical
Specifications).
• Ensure that the wires for probes, loads, and the
power supply are separated and far enough from each
other, without crossing or intertwining.
• In case of applications in industrial environments, the use of main filters (mod. FT1) in parallel
with inductive loads could be useful.
13.2
General Description
XEV20D is a stepper valve actuator intended either for
bipolar stepper valves or unipolar stepper valves. This
device has been thought to be used with ISaGRAF® environment and with programmable devices or in combination with instruments of i-CHILL 200CX series.
The maximum configuration of hardware is equipped
with:
44 • High Pressure CO2 Controller Installation and Operation Manual
026-1731 Rev 0 01-DEC-2014
• 2 configurable valve outputs to drive bipolar or unipolar valves
• Pb1/Pb2 configurable analog inputs: NTC/PTC/
Pt1000
13.4
Wiring Diagrams
13.4.1 One Valve Configuration
• Pb3/Pb4 configurable analog inputs: 4 to 20mA/0
to 5V/Pt1000
• CAN Bus serial line
• LAN to communicate with instrument of the same
series or devices of i-CHILL200CX series
13.3
Absolute Maximum
Power
XEV20D is able to drive a wide range of stepper
valves. Indicated in the following table are the maximum
values of current that the actuator can supply to the stepper
wiring. Select the correct transformer depending on the
application seeing the following table, for each kind of
driving and functioning is reported to the transformer to
use.
NOTE: The electrical power absorption of the
valve can be unrelated to refrigeration power
of the valve. Before using the actuator, read
the technical manual of the valve supplied by
the manufacturer and check the maximum current
used to drive the valve in order to verify that they are
lower than those indicated below.
Figure 13-2 - HPV Status Screen
13.4.2 Two Valve Configuration
Figure 13-1 - Valve Max Power
Figure 13-3 - Two Valve Configuration
• 45
13.5
Valve Connections
The following table is a quick reference on the connection mode for valves of different manufacturers:
Figure 13-5 - Valve Connections
Figure 13-6 - XEV20D
46 • High Pressure CO2 Controller Installation and Operation Manual
026-1731 Rev 0 01-DEC-2014
13.6
Serial Line - LAN Bus
The device can communicate through LAN Bus serial line only when the address is set correctly. The addressing is
made through the dip-switch called Address as shown below. The XEV20D address will have to be set to 1 to communicate with the High Pressure CO2 controller.
Figure 13-7 - XEV22D
• 47
13.7
LED Descriptions
The following table contains LED functions:
Figure 13-8 - LED Functions
13.8
XEV20D Technical
Specifications
Case
4 DIN
Connectors
Disconnectable Terminal Block
2.5 mm2 for valve outputs
and minifit connector for low
voltage section
Power Supply
24VAC/DC Absorption: 40VA
max.
Probe Inputs
2 configurable as NTC/PTC/
Pt1000
2 configurable as NTC/PTC/
Pt1000/4 to 20mA/to 5V
Valve Outputs
Refer to the Valve Max Power
Figure on page 44.
Serial Connection
CAN Bus and LAN for
iCHILL200CX
Data Storing
On non-volatile memory
(EEPROM).
Table 13-1 - XEV20D Technical Specifications
48 • High Pressure CO2 Controller Installation and Operation Manual
026-1731 Rev 0 01-DEC-2014
Case
4 DIN
Kind of Action
1B; Pollution Grade: 2
Software Class: A
Rated Inpulsive
Voltage
2500V;
Overvoltage Category: II
Operating
Temperature
-10 to 60°C (14°F to 140°F)
Storage Temperature: -30 to 85°C
(-22°F to 185°F)
Relative Humidity
20 to 85% (non-condensing)
Measuring and
Regulation Range
PTC probe: -50 to150°C (-58°F
to 302°F)
NTC probe: -40 to110°C (-40°F
to 230°F)
Pt1000 probe: -50 to100°C
(-58°F to 212°F)
Pressure transducer:
-1.0 to 50.0 Bar (-14.5 PSI to 725
PSI)
Resolution
0.1°C or 1°F; Accuracy@ 25°C:
±0.1°C ±1 digit
Table 13-1 - XEV20D Technical Specifications
• 49
The contents of this publication are presented for informational purposes only and they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described
herein or their use or applicability. Emerson Climate Technologies Retail Solutions, Inc. and/or its affiliates (collectively “Emerson”), reserves the right to modify the designs or specifications of such
products at any time without notice. Emerson does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any product
remains solely with the purchaser and end-user.
026-1731 01-DEC-2014 Emerson is a trademark of Emerson Electric Co. ©2014 Emerson Climate Technologies Retail Solutions, Inc. All rights reserved.