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MultiFlex CUB-TD

Emerson MultiFlex CUB-II, MultiFlex CUB-TD Installation And Operation Manual

026-1705 Rev 7 06-APR-2010
MultiFlex Condensing Unit Board
(CUB-II and CUB-TD) Installation and
Operation Manual
3240 Town Point Drive NW Suite 100
Kennesaw, GA 30144, USA
Phone: 770-425-2724
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, Com­puter Process Controls, Inc. reserves the right to make improvements to this manual, and the products described herein, at any time without notice or obligation.
Table of Contents
1 OVERVIEW OF THE MULTIFLEX CUB-II AND CUB-TD.................................................................................. 1
1.1. T
HE MULTIFLEX CUB-II.............................................................................................................................................. 1
1.2. T
HE MULTIFLEX CUB-TD........................................................................................................................................... 1
2 MOUNTING AND POWERING.................................................................................................................................. 2
2.1. S
NAP-TRACK INSTALLATION........................................................................................................................................ 2
2.2. T
HE PLUG-IN OUTPUT BOARD ..................................................................................................................................... 3
2.3. P
OWERING THE MULTIFLEX CUB BOARD ................................................................................................................... 3
2.3.1. Choosing Transformer Sizes ................................................................................................................................. 4
2.3.2. MultiFlex CUB Power Wiring............................................................................................................................... 4
2.3.2.1. New-Style MultiFlex CUB Boards (With Isolated Power Supply)....................... .. ............................. .............................. 5
2.3.2.2. Old-Style MultiFlex CUB Boards (No Isolated Power Supply)......................................................................................... 5
2.3.3. Wire Types and Maximum Distances.................................................................................................................... 6
3 THE I/O NETWORK .................................................................................................................................................... 7
3.1. W
IRING TYPES.............................................................................................................................................................. 7
3.1.1. Daisy Chains......................................................................................................................................................... 7
3.1.2. Network ID Numbers............................................................................................................................................. 7
3.1.2.1. Numbering the MultiFlex
CUB ................................................................................................................................................................................................... 8
3.1.3. Setting the Baud Rate............................................................................................................................................ 8
3.1.4. Setting the Terminating Resistance Jumpers ........................................................................................................ 8
4 CUB INPUT AND OUTPUT SETUP..................................................................... ...................................................... 9
4.1. T
HE INPUTS................................................................................................................................................................... 9
4.1.1. Connecting Sensors to the MultiFlex CUB........................................................................................................... 9
4.1.1.1. Wiring.......................................... ........................... ........................... ................................................................................. 9
4.1.1.2. Sensor Wiring Types .......................................................................................................................................................... 9
4.1.1.3. Input Type Dip Switches .................................................................................................................................................... 9
4.1.2. Power Connection............................................................................................................................................... 10
4.1.2.1. Current Ratings for On-Board Power Sources.................................................................................................................. 10
4.1.2.2. Powering Sensors Requiring 24VAC Off the Power Transformer.............................................. ..................................... 10
4.1.3. MultiFlex CUB Fixed Input Locations................................................................................................................ 10
4.2. T
HE OUTPUTS ............................................................................................................................................................. 11
4.2.1. Relay Output Ratings and Fuse Protection......................................................................................................... 12
4.2.2. Wiring Outputs to Points..................................................................................................................................... 12
4.2.3. MultiFlex CUB Fixed Outputs............................................................................................................................ 12
5 BOARD STATUS LEDS ............................................................................................................................................. 13
5.1. S
TATUS LED................................................................. .................................. ............................................................ 13
5.2. T
X AND RX LEDS....................................................................................................................................................... 13
5.3. C
ODE A AND CODE B LEDS ...................................................................................................................................... 13
5.4. R
ELAY OUTPUT LEDS................................................................................................................................................ 14
6 MULTIFLEX CUB-II AND CUB-TD SOFTWARE OVERVIEW......................................................... ............... 15
6.1. C
OMPRESSOR CONTROL.............................................................................................................................................. 15
6.1.1. Suction Pressure Compressor Control................................................................................................................ 15
6.1.2. Case Temperature Compressor Control............................................................................................................. 15
6.1.2.1. Pump Down .. ........................... ..................................................... .................................................................................... 15
6.1.2.2. Fallback Pressure Setpoints ............................. ........................... ...................................................................................... 15
vi • Table of Contents 026-1705 Rev 7 06-APR-2010
6.2. CONDENSER FAN CONTROL ....................................................................................................................................... 16
6.2.1. Temperature Differential (TD) Strategy ............................................................................................................. 16
6.2.1.1. TD Control Fail-Safes..................... ........................... .. ........................... .......................................................................... 16
6.2.2. Pressure Control Strategy.................................................... .................................. ... .......................................... 16
6.2.3. Case Temperature Control.................................................................................................................................. 17
6.3. D
EFROST CONTROL .................................................................................................................................................... 17
6.3.1. Defrost Termination............................................................................................................................................ 17
6.4. S
ENSOR CONTROL ...................................................................................................................................................... 17
6.4.1. How Cut In/Cut Out Control Works .................................. ................................. ................................................ 17
6.4.2. Motor Room Temperature Control..................................................................................................................... 18
6.4.2.1. Exhaust Fan Control .................................................... ..................................................................................................... 18
6.4.2.2. Example of a Motor Room Zone Temperature Configuration ........ ........................... ...................................................... 18
6.5. ALARM CONDITIONS (SAFETY MODES) ..................................................................................................................... 19
6.5.1. High Discharge Trip Safety Mode...................................................................................................................... 19
6.5.2. Compressor Proof Fail Safety Mode .................................................................................................................. 19
6.5.3. Compressor Oil Failure Safety Mode................................................................. ................................................ 20
6.5.4. Phase Fail Mode................................................................................................................................................. 20
6.6. D
OOR SWITCHES AND CLEAN (WASH) SWITCHES ..................................................................................................... 20
6.6.1. Door Switches..................................................................................................................................................... 20
6.6.2. Clean (Wash) Switches........................................................................................................................................ 21
7 THE MULTIFLEX CUB E2/ EINSTEIN INTERFACE......................................................................................... 22
7.1. A
DDING/DELETING A CUB ........................................................................................................................................ 22
7.1.1. Adding a CUB......................................................................... ............................................................................ 22
7.1.2. Deleting a CUB................................................................................................................................................... 23
7.2. V
IEWING THE CUB STATUS SCREEN ......................................................................................................................... 23
7.2.1. Inputs and Setpoints............................................................................................................................................ 24
7.2.2. Sensor Control .................................................................................................................................................... 25
7.2.3. Outputs and Operational States.......................................................................................................................... 25
7.2.4. Defrost................................................................................................................................................................. 26
7.2.5. KW Usage ........................................................................................................................................................... 26
7.3. P
ROGRAMMING THE CUB USING THE E2 OR EINSTEIN FRONT PANEL..................................................................... 26
7.3.1. Screen 1: General ............................................................................................................................................... 27
7.3.2. Screen 2: Setpoints.............................................................................................................................................. 28
7.3.2.1. Temperature Differential (TD) ................................................................. ........................................................................ 30
7.3.2.2. Traditional Strategy ...................... .................................................................................................................................... 30
7.3.3. Screen 3: Inputs .................................................................................................................................................. 31
7.3.4. Screen 4: Aux Inputs........................................................................................................................................... 32
7.3.5. Screen 5: CUB Inputs ......................................................................................................................................... 32
7.3.6. Screen 6: Defrost ................................................................................................................................................ 34
7.3.7. Screen 7: Outputs................................................................................................................................................ 35
7.3.8. Screen 8: CUB Outputs....................................................................................................................................... 37
7.3.9. Screen 9: Sensor Control.................................................................................................................................... 38
7.3.10. Screen 10: Alarms............................................................................................................................................. 39
7.3.10.1. Oil Failure Alarm Setpoints............................................................................................................................................ 39
7.3.10.2. Discharge Pressure Alarm .............................................................................................................................................. 40
7.3.10.3. High/Low Suction Pressure Alarms ......... .. ........................... ......................................................................................... 41
7.3.10.4. Compressor Proof Alarms .............................................................................................................................................. 41
7.3.10.5. Phase Fail Shutdown....................................................................................................................................................... 42
7.3.10.6. Door Switch Alarms ....................................................................................................................................................... 42
7.3.10.7. Wash Active Alarms....................................................................................................................................................... 42
7.3.10.8. Case Temperature Alarms .............................................................................................................................................. 42
7.3.10.9. Suction Temperature Alarms.......................................................................................................................................... 43
7.3.10.10. TD Condenser Control Alarms..................................................................................................................................... 43
MultiFlex CUB-II and CUB-TD I&O Guide Table of Contents • vii
8 THE MULTIFLEX CUB HAND-HELD INTERFACE........................................................................................... 44
8.1. CUB H
AND-HELD TERMINAL STATUS SCREENS ....................................................................................................... 44
8.1.1. Pressure Status.................................................................................................................................................... 44
8.1.2. Case Temp Status................................................................................................................................................ 44
8.1.3. Other Temperatures ............................................................................................................................................ 44
8.1.4. Input Summary Screen ........................................................................................................................................ 45
8.1.5. Outputs Summary Screen #1............................................................................................................................... 45
8.1.6. Outputs Summary Screen #2............................................................................................................................... 45
8.1.7. System Status....................................................................................................................................................... 45
8.1.8. Refrigeration Control Status............................................................................................................................... 45
8.2. A
LTERING CUB CONFIGURATION USING THE HAND-HELD TERMINAL.................................................................... 45
8.2.1. The Main Configuration Menu............................................................................................................................ 45
8.2.2. Navigation........................................................................................................................................................... 46
8.2.3. General Hand-Held Terminal Screens................................................................................................................ 46
8.2.3.1. Circuit Name......................................... ........................... ........................... ...................................................................... 46
8.2.3.2. Refrigerant Select................ ... .......................... ................................................................................................................. 47
8.2.3.3. Phase.................... ........................... .......................... ........................................................................................................ 47
8.2.3.4. Temp EU.................. ........................... ........................... .......................... ......................................................................... 47
8.2.3.5. Time and Date................................................................................................................................................................... 48
8.2.3.6. Daylight Savings Time ..................................................................................................................................................... 48
8.2.4. Setpoints Screens................................................................................................................................................. 48
8.2.4.1. Condenser Setpoints ......................................................................................................................................................... 49
8.2.4.2. TD Strat Info.......... ........................... ........................... ..................................................................................................... 49
8.2.4.3. TD Max............................................... ........................... .......................... ......................................................................... 49
8.2.4.4. Comb Method ........................................................... ........................... ............................................................................. 49
8.2.4.5. Min OFF/ON Times.......... ...................................................... .......................... ................................................................ 50
8.2.4.6. Condenser SPs .................................................................................................................................................................. 51
8.2.4.7. Condenser Fan 1 Setpoints ............................................................................................................................................... 51
8.2.4.8. Condenser Fan 2 Setpoints ............................................................................................................................................... 51
8.2.5. Alarm Setpoints Screens...................................................................................................................................... 52
8.2.5.1. Case Hi and Lo Temp ....................................................................................................................................................... 52
8.2.5.2. Phase Fail........ ...................................................... ........................... ................................................................................. 52
8.2.5.3. Shut Down On Proof......................................................................................................................................................... 52
8.2.5.4. Proof Failure ........ ........................... ..................................................... ............................................................................. 53
8.2.5.5. Oil Restart Delay .............................................................................................................................................................. 53
8.2.5.6. Digital Oil Failure............................................................................................................................................................. 53
8.2.5.7. High Discharge Alarm........................................................................... ........................................................................... 54
8.2.5.8. High Discharge Auto Resets............................................................................................................................................. 54
8.2.5.9. Door Switch.................. .......................... ........................... ........................... .................................................................... 54
8.2.5.10. Wash Switch ................................................................................................................................................................... 54
8.2.6. Defrost Setup Screens.......................................................................................................................................... 55
8.2.6.1. Defrost Type .......... .. ........................... .............................................................................................................................. 55
8.2.6.2. Fan Control .......... ................................................................................ ............................................................................. 55
8.2.6.3. Defrost Times ...................................................................... ........................... .................................................................. 56
8.2.6.4. Defrost Schedule Screens 1 and 2..................................................................................................................................... 56
8.2.7. Input Setup Screens............................................................................................................................................. 56
8.2.7.1. Input Setup ....................................................................................................................................................................... 56
8.2.8. Outputs Screens................................................................................................................................................... 58
8.2.9. Auxiliary Inputs Screens.................................................................... .................................................................. 58
8.2.9.1. Pulse KW Setup ..................................................... ........................... ............................................................................... 58
8.2.9.2. Analog KW Setup ............................................................................................................................................................ 58
8.2.9.3. Linear 1 and 2 Setup ......................................................................................................................................................... 58
8.2.10. Sensor Control Screens..................................................................................................................................... 59
8.2.10.1. Sensor Screen 1 (Name, Type) .......... ............................. ............................. .................................................................. 59
8.2.10.2. Sensor Screen 2 (Cut In/Out, Min ON/OFF).......... ............................. .. ............................. ............................................ 59
8.2.10.3. Sensor Screen 3 (Hi/Lo Alarm) ...................................................................................................................................... 60
viii • Table of Contents 026-1705 Rev 7 06-APR-2010
8.2.10.4. Sensor Control Screen 4 (Alarm Priority, Comb Method)............................................................................................. 60
APPENDIX A: TD QUICK START ..................................... .................................. ........................................................ 62
APPENDIX B: CASE TYPE DEFAULTS ................................................................ ..................................................... 68
MultiFlex CUB-II and CUB-TD I&O Guide Table of Contents • ix
1 Overview of the Multi-
Flex CUB-II and CUB-TD
The MultiFlex CUB-II and CUB-TD boards are “smart” input/output boards designed to con­trol single condensing units. A single condens­ing unit is a self-contained compressor and condenser bearing unit which controls refrigera­tion in a single case line-up or walk-in cooler. The MultiFlex CUB-II controllers are capable of commanding compressors, condensers, refriger­ation, and defrost for a single condensing unit using on-board I/O and control algorithms. The CUB-TD controller is a more limited board that controls only condensers, using a temperature differential control strategy.
The MultiFlex’s I/O Points
The compact size of the MultiFlex allows technicians to easily field-mount the MultiFlex CUB-II and CUB-TD in a panel or enclosure close to the single condensing unit, allowing for easy local connection of sensors and transducers. The board has 16 analog inputs (for connection to vital input sources, such as suction pressure transducers and case temperature sensors) and eight relay outputs, rated 2.0 amps max, for acti­vating and deactivating compressors, defrost, and condenser fans.
Independent System Control
The MultiFlex CUB-II and CUB-TD con­trollers are equipped with software and an enhanced processor, which gives them the capa­bility of controlling independently without the need of a central controller (such as CPC’ s E2 or Einstein RX Refrigeration Controller). However, the CUB-II and CUB-TD are designed to inter­face with an E2 or Einstein for purposes of dis­playing status on status screens, reporting alarms, and recording logs. The CUB-II and CUB-TD may be configured either with a CPC Hand-Held T erminal (HHT) or through the E2 or Einstein front panel.
1.1. The MultiFlex CUB-II
The MultiFlex CUB-II controllers are capa­ble of handling all aspects of single condensing unit control, including compressors, condensers, refrigeration, and defrost, using on-board I/O and control algorithms. The CUB-II is capable of controlling one single-stage compressor, refrigeration and scheduled/terminated defrost in a case circuit with up to six temperature inputs, and condenser control using either a control by pressure strategy (activates up to two fans to maintain a set discharge pressure) or temperature differential strategy (activates up to four fans to maintain a set difference between the ambient temperature and the drop leg refrigerant temper­ature).
1.2. The MultiFlex CUB-TD
The MultiFlex CUB-TD is a “stripped” ver­sion of the MultiFlex CUB-II that includes only an algorithm for temperature differential (TD) condenser fan control. Up to four condensing unit fans are cycled on and off as required to meet compressor unit heat of rejection load. The TD algorithm subtracts plenum air temperature from the drop leg temperature and uses the dif­ference between the two temperatures as a con­trol value. If the difference is higher than the setpoint, the fans are staged on. If the difference is lower than the setpoint, the fans are staged off.
The temperature differential control capabili­ties of the CUB-TD are identical to those of a CUB-II operating in temperature differential mode, except the CUB-TD controls condensers only. The CUB-TD only has inputs for reading temperatures and outputs for controlling up to four fans. For control of any other single con­densing unit subsystem, a CUB-II will neces­sary.
The MultiFlex CUB-II Overview of the MultiFlex CUB-II and CUB-TD • 1
2 Mounting and Power-
ing
The MultiFlex boards are usually mounted by the refrigeration equipment manufacturer. Therefore, the installer need only make the nec­essary connections between the boards and the site controller(s).
In some instances, an installer may be required to mount an I/O board. There are no restrictions on the location of these boards; how­ever, for ease of network configuration, it is rec­ommended that the boards be located adjacent to the E2 or Einstein. I/O boards may be mounted without an enclosure, but they should be mounted in a location that is not easily accessi­ble to avoid tampering or damage.
2.1. Snap-Track Installation
MultiFlex boards not supplied in a custom panel or other enclosure are supplied 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” mounting slots. Figure 2-1 shows this installation procedure.
2 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
Figure 2-1 - MultiFlex Snap-Track Mounting
Figure 2-2 provides mounting dimensions
for the MultiFlex board.
Figure 2-2 - MultiFlex Board Dimensions
2.2. The Plug-In Output Board
The additional board makes the MultiFlex CUB boards considerably taller than the Multi­Flex 16 and other CPC I/O boards. If you will be mounting these boards in an enclosure, the board will need at least 2.5” of clearance between the baseboard and the panel door.
2.3. Powering the MultiFlex
CUB Board
WARNING: All models of MultiFlex require a 24V AC Class 2 input power source. The Multi­Flex CUB-II requires the power source to be non-center-tapped. Refer to Section 2.3.1.,
Choosing Transformer Sizes for center tap usage.
CPC supplies a wide variety of 24VAC trans­formers with varying sizes and either with or without center taps. Table 2-1 shows the trans- former sizes and whether they are center-tapped or non-center-tapped.
Figure 2-3 - Exploded View — MultiFlex CUB-II
The MultiFlex CUB has an output sub-board that plugs to the top of the baseboard. Typically, these boards are shipped with the output board pre-installed on the board using stand-offs, so no additional hardware setup should be necessary.
Xformer P/N VA Rating Primary Voltage Center Tap?
640-0041 50 VA 110 VAC No 640-0042 50 VA 220 VAC No 640-0056 56 VA Multi-tap (120/208/240 VAC) Yes 640-0050 75 VA 110 VAC No 640-0045 75 VA 220 VAC No 640-0080 80 VA Multi-tap (120/208/240 VAC) Yes
Table 2-1 - Transformers Compatible with Datalink Module
The Plug-In Output Board Mounting and Powering • 3
2.3.1. Choosing Transformer Sizes
POWER LED
New Style
MultiFlex Board
(Top Left Corner)
NO POWER LED
Old Style
MultiFlex Board
(Top Left Corner)
24 VAC
24 VAC
In most site installations, a single trans-
former will power multiple devices. Choose a transformer with a VA rating large enough to power all devices that will be attached to it. Table 2-2 gives the VA ratings of the MultiFlex CUB in conjunction with other MultiFlex boards. Refer to your site controller’s manual for VA ratings of the other I/O boards that may be powered by one of these transformers.
Unit VA VAC Center-
Tapped?
MultiFlex 16 624Yes
MultiFlex 88,
88AO, 168,
and 168AO
MultiFlex RTU 15 24 NO MultiFlex CUB 15 24 NO
Table 2-2 - Device Power Requirements
15 24 NO
A new-style MultiFlex board has a green power LED located next to the 24VAC connec­tion terminal in the upper right corner of the cir­cuit board (see Figure 2-4 for reference).
2.3.2. MultiFlex CUB Power Wiring
The MultiFlex CUB boards do not use a cen­ter tap. Instead, the 0V terminal on the board should be connected to a separate earth ground.
Important! The rules that must be fol­lowed when connecting a MultiFlex CUB board to a transformer are different depend­ing on whether you have a "new style" Multi­Flex board with an isolated power supply (all MultiFlex boards shipped after November 1,
2002) or an "old style" MultiFlex board (all MultiFlex boards shipped before November 1, 2002).
Figure 2-4 - New-Style vs. Old-Style MultiFlex Board
If there is a green power LED next to the
connector, your MultiFlex is a new-style Multi-
Flex -- refer to Section 2.3.2.1., New-Style Mul­tiFlex CUB Boards (With Isolated Power Supply) for power wiring instructions.
If there is no green power LED next to the
connector, your MultiFlex is an old-style Multi-
Flex -- refer to Section 2.3.2.2., Old-Style Multi­Flex CUB Boards (No Isolated Power Supply)
for power wiring instructions.
4 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
2.3.2.1. New-Style MultiFlex CUB Boards
Earth ground. Use 14 AWG or larger. Keep as short as possible. Less than six inches is preferred.
(With Isolated Power Supply)
The new-style MultiFlex board can be con-
nected to any of the center-tapped transformers
mentioned in Table 2-2, provided the 0V termi-
nal of the board is connected to an earth ground.
NOTE: 14AWG or larger should be used for earth ground and the length should be kept short. Less than six inches is preferred.
A center-tapped transformer may power
both center-tapped and non-center-tapped
devices at the same time, as long as none of the
non-center-tapped MultiFlex boards are old-
style MultiFlex boards. If an old-style Multi-
Flex shares the same center-tapped transformer
as a device that uses the center tap, the old-style
MultiFlex will be damaged. Figure 2-5 shows
how to wire a non-center-tapped device to a cen-
ter-tapped transformer.
In addition, the MultiFlex CUB boards can
be powered by one of the 50VA or 75VA non­center-tapped transformers listed in Table 2-1 on page 3. Figure 2-6 shows how to wire the trans­formers to the MultiFlex boards.
Figure 2-6 - Non-Center-Tapped Transformer Wiring
2.3.2.2. Old-Style MultiFlex CUB Boards (No Isolated Power Supply)
Figure 2-5 - Wiring Non-Center-Tapped MultiFlex Boards to Transformers With a Center Tap
Like the new-style MultiFlex board, the old­style MultiFlex board can be connected to any of the center-tapped transformers mentioned in Table 2-2, provided you observe the following three rules:
Rule 1: Ground the 0V terminal on the old­style MultiFlex board to an earth ground.
Do not connect the center tap of the trans­former to the 0V terminal.
Rule 2: Do not power an old-style MultiFlex non-center-tapped board with a transformer that is also powering a center-tapped device.
This means you cannot connect an old-style MultiFlex non-center-tapped board to a trans­former that is powering a MultiFlex 16, 16AI, 8RO, 4AO, 8DO, or any previous generation CPC board that uses center-tapped power. Doing so will destroy the MultiFlex board.
Rule 3: The secondary of the transformer must not be grounded on any side.
Powering the MultiFlex CUB Board Mounting and Powering • 5
Verify that neither side of the transformer secondary is connected to earth ground before powering the old-style MultiFlex board. A grounded secondary will damage the MultiFlex board.
In addition, the old-style MultiFlex CUB boards can be powered by one of the 50VA or 75VA non-center-tapped transformers listed in Table 2-1 on page 3. Figure 2-6 shows how to wire the transformers to the MultiFlex boards.
2.3.3. Wire Types and Maximum Dis-
tances
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 I/O board s) For example, if you had an 80 VA load: 14 AWG: 24 ft 18 AWG: 9 ft (rounded down)
Figure 2-7 - Power Wire Lengths
For powering I/O boards, use only the listed wire types from Table 2-3. Three-conductor non- shielded cables are the recommended wire for connecting between the center-tapped trans­former and the I/O boards. Shielded cable should not be used for power wiring. The center tap should be wired with the third conductor to earth ground at the controller. (Use 14AWG and keep the length of wire short. Less than six inches is preferred).
Power Wiring Types
14 AWG Belden 9495 18 AWG Belden 9493
Table 2-3 - Power W iring Types
The wire length from the transformer and the number of boards connected to the same wire determines the type wire gauge used. In most cases, the distance between the I/O boards and the transformer that supplies power to them is not enough to be concerned with. But it is very important not exceed this maximum wire length or the boards will malfunction.
Sensors requiring 24VAC can be powered from the same transformer powering the input board as long as the resulting total load of both the input board(s) and the sensor(s) connected to the transformer does not exceed the trans­former’s VA rating, and the sensors have an iso­lated power supply . If the sensors do not have an isolated power supply, they could be damaged if connected with center-tapped or grounded sec­ondary transformers.
6 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
3The I/O Network
Although the MultiFlex CUB can operate as a stand-alone controller, it relies on an E2, Ein­stein, or REFLECS unit for advanced features such as remote dial-in/dial-out, logging, and alarm control. All MultiFlex boards and control­lers use an RS485 Network connection to com­municate with an E2, Einstein, and REFLECS site controllers. Technicians who are familiar with CPC’s previous generation 16AI, 8IO, and ARTC boards will find the network setup proce­dure for the MultiFlex CUB boards to be very much the same.
3.1. Wiring Types
CPC specs Belden #8761 shielded twisted pair cables for use as I/O Network 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:
put communication boards, and terminates at the last input or output board on the network. A dia­gram of this network arrangement is shown in
Figure 3-1.
Figure 3-1 - I/O Network Configurations
3.1.2. Network ID Numbers
Each device on an RS485 segment has a net-
work dip switch that must be used to assign the board a unique network ID number.
The network ID number 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.
Shielded? Yes
Conductor Type Twisted Pair
Gauge 18 - 24 AWG
Capacitance between
signal wires
Capacitance between
signal and shield
Nominal Impedance 12050
Table 3-1 - RS485 I/O Network Wiring Specifications
31 pF/ft or less
59 pF/ft or less
3.1.1. Daisy Chains
The RS485 Input/Output (I/O) Network con­nects all input and output communication boards together in a single open communications loop. This loop, or “daisy chain,” connects the E2, Einstein, or REFLECS to multiple input and out-
Boards of the same type should be numbered in sequence, starting with one and continuing with two, three, and so forth.
Wiring Types The I/O Network • 7
3.1.2.1. Numbering the MultiFlex CUB
The MultiFlex CUB is a unique board type on the RS485 Network by the CPC controllers. Each CUB that will be associated with an E2 or Einstein must have a unique number from 1 to 31, which is configured by setting the first five switches on dip switch bank S3.
3.1.4. Setting the Terminating Resis­tance Jumpers
All MultiFlex boards and other RS485 devices have a set of terminating resistance jumpers (one jumper for each wire lead). These jumpers are labeled JP2, JP3, and JP4 on the MultiFlex board.
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 OUT (toward the left edge of the board) position. All other devices on the daisy chain must be set to the IN (toward the center of the board) position. Figure 3-3 shows the proper terminating resis­tance jumper settings for the E2, Einstein, and for all I/O boards.
Figure 3-2 - CUB-II Baud Rate Switches
3.1.3. Setting the Baud Rate
All I/O boards have dip switches that deter­mine the baud rate at which they communicate. Currently, the baud rate dip switch in network components may be set at either 9600 or 19200 baud. Either may be used — refer to your site controller’s user manual for the baud rate recom­mendation (currently 9600 baud for REFLECS, E2, and Einstein controllers).
On all MultiFlex boards, switches 6 and 7 on S3 are used to set the baud rate. T o communicate at 9600 baud, set switch #6 UP and #7 DOWN. For 19200 baud, set switch #6 DOWN and #7 UP. Refer to Figure 3-2 for a visual look at how the switches must be set.
8 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
Figure 3-3 - I/O Network Termination Jumper Settings
4 CUB Input and Output
Setup
4.1. The Inputs
4.1.1. Connecting Sensors to the MultiFlex CUB
Wiring an input to the input points on a Mul-
tiFlex board requires three steps:
1. Connect the sensor’s signal wires to the two
terminals of an input point.
2. Set the input type dip switch that corre-
sponds to the point being connected.
3. If necessary , connect the sensor to one of the
5V or 12V power terminals.
4.1.1.1. Wiring
An input point on a MultiFlex board consists
of two terminals, as shown in Figure 4-1. One of these terminals, labeled SIG, reads the signal from the sensor, while the other, labeled 0v is where the sensor’s ground and/or cable shield wire is connected.
All Pressure Transducers, Humidity Sensors, and Re­frigeration Transducers
Pressure and refrigeration transducers and humidity sensors are to be wired with shielded, 3 conductor, at least 22 GA wire (Belden #8771 or equivalent).
Dewpoint and Light Level Sensors
These sensors are to be wired with shielded, 4 conductor at least 22 GA wire (Belden # 8729 or equivalent).
4.1.1.3. Input Type Dip Switches
Each MultiFlex input point has an input type dip switch that must be set. Input type dip switches are located in the switch banks labeled S1 and S2.
The input type dip switch tells the input board whether or not the sensor connected to the point is a resistive type sensor. Generally, if the sensor or transducer supplies its own voltage signal to the point, the dip switch should be set to the LEFT position. If the sensor uses variable resistance and requires voltage to be supplied to it from the input point, set the dip switch to the RIGHT position. Dip switches for unused points should be set to the RIGHT position.
Figure 4-1 - Input Board Points
4.1.1.2. Sensor Wiring Types
Specific wiring types are required for each
type of sensor used with E2, Einstein, or RMCC.
All Analog Temperature Sensors and Air Flow Sen­sors
Temperature and air flow sensors are to be wired with shielded, 2 conductor, at least 22 GA wire (Belden # 8761 or equivalent).
The Inputs CUB Input and Output Setup • 9
Figure 4-2 - Input Type Dip Switches for CUB Board
4.1.2. Power Connection
If power is needed to operate the sensor, four
points are provided on the MultiFlex board that supply DC power: one +12VDC point, and three +5VDC points. See Figure 4-3 for the location of these points.
Figure 4-3 - Input Board Power Sources
To connect to one of the DC power sources,
simply connect the sensor’s power wire to one of the terminals.
A sensor that requires 24VAC can be pow-
ered off the MultiFlex’s own 24VAC power con­nection. T o connect to the 24VAC power source, connect the sensor’s power wires to terminals AC1 and AC2.
4.1.2.1. Current Ratings for On-Board Power Sources
The maximum current that may be drawn from the +12VDC terminal is 100 milliamps. The maximum current that can be drawn from all three +5VDC terminals COMBINED is 50 milliamps.
4.1.2.2. Powering Sensors Requiring
24VAC Off the Power Transform­er
Some sensors that requires 24VAC can be powered off the MultiFlex’s own 24VAC power connection. To connect to the 24VAC power source, connect the sensor’s power wires to ter­minals AC1 and AC2.
This can only be done with sensors that keep the 24VAC signal isolated from its DC output signal (such as CPC’s Dewpoint Probe). If the output signal is not isolated from the 24VAC input, you must use a separate transformer.
4.1.3. MultiFlex CUB Fixed Input Lo-
cations
The MultiFlex CUB supports a large number of different types of input sources that might be found on a single condensing unit’s pressure control, condenser control, or refrigeration con­trol systems. Because input locations are speci­fied by the user in the system software, you can connect inputs from the condensing unit to any point on the CUB. However, to make setup eas­ier, the CUB has assigned default sensor loca­tions to a few of the inputs on the board.
Table 4-1 lists the inputs with assigned defaults. If you choose to not use the defaults listed, you may change any or all of them in the system software (see Section 7.3.3., Screen 3: Inputs and Section 8.2.7., Input Setup Screens).
CUB Input
Point
Number
1 Suction
2 Discharge
3 Oil Trans-
4 Case 1
16 Alarm
Label
Transducer
Transducer
ducer
Temp
Reset
Sensor to Connect
To This Point
0-100PSI Pressure Transducer, measuring suction pressure
0-500PSI Pressure Transducer, measuring discharge pressure
0-200PSI Pressure Transducer, for measur­ing oil pressure
Discharge air tempera­ture sensor for the cooler or case lineup
Digital contact closure (switch or push button) to reset alarms
10 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
Table 4-1 - CUB Default Inputs
4.2. The Outputs
The MultiFlex CUB has eight relays that
energize and de-energize to control output loads.
Decision #1 is made by setting the fail-safe
switch. This is a bank of eight switches on the
plug-in output module. Each switch corresponds
to an output on the board (switch #1 = output #1,
etc.).
When setting up an output on one of these re-
lays, you must make two important decisions:
1. Do you want an ON command from your controller to mean “energize the relay” or “de-energize the relay,” and
2. When the relay is de-energized, as is the case when the CUB goes offline or loses power, do you want the contacts to be OPEN or CLOSED?
HHT
Display
ON OFF
ON OFF
ON OFF
Contact
State
CLOSED OPEN
OPEN CLOSED
CLOSED OPEN
Equipment
State
ON OFF
OFF ON
OFF ON
Fail Safe
ON UP N.C
OFF UP N.O
OFF UP N.C.
Decision #2 is made either by setting a fail-
safe jumper (for the MultiFlex CUB) or by wir­ing the load to either the N.O. or N.C. terminals on the Form C contact (for the MultiFlex 16I8O).
T able 4-2 shows how the fail-safe s witch and
Form C contacts should be configured based on how you want the output to perform during both normal operation and during network/power loss.
Set Failsafe Switch
To:
Form C Contacts
Used:
ON OFF
ON OFF
ON OFF
Table 4-2 - Output Board Fail-Safe and Switch Settings
CLOSED OPEN
OPEN CLOSEDONOFF
CLOSED OPEN
OFF ON
ON OFF
ON DOWN N.O
OFF DOWN N.C
OFF DOWN N.O
The Outputs CUB Input and Output Setup • 11
4.2.1. Relay Output Ratings and Fuse
RELAY IS
CLOSED
ON POWE R
FAILURE
RELAY IS
OPEN ON
POWER FAILURE
Protection
Each relay output on the MultiFlex Combi­nation I/O boards is rated for up to 240 VAC with a maximum current of 2 amps.
Table 4-1 lists the inputs with assigned
defaults. If you choose to not use the defaults listed, you may change any or all of them in the system software (see Section 7.3.7., Screen 7: Outputs and Section 8.2.8., Outputs Screens).
Each relay is fused with a 2 amp fast-blow 5mm x 20mm fuse, Bussman GMA-2 or equiva­lent.
4.2.2. Wiring Outputs to Points
The MultiFlex CUB has Form C relay con­tacts. Figure 4-4 shows how to wire the three­terminal Form C contact.
One wire of the two-wire connection should always be connected to the middle terminal. The second wire must either be connected to the N.C. terminal (if you want the path to be closed when the relay is de-energized) or the N.O. terminal (if you want the path to be open during power fail­ure).
N.C. N.O. N.C. N.O.
Figure 4-4 - Form C Contact Wiring
CUB
Output
Point
Number
1 Compres-
2 Defrost Electric defrost heaters
3 Condenser
8 Alarm Out-
Table 4-3 - CUB Default Outputs
Label
sor
Fan #1
put
Device to Connect
To This Point
Compressor
or hot gas valve Condenser fan (or 1st
condenser fan if multi­ple fans are present)
Digital contact closure that is ON when an alarm condition is active in the condens­ing unit.
4.2.3. MultiFlex CUB Fixed Outputs
The MultiFlex CUB supports a large number of different types of output devices that might be found on a single condensing unit’s pressure control, condenser control, or refrigeration con­trol systems. Because output locations are speci­fied by the user in the system software, you can connect outputs from the condensing unit to any point on the CUB. However, to make setup eas­ier, the CUB has assigned default sensor loca­tions to a few of the inputs on the board.
12 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
5 Board Status LEDs
When a MultiFlex board is powered up, you
will be able to determine the operating status of
the board by observing its status LEDs. Figure
5-1 shows the location of the MultiFlex’s status
LEDs.
Figure 5-1 - MultiFlex Status LED Locations
5.1. Status LED
The Status LED blinks green once per sec­ond to show that the board is powered and oper­ational. If this light is dark, the board has likely lost power.
5.2. Tx and Rx LEDs
The Tx and Rx LEDs indicate when the Mul­tiFlex is sending or receiving messages on the RS485 Network.
The Tx LED blinks once every time the Mul­tiFlex sends a response to the E2, Einstein, or REFLECS. The Rx LED blinks once when the MultiFlex receives a message.
If the MultiFlex is connected to the network and set up to communicate with the controller, you should see these lights blinking regularly. If they do not, there may be a problem with the net­work.
5.3. Code A and Code B LEDs
All MultiFlex models except the MultiFlex 16 have two LEDs labeled Code A and Code B. These LEDs indicate failure conditions. When these LEDs are OFF, there are no failures active. When one or both of these LEDs are blinking, there are failure conditions. The rate of blinking indicates the type of failure:
Code A Failure Conditions
• Blinking fast (4 times/second) - There is a problem
with the flash memory or hardware clock on this board. This generally means the board is bad and must be replaced.
• Blinking slow (1 time/second) - The board is not re-
ceiving any messages addressed to it. This means ei-
Status LED Board Status LEDs • 13
ther the I/O Network is down or it has not yet been commissioned in the E2, Einstein, or REFLECS Network Configuration screen.
Code B Failure Conditions
• Blinking 2 times/second - The battery on this board
that backs up the CUB configuration during power failures has failed. If you see this light flashing, the battery will need to be replaced to avoid loss of con­figuration.
Also, check the position of the Enable Battery jump­er, located at the bottom right of the board just un­derneath the output plug-in board. If this jumper is set to the DOWN position, move it to the UP posi­tion. This will enable the battery and should cause the Code B light to stop flashing.
5.4. Relay Output LEDs
Each relay output point on a MultiFlex has an indicator LED that shows the status of the output. This LED is lit to show the output is ON, and unlit to show the output is OFF.
The definition of ON and OFF in this case is determined by the position of the fail-safe dip switch (see Table 4-2). Therefore, if the output’s switch is UP, a lit LED means the path is CLOSED for N.C. contacts and OPEN for N.O. contacts.
14 • MultiFlex CUB-II and CUB-TD I&O Guide 026-1705 Rev 7 06-APR-2010
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