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026-1720 Rev 4 06-APR-2010
MultiFlex ESR Installation and
Operation Manual
Page 2
Page 3
Computer Process Controls, Inc.
1640 Airport Road Suite #104
Kennesaw, GA 31044
Phone 770-425-2724
Fax 770-425-9319
ALL RIGHTS RESERVED
The information contained in this manual has been carefully checked and is believed
to be accurate. However, Computer Process Controls, Inc. assumes no responsibility
for any inaccuracies that may be contained herein. In no event will Computer Process
Controls, Inc. be liable for any direct, indirect, special, incidental, or consequential
damages resulting from any defect or omission in this manual, even if advised of the
possibility of such damages. In the interest of continued product development, 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.
FCC COMPLIANCE NOTICE
This device complies with Class B of Part 15 of the FCC Rules.
Page 4
Page 5
Table of Contents
1 INTRODUCTION.......................................................................................................................................................... 1
1.1. M
ULTIFLEX ESR AND ESR-8 BOARD DIFFERENCES ................................................................................................... 1
1.1. RS-485 I/O Network................................................................................................................................................. 1
1.1. Center-Tapped Transformer.................................................................................................................................... 1
1.1. Molex Connectors (Board P/N 810-1398)............................................................................................................... 1
1.1. Hand-Held Terminal (HHT) .................................................................................................................................... 1
1.1. Snap-Track Mounting .............................................................................................................................................. 1
1.2. M
ULTIFLEX ESR MOLEX CONNECTOR BOARD (DISCONTINUED) ............................................................................... 2
2 INSTALLATION........................................................................................................................................................... 2
2.1. P
ANEL MOUNTING AND HEAT DISSIPATION ................................................................................................................ 2
2.2. S
NAP-TRACK INSTALLATION........................................................................................................................................ 2
3 WIRING.......................................................................................................................................................................... 2
3.1. P
OWER.......................................................................................................................................................................... 2
3.2. V
ALVE WIRING............................................................................................................................................................. 3
3.2.1. Molex Connector (Discontinued) Board Wiring................................................................................................... 3
4 SETTING THE TERMINATING RESISTANCE JUMPERS ................................................................................. 4
5 SETTING THE NETWORK ADDRESS AND BAUD RATE .................................................................................. 4
6 SOFTWARE OVERVIEW........................................................................................................................................... 5
6.1. P
ROGRAMMING E2 VERSION 2.21 AND ABOVE ........................................................................................................... 6
6.2. S
TEP 1: ADD A MULTIFLEX ESR................................................................................................................................. 6
6.3. S
TEP 2: ADD A STANDARD CIRCUIT............................................................................................................................. 7
6.4. S
TEP 3: ASSOCIATE THE MULTIFLEX ESR......................................................................................................... .......... 7
6.5. S
TEP 4: SET UP THE STANDARD CIRCUIT .................................................................................................................... 8
6.6. S
TEP 5: SET UP THE MULTIFLEX ESR....................................................................................................................... 10
7 VALVE ZEROING ...................................................................................................................................................... 12
7.1. S
TEP 1......................................................................................................................................................................... 12
7.2. S
TEP 2......................................................................................................................................................................... 12
8 HAND-HELD TERMINAL........................................................................................................................................ 12
8.1. O
VERVIEW .................................................................................................................................................................. 12
8.2. S
CREENS ..................................................................................................................................................................... 13
8.2.1. Main Screen ........................................................................................................................................................ 13
8.2.2. Output Status Screens ......................................................................................................................................... 13
8.2.3. Alarm Status Screens .......................................................................................................................................... 13
8.2.4. Main Select Screen.............................................................................................................................................. 14
8.2.5. Valve Configuration Screens .............................................................................................................................. 14
8.2.6. Network Screen................................................................................................................................................... 14
VALVE SPECIFICATIONS TABLES............................................................................................................................15
E
MERSON FLOW CONTROLS STEPPER VALVES...................................................................................................................15
S
PORLAN (PARKER) STEPPER VALVES................................................................................................................................15
MultiFlex ESR I&O Manual Table of Contents • v
Page 6
1Introduction
8
3
7
24VAC CT 75 VAC Power Input
Valve Connectors (8)
I/O Network Input
Termination Jumpers
Network Address Switches
General Status LED
1
5
2
3
4
6
7
8
HHT Jack
TX and RX LEDs
9
10
Open LED (8)
Close LED (8)
9
10
1.1. MultiFlex ESR and ESR-8 Board
Differences
The MultiFlex ESR Valve Regulator board (P/N
810-3199), shown in (Figure 1-1), is an RS-485
I/O Network electronic stepper valve regulator
capable of driving up to eight stepper motor
valves, which are typically used to control temperature.
RS-485 I/O Network
The MultiFlex ESR communicates with the E2
directly over the RS-485 I/O network, unlike the
previous version of the board, which communicated with the controller over the Echelon network.
Center-Tapped Transformer
For power, a Class 2, 80VA 24VAC centertapped transformer is required for each MultiFlex ESR board. (Previous board versions did
not require a center-tapped power source.)
Molex Connectors (Board P/N 810-1398)
The discontinued MultiFlex ESR board’s valve
outputs are four-contact molex connectors
instead of the screw terminals. Valve cables having a four-contact molex connector are plugged
directly into the board. This board has been discontinued and replaced with the new MultiFlex
ESR board version (P/N 810-3199).
Hand-Held Terminal (HHT)
Figure 1-1 - MultiFlex ESR Board Layout
When controlling ECT Flow valves, the MultiFlex ESR will detect overcurrent, open wire,
stuck valve situations, and generate the appropriate alarms. For non-ECT Flow valves, the MultiFlex ESR will only detect overcurrent situations
and generate an alarm. (See Section 8.2.3.,
Alarm Status Screens for details on alarm
descriptions.)
Set configuration parameters, setpoints, and failsafe conditions of each valve with the HHT. By
using the HHT, each valve output can be set separately with a valve step rate and the total number of steps from closed to fully open.
Snap-Track Mounting
The MultiFlex ESR board fits into the standard
CPC 4" I/O board snap-track for mounting.
The MultiFlex ESR uses suction side variableposition evaporator regulators (ESRs) to vary
evaporator pressure for an entire circuit and is an
alternative to mechanical EPR control.
The MultiFlex ESR receives input data from a
CPC E2 controller (via the I/O Network) and
then regulates the stepper valves according to
the data from the E2.
1 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
Page 7
1.2. MultiFlex ESR Molex Connec-
24VAC CT 75 VAC Power Input
Valve Connectors (8)
I/O Network Input
Termination Jumpers
Network Address Switches
General Status LED
1
5
2
3
4
6
7
8
HHT Jack
TX and RX LEDs
8
3
7
9
10
Open LED (8)
Close LED (8)
9
10
3.5”
4.00”
10.00"
4.75”
TYP 2 PL
MULTIFLEX ESR BOARD
WEIGHT: 9.4 OZ.
O 0.220”
TYP 6 PL
9.5”
tor Board (Discontinued)
Figure 1-2 - MultiFlex ESR Molex Connector Board Layout Discontinued (P/N
810-3198)
2 Installation
that enclosure with the MultiFlex ESR, you may
need to ventilate the enclosure by installing air
circulation fans or other devices to aid in heat
dissipation.
2.2. Snap-Track Installation
Boards not supplied with an enclosure are 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 2-2 shows this installation procedure:
The MultiFlex ESR control board is designed to
be located in a central location, preferably near
the valves it is driving. Figure 2-1 shows the
mounting dimensions of the MultiFlex ESR
board:
Figure 2-1 - MultiFlex ESR Board Dimensions
2.1. Panel Mounting and Heat Dissipation
The MultiFlex ESR can generate a substantial
amount of heat when it draws up to a maximum
of 80 VA during operation. The MultiFlex ESR
is rated for a maximum ambient temperature of
65°C (150°F); therefore, depending on the size
of the enclosure and what other devices are in
MultiFlex ESR Molex Connector Board (Discontinued) Installation • 2
Figure 2-2 - MultiFlex ESR Snap-Track Installation
3 Wiring
3.1. Power
Each MultiFlex ESR board requires a Class 2,
80VA 24VAC center-tapped
power. The power connector (labeled J12) is
located in the top left corner of the board.
transformer for
Page 8
CPC transformer (P/N 640-0080) is a multi-
WIRING FOR 640-0080, 80VA Transformer
SECONDARY SIDE
Use 24VAC Center-Tapped Transformer
PRIMARY SIDE
240 208
C
120
(
N
E
U
T
R
A
L
)
(
H
O
T
)
120/208/240 VAC
L2
L1
Three-conductor non-shielded cables
are the recommended wire
for connecting between the
center-tapped transformer
and I/O boards.
Power Wiring Types:
14 AWG Belden 9495
18 AWG Belden 9493
24V CT 24V
AC1
GND
AC2
AC1
AC2
24VAC Center-Tapped
Earth ground the
GND (center-tapped)
terminal of each board
GND
BLU
R BLK
W
Wire Color Legend on
Each Valve Connector (8)
ECT Flow
Stepper Valve
MultiFlex ESR Board w/ Eight
Screw Terminal Connectors
(P/N 810-3199)
Stepper Valve
Harness
WHITE
BLACK
RED
BLUE
Match wire colors to
silk screen legend on
board terminals
tapped primary transformer that may be used
with the MultiFlex ESR board.
Refer to Figure 3-1 and follow the instructions
below for transformer power wiring:
1. Connect the three wires from the secondary
side of the transformer to the power connector. The AC should be run with a minimum of
18 AWG wire up to 10 feet, 16 AWG up to 20
feet, or 14 AWG up to 30 feet.
2. Connect 24VAC to AC1 and AC2.
3. Connect the center tap (CT) of the transformer to the GND center terminal of the power
connector.
4. Attach an additional 14 AWG or larger wire
from the center GND terminal to solid earth
ground. Keep the wire as short as possible, 6"
or less is preferred, and should be completed
for each board.
the cable and cable harnesses that are supplied
with the valves.
Figure 3-2 - Valve Connector Wi re Color Indicator
Figure 3-1 - Power Wiring - Center -Tapped Transformer
3.2. Valve Wiring
The stepper valves are wired to the board by
connecting the stepper valve harness to one of
the eight screw terminal connectors along the
top of the board (Figure 3-3) and matching the
wire colors to the legend on the connectors. Use
3 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
Figure 3-3 - ECT Flow Valve and New Board W iring Diagram
For Sporlan valves, match all wire colors except
the green wire. Instead, connect the green wire
to the silk screen blue wire legend (Figure 3-2).
3.2.1. Molex Connector (Discontinued)
Board Wiring
The stepper valves are wired to the board by
connecting the stepper valve molex connector to
one of the eight molex connectors along the top
of the board (Figure 3-4). Use the cable and
cable harnesses that are supplied with the valves.
NOTE: A valve cable harness may not be longer than 150 feet.
Page 9
Figure 3-4 - ECT Flow Valve and Old Board Wiring
RS485 I/O NET
NO TERMINATION
(Jumpers in the
DOWN position)
JP2 JP3
JP4
TERMINATION
(Jumpers in the
UP position)
JP2
JP3
JP4
For retrofits or stepper valve harnesses without a
mating molex connector, use the MultiFlex ESR
adapter cable (P/N 335-3275). Crimp-type
waterproof splices should be used to make the
connections.
For Sporlan valves used with these discontinued
boards, match all wire colors except the blue
wire. Instead, connect the blue wire to the Sporlan green wire.
proper terminating resistance jumper settings for
the MultiFlex ESR board.
Figure 4-1 - Daisy Chain Termination Jumper Settings
For more information about network configuration and termination, see the I/O Network wiring
section in your site controller’s user manual.
CAUTION: Always have the JP1 jumper
(located on the far right side of the board
opposite the Termination jumpers) set to the
Normal
correctly.
position, or the board will not operate
4 Setting the Terminat-
ing Resistance Jumpers
All MultiFlex ESR boards have a set of terminating resistance jumpers (one jumper for each
wire lead). These jumpers are labeled JP2, JP3,
and JP4 on the MultiFlex ESR board.
Set the termination jumpers UP (JP2, JP3, JP4)
if at either end of a daisy chain. Otherwise, set
jumpers DOWN.
The purpose of the jumpers is to indicate the two
ends, or termination points, of the segment. On a
daisy chain, one device at the beginning and one
device on the end must be terminated by placing
all three termination jumpers in the UP position.
All other devices on the daisy chain must be set
to the DOWN position. Figure 4-1 shows the
5 Setting the Network
Address and Baud Rate
Set the network address on the first five rockers
of the dip switch (labeled S1) on the MultiFlex
ESR board. Set the network baud rate using
rockers 6 and 7.
Valve Wiring Setting the Terminating Resistance Jumpers • 4
Page 10
Figure 5-1 - Network Address Settings
S1
Set the network address
using the first 5 rockers
of dip switch S1.
Valid address range 1-31.
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 1 BOARD 2 BOARD 3 BOARD 4
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 5
BOARD 6 BOARD 7 BOARD 8
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 9 BOARD 10 BOARD 11 BOARD 12
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 13 BOARD 14 BOARD 15 BOARD 16
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 17 BOARD 18 BOARD 19 BOARD 20
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 21 BOARD 22 BOARD 23
2345678
1
ON
BOARD 24
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 25 BOARD 26 BOARD 27 BOARD 28
2345678
1
ON
BOARD 29
2345678
1
ON
2345678
1
ON
BOARD 30
BOARD 31
Figure 5-2 - Baud Rate Settings
6 Software Overview
The MultiFlex ESR board is intended to interface closely with E2’s Standard Circuit application. Once a valve on the MultiFlex ESR board
has been associated with a Standard Circuit, the
Standard Circuit assumes control of the valve’s
position. The Standard Circuit must be specifically configured to control a MultiFlex ESR
5 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
valve so that the advanced capabilities provided
with the MultiFlex ESR will be enabled.
Valve Rescaling
The Standard Circuit has an enhanced control
strategy when it is configured to control a MultiFlex ESR valve. As with previous ESR control,
a PID algorithm is used to position the valve
during refrigeration mode in order to maintain
the circuit temperature setpoint. In addition, a
minimum and maximum valve percentage may
be specified. When this is used, the PID output
(0-100%) is rescaled to a control range between
the minimum and maximum valve percentage
parameters. This may be useful in situations
where the valve is slightly oversized and tends to
continuously overshoot the temperature setpoint.
Pulldown Mode
A new Standard Circuit control state named
Pulldown has been added. The Pulldown state is
optional and is, by default, disabled. When
enabled, the Standard Circuit will go into Pulldown following a defrost cycle or a case wash.
Also, if a door switch is configured and refrigeration mode is temporarily suspended due to the
door opening (such as with a walk-in box), a
Pulldown will be initiated when the door closes.
The Pulldown mode simply forces the valve to a
fixed position, as specified with the Pulldown
Percent parameter. The circuit will stay in Pulldown until the case temperature reaches the setpoint or the maximum time allowed in Pulldown
has been exceeded. The maximum time in Pulldown defaults to zero, which disables the Pulldown mode. By setting this to a valid time (up to
2 hours), Pulldown mode will be enabled.
Valve Failsafe
The Standard Circuit has additional valve failsafe capability. If a control failure occurs, such
as a loss of the control temperature sensor, the
valve will be instructed to go to a failsafe position. As with previous ESR control, the valve
may be configured to go to a fixed position, as
specified by the Temp Fail EEPR % parameter.
However, a ne w Valve Daily A verage Position is
now being calculated for MultiFlex ESR and
Page 11
ECT Flow valves. The valve may be configured
to go to this position during periods of control
failure. The Valve Daily Average Position is
determined by averaging the position of the
valve only during the refrigeration state. While
in Defrost or other circuit states, the average
position will not be updated. At midnight of each
new day, the Valve Daily Average Position is
updated to reflect the average position calculated
throughout the previous day. In addition, if a
communication failure occurs, the valve will be
instructed to go to a different failsafe position
(Comm Fail EEPR %) or for ECT Flow valves,
the Valve Daily Average Position may be used.
Lead Circuit
When a MultiFlex ESR circuit is defined as the
lead circuit in its associated Suction Group and
suction float has been enabled, the Standard Circuit will suspend normal PID control of the
valve while in the refrigeration state. Instead, the
Standard Circuit will force the valve to full open.
By doing this, the associated Suction Group will
be able to float the suction setpoint to the highest
possible value, while still maintaining the circuit
temperature setpoint.
Valve Alarms
When a Standard Circuit is associated with a
MultiFlex ESR valve, it also processes alarms
associated with that valve, including Stuck
Valve, Fault Wire, and Fault Overload. Stuck
Valve and Fault Wire are only ECT Flow valve
alarms.
3. Associate MultiFlex ESR - Assign the Multi-
Flex ESR to standard circuit(s) so the valve on
the board is associated or "mapped" to a circuit,
which will enable valve control. The association
creates auto hookup of circuit valve control and
alarm parameters between the circuit and the
MultiFlex ESR application. This association
should be completed prior to Step 4 - Standard
Circuit Setup to minimize the set up of standard
circuit(s) for MultiFlex ESR.
4. Standard Circuit Setup - A Standard Circuit
application must be set up as normal, (with all
case types, setpoints, and other parameters
defined) except
egy; the Temperature Control Strategy must be
set up as LINE UP(MFLEXESR)/DEF.
5. MultiFlex ESR Setup - Physical properties of
the valves connected to the MultiFlex ESR will
need to be specified in the MultiFlex ESR application in the E2 software.
the Temperature Control Strat-
6.2. Step 1: Add a MultiFlex ESR
A. Add Number of Boards
A MultiFlex ESR board must be added to the E2
in the same manner that an 8RO or a 16AI is
added in the network setup of the controller . This
is done from the Connected I/O screen of the E2
(Figure 6-1):
6.1. Programming E2 Version 2.21
and Above
Successful installation of a MultiFlex ESR
requires you to perform five main programming
steps in the E2 software:
1. Add MultiFlex ESR Board(s) - The E2 refriger-
ation controller must be programmed to communicate and utilize the MultiFlex ESR board(s) on
the network.
2. Add Standard Circuit(s) - The circuit must first
be added in the E2 before a circuit can be set up
and associated with the MultiFlex ESR board.
Programming E2 Version 2.21 and Above Software Overview • 6
Figure 6-1 - Connected I/O Screen
1. Press
Page 12
2. Press
3. Press the down arrow key until the MultiFlex
ESR field is highlighted.
4. Enter the number of MultiFlex ESRs connected to the E2 and press
5. Press to save changes and exit the
screen.
cally connected and can communicate. This auto
hookup of circuit valve control and alarm
parameters between the circuit and the MultiFlex ESR application minimizes the set up of
standard circuit(s) for MultiFlex ESR (Step 4).
T o access the MultiFlex ESR Association screen
from the Home screen:
6.3. Step 2: Add a Standard Circuit
Before a standard circuit can be set up and associated with the board, you must first add the circuit in the E2 from the Add Application screen.
1. Press
2. Press
3. Choose Standard Circuit from the list
(Press F4 for look-up) and use the arrow keys
to move to the How Many? field. Enter the
number of circuits you wish to add and press
1. Press
2. Press
3. Use the arrow keys to highlight the circuit
you wish to edit, and press
Figure 6-3 - Associations Screen
Figure 6-2 - Add Application Screen
6.4. Step 3: Associate the MultiFlex
ESR
Each standard circuit controls a single valve. In
this step, you must associate or "map" the valve
on the MultiFlex ESR board to a particular circuit. When a valve on the MultiFlex ESR board
is associated with a circuit, the two are automati-
7 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
The Circuit column displays all configured stan-
dard circuits in the E2. The MFlex ESR Appl
column displays a list of all MultiFlex ESR
applications in the E2 (press F4 to choose which
MultiFlex ESR board to associate with the circuit). The Valve column, selectable between 1
and 8 for the valve number, displays the valve
number the circuit is connected to.
NOTE: A valve may be associated to only one
circuit. Multiple valves cannot be assigned to a
single circuit.
Page 13
6.5. Step 4: Set Up the Standard
Circuit
The MultiFlex ESR works in conjunction with a
Standard Circuit application in E2 to control
case circuit temperature. Each Standard Circuit
application should be programmed as documented in the E2’s installation guide or the E2’s
user manual and/or online help.
To specify that the case circuit is going to be
controlled by a valve on a MultiFlex ESR board,
there are three important screens in the Standard
Circuit application that you will need to alter. To
edit a Standard Circuit application:
A. General Setup Screen
1. Press
2. Press - CIRCUITS.
3. If more than one circuit has been added, the
Circuits Summary page will open, displaying
all circuits in the E2. Use the arrow keys to
highlight the circuit you wish to edit, and
press
4. From that circuit’s Status screen, press
- SETUP.
NOTE: Use the F1 and F2 keys to scroll
between screens.
Figure 6-4 - General Setup Screen
Under the General Setup screen (C1 tab), the
Temp Ctrl Strat field tells the E2 what method
of control will be used. This field should be set
to LINE UP(MFLEXESR)/DEF to indicate a
MultiFlex ESR will control temperature.
NOTE: To see all available options, view
screens in the Full Options mode. Press
in E2 to turn Full Options mode ON.
+
B. Setpoints Setup Screen
Step 4: Set Up the Standard Circuit Software Overview • 8
Figure 6-5 - Setpoints Setup Screen
Page 14
Under the Setpoints Setup screen (C3 tab), the
TR field sets the throttling range of the MultiFlex ESR temperature control. The throttling
range is the number of degrees between a 0%
and 100% valve aperture in the Proportional
mode of PID control. In most cases, the default
value (10°F) is sufficient. If a different TR is
desired, enter it here.
C. Additional Setup Screen: MultiFlex ESR
Under the More Setup screen (C0 tab), set the
following parameters described in Table 6-1.
comm failure. When CommFailDefrost is set to
DISABLE, the advisory priority and type can be
configured: The following two advisory parameters will appear:
• AdvPrior - lets the user set the priority of
the Notice or Alarm logged if a defrost is
disabled due to a MultiFlex ESR comm failure.
• AdvTyp - lets the user select between
Notice or Alarm to be logged for the event
described above.
NOTE: There are multiple screens under the
CO: MORE tab. Use F1 and F2 to toggle
between available screens under this tab.
Figure 6-6 - More Tab: Additional MultiFlex ESR Setup Screen
Temp Fail EEPR % - Failsafe setting that is
used exclusively when the valve type (Valve
Mfg) under the MultiFlex ESR Valves Setup
screen is set to Other. The value set in this field
will be the position the valve goes to if the case
temperature sensor fails or the MultiFlex ESR
board goes offline. This failsafe setting is always
available.
CommFailDefrost - If set to ENABLE
(default), the scheduled defrost will occur if the
board is in comm failure (offline). If set to DIS-
ABLE, the circuit will disable any scheduled
defrost if the MultiFlex ESR board containing
the valve for this circuit is in comm failure (offfline). An advisory will be logged if a scheduled
defrost is disabled due to a MultiFlex ESR
Standard
Circuit Valve
Parameters
Min Valve % The minimum percentage the valve
can go to during refrigeration control. The valve will go to 0% (fully
closed) during defrost regardless of
what the minimum valve % has been
set to.
Max Valve % The maximum percentage the valve
can open during refrigeration control.
Pulldown % The percentage the valve will be
open during the pulldown period after defrost.
Max Pulldown Tm The maximum amount of time the
valve will remain in pulldown following a defrost. If exceeded, the
valve will resume PID control. Pulldown will terminate earlier than the
max pulldown time if the case temperature reaches setpoint.
Table 6-1 - MultiFlex ESR Valve Parameters - E2 More Tab
Description
9 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
Page 15
Standard
Circuit Valve
Parameters
Temp Fail EEPR % The MultiFlex ESR uses the value set
Temp Fail Use
Avg %
Comm Fail EEPR % The MultiFlex ESR uses the value set
Comm Fail Use
Avg %
CommFailDefrost If enabled (default), the scheduled
Table 6-1 - MultiFlex ESR Valve Parameters - E2 Mor e Tab
in this field if the case temperature
sensor fails. This feature is always
available.
If an ECT Flow valve has been selected, the MultiFlex ESR will have
the option to use the daily average
valve % if the case temperature sensor fails. This option is only available
when valve type is set to ECT Flow.
in this field if a communication failure with the board occurs. This feature is always available.
If an ECT Flow valve has been selected, the MultiFlex ESR will have
the option to use the Daily Average
Valve % if a communication failure
with the board occurs. This option is
only available when the valve type is
set to ECT Flow.
defrost will occur if the board is offline (comm fail). If disabled, and the
MultiFlex ESR board containing the
valve associated with this circuit is in
comm fail, the standard circuit will
skip any scheduled defrost and an advisory will be generated. Additionally, two configurable advisory
parameters will appear.
Description
ESR and press
number next to it. The MultiFlex ESR Sum-
mary screen will open.
Figure 6-7 -MultiFlex ESR Summary Scre en
4. If more than one MultiFlex ESR is listed,
choose the one you wish to edit, and press
, or simply enter the
5. From the status screen, press - SETUP.
NOTE: Use the F1 and F2 keys to scroll
between screens.
6.6. Step 5: Set Up the MultiFlex
ESR
Before setting up the MultiFlex ESR evaporator
stepper regulator, you must have completed
steps 1-4 so that the MultiFlex ESR boards are
added and configured correctly in your Standard
Circuit applications. In this step, you must specify the type of valves being used and (if necessary) the specifics of the valve such as step rate
and maximum number of steps.
To edit a MultiFlex ESR application:
1. Press
2. Press - Configured Applications.
3. Use the arrow keys to highlight MultiFlex
Step 5: Set Up the MultiFlex ESR Software Overview • 10
A. General Setup Screen
The General Setup screen is where general prop-
erties of the MultiFlex ESR application are specified. The only field on this screen you will edit
is the Name field. If you wish to assign a name
to this MultiFlex ESR application, enter it in this
field; otherwise, move to the Valves Setup
screen.
Page 16
Figure 6-8 - General Properties Screen
B. Valves Setup Screen
The Valves Setup screen (C4 tab) allows you to
specify the type of valve connected to each output on the MultiFlex ESR board:
it, define the following fields:
OvrClose% The Over Close Percentage is the
percentage of the MaxStep parameter that
the valve will attempt to close past its 0%
limit for defrost. This will ensure the valve is
fully closed when the circuit associated with
the valve goes into defrost.
For example, when a valve with an Over
Close Percentage of 5% and a Maximum
Steps value of 800 is called upon to over
close (i.e., defrost), the valve will travel to
the step that it counts as 0% and then attempt
to close 40 more steps. By doing this, any
error that may cause the valve to be slightly
open at 0% will be eliminated.
It is recommended that this value be set to
5% for all Emerson Flow Control valves. For
more information, refer to the Valve
Specifications tables at the end of this
manual.
Figure 6-9 -Valves Setup Screen
Enter specifics about the valves that are
connected to the MultiFlex ESR.
All valves on this screen are listed in eight rows
numbered one (#1) through eight (#8). The
number on each row corresponds to the similarly
numbered point on the MultiFlex ESR. For each
MultiFlex ESR point that has a valve attached to
Step Rate The Step Rate field corresponds to
the valve manufacturer’s recommended step
rate in steps-per-second. The default, 50
steps per second, is the correct step rate for
the ESR 12 and ESR 20 valves. If using
different types of valves, refer to the Valve
Specifications tables at the end of this
manual and enter the rate listed for your
valve type.
MaxStep
The MaxStep field is where you must
enter the total number of steps the valve
travels between fully closed (0%) and fully
open (100%). This is a physical property of
the valve. Refer to the Valve Specifications
tables at the end of this manual to determine
the total number of valve steps.
11 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
Page 17
Valve Mfg If you have already associated the
valve and circuit, select the valve type in the
appropriate field. Press the F4 button to
choose the type of valve used. If this field is
set to ECT Flow, the following options will
be available:
• Stuck Valve alarm - the valve is not moving
in response to commands:
Based on characteristics for this valve type,
this feature offers a high probability that if
the valve becomes stuck, a Stuck Valve
alarm will be generated.
• Open Wire alarm - at least one drive winding
of the valve is disconnected or has an open
coil (no current flow was detected).
• Over Current alarm - available if the Valve
Mfg field is either set to ECT Flow or
Other, the valve driver is reporting an over
current condition possibly caused by a
shorted driver winding.
facturer (Valve Mfg) is set to Other and the
valve harness becomes disconnected while the
MultiFlex ESR board is attempting to control,
zero the valve after the disconnect is resolved.
7.1. Step 1
To zero the valve, first configure the Step Rate
and Max Step parameters for the valve type. The
configuration can be done with either the E2
controller or CPC’s hand-held terminal (HHT).
For the parameters to be configured with the E2,
the HHT must be unplugged and disconnected
from the MultiFlex ESR board.
The Max Step parameter is the total number of
control steps for the valve from 0-100%, but the
physical valve may have a step range that is substantially larger than the Max Step parameter.
This is why the valve must be zeroed at initial
start-up.
7.2. Step 2
NOTE: All alarms attempt to auto reset continuously every 10 minutes after the alarm was
first detected.
7Valve Zeroing
During the installation process of the valves or
when a valve is replaced, the valve(s) must be
zeroed before the MultiFlex ESR board can
begin controlling.
The zeroing process closes the valve twice the
number of Max Steps and should sufficiently
"zero" ECT valves. For Sporlan and other valve
manufacturers that have a full travel much
greater than Max Steps, this process may need to
be repeated one or two more times to fully zero
the valve. Once the valve has been zeroed, the
process will not need to be repeated unless the
valve has been replaced or driven open beyond
its control range by a device other than the MultiFlex ESR board. Note that if the valve manu-
After the configuration of Step Rate and Max
Step parameters for the valve, disconnect the
power plug from the MultiFlex ESR board, then
reconnect the power plug to reapply power to the
MultiFlex ESR board. When power has been
reapplied to the board, all valves will begin to
close and the Close LED (located on the right
side under the valve connector on the MultiFlex
ESR board) will illuminate. After the valve
closes the Max Step parameter number of steps,
the valve will begin to open and the Open LED
(located on the left side under the valve connector on the MultiFlex ESR board) will illuminate.
The moment any Open LED illuminates, disconnect power from the board. Then reconnect
the power plug to reapply power to the MultiFlex ESR board.
8 Hand-Held Terminal
8.1. Overview
The hand-held terminal (HHT) connector is
located on the lower left side of the board and is
Step 1 Valve Zeroing • 12
Page 18
labeled as J2. The HHT allows each valve output
MULTIFLEX ESR
810-3198
VER:1.11F01
( PRESS )
V1:C 48% 0V:100%
V2:0 98% 0V: 5%
V3:I NA
V4:I 48%
V1: VALVE OK
V2: FAULT STUCK
V3: FAULT WIRE
V4: FAULT OVLD
to be set separately with a valve step rate and the
total number of steps from closed to fully open.
The HHT is able to indicate the position status of
each valve. The failsafe condition of each valve
can be set with the HHT.
However, once the HHT is removed, the settings
will go back to the values programmed at the E2
if online.
Valves may be manually positioned with the
HHT, which overrides control from the E2 controller . Fully closing and fully opening any valve
can be accomplished with a minimal number of
keystrokes.
points have not been configured (the MultiFlex ESR
board is using factory defaults for valve configurations).
8.2.2. Output Status Screens
The third and fourth screens will show the state
of all valves. Valves 1 - 4 are seen on one screen
and continue with 5 - 8 on the next. These
screens will allow an override to be placed on
the valve’s position.
Figure 8-2 - Output Status Screen
The HHT can be used to fully open the valve
(override to 100%) for brazing during the valve
installation process or evacuation of the system.
8.2. Screens
8.2.1. Main Screen
The HHT will display the following home or
main screen:
Figure 8-1 - Main Screen
NOTES: Press F1 at any time to return to the
Home screen. Use arrows to select fields and
scroll.
Possible internal failures or communication bus
problem messages:
• FAIL: FLASH/CLK - Either the flash executable
code has changed or the hardware clock is not functioning properly.
• FAIL: I/O NET - Unable to communicate with the
I/O Network.
• FAIL: USER CFG - The MultiFlex ESR board set-
Also shown are status indicators:
• I - Valve is idle
• O - Valve is opening
• C - Valve is closing
•A - Alarm
OV and its value will not appear unless the valve
has been overridden. Once the HHT has been
removed, all overrides will be erased.
8.2.3. Alarm Status Screens
The alarm screens provide information about
alarms that have been generated during operation of the valve.
Figure 8-3 - Alarm Status Screen
Possible alarm states:
• VALVE OK - Normal val ve operation. Valve is
ready for commands.
• FAULT STUCK - The valve is not moving or responding to commands: Based on characteristics for
this valve type, this feature offers a high probability
that if the valve becomes stuck, a Stuck Valve alarm
13 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
Page 19
will be generated.
SELECT: 1
2. NET CONFIG
1. VALVE CONFIG
VALVE:1 Other
MAX STEPS: 800
RATE: 50 OvrCls
Fail%: 100 5%
DIP Settings:
Address: 1
Baud : 9600
• FAULT WIRE - At least one drive winding is disconnected or has an open coil (no current flow was
detected).
• FAULT OVLD - The valve driver is reporting a
shorted driver winding.
8.2.4. Main Select Screen
The seventh screen (or accessed by pressing F2
on the HHT) will allow the user to select what
sub-system should be accessed. (Defaults to 1.)
For Valve, choose the type of valve being used.
Set to ECT Flow for ECT valve types or Other
for any other type of valve.
Max Steps is the total number of steps the valve
travels between fully closed (0%) and fully open
(100%).
Rate corresponds to the step rate of the valve (in
steps per second). The default, 50 steps per second, is the correct step rate for the ESR 12 and
ESR 20 valves.
OvrCls is the Over Close percentage that will be
used when setting a valve to 0% for defrost.
Figure 8-4 - Main Select/Configuration Screen
8.2.5. Valve Configuration Screens
The Option 1 screen will enable the user to view
valve configurations and to make temporary
changes to the settings. However, once the HHT
is removed, the settings will go back to the values programmed at the E2 if online. (Defaults
are Flow Control’s ESR 12 and ESR 20 valves.)
Figure 8-5 - Valve Configuration Screens
Use the up and down arrows to select the desired
valve (1-8). Use the right arrow to select the desired fields.
Fail % is the failsafe output percentage to use if
communications are lost with the E2.
8.2.6. Network Screen
The Option 2 screen will show the network settings for the MultiFlex ESR controller. There are
no editable fields on this screen. This display is a
reflection of the dip switch settings:
Figure 8-6 - DIP Switch Settings Screen
NOTE: This Network screen can also be
accessed by pressing the down arrow key once
from the Home screen.
• Valve: 1 - can be set to Other or ECT Flow
• Max Steps - can be set from 1-10000. Default is 800.
• Rate - can be set from 20-500. Default is 50.
• OvrCls - can be set from 0-20. Default is 5.
• Fail % - can be set from 0-100. Default is
100.
Screens Hand-Held Terminal • 14
Page 20
Valve Specifications Tables
Emerson Flow Controls Stepper Valves
TYPE ESR 12 ESR 20 ESVB
10-20 Ton
Voltage 12 VDC
24 VDC
12 VDC
24 VDC
12 VDC
24 VDC
ESVB (4)
1-4 Ton
12 VDC
24 VDC
ESV (4)
12 VDC
24 VDC
Control Suction Suction Liquid Liquid Liquid
Step Rate 50 50 50 50 (30 ok) 30
Max Steps 500/800
(1) 800 800 384 360 (2)
OverClose5%5%5%5%5%
Total Watts 10 10 10 3.4 12.8
Phase
(3)
Resistance
29 ohms
115 ohms
29 ohms
115 ohms
29 ohms
116 ohms
84 ohms
336 ohms
23.5 ohms
95 ohms
Hysteresis 0 0 0 0 0
Motor Bipolar Bipolar Bipolar Bipolar Unipolar
ESR, CC100
CCB
ESR, CC100
CCB
CC100
CCB
CC100
CCB
CC100
CCB
products
Notes:
(1) 500 steps for valves manufactured before year 2001. Identify using date code bef ore 0100 (e.g., 0052, 9902, 9848, or brass body size
~2" vs. ~2
(2) DO NOT exceed max steps of 384 for this valve.
(3) Shown for 12V and 24V motors, +/- 10% at 75°F.
(4) For ESV replacement with ESVB: 1. Swap the Flow Control colors RED and BLUE. 2. Cap off the YELLOW wire.
1/4" for 800 steps.
Sporlan (Parker) Stepper Valves
TYPE CDS-8 CDS-16
CDS-17
Voltage 12 VDC 12 VDC 12 VDC 12 VDC
Control Suction Suction Suction Suction
Step Rate 200 200 200 200
Max Steps 3064 6386 1596 3193/6386
OverClose 5% 10% 10% 10%
Total Watts 10 4 5.7 4
Phase (3)
75 ohms 75 ohms 72 ohms 75 ohms
Resistance
Hysteresis 0 0 0 0
Motor Bipolar Bipolar Bipolar Bipolar
ESR, CC100
CCB
ESR, CC100
CCB
products
15 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
SEI/EEV CDS-9
CC100
CCB
ESR, CC100
CCB
Page 21
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