Orion Dual Electronic Expansion Valve Module User Manual
Factory Packaged Controls
Coil Products
OE377-26-00057
(AAON Part #30916)
Dual Electronic Expansion
Valve Module Technical Guide
Table of Contents
GENERAL INFORMATION ................................................................................................................................. 3
Overview ......................................................................................................................................................................................3
Features .......................................................................................................................................................................................4
Adjustable Setpoints.....................................................................................................................................................................4
Confi gurations ..............................................................................................................................................................................4
UNIT START-UP PROCEDURES ........................................................................................................................ 5
DIMENSIONS AND MOUNTING ........................................................................................................................ 6
INSTALLATION & WIRING ................................................................................................................................7
INPUTS/OUTPUTS ............................................................................................................................................ 8
I/O Map.........................................................................................................................................................................................8
Stand Alone Input Commands......................................................................................................................................................8
SEQUENCE OF OPERATION ............................................................................................................................. 9
Initialization...................................................................................................................................................................................9
Normal Operation .........................................................................................................................................................................9
Modulation Routine ......................................................................................................................................................................9
DIAGNOSTICS ................................................................................................................................................ 10
Alarms ........................................................................................................................................................................................10
LED Descriptions........................................................................................................................................................................10
LED SCREENS ................................................................................................................................................ 12
Navigation and Main Screens Map ............................................................................................................................................12
Protected Screens Map and Main Menu Screens ......................................................................................................................13
Status V-A/B and V-A/B Alarm Screens .....................................................................................................................................14
Force Valves Screens ................................................................................................................................................................15
Setpoint Screens ........................................................................................................................................................................16
Confi guration Screens ................................................................................................................................................................17
Diagnostic Screens ....................................................................................................................................................................18
TROUBLESHOOTING ...................................................................................................................................... 19
OE275-01 Suction Pressure Transducer Testing for R410A Refrigerant ........................................................................................ 20
Coil Temperature Sensor T esting ...............................................................................................................................................21
www.aaon.com
WattMaster Controls Inc.
8500 NW River Park Drive · Parkville, MO 64152
Toll Free Phone: 866-918-1100
PH: (816) 505-1100 · FAX: (816) 505-1101 · E-mail: mail@wattmaster.com
Visit our web site at www.orioncontrols.com
WattMaster Form : AA-EXV-TGD-01A
Copyright January 2012 WattMaster Controls, Inc.
®
is a registered trademark of AAON, Inc., Tulsa, OK.
AAON
Neither WattMaster Controls, Inc. nor AAON
responsibility for errors or omissions in this document.
This document is subject to change without notice.
®
assumes any
Dual Electronic Expansion Valve Module
Overview
The OE377-26-00057 Dual Electronic Expansion V alve (EXV) Module
(AAON Part #30916) provides control of two electronic expansion
valves to maintain the superheat in the cooling circuits of the HVAC
unit. The module is designed only for R410-A refrigerant.
The EXV Module is used in stand-alone applications only.
General Information
YS102468 REV 3
R41
TB2
TB2
TB3
TB3
TB4
TB4
R41
+5V
+5V
SIG A
SIG A
GND
GND
+5V
+5V
SIG B
SIG B
GND
GND
COILTEMPA
COILTEMPA
COILTEMP B
COILTEMP B
GND
GND
GND
GND
VALVEA
VALVEA
D1
D1
VALVEB
VALVEB
D3
D3
D5
D5
D6
D6
D7
D7
D8
D8
GND
GND
J1
J1
YS102468 REV 3
WATTMASTER CONTROLS
WATTMASTER CONTROLS
MADE IN USA
MADE IN USA
TB1
TB1
RLYA
RLYA
RLYB
RLYB
COMMON
COMMON
STATUS
STATUS
ALARM
ALARM
COMM
COMM
POWER
POWER
VALVEADRIVE
VALVEADRIVE
BLACK
BLACK
WHITE
WHITE
RED
RED
GREEN
GREEN
DRIVING
DRIVING
VALVE B DRIVE
VALVE B DRIVE
BLACK
BLACK
WHITE
WHITE
RED
RED
C214
C214
.1uF
.1uF
GREEN
GREEN
DRIVING
DRIVING
SERIAL #
SERIAL #
C31
C31
.1uF
.1uF
TB7
TB7
TB6
TB6
Figure 1: OE377-26-00057 Dual Electronic Expansion Valve Module
Technical Guide
3
Dual Electronic Expansion Valve Module
Features and Applications
Features
The Dual Electronic Expansion Valve Module provides the following:
• Contains a 2x8 LCD character display and 4 buttons
that allow for status display, setpoint changes, and
confi guration changes.
• Can control two electronic expansion valves independently.
• Monitors suction pressure and coil temperature and
modulates electronic expansion valves to maintain
superheat.
• Provides active relays to monitor valve alarms.
NOTE: The Dual Electronic Expansion Valve Module contains
no user-serviceable parts. Contact qualifi ed technical per-
sonnel if your Dual Electronic Expansion Valve Module
is not operating correctly.
Adjustable Setpoints
The following describes some of the setpoints available for adjustment
using the LCD display on the Dual Electronic Expansion V alve Module:
• Superheat Setpoint - One setpoint is used for
both valves.
• Modulation Rate - This setpoint (in seconds) will
adjust how often the modulation routine will make a
valve adjustment.
• Proportional Window - This setpoint (in degrees)
will adjust how much of an adjustment will be made
according to how far away it is from setpoint.
Confi guration Settings
• Board Address – Can be addressed from 1 to 4.
Used as stand-alone, the default address is 1.
• Valve B Enable – When using the module for only
one valve, valve B can be disabled so false information
is not displayed such as alarms and sensor readings.
• Valve Steps – Confi gurable for what valve is being
used (1596, 2500, 3193, 6386)
• Max Valve Position – The maximum position each
valve will modulate (%).
• Min Valve Position – The minimum position each
valve will modulate (%).
• Suction Pressure A Calibration Offset –
Adjustable between -10 and 10 PSI.
• Suction Pressure B Calibration Offset –
Adjustable between -10 and 10 PSI.
4
Technical Guide
Dual Electronic Expansion Valve Module
AAON® Unit Start-Up Procedures
AAON® Unit Start-Up Procedures
NOTE: The following instructions were provided by AAON to set
up the unit. If you have any questions about this start-up
procedure, please contact AAON Technical Support.
Refrigeration Charging Sequence:
1. Determine valve size utilized on equipment part number from the
physical valve. There are currently 4 models used:
• SER-C (5-Ton Maximum Nominal Capacity)
• SER-D (13-Ton Maximum Nominal Capacity)
• SER-G (26-Ton Maximum Nominal Capacity)
• SER-J (48-Ton Maximum Nominal Capacity)
2. Determine circuit capacity and divide by valve Maximum
Nominal Capacity to determine average full refrigerant mass fl ow
Example: CC-B-045 Condensing unit; (2) 22.5 Ton Circuits,
Evaporator contains (2) SER-G EEV (Electronic Expansion Valve)
22.5/26 = 0.865 = 86.5%, Rounded to 87%
Fine-Tuning the EEV Module’s Setpoints for Best
Reaction Time and Effi ciency:
1. Ballpark the modulation rate based on line set length using the
following table as a guide:
Line Set Length Modulation Rate
15 15
30 20
45 30
60 35
75 40
90 45
120 50
Table 1: Modulation Rate Table
2. Ensure the outside air temperature, return air temperature, and
control setpoints do not change during calibration and fi ne-tuning
procedures.
NOTE: Consult with System Specifi cation and Unit Rating, as
lower or higher evaporator temperatures and other factors
play a role in the actual capacity the compressors may
deliver.
3. Ensure system is charged to a reasonable point to enable
compressor start and ensure that all other procedures dictated for
installation and startup have been followed from the unit IOM.
4. Set the EEV Module’s Valve to manual override position of 87%.
5. Ensure the space is fully loaded at design conditions to allow for
maximum capacity operation and lock the compressor to fullyloaded capacity.
6. Energize the compressor and ensure a solid column of liquid to the
EEV via verifi cation at the sight glass.
7. From the point of a full sight glass, follow standard charging
procedures to maximize effi ciency via sub cooling, and delta T at
the evaporator.
8. Disable the manual override position on the EEV Module and
allow automatic operation at the desired set point.
3. Power off the EEV Module completely to ensure the smart-start
routine does not skew the initial position of future tests.
4. Power on the EEV Module and initialize the unit to enable
compressor operation.
5. Monitor superheat on the EEV Module and mark the time system
started until superheat is maintained at a steady state within an
acceptable dead band for more than 60 seconds.
6. Note the time from startup to stable superheat as well as the
current modulation rate set point (this process should not take longer than 20 minutes. If it does, then check unit charge or unstable
operating conditions).
7. Adjust the modulation rate set point by 2-3 seconds in either
direction and repeat test from Step 4.
8. Compare and adjust change until the best modulation rate is
obtained for the fi nal setting.
9. Verify superheat operation and consistent solid column of liquid at
the sight glass. This may take up to 15 minutes.
10. Repeat instruction for Valve 2 starting with Step 3.
Technical Guide
5
Dual Electronic Expansion Valve Module
Dimensions and Mounting
Environmental Requirements
The Dual Electronic Expansion Valve Module needs to be installed in
an environment that can maintain a temperature range between -30°F
and 150°F and not exceed 90% RH levels (non-condensing).
Mounting
The Dual Electronic Expansion Valve Module is housed in a plastic
enclosure. It is designed to be mounted by using the 3 mounting holes
in the enclosure base. It is important to mount the module in a location
that is free from extreme high or low temperatures, moisture, dust, and
dirt. Be careful not to damage the electronic components when mounting the module.
See Figure 2 for Module dimensions (in inches).
0.18 DIA. TYP.
R41
R41
TB2
TB2
+5V
+5V
SIG A
SIG A
D5
D5
GND
GND
D6
D6
+5V
+5V
D7
D7
SIG B
SIG B
GND
GND
D8
COILTEMPA
COILTEMPA
COILTEMPB
COILTEMPB
GND
GND
GND
GND
VALVEA
VALVEA
D1
D1
VALVEB
VALVEB
D3
D3
D8
GND
GND
J1
J1
5.64
5.04
TB3
TB3
TB4
TB4
It is important to keep the module in a location that is free from extreme
high or low temperatures, moisture, dust, and dirt. Be careful not to
damage the electronic components.
Power Supply
The Dual Electronic Expansion V alve Module requires a 24 VAC power
connection with a minimum power rating of 1 VA.
WARNING: Observe polarity! All boards must be wired
GND-to-GND and 24 VAC-to-VAC. Failure to
observe polarity could result in damage to the
boards.
5.71
0.29
YS102468 REV 3
YS102468 REV 3
WATTMASTER CONTROLS
WATTMASTER CONTROLS
MADE IN USA
MADE IN USA
TB1
TB1
RLYA
RLYA
RLYB
RLYB
COMMON
COMMON
STATUS
STATUS
ALARM
ALARM
COMM
COMM
POWER
POWER
VALVEA DRIVE
VALVEA DRIVE
BLACK
BLACK
WHITE
WHITE
RED
RED
GREEN
GREEN
DRIVING
DRIVING
VALVE B DRIVE
VALVE B DRIVE
BLACK
BLACK
WHITE
WHITE
RED
RED
C214
C214
.1uF
.1uF
GREEN
GREEN
DRIVING
DRIVING
TB7
TB7
TB6
TB6
2.07
0.55
Note: Height is 1.49 inches.
4.14
Figure 2: OE377-26-00057 Dual Electronic Expansion Valve Module Dimensions
6
SERIAL #
SERIAL #
C31
C31
.1uF
.1uF
Technical Guide
Dual Electronic Expansion Valve Module
Installation & Wiring
Important Wiring Considerations
Please read carefully and apply the following information when wiring
the
Dual Electronic Expansion Valve Module Controller:
1. The Dual Electronic Expansion Valve Module requires a 24
VAC power connection with an appropriate VA rating.
2. Each Pressure Transducer must have its own 18-gauge
shielded twisted pair cable. The Drain Wire must be the “Gnd”
signal for the transducer.
3. All 24 VAC wiring must be connected so that all ground wires
remain common. Failure to follow this procedure can result in
damage to the module and connected devices.
COIL A - SUCTION
PRESSURE TRANSDUCER
COIL B - SUCTION
PRESSURE TRANSDUCER
COIL TEMP A
SENSOR
COIL TEMP B
SENSOR
RD
WH
BK
RD
WH
BK
Expansion Valve A
Expansion Valve B
GND
OE377-26-00057
Dual Electronic Expansion Valve
Module
R41
R41
TB2
TB2
+5V
+5V
SIGA
SIGA
D5
D5
GND
GND
D6
D6
+5V
+5V
D7
D7
SIG B
SIG B
GND
GND
D8
D8
TB3
TB3
COILTEMPA
COILTEMPA
COILTEMPB
COILTEMPB
GND
GND
GND
GND
GND
GND
VALVEA
VALVEA
D1
D1
VALVEB
VALVEB
D3
D3
TB4
TB4
J1
J1
4. All wiring is to be in accordance with local and
national electrical codes and specifi cations.
5. Check all wiring leads at the terminal block for tightness.
Be sure that wire strands do not stick out and touch adjacent
terminals. Confi rm that all transducers required for your
system are mounted in the appropriate location and wired into
the correct terminals.
WARNING: Observe polarity! All boards must be wired
GND-to-GND and 24 VAC-to-VAC. Failure to
observe polarity could result in damage to the
boards.
NOTE: NORMALLY
ALL RELAY OUTPUTS ARE
OPEN AND RATED FOR 24 VAC POWER ONLY
- 1 AMP MAXIMUM LOAD
YS102468 REV 3
YS102468 REV 3
WATTMASTER CONTROLS
WATTMASTER CONTROLS
MADE IN USA
MADE IN USA
TB1
RLYA
RLYA
RLYB
RLYB
COMMON
COMMON
VALVEA DRIVE
VALVEA DRIVE
BLACK
BLACK
WHITE
WHITE
RED
RED
GREEN
GREEN
DRIVING
DRIVING
VALVE B DRIVE
VALVE B DRIVE
BLACK
BLACK
WHITE
WHITE
RED
RED
C214
C214
.1uF
.1uF
GREEN
GREEN
DRIVING
DRIVING
SERIAL #
SERIAL #
STATUS
STATUS
ALARM
ALARM
COMM
COMM
POWER
POWER
TB1
RLYA
RLYB
COMM
VALVE A ALARM ENABLE
VALVE B ALARM ENABLE
HVAC UNIT CONNECTIONS
BK
WH
RD
GRN
TB7
TB7
TB6
TB6
EXPANSION VALVE A
BK
WH
RD
GRN
EXPANSION VALVE B
C31
C31
.1uF
.1uF
24 VAC
R
Figure 3: OE377-26-00057 Dual Electrical Expansion Valve Module Wiring Diagram
Technical Guide
7
Dual Electronic Expansion Valve Module
Inputs and Outputs
I/O Map
The following inputs and outputs are available on the Dual Electronic
Expansion Valve Module. See Table 2 below to reference the Input/
Output Map.
Binary Inputs
1 V alve A Enable
2 Valve B Enable
Binary Outputs
1 V alve A Alarm Relay
2 Valve B Alarm Relay
Analog Inputs
1 Coil A T emperature
2 Coil A Suction Pressure
3 Coil B Temperature
4 Coil B Suction Pressure
Stepper Motor Outputs
1 Expansion Valve A
2 Expansion Valve B
Stand-Alone Input Commands
Valve A Enable On/Off
A 24 volt signal to Binary Input #1 initiates the Valve A Enable
function. Once Valve A is enabled, it tries to maintain the desired
Superheat Setpoint. Valve A maintains the Superheat Setpoint until it loses the enable signal which then puts Valve A in Off mode.
Valve B Enable On/Off
A 24 volt signal to Binary Input #2 initiates the Valve B Enable
function. Once Valve B is enabled, it tries to maintain the desired
Superheat Setpoint. Valve B maintains the Superheat Setpoint until it loses the enable signal which then puts Valve B in Off mode.
Table 2: Dual Electronic Expansion Valve Module
Inputs & Outputs
8
Technical Guide
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