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2 • High Pressure CO2 Controller Installation and Operation Manual

026-1731 Rev 0 01-DEC-2014

1.2

Independent System
Control

The High Pressure CO2 controller can control the

HPV and BGV in a refrigeration Booster Transcritical

CO2 System. However, the High Pressure CO2 con-

troller is designed to interface with an E2. Network-

ing the High Pressure CO2 controller to a central

controller also allows you to view status on E2 and

UltraSite32 Site Manager status screens, report

alarms, and log point values.

The High Pressure CO2 controller configuration

can be programmed through the E2 front panel.

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Summary of Contents for 818-9010

Page 1: ...026 1731 Rev 0 01 DEC 2014 High Pressure CO2 Controller Installation and Operation Manual ...

Page 2: ......

Page 3: ...Emerson Climate Technologies Retail Solutions 1065 Big Shanty Road NW Suite 100 Kennesaw GA 30144 Phone 770 425 2724 Fax 770 425 9319 ...

Page 4: ......

Page 5: ...s 11 3 THE MODBUS NETWORK 12 3 1 WIRING TYPES 12 3 1 1 Daisy Chains 12 3 1 2 Network Addressing Visograph 14 3 1 2 1 Connecting the Visograph 14 3 1 2 2 Visograph Navigation 15 3 1 2 3 Setting the MODBUS Address 15 3 1 2 4 Versions 16 3 2 MODBUS TERMINATION 16 4 INPUTS AND OUTPUTS SETUP 17 4 1 INPUTS SETUP 17 4 1 1 Wiring Analog and Digital Inputs 17 4 2 OUTPUTS SETUP 20 4 2 1 Wiring Relay and Ana...

Page 6: ...al Configuration Screens 34 10 2 3 Valve Configuration Screens 34 10 2 4 I O Configuration Screens 35 10 2 5 XEV20D Configuration Screens 37 10 3 OVERRIDE SCREEN 37 11 HIGH PRESSURE CO2 CONTROLLER RANGES AND DEFAULT SETPOINT PARAMETERS 39 12 XEV20D SETUP AND NETWORK CONNECTION 41 13 STEPPER VALVE ACTUATOR QUICK REFERENCE GUIDE XEV20D 42 13 1 GENERAL WARNINGS 42 13 2 GENERAL DESCRIPTION 43 13 3 ABS...

Page 7: ...2 Controller I O Points The board has 6 analog inputs and 11 digital in puts with default configurations pre loaded for quick connection to for gas cooler pressure outlet gas cool er temperature flash gas receiver pressure and enable digital input Its 8 relay outputs rated 2 0 amps max are used for activating and deactivating alarms Its 4 analog outputs may be used for a 0 10 volt signal for exter...

Page 8: ...geration Booster Transcritical CO2 System However the High Pressure CO2 con troller is designed to interface with an E2 Network ing the High Pressure CO2 controller to a central controller also allows you to view status on E2 and UltraSite32 Site Manager status screens report alarms and log point values The High Pressure CO2 controller configuration can be programmed through the E2 front panel ...

Page 9: ...Common 24VAC DC digital inputs DI1 DI11 Common Connector for remote terminal VISOGRAPH maximum 1 terminal per controller RS485 Slave connector Serial port connector LAN or RS485 USB port for downloads BIOS ISaGRAF application maps of parameters remote display applications network configuration and Web site and uploads log files Connection with the computer via a USB ETH converter Table 2 1 Connect...

Page 10: ...itional power 12VDC 6 5V Additional power 5VDC 7 Out1 Analog output 1 0 10V 4 20mA Relay 8 Out2 Analog output 2 0 10V 4 20mA Relay 9 Supply Reference power supply 24VAC or 24VDC 10 Pb4 Configurable analog input 4 NTC PTC 0 20mA 4 20mA 0 10V 0 1V 0 5V DI 11 Pb5 Configurable analog input 5 NTC PTC 0 20mA 4 20mA 0 10V 0 1V 0 5V DI 12 Pb6 Configurable analog input 6 NTC PTC 0 20mA 4 20mA 0 10V 0 1V 0 ...

Page 11: ...mmon relays 1 2 3 and 4 42 RL1 Relay 1 normally open contact 43 RL2 Relay 2 normally open contact 44 RL3 Relay 3 normally open contact 45 RL4 Relay 4 normally open contact 46 RL5 Relay 5 normally open contact 47 C Common relays 5 6 7 and 8 48 C Common relays 5 6 7 and 8 49 RL6 Relay 6 normally open contact 50 RL7 Relay 7 normally open contact 51 RL8 Relay 8 normally open contact 60 Remote Display ...

Page 12: ... are powered with a voltage that differs from that supplied by the device 12V or 5V must be pow ered separately with another transformer do not use the same secondary of the controller s power in or der to prevent the inputs from malfunctioning or be ing damaged 2 3 2 Digital Inputs Table 2 4 Digital Inputs Type configurable via software parameter Opto insulated live contact 24VAC DC External powe...

Page 13: ...nalog outputs must be pow ered separately with another transformer do not use the same secondary of the controller s power in order to prevent the outputs from malfunc tioning or being damaged 2 3 4 Digital Outputs Table 2 6 Digital Outputs Type Relays with NO contacts Number of Outputs 8 Type of analog output configurable via software parameter Relays with normally open contact Maximum load 5A 25...

Page 14: ...8 High Pressure CO2 Controller Installation and Operation Manual 026 1731 Rev 0 01 DEC 2014 2 3 5 Dimensions Figure 2 2 Dimensions ...

Page 15: ... 9 2 3 6 Wiring Diagrams Figure 2 3 Wiring Diagrams NOTE To ensure control in case of a power failure it is recommended that a UPS be used on the High Pressure CO2 controller ...

Page 16: ... 9 USB Ethernet Adapter The IPS range of programmable controllers can be connected to a computer via an external adapter This adapter must be used in the processing environment for the application download in the controller This adapter is not set up for fixed or continuous connec tion If the adapter should be kept connected continu ously the room temperature must not exceed 50 C 122 F Figure 2 4 ...

Page 17: ...elden 9495 18 AWG Belden 9495 The wire length from the transformer determines the type wire gauge used In most cases the distance between the High Pressure CO2 controller and the transformer that supplies power to it is not enough to be of concern however it is very important NOT to exceed this maximum wire length or the controller will not operate correctly Use these formulas to determine if the ...

Page 18: ...lded twisted pair cables for use as MODBUS wiring or Belden 82761 and Belden 88761 for plenum installations If the recommended cable is not available in your area be sure the wiring meets or exceeds the following specs Shielded Yes Conductor Type Twisted Pair Gauge 18 24 AWG Capacitance between signal wires 31 pF ft or less 9 45 m or less Capacitance between signal and shield 59 pF ft or less 17 9...

Page 19: ...Figure 3 1 MODBUS Networking 13 ...

Page 20: ...ind it and communicate with it easily The network address of the High Pressure CO2 controller is set using add on devices called visographs P N 818 9002 3 1 2 1 Connecting the Visograph The visograph is connected with a 3 wire connection on pins 60 61 and 62 Figure 3 2 Network ID Settings CAUTION The High Pressure CO2 controller may be damaged if the wires are crossed when connecting the visograph...

Page 21: ...nfiguration menu from the main menu The configuration menu is password protected Figure 3 4 Main Menu From main menu press the T1 T3 T8 buttons together and hold until you see the Configuration screen Figure 3 5 Configuration Screen Highlight General Config and press the ENTER key T3 Figure 3 6 General Config Screen Press T8 to arrow over to the next screen Figure 3 7 General Config Screen Using t...

Page 22: ...hanged the High Pressure CO2 controller needs to be rebooted 3 1 2 4 Versions The High Pressure CO2 controller and Visograph ver sions are also shown on the Controller Info screen To see the High Pressure CO2 controller version please see the Visograph Section of the Status screen 3 2 MODBUS Termination If the High Pressure CO2 controller is located at the physical end of the MODBUS network instal...

Page 23: ...tpoint Shift Digital Input HTR Yes Yes 24VAC DC DI2 Enable Application Emergency Shutdown Digital Input Enable Yes Yes 24VAC DC DI3 Control Temp Selector Digital Input CTS Yes Yes 24VAC DC The application can use a local or E2 network value if online but the local value will have priority over the network value However if any sensor is in failure mode its corresponding network value will be used I...

Page 24: ...r the sen sors 18 High Pressure CO2 Controller Installation and Operation Manual 026 1731 Rev 0 01 DEC 2014 Terminal Number on Connector Name 1 24VAC Supply 2 Probe Input 1 default set as T1 Outlet Gas Cooler Temp 3 Probe Input 2 default set as P1 Outlet Gas Cooler Pressure 4 Probe Input 3 default set as P2 Flash Tank Receiver Pressure 5 12VDC 6 5VDC 7 Analog Output 1 default set as HPV Stepper Va...

Page 25: ...ed Figure 4 2 Digital Inputs Connectors 12 Probe Input 6 13 Temperature Common 14 Transducer Analog Output Common 15 Analog Output 3 16 Analog Output 4 Terminal Number on Connector Name 20 Digital Input 1 default set as HTR Relcaim Setpoint Shift 21 Digital Input 2 default set as ENABLE SHUTDOWN 22 Digital Input 3 default set as CTS Control Temp Selector 23 Digital Input 4 24 Digital Input 5 25 Di...

Page 26: ...utput in the application It will also have connectivity to an XEV20 Dual Valve which will drive two steppers valves using it for a high pressure valve and bypass gas valve The default configuration is Table 4 5 Analog Outputs Anlg Out Description Local Network LAN Out1 Stepper Valve 1 Yes Yes Yes Out2 Stepper Valve 2 Yes Yes Yes The relay outputs analog outputs and the XEV20 setup or assignment wi...

Page 27: ... 4 3 Relay Output Connectors The analog outputs are located on the same connector terminal as the controller power supply Pay attention to the analog outputs commons as they are shared on terminal 14 Voltage Common Figure 4 4 Analog Output Connectors ...

Page 28: ...the board is powered and operational If this light is dark the board has likely lost power 5 2 LED1 Network Status The amber colored LED1 indicates whether the High Pressure CO2 controller is online or offline with the E2 When the High Pressure CO2 controller is online the LED1 will turn on for one second and off for one second However if the High Pressure CO2 controller is offline the LED1 will t...

Page 29: ...res sure and temperature control values being read from the gas cooler outlet to calculate subcool In transcrit ical mode the HPV starts modulating to maintain a setpoint defined by an equation to achieve a virtual subcooling using only the pressure input as a control point 6 1 1 HPV Subcritical Mode Normal In Subcritical mode when the control temperature T1 or T2 is determined by digital input CT...

Page 30: ...ster Transcritical system when the tempera ture exceeds a certain value there is no longer an accurate temperature to pressure relation Because of this the con trol temperature of T1 or T2 defined by digital CTS will be the deciding factor of when the application will switches modes from subcritical to transcritical If the con trol temperature is above the HPV Mode setpoint the application will be...

Page 31: ...nds to modulate too fast during the transition By increasing the Trans_Time parameter this will slow the transitions and allow less modulation The same function will happen when transi tioning from Transcritical mode to Subcritical mode as well The Transcritical inputs outputs setpoint and PID parameters are listed below Table 6 4 Transcritical Inputs Inputs Description Type Temperature 1 T1 Activ...

Page 32: ...n the PID settings for Subcritical and Transcriti cal PID control Table 6 6 Analog Outputs Outputs Description Type Valve Output Valve Percentage Output 0 10VDC Only or LAN to XEV20D 6 1 3 HPV Heat Reclaim The local Reclaim Setpoint Shift HTR or network HTR digital input determines if the application is in Heat Reclaim The priority of the input source will be determined as described in Section 4 1...

Page 33: ...hed to Temperature 2 T2 as Con trol temperature Table 6 9 Analog Outputs Inputs Description Type Control Temp Selector CTS Enables T2 as Active Gas Cooler Temperature if Present 24 VAC DC CAUTION A separate 24V power supply must be used Do not use the same power supply that is used to power the controller 6 2 Bypass Gas Valve Control The bypass gas valve BGV only operates in one nor mal control mo...

Page 34: ...4 BAR 20 PSI BGV PB P Subcool Setpoint in Subcritical Mode 2 75 BAR 40 PSI BGV INC I Subcritical proportional band offset 100 Sec BGV DDER D Subcritical proportional band 0 Sec Table 6 12 BGV Output Outputs Description Type Valve Output Valve Percentage Output 0 10VDC Only or LAN to XEV20D 28 High Pressure CO2 Controller Installation and Operation Manual 026 1731 Rev 0 01 DEC 2014 ...

Page 35: ...on during emergency shutdown 7 1 Low Pressure Operation The application determines Low Pressure mode if the receiver pressure is below the Low Pressure setpoint In Low Pressure mode the application will open the HPV to a minimum user defined percentage set by the HPV Fail Lo parameter and close the BGV 7 1 1 Normal Operation Once the receiver pressure rises above the Low Pres sure valve setpoint p...

Page 36: ...ve to HPV Open Fail SC If CTS is true in transcritical mode and T2 fails switch to the failsafe using close rate to ad just valve to HPV Open Fail TC Table 7 2 Condensing and Control Temperature Chart Control Temp T Condensing Control Temp T Condensing C C C C 3 5 9 17 2 6 10 18 1 7 11 19 0 8 12 20 1 9 13 21 2 10 14 22 3 11 15 23 4 12 16 24 5 13 17 25 6 14 18 26 7 15 19 27 8 16 20 28 If a failure ...

Page 37: ... to monitor and wait for when the PID sets the valve percentage equal to or exceed the Cal Min Valve before initiating calibration mode to minimized system disruption 4 Cal Min Valve is the value for when the valve percentage has to equal to or exceed before executing cali bration mode IF Cal T Frame value is greater than 0 5 Direct is the direction the calibration mode will be initialize the valv...

Page 38: ...ay designated as the General Alarm For the Shutdown alarm this is true active if the enable input is not high from either the physical digital input and or E2 network if online with E2 Table 9 1 Alarm Designations Alarm Local Network Low Pressure Yes Yes High Pressure Yes Yes Sensor 1 Bad Yes Yes Sensor 2 Bad Yes Yes Sensor 3 Bad Yes Yes Sensor 4 Bad Yes Yes Sensor 5 Bad Yes Yes Sensor 6 Bad Yes Y...

Page 39: ...with their corresponding control values and parameters This includes the HPV dual and failure alarm operation modes The status screen also provides values to show valve modulation In addition the application version is available on the first status screen 10 1 1 Main Menu and Status Screens Bootup Screen Figure 10 1 Bootup Screen Main Menu Screen Figure 10 2 Main Menu Screen Highlight Status to en...

Page 40: ...and general configuration Under general configuration it will have a menu with the MODBUS address baud rate screens update time and date Sensor type Emerson Retail Solutions or Dixell engineering units pressure transducer settings shutdown delay and the factory default reset Note Before connect ing the High Pressure CO2 controller to E2 please make these preference changes since it will not be ava...

Page 41: ...ng press the T3 button or T5 button to change value and press T4 SET again to submit the change To see additional parameters in the General Config screen press the T8 button right arrow General Configuration Additional Screen Figure 10 11 General Config Additional Screen Press the T5 button down arrow to highlight the parameter you wish to change Press T4 SET to edit the value Once the parameter i...

Page 42: ...al Screen Figure 10 14 Valve Config Additional Screen Valve Configuration Additional Screen Figure 10 15 Valve Config Additional Screen Figure 10 16 Valve Config Additional Screen Figure 10 17 Valve Config Additional Screen Figure 10 18 Valve Config Additional Screen 10 2 4 I O Configuration Screens From the Configuration Screens the user will have the ability to configure the input and output def...

Page 43: ...bmit change To see additional parameters in the IO Config screen press the T8 button right arrow Once in the additional Valve Config screen you can press the T3 button left arrow to go back a screen or press the T1 but ton EXIT to exit back to the main Configuration screen IO Configuration Additional Screen Figure 10 20 IO Config Additional Screen Figure 10 21 IO Config Additional Screen Figure 10...

Page 44: ...utton down arrow to high the parame ter you wish to change Press T4 SET to edit the value Once the parameter is flashing press the T3 button or T5 button to change value and press T4 SET again to submit change To see additional parameters in the IO Config screen press the T8 button right arrow Once in the addi tional Valve Config screen you can press the T3 button left arrow to go back a screen or...

Page 45: ...Figure 10 29 Override Screen 39 ...

Page 46: ... Shift High Pressure Valve Transcritical 0 0 to 30 DBAR HPV RS Press Transcritical band offset 0 0 to 500 BAR HPV PB Press Transcritical proportional band 12 0 to 500 BAR HPV INC Integral sampling time 140 0 to 1000 Seconds HPV DER Derivative sampling time 0 0 to 1000 Seconds HPV DDER Derivative time 0 0 to 1000 Seconds HPV Max Maximum valve open 100 0 to 100 BGV Setpoint Receiver pressure setpoin...

Page 47: ... Transcritical with sensor failure 0 0 to 100 HPV Open Fail Lo Valve minimum opening during low pressure safety mode 15 0 to 100 BGV Open Fail Valve open during high pressure safety mode 0 0 to 100 TransMaxTime Transition time of the two Sub and Trans PID 180 30 to 600 Seconds Setpoints Description Default Range Unit Table 11 1 High Pressure CO2 Controller Ranges and Default Setpoint Parameters ...

Page 48: ...re Valve function and or the Bypass Gas Valve function The user has the option to use this driver or use the 0 10 voltage output from the High Pressure CO2 controller to another driver for controlling the valve If this driver is preferred please check the manufacturer valve technical specifications for the cur rent ratings and verify if the XEV20D is capable of driving the valve The XEV20D address...

Page 49: ...Figure 12 2 High Pressure CO2 Device Wiring and Network Connection 43 ...

Page 50: ...nsation from forming Warning Disconnect all electrical connections before performing any kind of maintenance Fit the probe where it is not accessible by the end user The controller must not be opened In case of failure or faulty operation send the controller back to the distributor with a detailed description of the fault Verify the maximum current that can be applied to each relay see Section 13 ...

Page 51: ... stepper wiring Select the correct transformer depending on the application seeing the following table for each kind of driving and functioning is reported to the transformer to use NOTE The electrical power absorption of the valve can be unrelated to refrigeration power of the valve Before using the actuator read the technical manual of the valve supplied by the manufacturer and check the maximum...

Page 52: ...Installation and Operation Manual 026 1731 Rev 0 01 DEC 2014 13 5 Valve Connections The following table is a quick reference on the connection mode for valves of different manufacturers Figure 13 5 Valve Connections Figure 13 6 XEV20D ...

Page 53: ...hrough LAN Bus serial line only when the address is set correctly The addressing is made through the dip switch called Address as shown below The XEV20D address will have to be set to 1 to communi cate with the High Pressure CO2 controller Figure 13 7 XEV22D ...

Page 54: ...tors Disconnectable Terminal Block 2 5 mm2 for valve outputs and minifit connector for low voltage section Power Supply 24VAC DC Absorption 40VA max Probe Inputs 2 configurable as NTC PTC Pt1000 2 configurable as NTC PTC Pt1000 4 to 20mA to 5V Valve Outputs Refer to the Valve Max Power Figure on page 44 Serial Connection CAN Bus and LAN for iCHILL200CX Data Storing On non volatile memory EEPROM Ta...

Page 55: ...ature 30 to 85 C 22 F to 185 F Relative Humidity 20 to 85 non condensing Measuring and Regulation Range PTC probe 50 to150 C 58 F to 302 F NTC probe 40 to110 C 40 F to 230 F Pt1000 probe 50 to100 C 58 F to 212 F Pressure transducer 1 0 to 50 0 Bar 14 5 PSI to 725 PSI Resolution 0 1 C or 1 F Accuracy 25 C 0 1 C 1 digit Case 4 DIN Table 13 1 XEV20D Technical Specifications ...

Page 56: ...d or its affiliates collectively Emerson reserves the right to modify the designs or specifications of such products at any time without notice Emerson does not assume responsibility for the selection use or maintenance of any product Responsibility for proper selection use and maintenance of any product remains solely with the purchaser and end user 026 1731 01 DEC 2014 Emerson is a trademark of ...

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