Emerson 818-9010 User manual

026-1731 Rev 0 01-DEC-2014
High Pressure CO2 Controller Installation
and Operation Manual

Emerson Climate Technologies Retail Solutions
1065 Big Shanty Road NW, Suite 100
Kennesaw, GA 30144
Phone: [phone]
Fax: [phone]

Table of Contents • v
Table of Contents
1 OVERVIEW ................................................................................................................................................................... 1
1.1 THE HIGH PRESSURE CO2 CONTROLLER I/O POINTS ................................................................................................... 1
1.2 INDEPENDENT SYSTEM CONTROL.................................................................................................................................. 2
2 HARDWARE SETUP.................................................................................................................................................... 3
2.1 CONNECTIONS............................................................................................................................................................... 3
2.2 INPUTS AND OUTPUTS .................................................................................................................................................. 4
2.3 TECHNICAL SPECIFICATIONS ........................................................................................................................................ 6
2.3.1 Analog Inputs ........................................................................................................................................................ 6
2.3.2 Digital Inputs ........................................................................................................................................................ 6
2.3.3 Analog Outputs ..................................................................................................................................................... 7
2.3.4 Digital Outputs...................................................................................................................................................... 7
2.3.5 Dimensions............................................................................................................................................................. 8
2.3.6 Wiring Diagrams.................................................................................................................................................... 9
2.3.7 Electrical Specifications ..................................................................................................................................... 10
2.3.8 Plastic Enclosure ................................................................................................................................................ 10
2.3.9 USB-Ethernet Adapter ........................................................................................................................................ 10
2.4 POWERING THE HIGH PRESSURE CO2 CONTROLLER .................................................................................................. 10
2.4.1 Choosing Transformer Sizes ................................................................................................................................ 10
2.4.2. Wire Types and Maximum Distances................................................................................................................. 11
3 THE MODBUS NETWORK ...................................................................................................................................... 12
3.1. WIRING TYPES............................................................................................................................................................ 12
3.1.1. Daisy Chains ....................................................................................................................................................... 12
3.1.2. Network Addressing - Visograph ........................................................................................................................ 14
3.1.2.1. 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 Analog Outputs ....................................................................................................................... 20
5 HIGH PRESSURE CO2 CONTROLLER STATUS LED....................................................................................... 21
5.1 POWER ON (PWR ON) LED ....................................................................................................................................... 22
5.2 LED1 NETWORK STATUS............................................................................................................................................ 22
6 SOFTWARE OVERVIEW ......................................................................................................................................... 22
6.1 HIGH PRESSURE VALVE CONTROL.............................................................................................................................. 22
6.1.1 HPV Subcritical Mode (Normal) ......................................................................................................................... 23
6.1.2 HPV Transcritical Mode (Normal) ...................................................................................................................... 24
6.1.3 HPV Heat Reclaim ............................................................................................................................................... 25
6.2 BYPASS GAS VALVE CONTROL ................................................................................................................................... 26
7 SAFETY OPERATION PARAMETERS FOR HIGH PRESSURE AND BYPASS GAS VALVES .................. 28

vi • Name of Manual 026-1731 Rev 0 01-DEC-2014
7.1 LOW PRESSURE OPERATION ........................................................................................................................................ 28
7.1.1 Normal Operation ................................................................................................................................................ 28
7.2 HIGH PRESSURE OPERATION ....................................................................................................................................... 28
7.2.1 Normal Operation ................................................................................................................................................ 28
7.3 SENSOR FAILURE ......................................................................................................................................................... 29
7.4 EMERGENCY SHUTDOWN ENABLE INPUT .................................................................................................................... 29
8 VALVE CALIBRATION FEATURE ........................................................................................................................ 30
9 ALARMS....................................................................................................................................................................... 31
10 VISOGRAPH.............................................................................................................................................................. 32
10.1 STATUS SCREEN......................................................................................................................................................... 32
10.1.1 Main Menu and Status Screens .......................................................................................................................... 32
10.2 CONFIGURATION SETUP SCREEN ............................................................................................................................... 33
10.2.1 Main Menu to Configuration Screens ................................................................................................................ 33
10.2.2 General Configuration Screens.......................................................................................................................... 34
10.2.3 Valve Configuration Screens.............................................................................................................................. 34
10.2.4 I/O Configuration Screens ................................................................................................................................. 35
10.2.5 XEV20D Configuration Screens......................................................................................................................... 37
10.3 OVERRIDE SCREEN .................................................................................................................................................... 37
11 HIGH PRESSURE CO2 CONTROLLER RANGES AND DEFAULT SETPOINT PARAMETERS ............. 39
12 XEV20D SETUP AND NETWORK CONNECTION ............................................................................................ 41
13 STEPPER VALVE ACTUATOR QUICK REFERENCE GUIDE XEV20D ...................................................... 42
13.1. GENERAL WARNINGS ............................................................................................................................................... 42
13.2 GENERAL DESCRIPTION ............................................................................................................................................. 43
13.3 ABSOLUTE MAXIMUM POWER................................................................................................................................... 43
13.4 WIRING DIAGRAMS.................................................................................................................................................... 44
13.4.1 One Valve Configuration ................................................................................................................................... 44
13.4.2 Two Valve Configuration ................................................................................................................................... 44
13.5 VALVE CONNECTIONS ............................................................................................................................................... 44
13.6 SERIAL LINE - LAN BUS ........................................................................................................................................... 45
13.7 LED DESCRIPTIONS ................................................................................................................................................... 47
13.8 XEV20D TECHNICAL SPECIFICATIONS ..................................................................................................................... 47

• 1
1 Overview
The High Pressure CO2 controller (P/N 818-9010)
application is a standalone controller that operates the
High Pressure Valve (HPV) and the Bypass Gas
Valve (BGV) in a Booster Transcritical CO2 system.
The controller has a heat reclaim feature, safety pa-
rameter operation for the flash gas receiver tank and
calibration feature for the HPV and BGV.
CAUTION! GND is Common, not earth
ground. Do not earth ground this device.
1.1 The High Pressure
CO2 Controller I/O
Points
The board has 6 analog inputs and 11 digital 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
external valve driver for either the HPV or BGV.
Figure 1-1 - High Pressure CO2 Controller
The High Pressure CO2 controller supports local
physical inputs and outputs and communicates with
the E2 controller (version 3.00 and higher) via the
RS485 MODBUS network.

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.

• 3
2 Hardware Setup
Figure 2-1 - High Pressure CO2 Controller
2.1 Connections
Connector Description
Connector for 24VAC/DC power supply
Analog inputs (Pb1 - Pb6, PbC)
Additional power: +5VDC, +12VDC, Common (-)
Analog outputs (Out1 - Out4, Common)
24VAC/DC digital inputs: DI1 - DI11, Common (-)
Connector for remote terminal (VISOGRAPH), maximum 1 terminal
per controller.
RS485 Slave connector
Serial port connector (LAN or RS485)
USB port for downloads (BIOS, ISaGRAF® application, maps of
parameters, remote display applications, network configuration, and
Web site) and uploads (log files).
Connection with the computer via a USB-ETH converter
Table 2-1 - Connections and Descriptions

4 • High Pressure CO2 Controller Installation and Operation Manual 026-1731 Rev 0 01-DEC-2014
2.2 Inputs and Outputs
Digital relay outputs
4 NO relays, 2 common
Digital relay outputs
4 NO relays, 2 common
Connector Description
Table 2-1 - Connections and Descriptions
Input
Number
Type of
Input Description
1 Supply Reference “-“/Common power (24VAC or 24VDC)
2 Pb1 Configurable analog input 1 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
3 Pb2 Configurable analog input 2 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
4 Pb3 Configurable analog input 3 (NTC, PTC, 0 - 20mA, 4 - 20mA, 0 - 10V, 0 - 1V, 0 - 5V, DI)
5 +12V Additional power +12VDC
6 +5V Additional power +5VDC
7 Out1 Analog output 1, 0 - 10V, 4 - 20mA, Relay
8 Out2 Analog output 2, 0 - 10V, 4 - 20mA, Relay
9 Supply 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 - 5V, DI)
13 PbC Common analog inputs (NTC, PTC, DI)
14
Voltage
Common
(-)
Additional power reference 5VDC and 12VDC, analog inputs
(0 - 20mA, 4 - 20mA, 0 -10V, 0- 1V, 0 - 5V), analog outputs
15 Out3 Analog output 3, 0 - 10V, 4 - 20mA, Relay
16 Out4 Analog output 4, 0 - 10V, 4 - 20mA, Relay
20 DI1 Digital input 1, 24VAC/DC
28 DI9 29 DI10 30 DI11
21 DI2 Digital input 2, 24VAC/DC
Table 2-2 - Description of the Inputs and Outputs

• 5
22 DI3 Digital input 3, 24VAC/DC
23 DI4 Digital input 4, 24VAC/DC
24 DI5 Digital input 5, 24VAC/DC
25 DI6 Digital input 6, 24VAC/DC
26 DI7 Digital input 7, 24VAC/DC
27 DI8 Digital input 8, 24VAC/DC
28 DI9 Digital input 9, 24VAC/DC
29 DI10 Digital input 10, 24VAC/DC
30 DI11 Digital input 11, 24VAC/DC
31
Digital
Common
(-)
Reference “-” for digital inputs from1 to 11 (if version with dry contacts, this input has to
be used only as common for the digital inputs)
40 C Common relays 1, 2, 3 and 4
41 C Common relays 1, 2, 3 and 4
42 RL1 Relay 1 normally open contact
43 RL2 Relay 2 normally open contact
44 RL3 Relay 3 normally open contact
45 RL4 Relay 4 normally open contact
46 RL5 Relay 5 normally open contact
47 C Common relays 5, 6, 7 and 8
48 C Common relays 5, 6, 7 and 8
49 RL6 Relay 6 normally open contact
50 RL7 Relay 7 normally open contact
51 RL8 Relay 8 normally open contact
60 Remote
Display Connection for VISOGRAPH remote terminal (Vnr)
61 Remote
Display Connection for VISOGRAPH remote terminal (+)
62 Remote
Display Connection for VISOGRAPH remote terminal (-)
63 RS485
Slave RS485 Slave connection (-)
Input
Number
Type of
Input Description
Table 2-2 - Description of the Inputs and Outputs

6 • High Pressure CO2 Controller Installation and Operation Manual 026-1731 Rev 0 01-DEC-2014
2.3 Technical Specifications
2.3.1 Analog Inputs
Table 2-3 - Analog Inputs
Analog
conversion type:
10-bit A/D converter
Number of
Inputs:
6
Type of analog
input:
(configurable
via software
parameter)
NTC Emerson Retail Solutions
(-50T110°C; 10KΩ±1% at 25°C)
PTC Emerson Retail Solutions
(-55T115°C; 990Ω±1% at 25°C)
Digital input (potential free
contact)
Voltage: 0 - V, 0 - 5V, 0 - 10V
(input resistance 3.7KΩ)
Current: 0 - 20mA, 4 - 20mA
(input resistance 100Ω)
Accuracy: NTC, PTC: ±1
0-1V: ±20mV
0-5V: ±100mV
0-10V:±200mV
2-20mA, 4-20mA: ±0.30mA
Additional
power:
+12V: 200mA in total (between
+12V and analog outputs)
+5V: 100mA
CAUTION! Any inputs that 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 power 24VAC/DC ±20%
Number of
Inputs:
11
Digital input
status variation
detection time:
100ms (in any case it depends on
the cycle time set by the user in
the given application)
CAUTION! Use another transformer (do
not use the same secondary of the control-
ler’s power) in order to prevent the inputs
from malfunctioning or being damaged.
64 RS485
Slave RS485 Slave connection (+)
65 LAN LAN Connection (-)
66 LAN LAN Connection (+)
Input
Number
Type of
Input Description
Table 2-2 - Description of the Inputs and Outputs

• 7
2.3.3 Analog Outputs
Table 2-5 - Analog Outputs
Type: Non opto-insulated internal power
Number of
Outputs:
4
Type of analog
output:
(configurable
via software
parameter)
4 configurable outputs 0-10VDC
4-20mA (Out1 - Out4)
Maximum load: 40mA (Out1 - Out4) max with
configured outputs 0-10VDC
400Ωmax with configured
outputs 4-20mA
22Ωper live analog output
Accuracy: Out1 - Out4: ±2% full scale
Resolution: 8-bit
CAUTION! The electrical devices con-
trolled by these analog 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(250VAC) SPST 5(2)A
CAUTION! Verify the capacity of the output
used. There is double insulation between the
digital outputs and the low voltage of the rest
of the circuit. Do not use different voltages for the
various groups of relays or within each group.

8 • High Pressure CO2 Controller Installation and Operation Manual 026-1731 Rev 0 01-DEC-2014
2.3.5 Dimensions
Figure 2-2 - Dimensions

• 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.

10 • High Pressure CO2 Controller Installation and Operation Manual 026-1731 Rev 0 01-DEC-2014
2.3.7 Electrical Specifications
Table 2-7 - Electrical Specifications
Power Supply: 24VAC +10/-15%, 50/60Hz, 20 -
36VDC
Consumption: From 30VA (VAC), From 25W
(VDC)
Connectors:
Molex connectors with low
voltage wiring (for IPS100D and
IPS400D)
Phoenix quick coupling
connectors for low voltage (for
IPS200D)
STELVIO 90° screw connectors
for digital outputs (250VAC, 6A
max)
Microprocessor: AT91SAM9260 32-bit 200Mhz
Permanent
FLASH
memory:
16Mb, in 8-bit chunks
RAM: 2x128Kb, in 16-bit chunks
Internal clock: Standard
2.3.8 Plastic Enclosure
Table 2-8 - Enclosure Specifications
Mount:
On a DIN rail (EN 50022, DIN
43880)
Fastened with screws via the
removable plastic flaps.
Material: PC-ABS Thermoplastic
Self-
extinguishing: V0 (UL94)
Comparative
Tracking
Index (CTI):
300V
Color: Black or White, depending on the
model
2.3.9 USB-Ethernet Adapter
The IPS range of programmable controllers can be
connected to a computer via an external adapter. This
adapter must be used in the processing environment
for the application download in the controller. This
adapter is not set up for fixed or continuous connec-
tion. If the adapter should be kept connected continu-
ously, the room temperature must not exceed 50°C
(122°F).
Figure 2-4 - USB-Ethernet Adapter
2.4 Powering the High
Pressure CO2
Controller
Retail Solutions supplies a wide variety of 24VAC
transformers with varying sizes without center taps.
(Table 2-9) shows the transformer sizes and are non-
center-tapped.
2.4.1 Choosing Transformer Sizes
The transformer used to power the High Pressure
CO2 controller should have at least a 30VA rating.
The High Pressure CO2 controller should not share a
transformer with any other devices. Figure 2-5 shows
how to wire the transformer to the High Pressure CO2
controller.
Table 2-9 - Compatible Transformers with CO2 Controller
Transformer P/N VA Rating Primary
Voltage
640-0041 50 VA 110 VAC
640-0042 50 VA 220 VAC

• 11
Neither side of the secondary should be connected
to ground. Also, do not connect the center tap (if pro-
vided on the transformer) to ground. The entire sec-
ondary of the transformer should be isolated from any
ground.
Figure 2-5 - Non-Center Tapped Transformer Wiring
2.4.2. Wire Types and Maximum
Distances
For powering I/O boards, use only the listed wire
types in Table 2-10. Two-conductor non-shielded
cables are the recommended wire for connecting the
transformer to the High Pressure CO2 controller.
Shielded cable should not be used for power wiring.
The center tap should be left disconnected if present
on the transformer.
Table 2-10 - Power Wiring Types
Power Wiring Types
14 AWG Belden 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 wire gauge
you are using fits within specification:
Table 2-11 - Power Wire Lengths
14 AWG:
Feet = 1920/VA
18 AWG:
Feet = 739/VA
(VA is the total VA rating of the controller)
For example, if you had an 80 VA load:
14 AWG: 24 ft.
18 AWG: 9 ft. (rounded down)
Sensors requiring 24VAC should not be powered
from the same transformer that is powering the input
board. Any devices that will be connected to the High
Pressure CO2 controller inputs or outputs must be
powered with a separate 24VAC transformer.

12 • High Pressure CO2 Controller Installation and Operation Manual 026-1731 Rev 0 01-DEC-2014
3 The MODBUS Network
Although the High Pressure CO2 controller can
operate as a stand-alone controller, it relies on an E2
unit for advanced features such as remote dial-in/dial-
out, logging, and alarm control. The High Pressure
CO2 controller uses an RS485 network connection to
communicate with E2 site controllers.
3.1. Wiring Types
Retail Solutions specs Belden #8761 shielded
twisted pair cables for use as MODBUS wiring (or
Belden #82761 and Belden #88761 for plenum
installations).
If the recommended cable is not available in your
area, be sure the wiring meets or exceeds the
following specs:
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
(17.98 m) or less
Nominal Impedance 12050
3.1.1. Daisy Chains
Connect the MODBUS network cable to the three-
terminal connector on the E2 COM port you wish to
assign as MODBUS. Reverse the polarity of +/- on
the RS485 cable between the E2 and the High Pres-
sure CO2 controller.

Figure 3-1 - MODBUS Networking
• 13

14 • High Pressure CO2 Controller Installation and Operation Manual 026-1731 Rev 0 01-DEC-2014
3.1.2. Network Addressing - Visograph
The network address makes a board unique from other boards on the network of the same type. This allows
the site controller to find it and communicate with it easily.
The network address of the High Pressure CO2 controller is set using add-on devices called visographs
(P/N 818-9002).
3.1.2.1. Connecting the Visograph
The visograph is connected with a 3-wire connection on pins 60, 61, and 62.
Figure 3-2 - Network ID Settings
CAUTION: The High Pressure CO2 controller
may be damaged if the wires are crossed when
connecting the visograph, especially if pin 60
(Vnr) is accidentally connected to + or –