Emerson iPro User manual

iPro Case Controller Installation and
Operation Manual
FW Version 1.01
026-1738 Rev 1

Emerson
1065 Big Shanty Road NW, Suite 100
Kennesaw, GA 30144 USA
Phone [phone]
Fax [phone]
www.emerson.com

Table of Contents • v
CONTENTS
1 GENERAL DESCRIPTION/ INTRODUCTION....................................................................................................... 1
2 ORDERING AND PART NUMBERS ......................................................................................................................... 2
3 MOUNTING AND HARDWARE OVERVIEW ........................................................................................................ 3
3.1. MOUNTING AND DIMENSIONS ...................................................................................................................................... 3
4 OVERVIEW ................................................................................................................................................................... 5
4.1. IPRO HARDWARE OVERVIEW ....................................................................................................................................... 5
4.2. DETAILED DESCRIPTION OF CONNECTORS FOR THE IPRO CASE CONTROLLER ........................................................... 6
4.3. VISOGRAPH OVERVIEW ................................................................................................................................................ 8
4.4. IPX106D HARDWARE OVERVIEW................................................................................................................................ 9
4.5. XEV20D HARDWARE OVERVIEW.............................................................................................................................. 11
4.6. XEV20D VALVE CONNECTIONS ................................................................................................................................ 12
4.7. XEV20D ABSOLUTE MAXIMUM POWER ................................................................................................................... 13
4.7.1. Description of XEV20D Connections ................................................................................................................. 13
4.8. CAN BUS COMMUNICATION CONNECTION................................................................................................................ 14
5 POWERING DEVICES AND WIRING.................................................................................................................... 15
5.1. TRANSFORMER SELECTION......................................................................................................................................... 15
5.2. WIRE TYPES AND MAXIMUM DISTANCE .................................................................................................................... 15
5.3. WIRE SELECTION GUIDELINES ................................................................................................................................... 15
5.4. POWERING THE IPRO CASE 
CONTROLLER ....................................................................................................................................................................... 15
5.5. POWERING XEV20D .................................................................................................................................................. 16
5.6. POWERING IPX106D .................................................................................................................................................. 16
5.7. WIRING VISOGRAPH DISPLAY .................................................................................................................................... 17
6 WIRING ANALOG INPUTS ..................................................................................................................................... 18
6.1. IPRO ANALOG INPUTS ................................................................................................................................................ 18
6.2. XEV20D ANALOG INPUTS ......................................................................................................................................... 18
6.3. IPX106D ANALOG INPUTS......................................................................................................................................... 18
7 WIRING DIGITAL INPUTS...................................................................................................................................... 19
7.1. IPRO DIGITAL INPUTS ................................................................................................................................................. 19
7.2. IPX106D DIGITAL INPUTS ......................................................................................................................................... 20
8 WIRING DIGITAL OUTPUTS ................................................................................................................................. 21
8.1. IPRO DIGITAL OUTPUTS ............................................................................................................................................. 21
8.2. IPX106D DIGITAL OUTPUTS ...................................................................................................................................... 22
9 WIRING ANALOG OUTPUTS ................................................................................................................................. 23
9.1. IPRO ANALOG OUTPUTS ............................................................................................................................................. 23
9.2. IPX106D ANALOG OUTPUTS ..................................................................................................................................... 24
10 SOFTWARE OVERVIEW ....................................................................................................................................... 25
10.1. TEMPERATURE MODE............................................................................................................................................... 25
10.2. SUPERHEAT SETPOINT .............................................................................................................................................. 25
10.3. REFRIGERATION CONTROL MODES .......................................................................................................................... 25
10.3.1. Standard Control Mode ................................................................................................................................. 25
10.3.1.1. Standard Mode Control Value 

vi • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
Calculation-Parameter CTM............................................................................................................................................................ 25
10.3.2. Superheat-Only Control Mode....................................................................................................................... 25
10.3.2.1. Superheat Only-EEV Management................................................................................................................................ 25
10.3.2.2. Superheat Only Mode-Control Value Failure................................................................................................................. 26
10.3.3. Suction Control Mode .................................................................................................................................... 26
10.3.3.1. Suction Control Mode-PID ............................................................................................................................................. 26
10.3.3.2. Configuring Controllers for Suction Control Mode ....................................................................................................... 26
10.3.3.3. Suction Mode-Refrigeration Relay Control.................................................................................................................... 27
10.3.4. Superheat and Suction Control Mode ............................................................................................................ 27
10.3.4.1. Superheat and Suction Control 
Mode-PID ........................................................................................................................................................................................ 28
10.3.4.2. Configuring Controllers for Superheat and Suction Mode ............................................................................................. 29
10.3.4.3. Superheat and Suction 
Control-Refrigeration Relay ............................................................................................................................................................ 30
10.3.5. Defrost Control and Operation ...................................................................................................................... 30
10.3.5.1. Initiation of Defrost ........................................................................................................................................................ 30
10.3.5.2. Master/Slave Defrost of a Lineup ................................................................................................................................... 30
10.3.5.3. Defrost Operation of Relays and Valves ........................................................................................................................ 30
10.3.5.4. Defrost Termination........................................................................................................................................................ 30
10.3.5.5. Wait Mode ...................................................................................................................................................................... 31
10.3.5.6. Synchronization of Defrost Schedules............................................................................................................................ 31
10.3.5.7. Defrost Heater Current Monitoring ................................................................................................................................ 31
10.3.5.8. Defrost Heater Lockout................................................................................................................................................... 31
10.4. LIGHTING CONTROL OVERVIEW ............................................................................................................................... 33
10.5. FAN CONTROL OVERVIEW........................................................................................................................................ 33
10.5.1. Fan Activation After Defrost Cycle................................................................................................................. 33
10.5.2. Fan Motor Current Monitoring....................................................................................................................... 34
10.5.3. System Enable/Disable.................................................................................................................................... 34
11 ELECTRONIC VALVES.......................................................................................................................................... 35
11.1. PRESENCE AND POSITION ......................................................................................................................................... 35
11.2. EEV AND EEPR CALIBRATION PROCEDURE............................................................................................................ 36
11.3. VALVE CALIBRATION FROM THE VISOGRAPH DISPLAY........................................................................................... 36
12 THE BACNET NETWORK ..................................................................................................................................... 37
12.1. WIRE TYPES.............................................................................................................................................................. 37
12.2. DAISY CHAIN WIRING .............................................................................................................................................. 37
12.3. CONFIGURING BACNET SETTINGS ........................................................................................................................... 38
12.3.1. BACnet MAC Address and Device ID............................................................................................................. 38
12.3.2. Setting BACnet APDU Timeout and BACnet Max Master.............................................................................. 38
13 MODBUS NETWORKING-MASTER SLAVE LINEUP...................................................................................... 40
13.1. WIRE TYPES.............................................................................................................................................................. 40
13.1.1. Daisy Chain Wiring........................................................................................................................................ 40
13.1.2. Setting the MODBUS Address and Baud Rate................................................................................................ 40
13.1.3. Defining Slave Case Controllers Within the Master........................................................................................ 41
14 USING THE VISOGRAPH....................................................................................................................................... 43
14.1. VIEWING TEMPERATURE INPUT STATUS .................................................................................................................. 44
14.2. VIEWING VALVE POSITIONS AND 
SUPERHEAT DATA ............................................................................................................................................................... 44
14.3. ENTERING THE VISOGRAPH MAIN MENU ................................................................................................................. 44
14.4. I/O CONFIGURATION................................................................................................................................................. 45
14.4.1. Analog Inputs ................................................................................................................................................... 45
14.4.1.1. Analog Input Options...................................................................................................................................................... 46

Table of Contents • vii
14.4.2. Digital Inputs ................................................................................................................................................... 48
14.4.2.1. Digital Input Options ...................................................................................................................................................... 48
14.4.3. Digital Outputs................................................................................................................................................. 49
14.4.3.1. Digital Output Options.................................................................................................................................................... 49
14.5. SYSTEM OVERRIDES ................................................................................................................................................. 50
14.6. TEST MODE .............................................................................................................................................................. 50
15 E2 SETUP ................................................................................................................................................................... 54
15.1. SET UP NETWORK PORTS AND BACNET SETTINGS ................................................................................................. 54
15.2. CONFIGURE E2E BACNET SETTINGS ....................................................................................................................... 55
15.3. ADD AND CONNECT IPRO CASE CONTROLLERS....................................................................................................... 56
15.4. COMMISSIONING THE DEVICE IN E2E ...................................................................................................................... 58
16 IPRO PARAMETER LIST....................................................................................................................................... 61
17 APPENDIX - IPRO CONNECTION DETAIL....................................................................................................... 70

General Description/ Introduction • 1
1 General Description/ Introduction
The iPro Case Controller is a microprocessor-based controller for use in controlling temperature and Superheat in refrigerated fixtures
and walk-in boxes. The controller is suitable for medium and low temperature applications and can control all loads in a refrigerated box
or fixture. These include lighting, fans, defrost heaters, and solenoid valves. The iPro Case Controller system 
is comprised of at least one iPro Case Controller and one to two XEV20D valve drivers depending on the installation. There is also an 
input/output expansion module supported by the software that can be used if needed, although typically the I/O available on the iPro
Case Controller is adequate for most installations. When more than one case or fixture is used within the refrigeration circuit, the iPro
Case Controller can communicate critical information between case controller devices via Modbus from device to device. The controller
can be integrated into an EMS system controller via Modbus or BACnet MS/TP/IP and is currently integrated into the Emerson E2E
rack controller using BACnet MS/TP or IP. The controller can also be configured to run completely standalone, controlling the 
refrigeration system with no commands sent from E2E or a higher-level EMS controller.
Overview of Capabilities
• Each case controller can manage control of up to three evaporators Superheat in one case with associated temperature sensors,
transducers and electronic valves.
• One master case controller can communicate with up to five (5) slave case controllers within each refrigeration circuit, six (6)
case lineup is the maximum configuration.
• Control one (1) EEPR for the refrigeration circuit lineup.
• Manages all loads in a refrigerated case: lighting, fans, defrost heaters, and solenoid valves.
Figure 1-1 - System Layout

2 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
2 Ordering and Part Numbers
Device Emerson Part Number
iPro Case Controller 818-9016
XEV20D Dual Stepper Valve Actuator 818-5003
IPX106D Input/Output Expansion Module 818-7000
Visograph 2.0 V2IPG Display (Pre-loaded) 818-9208
20’ Discharge Air Temperature Sensor (Green) 501-1122
20’ Defrost Termination Temperature Sensor (Orange) 501-1127
20’ Return Air Temperature Sensor (Purple) 501-1128
20’ Coil Outlet Temperature Sensor (Red) 501-1126
0-100 PSI transducer 800-2100
100 ohm resistor for RS485 master port 318-4000
0-5VDC 30, 60, 120 Amp Current Transducer for fan motors and 
defrost heaters current monitoring
251-7000
Table 2-1 - Ordering Information

Mounting and Dimensions Mounting and Hardware Overview • 3
3 Mounting and Hardware Overview
3.1. Mounting and Dimensions
In most situations, the iPro Case Controller will arrive at the customer’s site already installed within a case OEM fixture or within a 
pre-fabricated Emerson control panel. The installer need only make communication wiring and field sensor wiring terminations (if 
required). If the need arises for the installer to mount the iPro Case Controller elsewhere, the controller should always be mounted in a
moisture-free environment or an environment adequately protected from moisture.
The iPro Case Controller, XEV20D and IPX106D use a DIN rail mount for installation, see figures below for dimensions.
Figure 3-1 - iPro DIN Mounting
Figure 3-2 - Visograph Display Dimensions

4 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
Figure 3-3 - XEV20D Dimensions
Figure 3-4 - IPX Dimensions

iPro Hardware Overview Overview • 5
4Overview
4.1. iPro Hardware Overview
The iPro Case Controller is a microprocessor-based fully programmable controller. The controller is powered at 24VAC and uses a high
speed performance 32-bit ARM9 (200 MHz) microprocessor. The controller has 15 digital outputs, 20 digital inputs, 10 analog inputs
and six (6) analog outputs onboard. Technical specifications for onboard I/O can be found in Section 6.1., iPro Analog Inputs, Section
7.1., iPro Digital Inputs, Section 8.1., iPro Digital Outputs, and Section 9.1., iPro Analog Outputs. The iPro Case Controller has three
(3) serial communication ports, one (1) TCP/IP port and one (1) USB port. The RS485 master port is used to make the BACnet MS/TP
connection to E2E, and the RS485 slave port is used to connect to peer case controllers within a refrigeration circuit. The CAN Bus port
is used for iPro to communicate with other peripheral devices such as the XEV20D and IPX106D.
Figure 4-1 - iPro Wiring and Connections
Figure 4-2 - iPro Hardware

6 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
4.2. Detailed Description of Connectors for the iPro Case Controller
LEGEND
1GENERAL STATUS LED 8RS485 SLAVE PLUG-SLAVE CONTROLLER NETWORK
2RELAY OUTPUT CONNECTORS 9ANALOG INPUTS/24VAC POWER IN CONNECTOR
3LED 1 AND GENERAL ALARM LED 10 CAN BUS CONNECTION-FOR XEV20D&IPX MODULE
4RS485 TRANSMIT/RECEIVE LED 11 REMOTE DISPLAY PORT-VISOGRAPH
5DIGTIAL INPUT CONNECTOR 12 TCP/IP PORT-BACNET IP PORT
6BACNET MS/TP CONNECTION 13 USB PORT
7ANALOG OUTPUT CONNECTOR
Table 4-1 - iPro Hardware
Connector Description
Connector for 24VAC/DC power supply.
Analog inputs (Pb1 - Pb6, PbC).
Additional power: +5VDC, +12VDC, Common (-)
Analog outputs (Out1 - Out4, Common).
Opto-insulated analog outputs (Out1 - Out6, GND)
24VAC/DC power supply required for the opto-insulated analog outputs
Voltage-free opto-insulated digital inputs (DI1 - DI20, IDC)
Opto-insulated 24VAC/DC digital inputs (DI1 - DI20, GND)
USB port for downloads (BIOS, ISaGRAF® application, maps of parameters, remote
display applications, network configuration, website) and uploads (log files).
TCP/IP Ethernet port. Also used for BACnet IP connection.
Connector for remote terminal (VISOGRAPH), maximum two (2) terminals per 
iPro Case Controller.
CAN Bus port is used to connect the iPro Case Controller and XEV20D and IPX 
modules.
Table 4-2 - iPro Connections and Descriptions

Detailed Description of Connectors for the iPro Case Controller Overview • 7
RS485 Slave port is used to connect the Master and Slave Case Controllers Rx and Tx
LED to indicate that communication is active.
Closed circuit terminal (Term)
RS485 Master port is used to connect iPro Case Controller and Master Supervisory
Controller
Rx and Tx LED to indicate that communication is active Closed circuit terminal
(Term)
Digital relay outputs (for digital outputs with voltage-free contacts) three (3) NO
relays, one (1) common
Digital relay outputs (for digital outputs with live contacts) three (3) NO relays, one (1) 
common and two (2) voltage free (Neutral)
Digital relay outputs (for digital outputs with voltage-free contacts) five (5) NO relays,
one (1) common
Digital relay outputs (for digital outputs with live contacts) five (5) NO relays, one (1)
common and two (2) voltage free (Neutral)
Digital relay outputs
two (2) NO relays, one (1) common
Digital relay outputs (only for 215D versions)
five (5) NO relays, one (1) common and one (1) voltage free (Neutral)
Green LED to indicate the presence of power
Table 4-2 - iPro Connections and Descriptions

8 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
4.3. Visograph Overview
The local user interface for iPro Case Controller is Visograph 2.0 V2IPG. The Visograph is an LCD display with eight (8) keys (labeled 
T1-T8) on a membrane keyboard. The Visograph can be panel mounted or wall mounted as shown above in the Visograph dimensions
detail. The Visograph is powered from the iPro remote display port on iPro terminals 103, 104, 105. In most installations, each iPro Case
Controller will have its own Visograph display locally mounted for controller navigation and configuration. All parameters and 
configuration for the case controller can be edited from Visograph. The Visograph provides a quick and easy interface for viewing 
temperatures, alarm data, system status, valve percentages and status of outputs and loads. More on Visograph navigation is covered later
in this document.
Jumper to activate the RESCUE MODE
Yellow status LEDs (LED1) and red LED (ALARM) See relative paragraph
NOT USED IN CASE CONTROLLER
NOT USED IN CASE CONTROLLER
NOT USED IN CASE CONTROLLER
Figure 4-3 - Visograph
Table 4-2 - iPro Connections and Descriptions

IPX106D Hardware Overview Overview • 9
4.4. IPX106D Hardware Overview
The IPX is an input/output expansion board for use in 
combination with iPro Case Controller. The IPX has six (6) digital 
outputs, seven (7) analog inputs, three (3) digital inputs and three
(3) analog outputs. The case controller supports up to two (2) IPX
modules at one time. The IPX communicates with iPro Case 
Controller on the CAN Bus port, when XEV20D and IPX are 
present then the CAN Bus communication wiring is simply 
continued to the IPX in a daisy chain. When the IPX modules are
present they communicate at address 4 and 5.
Figure 4-4 - IPX106D
Figure 4-5 - IPX106D Wiring

10 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
Connector Description
Connector for 24VAC/DC power supply
Analog inputs (Pb1 - Pb5, PbC)
Voltage-free digital inputs (DI1 - DI3, DIC)
Additional power (+5VDC, +12VDC, GND)
Analog outputs (Out1..Out3, GND)
Analog inputs (Pb6 - Pb7, PbC)
Additional power (+5VDC, +12VDC, GND)
Digital relay outputs
Six (6) NO relays, two (2) common
CAN Bus Connector
Rx and Tx LED to indicate that communication is active
Closed circuit terminal (Term)
LAN serial port connector - NOT USED IN THIS APPLICATION OF IPRO CASE
CONTROLLER
Dip switch to set the address of the device.
Green LED to indicate the presence of power
Red status LED (ALARM)
Green LED to indicate the presence of power
Table 4-3 - IPX Connectors and Descriptions

XEV20D Hardware Overview Overview • 11
4.5. XEV20D Hardware Overview
The XEV20D is a stepper valve actuator is intended for either 
bipolar stepper valves or unipolar stepper valves. This device is
used in combination with the iPro Case Controller to drive the
electronic expansion valves and electric evaporator pressure 
regulator in the refrigerated case or walk in box. Each XEV20D
drives two (2) valves and the iPro Case Controller system 
supports a maximum of two (2) XEV20D per iPro. The XEV20D
communicates with the iPro Case Controller via the CAN Bus
port on both devices. When driving stepper valves with this 
actuator, check the valve manufacturer technical specifications
for the current ratings and verify if the XEV20D can drive the
valve selected for the system.
The XEV20D driver has onboard LED lights that show device status and the valves being controlled. See Table 4-5 below for LED
function descriptions.
Figure 4-6 - XEV20D
Figure 4-7 - XEV20D Wiring
LEGEND
1 VALVE 1 AND 2 WIRING CONNECTOR 5 ANALOG INPUTS/24VAC POWER
2 POWER ON AND ALARM LED 6 CAN BUS COMMUNICATION TX/RX LED
3 CAN BUS RS485 TERMINATION JUMPER 7 CAN BUS WIRING CONNECTOR
4 CAN BUS ADDRESS DIPSWITCHES 8 VALVE POSITION INDICATOR LED
Table 4-4 - XEV20D LED Light Descriptions

12 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1
4.6. XEV20D Valve Connections
The wires from the valve wiring harness should be terminated at the XEV20 connectors labeled valve 1 and valve 2. See Table 4-6 and
Table 4-7 below for terminal numbers associated with each valve wire color.
LED MODE MEANING
PWR ON On Tells that the model is powered correctly
ALARM On Tells that an alarm is present
TX/RX Blinking CAN Bus or LAN activity, communication activated
TX/RX On No link
OPEN V1 Blinking Valve 1 is opening
OPEN V1 On Valve 1 is completely opened
CLOSE V1 Blinking Valve 1 is closing
CLOSE V1 On Valve 1 is completely closed
OPEN V2 Blinking Valve 2 is opening
OPEN V2 On Valve 2 is completely opened
CLOSE V2 Blinking Valve 2 is closing
CLOSE V2 On Valve 2 is completely closed
Table 4-5 - XEV20D LED Functions
4 Wire Valves (Bipolar)
Terminal
Numbers
Alco EX Alco EX5/6 Sporlan SEI-SHE Sporlan CDS4-17 Danfoss ETS Carel E2V-E7V
1GREEN WHITE GREEN GREEN GREEN GREEN
2BROWN BLACK RED RED RED YELLOW
3YELLOW BROWN BLACK BLACK WHITE BROWN
4WHITE BLUE WHITE WHITE BLACK WHITE
5 - Common N/A N/A N/A N/A N/A N/A
Table 4-6 - Bipolar Valve Connections
5-6 Wire Valves (Unipolar)
Terminal Numbers Spolar Saginomiya EX3
1 BLACK BLACK BLUE
2 YELLOW YELLOW BLACK
3 RED RED BROWN
4 ORANGE ORANGE WHITE
5 - Common GRAY GRAY GRAY
Table 4-7 - Unipolar Bipolar Valve Connections