Emerson MultiFlex ESR User manual

026-1720 Rev 4 06-APR-2010
MultiFlex ESR Installation and
Operation Manual

Computer Process Controls, Inc.
1640 Airport Road Suite #104
Kennesaw, GA 31044
Phone [phone]
Fax [phone]
ALL RIGHTS RESERVED
The information contained in this manual has been carefully checked and is believed
to be accurate. However, Computer Process Controls, Inc. assumes no responsibility
for any inaccuracies that may be contained herein. In no event will Computer Process
Controls, Inc. be liable for any direct, indirect, special, incidental, or consequential
damages resulting from any defect or omission in this manual, even if advised of the
possibility of such damages. In the interest of continued product development, Com-
puter Process Controls, Inc. reserves the right to make improvements to this manual,
and the products described herein, at any time without notice or obligation.
FCC COMPLIANCE NOTICE
This device complies with Class B of Part 15 of the FCC Rules.

MultiFlex ESR I&O Manual Table of Contents • v
Table of Contents
1 INTRODUCTION.......................................................................................................................................................... 1
1.1. MULTIFLEX ESR AND ESR-8 BOARD DIFFERENCES................................................................................................... 1
1.1. RS-485 I/O Network................................................................................................................................................. 1
1.1. Center-Tapped Transformer.................................................................................................................................... 1
1.1. Molex Connectors (Board P/N 810-1398)............................................................................................................... 1
1.1. Hand-Held Terminal (HHT) .................................................................................................................................... 1
1.1. Snap-Track Mounting .............................................................................................................................................. 1
1.2. MULTIFLEX ESR MOLEX CONNECTOR BOARD (DISCONTINUED)............................................................................... 2
2 INSTALLATION........................................................................................................................................................... 2
2.1. PANEL MOUNTING AND HEAT DISSIPATION ................................................................................................................ 2
2.2. SNAP-TRACK INSTALLATION........................................................................................................................................ 2
3 WIRING.......................................................................................................................................................................... 2
3.1. POWER.......................................................................................................................................................................... 2
3.2. VALVE WIRING............................................................................................................................................................. 3
3.2.1. Molex Connector (Discontinued) Board Wiring................................................................................................... 3
4 SETTING THE TERMINATING RESISTANCE JUMPERS ................................................................................. 4
5 SETTING THE NETWORK ADDRESS AND BAUD RATE .................................................................................. 4
6 SOFTWARE OVERVIEW........................................................................................................................................... 5
6.1. PROGRAMMING E2 VERSION 2.21 AND ABOVE ........................................................................................................... 6
6.2. STEP 1: ADD AMULTIFLEX ESR................................................................................................................................. 6
6.3. STEP 2: ADD ASTANDARD CIRCUIT............................................................................................................................. 7
6.4. STEP 3: ASSOCIATE THE MULTIFLEX ESR................................................................................................................... 7
6.5. STEP 4: SET UPTHE STANDARD CIRCUIT .................................................................................................................... 8
6.6. STEP 5: SET UPTHE MULTIFLEX ESR....................................................................................................................... 10
7 VALVE ZEROING...................................................................................................................................................... 12
7.1. STEP 1......................................................................................................................................................................... 12
7.2. STEP 2......................................................................................................................................................................... 12
8 HAND-HELD TERMINAL ........................................................................................................................................ 12
8.1. OVERVIEW .................................................................................................................................................................. 12
8.2. SCREENS ..................................................................................................................................................................... 13
8.2.1. Main Screen ........................................................................................................................................................ 13
8.2.2. Output Status Screens ......................................................................................................................................... 13
8.2.3. Alarm Status Screens .......................................................................................................................................... 13
8.2.4. Main Select Screen.............................................................................................................................................. 14
8.2.5. Valve Configuration Screens .............................................................................................................................. 14
8.2.6. Network Screen................................................................................................................................................... 14
VALVE SPECIFICATIONS TABLES............................................................................................................................15
EMERSON FLOW CONTROLS STEPPER VALVES...................................................................................................................15
SPORLAN (PARKER) STEPPER VALVES................................................................................................................................15

1 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
1Introduction
The MultiFlex ESR Valve Regulator board (P/N
810-3199), shown in (Figure 1-1),is an RS-485
I/O Network electronic stepper valve regulator
capable of driving up to eight stepper motor
valves, which are typically used to control tem-
perature.
When controlling ECT Flow valves, the Multi-
Flex ESR will detect overcurrent, open wire,
stuck valve situations, and generate the appropri-
ate alarms. For non-ECT Flow valves, the Multi-
Flex ESR will only detect overcurrent situations
and generate an alarm. (See Section 8.2.3.,
Alarm Status Screens for details on alarm
descriptions.)
The MultiFlex ESR uses suction side variable-
position evaporator regulators (ESRs) to vary
evaporator pressure for an entire circuit and is an
alternative to mechanical EPR control.
The MultiFlex ESR receives input data from a
CPC E2 controller (via the I/O Network) and
then regulates the stepper valves according to
the data from the E2.
1.1. MultiFlex ESR and ESR-8 Board
Differences
RS-485 I/O Network
The MultiFlex ESR communicates with the E2
directly over the RS-485 I/O network, unlike the
previous version of the board, which communi-
cated with the controller over the Echelon net-
work.
Center-Tapped Transformer
For power, a Class 2, 80VA 24VAC center-
tapped transformer is required for each Multi-
Flex ESR board. (Previous board versions did
not require a center-tapped power source.)
Molex Connectors (Board P/N 810-1398)
The discontinued MultiFlex ESR board’s valve
outputs are four-contact molex connectors
instead of the screw terminals. Valve cables hav-
ing a four-contact molex connector are plugged
directly into the board. This board has been dis-
continued and replaced with the new MultiFlex
ESR board version (P/N 810-3199).
Hand-Held Terminal (HHT)
Set configuration parameters, setpoints, and fail-
safe conditions of each valve with the HHT. By
using the HHT, each valve output can be set sep-
arately with a valve step rate and the total num-
ber of steps from closed to fully open.
Snap-Track Mounting
The MultiFlex ESR board fits into the standard
CPC 4" I/O board snap-track for mounting.
Figure 1-1 - MultiFlex ESR Board Layout
8
3
7
24VAC CT 75 VAC Power Input
Valve Connectors (8)
I/O Network Input
Termination Jumpers
Network Address Switches
General Status LED
1
5
2
3
4
6
7
8
HHT Jack
TX and RX LEDs
9
10
Open LED (8)
Close LED (8)
9
10

MultiFlex ESR Molex Connector Board (Discontinued) Installation • 2
1.2. MultiFlex ESR Molex Connec-
tor Board (Discontinued)
2 Installation
The MultiFlex ESR control board is designed to
be located in a central location, preferably near
the valves it is driving. Figure 2-1 shows the
mounting dimensions of the MultiFlex ESR
board:
2.1. Panel Mounting and Heat Dis-
sipation
The MultiFlex ESR can generate a substantial
amount of heat when it draws up to a maximum
of 80 VA during operation. The MultiFlex ESR
is rated for a maximum ambient temperature of
65°C (150°F); therefore, depending on the size
of the enclosure and what other devices are in
that enclosure with the MultiFlex ESR, you may
need to ventilate the enclosure by installing air
circulation fans or other devices to aid in heat
dissipation.
2.2. Snap-Track Installation
Boards not supplied with an enclosure are sup-
plied with a snap-track for easy installation. The
insulation sheet and I/O board must be removed
from the track before the track is mounted. The
snap-track is mounted using the 0.1875” mount-
ing slots. Figure 2-2 shows this installation pro-
cedure:
3 Wiring
3.1. Power
Each MultiFlex ESR board requires a Class 2,
80VA 24VAC center-tapped transformer for
power. The power connector (labeled J12) is
located in the top left corner of the board.
Figure 1-2 - MultiFlex ESR Molex Connector Board Layout -
Discontinued (P/N 810-3198)
Figure 2-1 - MultiFlex ESR Board Dimensions
24VAC CT 75 VAC Power Input
Valve Connectors (8)
I/O Network Input
Termination Jumpers
Network Address Switches
General Status LED
1
5
2
3
4
6
7
8
HHT Jack
TX and RX LEDs
8
3
7
9
10
Open LED (8)
Close LED (8)
9
10
3.5”
4.00”
10.00"
4.75”
TYP 2 PL
MULTIFLEX ESR BOARD
WEIGHT: 9.4 OZ.
O 0.220”
TYP 6 PL
9.5”
Figure 2-2 - MultiFlex ESR Snap-Track Installation

3 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
CPC transformer (P/N 640-0080) is a multi-
tapped primary transformer that may be used
with the MultiFlex ESR board.
Refer to Figure 3-1 and follow the instructions
below for transformer power wiring:
1. Connect the three wires from the secondary
side of the transformer to the power connec-
tor. The AC should be run with a minimum of
18 AWG wire up to 10 feet,16 AWG up to 20
feet, or 14 AWG up to 30 feet.
2. Connect 24VAC to AC1 and AC2.
3. Connect the center tap (CT) of the transform-
er to the GND center terminal of the power
connector.
4. Attach an additional 14 AWG or larger wire
from the center GND terminal to solid earth
ground. Keep the wire as short as possible, 6"
or less is preferred, and should be completed
for each board.
3.2. Valve Wiring
The stepper valves are wired to the board by
connecting the stepper valve harness to one of
the eight screw terminal connectors along the
top of the board (Figure 3-3) and matching the
wire colors to the legend on the connectors. Use
the cable and cable harnesses that are supplied
with the valves.
For Sporlan valves, match all wire colors except
the green wire. Instead, connect the green wire
to the silk screen blue wire legend (Figure 3-2).
3.2.1. Molex Connector (Discontinued)
Board Wiring
The stepper valves are wired to the board by
connecting the stepper valve molex connector to
one of the eight molex connectors along the top
of the board (Figure 3-4). Use the cable and
cable harnesses that are supplied with the valves.
Figure 3-1 - Power Wiring - Center-Tapped Transformer
WIRING FOR 640-0080, 80VA Transformer
SECONDARY SIDE
Use 24VAC Center-Tapped Transformer
PRIMARY SIDE
240 208 C
120
(NEUTRAL)
(HOT)
120/208/240 VAC
L2 L1
Three-conductor non-shielded cables
are the recommended wire
for connecting between the
center-tapped transformer
and I/O boards.
Power Wiring Types:
14 AWG Belden 9495
18 AWG Belden 9493
24V CT 24V
AC1
GND
AC2
AC1
AC2
24VAC Center-Tapped
Earth ground the
GND (center-tapped)
terminal of each board
GND
Figure 3-2 - Valve Connector Wire Color Indicator
Figure 3-3 - ECT Flow Valve and New Board Wiring Diagram
NOTE: A valve cable harness may not be lon-
ger than 150 feet.
BLU
RBLK W
Wire Color Legend on
Each Valve Connector (8)
ECT Flow
Stepper Valve
MultiFlex ESR Board w/ Eight
Screw Terminal Connectors
(P/N 810-3199)
Stepper Valve
Harness
WHITE
BLACK
RED
BLUE
Match wire colors to
silk screen legend on
board terminals

Valve Wiring Setting the Terminating Resistance Jumpers • 4
For retrofits or stepper valve harnesses without a
mating molex connector, use the MultiFlex ESR
adapter cable (P/N 335-3275).Crimp-type
waterproof splices should be used to make the
connections.
For Sporlan valves used with these discontinued
boards, match all wire colors except the blue
wire. Instead, connect the blue wire to the Spor-
lan green wire.
4 Setting the Terminat-
ing Resistance Jumpers
All MultiFlex ESR boards have a set of termi-
nating resistance jumpers (one jumper for each
wire lead). These jumpers are labeled JP2, JP3,
and JP4 on the MultiFlex ESR board.
Set the termination jumpers UP (JP2, JP3, JP4)
if at either end of a daisy chain. Otherwise, set
jumpers DOWN.
The purpose of the jumpers is to indicate the two
ends, or termination points, of the segment. On a
daisy chain, one device at the beginning and one
device on the end must be terminated by placing
all three termination jumpers in the UP position.
All other devices on the daisy chain must be set
to the DOWN position. Figure 4-1 shows the
proper terminating resistance jumper settings for
the MultiFlex ESR board.
For more information about network configura-
tion and termination, see the I/O Network wiring
section in your site controller’s user manual.
5 Setting the Network
Address and Baud Rate
Set the network address on the first five rockers
of the dip switch (labeled S1) on the MultiFlex
ESR board. Set the network baud rate using
rockers 6 and 7.
Figure 3-4 - ECT Flow Valve and Old Board Wiring
Figure 4-1 - Daisy Chain Termination Jumper Settings
CAUTION: Always have the JP1 jumper
(located on the far right side of the board
opposite the Termination jumpers) set to the
Normal position, or the board will not operate
correctly.
RS485 I/O NET
NO TERMINATION
(Jumpers in the
DOWN position)
JP2 JP3 JP4
TERMINATION
(Jumpers in the
UP position)
JP2 JP3 JP4

5 • MultiFlex ESR I&O Manual 026-1720 Rev 4 06-APR-2010
6 Software Overview
The MultiFlex ESR board is intended to inter-
face closely with E2’s Standard Circuit applica-
tion. Once a valve on the MultiFlex ESR board
has been associated with a Standard Circuit, the
Standard Circuit assumes control of the valve’s
position. The Standard Circuit must be specifi-
cally configured to control a MultiFlex ESR
valve so that the advanced capabilities provided
with the MultiFlex ESR will be enabled.
Valve Rescaling
The Standard Circuit has an enhanced control
strategy when it is configured to control a Multi-
Flex ESR valve. As with previous ESR control,
a PID algorithm is used to position the valve
during refrigeration mode in order to maintain
the circuit temperature setpoint. In addition, a
minimum and maximum valve percentage may
be specified. When this is used, the PID output
(0-100%) is rescaled to a control range between
the minimum and maximum valve percentage
parameters. This may be useful in situations
where the valve is slightly oversized and tends to
continuously overshoot the temperature setpoint.
Pulldown Mode
A new Standard Circuit control state named
Pulldown has been added. The Pulldown state is
optional and is, by default, disabled. When
enabled, the Standard Circuit will go into Pull-
down following a defrost cycle or a case wash.
Also, if a door switch is configured and refriger-
ation mode is temporarily suspended due to the
door opening (such as with a walk-in box), a
Pulldown will be initiated when the door closes.
The Pulldown mode simply forces the valve to a
fixed position, as specified with the Pulldown
Percent parameter. The circuit will stay in Pull-
down until the case temperature reaches the set-
point or the maximum time allowed in Pulldown
has been exceeded. The maximum time in Pull-
down defaults to zero, which disables the Pull-
down mode. By setting this to a valid time (up to
2 hours), Pulldown mode will be enabled.
Valve Failsafe
The Standard Circuit has additional valve fail-
safe capability. If a control failure occurs, such
as a loss of the control temperature sensor, the
valve will be instructed to go to a failsafe posi-
tion. As with previous ESR control, the valve
may be configured to go to a fixed position, as
specified by the Temp Fail EEPR % parameter.
However, a new Valve Daily Average Position is
now being calculated for MultiFlex ESR and
Figure 5-1 - Network Address Settings
Figure 5-2 - Baud Rate Settings
S1
Set the network address
using the first 5 rockers
of dip switch S1.
Valid address range 1-31.
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 1 BOARD 2 BOARD 3 BOARD 4
2345678
1
ON
23456 78
1
ON
2345678
1
ON
2345678
1
ON
BOARD 5 BOARD 6 BOARD 7 BOARD 8
2345678
1
ON
2345678
1
ON
2345678
1
ON
2345678
1
ON
BOARD 9 BOARD 10 BOARD 11 BOARD 12
2345678
1
ON
23456 78
1
ON
2345678
1
ON
2345678
1
ON
BOARD 13 BOARD 14 BOARD 15 BOARD 16
2345678
1
ON
23456 78
1
ON
2345678
1
ON
2345678
1
ON
BOARD 17 BOARD 18 BOARD 19 BOARD 20
2345678
1
ON
23456 78
1
ON
2345678
1
ON
BOARD 21 BOARD 22 BOARD 23
2345678
1
ON
BOARD 24
2345678
1
ON
23456 78
1
ON
2345678
1
ON
2345678
1
ON
BOARD 25 BOARD 26 BOARD 27 BOARD 28
2345678
1
ON
BOARD 29
2345678
1
ON
23456 78
1
ON
BOARD 30 BOARD 31