Emerson iPro Installation And Operation Manual
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Emerson iPro Installation And Operation Manual

Emerson iPro Installation And Operation Manual

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

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  • Page 1 Case Controller Installation and Operation Manual FW Version 1.01 026-1738 Rev 1...
  • Page 3 Emerson 1065 Big Shanty Road NW, Suite 100 Kennesaw, GA 30144 USA Phone 770-425-2724 Fax 770-425-9319 www.emerson.com...

  • Page 5: Table Of Contents

    CONTENTS 1 GENERAL DESCRIPTION/ INTRODUCTION ....................... 1 2 ORDERING AND PART NUMBERS ......................... 2 3 MOUNTING AND HARDWARE OVERVIEW ......................3 3.1. M ............................3 OUNTING AND IMENSIONS 4 OVERVIEW ................................... 5 4.1............................5 ARDWARE VERVIEW 4.2. D ............6 ETAILED ESCRIPTION OF ONNECTORS FOR THE I...
  • Page 6 OSITIONS AND ................................44 UPERHEAT 14.3. E ......................... 44 NTERING THE ISOGRAPH 14.4. I/O C ..............................45 ONFIGURATION 14.4.1. Analog Inputs ..............................45 14.4.1.1. Analog Input Options..............................46 vi • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 7 E2E BAC ........................55 ONFIGURE ETTINGS 15.3. A ....................... 56 DD AND ONNECT I ONTROLLERS 15.4. C E2E ........................58 OMMISSIONING THE EVICE IN 16 IPRO PARAMETER LIST............................61 17 APPENDIX - IPRO CONNECTION DETAIL....................... 70 Table of Contents • vii...

  • Page 9: General Description/ Introduction

    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 ...

  • Page 10: Ordering And Part Numbers

    100 ohm resistor for RS485 master port 318-4000 0-5VDC 30, 60, 120 Amp Current Transducer for fan motors and  251-7000 defrost heaters current monitoring Table 2-1 - Ordering Information 2 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 11: 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 ...
  • Page 12 Figure 3-4 - IPX Dimensions Figure 3-3 - XEV20D Dimensions 4 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 13: Overview

    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.

  • Page 14: Detailed Description Of Connectors For The Ipro Case Controller

    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 6 •...
  • Page 15 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...

  • Page 16: Visograph Overview

    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.

  • Page 17: Ipx106D Hardware Overview

    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.
  • Page 18 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.

  • Page 19: 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 ...

  • Page 20: Xev20D Valve Connections

    5-6 Wire Valves (Unipolar) Terminal Numbers Spolar Saginomiya BLACK BLACK BLUE YELLOW YELLOW BLACK BROWN ORANGE ORANGE WHITE 5 - Common GRAY GRAY GRAY Table 4-7 - Unipolar Bipolar Valve Connections 12 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 21: Xev20D Absolute Maximum Power

    4.7. XEV20D Absolute Maximum Power The XEV20D can drive a wide range of stepper valves. Indicated in the following table are the maximum values of current that the  actuator can supply to the stepper wiring. NOTE: The electrical power absorption of the valve can be unrelated to refrigeration power that valve has. Before using the actuator, read the technical manual of the valve supplied by the manufacturer and check the maximum current used to drive the valve to verify that they are lower than those indicated below.

  • Page 22: Can Bus Communication Connection

    8. For successful communication to occur, the addressing dip switches on the XEV20 must be set correctly. When one (1) XEV20D driver is being used by the iPro Case Controller, then the dip switch address will be (two) 2, when two (2) XEV20D modules are being installed, the modules should be address 2 and 3.

  • Page 23: Powering Devices And Wiring

    Table 5-3 - Power Wire Lengths these devices. Transformer requirements are a minimum of 20VA for the iPro Case Controller and the iPro must not share a  transformer with any other devices. The transformer power  5.3. Wire Selection Guidelines requirements of the IPX106D are a minimum of 10VA and ...

  • Page 24: Powering Xev20D

    Phoenix quick coupling connectors for terminals 1 and 7 on the wiring harness. Reference Table 5-1 for low voltage transformer selection and part numbers. The iPro Case Controller  STELVIO 90° screw connectors for  digital outputs (250VAC, 6A max) currently supports a maximum of two (2) XEV20D.

  • Page 25: Wiring Visograph Display

    5.7. Wiring Visograph Display The Visograph connection to iPro is made with three (3) wires from the iPro remote display port terminals 103,104,105 to the  Visograph wiring connector terminals 1,2,3 located on the back side of the Visograph. The wire type used for this connection should be Belden #8771.

  • Page 26: Wiring Analog Inputs

    Wiring Analog Inputs 6.1. iPro Analog Inputs The iPro analog inputs are located on the same connector as the controller power supply. The iPro Case Controller has 10 analog inputs available, a 5VDC power supply and a 12VDC power ...

  • Page 27: Wiring Digital Inputs

    7.1. iPro Digital Inputs The iPro digital inputs are located on their own 22-pin connector along the bottom of the device. The iPro provides a maximum of 20 opto-insulated digital inputs that are configurable through the Visograph display. See figures below for connection details.

  • Page 28: Ipx106D Digital Inputs

    TYPE: Opto-insulated voltage free contact NUMBER OF INPUTS: NOTES: Do not use live contacts to prevent the inputs from being damaged. Table 7-2 - IPX106D Digital Input Specifications 20 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 29: Wiring Digital Outputs

    8.1. iPro Digital Outputs The 15 digital outputs are located across four (4) separate connectors across the top side of the iPro Case Controller. The normally open outputs on each connector share the same common and are not fused. Make sure to use the same voltage for all loads connected to these relays;...

  • Page 30: Ipx106D Digital Outputs

    8.2. IPX106D Digital Outputs The IPX106D has six (6) digital outputs with normally open contacts that can be used in addition to iPro digital outputs if required.  The IPX relays are split into two different groups: terminals 40-43 and terminals 44-47, each having its own common (43 and 44).

  • Page 31: Wiring Analog Outputs

    9.1. iPro Analog Outputs The iPro Case Controller has six (6) opto-insulated analog outputs available along the bottom side of the device on terminals 21-30. Because the analog outputs are opto-isolated, they must be powered separately from the case controller device by 24VAC at terminals 28-29.

  • Page 32: Ipx106D Analog Outputs

    The IPX expansion module has (three) 3 additional analog outputs available that can be used with the case controller if needed.  The outputs are located on terminals 20-23. Note that the IPX AO do not require dedicated 24VAC power like iPro analog outputs.

  • Page 33: Software Overview

    (coil outlet) per evaporator to The iPro Case Controller controls the temperature, defrost and  make the Superheat calculation. All three (3) EEV PID loops Superheat for the refrigerated case or walk-in box based on the ...

  • Page 34: Superheat Only Mode-Control Value Failure

    S2Addr Modbus address of slave device 2 3 if 2 slave CC are present; otherwise set at 0 Table 10-2 - Master Controller Configurations for Suction Control Mode 26 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 35: Suction Mode-Refrigeration Relay Control

    S3Addr Modbus address of slave device 3 4 if 3 slave CC are present; otherwise set at 0 S4Addr Modbus address of slave device 4 5 if 4 slave CC are present; otherwise set at 0 S5Addr Modbus address of slave device 5 6 if 5 slave CC are present;...

  • Page 36: Superheat And Suction Control  Mode-Pid

    Manual or Automatic mode by setting the P value. When the P value is set to 0, the application will automatically adjust the proportional band value to find the best stable value for regulation. 28 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 37: Configuring Controllers For Superheat And Suction Mode

    10.3.4.2. Configuring Controllers for Superheat and Suction Mode To configure the controller as a master in the Superheat and Suction mode, the following parameters must be set: Parameter Description Parameter Value for Master Controller Control Type Superheat and Suction User choice, Average Lineup  SSCP Superheat and suction control probe selection Recommended...

  • Page 38: Superheat And Suction  Control-Refrigeration Relay

    Wait parameters SHDef% and SuctionDef%. The refrigeration  mode. relay is driven to the OFF position and the defrost relay is switched to ON. 30 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 39: Wait Mode

     transducer. The current transducer should be placed on the defrost circuit for the entire case. The current transducer is Emerson P/N 251-7000 and is a 0-5VDC signal, split core sensor with a selectable range of 30, 60, and 120 amps. The case controller will monitor the defrost heater amperage once the relay call for the defrost heater is ON.
  • Page 40 0-60 Amps sidered ON defrAmpDel Time delay for defrost heater status to change to ON 1-90 Seconds once the threshold is reached. Table 10-8 - Defrost Parameter List 32 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 41: Lighting Control Overview

    10.4. Lighting Control Overview The case controller will control the light relay based on an internal schedule. The scheduled on and off times are repeated every day. The controller does not depend on a supervisory controller or E2e for lights scheduling however the ON/OFF times are adjustable from E2E.

  • Page 42: Fan Motor Current Monitoring

    The case controller has the ability to monitor the fan motor RMS current of each case through the use of an external current transducer. The current transducer should be placed on the fan circuit for the entire case. The current transducer is Emerson P/N 251-7000 and is a 0-5VDC signal, split core sensor with a selectable range of 30, 60, and 120 amps.

  • Page 43: Electronic Valves

    Electronic Valves 11.1. Presence and Position Depending on the application of the case controller, the system may be using 0-3 expansion valves or 1 EEPR valve. The position of the valves on the XEV20D driver is fully configurable and is managed by the following parameters: Parameter Description Defines if the EEV driver is used or not: Not present, XEV20D.

  • Page 44: Eev And Eepr Calibration Procedure

    SET to save the selection. The value will remain at YES for a few seconds while the calibration is performed and will  automatically toggle back to NO. 36 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 45: The Bacnet Network

    For communication with the E2E controller the case controller uses an RS485 network and BACnet MS/TP. 12.1. Wire Types Emerson specs General Cable 92454A (Emerson P/N 135-0600) shielded twisted pair cables for use as BACnet MS/TP wiring. 12.2. Daisy Chain Wiring The BACnet MS/TP connection should be wired in a daisy chain topology, no star or T configurations are allowed.

  • Page 46: Configuring Bacnet Settings

    Press the T2 key to enter System Configuration and press T1  case controller saves and automatically reboots to for System.  re-initialize with the new address after a period of 7 minutes. Do not reboot manually.) 38 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 47 Figure 12-6 - MSTP Max Master Press the T5 key to move the cursor to the  MSTP MaxMaster field. Press T4 set to edit and use T3/T5 to move the values to the desired selection. The MSTP Max Master is the highest network address that the controller will poll for and attempt to discover.

  • Page 48: Modbus Networking-Master Slave Lineup

    The Modbus connection does not and should not be extended to all controllers within a store. 13.1. Wire Types Emerson specs General Cable 92454A (Emerson P/N 135-0600) shielded twisted pair cable for use as MODBUS network wiring. 13.1.1. Daisy Chain Wiring The MODBUS network must be wired in a daisy chain topology, no star or T configurations are allowed.

  • Page 49: Defining Slave Case Controllers Within The Master

    Press and hold the T4 key for three (3) seconds to enter the After saving the address selection press the T6 (right arrow main menu: key) two times to page over to reboot: Figure 13-4 - Reboot Arrow down until reboot NO is selected, press T4 to edit and Figure 13-2 - Enter the Main Menu By Pressing the T4 Key change the value to YES.
  • Page 50 1. Press SET to edit and SET to save the selection. Repeat this process until all present slaves are addressed. Set an address of 0 for unused slave controllers. 42 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 51: Using The Visograph

    Using the Visograph Represents the system in a Pump-out mode where EEVs and LLSV are closed and the EEPR valve is open for a specified amount of time before closing. 2 - The evaporator fan status icon gives the user a quick indicator if the fan is ON or OFF.

  • Page 52: Viewing Temperature Input Status

    T8 can be used to exit submenus and the Main Menu back to the home screen. Figure 14-4 - Valve Overview Tab To see in-depth data for a specific EEV valve, select the  corresponding EEV tab with the T4-T6 keys. 44 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 53: I/O Configuration

    Select T3 for iPro AI Configuration, T5 for XEV20_Config, T6 for Expansion 1 (IPX1_Config) AI Configuration or T7 for Expansion 2  (IPC2_Config) AI Configuration. Example of iPro AI Configuration, press T3 for iPro AI_Config. The iPro analog input selections are shown below. I/O can be set by using T3/T5 keys to navigate and T4 to edit and save.

  • Page 54: Analog Input Options

    Analog Input Description Hardware Available Input is not used Fan amperage current transducer FanAmps iPro or IPX Defrost amperage current transducer DefrAmps Table 14-1 - Analog Input Options 46 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 55 DefrTerm1 Defrost cycle termination temperature sensor 2 DefrTerm2 Defrost cycle termination temperature sensor 3 DefrTerm3 Defrost cycle termination temperature sensor 4 iPro, IPX, or EXV20D DefrTerm4 Defrost cycle termination temperature sensor 5 DefrTerm5 Defrost cycle termination temperature sensor 6 DefrTerm6...

  • Page 56: Digital Inputs

    ON/TRUE for DI1 in the logic of the controller. DI01P=Close, a closed signal input on digital input 1 results in a logical value of ON/TRUE in the logic of the controller. 48 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 57: Digital Outputs

    Figure 14-15 - DO Configuration box LLSV Alarm Relay for con- Press SET to change a DO_Config. The iPro comes defaulted trolling output with D04=Refrigeration relay, D05=Defrost, D06=Fan and of alarm signal D07=Lights. Press the T7 key to scroll to relay polarity.

  • Page 58: System Overrides

    T4 to save the override value. The override will be active for 30 minutes unless manually removed. To cancel the override, edit The iPro Case Controller has a menu where system relay output the value to -1 and save.
  • Page 59 Figure 14-20 - Command Screen Figure 14-22 - Digital Inputs Screen Once in the Command screen, press and hold T6 Test for a. Use the T8 key to move to the next section of tests after three (3) seconds to enter Test mode, the first stage is the digital input testing is complete.
  • Page 60 The feedback value is Active once the amperage value rises above a programmed threshold. Use the T6 key to advance to the next relay and the T8 key to advance to the next series of tests. Figure 14-24 - Pressure Inputs Tests Screen Electronic Valve Tests - This mode is designed to allow the user to quickly command the electronic valves to the fully open or fully closed position in order to check the operation...
  • Page 61 Verify that the open LED on the XEV20D drivers is solid orange and not blinking. A blinking light on the open LED indicates the valve is still driving open. After the LEDs  indicate that the valves are finished driving fully open, the controller can be powered down for shipping.

  • Page 62: E2 Setup

    BACnet MS/TP communication: COM2, COM4 and COM6 are the available RS485 ports on the E2E power interface board. 15.1. Set Up Network Ports and BACnet Settings Before setting up an iPro Case Controller in the E2E, the port that has the BACnet MS/TP cable connected to it must be set up as a  BACnet MS/TP port.

  • Page 63: Configure E2E Bacnet Settings

    Three fields will become visible underneath the COM4 Connection that pertain to the way the device communicates: • COM4 DevId -This is the E2E BACnet Device ID; set this to a unique number from all other BACnet nodes on the network in the range of 0-4194303.

  • Page 64: Add And Connect Ipro Case Controllers

    15.3. Add and Connect iPro Case Controllers To enable communications between the E2E and the iPro Case Controllers, the devices must be added to E2E and addressed. Log into the E2E with level 4 access or higher.
  • Page 65 Connected I/O Boards and Controllers. Figure 15-4 - E2E Connected I/O Net Screen - Third Party Tab In the Connected I/O screen under the Third Party tab, enter the number of iPro CC devices in the Quantity field. ...

  • Page 66: Commissioning The Device In E2E

    Select the BACnet MS/TP network, the E2E will then scan for available devices: Figure 15-6 - E2E Scan for Available BACnet Devices The E2E will display a list of the devices discovered during the scan: 58 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 67 Figure 15-7 - BACnet Devices Found The number in parenthesis is the BACnet MAC address and the other number is the BACnet Device ID. Select the device you want  to commission and press on the E2E keypad. Figure 15-8 - Select Device to Commission ...
  • Page 68 Figure 15-9 - BACnet Device ID Is Set  Then press the button to save and exit back to the Network Summary screen: Figure 15-10 - Network Summary Screen 60 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...

  • Page 69: Ipro Parameter List

    Configuration of Probe 6 AIC07 Configuration of Probe 7 AIC08 Configuration of Probe 8 AIC09 Configuration of Probe 9 AIC10 Configuration of Probe 10 Table 16-1 - iPro Parameter List Commissioning the Device in E2E iPro Parameter List • 61...
  • Page 70 Probe 9 value at max AI10_min Probe 10 value at min AI10_max Probe 10 value at max Defrost Parameters Defrost Type Electric/Hot Gas Table 16-1 - iPro Parameter List 62 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 71 DIC17 Configuration of Digital Input 17 DIC18 Configuration of Digital Input 18 DIC19 Configuration of Digital Input 19 DIC20 Configuration of Digital Input 20 Table 16-1 - iPro Parameter List Commissioning the Device in E2E iPro Parameter List • 63...
  • Page 72 Configuration of Relay 11 RLC12 Configuration of Relay 12 RLC13 Configuration of Relay 13 RLC14 Configuration of Relay 14 RLC15 Configuration of Relay 15 Table 16-1 - iPro Parameter List 64 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 73 EEPR - Filter on the temperature 1-100 Seconds EEPR_InitS EEPR - Steps Init Regulation Minimum of 2, maximum adjusts based on MaxS. 1=10 steps Table 16-1 - iPro Parameter List Commissioning the Device in E2E iPro Parameter List • 65...
  • Page 74 EEV1 - Extra steps used for the first calibration after ExtraS_Cal_- 1-2500 Steps Time EEV1_LSH EEV1 - Min Superheat Alarm Threshold 0-Setpoint EEV1_MSH EEV1 - Max Superheat Alarm Threshold 0-90° Table 16-1 - iPro Parameter List 66 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 75 Timer used for first calibration 0-480 Hours RackID Rack ID See selection list CircNum Circuit number 1-999 CaseID Case ID Refrigeration Control Parameters LTSet Low Temperature Setpoint -40-90° Table 16-1 - iPro Parameter List Commissioning the Device in E2E iPro Parameter List • 67...
  • Page 76 XEV20_1 - Probe 3 value at max Selectable based on probe type AI04_1_min XEV20_1 - Probe 4 value at min AI04_1_max XEV20_1 - Probe 4 value at max Table 16-1 - iPro Parameter List 68 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 77 XEV20_2 - Probe 4 value at min AI04_2_max XEV20_2 - Probe 4 value at max XEV20_1_VT XEV20_1 - Valve Motor Type Unipolar/Bipolar Wave/Bipolar Normal XEV20_2_VT XEV20_2 - Valve Motor Type Table 16-1 - iPro Parameter List Commissioning the Device in E2E iPro Parameter List • 69...

  • Page 78: Appendix - Ipro Connection Detail

    Appendix - iPro Connection Detail 70 • iPro Case Controller I&O Manual FM V1.01 026-1738 Rev 1...
  • Page 80 Emerson Climate Technologies Retail Solutions, Inc. and/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.

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