XT-70 Ventilation Control Panel Technical Manual Revision 4.6

Transcription

1 XT-70 Ventilation Control Panel Technical Manual Revision 4.6 BTU Ventilation Corporation US Highway 10 Perham, Mn USA Phone (218) Fax (218) Manual Copyright BTU Ventilation Corp 2011

2 XT-70 Control Panel 2 CHAPTER 1 REVISIONS 1.1 MANUAL REVISIONS 1.2 XT SOFTWARE REVISIONS CHAPTER 2 CONTENTS TROUBLE SHOOTING 2.1 FIELD REPORTED PROBLEMS 2.2 XT MICROPROCESSOR IDENTIFICATION 2.3 POWER SUPPLY VAC SOLID STATE OUTPUT 2.5 TEMPERATURE INPUT 2.6 HUMIDITY SENSOR 2.7 CO2 SENSOR 2.8 DIGITAL INPUTS 2.9 XT MULTIPLE DOOR OUTPUT 2.10 XT SINGLE DOOR OUTPUT 2.20 REV B XT & DOOR CONTROLS 2.21 REV B SINGLE DOOR CHAPTER 3 FIELD MODIFICATIONS 3.1 XT SINGLE DOOR MOD 3.2 XT MULTIPLE DOOR MOD 3.3 XT HUMIDITY & CO2 MOD CHAPTER 4 XT MODES OF OPERATION 4.1 XT OPERATION AND ALARM MODES 4.2 OPERATING MODES 4.3 ALARM MODES CHAPTER 5 OPERATING PARAMETERS 5.1 DESCRIPTION OF FLASH PARAMETERS CHAPTER DEFINITIONS CHAPTER 7 E2 PARAMETERS SETTING E2 PARAMETERS 7.1 WEB INTERFACE AND SETTINGS CHAPTER 8 COLOR TOUCH SCREEN PROGRAM UPDATE 8.1 HOW TO UPDATE THE G70 SOFTWARE

3 XT-70 Control Panel 3 CHAPTER 9 COLOR TOUCH SCREEN QUICK PROGRAM REF 9.1 G70 HMI FIELD UPDATE QUICK CHAPTER VAC FIELD WIRING CHAPTER VAC FIELD WIRING SENSOR FIELD WIRING 11.1 LOW VOLTAGE SENSOR FIELD WIRING CHAPTER 12 INPUT / OUTPUT FIELD WIRING 12.1 LOW VOLTAGE INPUT / OUTPUT FIELD WIRING CHAPTER 13 RABBIT FIRMWARE UPDATES 13.1 RABBIT FIRMWARE BOOTLOADER CHAPTER 14 RABBIT BOOTLOADER RABBIT FIRMWARE BOOTLOADER 003 CHAPTER SEND A TEXT MESSAGE CHAPTER 16 HOW TO SEND TEXT MESSAGES BY ANALOG P1 PROCESSOR UPDATE 16.1 MICROCHIP MPLAB ICD MICROCHIP MPLAB ICD 2 PROGRAM INSTALLATION PROCEDURE CHAPTER 17 SDX DOOR CONTROLS 17.1 SDX DOOR CARD FEATURES 17.2 TYPICAL PULSE INPUTS 17.3 XT PULSE INPUT MA PULSE OR LINEAR INPUT 17.5 SDX DOOR CONTROLS CARD NUMBER ASSIGNMENT 17.6 SDX SYSTEM EXAMPLES DOOR SDX SYSTEM STAGING 17.8 ACTUATOR FIELD WIRING XT ORIGINAL 17.9 ACTUATOR FIELD WIRING XT REV B SDX MULTIPLE CARD WIRING XT ORIGINAL SDX MULTIPLE CARD WIRING XT REV B ACTUATOR POTENTIOMETER SETTING SDX DOOR LABELING SDX DOOR PROGRAMMING SDX DOOR PROGRAMMING SDX DOOR PROGRAMMING USING TERMINAL

4 XT-70 Control Panel SDX ORIGINAL CARD VS SDX REV A CARD CHAPTER 18 COM INTRODUCTION 18.2 IP ASSIGNMENTS 18.3 XT PANEL IP SETUP 18.4 COM1000 FLASH UTILITY 18.5 COM1000 CONFIGURATION 18.6 NETWORK TESTING CHAPTER 19 DIAL UP ACCOUNT 19.1 SETTING UP A DIAL UP ACCOUNT 19.2 USING YOUR WEB BROWSER CHAPTER 20 CR-110 Refrigeration Control 20.1 Freq Drive Compressor Application

5 XT-70 Control Panel MANUAL REVISIONS: CHAPTER 1 REVISIONS JB added software revision section JB added trouble shooting section JB added HMI Programming Quick Guide pages JB modification on Humidity dropping resistor JB section for rabbit update with bootloader 003 and software JB add table of contents to manual JB addition of Com 1000 setup changes to instructions for setup of MPLAB JB door updates JB door position updates JB door position corrections JB major updates with Rev B boards JB cr-110 applications 1.2 XT P1 ANALOG PROCESSOR: ************************************************************************* V Added refrigeration fail mode. It's based off of IN3. If IN3 is clsed for 30s, alarm mode 4 (ref fail) is initiated. If the system is in this alarm mode, the system goes to standby anytime refrig or recirc is called for. ************************************************************************* V Changed the osah test routine to be dependant on the climacell switch. If the switch is off, the alarm is disabled. ************************************************************************* V Changed the ref fail alarm mode to only be valid when ref switch in auto. ************************************************************************* V Changed the run time accumulator to be more accurate. Now look at start/stop switch and clear remote control bytes in flash if the switch is at "stop". Added a control byte to flash to control pile differential. freq_ctrl = 1 enables pile differential. Changed revision to 41 to cover Tom's goof of ignoring leading zeros ************************************************************************* V Added a reset command (<RESET>xxxx). It comes from the Rabbit and resets the processor. Added a 10ms delay in single door pulse mode when the DIR relay changes direction Added a fan_fail check when in recirc mode Changed fan_fail in refrig mode to come on in a fixed 5 sec. ************************************************************************* V Changed the 10ms delay in the single door control to a half second. ************************************************************************* V Had a bug in the humidity control routine that was causing the hx_output to "wrap around" when the correction was decremented. This only came into play when the min on time was zero. *************************************************************************

6 XT-70 Control Panel 6 V Had a bug in the humidity control routine. I was looking at the cell switch for hum1 and hum2 control. ************************************************************************* V Changed the cav control to deal with the fact that I was expecting a hex number but the Rabbit was sending a decimal number. Now convert that number to the hex equivalent. ************************************************************************* V Fixed a bug in the last version where I was overwriting the calculated byte. ************************************************************************* V Fixed a bug in the erv routine where the AUX1 wasn't being set in the outputs routine. Changed the way cooling is terminated. Added a rise above setpoint timer that keeps the cooling_ras routine from terminating cooling until the timer has timed out. Also changed it so that cooling won't terminate until osat > start AND plenum temp > setpoint + ras Found the ras wasn't working as intended because I needed to multiply the ras value by 10 (it's in whole degrees) ************************************************************************* V Had the cooling termination flags wrong in the previous version. Also changed ras back to 10ths and hard wired the ras timer to 3 minutes (180 sec). ************************************************************************* V Added a 45s delay before clearing the coola_fg when osat > start. This keeps it in cooling in case of a quick blip in the osa temp. Changed the way I was filtering the analog inputs. Instead of reading the A/D and then converting to temp and then filtering the temps, I now filter the A/D counts and calculate temps after the filter is averaged. It should be a little more accurate and prevent glitches from skewing the temps briefly. It should also speed up the voltmeter routine since it only has to calculate temps once, when the filter is averaged, instead of every pass. No longer load 0x7FFF into the filter if a sensor is out of range. Now I look at the o/r flag when the filter is averaged. The temp is loaded as 0x7FFF directly and the filter results discarded if the o/r flag is set. ************************************************************************* V Changed the way the plenum temps were being averaged. Now, no longer average in the out of range plenum sensor. This was causing odd readings, since the o/r sensor is set to 0x7FFF. This would read out or so on the HMI. Now, if one sensor is o/r, I simply use the good sensor for the displayed temp as well as the good sensor count for the pid. If both sensor are o/r, I set the display temp to 0x7FFF and set the pl_count to sp_count, which prevents any pid control while the sensors are bad. Added a co2 config byte to E2. This determines the range of the sensor used. See comments for different values. ;************************************************************************* ; V Added a heat mode control whenever the fan is on. See heat_control in control.asm for comments. For now, all parameters are set ; in E2 but will be moved to flash later. ; ; Changed the calc_co2_ctrl to interact with the heat control. Now sets flag when the heat should be on. There is a new separate routine ; which looks at the flags set in either calc_co2_ctrl or heat_control and turns on/ off the heat based on those. Either one can turn on the ; heat output but both must be off to turn it off. ;************************************************************************* ; V Changed the heat control to still change the heat pw if the old error and new error were equal. ;************************************************************************* ; V Changed the heat control to increment the heat pw when ever olderror < error, since getting cooler. ;************************************************************************* ; V Changed the heat control to increment the heat pw when olderror = error,

7 XT-70 Control Panel 7 ; when error <.6 degrees ;************************************************************************* ; V Had a bug in the last fixed. Didn't update if olderror</= error. ;************************************************************************* ; V Changed the heat routine to clear output if at or over setpoint. Also changed it ; to decrement the heat pw if at or over heat setpoint until the heat pw hits zero. ;************************************************************************* ; V Fixed a bug in last update. Was jumping to the wrong place and still clearing if ; plen temp = heat setpoint. ;************************************************************************* ; V Changed heat routine to freeze at current pulse size if heat setpoint = plenum temp. ;************************************************************************* ; V Added PW and PR commands to write and read E2. These commands come from the HMI, via the Rabbit. ; ; This is the last version that will use the old style a_mode. ;************************************************************************* ; V Changed the way the filter worked. If you changed the filter "mid-stream", you could get some oddball values, since the base had changed. Now I save the current filter value when I reload the filter and use it to divide. Changed the WW_send so that it wouldn't send the temp if o/r. Before, it just looked at the o/r flag, which is cleared after every filter pass, so it was possibe to get WW command between time flag cleared and before set again with o/r reading. It would then display temp of (for 0x7FFF = 32767). Had a bug in the high co2 routine which bypassed the timer. Any high reading would trigger alarm. This is the last version that will use the old style a_mode. ;************************************************************************* ;************************************************************************* ; V Added door defrost capability. ; ; Added air fogger mode, which uses aux2 along with hum1. The register aux2_cfg sets this mode if it's set to 0xAF. ;************************************************************************* ; V Since I changed the defrost variables from E2 to the flash in bank 3 (from Rabbit), there was a chance that the variables ; would be loaded before the Rabbit sent the flash variables. Now, the def interval timer is loaded during the sud timer period at ; startup once an XT string is received. ; ; Now, if the def_intvl is set to zero, it forces a defrost interval. ;************************************************************************* ; V Added a pile_diff variable to the flash. This value lets you choose the reference temperature when ; calculating the pile differencial for the freq drive. ;************************************************************************* ; V Changed the RESET command to require the PW command <PW01RESET>xxxx. ;************************************************************************* ; V Found a bug in the calc_co2_ctrl routine. The heat on/off part should have only been run in cooling and if the heat switch on. ; Was jumping into the co2 calc routine if not in cooling, instead of bypassing it.

8 XT-70 Control Panel 8 ; ; Streamlined the set_refrig routine. ; ; Changed the refrig_co2 to no longer set the door_acc to the max door if the door_pos went over mdo. Also now will not update if the update ; would push the door position over the mdo. If the door_pos is over mdo for some reason, will now send a close pulse. ;************************************************************************* ; V Removed the door position calculation accidently in the last revision. Changed the routine to calculate door position ; every 500ms if system is in refrigeration. ;************************************************************************* ; V Found I was possibly accidently modifying the door position accumulator in the door_pos_open routine. ;************************************************************************* ; V When clearing pwm1 (refrig), it was causing the output of the isolator to float. If using ext relays, the kickback would cause the refrig output to jump up to max out. Now, instead of clearing pwm1, setting it to 1 ma so it's not floating. ;*************************************************************************

9 XT-70 Control Panel 9 CHAPTER 2 TROUBLE SHOOTING 2.1 FIELD REPORTED PROBLEMS PROBLEM DOORS WILL NOT OPEN IN COOLING WITH MULTIPLE DOOR SYSTEM. The system is in cooling, plenum temperature above the Setpoint, yet the doors were not opening. A check of the open and close inputs on the SDX card found that we had 12vdc steady on the Close input, and a pulsing 12vdc on the open input. This was telling the card to open and close the door at the same time. The SDX will always give priority to the Close input. Thus the door could not open. The reason for the Close signal always being on was the close relay not getting enough drive to pick it up. The solution is to add a 10k resistor on the back of the XT switch card. This is outlined in the multiple door mod in this manual. Future revision of this card will solve this issue. PROBLEM WHEN THE PANEL WAS RUNNING, PRESSING THE STOP BUTTON WOULD SHUT THE PANEL DOWN, BUT THE MODE WOULD SHOW STANDBY. A fly back diode for the close relay output was providing a return path when used with a solid state pulse relay. The solution requires the removal of a diode on the main XT card, and cutting a trace and adding a wire on the switch card. This is outlined in the single door mod in this manual. PROBLEM CLOCK WOULD LOOSE TIME WHEN THE XT PANEL WAS POWERED DOWN. The clock battery socket was installed upside down. Use a voltmeter, should have +3.2 vdc with red lead on bottom of battery and black lead on the top of battery. Tim reports being able to remove the battery and bend the clips so that the + was at the bottom. PROBLEM NEW PANEL, NO READINGS ON TEMPS OR HUMIDITY'S The E2 memory parameters had not been programmed. The filter setting had 255, this setting will not allow any reading to filter thru. The E2 memory was defaulted using the HMI and everything went to working. PROBLEM Rev B XT-MB board, software When the door pulse switches were set to +12vdc, and in the Cooling mode, the 0-20ma refrigeration output would go to 20ma and then back to 0. This problem only existed when using external pulse relays with the Rev B board. It was found that the input to the opto isolator was floating when the PWM was set to 0. The PWM was set to output 1ma when at zero percent rather than 0. Analog version 1.69 corrected this issue.

10 XT-70 Control Panel XT TROUBLE SHOOTING MICROPROCESSOR IDENTIFICATION INPUT P2 PROCESSOR IN CIRCUIT PROGRAMMING PLUG INPUT P2 PROCESSOR U11 ANALOG P1 PROCESSOR IN CIRCUIT PROGRAMMING PLUG ANALOG P1 PROCESSOR U4 BLINKING GREEN LED INDICATES PROCESSOR RUNNING. NON BLINKING LED INDICATES PROGRAM MODE OR NON FUNCTIONAL PROCESSOR.

11 XT-70 Control Panel XT TROUBLE SHOOTING POWER SUPPLY INPUT VOLTAGE SPIKE PROTECTOR. WILL SHORT CIR- CUIT AT 50VAC AND BLOW FUSE. CAN BE REMOVED AND CHECK WITH OHM METER. SHOULD SHOW NO RE- SISTANCE IF GOOD. IF YOU ARE SHOWING ANY RESIS- TANCE SHOULD BE REPLACED. IF NECESSARY YOU CAN LEAVE THE VOLTAGE PROTECTOR OUT OF THE CIRCUIT. OUTPUTS ARE ACTIVE ONLY WHEN FANS ARE RUNNING, OR OUTPUT 3 (green light and fans) is on. THESE OUTPUTS ARE OPTO ISO- LATED AND EACH HAVE A CORRESPONDING VOLTAGE INPUT ISO2 AND ISO1. J44 J46 G I V G I V Freq Drive 0-10 vdc 0-20 ma Refrigeration 0-10 vdc 0-20 ma F1 1.5A FB J47 J45 24 VAC ISO2 ISO1 24 VAC.5 AMP STANDBY.8 AMP COOLING ADD.15 FOR CO2 SENSOR ISO2 AND ISO1 SHOULD EACH HAVE VAC WHEN THE FANS ARE RUNNING. NO VOLT- AGE SHOULD BE PRESENT WHEN FANS ARE OFF. USE AC VOLTMETER TO MESURE INPUT VOLTAGE AND INPUT CURRENT MA OUTPUT 0-10 VDC OUTPUT G I V MA G I V VDC

12 XT-70 Control Panel XT TROUBLE SHOOTING 110 VAC SOLID STATE OUTPUTS RED LED OUTPUT ON WHEN MODULE IS TURNED ON. ALL OUTPUTS HAVE REPLACEABLE 2A FUSE. PRY THE WHITE COVER UP TO REPLACE FUSE. E N 120 VAC EARTH GROUND NEUTRAL 120 VAC RED LIGHT YELLOW LIGHT GREEN LIGHT & FAN EVAP PUMPL HUMID 1 HUMID 2 HEATER AUX 1 AUX 2 CAVITY 120VAC ALL VAC OUTPUTS TIED TOGETHER BOTH TERMINALS ON ALL OUTPUTS TIED TO- NOTE - ALL SOLID STATE OUTPUTS ARE 120 VAC. SOLID STATE OUTPUTS REQUIRE A LOAD TO OPERATE PROPERLY. WITH NO CONNECTION TO MOD- ULE YOU MAY READ UP TO 80 VAC WITH OUTPUT TURNED OFF. WHEN AT- TACHING RELAYS, ALWAYS USE A DOUBLE POLE RELAY. A SINGLE POLE RELAY MAY NOT DROP OUT.

13 XT-70 Control Panel XT TROUBLE SHOOTING TEMPERATURE INPUTS TEMPERATURE SENSORS CAN BE TESTED USING A OHM METER. UNPLUG THE SENSOR FROM THE XT CARD. TEMPERATURE INPUT 2250 THERMISTOR A 2250 THERMISTOR WILL READ 2250 OHMS AT 25 C OR 77 DEGREES F. AT 40 DEGREES THE THERMISTOR WILL READ APPROXIMATELY 5880 OHMS. THE SENSOR SHOULD ALWAYS READ OHMS. THE WARMER IT IS, THE LESS RESISTANCE IT WILL READ. A READING OF NO OHMS WOULD INDICATE A BAD SEN- SOR OR BROKEN WIRE. TYPICAL 1-3 VDC 0 VDC OUT OF RANGE VDC OUT OF RANGE NO SENSOR = VDC USE THE TABLE TO MEASURE A VOLTAGE AND CONVERT IT TO A TEMPERATURE. NOTE - THERE SHOULD NEVER BE A DCV BETWEEN THE SHIELD AND EITHER THE RED OR BLACK WIRE OF THE SENSOR. THE SHIED PRODUCE A LOW OHM READING TO GROUND. TROUBLE SHOOTING: LOSS OF FIRST OR SECOND BANK OF SENSORS. THERE ARE TWO A2D S ON BOARD THE XT CARD. EACH ONE WILL MEASURES 8 SENSORS. THE A2D S PROVIDE A REFERENCE VOLTAGE TO THE SENSOR AND IS A COMMON VOLTAGE. THIS REFERENCE IS ON THE RED WIRE. IF THE RED WIRE IS SHORTED TO THE SHIED OR GROUND IT WOULD PRODUCE A LOSS OF THE ENTIRE BANK OF SENSORS. REMOVE EACH SENSOR ONE AT A TIME UNTIL THE READINGS RE- TURN AND DETERMINE WHICH CABLE IS SHORTED. TEMPERATURE VDC SENSOR OHM'S

14 XT-70 Control Panel XT TROUBLE SHOOTING HUMIDITY INPUTS HUMIDITY SENSOR 4-20 MA OUTPUT + - ma DC MILLIAMP METER TYPICAL 4-20 MA < 4 ma OUT OF RANGE > 20 ma OUT OF RANGE MEASURE THE ma OUTPUT OF THE TRANSDUCER. HUMIDITY = ((ma - 4) * 100 ) / 16 EXAMPLE: MEASURED VALUE = 12.0 ma HUMIDITY = ((12.0-4) * 100 ) / 16 = 50.0 % WITH OR WITHOUT A SENSOR THE TWO OUTSIDE TERMINAL SHOULD HAVE A MINIMUM OF 16 VDC TO A MAX OF 36 VDC.

15 XT-70 Control Panel XT TROUBLE SHOOTING CO2 INPUT CO2 SENSOR 4-20 MA OUTPUT + ma - ma DC MILLIAMP METER TYPICAL 4-20 MA < 4 ma OUT OF RANGE > 20 ma OUT OF RANGE MEASURE THE ma OUTPUT OF THE TRANSDUCER. CO2 = ((ma - 4) * ) / 16 EXAMPLE: MEASURED VALUE = 12.0 ma co2 = ((12.0-4) * ) / 16 = 5000 ppm WITH OR WITHOUT A SENSOR THE TWO OUTSIDE TERMINAL SHOULD HAVE A MINIMUM OF 16 VDC TO A MAX OF 36 VDC.

16 XT-70 Control Panel XT TROUBLE SHOOTING DIGITAL INPUTS IN1 FAN PROVING WITH FAN OFF SHOULD HAVE APPROXIMATELY 11.5 VDC WITH FAN ON SHOULD HAVE 0 VDC IN2 CELL PROVING IN3 REFRIG FAIL ALL INPUTS OPERATE THE SAME. WITH THE CONTACT OPEN, SHOULD HAVE 11.5 VDC. WITH CONTACT CLOSE SHOULD HAVE 0 VDC. IN4 REMOTE STANDBY IN5 SPARE IN6 SPARE IN7 SPARE IN8 IP / PASSWORD IF YOU FORGET THE PASSWORD OR IP NUMBER, YOU CAN INSTALL A JUMPER ON IN8. POWER THE UNIT DOWN AND BACK UP AND USE THE IP ADDRESS TO GET INTO THE WEB PAGE. THE USER NAME WILL DEFAULT TO barj AND PASSWORD TO barj. YOU CAN CHECK ON THE IP AND SET A NEW PASSWORD IF NECESSARY. WHEN DONE, REMOVE THE JUMPER AND POWER THE UNIT OFF AND BACK ON.

17 XT-70 Control Panel XT TROUBLE SHOOTING DOOR CONTROLS MULTIPLE DOOR OPEN AND CLOSED OUTPUT PULSES START / STOP SWITCH MUST ME IN START TO OPERATE DOORS THE XT PANEL USES A FAIL SAFE CLOSE PULSE. THIS IS DONE WITH A NORMALLY CLOSED CONTACT. IF THE POWER WERE TO FAIL FOR ANY REASON ON THE XT CARD THE DOORS WOULD GO CLOSED. CLOSE MULTIPLE DOOR CONTROLLER 12VDC SPST NORMALLY CLOSED CONTACT RELAY NORMALLY PICKED UP AND WILL DROP OUT TO CLOSE DOOR NOTE - THE CLOSE PULSE WILL DROP THE RELAY OUT TO PRO- DUCE A PULSE TO THE DOOR CON- TROL. THE OPEN RELAY WILL PICK UP TO PRODUCE AN OPEN PULSE. OPEN 12VDC SPST NORMALLY OPEN CONTACT RELAY NORMALLY DROPPED OUT AND WILL PICK UP TO OPEN DOOR DOOR MANUAL / AUTO OPERATION DOOR OPEN DOOR CLOSE TO MANUALLY OPEN THE DOOR, PLACE THE CLOSE SWITCH IN THE OFF POSITION AND THE OPEN SWITCH TO THE OPEN PO- SITION. MAN OFF AUTO MAN OFF AUTO TO MANUALLY CLOSE THE DOOR, PLACE THE OPEN SWITCH IN THE OFF POSITION AND THE CLOSE SWITCH TO THE CLOSE POSITION. FOR NORMAL OPERATION THE DOOR SWITCHES WOULD BE IN THE AUTO MODE. TO DISABLE ANY DOOR MOVEMENT SWITCH BOTH SWITCHES TO THE OFF POSITION. NOTE - THE START / STOP SWITCH MUST BE IN THE START POSITION TO MANUALLY MOVE THE DOORS. A LOW TEMP OR AIR RESTRICTION WILL ALSO PREVENT MANUAL DOOR MOVEMENT.

18 XT-70 Control Panel XT TROUBLE SHOOTING DOOR CONTROLS SINGLE DOOR START / STOP SWITCH MUST ME IN START TO OPERATE DOORS FOR A SINGLE DOOR CONTROL THE XT PANEL PRO- DUCES A DIRECTION OUTPUT AND THEN A PULSE OUT- PUT. WITH THE DIRECTION RELAY DROPPED OUT, OR NO VOLTAGE ON J20 THE DIRECTION IS SET TO CLOSE. THE DIRECTION RELAY IS PICKED UP, OR 12VDC ON J20 THEN THE DIRECTION IS SET TO OPEN. AT ANY TIME A PULSE WILL THEN MOVE THE DOOR IN THE DIRECTION OF THE SETTING OF THE DIRECTION RELAY. J16 PULSE DIRECTION PULSE CONTROL THIS ALLOWS FOR A VERY SOFT START AND PRECISION MOVEMENT OF THE RAM. J20 DIRECTION CONTROL THE LIMIT SWITCH WILL CONTROL THE APPLICATION OF THE PULSE. START / STOP J3 DOOR MANUAL / AUTO OPERATION DOOR OPEN OPEN CLOSE AUTO DOOR CLOSE OFF PULSE AUTO TO MANUALLY OPEN THE DOOR, PLACE THE OPEN SWITCH IN THE OPEN POSITION AND THE CLOSE SWITCH TO THE PULSE POSITION. TO MANUALLY CLOSE THE DOOR, PLACE THE OPEN SWITCH IN THE CLOSE POSITION AND THE CLOSE SWITCH TO THE PULSE POSITION. FOR NORMAL OPERATION THE DOOR SWITCHES WOULD BE IN THE AUTO MODE. TO DISABLE ANY DOOR MOVEMENT SWITCH PULSE SWITCH TO THE OFF POSITION. NOTE - THE START / STOP SWITCH MUST BE IN THE START POSITION TO MANUALLY MOVE THE DOORS. A LOW TEMP OR AIR RESTRICTION WILL ALSO PREVENT MANUAL DOOR MOVEMENT.

19 XT-70 Control Panel XT TROUBLE SHOOTING DOOR CONTROLS SINGLE DOOR REV B START / STOP SWITCH MUST ME IN START TO OPERATE DOORS FOR A SINGLE DOOR CONTROL THE XT PANEL PRO- DUCES A DIRECTION OUTPUT AND THEN A PULSE OUT- PUT. WITH THE DIRECTION RELAY DROPPED OUT, OR NO VOLTAGE ON J20 THE DIRECTION IS SET TO CLOSE. THE DIRECTION RELAY IS PICKED UP, OR 12VDC ON J20 THEN THE DIRECTION IS SET TO OPEN. AT ANY TIME A PULSE WILL THEN MOVE THE DOOR IN THE DIRECTION OF THE SETTING OF THE DIRECTION RELAY. J16 PULSE DIRECTION PULSE CONTROL THIS ALLOWS FOR A VERY SOFT START AND PRECISION MOVEMENT OF THE RAM. THE LIMIT SWITCH WILL CONTROL THE APPLICATION OF THE PULSE. J20 DIRECTION CONTROL UP FOR SINGLE DOOR (DIR-GO) DOWN FOR PULSE PULSE CONTROL DIRECTION - GO CONTROL DOOR OPEN DOOR CLOSE DOOR DIRECTION DOOR PULSE MAN OFF AUTO MAN OFF AUTO OPEN CLOSE AUTO ON OFF AUTO

20 XT-70 Control Panel XT TROUBLE SHOOTING DOOR CONTROLS SINGLE DOOR REV B S3 CAVITY ON START / STOP S2 AUX 2 ON START / STOP S1 AUX 1 ON START / STOP S6 DIRECTION / GO PULSE S5 CLOSE +12vdc CLOSE DRY CONTACT S7 OPEN +12vdc OPEN DRY CONTACT

21 XT-70 Control Panel 21 CHAPTER 3 FIELD MODIFICATIONS 3.1 XT FIELD MODIFICATION DOOR CONTROLS SINGLE DOOR THIS DOES NOT APPLY FOR REV B CARDS SINGLE DOOR FIELD MODIFICATION NOTE - THIS APPLIES ONLY TO SINGLE DOOR SYSTEMS USING PULSE AND DIRECTION RELAYS DO NOT DO MODIFICATION FOR MULTIPLE DOORS PROBLEM: When the panel was running, pressing the Stop button would shut the panel down, but the mode would show standby. A fly back diode for the close relay output was providing a return path when used with a solid state pulse relay. This diode was not needed and when removed solved the problem, but introduced another issue of the door not going closed in Shutdown. Investigation into this uncovered a hidden design issue on the Switch card. SOLUTION: The solution requires the removal of a diode on the main XT card, and cutting a trace and adding a wire on the switch card. The diode can be easily removed in the field. The mod to the switch card can also be done in the field if you are comfortable soldering small wires. Other wise a board can be modified in the shop and shipped out for replacement. REVISION: The next revision to the switch card will reflect this change and be backwards compatible. Diode D12 needs to be removed. J16 PULSE This is best done using a solder iron, heating up one end, and prying it up at the same time. If no soldering iron is available, then you can use some side cutters and dike it out of the board. Try not to damage the circuit card. J20 D12 DIRECTION DIRECTION CONTROL PULSE CONTROL START / STOP J3 PROCEED TO NEXT PAGE TO FINISH MODIFICATION

22 XT-70 Control Panel 22 XT FIELD MODIFICATION DOOR CONTROLS SINGLE DOOR SINGLE DOOR FIELD MODIFICATION STEP 2 This mod is to the switch card on the back of the XT hinged cover. Note - you do not have to remove the card to make this mod. Unscrew the two hinge screws on the cover and unplug the ribbon cable to remove from cabinet and make it easier to do the mod. Back side off switch card Use a razor knife to cut the trace between the upper and middle trace. Use a ohm meter to verify that the trace is cut. Use a small piece of wire and solder to either of the bottom two connections and solder the other end to the 6th terminal down on the left side of the ribbon cable.

23 XT-70 Control Panel XT FIELD MODIFICATION PULSE DOOR CONTROLS MULTIPLE DOOR MULTIPLE DOOR FIELD MODIFICATION NOTE - THIS APPLIES ONLY TO MULTIPLE DOOR SYSTEMS USING OPEN AND CLOSE PULSES AND RELAYS DO NOT DO MODIFICATION FOR SINGLE DOORS PROBLEM: The close output on the XT board does not provide enough drive to pick up the close relay. Most single pole relays will pick up, but occasionally one will be marginal. A double pole relay will not pick up. Use a DC voltmeter to measure the voltage on the close relay, it should be at least 10vdc when relay pick up. A symptom would be the door would not go open because the close relay is not picking up. SOLUTION: Solder on a 10k 1/4 watt resistor on the switch card. REVISION: The next revision to the switch card will reflect this change and be backwards compatible. Back side off switch card Solder a 10k resistor between the pads as shown. 10k

24 XT-70 Control Panel XT FIELD MODIFICATION 4-20ma input THIS MODIFICATION IS FOR THE FOUR 4-20MA INPUTS ON THE CARD. THE ONLY INPUT THAT IS REALLY AFFECTED AND NEEDS THE MODIFICA- TION IS THE PLENUM HUMIDITY SENSOR INPUT. THE SYMPTOM IS THAT THE PLENUM HUMIDITY SENSOR READS LOW. PROBLEM: The XT card incorporated a 800 ohm series resistor to prevent over current and over voltage if the sensors wires were to short. Some humidity sensors when reading in the 90 % range do not have enough drive. The main sensor affected is the Plenum Humidity sensor. The outside humidity sensor and the CO2 sensor are not affected as much since they rarely operate in the 15ma plus range. SOLUTION: Solder on a wire jumper across the 800 ohm resistor. REVISION: The next revision to the main card will correct this situation. Details of Modification Use solder iron to tin the end of an old resistor. Solder to top end of 821 resistor. Then bend the lead down to bottom and solder and cut off. UPPER RIGHT CORNER OF XT CARD OSH PLEN H RETURN H CO2 Solder Solder 821 Short each one of the 821 resistors Cut OLD RESISTOR, USE LEAD TO SHORT 821 RESISTOR.

25 XT-70 Control Panel 25 CHAPTER 4 MODES OF OPERATION 4.1 XT Operation and Alarm Modes: The XT Panel operates differently that conventional panels. It has a Operation Mode, and a Alarm Mode. Depending on how the Alarm mode is set up, you could continue running in an Alarm mode. Example - Cell Pump failure. The Alarm mode would indicate a cell failure, send out the alarm, indicate a alarm (blinking red light) but continue to run in cooling or refrigeration. Wet bulb calculation would be shut off. 4.2 Operation Modes: Shutdown: Shutdown can only be caused by the Stop / Start switch being in the Stop position. Standby: Any alarm will cause the Red light to pulse on and off. Standby can only be caused by the time clock having no time available, or cooling air not be available. Cooling: Any alarm will cause the Red light to pulse on and off. Cooling mode can only be caused when cooling air available. Refrig: Any alarm will cause the Red light to pulse on and off. Refrig mode can be caused when cooling air is not available and the time pin is set for Refrig Run. Refrig mode can also be activated when the time pin is set to Refrig only. Timed Run:Any alarm will cause the Red to pulse on and off. Timed Run will be triggered by a Refrig time pin and no cooling air available and no refrigeration available. Remote Stop: The remote stop is a soft stop from either the HMI or web interface. Test: The test mode is a special mode that allows you to remotely test all outputs. This is entered into either from the HMI or the web interface. Low Temp:The Low Temp Alarm is triggered by the back up Plenum Low Temp limit. It is a must shut down and can only be reset with the Start / Stop switch. Air Restriction: The Air Restriction alarm is triggered by the air differential switch. It is a must shut down and can only be reset with the Start / Stop switch.

26 XT-70 Control Panel 26 Power Fail: Loss of 110vac control power. Remote Standby: Any alarm will cause the Red light to pulse on and off. Remote Standby could be caused by a remote shutdown or a demand meter shut- Alarm Standby: Any alarm condition that was set to shut the system down. Heat: Any alarm will cause the Red light to pulse on and off. Heat mode is activated when the system has been in any of the Cooling modes and the MCR timer has timed out, and the Plen_A drops below the SP - Heat_diff. The Heat AOM switch must be in Auto also. Fan Failure: The Fan Failure alarm will trigger when the Fan output is on, and the Fan current switch input is off IN1, and the Fan AOM switch is in auto. This is a must shutdown of the system. There is a programmable FF_timer. Fan Off: The Fan Off Alarm will trigger when the Fan AOM switch is turned off. SP Alarm: The setpoint is out of range, or other critical operating parameters are corrupt. 4.3 Alarm Modes: Low Deviation: The Low Dev alarm will trigger when the Plen_A drops below this point for a programmable time, and the fans are running. This alarm can produce a shutdown or optional operations. High Deviation: The High Deviation alarm will trigger when the Plen_A rises above this point for a programmable time, and the fans are running. The alarm can produce a shutdown or optional operations. Fan Manual: The Fan Manual Alarm will trigger when the Fan AOM switch is turn to manual. The alarm can produce a shutdown or optional operations. Cell Pump Fail: The Cell AOM switch must be in Auto, and the Cell pump input IN2 must have a closed contact. There is a programmable CPF_timer. Refrigeration Fail: The Refrig Alarm is a dry contact in IN3. The Refrig AOM switch must be in Auto. The alarm can produce a shutdown or optional operation. Plen Sensor Fail: The Plen sensor alarm is triggered by a programmable plen sensor difference between plen 1 and plen 2. There is also a programmable timer associated with this alarm. The alarm can produce a shutdown or optional operation.

27 XT-70 Control Panel 27 OSA Sensor Fail: The outside air sensor alarm is triggered by a out of range sensor. There is also a programmable timer associated with this alarm. The alarm can produce a shutdown or optional operation. OSH Sensor Fail: The outside humidity sensor alarm is triggered by a out of range sensor. There is also a programmable timer associated with this alarm. The alarm can produce a shutdown or optional operation. Low Humidity : The Low Humidity alarm is triggered by a plenum humidity lower than the alarm point. The system must be in a valid operating mode, and there is an associated timer with it. The alarm can produce a shutdown or optional operation. High CO2: The High CO2 alarm is triggered by a CO2 level greater than the alarm point. The system must be in a valid operating mode, and there is an associated timer with it. The alarm can produce a shutdown or optional operation. Pile Diff. High: The Pile differential between two designated sensors has exceeded the preset limit.

28 XT-70 Control Panel Operating Parameters: Parameter Description Value Range Default Fan_MOA Cell_MOA Humid1_MOA Humid2_MOA Heat_MOA Aux1_MOA Aux2_MOA Cavity_MOA DoorO_MOA DoorC_MOA Refrig_MOA CHAPTER 5 OPERATING PARAMETERS Fan Manual-Off-Auto Switch Cell Manual-Off-Auto Switch Humid1 Manual-Off-Auto Switch Humid2 Manual-Off-Auto Switch Heat Manual-Off-Auto Switch Aux1 Manual-Off-Auto Switch Aux2 Manual-Off-Auto Switch Cavity Manual-Off-Auto Switch Door Open Manual-Off-Auto Switch Door Close Manual-Off-Auto Switch Refrigeration Manual-Off-Auto Switch RTC Run Time Clock Program Cooling OSA_Diff Outside Air Differential Program +/- 50 F -1 Diff_Ref Differential Reference Program SP, P1-P8 SP Wet_D Wet Bulb Depression Calculated 0-25 F Wet_A Wet Bulb Adjusted Program 0-25 F Start_T Start Temperature Calculated F SP Temperature Setpoint Program F 45.0 HSP Humidity Setpoint Program % 95.0 CO2_SP CO2 Setpoint Program ppm 2000 TSP Target Setpoint Program F 45.0 TCH Target Cooling Hours Program hrs 0 TRR Target Ramp Rate Program F 0 LHA Low Humidity Alarm Program % 90.0 HCO2A High CO2 Alarm Program ppm 3000 Cavity_D Cavity Differential Program F 18 FD_Output Freq Drive Output Program % 100 FD_Min Freq Drive Minimum Output Program % 50 FD_Update Freq Drive Update Time Program hrs 0 FD_Diff Freq Drive Pile Differential Program FD_Ref_SP Freq Drive Refrigeration Output Program % 100 FD_Timed_SP Freq Drive Timed Output Program % 75

29 XT-70 Control Panel 29 Operating Parameters: Parameter Description Value Range Default OSA_T Outside Air Temperature Measured F OSA_H Outside Humidity Measured % Plen_H Plenum Humidity Measured % RTN_H Return Humidity Measured 0-100% CO2 CO2 Level Measured ppm Door Open Fresh Air Door Open Percent Calculated % Plen_A Plen1 & Plen2 average temperature Calculated Fan Fan percent of operation Calculated % Refrig Level Refrigeration level of operation Calculated % Last Stop Time since last Shutdown Calculated hrs P1 Pile 1 Temperature Measured F RTN Return Temperature Measured F P2 Pile 2 Temperature Measured F P3 Pile 3 Temperature Measured F P4 Pile 4 Temperature Measured F P5 Pile 5 Temperature Measured F P6 Pile 6 Temperature Measured F P7 Pile 7 Temperature Measured F P8 Pile 8 Temperature Measured F E2 Parameters Filter Sensor Digital Filter Program KP_P Cooling Proportional Gain Program KI_P Cooling Integral Gain Program KD_P Cooling Derivative Gain Program Update_TP Cooling Update Time Program I_Mult_P Cooling Integral Multiplier Program D_Mult_P Cooling Derivative Multiplier Program Min_PW Cooling Minimum Pulse Width Program Cell_EFF Cell Efficiency Program % 90 MCR Minimum Cooling Run Time Program min 5 RAS Rise above Setpoint Program F 3 HDT High Deviation Timer Program min 10 LDT Low Deviation Timer Program min 3

30 XT-70 Control Panel 30 Operating Parameters: Parameter Description Value Range Default CAT Cooling Air Timer Program min 3 FFT Fan Fail Timer Program min 1 CFT Cell Fail Timer Program min 1 PSFT Plenum Sensor Fail Timer Program min 3 OTSFT Outside Temp Sensor Fail Timer Program min 3 OHSFT Outside Humid Sensor Fail Timer Program min 3 LHT Low Humidity Timer Program min 60 HCO2T High CO2 Timer Program min 60 PSDT Plenum sensor Differential Timer Program min 15 Cavity_Config Cavity Sensor Configuration Program 1-8, MRR Minimum Refrigeration Run Time Program min 30 KP_1 Refrigeration Proportional Gain Program KI_1 Refrigeration Integral Gain Program KD_1 Refrigeration Derivative Gain Program Update_T1 Refrigeration Update Time Program I_Mult_1 Refrigeration Integral Multiplier Program D_Mult_1 Refrigeration Derivative Multiplier Program CO2_PW Refrigeration Door Minimum Pulse Width Program DT Door Time Program sec 180 RMOL Refrigeration Minimum Operating Level Program % 30 RMOL_Update Refrigeration Minimum Operating Timer Program sec 60 CO2_RAS CO2 Purge Rise above Setpoint Program F 5 Max_Door CO2 Purge Max Door Open Program % 20 CO2_Diff CO2 Differential Program ppm CO2_Update CO2 Purge Timer Program min 3 ROL_Start_Dly Refigeration Min Operation Start Delay Program min 5 AUX 1_config Aux Switch 1 configuration Program 0,1 0 AUX 2_config Aux Switch 2 configuration Program 0,1 0 Door_Config Door Configuration Program 0,1 0 Cool_Hrs Cooling hrs in ramp mode Program CO2_cnfg CO2 Sensor Configuration Program 0,1,2,3,4 0 Heat_Diff Heat Differential 1/10ths Program 2 Heat_Update Update time for Heat Program sec 40 Heat_PW Heat on pulse width Program sec 5 200

31 XT-70 Control Panel 31 CHAPTER 6 E2 PARAMETERS FILTER KP_P KI_P KD_P UPDATE_TP I_MULT_P D_MULT_P MIN_PW: CELL_EFF: The filter is a value from 1 to 10. This number will weight the analog values for all the temperatures, humidity and CO2 readings. The default value is 6, increasing this value will cause the readings to be more highly filtered and slower to change. Cooling proportional gain. The default value is 8, increasing this value will cause the overall system performance to become faster. Cooling integral gain. The default value is 1. The integral gain produces an error based on small errors over time. Increasing this value will cause the small error to be amplified over time, and the system to be more sensitive to small errors. Cooling Derivative gain. The derivative is produced by a sudden change in the error. If the temperature is several degrees above setpoint, the PID will ramp quickly. The error may not change much until the door reaches a given position. At this point the tempera ture would drop quickly. The derivative acts like a brake and will offset the error when large changes are being made. If the temperature over shoots at start up, you would want to increase the Derivative. The default setting is 100. This value is in 1/10 s of a second, and determines when the PID loop is updated. The default value is 40. Increasing this value will slow down the entire loop, decreasing will cause the loop and response to speed up. Integral Timer Multiplier. The default setting is 3, which means the integral will be calculated every three update times. This is an engineering variable and should normally not be changed. Derivative Timer Multiplier. The default setting is 2, which means the derivative will be calculated every two update times. This is an engineering variable and should normally not be changed. This is the minimum pulse width time. A value of 0 will disable this function. The default setting is 0, and the value is in milliseconds. Some door controllers will not respond to small pulses and this could be used to provide a minimum pulse width. Cell efficiency. The efficiency of different evaporative cooling cells can vary greatly depending on a number of variables. CELL_EFF allows you to set the efficiency of a given Evaporative cooling system. This can be determined by setting the Cell to 100 percent and watching it on a good warm dry day. The setting is from 0 to 100 percent. MIN_COOLING_RUN: This variable is in minutes and will guarantee that once you go into the Cooling mode, you will stay in this mode for a minimum run time and not short cycle. Typical settings would be from 15 to 30 minutes. The default setting is 5 minutes. RAS: HI_DEV_TIMER: Rise above Setpoint. The RAS variable is the amount the Plenum can rise above setpoint before cooling air is terminated. For this variable to be active the OSA needs to be above the Start Temperature. This setting is in 1/10ths of a degree. The default setting is 5, or.5 degrees. High deviation timer. This timer will determine how long the Plenum temperature can remain above the High Deviation point before a High Deviation Alarm will occur. The default setting is 10, and the units of measure are minutes.

32 XT-70 Control Panel 32 E2 Parameters Definition: LO_DEV_TIMER: COOL_AIR_TIMER: FAN_FAIL_TIMER: CELL_FAIL_TIMER: PLEN_SEN_FAIL: OSA_TEMP_FAIL: OSA_HUMID_FAIL: LOW_HUMID_TIMER: HIGH_CO2_TIMER: PLEN_SEN_DIFF: Low deviation timer. This timer will determine how long the Plenum temperature can remain below the Low Deviation point before a Low Deviation Alarm will occur. The default setting is 3, and the units of measure are minutes. Cooling Air Available Timer. When the mode changes from Cooling to Standby, this timer will be active. This setting will force the mode to stay in Standby until this amount of time elapses. This is to prevent short cycling when OSA cooling is marginal. The default setting is 3 minutes. Fan Failure Timer. When the fans are given a signal to start this timer will start timing and will be reset once the fans are proven. If the fans fails to start, you will get a Fan Fail Alarm after this amount of time elapses. The default setting is 1 minute. A setting of 0 will disable the Fan Fail Alarm. Cell Pump Failure Timer. When the Cell Pump is given a signal to start this timer will start timing and will be reset once the cell is proven. If the pump fails to start, you will get a Cell Pump Fail Alarm after this amount of time elapses. The default setting is 0, which will disable the Cell Fail Alarm. A typical setting would be 1 minute. Plenum Sensor Fail Timer. If the plenum sensor were to short, open, or have the sensor difference exceed the PLEN_SEN_DIFF setting, this timer would have to time out before you would get a Plenum Sensor Fail Alarm. The default setting is 3 minutes, and a 0 setting will disable the alarm. Outside Air Sensor Fail Timer. If the outside air sensor were to short or go open, this timer would have to time out before you would get a Outside Sensor Fail Alarm. The default setting is 3 minutes, and a 0 setting will disable the alarm. Outside Air Humidity Sensor Fail Timer. If the outside humidity sensor were to fail, this timer would have to time out before you would get a Outside Humidity Fail Alarm. The default setting is 3 minutes, and a 0 setting will disable the alarm. Plenum Low Humidity Timer. If the Plenum Humidity were to fall below the Low Plenum Humidity Setpoint, this timer would have to elapse before a Alarm would be active. The default setting is 60 minutes, and a setting of 0 will disable the alarm. High CO2 Timer. If the CO2 level were to go above the CO2 Setpoint, this timer would have to elapse be fore the High CO2 Alarm would be active. The default setting is 60 minutes, and a setting of 0 will disable the alarm. Plenum Sensor Difference Alarm. The Plenum has 2 sensors which are averaged for accurate temperature control. If the reading between these two sensors were to be greater than this setting, then the Plenum sensor fail timer would start timing out, for a Plenum Sensor Fail Alarm. This setting is in 1/10ths of a degree. The default setting is 15 or 1.5 degrees. A setting of 0 will disable this alarm.

33 XT-70 Control Panel 33 E2 Parameters Definition: CAVITY_CONFIG: Cavity Sensor Configuration. The cavity uses two sensors for control, one for the cavity wall or cavity return air sensor and one for the pile sensor. The configuration setting allows you to choose which sensors to use. The first number is the wall sensor and the second number is the pile sensor. Example: If you want P1 to be the Pile Sensor and P8 to be the wall sensor, then the setting would be 18. The default setting is 18. MIN_REFRIG_RUN: KP_1 KI_1 KD_1 UPDATE_T1 I_MULT_1 D_MULT_1 CO2_PW: DOOR_TIME: Minimum Refrigeration Run. This setting will allow the refrigeration to run for a minimum time, regardless of cooling air availability. Default setting is 30 minutes. Refrigeration proportional gain. The default value is 8, increasing this value will cause the overall system performance to become faster. Refrigeration integral gain. The default value is 1. The integral gain produces an error based on small errors over time. Increasing this value will cause the small error to be amplified over time, and the system to be more sensitive to small errors. Refrigeration Derivative gain. The derivative is produced by a sudden change in the error. If the temperature is several degrees above setpoint, the PID will ramp quickly. The error may not change much until the refrigeration reaches a given level. At this point the temperature would drop quickly. The derivative acts like a brake and will offset the error when large changes are being made. If the temperature over shoots at start up, you would want to increase the Derivative. The default setting is 100. This value is in 1/10 s of a second, and determines when the PID loop is updated. The default value is 40. Increasing this value will slow down the entire loop, decreasing will cause the loop and response to speed up. Integral Timer Multiplier. The default setting is 3, which means the integral will be calculated every three update times. This is an engineering variable and should normally not be changed. Derivative Timer Multiplier. The default setting is 2, which means the derivative will be calculated every two update times. This is an engineering variable and should normally not be changed. CO2 Door Pulse Width. This setting will determine the pulse width for door opening and closing during CO2 purging or load control while running Refrigeration. The default setting is 1000 milliseconds. Door open time. This time in seconds will determine the door position. This value is determined by timing the door open cycle and door closed cycle. The two values should be averaged. The default setting is 70 seconds. REF_LEVEL: Refrigeration minimum operation level. The system will uses the fresh air doors to maintain a minimum operating level. This will keep the refrigeration from

34 XT-70 Control Panel 34 E2 Parameters Definition: short cycling under light loads and also provides a constant CO2 purge. The default setting is 50 percent. ROL_UPDATE: CO2_RAS: MAX_DOOR: CO2_DIFF: CO2_UPDATE: ROL_START_DLY: AUX 1_CONFIG: Refrigeration operating level update timer. This timer will determine how often the doors can be pulsed to maintain the minimum refrigeration operating level. The default setting is 20 seconds. CO2 purge rise above setpoint. If the plenum rises above setpoint this amount during refrigeration, the doors will be blocked from opening any further. This value is in 1/10 s of a degree. CO2 purge max door opening. This setting will only allow the fresh air doors to open a maximum amount during a CO2 purge for refrigeration. CO2 differential. This setting will determine how far below the CO2 Setpoint that the purge will go before shutting off. The default setting is 200 ppm. CO2 Purge Timer. This timer will determine how often the CO2 control Logic is updated. The default setting is 10 minutes. Refrigeration operating level start delay. This timer provides an initial delay for the minimum loading control logic. The default setting is 5 minutes. This setting will configure the Aux 1 output for different control configurations. A setting of 0 will cause the Aux 1 output to follow the fan operation. A setting of 1 will configure Aux 1 for ERV control. Energy Recovery Ventilator Control turns on the Aux 1 output when CO2 levels exceeds the CO2 SP and shuts off when the CO2 Level drops below the CO2_DIFF. AUX 2_CONFIG: DOOR_CONFIG CO2_CONFIG This setting will configure the Aux 2 output for different control configuration. A setting of 0 will cause the Aux 2 output to follow the fan operation. This setting will configure the XT Door Open & Close outputs for different control configurations. A setting of 0 will configure the outputs for Pulse Control. Pulse Control will cause the open output to produce a open pulse and the close output to produce a close output. A setting of 1 will configure the outputs for Directional control. Directional control will cause the Open output to set a Directional output and the close output to produce a pulse to either drive the doors open or close. The default value for this setting is 0. This setting will Configure the XT CO2 input (AN16) for a variety of CO2 sensor ranges. The default value for this setting is 0. A setting of 0 = ppm 1 = ppm 2 = ppm 3 = ppm 4 = ppm HEAT_DIFF Heat Differential. This setting will determine how far below Temp SP the Plenum temperature can drop before the Heat mode is activated. This setting is in 1/10ths of a degree. The default setting is 2 or 0.2 degrees

35 XT-70 Control Panel 35 E2 Parameters Definition: HEAT_UPDATE HEAT_PW Heat Update Time is the time period that must elapse before the Heat ON time will increased or decreased. This setting is in seconds and has a range of The default setting is 40 seconds. Heat Pulse Width is the amount of time that the heat ON time will increase or decrease. This setting is in seconds and has a range of The default setting is 5 seconds. Heat Example: The Goal of the heat mode is to maintain the plenum temperature between SP and the Heat differential by cycling the Heater on & off. The amount of Time ON and Time OFF will change as needed to maintain a steady Plenum Temp. With Heat Diff (0.2f), Heat update (40 sec) and Heat pulse width (5 sec). If the Plenum temp drops 0.2f below Temp SP. Heat output will be on for 5 Seconds and off for 35 seconds. If Plenum temp continues to drop further below the SP-Heat Diff. Heat output will increase to 10 sec ON & 30 sec OFF. Heat ON time will continue to increase, if needed, 5 seconds every 40 seconds until the heat stays on for 40 seconds of every 40 seconds. When Plenum temperature is between SP and the Heat Diff the time ON & time OFF will halt and neither increase or decrease, If the Plenum temperature has not changed since the previous update. If the Plenum temperature has climbed since the previous update, the time ON will decrease 5 seconds. If the plenum temperature has dropped since the previous update the time ON will increase 5 seconds. If the Plenum temp climbs to SP the heat ON time will decrease to 0.

36 XT-70 Control Panel Setting E2 Parameters: CHAPTER 7 SETTING E2 PARAMETERS The E2 memory parameters are different than the flash parameters. All of the flash parameters can be programmed using the HMI. The E2 memory parameters are composed of values that are not frequently changed. These values would primarily be setup at panel installation. The only way that these parameters can be changed is by using the web interface. Using the Web interface, the E2 parameters can be changed. To set all values to the Defaults, click on the Set To Defaults buttons. To look at the current values, click on the Load button. Any of the values can be changed, then click on Save to store the new values.

37 XT-70 Control Panel 37 Setting E2 Parameters: Page two of E2 memory Parameters.

38 XT-70 Control Panel 38 CHAPTER 8 COLOR TOUCH SCREEN PROGRAM UPDATE 8.1 G70 HMI PROGRAMMING To change the HMI setup or to download a new program, you must enter the Power On Setup Mode. Press and hold upper left corner, and power unit up. After a few seconds the unit will display Power On Setup. You can now make changes. Power On Setup: The Power On Setup utility is used to set up or change the operation settings of the terminal. Power On Setup includes functions to do the following: Download new firmware to the terminal Download user applications to the terminal Select the application mode Set communications settings for the terminal Adjust display settings (contrast, backlight, orientation) Enter network (Ethernet) settings Enter / change password (if used) Perform touch screen calibration Set the real time clock Back: move between categories, functions and options Select: select a category, function or option Next: move between categories, functions and options

39 XT-70 Control Panel 39 G70 HMI PROGRAMMING Power On Setup FLASH MEMORY App Mode: Run App Erase FFS CALIBRATION Temp: 22.3 C Date: Tue 12 Jul 05 Time: 13:08:25 Touch Screen DISPLAY Contrast (133) Backlight (255) Orient: Landscape Dcache: All NETWORK IP: Sub: Gate: l BACK SELECT NEXT Power On Setup: The Power On Setup utility is used to set up or change the operation settings of the terminal. Power On Setup includes functions to do the following: Download new firmware to the terminal Download user applications to the terminal Select the application mode Set communications settings for the terminal Adjust display settings (contrast, backlight, orientation) Enter network (Ethernet) settings Enter / change password (if used) Perform touch screen calibration Set the real time clock Back: move between categories, functions and options Select: select a category, function or option Next: move between categories, functions and options Use the back and next key to navigate thru the different categories. Press the Select key to

40 XT-70 Control Panel 40 G70 HMI PROGRAMMING select a category. The next and back keys can be used to change a value. NETWORK: The default value for the HMI IP address should be for a local display. If you are using multiple HMI s or Remote HMI s then the IP address may be different. This address should always be noted, as it is used for update the HMI. If any changes are made, you must use the Done category and then select the save and exit. Note - the HMI contains to programs. One is call firmware and is the operating system, much like XP or Windows. The factory will from time to time come up with new features for the HMI and to use these features would require an update to the firmware. The other program is call the Application, and is the program that generates the screens and all the communications. To download firmware or an application program the HMI must be in the download mode. To enter into the download mode, bring the HMI up in the Power On Setup mode. Position the cursor on the FLASH MEMORY category Press the SELECT button, cursor should move to the App Mode Press the SELECT button, cursor should move to the Run app Press the BACK button, App Mode should change to Download Press the SELECT button, cursor should move to App Mode Press the BACK button twice, cursor should move to DONE Press the SELECT button twice The HMI should now be ready to download application. Note the IP address on the screen. Also the Firmware version should be or newer. If the Firmware version is older, then it will be necessary to down load the Firmware first.

41 XT-70 Control Panel 41 G70 HMI PROGRAMMING In order to use the Ethernet download, you lap top must be on the same subnet. The subnet is the first three numbers of the IP address. Use the Upgrade firmware Button to update the HMI operating system. The G70 and G75 may use two different operating systems, depending on the type of processor being used. The older units use a MIPS 92 mhz processor, and will use the mips bin files. The newer units use a X- Scale processor and need to be upgraded with the xscale bin files. The current version of operating system is The only time that you would need to upgrade the operating system, is when we were to upgrade our PC programming software. The programming software for the G70 and G75 is a bff file.

42 XT-70 Control Panel G70 HMI FIELD UPDATE QUICK Equipment needed: Laptop, QlarityDownloader.exe program, HMI update bff file and a straight Ethernet Cable. Power up your lap top and plug the Ethernet cable into the lap top and also into a spare slot on the Ethernet hub in the panel. If you are using a wireless card or internal wireless you may need to disable it. This can be done by right clicking on my network places, and going to properties. Note - if you do not have a Ethernet port or want to use a serial port, you would need to order a power supply and cable from BTU. Part number PO Your laptop needs to be on the same subnet as the HMI. The subnet is the first three sections of the IP number. At the time the subnet for all HMI units is To check you lap top, go to Start, Run and type in cmd You will get a dos window. Type ipconfig CHAPTER 9 COLOR TOUCH SCREEN FILED UPDATE Check your ip address, if it starts out then you are ready to go. If not, then close the command prompt and do the following. Right Click on you network places icon. Click on properties, choose your Local area connection, right click and the click on properties. Double click on internet protocol. You should now have a screen like this. Most laptops will be configured to obtain an IP address automatically. If this is the case, then select the Use the following IP address and use the following numbers. IP and Subnet mask Press OK, and exit out of the program. You should not be setup for communicating with the XT HMI and Rabbit. Sometimes you may have to reboot your lap top to get the setting to take.

43 XT-70 Control Panel 43 G70 HMI FIELD UPDATE QUICK GUIDE To update the software on the HMI, you must put it into a download mode. Use 2amp breaker inside the panel to power XT panel down. Press and hold upper left corner, and close the 2 amp breaker. After a few seconds the unit will display Power On Setup.

44 XT-70 Control Panel 44 G70 HMI FIELD UPDATE QUICK GUIDE Power On Setup FLASH MEMORY App Mode: Run App Erase FFS CALIBRATION Temp: 22.3 C Date: Tue 12 Jul 05 Time: 13:08:25 Touch Screen DISPLAY Contrast (133) Backlight (255) Orient: Landscape Dcache: All NETWORK IP: Sub: Gate: l BACK SELECT NEXT Press the SELECT button, cursor should move to the App Mode Press the SELECT button, cursor should move to the Run app Press the BACK button, App Mode should change to Download Press the SELECT button, cursor should move to App Mode Press the BACK button twice, cursor should move to DONE Press the SELECT button twice The HMI should now be ready to download application. Note the IP address on the screen. Firmware version xxxxxxxxxxxxxx Built xxxxxxxxxxxxxxxxx Download application ( ) Note - the IP number ( ) might be different depending on the application. You will need this number to download the new program.

45 XT-70 Control Panel 45 G70 HMI FIELD UPDATE QUICK GUIDE You should have a separate directory on you laptop for the downloader program and bff file. Double click on the QlarityDownloader.exe program. You should get the following screen: Make sure the IP Address of unit is the same number as shown on the HMI. If not, then type in the correct number. The download file is has an extension of bff. Use the Browse button to select the correct file. Click on Download Application. When finished downloading, the HMI will automatically reboot. The new version number should show up in the bottom right corner of the main screen. Note - if you are upgrading multiple units, you can leave this program up and running, unplug the Ethernet connection and plug into the next unit. Put the HMI in the download mode, and verify the IP number. The Click on the Download Application.

46 XT-70 Control Panel 46 CHAPTER VAC FIELD WIRING VAC FIELD WIRING J2 J7 J FAN FREQ DRIVE 120VAC RELAY FAN 120VAC MAG STARTER NON FREQ DRIVE OPTION HUMID 1 HEAD MAG STARTER HUMID 2 HEAD MAG STARTER OL OL OL RED LIGHT YELLOW LIGHT GREEN LIGHT FREQ DRIVE OPTION RELAY TO DRIVE START INPUT HUMIDITY CONTROL OPTION THE HUMIDIFER HEADS ARE ON ANY TIME THE FANS ARE RUNNING. THE PUMPS ARE PULSED ON AND OFF. GND UPS NEUTRAL SYSTEM NEUTRAL UPS L1 SYSTEM L1 UPS CONNECTION 120 vac male plug 120 vac female plug 120 vac PANEL POWER G N L1

47 XT-70 Control Panel VAC FILED WIRING J11 J15 J18 J EVAP PUMP 120VAC MAG STARTER HUMID 1 120VAC PUMP RELAY HUMID 2 120VAC PUMP RELAY RETURN AIR HEATER 120VAC MAG STARTER OL OL J23 J25 J AUX 1 120VAC MAG STARTER AUX 2120VAC MAG STARTER CAVITY 120VAC MAG STARTER OL OL OL SYSTEM NEUTRAL

48 XT-70 Control Panel 48 CHAPTER 11 SENSOR FIELD WIRING 11.1 LOW VOLTAGE SENSOR FIELD WIRING PLENUM 1 PLENUM 2 OUTSIDE AIR RETURN PILE 1 PILE 2 AN1 S AN2 S AN3 S AN4 S AN5 S AN6 S PILE 3 PILE 4 PILE 5 PILE 6 PILE 7 PILE 8 AN7 S AN8 S AN9 S AN10 S AN11 S AN12 S OUTSIDE HUMIDITY PLENUM HUMIDITY RETURN HUMIDITY RETURN CO2 HUMIDITY SENSOR 4-20MA HUMIDITY SENSOR 4-20MA HUMIDITY SENSOR 4-20MA CO2 SENSOR 4-20MA ma AN13 AN14 AN15 AN15

49 XT-70 Control Panel 49 CHAPTER 12 INPUT / OUTPUT FIELD WIRING 12.1 LOW VOLTAGE INPUT / OUTPUT FIELD WIRING IN1 FAN PROVING IN2 CELL PROVING IN3 REFRIG FAIL IN4 REMOTE STANDBY IN5 SPARE IN6 SPARE IN7 SPARE Rev B board: The external open and close relays are on board with the new updated Rev B board. The close relay uses a normally close contact for the on board relay, just as shown with the original board. The Rev B board has the option of using either a dry contact or a 12vdc output signal. See the SDX section of the manual for more information. IN8 IP OVERRIDE CLOSE 12VDC SPST NORMALLY CLOSED CONTACT RELAY NORMALLY PICKED UP AND WILL DROP OUT TO CLOSE DOOR OPEN 12VDC SPST NORMALLY OPEN CONTACT RELAY NORMALLY DROPPED OUT AND WILL PICK UP TO OPEN DOOR J44 FREQ DRIVE 0-20MA V I G + - J4 AIR RESTRICTION J46 REFRIG 0-20MA V I G + - J5 LOW TEMP NOTE - LOW TEMP IS SHOWN IN NORMAL CONDITION. SHORT CIRCUIT MUST BE ON TOP TWO PINS FOR PANEL TO COME OUT OF SHUTDOWN.

50 XT-70 Control Panel RABBIT FIRMWARE BOOTLOADER CHAPTER 13 RABBIT FIRMWARE UPDATES The Rabbit is the heart of the XT-70 control panel. It functions as the communications hub, and record keeper for the XT card. Currently you need a special cable and program to upgrade the software for the rabbit. We have developed a boot loader program that allows us to remotely upgrade the software via the Ethernet connection. The boot loader program is a resident program that allows you to download a new bin file and then activate it. The rabbit will hold two programs, the old one and the new one. With the proper authorization, you can access the Firmware manager from the Site Configuration page. To update the rabbit, click on the Browse button and select the new bin file. Then click on Upload and the new file will be uploaded to the rabbit. Once loaded the new file should show up in the INACTIVE status. Click on the Activate button to initialize the new software. When the rabbit powers up, it will load the ACTIVE file. Note - to use this new feature, the bin file being Uploaded, must be ver or greater. The old version will not load, and could only be loaded using the zworld programming cable. Updating old and new rabbits with the boot loader: To use this feature the rabbit must be loaded one time with the boot loader file XT bootloader 001.bin The only way that you can do this is with the zworld programming cable. Use the

51 XT-70 Control Panel 51 standard procedure, and download the bootloader 001.bin file. Once you have loaded this file, connect your pc to the rabbit Ethernet port. Note - this can be done thru a hub, crossover cable or other ways. The first time you install the bootloader, you need to be aware of a number of possibilities. Once the bootloaded is install, future updates are very simple and do not require the follow cautions. Browse to and you should get the firmware manager shown on the previous page. Note - this will happen only the first time that you update the old rabbits to this processor, or programming a new rabbit. Once the rabbit has the new 037 or new software, you will have to access the firmware manger from the site configuration page. Upload the new bin file, and then activate it using the button. At this point if this is an old rabbit and it has a IP different than the , the first web page would not load. You would at this point go back to the original IP. The best thing at this point is to power down the rabbit, and power back up and load the new web file using the /upload.htm process. Note - once rebooted with the new 037 or new bin file, the web pages are running off of the panel code, not the new bootloader code. From now on each version of the XT panel firmware will possess the ability to upload new versions of itself. Once you have gone thru this process, you will be able to upload simply by accessing the firmware manger. Should something go wrong with the rabbit firmware that prohibits you from uploading, there is a back door. Place a jumper across pins 2 and 9 of J49. Re power the board, and browse to You are now back in the bootloader code. This will allow you to upload new firmware. Be sure to remove the jumper before activating new XT panel firmware.

52 XT-70 Control Panel 52 CHAPTER 14 RABBIT BOOTLOADER RABBIT FIRMWARE BOOTLOADER The rabbit bootloader is the heart of being able to easily update the rabbit software. The initial version 001 had some problems. Version 003 has changed the approach and is solid. Unfortunately changing the bootloader is not a easy process and requires the use of a rabbit programming cable. This should be done by only factory authorized personnel. Note - you will need a small black 2 pin jumper, to be able to access the rabbits back door. 1. Unhook the panel from the network, and plug your lap top into the panel network switch. 2. Go to the panel web page, then to the config sight page. Record all the settings for the config page. A. IP address B. Subnet Mask C. Gateway D. Name E. Panel # F. UDP port 3. Power the XT panel down and connect the rabbit program cable. Power up and use the rabbit utilities to load bootloader 003. Power the XT panel down and remove the cable when done. 4. Install the little black jumper on pins 2 & 9 of the white J49 socket. This is the second set of pins from the top on J49. Install a short on IN8 on the top right side of the XT card. The little black jumper on the J49 will force the bootloader to a IP of The short on IN8 will force the user name to barj and the password to barj. With jumpers installed power the XT board back up. 5. Use your lap top to access web page , this should bring up the bootloader page. Use the Browse button to select the XT Panel bin file. Click on Upload. Now click on the Activate button across from the software. 6. When done, the web server should ask you for your user name and password. Use barj for the user name and barj for the password. This should bring you to the main web page. 7. Go to the web sight 8. If your panel has been recently updated, you should only have to upload the config.htm file. Upload this file. If you have old files, then go thru and update each file. 9. Go back to the main page, and then click on Config Site. 10. Click on the Default Settings button. You may get a message that document contains no data. Click on ok. Press on F5 to refresh the page. 11. Go thru each category on the config page and type in the correct information. Note - you can press submit for each change, and wait until you have all changes made to save the data. 12. There is two new values. On the Ethernet dropdown, there is a DNS server tab. You

53 XT-70 Control Panel 53 will need to call your ISP to get the DNS server number. You may also be able to check your router for the DNS number. 13. The last tab will now say . If you wish to use the functions, you will need to enter this data. The SMTP server is your mail server. It should have the following form smtp.ultraplix.com It should be smtp. and then your provider. Then set your panel address and the recipients address. 14. If you want to use the text messaging, check the address for your cell phone provider. You can find the list in this manual. 15. Power the XT panel down and remove both the jumpers. Power back up and connect the network cable and make sure all is working on the designated IP address.

54 XT-70 Control Panel Text messaging using Send a Text Message Service Providers CHAPTER 15 HOW TO SEND TEXT MESSAGE BY The following text messaging service providers are supported. Alianet (NBTel, MTT, NewTel, and Island Tel) (from: 11, msg: 140, total: 140)Enter your phone number. Message is sent to number@wirefree.informe.ca Alltel (from: 50, msg: 116, total: 116)Enter your phone number. Goes to number@message.alltel.com. Ameritech (ACSWireless) (from: 120, msg: 120, total: 120)Enter your phone number. Goes to number@paging.acswireless.com Arch Wireless (from: 15, msg: 240, total: 240)Enter your phone number. Sent via (assumes blank PIN) AU by KDDI (from: 20, msg: 10000, total: 10000)Enter your phone number. Goes to username@ezweb.ne.jp BeeLine GSM (from: 50, msg: 255, total: 255)Enter your phone number. Goes to number@sms.be .ru Bell Mobility Canada (from: 20, msg: 120, total: 120)Enter your phone number, including the 1 prefix. Goes to number@txt.bellmobility.ca Bellsouth (from: 20, msg: 160, total: 160)Enter your phone number. Goes to number@bellsouth.cl BellSouth Mobility (from: 15, msg: 160, total: 160)Enter your phone number. Goes to number@blsdcs.net Blue Sky Frog (from: 30, msg: 120, total: 120)Enter your phone number. Goes to number@blueskyfrog.com Boost (from: 30, msg: 120, total: 120)Enter your phone number. Goes to number@myboostmobile.com Cellular South (from: 50, msg: 155, total: 155)Enter your phone number. Messages are sent to number@csouth1.com CellularOne (Dobson) (from: 20, msg: 120, total: 120)Enter your phone number. Goes to number@mobile.celloneusa.com CellularOne West (from: 20, msg: 120, total: 120)Enter your phone number. Goes to number@mycellone.com Centennial Wireless (from: 10, msg: 110, total: 110)Enter your phone number. Sent via Cincinnati Bell (from: 20, msg: 50, total: 50)Enter your phone number. Goes to number@gocbw.com Cingular (from: 20, msg: 160, total: 160)Enter your phone number. Goes to number@mobile.mycingular.com Cingular Blue (formerly AT&T Wireless) (from: 50, msg: 150, total: 150)Enter your phone number. Goes to number@mmode.com Cingular IM Plus/Bellsouth IPS (from: 100, msg: 16000, total: 16000)Enter 8 digit PIN or user name. Goes Cingular IM Plus/Bellsouth IPS Cellphones (from: 100, msg: 16000, total: 16000)Enter phone number. Goes Claro (from: 20, msg: 160, total: 160)Enter your phone number. Goes to number@clarotorpedo.com.br Comviq (from: 20, msg: 160, total: 160)Enter your phone number. Goes to number@sms.comviq.se Dutchtone/Orange-NL (from: 15, msg: 150, total: 150)Enter your phone number. Messages are sent to number@sms.orange.nl Edge Wireless (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@sms.edgewireless.com EinsteinPCS / Airadigm Communications (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@einsteinsms.com EPlus (from: 20, msg: 480, total: 480)Enter your phone number. Goes to number@smsmail.eplus.de. Estonia Mobile Telefon (from: 20, msg: 160, total: 160)Enter your phone number. Sent via webform.

55 XT-70 Control Panel 55 Fido Canada (from: 15, msg: 140, total: 140)Enter your phone number. Goes to Golden Telecom (from: 20, msg: 160, total: 160)Enter your phone number or nickname. Messages are sent to Idea Cellular (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to Kyivstar (from: 30, msg: 160, total: 160)Sent by addressing the message to LMT (from: 30, msg: 120, total: 120)Enter your username. Goes to Manitoba Telecom Systems (from: 20, msg: 120, total: 120)10-digit phone number. Goes Meteor (from: 20, msg: 160, total: 160)Enter your phone number. Goes to Metro PCS (from: 20, msg: 120, total: 120)10-digit phone number. Goes to Metrocall Pager (from: 120, msg: 120, total: 120)10-digit phone number. Goes to MobileOne (from: 20, msg: 160, total: 160)Enter your phone number. Goes to Mobilfone (from: 20, msg: 160, total: 160)Enter your phone number. Goes to Mobility Bermuda (from: 20, msg: 160, total: 160)Enter your phone number. Goes to MTS Primtel (from: 20, msg: 160, total: 160)Enter your phone number. Sent via web gateway. Alianet (NBTel, MTT, NewTel, and Island Tel) (from: 11, msg: 140, total: 140)Enter your phone number. Message is sent to Netcom (from: 20, msg: 160, total: 160)Enter your phone number. Goes to Nextel (from: 50, msg: 126, total: 126)10-digit phone number. Goes to Note: do not use dashes in your phone number. NPI Wireless (from: 20, msg: 160, total: 160)Enter your phone number. Goes to NTC (from: 20, msg: 160, total: 160)Enter your phone number. Sent via web gateway. O2 (formerly BTCellnet) (from: 20, msg: 120, total: 120)Enter O2 username - must be enabled first at Goes to username@o2.co.uk. O2 M-mail (formerly BTCellnet) (from: 20, msg: 120, total: 120)Enter phone number, omitting intial zero - must be enabled first by sending an SMS saying "ON" to phone number "212". Goes to +44[number]@mmail.co.uk. Optus (from: 20, msg: 114, total: 114)Enter your phone number. Goes Orange (from: 20, msg: 160, total: 160)Enter your phone number. Goes You will need to create a user account at orange.net first. Oskar (from: 20, msg: 320, total: 320)Enter your phone number. Goes Other (from: 15, msg: 100, total: 100)If your provider isn't supported directly, enter the address that sends you a text message in phone number field. To be safe, the entire message is sent in the body of the message, and the length limit is really short. We'd prefer you give us information about your provider so we can support it directly. Pacific Bell Cingular (from: 20, msg: 120, total: 120)10-digit phone number. Goes Pagenet (from: 20, msg: 220, total: 240)10-digit phone number (or gateway and pager number separated by a period). Goes to number@pagenet.net. PCS Rogers (from: 20, msg: 125, total: 125)10-digit phone number. Goes to number@pcs.rogers.com. Requires prior registration with PCS Rogers. Personal Communication (Sonet) (from: 20, msg: 150, total: 150)Enter your phone number. Goes to sms@pcom.ru with your number in the subject line. Plus GSM Poland (from: 20, msg: 620, total: 620)10-digit phone number. Goes to number@text.plusgsm.pl. Powertel (from: 20, msg: 120, total: 120)10-digit phone number. Goes to number@ptel.net Primtel (from: 20, msg: 150, total: 150)Enter your phone number. Goes to number@sms.primtel.ru PSC Wireless (from: 20, msg: 150, total: 150)Enter your phone number. Goes to number@sms.pscel.com Qualcomm (from: 20, msg: 120, total: 120)Enter your username. Goes to username@pager.qualcomm.com Qwest (from: 14, msg: 100, total: 100)10-digit phone number. Goes Safaricom (from: 15, msg: 160, total: 160)Goes Satelindo GSM (from: 15, msg: 160, total: 160)Goes SCS-900 (from: 15, msg: 160, total: 160)Goes Simple Freedom (from: 15, msg: 160, total: 160)Goes Skytel - Alphanumeric (from: 15, msg: 240, total: 240)Enter your 7-digit pin number as your number and your message will be mailed to pin@skytel.com Smart Telecom (from: 15, msg: 160, total: 160)Enter your phone number. Goes Smarts GSM (from: 11, msg: 70, total: 70)Enter your phone number. Sent via

56 XT-70 Control Panel 56 smsgate.exe Southern Linc (from: 15, msg: 160, total: 160)Enter your 10-digit phone number. Goes Sprint PCS (from: 15, msg: 160, total: 160)Enter your 10-digit phone number. Goes Sprint PCS - Short Mail (from: 15, msg: 1000, total: 1000)Enter your phone number. Goes SunCom (from: 18, msg: 110, total: 110)Enter your number. will be sent to number@tms.suncom.com. SureWest Communications (from: 20, msg: 200, total: 200)Enter your phone number. Message will be sent to number@mobile.surewest.com SwissCom Mobile (from: 20, msg: 10000, total: 10000)Enter your phone number. Message will be sent to number@bluewin.ch T-Mobile Germany (from: 15, msg: 160, total: 160)Enter your number. will be sent to number@t-d1-sms.de T-Mobile Netherlands (from: 15, msg: 160, total: 160)Send " ON" to 555 from your phone, then enter your number starting with will be sent to number@gin.nl T-Mobile UK (from: 30, msg: 160, total: 160)Messages are sent to number@t-mobile.uk.net T-Mobile USA (from: 30, msg: 160, total: 160)Messages are sent to number@tmomail.net T-Mobile USA (Sidekick) (from: 30, msg: 10000, total: 10000)Messages are sent to username@tmail.com Tele2 Latvia (from: 20, msg: 160, total: 160)10-digit phone number. Goes to number@sms.tele2.lv. Telefonica Movistar (from: 20, msg: 120, total: 120)10-digit phone number. Goes to number@movistar.net Telenor (from: 20, msg: 160, total: 160)10-digit phone number. Goes to number@mobilpost.no. Telia Denmark (from: 20, msg: 160, total: 160)8-digit phone number. Goes to number@gsm1800.telia.dk. Telus Mobility (from: 30, msg: 120, total: 120)10-digit phone number. Goes to 10digits@msg.telus.com. The Phone House (from: 20, msg: 160, total: 160)10-digit phone number. Goes to number@sms.phonehouse.de. TIM (from: 30, msg: 350, total: 350)10-digit phone number. Goes to number@timnet.com. UMC (from: 10, msg: 120, total: 120)Sent by addressing the message to number@sms.umc.com.ua Unicel (from: 10, msg: 120, total: 120)Sent by addressing the message to number@utext.com US Cellular (from:, msg: 150, total: 150)Enter a 10 digit USCC Phone Number. Messages are sent via usc.ztango.com/uscwmss Verizon Wireless (from: 34, msg: 140, total: 140)Enter your 10-digit phone number. Messages are sent via to number@vtext.com. Verizon Wireless (formerly Airtouch) (from: 20, msg: 120, total: 120)Enter your phone number. Messages are sent to number@airtouchpaging.com. This is ONLY for former AirTouch customers. Verizon Wireless customers should use Verizon Wireless instead. Verizon Wireless (myairmail.com) (from: 34, msg: 140, total: 140)Enter your phone number. Messages are sent via to number@myairmail.com. Vessotel (from: 20, msg: 800, total: 800)Enter your phone number. Messages are sent to roumer@pager.irkutsk.ru. Virgin Mobile Canada (from: 20, msg: 140, total: 140)Enter your phone number. Messages are sent to number@vmobile.ca. Virgin Mobile USA (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@vmobl.com. Vodafone Italy (from: 20, msg: 132, total: 132)Enter your phone number. Messages are sent to number@sms.vodafone.it Vodafone Japan (Chuugoku/Western) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@n.vodafone.ne.jp Vodafone Japan (Hokkaido) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@d.vodafone.ne.jp Vodafone Japan (Hokuriko/Central North) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@r.vodafone.ne.jp Vodafone Japan (Kansai/West -- including Osaka) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@k.vodafone.ne.jp Vodafone Japan (Kanto/Koushin/East -- including Tokyo) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@t.vodafone.ne.jp Vodafone Japan (Kyuushu/Okinawa) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to number@q.vodafone.ne.jp Vodafone Japan (Shikoku) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to num-

57 XT-70 Control Panel 57 Vodafone Japan (Touhoku/Niigata/North) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to Vodafone Japan (Toukai/Central) (from: 20, msg: 160, total: 160)Enter your phone number. Messages are sent to Vodafone Spain (from: 20, msg: 90, total: 90)Enter your username. Messages are sent to Vodafone UK (from: 20, msg: 70, total: 90)Enter your username. Messages are sent to Voicestream (from: 15, msg: 140, total: 140)Enter your 10-digit phone number. Message is sent via the gateway, since they changed their web gateway and we have not gotten it working with the new one yet. Weblink Wireless (from: 20, msg: 160, total: 160)Enter your phone number. Goes WellCom (from: 20, msg: 160, total: 160)Enter your phone number. Goes WyndTell (from: 20, msg: 480, total: 500)Enter username/phone number. Goes

58 XT-70 Control Panel MICROCHIP MPLAB ICD 2 CHAPTER 16 ANALOG P1 PROCESSOR UPDATE Procedure for updating the Analog P1 processor on the XT card: Note - this procedure allows you to read all the E2 parameters from the existing chip before erasing and will then program the E2 parameters along with the new hex file. 1. Power the XT card down, plug in the ICD 2 plug into the J13 plug on the XT panel. 2. Power the XT card up. 3. Start the MPLAB IDE program 4. Click on the Programmer tab, Select Programmer, then select 1. MPLAB ICD 2 This output window should pop up and after a few seconds you should get the MPLAB ICD 2 Ready. If you do not get the MPLAB ICD 2 Ready, then check connections, make sure the XT is powered up, and all plugs are in. Note - When the ICD 2 programmer is plugged in correctly, the CR1 green led next to the analog processor should not be blinking. Once in a while it may be necessary to reboot your Laptop to get the USB connection to the programmer to take. 5. Click on the View tab, then select 5. EEPROM. You should get the following pop up window.

59 XT-70 Control Panel Click on the Programmer tab, then select Read. The EEPROM window should turn partially Red. The Red values are the EE parameters that are stored on the chip. 7. Click on the File Tab, then select Import. Open the desired Analog hex file, example would be XT Analog V1.49.hex. The output window should now show loaded and the correct file. 8. Click on the Programmer tab, then select Program. You should get the following screen. If you get the following screen, you have had a successful program and reinitialized the prior E2 parameters. Note the EEPROM Verify Succeeded and the Programming Succeeded. At this point power down the XT panel, disconnect the programming cable and apply power. CR1 should now be blinking and you should be ready to go.

60 XT-70 Control Panel MICROCHIP MPLAB ICD 2 PROGRAM INSTALLATION PROCEDURE This Programmer is commonly referred to as the puck programmer, primarily because it looks like a hockey puck. It can be purchased from Digikey - part number - DV ND It costs about $ It is used to program the PIC 18 series Microchip microprocessors The following is a step by step process to install the software that comes with the programmer. Before installation - DO NOT CONNECT ICD2 to PC computer. Start: Double-click on the setup.exe file. At Welcome screen, click next Click I Accept then next Make sure Complete is checked, then click on Next At Choose Destination Directory window, click Next At the Copying Files window, click Next. After copying the files, several windows will pop up, asking if you want to view the installation instructions. Click No on all of them. One window may only have OK as a choice. Choose OK to close. Click Finish. Close the Document Viewer program. In Windows Explorer, go to C\Program Files\MPLAB IDE\Utilities\MPUsbIRU Double-click on MPUsbIRU.exe Check ICD 2 and click on Pre-Install. When it says Done in the lower box, click Close.

61 XT-70 Control Panel 61 Click No when asked to save the log. With nothing else running, plug in the ICD2 into the USB port PLUGGED INTO CIRCUIT BOARD DO NOT HAVE ICD2 A Found New Hardware wizard will start - click Next. A message may come up asking if it is okay to install the driver. Click Yes. Click Finish Repeat process when the next Found New Hardware window comes up. BEFORE STARTING MPLAB: Plug the ICD2 into the device to be programmed and power up the device. Start MPLAB IDE MPLAB defaults to the PIC 18F452. If you are programming a different chip, click configure on the menu bar, then select device. Change the drop down box to the desired chip - then click OK Import the hex file by clicking on File > Import.. Browse to the location of the hex file, se lect the hex file, the click open. Next, enable the programmer. On the menu bar, click Programmer > Select Programmer > MPLAB ICD2 A wizard starts up, click next Make sure USB is selected, then click next Make sure target has own power supply is selected, click next Check the MPLAB IDE automatically connects to the MPLAB ICD2 box, then click next. Click Next on the next screen Click Finish Click OK when asked about downloading new operating system.

62 XT-70 Control Panel 62 At the FYI window, click OK MPLAB will download the operating system. When finished, you should see the message MPLAB ICD2 ready in the output window. To program a chip, click on Programmer > Program on the menu bar. When the output window reads Programming succeeded, MPLAB ICD2 ready, shut down MPLAB and disconnect the ICD2 from the device. Default the device, and cycle the power. Quick steps for programming a device 1) Connect the ICD2 to the device to be programmed and power up the device. 2) Start MPLAB IBE 3) Select ICD2 programmer 4) Select View, EEPROM 5) Select Programmer, Read 6) Select File, Import Hex file 7) Select Programmer, Program 8) Power down device being programmed & move program plug to next device 9) Power up new device, Repeat steps 5 thru 8 to program addition devices

63 XT-70 Control Panel 63 CHAPTER 17 SDX DOOR CONTROLS OPTIONS 17.1 SDX DOOR DRIVE CARD FEATURES: Zero crossing switch power supply. No relay arcing Pulse contact input Pulse 4-20ma input 4-20 ma linear input isolated 4-20 ma linear input non isolated 0-10vdc input Dual doors per card Test - Off - ON switch for each door Isolated 4-20 ma vdc output 4 cards, up to 8 doors On board communications Automatic HMI setup Door fail bypass Blown fuse detection Direction and GO push button for each door Exact door position feed back Over all multiple door position 17.2 Typical Pulse Input Optional 4-20ma output for Louvers OPEN CLOSE Pulse inputs from Control Panel OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G SDX TERMINAL BLOCKS

64 XT-70 Control Panel 64 CHAPTER 17 SDX DOOR CONTROLS OPTIONS 17.3 XT Pulse Input Optional 4-20ma output for Louvers XT-70 Rev A Close Open OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G ma pulse or Linear Optional 4-20ma output for Louvers Or existing DR-420 cards (+) (-) 4-20ma isolated input OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G

65 XT-70 Control Panel 65 CHAPTER 17 SDX DOOR CONTROLS 17.5 SDX DOOR CONTROLS CARD NUMBER ASSIGNMENT The SDX door controls provides a very flexible way to control up 8 doors. Each card will control 2 doors, and are designated Door A and Door B. Card 1 would always control the Master Doors, cards 2,3, and 4 would be for volume doors. The card number and staging is done with 4 on board dip switches. Use switches 1 & 2 to set the card number. Switches 3 & 4 are used to set up to 4 stages CARD 1 CARD 2 CARD 3 CARD 4 Set switches 1 & 2 according to the above diagram. Drive A Drive B SDX CARD The SDX card can have up to 4 Stages. Stage one will be the first to open, Stage 2 next, Stage 3 next and then Stage 4. On the close cycle, Stage 4 will close first, Stage 3 next, Stage 2 next and Stage 1 will close last. Doors A & B on each card can be set to different stages. Each Drive A or B can be set for two different stages. On Card 1 either drive A or B can be set for either Stage 1 or 2. Drives A or B on Card 2 can be set for Stage 2 or 3. Drives A or B on Card 3 can be set for Stage 2 or 3. Drives A or B on Card 4 can be set for Stage 3 or 4. CARD # 1 STAGE 1 OR 2 DOOR A & B CARD # 2 STAGE 2 OR 3 DOOR A & B DOOR A SW 3 DOOR B SW 4 DOOR A SW 3 DOOR B SW 4 STAGE 1 OFF STAGE 1 OFF STAGE 2 OFF STAGE 2 OFF STAGE 2 ON STAGE 2 ON STAGE 3 ON STAGE 3 ON

66 XT-70 Control Panel 66 CARD # 3 STAGE 2 OR 3 DOOR A & B CARD # 4 STAGE 3 OR 4 DOOR A & B DOOR A SW 3 DOOR B SW 4 DOOR A SW 3 DOOR B SW 4 STAGE 2 OFF STAGE 2 OFF STAGE 3 OFF STAGE 3 OFF STAGE 3 ON STAGE 3 ON STAGE 4 ON STAGE 4 ON 17.6 SDX SYSTEM EXAMPLES 6 DOOR SDX SYSTEM STAGING DOOR 1 DOOR 2 DOOR 3 DOOR 4 DOOR 5 DOOR 6 A B A B A B CARD 2 CARD 1 CARD

67 XT-70 Control Panel DOOR SDX SYSTEM STAGING DOOR 1 DOOR 2 DOOR 3 DOOR 4 DOOR 5 DOOR 6 A B CARD A B CARD A B CARD

68 XT-70 Control Panel ACTUATOR FIELD WIRING (ORIGINAL XT MAIN CARD) Drive Head - Top View RET. EXT. 2 3 Heater 4 5 (-) yellow 6 (+) red XT-70 CLOSE J16 Blue Blue//White Black Yellow Red Brown/White Brown Green White OPEN J20 V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B Rev A CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac

69 XT-70 Control Panel ACTUATOR FIELD WIRING (XT REV B MAIN BOARD) Drive Head - Top View RET. EXT. 2 3 Heater 4 5 (-) yellow 6 (+) red XT-70 Rev B Switches set for Dry Contact J16 Blue Blue//White Black Red Yellow Brown/White Brown Green White J20 V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B Rev A CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac

70 XT-70 Control Panel SDX MULTIPLE CARD WIRING ORIGINAL XT MAIN CARD CLOSE OPEN J16 XT-70 J20 J52 MAIN RS-485 V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac 120 VAC 120 VAC V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac 120 VAC

71 XT-70 Control Panel SDX MULTIPLE CARD WIRING XT MAIN CARD REV B XT-70 Rev B Switches set for dry contact J16 J16 XT-70 Rev B MAIN J52 RS-485 V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac 120 VAC 120 VAC V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac 120 VAC

72 XT-70 Control Panel ACTUATOR POTENTIOMETER SETTING In order to determine an accurate door position, the feed back potentiometer needs to be set. This potentiometer has nothing to do with the door control, but only provides a accurate door position. The setting of the potentiometer is the same with either a 24 or 36 actuator. Drive Head - Top View Heater RET. EXT (-) yellow 6 (+) red Make sure that you are wired as shown on pins 8 and 9. Fully extend the actuator, so that the door is closed. Unhook one of the wires, and use a ohm meter to measure between pins 8 & 9. The potentiometer needs to be adjusted for 1000 ohm s or 1K. Reconnect the wire, and cycle the door fully open and then fully closed. This will cause the SDX card to read the limits and convert the readings to a 0 to 100 percent opening.

73 XT-70 Control Panel SDX DOOR LABELING The HMI now has a display that shows the status of the SDX door card. In order to use this feature, you need to assign a number to each of the doors. This is different from the card number and each card will have two door numbers. To do this at the present time, you need to use terminal to save the number in to the card E2 memory. The doors should be numbered from left to right looking at the doors from the outside of the building. Thus the display would be looking at the front side of the doors. The first thing is the set your cards up for the door staging and then you can assign the doors numbers to the cards. The display will automatically determine how many doors you have in the system and will show the rest as grayed out. To set the door numbers, you will need to bring up terminal and use a RS-485 converter. Terminal needs to be set up for 9600 baud. When the connected you should see short strings every few seconds from each card. The first two characters of the string will identify the card number.

74 XT-70 Control Panel SDX DOOR PROGRAMMING The XBase program can be configured to program CR-110, CO2 controllers and SDX cards. To setup the load the sdx.inf file from the SDX section of the web tech page. Paste this sdx.inf file into the xbase directory. Create a shortcut to your desktop and the right click on the shortcut and modify the Target with a space and the SDX. This will cause the XBase program to open with the sdx.inf format file. Use a RS-485 converter like you were going to program a CR-110 and plug into the white communications plug on any of the SDX cards.

75 XT-70 Control Panel SDX DOOR PROGRAMMING The SDX Pulse input is designed to interface with any dry contact open and close pulse system. These pulses are then converted to a direction and go signal for the actuators, giving you all the advantages of the SDX card. With this option, you also get a 4-20ma output signal for a return air louver. The Pulse input takes a 12vdc input signal. If you are using a dry contact, then you can pick up the 12vdc on the SDX card.

76 XT-70 Control Panel SDX DOOR PROGRAMMING The 4-20ma PULSE input is designed to respond to the current pulse produced by the Galaxy panel. This pulse is neutral at 12ma, open at 16ma, and closed at 8ma. The 4-20ma LINEAR input is used when the temperature control output is 4-20ma. Staging on the doors is done by using the START and END percentages programmed on the SDX card. 0 % is equal to 4ma and 100 % is equal to 20ma. The feed back pot on the actuator must be used in this application. The SDX in this mode can be used for a direct replacement of the DR-420. The 0-10vdc LINEAR input is used when the temperature control output is 0-10vdc. Staging on the doors is done by using the START and END percentages programmed on the SDX card. 0 % is equal to 0vdc and 100 % is equal to 10vdc. The feed back pot on the actuator must be used in this application.

77 XT-70 Control Panel SDX DOOR PROGRAMMING The SDX card keeps track of the cumulative time it takes the door to move from one limit switch to the other. If this time is exceeded and the door is not on a limit, the door will alarm. This will cause the next door to start staging. The alarm is self clearing if the door returns to its limit. Two parameters Door Fail A and Door Fail B, need to be programmed on the SDX card. Typical settings are 70 seconds for a 24 actuator and 110 seconds for a 36 actuator. The SDX door controller has two parameters Door # A & Door # B. This parameter is used to determine the order that the doors are displayed on the graphical interface. The graphical interface is looking from left to right on the outside of the building. The number 1 door is the door farthest to the left. The Start and End percentages only come into play when using the 4-20ma linear or 0-10vdc linear modes. If you have two doors, you could set Door A for a Start of 10% and a End of 50%. Door B would be set for a Start of 50% and a End of 100%. This is a flexible way to stage the doors in any manner you want SDX DOOR PROGRAMMING USING TERMINAL

78 XT-70 Control Panel 78 V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac RS-485 cable or Plug Each card has two E2 memory address for the door number. Door A has a E2 address of $05, and Door B has a E2 address of $06. Create a Function key in terminal to program the door number. The format is as follows: <EW card # 0506 door A # door B #>cksum. Example: Set door A to 01 and door B to 04 on card 02 Example: Set door A to 02 and door B to 03 on card 01 <EW >0047 <EW >0047 You can do all cards on the same RS-485 connection, since they are all connected together. On the new Rev A cards there is a white RS-485 plug on the bottom right corner that is just like the ones on the XT and CR-110 cards. This is so you can just plug in and not have to wire the 485 connection in. RS-485 connection to SDX cards. RS-485 SDX RS-485 SDX CC - + CC - + G MAIN XT-MB XT RS-485 communications connection to SDX Door drive card. - + AUX Upper left corner of the XT main circuit card. G - +

79 XT-70 Control Panel SDX original card and SDX Rev A card DRIVE A DRIVE B RET. EXT. RET. EXT. Note - The wiring of the limit switches on the original SDX and the new Rev A SDX are identical. The Rev A has logic to the microprocessor for the limit switches reversed to correct a previous issue. Bottom line - The SDX software will adapt for either the original or the Rev A SDX card. You will need to tell the software which version of card it is being used in. V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac 17.9 SDX E2 memory setup Parameter E2 Address Default Description Filter or FF Digital Filter Baud Rate or FF 00 = 9600 Input Type or FF 00 = Pulse 01 = 4-20ma Pulse Drive A # to 08 for Door number Drive B # to 08 Door number Card Revision or FF 01 = Rev A 00 = Original Note - if the E2 memory has not been programmed it will have FF in its memory locations. The table above shows the defaults of a number or FF. If the memory location has FF in it, the card will automatically use the default number. For example the Filter parameter. If it has not been programmed, then it will see FF and use the value 06. The main values that need to be programmed with the version 1.11 or newer software, is the Drive A & B numbers, and the Card Revision number is using an original SDX card. On the Rev A SDX the door numbers are the only critical parameter, since the FF default is for the Rev A card.

80 XT-70 Control Panel 80 There are two ways of setting the E2 parameters on the SDX card. One is with terminal, as described in the previous pages. A more simpler approach involves using the Hockey puck, or fixed programmer that is used on the XT P1 processor. Section 16.1 of this manual describes how to read the E2 memory on the Pic 18 series processor. When you read the E2 memory in the process, you can also double click on the value and change it. The next step in the process is to import the SDX.hex file and then program the chip. When you click on program, the new E2 values will be sent to the processor. Referring back to the E2 memory address table, you can easily identify the current settings of the card. In this example: Filter = 06, Baud Rate = 00 or 9600, Input type = 00 or Pulse, Drive A = Door 2, Drive B = Door 3, Card Revision = 00 or original SDX card.

81 XT-70 Control Panel ACTUATOR FIELD WIRING SCX Single Door Card Drive Head - Top View RET. EXT. 2 3 Heater 4 5 (-) yellow 6 (+) red Yellow Red Black Blue//White Blue Green White Brown/White Brown 18 vac 2.5 amp SB HEATER XT-70 SCX J16 J20

82 XT-70 Control Panel ACTUATOR FIELD WIRING SCX Single Door Card S3 CAVITY ON START / STOP S2 AUX 2 ON START / STOP S1 AUX 1 ON START / STOP S6 DIRECTION / GO PULSE S5 CLOSE +12vdc CLOSE DRY CONTACT S7 OPEN +12vdc OPEN DRY CONTACT DIRECTION / GO PULSE

83 XT-70 Control Panel ACTUATOR FIELD WIRING SCX Single Door Card DIRECTION - GO CONTROL DOOR DIRECTION OPEN CLOSE AUTO DOOR PULSE ON OFF AUTO When operating the SCX in manual, use the open switch to set for open or close, then use the close door switch to switch from OFF to On to run the door. In order to operate the SCX in Auto the DOOR_CONFIG byte must be set to 1 for the original XT card and 2 for Rev B. For Pulse the DOOR_CONFIG must be 0. You must be using ver 1.82 or later for the P1 Analog processor.

84 XT-70 Control Panel ACTUATOR FIELD WIRING SCX Single Door Card SCX Trouble Shooting Manual Test: Position both Open and Close switches to off. Start / Stop switch to Start. You should not have either the green led on for the Open and Close switches. Flip the Open switch to Man, and then toggle the Close switch from OFF to Man to open the door. To close the door switch the Open switch to OFF and then toggle the Close switch from OFF to Man to close the door. If the manual operation works, then switch the open and close switches to Auto and test the door control in Cooling. On the Dir input on the SCX card, you will have 12vdc when you are set to open. If set to close you will have 0vdc. On the Pulse input, you will have 12vdc when ever the drive is active during the pulse.

85 XT-70 Control Panel INTRODUCTION CHAPTER 18 COM1000 NETWORKING On many of the XT panel installations the only form of communications is a phone line. With a single XT panel you can simply plug a modem in to the XT board. This will allow you to set up a dial up PPP connection to the panel. Once connected you can use a web browser to communicate with the panel. Records can also be downloaded directly into an Excel spread sheet. The problem comes when you get more than one XT panel at a complex with only a dial up phone line. We have been working with the manufacturers of a device called the Com1000 to provide a dial up network. The Com1000 is much like a router, only it has a modem connection and functions as a PPP server. This would be the same type of connection used to connect with a ISP for internet service. Panel 01 Phone Line Panel 04 MODEM Serial COM1000 Panel 02 Panel 05 Ethernet Hub CAT5 Ethernet Panel 03 Panel 06 This example will be used In this documentation

86 XT-70 Control Panel IP ASSIGNMENTS DEVICE IP GATEWAY TCP PORT UDP PORT COM XT PANEL XT PANEL XT PANEL XT PANEL XT PANEL XT PANEL The above table shows a possible configuration for the 6 XT panels. Note - the TCP and UDP ports are the same. This allows the com1000 to route either TCP or UDP with one IP forward. This can also be used with routers to simplify the setup. Note - the panel Gateway must be set to the IP of the Com XT PANEL IP SETUP Use the embedded web server to setup each of the XT panels to the desired IP address and port number. It is best to have the XT panel separated from the network when changing IP numbers. Note - you can use a jumper on the IN 8 to default the panel to Use the following screens to setup the XT panel. Note - the DNS server will depend on the server and will be setup at a later date. 4001

87 XT-70 Control Panel COM1000 FLASH UTILITY If you have not loaded the Com1000 Flash Utility 3.6 and the Com1000 Configuration Utility 2.45 on your PC, then go to the following web sight and download these programs: They are located near the bottom of the page. You will also need to download the latest bin file C bin or later version. If this file is not listed you can download it from the Bar J page. The first step is to use the Flash Utility to update the operating program. If the Com1000 has already been updated, proceed to the Configuration Utility. To update the Com1000 operating program use the flash utility program and browse to the latest file. Use a standard RS-232 cable to connect the desired com port on your PC and also to the terminal port on the com1000. Click on the Start button and you will be prompted to reset the Com1000. Press the reset button next to the Ethernet port on the Com1000. Be patient, it will take some time.

88 XT-70 Control Panel COM1000 CONFIGURATION Note - use can use either a Ethernet connection or a RS-232 connection to communicate with the Com1000 for parameter setup. The RS-232 is slow, thus it is recommended that you use the Ethernet connection. You must set your lap top up to the same subnet, just like you do for the XT panel. In this example you could use , just as long as the first three numbers are the same and the last number is different than the other devices. Under the Connection Type, select LAN and then connect. You should find the Com1000 and then load all the values. The Com1000 allows you to save a setup as a template. I have created a 6 panel template that can be downloaded from the bar j web site. Download this program then go to File Open and the new values will be displayed in yellow under New Value. Click on the Write button and follow the prompts. Next you need to click on the termi-

89 XT-70 Control Panel 89 In the terminal window type in AT*MSETUP=ATS0=1 and then Enter. You should get a OK back. To Save the values type in AT&W and the Enter. You should get a OK back. This is necessary due to a software bug in the configuration Utility. This should be fixed soon and it will not be necessary. The Com1000 should now be ready to go. You should power the Com1000 and the Modem down at this point and then power back up. Try calling the modem and make sure that it answers.

90 XT-70 Control Panel 90 The default user name and password for the Com1000 dial up is com1000 and com1000. It is suggested that you leave this as the default and use the remember password feature in the dial up connection. This gets you access to the network only, each panel will still have it s own security. Note below the Password is the PPP server (Peer) IP. This IP is what you will use with your Browser to access the panels on the Dial up account.

91 XT-70 Control Panel NETWORK TESTING You can download a free UDP test tool from the following address: This is like a terminal program and works great for testing out your network. Under the remote IP address enter the address of the desired panel and its Port number. Then enter a <GR01>0047 or appropriate panel number. Click on the send and you should get back the received data string. Check each of the panels.

92 XT-70 Control Panel SETTING UP A DIAL UP ACCOUNT This will lead you thru the set up of a dial up account on your PC for the XT1000. Got to Start, Setting and then New Connection Wizard. Select Connect to the Internet. Select Setup My Connection Manually. Select Connect Using a Modem. Type in the Name of the Complex, for the connection name. Type in the Phone number. Select Anyone Use. Type in com1000 for user name and password. Uncheck both options for defaults. Select Finish. CHAPTER 19 DIAL UP ACCOUNT Go to Start, Settings and network connection. Select the connection you just made. Click on Properties

93 XT-70 Control Panel 93 Under the General Tab, under Connect using, you should be showing the modem that you are using on your PC. Click on the Configure button. All Hardware features should be Enabled. Click on OK

94 XT-70 Control Panel 94 Click on the Settings button and make sure the first two PPP settings are checked. Click on the Properties Button and make sure that you are set up to Obtain an IP address automatically.

95 XT-70 Control Panel 95 You can access your new dial up account by going to Start, Settings and Network connection. A short cut can also be created from this menu. To call the storage, click on dial and wait for a connection. Once a connection has been established you can open your internet browser USING YOUR WEB BROWSER Once you have connected via a dial up connection, you would use the PPP IP address of the Com1000 along with the TCP port for the panel. Example: For Panel 1 you would use For Panel 2 you would use Download records into Excel for panel 1, use

96 XT-70 Control Panel 96 CHAPTER 20 New 3365 Rabbit OLD RABBIT NEW RABBIT The major difference between the two rabbits, is that the New 3365 has an added IC. The old rabbit has the pads on the board, but does not have the IC installed. New IC on 3365 No IC on old rabbit Once the software is loaded on each rabbit, they will both perform the same and you can not tell the difference. Rabbit had one of its main IC s be discontinued, and came out with the new 3365 to replace the old one. The 3365 required some major changes to the program, so we decided to maintain two different sets of software. When we make changes, we will update both rabbits so you can continue to have all features. The new rabbit requires the use of a plug in memory card. The power should always be off when plugging or unplugging the memory card. We are currently using the 32meg XD picture cards. We can use a larger card, but may require a program change. The 3365 uses the memory card for the bootloader, main program, records and main flash parameters. This new program incorporates all the web pages into it, and does not require the loading of the individual pages Initialization Process Plug the 3365 into a XT main board. Install the 32 meg XD picture card into the rabbit. Use the rabbit programming cable, along with the RFU software to download the new boot loader software XT_3365_bootloader 100.bin. Power the card down and remove the programming cable. In stall a small black jumper across pins 2 & 9 of the J49 socket. This will force the bootloader page to come up the address of Once you have the bootloader program up, use browse to find the XT_ bin program. Click on download to load the new program. Then click on activate and you should be up and running. Power down and remove the small black jumper on J49. You can now access the rabbit at to set all the parameters. Be sure and erase the records initially. You can program up the flash cards, and then just insert into a new rabbit and it will come up and run. All parameters and programs are in the flash card.

97 XT-70 Control Panel 97 APPLICATION NOTE INDEX APP-1 Compressor Freq Drive (Freq Drive Compressor Control) This application Note will describe how to use the CR-110 to control a freq drive compressor for load control. This example will use a 4 compressor skid. Each compressor will have a CR-110 on it and they will be numbered 01,02,03, and 04. Compressor 01 will have a freq drive connected to it, with a minimum setting of 30%. This example is also using two sets of parallel compressors. C1 & C2 are parallel, and C3 & C4 are parallel. I will address the parallel aspect of it at the end of the application note. APP-2 Compressor Suction Control (Multiple Thermostat Controlled LLS) This application Note will describe how to use the CR-110 to control the suction pressure instead of temperature. In this application, a number of unit coolers are used with independent LLS control for multiple temperature zones. The compressor suction Setpoint will be set for the lowest suction pressure needed. APP-3 Nelson Chiller (CR-110 retrofit on a old surplus chiller) This application Note will describe how to use the CR-110 to control 4 forty hp parallel compressors. The compressor have one LLS and one expansion valve. Each compressor has 2 unloaders, providing a total of 12 stages of refrigeration. The evaporator is a tube chiller bundle used to chill 20,000 gallons of process water to 40 degrees. APP-4 ER-110 (Use of the ER-110 Electronic Expansion Value) This application Note will describe how to use the ER-110 to control two electronic expansion valves from one ER-110A card. Both of the EEV s must be on the same condenser unit. Other options for single EEV and for EEV / EPR valves are also available. APP-5 Screw Compressor (Use of the CR-110 to control Screw Comp) This application Note will describe how to use the CR-110 to control either Copeland or Hitachi Screw Compressors. The main difference between the Hitachi and the Copeland is the Hitachi has an extra fast unload solenoid. A additional relay and time delay is used for the fast unload at start up. APP-6 SDX Door Control (Use the SDX to replace the DR-4-20 door control) This application Note will describe how to use the SDX card to directly replace a DR-420 that is operating in the 4-20ma mode, using a potentiometer to provide feed back for door position. Note - the SDX card has to be a rev A or greater to use this feature. APP PID Loop Control (Explanation of new style PID Loop for XT) This application note will describe how to implement and tune the new XT PID The new PID loop can run in either a Cooling or Heat Mode. APP-8 Fresh Air Timed Purge When the XT panel has a CO2 sensor, this application of the Timed Purge will not be applicable. When the XT panel does not have a CO2 sensor, then it must rely on a timed operation to purge the CO2 build up. APP-9 CR-110 Air Defrost On Seed Potato s the temperature can be taken as low as 36 degrees. Running refrigeration at this temperature will form ice. An air defrost will simply shut off the refrigeration for a set amount of time and allow the coil to defrost. This application note will define the CR-110 defrost parameters.

98 XT-70 Control Panel 98 APPLICATION NOTE INDEX APP-10 Ambient Reverse Loading ARL ( Ambient Reverse Loading) is a new way to bring fresh air into a storage during long runs of Refrigeration. The bottom line, is that Potato s need fresh air!! There are many different gases that build up in a storage and can affect the health of a storage. CO2 is the easiest to measure of these gases, and is always present when the buildup of gases occurs. Thus CO2 is the best and easiest gas to measure and use for control. APP-11 Heat Recovery Ventilator A heat recovery ventilator (HRV) can help make mechanical ventilation more cost effective by reclaiming energy from exhaust airflows. HRVs use heat exchangers to heat or cool incoming fresh air, recapturing 60 to 80 percent of the conditioned temperatures that would otherwise be lost. This application note will describe operation of a HRV in a refrigerated locker. APP-12 Network Router Setup A router is used to provide a sub network of IP numbers and provide access to the outside world. For use in our world, it allows the use of one static IP number to access a large number of panels using different ports. When the request comes into the router on a given port, the router will look up the corresponding internal IP number and route the information to it. APP-13 Rack Refrigeration System The system this application note is written for is at the Hancock Research Center in Wisconsin. This system has 18 evaporators, each associated with a individual bin and XT panel. Each bin has an independent Setpoint and can require hot gas defrost at any time, depending on the temperature. A parallel compressor rack system, was the most logical way to go. APP-14 CR-110 Basic Refrigeration This application Note will describe how to hook up and program CR-110 for Basic Refrigeration and Air Defrost Profiles. This information is primarily for doing a retrofit in the field. A new feature has been added that allows the use of a third unloader. Output 4 can now be either condenser fan 4 output or unloader 3 output. If you specify the number of unloaders less than 3 then the output 4 is the condenser fan. Setting the number of unloaders to 3 will activate the output 4 as unloader 3. APP-15 CR-110 Basic Refrigeration & Parallel compressors This application Note will describe how to hook up and program CR-110 for Basic Refrigeration and using parallel compressors. This information is primarily for doing a retrofit in the field. If the compressor is over 30hp it is recommended to use a relay to drive the compressor mag. The inrush current on the larger contactors can be enough to cause the on board fuse to blow. This example will show the additional relay. A lot of compressor may share condenser fans. This example will also show how to hook up two CR-110 cards for parallel condenser fans. APP-16 CR-110 Screw Compressor Soft Start This application deals with a screw compressor where the amps needed to be limited because of a 200 amp service. The program changes involve adding some parameters to compare to the amp reading and unload the compressor if necessary. The other component involves the starting of the compressor. A soft start device is being used and has a number of conditions that need to be met.

99 XT-70 Control Panel 99 APP-17 RS-485 Communications APPLICATION NOTE INDEX This application note will explain RS-485 communications and field applications. APP-18 ER-110 Saving Energy This application note covers some of the advantages of using the ER-110 with the electronic expansion valves. This note has some real data to show the possibilities and savings. APP-19 Refrigeration Suction Control This application note covers some new advances using suction pressure control on screw compressors. The results from this type of control are the best in the industry. APP-20 Xbase Installation & Update This application note covers how to install Xbase for all the different devices. APP-21 Suberizer Door Configuration This application note covers the wiring and interface to Suberizer Doors. APP-22 Freq Drive Wiring & Setup There are many ways to wire the controls for VFD s, this note is our latest thinking on the controls. APP-23 Basic Refrig CR-110 parameters This goes thru each of the E2 parameters APP-24 ER-110 Electronic Expansion Valve & EPR Parameters This gives information on each of the ER-110 parameters and using a ERP valve. APP-25 App-26 App-27 APP-28 CR-110 Freq Drive Compressor using Suction Control XT Panel Records and Excel Spredsheet Rack Refrigeration with VFD s Screw comp CR-110 parameters APP-29 HMI update from 16.7 to 17.2 App-30 App-31 App-32 App-33 App-34 XT Panel and the ER-110 EPR suction control XT Panel Return Heat Aux control 2009 XT Purge Control TP Link Router Setup XT Panel Setup

100 XT-70 Control Panel 100 APP-35 APPLICATION NOTE INDEX Staging a Scroll & a VFD Recip Compressor This application note documents a unique two compressor application. APP-36 APP-37 APP-38 APP-39 APP-40 APP-41 APP-42 APP-43 Staging VFD Compressor using Gorman Panel Independent EEV configuration Sweet Potato Opertion Zbase programming interface CR-110 VSC (VFD & Screw) profiles & settings Using a Belimo Actuator for exhaust door control How to program a XT Micro Two VFD Compressor Staging

101 XT-70 Control Panel 101 CR-110 Application Note APP-001 COMPRESSOR FREQ DRIVE APPLICATION This application Note will describe how to use the CR-110 to control a freq drive compressor for load control. This example will use a 4 compressor skid. Each compressor will have a CR-110 on it and they will be numbered 01,02,03, and 04. Compressor 01 will have a freq drive connected to it, with a minimum setting of 30%. This example is also using two sets of parallel compressors. C1 & C2 are parallel, and C3 & C4 are parallel. I will address the parallel aspect of it at the end of the application note. Theory Compressor C1 can be modulated between 30% and 100%. Depending on the number of compressors in the system, C1 will span different input signals. With 4 compressors C1 will run from 30 to 100% with an input span of 25%, for 2 compressors, C1 would span 50%. C1 will float its span, over the entire 0-100% input signal. The term float means that if the input signal was at 40% and C1 at 100%, C1 would stay at 100% as long as the input signal was increasing. Once the input signal start to decrease, C1 would immediately start to back off, regardless of where the input signal was. Example, C1 is at 100% with a 30% input signal and the input signal continued to climb to 50% where another compressor kicked in. The additional capacity satisfied the cooling load, and the input signal started to drop. The additional compressor would continue to run, but C1 would immediately start to back off. The additional compressor staging would match the span of C1. In this case additional compressors would be staged every 25%. Logic For compressor 01, we will use a relay on out 5 instead of a mag starter. This relay will give the freq drive a dry contract to start. Compressors 02,03, & 04 will be wired as basic refrigeration and operate as normal. The will be no compressor rotation, and the staging values will be fixed from 0 to 100 percent. The suggested settings would be: C1 on at 10%, off at 5%. C2 on at 50%, off at 25%. C3 on at 75%, off at 50%. C4 on at 100%, off at 75%. The freq drive should be set for 0-20ma, and have a minimum setting of 30%. The minimum setting on the CR-110 should be set for 30% also. This will output 6ma s minimum. The CR- 110 will use a 0-20ma signal for a 0-100% span. Compressor 01 uses a unique PID setting to drive the compressor. The CR-110 would have a PID setting of comp freq in the PID drop down menu on the control tab. Also on the control tab is a manual output setting. This application uses this value to set the span for the output to all the cards. For 4 compressors this value should be set to 25%. Thus the freq

102 XT-70 Control Panel 102 drive will go from 30% to 100% for a 25% increase in the input signal from the control panel. The unique operation allows compressor 01 to float its 0-25% operation anywhere in the 0-100% input signal. Compressor 01 would start when the liquid line solenoid opens at 10%. At this point the compressor would be running at 30 of speed or minimum setting. As the input signal from the control panel increases by 25%, the compressor would ramp up to 100%. As the control signal continues to increase up to 50 %, the second compressor would start. Compressor 01 would remain at 100% as long as the input signal was not decreasing. As soon as the input signal started to decrease, Compressor 01 would then start to ramp down. Compressor 01 will go from 30% to 100% of speed, and it floats anywhere in the input signal. Thus it is the first to ramp up or down, when it is not at its limits. Another example would be, if the panel was calling for 90% output. Compressor 01 would ramp up to 100%, Compressors 02,03 and 04 would all come on. Compressor 01 would then start to decrease to match the need output. This application has two unique features. One is the freq drive on Compressor 01, the other is the parallel compressor. In a parallel compressor, only one compressor can pump down. In this situation, there are two sets of parallel compressor, so one compressor in each set must be designated to pump down. With this situation, we can not rotate compressor. I will first describe the setup of compressor C1 and then list the setup for C2,C3 & C4. C1 is setup for Basic Refrig and a 4-20ma Input mode. Since C1 and C2 are operating in parallel, C1 is designated to pump down. This is done by not checking the Tandem or Parallel boxes. On C2 we will check the Parallel box. The Parallel box will keep the compressor from pumping down, unless it is the lead compressor. In this application the rotation is turned off so that C1 is always the lead compressor.

103 XT-70 Control Panel 103 The Low Operator setting should be adjusted for the application. Short Cycle Timer can be set to desired time. A short time of 10 s is handy for testing. The Rotation is shut off by setting it to 0. The number of Compressors must be set the total number of compressors. This will active the passing of the input signal to each of the cards via the comp RS-485 port. The alarms can be set to the desired setting, a 0 in the timers will disable the alarm. On C1 there are no unloaders, so we set the LLS only. If the condenser fans seem to cycle, you may want to increase the Cond Fan Diff setting. System Drop setting can be adjust for the minimum discharge pressure that the head will float to. Minimum head pressure setting is equal to System Drop + Suction pressure.

104 XT-70 Control Panel 104 None of the Defrost Parameters are being used. The PID Mode only for C1, is selected as Comp Freq. Min Output is the lowest percentage of the 0-20ma signal from the CR-110 to the freq drive. Man Output sets the span for the 0-20ma signal to the freq drive. A setting of 25 % will allow the drive to go from 30% or minimum setting to 100% for a 25% change of the control panel input signal. The rest of the values are not used in this application.

105 XT-70 Control Panel 105 The Com Terminal can be used to verify sensors and operation. CR-110 Settings for each Compressor 7/14/2006 Comp 01 Comp 02 Comp 03 Comp 04 Data Name Value Value Value Value Lead Diff Filter Backup Diff DPA Comp_off Comp_on Short_Cycle Low_Suc_A Low_Suc_T Suction Drop System Drop Temp Termination Control Point Cond Fan Diff OSA Diff Liquid Line OFF Individual settings Liquid Line ON No Rotation

106 XT-70 Control Panel 106 Unloader Unloader Unloader Unloader Low SP Low SP Low SP Low SP Defrost_off Suc Diff DIT DTT SP Proportional Integral Derivative Update Min Output Man Output Dead Band Max Def HHPU VIDT Rotation Evap SH SP Compressors Unloaders LSH Inst SHeat Lo SHeat Hi SHeat Timer Low_Ambient Coil_Dry Unloader Unloader PID Term KI_div KI_div KI_Thresh PID Scale

107 XT-70 Control Panel 107 Profile Basic Ref Basic Ref Basic Ref Basic Ref Mode Balanced Balanced Balanced Balanced Gas Type R-22 R-22 R-22 R-22 Input Mode 4-20ma 4-20ma 4-20ma 4-20ma PID Mode Comp Freq None None None Only Comp 1 set for Freq Network Use Network 5 for XT panel Unit Tandem no no no no Parallel no yes no yes C1 & C3 will pump down LLS Reverse no no no no UL1 Reverse no no no no UL2 Revers no no no no Note - Individual differences for compressors have been highlighted. Dead Band setting: The Dead Band setting of 0 will allow the individual cards to all see the control panel full input signal. When using compressor rotation, the Dead Band is set to the number of compressors, divided into 100. If you have 4 compressors normally the Dead Band would be set for 25%. This would split up the percentage each compressor sees, and the LLS and Unloaders would all be set the same on each compressor to span 0 to 25%. In this case, we can not rotate compressors since we are Parallel and some other issues. Thus we set the Dead Band to 0, and then set the LLS for each compressor to stage from 0 to 100% LLS settings: Each of the four cards have to have the LLS set individual for the 0 to 100% input signal. PID Mode: The PID mode for C1 needs to be set to Comp Freq, and None for all others. Parallel: The Parallel check box when checked will allow only the lead compressor to pump down. Since we have no rotation in this application, the lead compressor will always be C1. C2 is in parallel with C1, thus we check the Parallel box for C2 to prevent it from trying to pump down. C2 will turn on and off with the LLS settings. C3 and C4 are in parallel, and C3 is designated as the pump down compressor. Thus C4 needs to be checked as Parallel to keep it from trying to pump down. Since this application is connecting to a XT panel the network should be designated as 5.

108 XT-70 Control Panel 108 Compressor Suction Control CHAPTER 20 CR-110 Application Note APP-002 This application Note will describe how to use the CR-110 to control the suction pressure instead of temperature. In this application, a number of unit coolers are used with independent LLS control for multiple temperature zones. The compressor suction Setpoint will be set for the lowest suction pressure needed. Theory The CR-110 uses a PID loop to maintain a Suction Setpoint. The compressor turn on point is set 5 psi below the Suction pressure Setpoint. Up to 3 unloaders can be used to load and unload the compressor to maintain the Suction Setpoint. The PID will produce a output signal from 0 to 100%. The compressor will start when the suction pressure reaches to turn on point. The LLS, and unloader outputs (6,7,8) will all act as unloaders. Normal convention is the unloader is deenergized to load. Xbase now has a option to reverse this logic if necessary. Logic The pump down mode of the CR-110 has been removed for this application, in that the operation of the LLS is not part of the CR-110 operation. The CR-110 will be in refrigeration anytime the compressor is running. The compressor will turn on at the Low Operator Com-

109 XT-70 Control Panel 109 pressor turn on point, and off at the compressor turn off point. The PID loop runs all the time and will produce a signal call cooling demand from 0 to 100 %. The settings for the LLS and unloaders will cause all three to cycle on and off. If the suction pressure is greater than the Suction Setpoint, and climbing, then the PID loop will increase the signal and the unloader will load up to bring the pressure back to Setpoint. The profile is called Basic Suction, and the input mode needs to be Setpoint. A 100 psi transducer needs to be used for the suction pressure. If the unloaders are reverse from the normal operation, use the check boxes to change the operation. The low operator Comp_on value should be 5 psi less than the Suction Setpoint. Unloaders need to be set for the number of unloaders on the compressor. The Discharge Pressure Alarm, and High Head Pressure Unload should be set for the appropriate values. The Low Suction Alarm should be set for 15 psi lower than the Suction Setpoint. The timer should be set for 3 to 5 minutes. Low Super Heat Alarm should be set for 0 and not used. The Super Heat alarm Window is typically 12 for low, 50 for high, and 10 minutes.

110 XT-70 Control Panel 110 The Liquid Line setting is for Unloader 1, Unloader 2 is for Unloader 3, and Unloader 2 for Unloader 3. The Unload Low Suction Override is not used in this application. No Parameters are used in the Defrost settings.

111 XT-70 Control Panel 111 The Liquid Line setting is for Unloader 1, Unloader 2 is for Unloader 3, and Unloader 2 for Unloader 3. The Unload Low Suction Override is not used in this application. The PID mode needs to be Suction. SP is the suction pressure Setpoint in psi. The PID loop is a PI loop for this application. The D value is set to 0. The Update time is in.1 sec and is set for 50 or 5 seconds. P is set for 15, and I for 5. KI_div is 10, KI_Thresh is 3, KI_div2 is 20 and PID Scale is 0. These values are for factory testing only and should not be changed.

112 XT-70 Control Panel 112 The Com Terminal can be used to monitor the Suction pressure and other parameters.

113 XT-70 Control Panel 113 Nelson Chiller CR-110 Application Note APP-003 This application Note will describe how to use the CR-110 to control 4 forty hp parallel compressors. The compressor have one LLS and one expansion valve. Each compressor has 2 unloaders, providing a total of 12 stages of refrigeration. The evaporator is a tube chiller bundle used to chill 20,000 gallons of process water to 40 degrees. Theory The CR-110 uses a PID loop based of off sensor 7 (outlet) and SP for card # 1. The PID loop produces a 0-100% signal that is passed on to each of the CR-110 cards. Each CR-110 card is set up to span 25% for the LLS and unloaders. Thus with 4 compressors the lead compressor will be fully loaded at 25%, 2nd compressor fully loaded at 50%, 3rd compressor fully loaded at 75% and the forth compressor fully loaded at 100%. As the compressors rotate, they just change percentages and rotate 1,2,3 and 4 then back to 1. The lead compressor is the only compressor that will pump down. Start Up Caution should be used when starting the system for the first time. It is recommend to bring one compressor on at a time. The circulation pump should be checked and operation verified before starting any of the compressors. The Setpoint should be set slightly below the outlet temperature so that the PID loop will come up slowly and allow the first compressor to run and load up. Gradually bring SP down to desired temperature and bring all compressors on line. Logic The Chiller profiles has several safeguards against freezing. The first is the low pressure control parameters. These parameters will unload the compressor if the suction pressure is running too low. These parameters will need to be adjust for this application. The second safeguard, looks at the chiller outlet temperature. If this temperature ever drops below the SP by 3 degrees, the PID loop is immediately set to zero. The PID loop parameters can be changed to set the desired response of the system.

114 XT-70 Control Panel 114 Nelson Chiller 7/17/2006 Comp 01 Comp 02 Comp 03 Comp 04 Data Name Value Value Value Value Lead Diff Filter Backup Diff DPA Comp_off Comp_on Short_Cycle Low_Suc_A Low_Suc_T Suction Drop System Drop Temp Termination Control Point Cond Fan Diff OSA Diff Liquid Line OFF Liquid Line ON Unloader 1 OFF Unloader 1 ON Unloader 2 OFF Unloader 2 ON Low SP 1 OFF Low SP 1 ON Low SP 2 OFF Low SP 2 ON Defrost_off Suc Diff DIT DTT SP Proportional Integral Derivative Update Min Output Man Output Dead Band Max Def HHPU VIDT Rotation Evap SH SP Compressors Unloaders LSH Inst

115 XT-70 Control Panel 115 SHeat Lo SHeat Hi SHeat Timer Low_Ambient Coil_Dry Unloader Unloader PID Term KI_div KI_div KI_Thresh PID Scale Profile Pro Chill Pro Chill Pro Chill Pro Chill Mode Balanced Balanced Balanced Balanced Gas Type R-22 R-22 R-22 R-22 Input Mode Setpoint Setpoint Setpoint Setpoint PID Mode SP SP SP SP Network Unit Tandem no no no no Parallel yes yes yes yes LLS Reverse no no no no UL1 Reverse no no no no UL2 Revers no no no no is checked if using 100 psi xducer on the suction and 500 psi on discharge. Check psi if using both 500 psi xducers. Check Parallel if all compressors are in a parallel configuration and the lead compressor is the only compressor to pump down. Note - at this point the Reverse checks do not work in the Chiller profile.

116 XT-70 Control Panel 116 Low Operator values should be set according to application. Super Heat Alarm Window is disabled with the SHeat Timer set to 0. Once the system is up and running and super heats stabilized, these setting should be set. The Low Suction alarm needs to be set according to the system temperatures and Setpoint. This is a critical alarm in the chiller system. The minimum head pressure is the System Drop + Suction pressure. If the head pressure is running to low, you can adjust the System Drop. The LLS and Unloaders should be set for a span of 25% with 4 compressors. Adjust the Unload Low Suction Override according to the desired setpoint. With a water system, great care much be taken not to freeze the system up.

117 XT-70 Control Panel 117 No defrost parameters are used in this application. The main PID parameters are the Porportional, Integral, Derivative, and the Update time. This application does not use Derivative, so it is set to 0. If the system is not responding fast enough, the Update timer should be lowered. The Update time is.1 sec increments, thus 50 is equal to 5 seconds.

118 XT-70 Control Panel 118 Double EEV ER-110 Application Note APP-004 This application Note will describe how to use the ER-110 to control two electronic expansion valves from one ER-110A card. Both of the EEV s must be on the same condenser unit. Other options for single EEV and for EEV / EPR valves are also available. Theory The ER-110 uses a PID loop based off of the evaporator suction superheat. The superheat is calculated from the suction pressure and temperature. The EEV is a electronic valve with a stepper motor on a needle valve. This allows you to have a very accurate control of the amount of refrigerant being injected into the evaporator. The ER-110 has a evaporator super heat Setpoint, and the EEV is constantly adjusted to maintain the evaporator super heat. Start Up When initially starting up, the com terminal in Xbase should be used to monitor the sensors and values. Make sure that all sensors are reading correctly before firing the system up. On initial start up make sure that the suction pressure come up as anticipated. The Super Heat should stabilize with in 5 minutes of the LLS opening. It is a good idea to start with a higher Super Heat SP initially like 20 degrees, just to verify operation of the system. Logic The ER-110 uses modes, like the CR-110. The four leds, counting from the right, will show the modes just like the CR-110. All leds off indicate a standby mode. Standby occurs when the liquid line solenoid is in the off position. The ER-110 uses a current donut with multiple wraps of one of the control wires for a 110VAC LLS valve. Thus, when the LLS opens, the current donut detects current and provides a dry contract closure on Input 5. This will tell the ER-110 card to go into the Refrig mode. In the Refrig mode, the ER-110 will open both EEV s to a initial position. The default value is 40%. Both valves will stay at this initial position for a settling time. The default value is 10 seconds. In reality, this settling time should be about 30 seconds. Initially, when the system first starts, the evap super heat will be well above 50 degrees. The super heat will rapidly decrease, so the settling time should be set to the amount

119 XT-70 Control Panel 119 of time it takes the superheat to drop below 40 degrees. Once the settling time has timed out the ER-110 will start the PID loop. This loop will start moving the valve, to maintain the Super Heat Setpoint. The super heat of the evaporator greatly affects the super heat of the compressor. The CR-110 uses a 4-20ma signal to ramp the Super Heat Setpoint of the Evaporator up and down to keep the compressor within a superheat window. When the LLS valve closes, the ER-110 will close both valves. The ER-110 documentation and XBase refers to EEV1 as valve A and EEV2 as valve B. Wiring Diagram One psi suction pressure transducer is used for both evaporators. Separate temperature sensors are used on each evaporator.

120 XT-70 Control Panel 120 Xbase Software Xbase software is used to setup and test the ER-110. Xbase is used for a number of different applications, and has different configuration files. If you start Xbase with out a modified short cut, it will default to the xbase.inf file. This file is used for the CR-110. The ER-110 will use a ER-110.inf file to start xbase. Create a short cut on your pc for the xbase.exe file. Right click and go to properties. The Xbase software should be V4.0.8 or newer. The ER-110.inf file should have a date of On the target line, use a space after the then type in ER-110. Rename the shortcut ER-110. When using the short cut, you will now come up with the ER-110 unique settings. If this is a new start up, you can pre load Xbase with the ER-110 default values by selecting the Configure drop down. This simply loads Xbase, you still need to set parameters.

121 XT-70 Control Panel 121 This profile uses Double EEV since we have two valves A & B. If you are using a single valve use the Single EEV profile. The network for the ER- 110 must be 1 higher than the CR-110 controlling the condenser unit. For XT panels the CR-110 must be a network 5 or 7and the ER-110 must be a network 6 or 8. It is highly recommended that you use only a psi suction transducer. The Ma Signal is not used. No values on the Compressor tab are used. T_Enable stands for terminal enable. This is a special mode developed for R& D. If you change this value to 71, it will spit out a PID string every update of the PID loop. All other polling devices, XT or G55 should be disconnected from the communications when using the PID terminal puke. The terminal setting is The Com terminal on Xbase will not work for this application. Be sure and turn it off when done.

122 XT-70 Control Panel 122 The KI_div, Ki_div2 & KI_thresh are for factory use only and should not be used. Ki_div allows you to scale the effect of the integral. Ki_div2 will scale the integral when the error is greater than the KI_Thresh. This will allow you to compensate for very large errors. The Init Pos is the value both valves will initially travel to when the LLS first opens. The valves will stay in this position for the Settle time in seconds. The compressor loading values are not used in this application. On the Defrost tab no values are used.

123 XT-70 Control Panel 123 The P value is a multiplier for the new error minus the old error. There must be a change for the P to have any effect. The I value is the multiplier for the current error. The D value is not used in this application and should be 0. Update is the time between PID updates. This is in.1 s of a second, and should be lengthened to slow the system down. V1 & V2 steps. This is the number of steps in the valve motor. Most EEV s are Max SP is the high window for the Evap SH SP when in the auto ramp mode and connected to the CR-110. This is the highest setting that the CR-110 can pulse the SP to. Min SP is the low window and the lowest value the CR-110 can pulse the SP to. The Min Output is the lowest setting that the PID can take the valve to. The Man Output setting will allow you to change the PID mode to manual and would cause the valve to open to this position. The Evap SH SP is the desired Super Heat Setpoint. PID Mode. This should be in Auto, except when testing and you could use the manual mode. Great care should be used when running in manual. The manual mode would typically only be used at start up for testing or when evacuating the system initially. The com terminal can be used to monitor the ER-110.

124 XT-70 Control Panel 124 Screw Compressor CR-110 Screw Compressor Application Note APP-005 This application Note will describe how to use the CR-110 to control either Copeland or Hitachi Screw Compressors. The main difference between the Hitachi and the Copeland is the Hitachi has an extra fast unload solenoid. A additional relay and time delay is used for the fast unload at start up. Theory The screw compressor uses a slide valve to vary its capacity from 30% to 100%. This slide valve is pulsed using a load and unload solenoid. The Cr-110 will use output 7 for the load solenoid and output 8 for the unload solenoid. Sensors The pressure sensors and temperature sensors are located right next to the compressor. Ch 5 is not used at this point. Ch 6 is the 0-20ma or 4-20ma signal from the control panel. Ch 7 is a 0-5vdc current transducer. The transducer has a switch for selecting different ranges. Make sure that the CR-110 is programmed for the correct setting. Ch 8 is a current switch that provides a dry contact when the Crank Case heater is on.

125 XT-70 Control Panel 125 CR-110 Outputs The first 4 outputs are the condenser fans and may take a number of different configurations. This drawing shows the load and unload slide solenoids. The current switch is used to tell the ER-110 that the LLS is open. This unit has 3 ER-110 s so a relay LLP was used to activate each of the ER-110 s.

126 XT-70 Control Panel 126 Logic This app note will cover the basic screw compressor. When ever the compressor is not in Refrigeration, the CR-110 will pulse the unload solenoid every 5 minutes for 30 seconds. When the compressor first starts, it will remain unloaded for 60 seconds. The LLS will open when the output from the control panel exceeds the LLS on setting. The CR-110 will then go into the refrigeration mode and start the compressor. The screw compressor uses two new variables, Span U and Span L. Span L is the output percentage when the compressor will be fully unloaded. The Span U is the output percentage when the compressor will be fully loaded. Example - two compressor system. First compressor would be fully loaded at 50 % and would be fully unloaded at approximately 15 %. Second compressor would be fully loaded at 100 % and fully unloaded at approximately 65 %. The CR-110 will pulse the load and unload solenoids depending on the cooling demand. The pulse width is set by the Pulse Width variable. A Off Time variable is used for the off time between pulses.

127 XT-70 Control Panel 127 Xbase Software Xbase software is used to setup and test the CR-110 screw software. Xbase is used for a number of different applications, and has different configuration files. If you start Xbase with out a modified short cut, it will default to the xbase.inf file. This file is used for the CR-110. The CR-110 screw application will use a screw.inf file to start xbase. Create a short cut on your pc for the xbase.exe file. Right click and go to properties. The Xbase software should be V4.0.9 or newer. The screw.inf file should have a date of or newer. On the target line, use a space after the then type in Screw. Rename the shortcut Screw. When using the short cut, you will now come up with the Screw compressor unique settings. If this is a new start up, you can pre load Xbase with the Screw default values by selecting the Configure drop down. This simply loads Xbase, you still need to set parameters.

128 XT-70 Control Panel 128 The profile is called Basic Screw. The pressure transducer selection refers to the suction transducer and is set at 100 psi for most applications. When using a XT or Galaxy control panel the input mode will be Ma Signal. For a Galaxy panel you should select 4-20ma and 0-20ma for the XT panel. The Comp off / on variable are the suction pressure setting for the low operator. Short cycle prevents the compressor from instantly restarting. The Rotation setting is the time in minutes between compressor rotation. Setting the Rotation to zero will disable this function and will remove the percentage outputs offset. The Compressor setting is the number of compressors in the network that will rotate. It must be set correct even if you are not using rotation.

129 XT-70 Control Panel 129 High Dis A - high discharge alarm. This is the soft high discharge pressure soft alarm. When the discharge pressure is greater than the High Dis A setting the system will shutdown and lock out in alarm. High Dis U - high discharge unload. If during the refrigeration cycle the Dis Pressure is greater than the High Dis U, the unload solenoid will be pulsed on each update until the Dis Pressure drops by 15 psi. At this point, normal operation will resume. A zero in the High Dis U will disable this function. Low Suc A - low suction alarm. This is the low suction alarm shutdown. If the suction pressure is less than the Low Suc A setting for the amount of time in the Low Suc T, then the system will shutdown and lockout on low suc alarm. AMP Xducer - This setting allows you to match the software with the settings on the amp transducer. 0 = 50amp, 1 = 100amp, 2=200amp. SHeat Lo - Superheat Low setting. If the compressor suction superheat is below this setting for the SHeat Timer setting, then the system will shutdown and lock out. A setting of zero in the SHeat Timer will disable this alarm. SHeat Hi - Superheat Hi setting. If the compressor suction superheat is above this setting for the SHeat Timer setting, then the system will shutdown and lock out. A setting of zero in the SHeat Timer will disable this alarm. Sheat Timer - This timer is active when the compressor Superheat is above the Sheat Hi, or below the Sheat Lo settings.

130 XT-70 Control Panel 130 Mode - Balanced Head Pressure is the recommended mode for the condenser operation. System Drop - This is the total drop in the system and will determine the lowest operating point for the condenser. Suction pressure + System drop is the operating Setpoint for the condenser fans. Gas Type - This allows for the selection of different types of gas. Control Point - This only applies if you have Fixed Head pressure selected for the Mode. Cond Fan Diff - the balanced head pressure will determine the operating pressure and then the fans will be cycled on and off to control at this point. The Diff is the difference between the fan stages. PID Term - this should normally be set to zero. This is for testing only, and will spit out PID values continuously every update if set to 71. LLS OFF & LLS ON - this is the setting for the liquid line solenoid. The percentage is calculated by the 0-20ma or 4-20ma signal from the control panel. Span U & Span L - these two values set the bottom and top operating range for the slide valve. The number of compressors in the circuit will determine how the range is divided up. Oil Press & Oil Time - the oil pressure is the Discharge Pressure - Suction Pressure. Any time the compressor is running, the pressure differential needs to be greater than the Oil Pressure setting. If the pressure has not built during the Oil Time, the system will shutdown and lockout. Low Suc U & Low Suc D - low suction unload and low suction differential. If during the refrigeration cycle the suction pressure is less than the Low Suc U for 1 minutes, the unload solenoid will be pulsed on each update until the suction pressure rises to Low Suc U + Low Suc D. Once this happens, normal operation will resume. A zwero in the Low Suc U will disable

131 XT-70 Control Panel 131 this function. Dis Temp U - Discharge Temperature Unload. If during the refrigeration cycle the Dis Temp is greater than the Dis Temp U for 1 minute, the unload solenoid will be pulsed on each update until the Dis temperature drops by 10 degrees. At this point normal operation will resume. A zero in the Dis Temp U will disable this function. Dis H Temp - Discharge High Temperature. If during the refrigeration cycle the Dis Temp is greater than the Dis H Temp for 3 minutes, the system will shutdown and lock out. No Parameters are currently used on this tab.

132 XT-70 Control Panel 132 For this application the PID loop is not being used. Thus the default values for Proportional, Integral, Derivative, KI_div2, PID Scale, Update, KI_div and KI_Thresh are not critical. Output Offset - this is used when the compressor rotation is on. For two compressors this should be set to 50. The panel output signal is then adjusted with this value. Example - two compressor system, with a 75% output. Both systems are set to open the LLS at 10%. If compressor 1 is the lead compressor, it will operate seeing the full 75% signal. Compressor 2 would subtract the Output Offset from the 75% signal, and thus would have a 25% signal, which would be enough to have the LLS on, and the slide valve starting to open. The reason for this, is to be able to keep the LLS, Slide U and Slide L the same for multiple compressors. Thus when rotation occurs, each compressor will subtract the offset depending where it is at. Example - on a 4 compressor system, the offset would be 25 % and each compressor would use multiples of the 25%. The last compressor in the rotation would subtract 75% from the control signal. Thus when the control signal reached 100% it would subtract 75% and still have 25% and be fully loaded. With all this said, in this application we have the rotation turned off, so the offset does not affect the signal that the system is seeing. The LLS, Slide U, and Slide L must be set on each compressor for the desired staging from 0 to 100%. ER Enable - this will enable the CR-110 logic for controlling a ER-110 card with electronic expansion valves. A 1 will enable and a 0 will disable. When enabled, you must have a ER- 110 associated card, or the CR-110 will go off on an EEV alarm.

133 XT-70 Control Panel 133 CR-110 Modes of Operation: Normal Standby Refrigeration Defrost Pump Down Short Cycle Shutdown Coil Dry Alarm High Dis Press DP Sensor A SP Sensor A Low Suc A External A Superheat A Temp Sensor A Fan Fail A Oil Pressure A High Temp A CCH A EEV A Pre Alarm Low S Unload High D Unload High T Unload High Current

134 XT-70 Control Panel 134 SDX Door Control (DR-420 replacement) SDX Linear Application Note APP-006 This application Note will describe how to use the SDX card to operate in the 4-20ma mode, using a potentiometer to provide feed back for door position. Note - the SDX card has to be a rev A or greater to use this feature. Theory When operating in the 4-20ma linear mode, the SDX receives a 4-20ma signal from a control panel and will position the fresh air doors accordingly. In the 4-20ma mode, the SDX will convert the 4-20ma signal to a percentage output, and run the actuator to position the door accordingly. The SDX uses the position of the open and close limit switch to convert the potentiometer reading to a % output. For this to happen you need to manually run the door full open to the limit switch and then full closed to the limit switch. The SDX will remember these reading and use them to calculate the percentage. Wiring - Single or Two door system Optional 4-20ma output for Louvers (+) (-) 4-20ma isolated input OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G 18vac 24vac ISO Main power supply for doors Control power supply Isolated supply for optional 4-20ma louver output

135 XT-70 Control Panel 135 Wiring - multiple SDX cards Optional 4-20ma output for Louvers Or existing DR-420 cards Card # 1 only 4-20ma isolated input (+) (-) (+) (-) OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G (+) (-) OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G (+) (-) OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G (+) (-) OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G When using multiple cards the 4-20ma signal has to be daisy chained to each card. The SDX s can have up to 4 cards chained together. Each card has a max voltage drop of 6vdc. Thus if you have the max of 8 doors with 4 cards you would need to have a minimum of 24vdc supply for the 4-20ma signal. Most of the systems will be a max of 6 doors or 3 cards, and the require a max of 18vdc. Most of the Galaxy systems should be able to drive at least 3 cards.

136 XT-70 Control Panel 136 Wiring - Actuator head Drive Head - Top View RET. EXT. 2 3 Heater 4 5 (-) yellow 6 (+) red Blue Blue//White Black Yellow Red Brown/White Brown Green White V I G V I G HEATER OUTPUT 4-20 ma 12vdc OPEN CLOSE 4-20ISO 0-10V OLS CLS OLS CLS DRIVE A DRIVE B Rev A CPU CPU GO TEST OFF GO TEST OFF 18vac 24vac ISO RS-485 DIR RUN DIR RUN 18vac

137 XT-70 Control Panel 137 Dip Switch Settings CARD 1 CARD 2 CARD 3 CARD 4 Each SDX card needs to have a unique number 1 to 4. Use dip switches 1 & 2 to define the card. In the 4-20ma mode switch 3 & 4 are not used. Door Staging Door staging is done using Xbase programming software. Each door can be assigned a window any where between 0 to 100 %. Thus you can come up with any kind of staging imaginable. We will refer to the stage window as the percent the door is set to go from full closed to full open. In a three door system, door 1 would typically be set to for a stage window of 0 to 50%. Doors 2 & 3 would be set for a stage window of 50 to 100 %. Note - the smaller the stage window is, you will need to increase the dead band zone. The dead band is the zone plus or minus where the door will not move. Example - with a dead band set to 2 %, the input signal would have to go 2 % above or below the door position for the door to move. It is never recommended that you set the stage window below 25%. Low percentage stage window should be done for volume doors only. The larger the stage window, the finer the door adjustment and control will be. In the previous example of a 3 door system, it might be far better to span door 1 from 0 to 75 % and keep door 2 & 3 at 50 to 100%. It even might work well to span door 1 from 0 to 100%.

138 XT-70 Control Panel 138 SDX Programming When programming the SDX card your Xbase should be Version or newer. Use the sdx.inf file dated or newer, with this version. The hex file for the SDX card should be version 1.29 or later. 1 When setting a new card, you can use the default settings under the Configure drop down. This will load all the settings needed for the SDX card to operate correctly. You will need to customize the values depending on how you want to set it up. For this application you will need to set the INPUT to 4-20ma LINEAR. You will not need to set the address, as it is set using the dip switches on the card. The Filter setting should be at 1. This applies a digital filter to the incoming 4-20ma signal from the control panel. The higher the number up to 10 will filter the signal heavier. A smaller signal will filter less. This could be useful in the 4-20ma signal is fluctuating greatly. None of the other parameters on the main Setup Screen are used.

139 XT-70 Control Panel 139 SDX Programming None of the parameters on the compressor tab are used. The Card Rev drop down must be set correctly for the SDX to function. If you are using an older original card, select the Original under the drop down. Note - for all 4-20ma linear applications, you must use a Rev A card.

140 XT-70 Control Panel 140 in.025 sec, a default setting of 80 will give a off time of 2 sec s. Lin_update - this is the time in.1sec that an update will happen. This is just like the PID update timer. Shorting the time will make the door more responsive and lengthening the time will decrease the response. The default setting is 4. Off_Time A - this is the amount of time that door A will be off after a match occurs. The time is in.025 sec, a default setting of 80 will give a off time of 2 sec s. Off_Time B - this is the amount of time that door B will be off after a match occurs. The time is Low_dbA - this is a dead band setting when the door is below 70% opening. The default setting is 1 percent. Thus the input signal would have to move a least 1 % to get the door to move. A setting of 0 can be used, but will cause the door to move at any change of input signal. This applies to door A. High_dbA - this is a dead band setting when the door is above 70% opening. The default setting is 2 percent. Thus the input signal would have to move a least 2 % to get the door to move. This value could be set to 1 %, field test will be needed to verify the setting. This applies to door A. Low_dbB - this is a dead band setting when the door is below 70% opening. The default setting is 1 percent. Thus the input signal would have to move a least 1 % to get the door to move. A setting of 0 can be used, but will cause the door to move at any change of input signal. This applies to door B. High_dbB - this is a dead band setting when the door is above 70% opening. The default setting is 2 percent. Thus the input signal would have to move a least 2 % to get the door to move. This value could be set to 1 %, field test will be needed to verify the setting. This applies to door B.

141 XT-70 Control Panel 141 Door Fail A - this value is not used in the 4-20ma linear mode. Door Fail B - this value is not used in the 4-20ma linear mode Out St - this is the start percentage for the isolated 4-20ma output that is used to drive a set of louvers. A default setting of 0 is recommended Out End - this is the end percentage for the isolated 4-20ma output that is used to drive a set of louvers. A default setting of 100 is recommended. Note - the 4-20ma louver signal is based on total door position. The SDX card number 1 will calculated the overall door position and the output a corresponding 4-20ma signal. Use the start and end values for the desired range. Door A # - this is the door number that will tell the HMI which door it is. If you are not using position A, then a zero needs to be entered in. Door B # - this is the door number that will tell the HMI which door it is. If you are not using position B, then a zero needs to be entered in. Start A - this is the start position for door A. End A - this is the end position for door A. Start B - this is the start position for door B. End B - this is the end position for door B. Note - it is not recommended to go below a 30 percent window between Start and End. The larger the window, the better control and smaller movements the door will have. The door windows can be overlapped for staging.

142 XT-70 Control Panel 142 The Com Terminal can be used to monitor what is going on with the door. Click on the unit no. to select which card you want to view. The Door Open position is the actual door position In Door A is a calculated value depending on the stage window. Example - stage window 0-50% for door A. With a 50% input signal from the control panel, the 4-20ma In Door A should read 100 %. When the 4-20ma In percentage changes, then the door will move to match up. NOTE - WHEN EVER YOU UPDATE THE SDX SOFTWARE OR ARE INSTALLING A NEW CARD OR ACTUATOR, YOU MUST MANUALLY RUN THE DOOR FULL OPEN AND THEN FULL CLOSE. THIS IS CRITICAL FOR THE SDX TO CALIBRATE THE DOOR POSITION POT. WITH THE DOOR FULLY CLOSED, AND THE PLUG REMOVED FROM THE SDX CARD, THE TWO WIRES FROM THE POTENTI- OMETER SHOULD READ ABOUT 1000 OHMS.

143 XT-70 Control Panel PID LOOP CONTROL PID LOOP 2007 Application Note APP- 007 This application note will describe how to implement and tune the new XT PID The new PID loop can run in either a Cooling or Heat Mode. Theory PID Control works by making adjustments to the output at a constant rate called the update rate (usually 2-6 seconds). For every update that occurs, PID Control takes a reading from the input sensor, measures the distance between the input and the setpoint (error), makes a series of calculation, and adjusts the output percentage in such a way as to move the input towards the setpoint in the most efficient manner. The calculations that determine the new value of the output after each update are made by three different modes of control: Proportional (P) mode, Integral (I) mode, and Derivative (D) mode. Each mode of control makes its own adjustment to the output percentage, and the three adjustments are added to the previous output percentage to determine the new output percentage. NEW OUT % = OLD OUT % + P + I + D P Proportion Mode I Integral Mode D Derivative Mode Tries to stop the error from changing. Measures difference between current and previous error, and adjusts output percentage to prevent any further movement. Tries to bring the error to zero ( input = setpoint). Tries to slow or stop a rapidly changing error so P and I Modes may effectively work to eliminate it. Proportional Constant Kp The Proportional constant is simply a multiplier that can be used to fine tune the size of the Proportional Mode adjustment. Raising the value of Kp results in a greater reaction to input value changes, while lowering it results in a smaller reaction. The P setting will only affect the output when it sees a change of input from the previous update. If the plen temperature does not change from one update to the next, the

144 XT-70 Control Panel 144 P will have no effect on the output. This is completely different than the old PID. The P is always trying to stop change and create a steady state condition. If you are above SP but the Plen temp is dropping quickly, it will be the effect of the P that will actually cause the door to pulse close, even though you are above Setpoint. A good way to test the effect of P is to set the I and D to zero. Then you can watch the temperature change and see the exact amount that the output changes. Changing P at this point will have a significant effect. The key is to find the right balance between the P, I, and D. Caution, to high of a P, will cause the system to take large steps and be unstable. P does not care if you are above Setpoint or below, it can produce a positive or negative change in either case. It just wants to stop the temperature from changing. If you use P only with out I, you will eventually find a temperature away from Setpoint that will just flat line. Proportional change = Kp * (current error - previous error) This is a highly simplified version. The error is defined as the difference between the plenum temp and the Setpoint. Integral Constant Ki The I value is what will cause the output to change when the plenum temp is steady state and not changing. For example if the plenum temp is sitting.5 degrees above or below and the output is not changing, you should increase I. The I will always produce a positive change when above the Setpoint and a negative change when below the Setpoint. Start with a small I and increase it for more action. Integral change = Ki * (current error) Derivative Constant Kd The Derivative Mode constantly analyzes the rate of change of the error, makes a prediction about what the future error will be, and makes an adjustment to the output in an attempt to reduce the rate of change in the error. In a lot of systems, D is not used and is set to 0. The CR-110 and ER-110 both use no D. The D can be slowly added, is primarily responsible for the initial start up of the system, and the first approach to Setpoint from the output starting at 0. To little D and the plenum temperature may overshoot the Setpoint, to much D and the system can become very unstable. Derivative change = Kd * (Error - (2 * previous error / time) + ( previous previous error / time)

145 XT-70 Control Panel 145 For documentation purposes I have included the actual formula that calculates the PID. The Correct value that is added or subtracted from the output is: Correction = [Ki * U_val] / Ki_div +[Kp + 10 * Kd / U_val] * error - [Kp + 20 * Kd / U_val] * previous error + [10 * Kd / U_val] * previous previous error CURRENT PID VALUES BEING TESTED: FRESH AIR DOORS REFRIGERATION FILTER 6 KP_P 50 KP_I 20 KI_P 8 KI_I 4 KD_P 20 KD_I 10 UPDATE_TP 150 UPDATE_TI 100 I_MULT_P 0 I_MULT_I 3 D_MULT_P 50 D_MULT_I 50 MIN_PW 150 Note that the update times for both the fresh air doors and refrigeration are quite large in tens of a sec. These values worked very well here in the office, but may need to be tweaked in the field. You must be running P1 New PID V2.09 or greater for the new PID and to use these values. When programming, read the EE as normal, program P1 with the new software, then make the changes to the PID parameters.

146 XT-70 Control Panel 146 THEORY Fresh Air Timed Purge Application Note APP- 008 When the XT panel has a CO2 sensor, this application of the Timed Purge will not be applicable. When the XT panel does not have a CO2 sensor, then it must rely on a timed operation to purge the CO2 build up. CO2 can build up in a storage during very cold ambient air conditions, a Timed Run, or during a Refrigeration Run. During times of very cold ambient air, the only way to purge the building is to turn on the Return Air heaters for a period of time. This will raise the return air temperature several degrees and force the fresh air doors open to purge the system. For a purge during a Timed Run or a Refrigeration Run, the fresh air doors will open to a certain percentage for the purge time. HMI software 13.1 and greater has a change to the MISCELLANEOUS screen that adds the TIME PURGE parameters. Setting the hours to 0 will disable the Time purge cycle. COOLING OPERATION: For this example we will use the following settings. IF OSA < 15 INITIATE PURGE CYCLE FOR 5 MIN EVERY 8 HOURS. If the OSA is less than 15 degrees, and the Heat switch is in auto, the return air heater would turn on for 5 minutes every 8 hours. NOTE - IF YOU ARE RUNNING IN A TIME PURGE MODE, YOU WILL NEED TO ADJUST THE OSA SETTING FROM THE WINTER MONTHS TO THE SPRING WHEN RUNNING IN REFRIG. THIS IS WHERE A CO2 SENSOR WILL SOLVE THE NEED FOR SETTING CHANGES.

147 XT-70 Control Panel 147 REFRIGERATION OPERATION: For this example we will use the following settings. IF OSA < 80 INITIATE PURGE CYCLE FOR 5 MIN EVERY 8 HOURS. If the OSA is less than 80 degrees, the fresh air doors would be pulsed open to the min door setting for 5 minutes every 8 hours. During this time the refrigeration would run normal. IF OSA < XX INITIATE PURGE CYCLE FOR YY MIN EVERY ZZ HOURS Time Purge Back to Start ZZ Hours = 0 no yes RUN Hours > ZZ no yes Mode = Cooling no yes OSA < XX yes no Mode = Timed no yes Heat Switch Auto yes no Mode = Refrig yes Heat on for YY minutes no Back to Start OSA < XX yes no Pulse Fresh Air Doors to Max Open for XX minutes

148 XT-70 Control Panel 148 SETTING UP THE XT PURGE CYCLE: Currently there are 6 different options to chose from for purge cycles in the XT panel. Press the outside middle left button to access the E2 parameters using the HMI. The PURGE_CNFG byte is used to set up the different cycles. Program in a number for the desired operation. 0 = No Purge or ARL / CO2 1 = Time Purge, no ARL / CO2 2 = ARL, no CO2 or Time Purge 3 = ARL / CO2, no Time Purge 4 = ERV, no CO2 5 = ERV / CO2 Note - ERV (Energy Recovery Ventilator) is explained in another application note.

149 XT-70 Control Panel 149 THEORY CR-110 Air Defrost Application Note APP 009 On Seed Potato s the temperature can be taken as low as 36 degrees. Running refrigeration at this temperature will form ice. An air defrost will simply shut off the refrigeration for a set amount of time and allow the coil to defrost. This application note will define the CR-110 defrost parameters. XBASE

150 XT-70 Control Panel 150 The CR-110 has two different ways to trigger a defrost cycle. The first is a VID (Variable initiated Defrost). VID establishes a trend of the suction pressure and then will look for a drop in pressure. The second method simply looks at the amount of run time since the last defrost and will initiate a defrost. Defrost Parameters VIDT This parameter is the amount of elapsed run time before a suction trend is established. A typical value would be 30 minutes. Suc Diff This is the differential that is subtracted from the suction trend pressure. A typical setting would be 3 psi. Example: if a suction trend of 45 psi was established after a 30 minute run, then the target defrost pressure would be 42 psi. The suction pressure would have to drop below 42 psi to initiate a VID defrost. DIT This is a timer that will count down only when the suction pressure is below the VID. In the above example the suction pressure would have to remain below 42 psi, for the duration of the DIT timer. At any point if the suction pressure raise above the VID the timer is reloaded. A typical setting would be 10 minutes. Max Def This is a over ride timer that will trigger a defrost cycle if the VID does not. A typical setting would be 180 minutes. DTT This is the defrost termination timer. Once the defrost is initiated, the DTT time will be active. Once the DTT timer has elapsed, the defrost will be terminated. Manual Defrost Initiate A defrost can be remotely triggered by using the UDP test tools program. The command is ID and the format is <IDxx>0047. The xx is the compressor number. In this example the compressor is 51. You need to convert 51 to hex, which would be $33. Thus to initiate a defrost you would send <ID33>0047. We are planning on adding a defrost initiate on the refrigeration page of the HMI.

151 XT-70 Control Panel 151 THEORY Ambient Reverse Loading & CO2 Control Application Note APP 010 ARL ( Ambient Reverse Loading) is a new way to bring fresh air into a storage during long runs of Refrigeration. The bottom line, is that Potato s need fresh air!! There are many different gases that build up in a storage and can affect the health of a storage. CO2 is the easiest to measure of these gases, and is always present when the buildup of gases occurs. Thus CO2 is the best and easiest gas to measure and use for control. ARL is a way to use the fresh air doors to false load the refrigeration system in times of low load conditions. In the past, hot gas injection has been used to false load the system, but did nothing to control the build up of CO2. When the OSA conditions are right, opening the fresh air doors will introduce fresh air and heat to the plenum. The heat will cause the refrigeration to increase and keep it from shutting off. There are a number of cautions to be aware of and guard against in this type of operation. Simply opening the doors to some predefined setting, can cause plenum temperature fluctuations to occur. Note - the XT panel is the only panel in the industry that can operate the 0-20ma refrigeration circuit and pulse the fresh air doors at the same time. The design of the ARL logic incorporates a second PID loop, so that the Door PID and Refrigeration PID can run at the same time. The following flow chart, shows the logic for the Cooling Mode. CO2 SP = CO2 Setpoint, set on main screen of the HMI. Diff = CO2 Diff, set on E2 parameters page. Default setting is 200 ppm

152 XT-70 Control Panel 152 When operating in the Refrigeration mode, the operation will be based on the following flow chart. There is an initial Refrigeration Start delay before the control can start. The OSA must be greater than the Start temp before the system can also run the ARL logic. ARL Back to Start yes Mode = Refrig no Mode = Cooling no Door Closed yes REF/CO2 Start delay no yes OSA > START TEMP no yes REFRIG Output < MIN Operating Level yes RUN PID HEAT MODE no Purge_CFG = 2 no yes CO2 > CO2 SP no yes RUN PID HEAT MODE & CO2 PURGE SP = SP + CO2 PLEN RISE CO2 < CO2SP - DIFF yes no

153 XT-70 Control Panel 153 PARAMETER EXPLANATION PURGE_CYCLE, this is a E2 and would need to be set to 3 for the ARL and CO2 purge to function. REF / CO2 Start Delay, this is the amount of time in minutes that you want to wait on initial start up of the refrigeration system before the ARL logic is implemented. This is an E2 parameter called ROL_START_DLY, the default setting is 5 minutes. This may want to be increased, depending on the amount of time your system takes to start up and get past the first stage of Refrigeration. MIN Operating Level, this would typically be the point that you have the first stage of Refrigeration set to turn on. This is a E2 parameter called REF_LEVEL. If the Refrigeration output falls below this setting, the ARL will be activated. The will cause the fresh air doors to go into a PID Heat Mode. The max amount the door will open is an E2 parameter call MAX_DOOR. This is a critical setting and typically would be 20%. Note - the flow chart shows a Purge_CFG = 2. This is used for another application, and when viewing the flow chart, you should take the no branch. CO2SP, this is the CO2 Setpoint and is set on the Main HMI screen. DIFF, this is the CO2 differential setting and is a E2 parameter call CO2_DIFF. The default setting is 200 ppm. When the Refrigeration is running above the minimum operating level and the CO2 builds above the CO2 Setpoint, the PID Heat modes operates differently. Instead of running off of the temperature Setpoint, it adds to the Setpoint a parameter called CO2_RAS. This parameter is in 1/10th of a degree, and a typical setting would be 5 or.5 degrees. Example: if you had a temperature setpoint of 45.0 degrees, the refrigeration was running above the minimum setting and the CO2 was above the CO2 Setpoint. The PID heat mode would be activated, to control at a Setpoint of or 45.5 degrees. This would cause the fresh air doors to open, and the refrigeration output would ramp up. The doors would only open to the MAX_DOOR setting, and as soon as the CO2 drop below the CO2SP - Diff, it would close the doors. In this operation, you are guaranteed that the Plen would not rise more than a 1/2 degree.

154 XT-70 Control Panel 154 THEORY Heat Recovery Ventilator Application Note APP 011 A heat recovery ventilator (HRV) can help make mechanical ventilation more cost effective by reclaiming energy from exhaust airflows. HRVs use heat exchangers to heat or cool incoming fresh air, recapturing 60 to 80 percent of the conditioned temperatures that would otherwise be lost. This application note will describe operation of a HRV in a refrigerated locker. OPERATION The HRV mode operates in two different configurations. If the Purge_CFG byte is set to 4, it will operate with out a CO2 sensor. Setting the Purge_CFG byte to 5, will set the logic to operate with a CO2 sensor. Aux 1 is the controlling output for the HRV. The following flow chart is without a CO2 Sensor. IF OSA < XX INITIATE PURGE CYCLE FOR YY MIN EVERY ZZ HOURS ERV Back to Start Hours = 0 no yes Mode = Timed no yes RUN Hours > ZZ yes no Mode = Refrig no yes OSA < XX yes no Aux 1 Switch Auto no yes Back to Start Aux 1 on for YY minutes

155 XT-70 Control Panel 155 OPERATION Setting the Purge_CFG byte to 5, will set the logic to operate with a CO2 sensor. Aux 1 is the controlling output for the HRV. The following flow chart is with a CO2 Sensor. ERV / CO2 Mode = Refrig no yes Aux 1 Sw = Auto no yes CO2 > CO2SP yes no CO2 < CO2 SP - DIFF no yes AUX 1 = OFF Mode = Timed yes AUX 1 = ON no Back to Start

156 XT-70 Control Panel 156 THEORY Network Router Setup Application Note APP 012 A router is used to provide a sub network of IP numbers and provide access to the outside world. For use in our world, it allows the use of one static IP number to access a large number of panels using different ports. When the request comes into the router on a given port, the router will look up the corresponding internal IP number and route the information to it. SETUP Most routers are set on an internal IP address of To access the router plug you lap top into the router. The router should assign you lap top a IP number using the DHCP feature. Bring up you internet explorer and type in and it should come up and ask for a user name and password. Leave the user name blank and type in admin for the password. Once you are in you should get the following page. You provider should give you a static IP number, a default gateway number, a 1 or 2 DNS numbers. These numbers need to be assigned in this setup page.

157 XT-70 Control Panel 157 Next click on the DHCP tab. In most case you would want the DHCP to be Enabled. The Starting IP Address should be set at 100, this will ensure that you it won t assign the same number as one of the panels. When done, click on Apply. Next click on the Advanced tab. Then click on the Forwarding tab. This page is where the outside ports are forwarded to the inside IP numbers Both Both Both This example is for 9 XT panels, with ports from 4061 to The corresponding inside IP numbers are thru Both Both Both When done, click on Apply Both Both Both Both

158 XT-70 Control Panel 158 THEORY Rack Refrigeration Application Note APP 013 The system this application note is written for is at the Hancock Research Center in Wisconsin. This system has 18 evaporators, each associated with a individual bin and XT panel. Each bin has an independent Setpoint and can require hot gas defrost at any time, depending on the temperature. A parallel compressor rack system, was the most logical way to go. Each of the evaporators, has a electronic expansion valve (EEV) and a electronic pressure regulator (EPR) on it. The XT panel sends a 0-20ma signal to a ER-110 control card. The ER- 110 controls both the EEV and EPR, and also the defrost cycle. Each of the compressors have a CR-110 controlling it. The compressors are controlled on suction pressure, and the suction pressure Setpoint is set to be sufficient for the coldest Setpoint. OPERATION The system is composed of 3 compressors, C1 7hp, C2 10hp and C3 15hp. C1 is the controlling compressor and sends a output percentage to C2 and C3. The system is dependent on C1 to run. It could run with C2 or C3 shut off. The suction Setpoint is set on the C1 compressor. A typical setting would be 35 psi, this would allow a room temperature of down to 30 degrees. With this setting the compressors will cycle on and off to maintain this suction pressure. C1 is the only compressor that will pump down. The suction pressure is maintained by a PID loop running in C1. The PID loop will calculate a output signal from 0 to 100 %. This will show up on each of the compressors as output. Each compressor will start or stop according to this output signal. The staging is set as follows: C1 on at 15 % and off at 1 % C1 unloader, loaded at 30% and unloaded at 15% C2 on at 50% and off at 20% C3 on at 80% and off at 50% C3 and C2 on at 100% and off at 90%

159 XT-70 Control Panel 159 SPECIAL OPERATION When compressor C3 starts at 80 percent, C2 will shut of and not start until 100%. C2 and C3 will both run until the signal drops below 90 %, at which time C2 will shut off. When the signal drops below the C3 shut off point, C2 will then start. C1 C2 C3 C2 & C Compressor C1 is the only compressor that has a unloader on it and provides the most flexibility and has been designated as a floater. As a floater, it can float any where in the % signal range. C1 as shown, has a 30% window. This window can be adjusted to what ever you want. This window includes the unloader. If the signal is 0 and starts to rise, C1 will be the first to start as the signal gets above 15%. If the signal were to continue to climb, C1 unloader would load up, and the nc2 would start at 50%. The high end of the C1 operating window, will stay with the signal as long as it continues to increase. Lets say that at 60%, the signal starts backing off and goes to 45 %. C2 would continue to run, but C1 rode the window up to 60% and with the 15% decrease it will now shut its unloader off and run at 1/2 capacity. C1 will move its window with the signal, for the entire range. The top of the window will start to move when the signal is greater than the top value. If the signal were to drop more than the bottom of the window, then the window will start moving down. C1 can then operate any where in the % range in conjunction with any of the other compressors. C2 and C3 both have a standby input on Ch 6. If you short Ch 6 the compressor will go into standby. This option is used only on the C2 compressor. C2 is currently set to start at any output greater than 50%. The standby input is used when C3 turns on at 80%. Any time C3 turns on, a relay contact is used to turn C2 off. If the output goes to 100%, then C3 will turn on another output that will lift the standby contact on Ch6 and allow both C3 and C2 to run. Two relays are used to accomplish this, C2-7 and C2-8. C2-7 picks up any time C3 is running and C2-8 is connected to out 7 on C2. C2-8 is on when the output gets to 100% and off when it drops to 90%. C2-7 C2-8 Ch 6 input C2

160 XT-70 Control Panel 160 This is some of the information for compressor C1. The cooling demand is the overall output percentage that all the compressors are being staged at. The Aux cool d is the floating window for compressor C1. It is currently at 25 %. HOT GAS INJECTION On a parallel rack system, it is very important that the last compressor does not shut off. With only one or two evaporators running, the small compressor running unloaded, would cycle on and off. To solve this problem a hot gas liquid injection system is used. A hot gas solenoid valve and mechanical TX valve is used to inject hot gas into the suction line. When the Hot gas injection is turned on the suction pressure will increase and the PID loop controlling the suction pressure will raise the output percentage. C1 uses output 8 to turn the Hot gas on and off. Under the system tab on Xbase, the parameter unloader 3 is used to set the percentage for the Hot Gas injection. This is set for 0 and 15 %. These setting would have the hot gas injection on, any time the output percentage goes below 15%. A relay contact from each of the evaporators are paralleled and then series with the output 8 from C1. The contact will shut of the hot gas and allow pump down if all evaporators are off. This hot gas injection works very well, and typically will be pulsed on for about 10 sec s. This is enough to raise the output, but the suction pressure remains very stable.

161 XT-70 Control Panel 161 CONDENSER FANS Each of the 4 condenser fan outputs are paralleled on C1, C2 and C3. Thus any of the cards can stage the fans on. The condenser is a Split condenser with a control valve. The condenser valve only opens when C3 is running. C2-7 C2-8 Ch 6 input C2

162 XT-70 Control Panel 162 Basic Refrigeration & Air Defrost Application Note APP 014 This application Note will describe how to hook up and program CR-110 for Basic Refrigeration and Air Defrost Profiles. This information is primarily for doing a retrofit in the field. A new feature has been added that allows the use of a third unloader. Output 4 can now be either condenser fan 4 output or unloader 3 output. If you specify the number of unloaders less than 3 then the output 4 is the condenser fan. Setting the number of unloaders to 3 will activate the output 4 as unloader 3. Cold Weather start is another new feature. The Low_ambient setting if set to zero will disable this feature. This is a timer in seconds, and will start the compressor when the liquid line is opened, and keep the compressor running for the programmed time in seconds. L1 Comp mag aux contact b 120vac Crankcase Heater N This is a basic wiring diagram for the two profiles Basic Refrigeration and Air Defrost. If the compressor mag is greater than 40hp, a 120vac relay should be used to pull in the mag. All other outputs can be wired direct. Compressor Overload HP Fail Oil Fail Internal Switch L 220 M J3 01 CF1 02 CF2 J CF4 /UL3 CF3 C1 06 LLS 07 UL1 CR C C UL2 CF1 - Condenser Fan 1 mag. CF2 - Condenser Fan 2 mag. CF3 - Condenser Fan 3 mag. CF4 - Condenser Fan 4 mag C1 - Compressor mag LLS - Liquid line solenoid UL1 - Un-loader # 1 UL2 - Un-loader # 2 UL3 - Un-loader # 3

163 XT-70 Control Panel 163 Sensor Wiring Discharge pressure Suction pressure Compressor Suction temp Discharge temp 0-20ma input The discharge pressure transducer is always psi. The suction pressure transducer works best with a psi, but a psi could also be used. On the Main Setup, select the type of suction transducer you are using amp Transducer Compressor Amps 7 8 CR-110 Under the profile drop down select either Air Defrost of Basic Refrigeration. Under the Pressure Transducer select either or depending the type of suction transducer you are using. Select the type of Ma signal, XT panels use a 0-20ma, where a Galaxy panel uses a 4-20ma signal.

164 XT-70 Control Panel 164 The Low Operator setting should be adjusted for the application. Short Cycle Timer can be set to desired time. A short time of 10 s is handy for testing. The Rotation is shut off by setting it to 0. The number of Compressors must be set the total number of compressors. This will active the passing of the input signal to each of the cards via the comp RS-485 port. The alarms can be set to the desired setting, a 0 in the timers will disable the alarm. On C1 there are no unloaders, so we set the LLS only. If the condenser fans seem to cycle, you may want to increase the Cond Fan Diff setting. System Drop setting can be adjust for the minimum discharge pressure that the head will float to. Minimum head pressure setting is equal to System Drop + Suction pressure.

165 XT-70 Control Panel 165 Basic Refrigeration & Parallel compressors APP 015 This application Note will describe how to hook up and program CR-110 for Basic Refrigeration and using parallel compressors. This information is primarily for doing a retrofit in the field. If the compressor is over 30hp it is recommended to use a relay to drive the compressor mag. The inrush current on the larger contactors can be enough to cause the on board fuse to blow. This example will show the additional relay. A lot of compressor may share condenser fans. This example will also show how to hook up two CR-110 cards for parallel condenser fans. L1 Compressor Overload Comp mag aux contact b HP Fail 120vac Crankcase Heater Oil Fail N This is a basic wiring diagram for Basic Refrigeration using Parallel compressors and Parallel condenser fans. Relay R1 is used just if the compressor is over 30hp. Relay R2 is a isolation relay that is needed if you are paralleling condenser fans for two CR-110 cards. L M R2 Internal Switch 220 Parallel Compressor # 2 J J3 01 CF1 02 CF2 J C C CF4 /UL3 UL1 R1 CF3 LLS UL2 C1 R2 R1 R2 CF1 - Condenser Fan 1 mag. CF2 - Condenser Fan 2 mag. CF3 - Condenser Fan 3 mag. CF4 - Condenser Fan 4 mag C1 - Compressor mag LLS - Liquid line solenoid UL1 - Un-loader # 1 UL2 - Un-loader # 2 UL3 - Un-loader # 3 CR-110 R1 - Compressor Aux Relay R2 - Parallel Isolation Relay

166 XT-70 Control Panel 166 L1 Comp mag aux contact b 120vac Crankcase Heater N This wiring diagram is shown with out the compressor aux relay R1. R2 is used to isolate the safety's when paralleling condenser fans from a 2nd CR- 110 card. Compressor Overload HP Fail Oil Fail L M R2 Internal Switch 220 Parallel Compressor # 2 J CR-110 J3 J C C 240 CF2 CF4 /UL3 UL1 CF1 CF3 LLS UL2 R2 C1 R2 CF1 - Condenser Fan 1 mag. CF2 - Condenser Fan 2 mag. CF3 - Condenser Fan 3 mag. CF4 - Condenser Fan 4 mag C1 - Compressor mag LLS - Liquid line solenoid UL1 - Un-loader # 1 UL2 - Un-loader # 2 UL3 - Un-loader # 3 R1 - Compressor Aux Relay R2 - Parallel Isolation Relay 120 Sensor Wiring Discharge pressure Suction pressure Compressor Suction temp Discharge temp 0-20ma input The discharge pressure transducer is always psi. The suction pressure transducer works best with a psi, but a psi could also be used. On the Main Setup, select the type of suction transducer you are using amp Transducer Compressor Amps 7 8 CR-110

167 XT-70 Control Panel 167 Under the Pressure Transducer select either or depending the type of suction transducer you are using. Select the type of Ma signal, XT panels use a 0-20ma, where a Galaxy panel uses a 4-20ma signal The Parallel compressor box needs to be checked on both CR-110 compressors. When this box is checked, only the lead compressor will pump down. The Low Operator setting should be adjusted for the application. Short Cycle Timer can be set to desired time. A short time of 10 s is handy for testing. The Rotation is shut off by setting it to 0. Compressor rotation will work fine on the parallel compressors. The number of Compressors must be set the total number of compressors. This will active the passing of the input signal to each of the cards via the comp RS-485 port. The alarms can be set to the desired setting, a 0 in the timers will disable the

168 XT-70 Control Panel 168 The minimum head pressure is the System Drop + Suction pressure. If the head pressure is running to low, you can adjust the System Drop. The LLS and Unloaders should be set for a span of 50% with 2 compressors. Adjust the Unload Low Suction Override according to the desired setpoint. If the condenser fans seem to cycle, you may want to increase the Cond Fan Diff setting. No Defrost parameters are used in this application.

169 XT-70 Control Panel 169 The main parameter on this page is the Dead Band setting. For a 2 compressor system this should be set to 50%. This sets up the 0-100% signal coming from the panel. If you had 4 compressors the setting would be 25%.

170 XT-70 Control Panel 170 Screw Compressor Current Limiting & Soft Start APP 016 This application deals with a screw compressor where the amps needed to be limited because of a 200 amp service. The program changes involve adding some parameters to compare to the amp reading and unload the compressor if necessary. The other component involves the starting of the compressor. A soft start device is being used and has a number of conditions that need to be met. A new screw.inf ( ) or later needs to be used to show the new parameters. The new parameters are as follows: RLA_Alarm if this values is exceeded for the RLA_Time, the CR-110 will trip off on a high current alarm. This is a new alarm and the led s should indicate the following: HIGH CURRENT ALARM RLA_Time this value is in seconds, with a limit of 250. If the compressor amps is above the RLA_Alarm point for this amount of time, it will trigger a High Current Alarm. RLA_Limit if the compressor amps exceed the RLA_Limit, then the conventional loading is stop and the compressor is unloaded until the amps drop 5. This screen shows the new RLA_Alarm and RLA_Time parmareters. The RLA_Alarm is in amps and the RLA_Time is in seconds.

171 XT-70 Control Panel 171 This screens show the new parameter RLA_Limit. Its unit of measure is amps. SOFT START: The soft start is made up of two components, the isolation contactor and the soft start device. The soft start device has a contact that will close once the device is up and running. This contact will pick up a alarm relay. The alarm relay has a normally closed contact that goes to input 5 of the CR-110. On compressor start up, the CR-110 will monitor the R2 contact and will expect to see it close within a programmable time. If the alarm contact does not close with in 30 seconds, it will then it will go out on a Soft Start Fail. Under a normal start, the output 5 of the CR-110 will pickup and enable relay that will supply a contact to the soft start and also enable the circuit for the Isolation contactor. Once the soft start picks up the alarm relay, the Isolation Contactor will close. If the compressor is running and the alarm contact opens, the compressor will shut down on a Soft start Fail alarm. It will stay locked out for 3 minutes, and then will do a card reset and try a restart.

172 XT-70 Control Panel 172 Control Circuit: N CR-110 output 5 R1 R1 Soft Start Enable CR-110 Common Soft Start Alarm Contact Open on Alarm Enable Relay R2 Alarm Relay R2 Soft Start Alarm Input 5 CR-110 R1 R2 Isolation Contactor C1 Normal Start: R1 picks up when refrigeration is being called for. As soon at R1 picks up, the soft start begins its ramp up. Shortly after the soft start enable the soft start alarm contact will pick up. This will cause R2 to pickup and the isolation contactor will close. Normal Stop: R1 de-energizes and tells the drive to ramp down to shutdown. As soon as R1 drops out the Isolation Contactor drops out. Soft Start Fail Alarm: The soft start alarm contact will cause R2 to drop out. This will cause R2 to drop out and produce a Soft Start Alarm on the CR-110. After 3 minutes, the CR-110 will reset and try to run again. If the Soft Start Alarm happens on start up, then the CR-110 will lockout on alarm and stay locked out.

173 XT-70 Control Panel 173 RS-485 Communications Network APP 017 This application note will explain RS-485 communications and field applications. RS-485 comes in two forms, 4-wire and 2 wire. This application will deal with the 2 wire only, as there are very few of the 4-wire systems left. Some of the early Galaxy systems used a 4 wire RS- 485 system. The RS wire is actually a 3 wire using a plus, minus and a signal ground. The ground is not used for communications, but will limit the potential difference between the two devices communicating. Under normal conditions the RS-485 is in a idle state with all the receivers active. Only one transmitter can be active at a time, so typically there is a master and all other are slaves. The CR-110 is an exception in that card # 1 will transmit a short string of information every six seconds. The rabbit on the XT card is the main master and the CR # 1 just looks for an open spot to transmit its data. RS-485 is considered half duplex, you can either transmit or receive, but not at the same time. The main purpose of this application note is to address the issue of how to Bias a RS- 485 network. RS-485 IC + + RS-485 IC XMIT - - XMIT REC REC This is a typical RS wire non biased system. You can have up to 32 devices on a singe RS-485 network. + RS-485 IC If you take a DC voltmeter and measure between the + and - you will have about.250 vdc. This is marginal in that it takes at least.200 vdc difference for the network to work. An indication of a unbiased network would be an unrecognizable character when using terminal. The strings should be clean and contain no garbage. - XMIT REC

174 XT-70 Control Panel 174 RS-485 IC ohm +5vdc + RS-485 IC XMIT - - XMIT 680 ohm REC REC This drawing show the addition of a pull up resistor and a pull down resistor. This will force the network into a high state, with a differential of about 4 volts. This needs to be only at one location in the network. The resistance should not be lower than 680 ohms, but could be higher, up to 4.7k ohm. + - RS-485 IC XMIT REC The B&B opto isolators each contain a 4.7k pull up and pull down resistor. If you have a Galaxy network with the B&B opto s, then you should not have a problem. Measuring the difference between the plus and minus will tell you if it is biased ok. You should have a minimum of.45 vdc, anything less should have additional bias resistors. We will now deal with the CR-110 s, ER-110, SDX and the XT panel. The XT panel has two dedicated RS-485 ports and one that can be either RS-485 or RS-232. The Main RS-485 port on the XT board J52 is used for the SDX door card. The Aux RS-485 port J50 is used for the CR-110 and ER-110 cards. Both of these ports should have the pull up and pull down resistors. There are several option in how you can accomplish this: 680 ohm 680 ohm Top View White female 10 pin bias plug. The SDX, CR-110 and ER-110 all have a matching male 10 pin plug. BTU has these plugs made up and you simply plug one into one of the devices. Remember it only takes one plug on each network. The location of the plug does not matter. Note - we are not using a termination resistor in these applications. Termination resistors should only be used at much higher baud rates and long transmission cables.

175 XT-70 Control Panel 175 V I G V I G O C O C HEA OUT O CLO 4-0- DRIVE DRIVE Rev A CP CP GO DI TE OF RU GO DI TE OF RU 18v 24v IS 18v RS- J16 SDX door drive card. Plug the bias plug into the J16 socket on the SDX card. You need only one of the plugs for the network. CR-110 refrigeration control card. Plug the bias plug into the J13 socket on the CR-110 card. You need only one of the plugs for the network. SEN- J1 1 PD 2 3 CR 24V AC S2 + 4 A J 36 V 8 CR-110 V J2 CR CR CR CR CR CR CR C C C C C C C K K K K K K K C K C K J1 J J C ER-110 refrigeration control card. Plug the bias plug into the J1 socket on the ER-110 card. If you have ER and CR cards on one network, you only need one Bias Plug. SEN ER-110

176 XT-70 Control Panel 176 SENSORS J1 1 PD 2 3 CR1 24AC S2 OFF J13 6 J7 36V 7 V CR1 CR1 CR1 CR1 CR1 CR2 CR2 CR CR CR CR CR CR CR K K K K K K K J3 J CR K C K J17 C I If you are having communications issues and do not have a bias plug, you can use two resistors, between 680 ohm and 4.7k ohm. The closer to 680 ohm the better. Connect a resistor to each of the + and - terminals on the RS-485 connector. Solder a small wire on to the other end of the resistor and terminate on channel 1 with the discharge sensor. Connect the plus resistor with the red wire on terminal 1. Connect the minus resistor on the back wire on terminal 3. AUX 5 8 CR-110 J20 G55 & G70 local HMI interfaces. There are some applications where a local HMI interface is used with the CR-110 s and the ER-110 s. It will greatly improve the communications if a bias plug is used. The bias plugs can be ordered from BTU, part # If you want to make your own plugs, you can order the following parts from Digi Key. Blank Plugs H3813-ND Pins H3832-ND 680 resistor P680BACT-ND A special set of crimp pliers are needed to crimp the pins on the resistors. The only part number I have is for Mouser

177 XT-70 Control Panel 177 RS-485 interface for PC or Laptop: B& B Electronics makes a USB opto isolated RS-485 converter that works very well for monitoring and running Xbase programs on the different products. You can make up a cable using the same plug as the bias and be able to plug directly into the XT, CR-110, SDX and ER-110. B&B part number USOTL4 gnd RDB + RDA - TDB + TDA - gnd Converter Wiring Top View of Molex Plug

178 XT-70 Control Panel 178 ER-110 Saving Energy APP 018 This application note will discuss ways to make your refrigeration system run more efficiently using the ER-110 and electronic expansion valves. The two main benefits are allowing the evaporator fans to run at a greatly reduced rate and running at the ideal evaporator superheat setting. Mechanical expansion valves have a very limited range and can not adjust enough to control superheat at significantly reduced air flows (below 70%). Some valves may not be able to even control down to 70%. The electronic valves are driven by a electric stepper motor and provide a much more precise control. We have been able to control superheats using the ER-110 down to a evaporator fan speed of 40%. We have learned a great deal about the ideal superheat settings over the last year. As the ambient temperature varies, the ideal superheat setpoint will also vary. With mechanical valves, it is virtually impossible to change the superheat settings for different operating parameters. JMC and IVI use the Sporlan control board, and are stuck with a fixed setpoint. There are huge energy saving to be had by running the lowest possible evaporator superheat for a given set of parameters. The following data will show exactly what I am talking about. When the ambient temperature is very warm, you can get far more cooling out of your evaporator by lowering the superheat setpoint and at the same time keeping your compressor cooler and raising the suction pressure. When you are in a position of running very low loads, you can increase the superheat on the evaporator making it less efficient and keeping the compressor from short cycling. The following real data shows how significant changing the evaporator superheat can be. Note - the OSA is 101 degrees and the compressor is running at 100% and not able to maintain plenum setpoint. This system has a 120hp screw compressor with 6 evaporators all with electronic expansion valves. Also this system has been running at 55% on the evaporator fans for some time. When this was recorded all the evaporator super heat setpoints were at 10 degrees.

179 XT-70 Control Panel 179 Note - Compressor parameters. Discharge 293 Suction 47 Super Heat 22 Amps 126 Evaporator Super Heat 10 degrees 1 Hour Later Evaporator Superheat Setpoint 6 degrees One hour later after changing the evaporator superheat setpoint to 6 degrees. Note - Outside air temperature still 101 degrees, evaporator fans 55%. Plenum temperature has been reached and the compressor has backed off to 69%. This shows how dramatic changing the Superheat Setpoint in the evaporator can be. The following page shows the change in operating parameters. The discharge pressure dropped from 293 to 286 psi. The suction pressure rose from 47 to 52 psi. The super heat at the compressor dropped from 22 to 14 degrees. The amps on the compressor dropped from 126 to 106.

180 XT-70 Control Panel 180 Note - the discharge temperature of the compressor also dropped by 15 degrees. As this data shows there is a great need to be able to adjust the evaporator superheat setpoint to achieve maximum efficiency. This system happens to be a screw compressor, but these results apply to all types of compressor and evaporators. The larger the variations in ambient conditions, the greater the need for changing the evaporator superheat setpoint. These tests have lead us to develop some new software that establishes communications between the evaporator electronic expansion valve ER-110 controller and the compressor controller CR-110 card. The Compressor controller will now communicate to the Evaporator controller its temperature and superheat. The Evaporator controller will then adjust its superheat to keep the compressor at the idea operating temperature. This also allows the evaporator to operate at its highest efficiency.

181 XT-70 Control Panel 181 Refrigeration Suction Control APP 019 This application note will detail the operation of our new suction pressure control. This control is primarily focused on screw compressors, but will also be applicable using a freq drive on a reciprocating compressor. One of the big problems with a screw compressor is what to do with the 0-20 or 4-20ma signal. The screw compressors have no feed back on the slide valve so it is very difficult to match up for a call of say 50% capacity. MCS controls use a current sensor and try to match it to the input signal. The problem with this is that the head pressure can vary greatly and will cause this to vary all over. The unique solution that we have developed is to use Suction pressure control. The 0-20ma or 0-100% input signal will determine the suction pressure setpoint. You can program a suction setpoint and a span. The 0-100% signal from the panel will cause the suction setpoint to float from the setpoint thru the span. Example - suction setpoint = 60 psi, span = 15 psi. The floating suction setpoint will float from 60 psi to 45 psi depending on the input signal. The CR-110 will pulse the screw compressor up and down to maintain the floating suction setpoint. Thus no feed back is required. This prevents any low suction conditions and allows very accurate temperature control. Tests have shown temperature control better than +\-.1 degree. The wiring and controls on the screw compressor are the same as the conventional controls. The shorter the span the more accurate temperature control you will have. We are in the process of using some other parameters to determine the ideal suction pressure for any given conditions. This application will deal with the setup and operation of the current suction controls. Control Parameters: Suc SP (Suction Setpoint) - this is the highest value the suction pressure would run. Suc Span (Suction Span) - this is the span that the suction setpoint will float. Typical setting would be from 10 to 20 psi. This is always applied on the low side of the suction setpoint. Example would be a Suc SP = 60 and a Suc Span 20 psi. The Suction Setpoint would then float between 60 and 40 psi depending on the upper and lower settings. Span L (Span Low) - this is the value in percent that will define the lower operation point of the compressor. Span H (Span High) - this is the value in percent that will define the high operation point of the compressor. Example - Suc SP = 60, Suc Span = 20, Span L = 30, Span H = 100. When the output signal of the panel reached 30%, the Floating Suction Setpoint (FSP) would equal 60 psi. As the signal increased the FSP would linearly decrease until 100% would equal 40 psi.

182 XT-70 Control Panel 182 Example 2 - (Multiple compressors) Suc SP = 60, Suc Span = 20, Span L = 30, Span H = 50. When the output signal of the panel reached 30%, the Floating Suction Setpoint (FSP) would equal 60 psi. As the signal increased the FSP would linearly decrease until 50% would equal 40 psi. The CR-110 uses a PID loop to control the floating suction setpoint. This is very accurate and will maintain a very steady suction pressure. See application note 5 for more detail information on the CR-110 operation on a screw compressor. This is an example of a single screw compressor running suction pressure control. The panel output is 41% and this is producing a Floating Suction Setpoint of 56psi. The actual suction pressure is 57psi. The CR-110 will constantly pulse the screw compressor to try and maintain the FSP of 56 psi. Screw compressor slides have a tendency to drift and not hold a given position. This is a real problem for the MCS controller, but here we are simply trying to match up the suction pressure with the FSP, so it does not matter.

183 XT-70 Control Panel 183 This is the screen where you set the Span L and Span U. This example is for a single compressor and spans to 100%. The liquid line solenoid will come on at 20% and the floating suction setpoint will span between 20 to 100 percent.

184 XT-70 Control Panel 184 This is the setup up for the Suc SP and the Suc Span. You also need to select Floating Suc for the PID mode. This example has Suc SP at 60 and Suc span at 15. This will allow the suction pressure setpoint to span from 60 to 45 psi.

185 XT-70 Control Panel 185 This is an example of what suction pressure control can do. This is a seven day graph, the plenum temperature is yellow and underneath the red setpoint line. You can see three times in seven days that we were.1 degrees off, the rest of the time we were exactly on setpoint. The last.1 bump was self inflicted as I was doing some tests. Note the return air raising in the heat of the day. This system was also doing CO2 purging during this time and we still remained on Setpoint.

186 XT-70 Control Panel 186 XBASE 2007 installation New and Update APP 020 Xbase is a software program that is used for setting parameters for the SDX door control, CR- 110 basic refrigeration, CR-110 Screw compressors and ER-110 electronic expansion valves. This version contains all the latest inf setup files. The software is available for down load from the technical web site. The download is a zip file that should be unzipped and then burned on a CD. If you do not want to burn it on a cd then unzip it into a temporary folder on your C drive. If you are installing out of a temporary folder, run the SUwis.exe file to start the install. If you install it from the CD it should start automatically, if not run the SUwis.exe on the CD. The will install the software in the C:\Program Files\BTU\Xbase folder. The old Xbase was installed in a Compucol folder. Once it is finished installing, it will put a Xbase icon on your main screen. Right click and remove this short cut. If you have any other Xbase icon s on your screen, remove these as well. Open up your windows explorer and go to C:\Program Files\BTU\Xbase folder. Right click on the Xbase.exe file, select Send To, then Desktop (create shortcut). Do this four times to put four shortcuts on your desktop.

187 XT-70 Control Panel 187 You should now have four shortcuts to Xbase. Right click on each one and rename them the following: CR-110, ER-110, SCREW, You should now have the four new short cuts. The CR-110 shortcut should now open Xbase for you. Right click on the ER-110 shortcut and select properties. After the type in a space then ER-110 Then click on Apply. This will cause Xbase to initialize for the ER-110 card.

188 XT-70 Control Panel 188 Right click on the SCREW shortcut and select properties. After the type in a space then SCREW Then click on Apply. This will cause Xbase to initialize for the SCREW compressor.

189 XT-70 Control Panel 189 Right click on the SDX Door shortcut and select properties. After the type in a space then SDX Then click on Apply. This will cause Xbase to initialize for the SDX Door card.

190 XT-70 Control Panel 190 Suberizer Door Configeration APP 021 The Suberizer door takes a different configuration than the BTU door controls. Suberizer should be set for door config 3. This will affect the speed of the door and also the door percentage reading. This application note will show how to setup and configure the door. The door potentiometer will connect up on the Pile 8 temperature sensor marked AN12. OUTSIDE HUMIDITY PLENUM HUMIDITY RETURN HUMIDITY RETURN CO2 PILE 7 PILE 8 HUMIDITY SENSOR 4-20MA HUMIDITY SENSOR 4-20MA HUMIDITY SENSOR 4-20MA CO2 SENSOR 4-20MA ma AN11 S AN12 S AN13 AN14 AN15 AN15 The potentiometer should be wired between the wiper and one end of the pot. As the door opens the resistance between the two wires should increase. If it is decreasing then use the other end of the pot. Measure the resistance when unplugged from the board. Run the door fully open and then fully closed and make sure the pot does not hit its stops. AN12 Use a DC voltmeter to measure the voltage at these points with the potentiometer plugged in. AN12 AN13 It is very important to use the common on AN13 as the 3rd pin on AN12 is a earth ground and not a dc common. With the door closed measure the dc voltage and record it. Then open the door fully and record the dc voltage. The voltage for the door closed should be higher than the voltage for the door open. If not the pot is wired backwards.

191 XT-70 Control Panel 191 Once you have recorded the values for the door open and door closed, enter these values in the E2 parameter screen. In the above example the DOOR CLOSED POS is 3917 vdc. The decimal place need to be removed and you need to have four places would be represented as Example vdc would be 3900, you need to have four places with the leading digit being on the left, add zeros if necessary. NORMALLY CLOSED CONTACT RELAY NORMALLY PICKED UP AND WILL DROP OUT TO CLOSE DOOR J16 XT-70 CLOSE 12VDC SPST Suberizer LS4 terminal Suberizer C terminal J20 XT-70 OPEN NORMALLY OPEN CONTACT RELAY NORMALLY DROPPED OUT AND WILL PICK UP TO OPEN DOOR 12VDC SPST Suberizer LS3 terminal

192 XT-70 Control Panel 192 General: Freq Drive Wiring & Setup APP 022 This application note will deal with how to wire and program multiple frequency drives. There are many different drive types being used, but all have similar inputs, outputs and setup parameters. This application will deal with the Allen Bradley Power flex units, but will describe the parameters in a manner that you should be able to translate to your particular drive. Objective: Just about every one has a different way of wiring the drives. We would like to standardize the wiring and provide the simplest and cleanest way to wire these drives. Depending if you are running refrigeration or not, there are certain parameters that should be set on all drives and we will go through the complete setup. Start Contact: In the past we have always used a start contact from the control panel. Typically this would require a dry contact for each drive, which is a lot of extra wiring and expense. Our new approach will not use a start contact. The XT panel provides a 0-20ma or a 0-10vdc output for the drives. This is an opto isolated output and uses a separate transformer to supply the power. The power for this transformer is supplied by the fan output module. Thus, regardless of what output the panel is calling for on the freq drive, the output will be zero until the fan output is energized on the panel. This is a good safety feature and will allow us to start the drives using the analog signal only. The simplest and best approach is to use the 0-10vdc output and not the 0-20ma. Using the 0-10vdc will allow you to use two wires and parallel all drives. One of the issues with using a Start contact was that it was dry from the XT panel. The drives require a 24vdc signal to activate the Start circuit. Many schemes were developed using the 24vdc from the drive, but all had issues. If you use the power supply from one drive, all drives would fail if you lost that one drive. To overcome this requires the use of a dry contact for each drive, which really complicates the wiring. Bottom line, it will require only 2 wires from the panel to control any number of drives. The objective is to use one 4 conductor cable from the panel to the first drive and then daisy chain the 4 conductor in and out of each drive. It is recommended that you use a red (+) and black (-) conductor for the 0-10vdc signal.

193 XT-70 Control Panel 193 On the AB drives the analog input for the 0-10vdc is terminals 13(+) and 14(-). Note - you must set dip switch A01 to 10v. Each manufacture will have jumpers or switches to allow you to select either 0-10vdc or 0-20ma inputs. On the AB we are using Analog input 1 (most drives have more than one analog input). It is recommended to standardize the use of analog input 1 for all drive manufactures. Drive 1 Drive 2 Drive 3 Drive XT-70 J44 FREQ DRIVE 0-10vdc V I G You can hook any number of drives up in this configuration. BTU has some new 4 conductor cable 20 awg that is rated at 600 volts. This cable could be run from the XT to the VFD s in the same wire way as the Power / Motor leads and meet NEC. Fan Proving: This application will show how to hook up the fan proving on each drive using one pair of wires. It is recommended that you use the white and green conductors to standardize the fan proving. Each of the different manufactures of freq drives supply up to 4 relay outputs. We will use one of the relays to provide a closure whenever the drive is running. On the AB drives we will use Relay output 1. Terminals R1 and R2 are the normally open contacts for relay output 1. Drive 1 Drive 2 Drive 3 Drive 4 R1 R2 R1 R2 R1 R2 R1 R2 XT-70 IN1 Fan FAil T055 is the AB parameter for relay output 1. Set T055 = 2. This will cause relay output1 to energize anytime that the drive is running. You should have a similar setting on all the other manufactures. Any fault or alarm will shut the drive off and output 1 will de-energize.

194 XT-70 Control Panel 194 Start / Stop Input: All VFD manufactures have inputs that you can use a Stop / Start switch on. The key to making this work is to use a second VFD output relay for the Stop / Start switch. The relay will be programmed to pickup when the 0-10vdc signal is above 15%. On the AB drives, terminal 01 is the Stop input and 02 is the Start / Run FWD input. To wire a start / stop switch, you would wire as shown below. When the relay R2 energizes, the drive will start. When it drops out, the drive will stop. Drive vdc R2 Start / Stop Relay Relay Output 2 Setup: Each VFD manufacturer will have a list of settings that will control Relay Output 2. For AB the parameter is T060 Relay Out2 Set. A setting of 11 is the Analog Input Loss. A loss of the Analog 0-10vdc signal will cause Relay Output 2 to energize. A loss of signal is described as less than 1vdc. Note - when the analog input signal is 1 vdc or greater, then the Relay Output 2 will be de-energized, thus we need to use the normally closed contact for the R2 start signal. The normally closed contact for Relay Output 2 on the AB is R5 & R6. Each drive would be wired as shown below R1 R2 R3 R4 R5 R Stop Input 02 Start Input vdc R5 Relay common R6 Relay Normally Closed

195 XT-70 Control Panel 195 Soft Start and Stop: All drive manufactures have an Acceleration Time and a Deceleration Time. These two parameters should be set to 60 seconds. This will allow a gradual ramp up and ramp down during starting and stopping. If you are running Refrigeration you may want to set the Deceleration to 120 seconds to allow the evaporator to be cleared of any liquid. DC Brake Start: This parameter will apply the brake to stop the fan from spinning before starting the fans. AB Setup Parameters: All other parameters are set to default settings.

196 XT-70 Control Panel 196 Complete Wiring Diagram for 2 Drive AB System: All other parameters are set to default settings.

197 XT-70 Control Panel 197 Basic Refrigeration CR-110 Parameters APP 023 This application note will explain the parameters associated with the set up of a CR-110 card for Basic Refrigeration, Polor Pak, Reverse Hot Gas, Air Defrost and Elec Defrost. This document uses the xbase.inf (6-6-08) file. Other app notes will cover the screw and vfd units. Profile: The Profile is used to select the desired operation of the CR-110. Valid profiles for this application are Basic Refrig, Polar Pak, Reverse Hot Gas, Air Defrost and Electric Defrost. four. Filter: This is a digital filter for all the analog inputs. It can be set from 1 to 10. One would be the least filtering and ten would be the max filtering. The recommended filter setting is Network: This is the first number assigned to a condenser unit. Example - CR card address 01 would be network 0, compressor 1. CR card address 12 would be network 1 and compressor 2. A network is defined as a group of compressor that will stage together. Example - You could have two separate systems with multiple compressors on the same communications bus, one group would be network 0 and the other network 1. For system running on non XT-70 control panels the network is typically 0-4. For XT panels the network must be 5 or 7. Unit: The unit number is assigned starting with 1 and can go up to 8. Example - a two compressor system would have units 1 and 2. For staging and rotation, you must always start at 1 and go consecutive. Set Address: The Set Address is used to change the address of the CR card. When checked, you can change the address of the card. Note - the CR card must be in the test mode before it will accept a new address. To change the CR card to the test mode, turn the S2 switch to the center off position. Then turn the S2 switch first to the RUN position and then, within three seconds switch to the PD position. All the LED indicators should be lit when in the test position.

198 XT-70 Control Panel 198 Input Mode: The input mode allows you to select the type of input you are using for the staging of the system. Ma Signal, Setpoint, Pulse and Setpoint C are valid inputs. Ma Signal is selected if you are using a 4-20ma or 0-20ma signal from a control panel. Pulsed is selected if you are using a IVI or panel that produces a open and close dry contact for control. Setpoint and Setpoint C are used when a thermistor on the CR card is used for temperature control. Setpoint C is used for controlling in degrees Celsius. Pressure Transducer: This refers to the range of the suction transducer that you are using. The discharge transducer is always a psi transducer. The suction transducer could be a or psi transducer. Tandem: Not used Parallel: If you check this box, the compressor will not pump down when the LLS closes. This should be check on compressor in a parallel system that you do not want to pump down. LLS Reverse: If you check this box, the LLS output will be normally closed. UL1 Reverse: If you check this box, the UL1 output 7 will be normally closed. Note - currently the output is on when unloaded. UL2 Reverse: If you check this box, the UL1 output 7 will be normally closed. Note - currently the output is on when unloaded.

199 XT-70 Control Panel 199 Comp_off: Suction pressure at which compressor will shut off during pump down. Comp_on: Suciton pressure at which compressor will come on in Refrigeration. Short_Cycle: The short cycle timer will prevent the compressor from short cycling. Set the SCT value, in seconds for the desired off time, before the compressor can restart. Rotation: This timer is minutes and is used to switch the lead compressor. Once compressor # 1 has run the rotation setting, it will rotate the lead to the number two compressor. The staging for compressor # 1 will shift to compressor # 2 and the last compressor will send its staging to compressor # 1. The number of compressors must be set above 1 for this feature to be active. Compressors: Set this for the number of compressors in the network that will be staged. Unloaders: Set this for the number of Unloaders on the compressors. Low_Ambient: This should normally be set for zero to disable it. The UOM is seconds and this value is used for a cold weather start. If you are operating in extreme cold weather so that when the LLS is open the suction pressure will not raise, then you can use this value. A typical setting would be 30 seconds. When the LLS opens the compressor will immediately start and run for 30 seconds. If the suction pressure raises during this time it would continue to run. If the suction pressure does not raise, then it would short cycle and try running again. DPA: (Discharge Pressure Alarm) This is a soft high head pressure alarm. It should be set about 30 psi less than the mechanical high pressure switch. HHPU: (High Head Pressure Unload) When the ambient air temperature exceeds the rating of the condenser, the condenser no longer has the ability to reject the full load heat. This can produce a nuisance high head pressure alarm. The HHPU feature will automatically unload the compressor, and prevent this alarm. The HHPU setting should be set below the soft high head alarm. Example - if set for 300 psi, unloader # 2 would unload when the discharge exceeded 300 psi. It would reset

200 XT-70 Control Panel 200 when the pressure dropped below 295. If the pressure exceeded 310 psi, unloader # 1 would also unload, the reset point would be 305. Thus you can set the HHPU for any pressure and the reset will be at 5 psi less and the unload point for the #1 unloader will be 10 psi above. Low_Suc_A: (Low Suction Alarm) This alarm has two components; first is the low suction pressure point and second is the timer. The alarm is active only in the refrigeration, defrost, and pump down modes. If the suction pressure drops below this setting and remains there for the duration of the timer, the system will shut down and go into an Alarm mode. A value of zero in the timer will disable the alarm. Low_Suc_T: (Low Suction Timer) This is the timer for the Low Suction Alarm. The UOM is minutes and a typical value would be 5. A setting of zero will disable the alarm. LSH INST: (Low Super Heat Instantaneous) This alarm should not be used and needs to have a value of 0. SHeat Lo: (Super Heat Lo Alarm) This is the low side of the compressor suction super heat alarm window. If the suction super heat drops below this value and the associated timer expires the compressor will be shut down. A typical setting would be 8 degrees. SHeat Hi: (Super Heat Hi Alarm) This is the high side of the compressor suction super heat alarm window. If the suction super heat raises above this value and the associated timer expires, the compressor will be shut down. A typical setting would be 30 degrees. SHeat Timer: (Super Heat Timer) This is the timer for the Lo and Hi super heat window. A typical setting would be 10 minutes. A setting of zero will disable this alarm.

201 XT-70 Control Panel 201 MODE: (Condenser Fan Mode of Operation) The mode refers to the type of air cooled condenser fan control that is desired. Fixed Head Pressure uses the Control Point setting and Cond Fan Diff to cycle the condenser fans off and on. Balanced Head Pressure control will float the head pressure depending on the ambient air conditions. The lowest pressure that the system will float to is the System Drop plus the suction pressure. The Cond Fan Diff is used to stage the condenser fans. Balanced PID Pressure control will produce a 4-20ma signal for a variable freq drive condenser fan. System Drop: This is the total system pressure drop. A typical value would be 70 psi. The Balanced Head pressure Mode uses this value for controlling the head pressure. The controlling pressure is determined by the suction pressure plus the System Drop. Gas Type: Select the type of gas being used. This is a critical selection that allows the proper super heat to be calculated. Control Point: This is the desired head pressure in psi. This value is only used in the fixed head pressure control, or if one of the parameters used in the Balanced Head pressure control is missing.

202 XT-70 Control Panel 202 Control Fan Diff: Rather than have to enter all the values for each stage of the condenser fans to cut in and out, a differential value is used. The recommended value is 5 psi. Stage 1 Stage 2 Stage 3 Stage 4 OFF CP CP + D CP + 2D CP + 3D ON CP + 2D CP + 3D CP + 4D CP + 5D Example Control point = CP = 200 Differential = D = 10 OFF ON OSA Diff: This value is not used and should be set to zero. PID Term: This is a value that is used for engineering only. It should be set to zero. The following values are based on a 0-100% output. Liquid Line Off - On: The first value is the Liquid Line off value and the second is the on value. These values are in percent and will determine when the LL solenoid will open and when it will close. A typical value would be 5% off and 10% on. Unloader 1 Off - On: The first value is the Unloader 1 off value and the second is the on value. On would mean that the cylinder is loaded and pumping. The staging will depend on the number of compressor in the system. Unloader 2 Off - On: The first value is the Unloader 2 off value and the second is the on value. On would mean that the cylinder is loaded and pumping. The staging will depend on the number of compressor in the system. Low SP 1 On - Off: If the suction pressure drops below the first On value, unloader # 1 will unload. As soon as the suction pressure raises above the off value, the unloader will return to normal operation. Low SP 2 On - Off: If the suction pressure drops below the first On value, unloader # 2 will unload. As soon as the suction pressure raises above the off value, the unloader will return to normal operation.

203 XT-70 Control Panel 203 VIDT: (Variable Initiated Defrost) This is a unique way in which a trend is established for determining the suction pressure operating point. This timer is sets the length of time that the trend is taken. This allows the CR- 110 to determine a defrost initiation based on a drop in suction pressure rather than just time. A normal setting would be between 30 and 60 minutes. Set to zero to disable. Suc Diff: (Suction Differential) Once a trend is established for the suction pressure, this value would be subtracted from the trend suction pressure and would be used to initiate a defrost cycle when the suction pressure was below this calculated value for a given time. A normal setting would be 3-5 psi. Set to zero if this operation is not desired. DIT: (Defrost Initiated Timer) This is the amount of time the suction pressure would be below the Suc Diff point before initiating a defrost. A setting of zero will disable this feature. Max Def: (Max Defrost Time) This is the time in minutes for the next defrost. If a defrost is not initiated using the VIDT then this time will initiate a defrost. Set to zero to disable all defrost cycles. Defrost_Off: (Defrost Termination Pressure) This is used for hot gas defrost termination. As soon as the discharge pressure rises above this value, the defrost will be terminated. Temp Termination: This value is not used and should be set to zero. DTT: (Defrost Termination Timer) This is the time in minutes that the defrost cycle will run before being terminated. A setting of zero will disable this feature. For hot gas defrost, this time will over ride the discharge pressure termination. Coil_Dry: (Coil Freeze) This is the time in seconds that the coil will be dried after the defrost termination. The system will run with the compressor and the LLS open, but the evaporator fans will be off.

204 XT-70 Control Panel 204 Proportional: This value is only used when the PID Mode setting is other than None. The Proportional constant is simply a multiplier that can be used to fine tune the size of the Proportional Mode adjustment. Raising the value of P results in a greater reaction to input value changes. A typical setting would be Integral: This value is only used when the PID mode setting is other than None. The I value is what will cause the output to change when the input is not changing and is steady state. Increasing this value to much will cause the system to become unstable. A typical value would be 5. Derivative: This value is only used when the PID mode setting is other than None. The Derivative is constantly analyzing the rate of change of the error, makes a prediction about what the future error will be and makes adjustment to the output in an attempt to reduce the rate of change in the error. For most cases the derivative is disabled by setting it to zero. SP: (Setpoint) This value is only used when the input mode is Setpoint or Setpoint C. This would be used as a stand alone controller and would use a thermistor for a controlling sensor. If you are not using Setpoint or Setpoint C the value does not matter. COMP SH H (Compressor Super Heat High) This value is for the automatic compressor super heat control. It should be set to zero if not using this feature. This is the high value for the desired window for the compressor operation. Typical compressor suction superheat operation should be maintained between 18 to 20 degrees. In this case you would set the Comp SH H to 20 and the Comp SH L to 18. This feature is only available when using the ER-110 controller.

205 XT-70 Control Panel 205 COMP SH L (Compressor Super Heat Low) This value is for the automatic compressor super heat control. It should be set to zero if not using this feature. This is the low value for the desired window for the compressor operation. Typical compressor suction superheat operation should be maintained between 18 to 20 degrees. In this case you would set the Comp SH L to 18 and the Comp SH H to 20. This feature is only available when using the ER-110 controller. EV_UPDATE: (Evaporator Update time) This is the time in minutes that the CR-110 broadcasts to the ER-110 cards for an update on the Super Heat Setpoint. A typical setting would be 10 minutes. SH SAFETY: (Super Heat Safety) This is a safety setting for the compressor suction superheat. A typical setting would 10 degrees. If the compressor suction superheat dropped below this setting the CR-110 would broadcast to all ER-110 to default to a super heat Setpoint of 12 degrees. As soon as the compressor super heat warmed back up, then auto control would resume. Amp: If an amp transducer is being used this parameter will select the range of the transducer. 0 = 0-50 amps, 1 = amps, 2 = amps. Update: This is the update time for the PID loop and is active only when the PID is being used. This is in 10ths of a second. A typical setting would be 50 which would be 5 seconds. The PID loop is active only when running an input mode of Setpoint or Setpoint C. It is also active if using a freq drive on the compressor or running suction control. Min Output: This is only used when the PID Mode is Comp Freq. Min output is the lowest percentage of the 0-20ma signal from the CR-110 to the freq drive. Man Output: Man Output sets the span for the 0-20ma signal to the freq drive. A setting of 25% will allow the drive to go from 30% or minimum setting to 100% for a 25% change of the control panel input signal. Dead Band: The Dead Band setting is used for compressor rotation. If you only have one compressor, this setting is not used. If you have two compressors, this setting would be 50 %. If you have three compressors then set it for 33% and for four compressors set it for 25 %. The liquid line solenoid and unloaders should be staged less than this setting. Example if you have two compressors, all staging on both compressors should be from 0-50%. In this example the lag compressor will subtract 50% from the output of the lead compressors. This will cause the lag to stage from % but have the same settings as the lead compressor.

206 XT-70 Control Panel 206 Evap SH SP: (Evaporator Super Heat Setpoint) This parameter is only used when the CR-110 card is used in conjunction with a ER-110 card. This is the actual value that is being broadcast to the ER-110 cards for their Super Heat Setpoint. This value will automatically change if the auto super heat control is active. If you are running in auto super heat, the CR-110 constantly monitors and averages the compressor suction super heat. If the suction superheat is outside of the super heat window, then it will change the Evap SH SP and broad cast this value to all the associated ER-110 cards. KI_div: (PID Scaling parameter) This is for engineering only, do not change this value. The default value is 10. EV HI Limit: (Evaporator High Limit) When running in auto super heat mode, this is the High Limit that the super heat setpoint can be incremented to. EV LO Limit: (Evaporator Low Limit) When running in auto super heat mode, this is the Low Limit that the super heat setpoint can be decremented to. PID Mode: For most of the application this should be set to None. If you are using a VFD on a compressor or running suction control you need to use the CR-110 VSC software and inf file.

207 XT-70 Control Panel 207 ER-110 Parameters ER-110 Electronic Expansion Valve Parameters APP 024 This application note will define each of the parameters used on the ER-110 card. The card s main purpose is to control a stepper valve for the superheat control on an evaporator or a stepper valve controlling the suction pressure on an evaporator. The ER-110 card can control two valves with one card. Profile: The Profile is used to select the desired operation of the ER-110. Valid profiles for this application are Double EEV, Single EEV and EEV-EPR. Filter: This is a digital filter for all the analog inputs. It can be set from 1 to 10. One would be the least filtering and ten would be the max filtering. The recommended filter setting is four. Network: This is the first number assigned to a condenser unit. Example - ER card address 01 would be network 0, evaporator 1. ER card address 12 would be network 1 and evaporator 2. A network is defined as a group of cards that work together on the same system. Example - You could have two separate systems with multiple compressors and evaporators on the same communications bus, one group would be network 0 and the other network 1. For system running on non XT-70 control panels the network is typically 0-4. For XT panels the network must be 5 or 7 for compressors and 6 or 8 for evaporators. Unit: The unit number is assigned starting with 1 and can go up to 8. Set Address: The Set Address is used to change the address of the ER card. When checked, you can change the address of the card. Note - the ER card must be in the test mode before it will accept a new address. To change the ER card to the test mode, turn the power off and put a jumper on input 8. Then turn the power back on. The four red LED indicators should be lit when in the test position. Input: The input selection tells the card how to operate. If the card is being used as a EEV only, select the None mode. If you are using the card as a EEV and EPR, select the type of input

208 XT-70 Control Panel 208 signal for the controller. It could be either a 0-20ma or a 4-20ma. Pressure Transducer: It is highly recommended that a psi suction transducer be used. Select the appropriate transducer. Ma Signal: The ma selection is not used. These values have to do with a new mode of operation. This has not been fully tested in the field and should not be used at this time. Version 2.53 and higher use these parameters. At this time it is suggested that all values be set to zero. This will disable this feature. Failsafe operating mode: One of the issues of using electronic expansion valves is the possibility of having a temperature sensor drift. This can cause the superheat to be read wrong and have the valve position wrong. This is the same thing that can happen with a mechanical valve that develops a leak in either the pressure or temperature. The only way to safeguard this is to use a second temperature sensor. The ER has two extra temperature sensors on input 7 & 8. To activate the failsafe mode, install an extra sensor in the same position as the current suction temperature sensor. Input 7 would measure the suction temperature for valve A and input 8 is for valve B. If the difference in the two sensors varies more than the difference parameter for the set number of seconds, the card will go into a suction sensor fail and then would preposition the valve to the Failsafe position. This would allow systems with multiple evaporators to continue to run without shutting the entire system down. SH_A_Diff & SH_B_Diff: These are the differential setting for each valve. A typical setting would be two degrees. If there was more than two degrees between the two suction sensors then the alarm timer would start. Once the timer times out the valve will be positioned to the Failsafe percentage. The Failsafe percentage could be zero or say 10 percent. T_Enable: T_Enable is used for engineering. It enables the PID calculations to stream in terminal. It should be set to zero.

209 XT-70 Control Panel 209 KI_div: This is an engineering unit and should be defaulted to 10. KI_div2: This is an engineering unit and should be defaulted to 20. selection that allows the proper superheat to be calculated. Gas Type: Select the type of gas being used. This is a critical PID Scale: This is an engineering unit and should be defaulted to 0. Init Pos: When the system first goes into Refrigeration, the valve should initially go far enough open to allow the compressor to start and not pull the suction pressure down. A typical setting would be 20 to 30 percent. If this percentage is too high, it may cause the superheat to drop. Settle: The Settle parameter is the time in seconds that the valve will remain in the Init Pos. Once this time is up, the valve will go to its normal PID operation. KI_Thresh: This is an engineering unit and should not be changed. The default is three. LLS OFF & ON: The ER card is driven by a input signal from the control panel. This input signal goes from 0 to 100%. The output of the ER card will open and close the Liquid Line Solenoid based on this percentage. Def Enable: This setting is in psi and will determine when the defrost is active. The suction pressure must be less than this value for the defrost cycle to be active. This parameter is only used when the ER card is being used to initiate the defrost. This typically would be when the card is set to control a EEV and EPR. A zero will disable the defrost cycle. Def Cycle: If the Suction pressure is below the Def Enable, this is the time in minutes until the defrost is

210 XT-70 Control Panel 210 initiated. Def End: This is the length of the defrost cycle in minutes. Coil Dry: Once the defrost cycle is over, the mode will change to Coil Dry. This is the time in seconds where the LLS will open without the evaporator fan running. This will freeze the free water on the coil before the fans turn on. Proportional: This value is only used when the PID mode setting is Auto. The proportional constant is simply a multiplier that can be used to fine tune the size of the Porportional mode adjustment. Raising the value of P results in a greater reaction to input value changes. A typical setting would be P only produces an output when there is a change. Too much P, will override I. Integral: This value is only used when the PID mode setting is Auto. The I value is what will cause the output to change when the input is not changing and is steady state. Increasing this value too much will cause the system to become unstable. A typical value would be 5. Derivative: This value is only used when the PID mode setting is Auto. The derivative is constantly analyzes the rate of change of the error, makes a prediction about what the future error will be and makes adjustments to the output in an attempt to reduce the rate of change in the error. For most cases the derivative is disabled by setting it to zero. V1 Steps: This depends on the type of valve. Most of the EEV valves are 1596 steps. The EPR could be 2500 or 6396 steps. This is a critical value because of the scaling of the valve from 0 to 100 percent. V1 would normally be the EEV and V2 would be the EPR if used. Max SP: Max Setpoint is the high limit of the superheat setpoint for the evaporator. This is only used when the evaporator is running in dynamic superheat control. Dynamic superheat control is when the compressor sends a new superheat setpoint to the evaporator based on its suction superheat. The new superheat setpoint must be lower than the Max SP or it will be rejected.

211 XT-70 Control Panel 211 Min SP: Min Setpoint is the low limit of the superheat setpoint for the evaporator. This is only used when the evaporator is running in dynamic superheat control. Dynamic superheat control is when the compressor sends a new superheat setpoint to the evaporator based on its suction superheat. The new superheat setpoint must be lower than the Min SP or it will be rejected. Valve Limit: This setting will determine how the valve will act at 100% opening. A setting of zero will continue to pulse the valve open even when it is at 100%. This guarantees the valve will go full open. A setting of one will cause the pulse to stop when the math shows it to be at 100%. It is recommended to use the setting of zero. Comp #: This only applies when running dynamic superheat control. Set to zero if not using dynamic superheat control. Each compressor has a number and when running dynamic superheat control will broadcast it s number along with a new superheat setpoint. Each evaporator associated with the compressor should have the compressor number programmed in this parameter. One network is used on all compressors and evaporators and this allows each evaporator to receive the correct broadcast. Coil DT: The Coil DT is used to calculate the ideal suction pressure. The ideal suction pressure is used with a EPR (evaporator pressure regulator). The EPR is used to control the suction pressure of the evaporator. The Coil DT setting will determine the lowest temperature setting for the evaporator. The XT panel passes the temperature setpoint to the ER card. For example: XT Setpoint = 55 degrees, Coil DT = 8 degrees then 55-8 = 47 degrees. The coldest the coil would get would be 47 degrees. This is then converted to pressure and used to set the span for the EPR valve. Update: This is the update time for the PID loop and is active only when the PID is being used. This is in 10ths of a second. A typical setting would be 50, which would be 5 seconds. Min Output: When in Refrigeration this parameter will limit the low end of the valve. If set for 10% the valve would not close past 10%. The recommended setting is zero. Man Output: This setting pertains to valve two only. If in the manual mode, valve two will position to this setting. The recommended setting is zero. V2 Steps: This depends on the type of valve. Most of the EEV valves are 1596 steps. The EPR could be 2500 or 6396 steps. This is a critical value because of the scaling of the valve from 0 to

212 XT-70 Control Panel percent. V1 would normally be the EEV and V2 would be the EPR if used. Evap SH SP: This is the evaporator superheat setpoint. The PID will adjust the EEV to try and maintain the Evap SH SP. If the dynamic superheat is active this parameter will be controlled from the CR card on the designated compressor. EPR SP: This is only active when running in the EEV-EPR profile. The EPR Setpoint is a calculated pressure that is the lowest pressure that would be needed to maintain the current XT temperature Setpoint. The following will explain how this value is calculated. Example: Current XT Setpoint 48 degrees F Coil DT = 5 degrees F Super Heat Setpoint = = 35 degrees F 35 degrees F = 61 psi using R22 61 psi would be the current EPR SP. As the temperature setpoint for the XT panel changed, the EPR SP would also change. Range = 15 psi In this example 61 psi would be the lowest suction pressure of the evaporator for 100 % output from the XT panel. The highest suction pressure with 0% output from the XT panel would be 61 psi + 15 psi or 86 psi. The Coil DT and Range settings can change these parameters for the given situation. Range: The range is in psi and sets up the span of the suction pressure. The XT panel outputs a 0-20ma signal for temperature control. The range will set up the span of the floating suction setpoint for a signal from 0 to 20ma. For example: if the Range is set at 15 psi, at 100 percent or 20 ma the suction pressure would be 15 psi lower than at 0 percent or 0ma output. The higher the Range, the less resolution you will have. SH_Diff: This setting is only if you are using a EPR valve. Normally when using a EPR valve the condenser unit is a rack system that has a lot of potential to pull the suction down. In the process of pulling a room down to a low temp, it is possible to pull the suction so hard that the EEV can be wide open and not able to deliver enough refrigerant. In this case the superheat will

213 XT-70 Control Panel 213 go high and the efficiency of the coil will diminish make the problem worst. Under these conditions raising the suction pressure will solve the problem. If the evaporator suction superheat raises above the suction superheat setpoint by the SH_Diff amount, it will automatically raise the floating suction setpoint by 1 psi every four minutes. Once the superheat comes below this window the floating suction setpoint will resume normal calculations. A setting of zero will disable this feature. Communications Terminal Window: The communications window allows a quick look at all the major parameters on a five second update. The Floating SP is the calculated suction pressure setpoint for the given conditions. The EPR valve should be adjusting to maintain this value. The Cooling Demand is the cooling percentage coming from the XT panel. The EPR Setpoint is the lowest calculated pressure needed to maintain the XT temperature Setpoint. Pressure Offset is the amount the suction pressure has been raised in the case of high superheat.

214 XT-70 Control Panel 214 CR-110 Freq Drive Compressor Suction Control Application Note APP-025 Freq Drive Compressor This application Note will describe how to use the CR-110 to control a compressor with a VFD and using Suction control. Application note 001 describes using a VFD on a compressor, but without suction control. Suction control uses the ma signal from the panel to create a floating suction Setpoint. The CR will then control the compressor to maintain the suction pressure. Application note 19 shows how to setup the parameters for suction control. Theory The VFD is used to operate the compressor from 30% to 100% output by varying the speed of the compressor. The CR card will control the VFD to hold a constant suction pressure. The suction Setpoint has a span that is controlled by the 0-20ma signal from the control panel. Sensors The pressure sensors and temperature sensors are located right next to the compressor. Ch 5 is not used at this point. Ch 6 is the 0-20ma or 4-20ma signal from the control panel. Ch 7 is a 0-5vdc current transducer. The transducer has a switch for selecting different ranges. Make sure that the CR-110 is programmed for the correct setting. Ch 8 is a current switch that provides a dry contact when the Crank Case heater is on.

215 XT-70 Control Panel 215 Freq Drive Compressor High Voltage Wiring Freq Drive Condenser Fans High Voltage Wiring An option is to use a VFD to control the head pressure of the compressor. This provides a very smooth operation and helps with the overall control. This requires a separate pressure transducer that connects directly to the VFD. The pressure Setpoint is programmed in the VFD.

216 XT-70 Control Panel 216 CR-110 Communications and VFD Control J13 is the main communications connection to the CR & ER cards. J7 is the 4-20 ma output to the VFD for the compressor. J7 will also provide a 0-10vdc signal to the freq drive if preferred. Use the C and V terminals on J7 for 0-10vdc. CR-110 VFD Condenser Fan Control When using a VFD on the condenser fans, a single relay is used to provide a start signal to the drive. The drive will then use a PID loop to control the pressure to a Setpoint save in the drive.

217 XT-70 Control Panel 217 CR-110 Condenser Fan Control The first 4 outputs are the condenser fans and may take a number of different configurations. CR-110 VFD Compressor and LLS Valve Control The CPR relay is used to provide a start signal to the compressor VFD and also provide a start signal to the oil switch. A fault contact from the VFD drive is also used to trigger an external alarm on the CR card.

218 XT-70 Control Panel 218 XT Panel Records and Excel Spreadsheets APP-026 General: The XT-70 control panel up to 25 parameters to be chosen to use for records. Not only can the specific parameters to use be chosen, but so can the order of the records. The XT-70 will save 78,000 records and then will rollover when full by deleting the oldest record and replacing it with a new one. The records can be downloaded from a web browser or from the HMI. When downloaded with a web browser, they are loaded into a spreadsheet. It is also possible to access the data directly from a pre-setup template. The XT-70 will also store refrigeration records for up to ten devices. The ten devices can be any combination of CR and ER cards. It will store up to records for each device. The records will also rollover when the slot is filled. They can be downloaded like the XT records. The records are composed of both a historical averaged record and also an activity log. The time for the historical averaged record can be set. The activity log record will be generated any time there is a mode change. The activity record is not averaged and is an instantaneous record. Records Setup: The format of the records is controlled by a CSV file that can be edited in Excel. This file will also allow the changing of the names of the pile sensors and the humidity and CO 2 sensors. There are numerous files already built that can be used and modified. These files are available on the BTU Tech website. At any time, it is possible to download the existing file that the XT panel is using and make changes to it. Access the panel via the webpage and click on On the Configuration page, click on Inf Manager Now click on Click on OK and the file will open in Excel. Click on File> Save As.. and use a name that will describe the panel. Changes can now be made. When done, save the file and upload it back into the panel.

219 XT-70 Control Panel 219 The following shows the format of the CSV file. The sensors highlighted in yellow can be named. The record index refers to the order in which the values will appear in the records. All record index fields must have a value. If not being used, then insert a zero. [XT_INF_01] TERMINAL LABLE [XT] <Plenum T - reference only> <record index> <Start - reference only> <record index> <Outside T - reference only> <record index> <Return T - reference only> <record index> <Pile 1 - configurable> <record index> AN5 <Pile 2 - configurable> <record index> AN6 <Pile 3 - configurable> <record index> AN7 <Pile 4 - configurable> <record index> AN8 <Pile 5 - configurable> <record index> AN9 <Pile 6 - configurable> <record index> AN10 <Pile 7 - configurable> <record index> AN11 <Pile 8 - configurable> <record index> AN12 <Outside H - configurable> <record index> H1 <Plenum H - configurable> <record index> H2 <CO2 level - configurable> <record index> H4 <Door Open - reference only> <record index> <Operation Mode - reference only> <record index> <Secondary Mode - reference only> <record index> <Refrig Output - reference only> <record index> <switch status 1 - reference only> <record index> <switch status 2 - reference only> <record index> <switch status 3 - reference only> <record index> <output status - reference only> <record index> <Return H - configurable> <record index> H3 <Freq Drive Current - reference only> <record index> <Daily Run - reference only> <record index> <CPH - reference only> <record index> <Pile T - reference only> <record index> <Pile H - reference only> <record index> <setpoint - reference only> <record index> <target - reference only> <record index> <CO2 SP - reference only> <record index> <humid sp - reference only> <record index> <cooling sp - reference only> <record index> <refrig sp - reference only> <record index> <timed sp - reference only> <record index>

220 XT-70 Control Panel 220 CSV Example: Highlighted names can be changed to any name you want, with a ten character maximum. [XT_INF_01] [XT] PLENUM T 4 START 5 OUTSIDE T 6 RETURN T 7 NE 8 NW 9 SE 10 SW 11 Middle E 12 Middle 13 Center 0 Unused 0 OSA H 14 PLEN H 15 CO2 17 DOOR OPEN 18 OPERATION MODE 1 SECONDARY MODE 2 REFRIG OUTPUT 19 SWITCH STATUS 1 20 SWITCH STATUS 2 0 SWITCH STATUS 3 0 OUTPUT STATUS 21 RTN H 16 FREQ DRIVE CURRENT 0 DAILY RUN 0 CPH 0 PILE T 0 PILE H 0 SETPOINT 3 TARGET 0 CO2 SP 0 HUMID SP 0 COOLING SP 0 REFRIG SP 0 TIMED SP 0 The numbers refer to the order of the records. In this example, the operation mode will be the first value, then the secondary mode, setpoint and so on. Timestamp OPERATION MODE SECONDARY MODE SETPOINT PLENUM T START OUTSIDE T 4/2/2009 0:00 WARMING

221 XT-70 Control Panel 221 Refrigeration records: [CARD_1] 1 Discharge Pressure 1 Suction Pressure 2 Suction Super Heat 3 Amps 0 Output 4 Mode 5 Lead Compressor 6 Suction Temp 7 Discharge Temp 0 [CARD_2] 1 Discharge Pressure 1 Suction Pressure 2 Suction Super Heat 3 Amps 0 Output 4 Mode 5 Lead Compressor 6 Suction Temp 7 Discharge Temp 0 [CARD_3] 2 Suction Press A 5 Suction Temp A 6 Suction Press B 7 Suction Temp B 8 Super Heat SP 2 Super Heat A 3 Super Heat B 4 Valve pos A 9 Valve pos B 10 Mode 1 The refrigeration records are laid out in the same CSV file as the XT records. There can be up to ten devices and can be cut and paste to match up to the system. All cards must be in order, starting with Card 1. Below each card, identify the card type. 1 = CR-110 and 2 = ER-110 (required). The numbers will set the order in which the values will appear. Once the file is set as desired, then save it as a CSV file and use a name that references the given panel. Now upload the new file to the XT panel. Generally, when changes are made to this file, the records should be cleared.

222 XT-70 Control Panel 222 Records Request: There are a number of ways to retrieve the records from the XT. The first and easiest way it to use the web interface and select the desired date. Any start date and ending date that has valid records can be entered. The start date begins at midnight. Thus, if today is the 4/2/09 and only today's records are wanted, use a start date of 4/2/09 and an end date of 4/3/09. When Retrieve records is clicked on, a choice is given to save the records or to open them in a spreadsheet. The next way to get records involves using a host of other applications to download the records. This could be a database, a spreadsheet or a custom program. Any records request involves the IP address of the panel. There is a variable format that would allow one to automatically pull records from any date and there is also a two day and a seven day fixed dump of records. The two day and seven day format are addressed here first. The format for the last two days records is address>/records_2days.csv The format for the last seven days records is address>/records_7days.csv For example, to retrieve the last two days of records for an XT-70 panel at at HTTP port 4005, the request would be: To load these records in an Excel spreadsheet, do a file open and use that address for the File name: field. The XT panel acts much like a harddrive. The difference is that the address or path is via the internet to gain access the XT.

223 XT-70 Control Panel 223 Two day and Seven day Templates: The purpose of a template is to set up some predefined graphs and to be able to instantly download the data and apply it to the graphs. Excel allows one to build and save templates. Excel s normal file extension is xls. An Excel Template will have an extension of xlt. With a Template, one can set up graphs and different displays which will automatically load the data for the last two days or seven days when the spreadsheet is opened. The best way to start is with the BTU Potato Template.xlt file. Open this file (it may take a while to timeout if it is not pointed toward any data). The first thing to do is to point it toward the correct XT panel. To do this, click on the Record Tab at the bottom. Click on any cell, then go Data> Get External Data> Edit Text Import. Type in the IP address of the panel using the colon between the IP number and the HTTP port number. Records for either the last two days or seven days can be chosen here. Click on Open and the file should load the new data for the last two or seven days. Do a Save As on this file and name it according to the panel name. Make sure that the file extension yis for a template (xlt) and not a worksheet (xls). Now any time this file is opened, the last two days of data will automatically be loaded.

224 XT-70 Control Panel 224 Excel Graphs & Templates: The main part of the template is to get the data to load into the records page. The trick is that the exact number of records is unknown. Thus when the graphs are set up, they have to be inclusive of just the data. The BTU template can easily be modified it for a specific application. Chart 1 is a dual axis graph and has temperatures on the left side and output percentage on the right side. To make a change to the parameters being graphed, right click on the graph and select Source Data. Remove parameters by clicking on the parameter and then Remove. To change a parameter, select the parameter, determine which column the needed parameter is in and then change the alpha character in both the Name and Values boxes. the Values field. To add a button, click on Add. Then go to one of the other sensors and copy the Name string and paste it in to the new one and change the alpha character to match the desired value. Repeat for

225 XT-70 Control Panel 225 Getting Date Specific Data: The second way to download data automatically is by using a date specific format. This will send a beginning date and ending date for the records. The request string would be as follows: address:port #>/records.csv?a=x&b=x&c=x&d=x&e=x&f=x&g=1&h=x Where a = record start month b = record start day c = record start year d = record end month e = record end day f = record end year x = value for corresponding variable g = 1 this variable is only needed if the request is sent by an automated device, i.e. HMI, VPN, etc. It forces the formatting of the CSV to be strictly comma separated values with no other HTTP formatting. h = 0 to 10 this variable indicates which device the request is for: 0 = XT, 1 to 10 = refrigeration cards Example: to request records from a panel with an IP address of , HTTP port 4005, start date and end date of , send the following request:

226 XT-70 Control Panel 226 Rack Refrigeration With VFD s Application Note APP-027 THEORY This application uses the special CR-110 Rack software. This system application note is for a rack system with three compressors. Compressor C1 is 7hp, Compressor C2 is 25hp and Compressor C3 is 50hp. Each of the three compressors is equipped with a VFD on the compressor that is being driven from a CR-110 card. All three compressors are connected in parallel. Each compressor will run its own PID loop with some conditions. The three CR cards are supervised by a Micrologix s 1100 PLC. Each of the CR card has two relay outputs that are adjustable. One comes on when the VFD is running at max freq and the other is closed when the VFD is running at minimum percentage. Each of the two outputs of the CR cards are tied to the PLC. When any of the XT panels are running in refrigeration a dry contact is used to tell the PLC to go to a refrigeration mode. If there is no call for refrigeration, then the PLC sets the mode to zero and compressor one will pump down. This same contact on CR 1 is used on input 5 to force pump down. The PLC controls each of the CR cards using a dry contact output that goes on input 6 of each of the cards. C1 is the only compressor that is set to pump down, C2 and C3 are set as parallel compressors. Compressor C1 has a address of 01, compressor C2 is 11 and compressor C3 is 21. The reason for the individual networks is so each one will run independently. The PLC determines the over all mode of operation. The different modes are as follows: Mode 0 Mode 1 Mode 2 Mode 3 Mode 4 Mode 5 Mode 6 Mode 7 Standby Compressor C1 running, C2 & C3 off Compressor C2 running, C1 & C3 off Compressor C1 & C2 running, C3 off Compressor C3 running, C1 & C2 off Compressor C3 & C1 running, C2 off Compressor C3 & C2 running, C1 off Compressor C3 & C2 & C1 running Each of the CR cards when in Refrig will adjust it output to the VFD to maintain the Suction Setpoint. If any of the compressors alarm, the PLC will skip modes that require that compressor to run. Each of the individual evaporators will have a ER-110 card that will drive both a EEV and EPR valve. The card will get a 0-20ma signal from a XT-70 control panel. The ER-110 will then calculate the ideal suction pressure range for the given Setpoint. It will then modulate the EPR valve to control to this pressure. The Rack system needs a suction Setpoint that will be low enough for the coldest evaporator. OPERATION When using a VFD on a compressor, typically 30% is the lowest you should run the compres-

227 XT-70 Control Panel 227 sor. Using 30% as a minimum you can get the range as follows: C1 30% = 4.5hp C2 30% = 12hp C3 30% = 22hp 100% = 15hp 100% = 40hp 100% = 75hp C1 is the only compressor that will pump down. C2 and C3 will start only when there start contact applied to input 6 and the suction pressure is above the compressor start setting. The controls panels for each of the bins has a dry contact output when calling for refrigeration. This controls a relay, that when de-energized will force C1 to pump down. Input 5 on C1 is used for pump down. A closed contact on input 5 will cause C1 to ignore the parallel check box. All compressors will be checked as parallel. Each compressor will run its own suction pid loop and make adjustments to the VFD on its compressor. To program each compressor to run independently each one has to have its own network number and be compressor 01. So for three compressors, the would be numbered C01, C11 and C21. Typical setting for the compressors are: C01 runs all the time there is demand and a start contract. C11 runs when C01 is above 90% loaded and will shut off when C01 is at 30%. C21 runs when C11 is above 90% loaded and will shut off when C11 is at 30%.

228 XT-70 Control Panel 228 WIRING Discharge pressure Suction pressure 1 2 Compressor C01 VFD amp output 0-5 vdc Compressor Suction temp Discharge temp Pump Down Contact Start Contract from Evaporator Crank Case A closed contact on input 5 will cause the CR-110 Rack software to ignore the parallel check box. J C01 CR-110 To Compressor C Compressor C11 Compressor Suction temp 3 Discharge temp 4 C J VFD amp output 0-5 vdc Crank Case C11 CR-110

229 XT-70 Control Panel 229 To compressor C Compressor C21 Compressor Suction temp 3 Discharge temp 4 C J VFD amp output 0-5 vdc Crank Case C21 CR-110 PROGRAMMING & SETUP For the Profile, select VFD Compressor. This will set the CR-110 to output a 0-10vdc or 0-20ma signal to the VFD on the Compressor. The Input Mode needs to be set to Setpoint. This will force the system to run off of a Suction Setpoint instead of a signal from a panel or temperature controller. For all Compressors you need to check the Parallel box. If this box is check the compressor will not pump down. C01 will be the only compressor to pump down. It has a contact on input 5 that when closed will cause the parallel box to be ignored.

230 XT-70 Control Panel 230 For this application, the Rotation should be set to zero and the Compressors set to 1. The High Dis A will shut the system down with an alarm. The High Dis U will unload the system when the discharge pressure is greater than this value. The LLS Off and LLS On setting are not used in this application. Span L and Span U are not used on this application. The High setting is percentage and works off of the PID output that controls the VFD. Output 7 will turn on when the PID output gets above the High setting and the suction pressure goes above the Suc SP plus the H_Diff. There is a 3 psi differential that will shut off output 7. Output 8 will turn on if the PID output drops be low the Low setting and the suction pressure drops the L_Diff setting below Suc SP. There is a 3 psi differential that will shut off output 8. Once started, each compressor will run its own PID loop and adjust the compressor VFD.

231 XT-70 Control Panel 231 Each compressor must have the PID adjusted for that unit. The Suc SP is the value the rack will try and maintain for suction pressure. Each compressor must have the same Suc SP value. The PID Mode must be set to Comp Freq for each of the compressors. The Min Output is the lowest value for the compressor VFD. Most compressors should not be run below 30%. The Man Output is used for scaling and should be set for 100% on each compressor.

232 XT-70 Control Panel 232 Screw Compressor CR-110 Parameters APP 028 This application note will explain the parameters associated with the set up of a CR-110 card for a Screw Compressor. This document uses the Screw.inf ( ) file. Other app notes will cover the VFD units. The CR-110 software is the VSC (variable speed compressor). Profile: The Profile is used to select the desired operation of the CR-110. Valid profiles for this application are Basic Screw, VFD Screw and VFD Comp. Filter: This is a digital filter for all the analog inputs. It can be set from 1 to 10. One would be the least filtering and ten would be the max filtering. The recommended filter setting is four. Network: This is the first number assigned to a condenser unit. Example - CR card address 01 would be network 0, compressor 1. CR card address 12 would be network 1 and compressor 2. A network is defined as a group of compressor that will stage together. Example - You could have two separate systems with multiple compressors on the same communications bus, one group would be network 0 and the other network 1. For system running on non XT-70 control panels the network is typically 0-4. For XT panels the network must be 5 or 7. Unit: The unit number is assigned starting with 1 and can go up to 8. Example - a two compressor system would have units 1 and 2. For staging and rotation, you must always start at 1 and go consecutive. Set Address: The Set Address is used to change the address of the CR card. When checked, you can change the address of the card. Note - the CR card must be in the test mode before it will accept a new address. To change the CR card to the test mode, turn the S2 switch to the center off position. Then turn the S2 switch first to the RUN position and then, within three seconds switch to the PD position. All the LED indicators should be lit when in the test position. Input Mode: The input mode allows you to select the type of input you are using for the staging of the sys-

233 XT-70 Control Panel 233 tem. Ma Signal, Setpoint, Pulse and Setpoint C are valid inputs. Ma Signal is selected if you are using a 4-20ma or 0-20ma signal from a control panel. Pulsed is selected if you are using an IVI or panel that produces open and close dry contacts for control. Setpoint and Setpoint C are used when a thermistor on the CR card is used for temperature control. Setpoint C is used for controlling in degrees Celsius. Setpoint is also used for a rack system when you have a suction Setpoint. Pressure Transducer: This refers to the range of the suction transducer that you are using. The discharge transducer is always a psi transducer. The suction transducer could be a or psi transducer. Tandem: Not used Parallel: If you check this box, the compressor will not pump down when the LLS closes. This should be check on compressor in a parallel system that you do not want to pump down. LLS Reverse: If you check this box, the LLS output will be normally closed. UL1 Reverse: If you check this box, the UL1 output 7 will be normally closed. Note - currently the output is on when unloaded. UL2 Reverse: If you check this box, the UL1 output 7 will be normally closed. Note - currently the output is on when unloaded.

234 XT-70 Control Panel 234 Comp_off: Suction pressure at which compressor will shut off during pump down. Comp_on: Suction pressure at which compressor will come on in Refrigeration. Short_Cycle: The short cycle timer will prevent the compressor from short cycling. Set the SCT value, in seconds, for the desired off time before the compressor can restart. Rotation: This timer is in minutes and is used to switch the lead compressor. Once compressor # 1 has run the rotation setting, it will rotate the lead to the number two compressor. The staging for compressor # 1 will shift to compressor # 2 and the last compressor will send its staging to compressor # 1. The number of compressors must be set above 1 for this feature to be active. Compressors: Set this for the number of compressors in the network that will be staged. RLA_Alarm: This deals with a screw compressor where the amps need to be limited on start up and run. See app note 016 for more detail. Set to zero to disable. RLA_Time: This deals with a screw compressor where the amps need to be limited on start up and run. See app note 016 for more detail. Set to zero to disable. High Dis A: (High Discharge Pressure Alarm) This is a soft high head pressure alarm. It should be set about 30 psi less than the mechanical high pressure switch. High Dis U: (High Discharge Pressure Unload) When the ambient air temperature exceeds the rating of the condenser, the condenser no longer has the ability to reject the full load heat. This can produce a nuisance high head pressure alarm. The High Dis U feature will automatically unload the compressor, and prevent this alarm. The High Dis U setting should be set below the soft high head alarm. Example - if set for 300 psi, it pulses the screw to unload or lowers the VFD by 5% every update time until the pressure drops 15 psi. It will then resume normal operation. Low_Suc_A: (Low Suction Alarm) This alarm has two components; first is the low suction pressure point and the second is the

235 XT-70 Control Panel 235 timer. The alarm is active only in the refrigeration, defrost, and pump down modes. If the suction pressure drops below this setting and remains there for the duration of the timer, the system will shut down and go into an Alarm mode. A value of zero in the timer will disable the alarm. Low_Suc_T: (Low Suction Timer) This is the timer for the Low Suction Alarm. The UOM is minutes and a typical value would be 5. A setting of zero will disable the alarm. AMP Xducer: (Compressor amp draw) If an amp transducer is being used this parameter will select the range of the transducer. 0 = 0-50 amps, 1 = amps, 2 = amps. SHeat Lo: (Superheat Lo Alarm) This is the low side of the compressor suction superheat alarm window. If the suction super heat drops below this value and the associated timer expires, the compressor will be shut down. A typical setting would be 8 degrees. SHeat Hi: (Superheat Hi Alarm) This is the high side of the compressor suction superheat alarm window. If the suction super heat raises above this value and the associated timer expires, the compressor will be shut down. A typical setting would be 30 degrees. SHeat Timer: (Superheat Timer) This is the timer for the Low and High superheat window. A typical setting would be 10 minutes. A setting of zero will disable this alarm.

236 XT-70 Control Panel 236 MODE: (Condenser Fan Mode of Operation) The mode refers to the type of air cooled condenser fan control that is desired. Fixed Head Pressure uses the Control Point setting and Cond Fan Diff to cycle the condenser fans off and on. Balanced Head Pressure control will float the head pressure depending on the ambient air conditions. The lowest pressure that the system will float to is the System Drop plus the suction pressure. The Cond Fan Diff is used to stage the condenser fans. Balanced PID Pressure control will produce a 4-20ma signal for a variable freq drive condenser fan. System Drop: This is the total system pressure drop. A typical value would be 70 psi. The Balanced Head pressure Mode uses this value for controlling the head pressure. The controlling pressure is determined by the suction pressure plus the System Drop. Gas Type: Select the type of gas being used. This is a critical selection that allows the proper super heat to be calculated. Control Point: This is the desired head pressure in psi. This value is only used in the fixed head pressure control, or if one of the parameters used in the Balanced Head pressure control is missing.

237 XT-70 Control Panel 237 Control Fan Diff: Rather than have to enter all the values for each stage of the condenser fans to cut in and out, a differential value is used. The recommended value is 5 psi. Stage 1 Stage 2 Stage 3 Stage 4 OFF CP CP + D CP + 2D CP + 3D ON CP + 2D CP + 3D CP + 4D CP + 5D Example Control point = CP = 200 Differential = D = 10 OFF ON RLA Limit: This deals with a screw compressor where the amps need to be limited on start up and run. See app note 016 for more detail. Set to zero to disable. PID Term: This is a value that is used for engineering only. It should be set to zero. The following values are based on a 0-100% output. Liquid Line Off - On: The first value is the Liquid Line off value and the second is the on value. These values are in percent and will determine when the LL solenoid will open and when it will close. A typical value would be 5% off and 10% on. Span L: (Span Low end) The span adjustment allows you to set different compressors to span parts of the 0-100% cooling demand signal. The Span L is the output percentage when the compressor will be fully unloaded. Span U: (Span Upper end) The span adjustment allows you to set different compressors to span parts of the 0-100% cooling demand signal. The Span U is the output percentage when the compressor will be fully loaded. Oil P & Oil Time: The oil pressure is the Discharge Pressure - Suction Pressure. Any time the compressor is running, the pressure differential needs to be greater than the Oil Pressure setting. If the pressure has not built during the Oil Time, the system will shutdown and lockout. Low Suc U & Low Suc D: (Low Suction unload and Low Suction Differential) If during the refrigeration cycle the suction pressure is less than the Low Suc U for 1 minute, the unload solenoid will be pulsed on each update until the suction pressure rises to Low Suc

238 XT-70 Control Panel 238 U + Low Suc D. On a VFD the speed will be decreased by 5% each update cycle. A zero in the Low Suc U will disable this function. Dis Temp U: (Discharge Temperature Unload) If during the refrigeration cycle the Dis Temp is greater than the Dis Temp U for 1 minute, the unload solenoid will be pulsed on each update until the Discharge temperature drops by 10 degrees. On a VFD the speed will be lowered by 5% on each update cycle. Once the temperature drops by 10 degrees, normal operation will be resumed. A zero in the Dis Temp U will disable this function. Dis H Temp: (Discharge High Temperature) If during the refrigeration cycle the Dis Temp is greater than the Dis H Temp for three minutes, the system will shutdown and lock out. VIDT: (Variable Initiated Defrost) This is a unique way in which a trend is established for determining the suction pressure operating point. This timer sets the length of time that the trend is taken. This allows the CR- 110 to determine a defrost initiation based on a drop in suction pressure rather than just time. A normal setting would be between 30 and 60 minutes. Set to zero to disable. Suc Diff: (Suction Differential) Once a trend is established for the suction pressure, this value would be subtracted from the trend suction pressure and would be used to initiate a defrost cycle when the suction pressure was below this calculated value for a given time. A normal setting would be 3-5 psi. Set to zero if this operation is not desired. DIT: (Defrost Initiated Timer) This is the amount of time the suction pressure would be below the Suc Diff point before initiating a defrost. A setting of zero will disable this feature. Max Def: (Max Defrost Time) This is the time in minutes for the next defrost. If a defrost is not initiated using the VIDT, this time will initiate a defrost. Set to zero to disable all defrost cycles. Defrost_Off: (Defrost Termination Pressure) This is used for hot gas defrost termination. As soon as the discharge pressure rises above this value, the defrost will be terminated.

239 XT-70 Control Panel 239 Temp Termination: This value is not used and should be set to zero. DTT: (Defrost Termination Timer) This is the time in minutes that the defrost cycle will run before being terminated. A setting of zero will disable this feature. For hot gas defrost, this time will override the discharge pressure termination. Coil_Dry: (Coil Freeze) This is the time in seconds that the coil will be dried after the defrost termination. The system will run with the compressor and the LLS open but the evaporator fans will be off. Proportional: This value is only used when the PID Mode setting is other than None. The Proportional constant is simply a multiplier that can be used to fine tune the size of the Proportional Mode adjustment. Raising the value of P results in a greater reaction to input value changes. A typical setting would be P only produces a output when there is change. Example - on suction control, if the suction pressure was not changing then P would not affect the output. Too much P and it will override the integral. Integral: This value is only used when the PID mode setting is other than None. The I value is what will cause the output to change when the input is not changing and is steady state. Increasing this value too much will cause the system to become unstable. A typical value would be 5. Example - on suction control, if the suction pressure was not at Setpoint and the screw or VFD was not changing, then increase the value of I. Derivative: This value is only used when the PID mode setting is other than None. The Derivative is constantly analyzing the rate of change of the error, makes a prediction about what the future error will be and makes adjustment to the output in an attempt to reduce the rate of change in

240 XT-70 Control Panel 240 the error. For most cases the derivative is disabled by setting it to zero. SP: (Setpoint) This value is only used when the input mode is Setpoint or Setpoint C. This would be used as a stand alone controller and would use a thermistor for a controlling sensor. If you are not using an input of Setpoint or Setpoint C the value does not matter. This is not used when running suction pressure control. COMP SH H (Compressor Superheat High) This value is for the automatic compressor superheat control. It should be set to zero if not using this feature. This is the high value for the desired window for the compressor operation. Typical compressor suction superheat operation should be maintained between 18 to 20 degrees. In this case you would set the Comp SH H to 20 and the Comp SH L to 18. This feature is only available when using the ER-110 controller. COMP SH L (Compressor Superheat Low) This value is for the automatic compressor superheat control. It should be set to zero if not using this feature. This is the low value for the desired window for the compressor operation. Typical compressor suction superheat operation should be maintained between 18 to 20 degrees. In this case you would set the Comp SH L to 18 and the Comp SH H to 20. This feature is only available when using the ER-110 controller. EV_UPDATE: (Evaporator Update time) This is the time in minutes that the CR-110 broadcasts to the ER-110 cards for an update on the Superheat Setpoint. A typical setting would be 10 minutes. SH SAFETY: (Superheat Safety) This is a safety setting for the compressor suction superheat. A typical setting would 10 degrees. If the compressor suction superheat dropped below this setting the CR-110 would broadcast to all ER-110 to default to a superheat Setpoint of 12 degrees. As soon as the compressor super heat warmed back up, then auto control would resume. A setting of zero will disable this function. Suc Span: (Suction Span) This is the span that the suction setpoint will float. Typical setting would be from 10 to 20 psi. This is always applied on the low side of the suction setpoint. Example would be a Suc SP = 60 and a Suc Span = 20 psi. The Suction Setpoint would then float between 60 and 40 psi depending on the upper and lower settings. See App note 019 for more detail. For a Rack system you do not want the Suction Setpoint to change so a setting of zero would disable the floating suction setpoint. Update: This is the update time for the PID loop and is active only when the PID is being used. This is in 10ths of a second. A typical setting would be 50, which would be 5 seconds. The PID loop is active only when running an input mode of Setpoint or Setpoint C. It is also active if using a freq drive on the compressor or running suction control.

241 XT-70 Control Panel 241 Min Output: This is only used when the PID Mode is Comp Freq or VFD F Suc. Min output is the lowest percentage of the 0-20ma signal from the CR-110 to the freq drive. Man Output: Man Output sets the span for the 0-20ma signal to the freq drive. A setting of 25% will allow the drive to go from 30% or minimum setting to 100% for a 25% change of the control panel input signal. Output Offset: The Output Offset setting is used for compressor rotation. If you only have one compressor, this setting is not used. If you have two compressors, this setting would be 50 %. If you have three compressors set it for 33% and for four compressors set it for 25 %. The liquid line solenoid and unloaders should be staged less than this setting. Example if you have two compressors, all staging on both compressors should be from 0-50%. In this example the lag compressor will subtract 50% from the output of the lead compressors. This will cause the lag to stage from % but have the same settings as the lead compressor. Evap SH SP: (Evaporator Superheat Setpoint) This parameter is only used when the CR-110 card is used in conjunction with a ER-110 card. This is the actual value that is being broadcast to the ER-110 cards for their Superheat Setpoint. This value will automatically change if the auto superheat control is active. If you are running in auto superheat, the CR-110 constantly monitors and averages the compressor suction superheat. If the suction superheat is outside of the super heat window, then it will change the Evap SH SP and broadcast this value to all the associated ER-110 cards. EV HI Limit: (Evaporator High Limit) When running in auto superheat mode, this is the High Limit that the superheat setpoint can be incremented to. EV LO Limit: (Evaporator Low Limit) When running in auto superheat mode, this is the Low Limit that the superheat setpoint can be decremented to. Suc SP: (Suction Setpoint) For a Rack System, this would be set to the lowest suction pressure any of the evaporators would need to maintain temperature. For a non Rack system being controller by a XT panel, this would be the highest value of suction pressure that would be required for the temperature. PID Mode: There are three valid modes of operation, Comp Freq, VFD F Suc and Screw F Suc. The Comp Freq is used when you do not want the floating suction setpoint operation. Typical use would be for a rack system running on a fixed suction setpoint or an application where a con-

242 XT-70 Control Panel 242 trol panel is being used to supply a ma input or pulse input signal and the VFD compressor will adjust its speed to control temperature. The VFD F Suc (VFD Floating Suction) and the Screw F Suc (Screw Floating Suction) are used when you want a floating suction setpoint. See app note 019 for more information.

243 XT-70 Control Panel 243 HMI update from 16.7 to 17.2 or Greater APP 029 Problem: When upgrading from 16.7 to a higher rev, initially then is an error that occurs. This is due to the elimination of the http port data on the setup. Initially the records were downloaded into the HMI via http. This was not very reliable and there were a number of issues with this type of down load. To get around this the hmi program was changed to create its own records. These records were recorded on time only and did not provide a activity log. It also became very complex when displaying and recording ten different units. The new software above 16.7 will down load the records from the rabbit using UDP format. This also gives the ability to download a specific date. This application note will walk through the process of updating the HMI to ver Update: Do the update using the normal procedure. Once the unit reboots and runs the new 17.2 program you will get the following screen. This procedure is the same for the G70 & G75. As soon as this screen appears, press the Dismiss Button right away. You should see it depress slightly indicating that it has accepted the stroke. Immediately press the upper right hand outside button. Wait until the setup screen appears. The setup screen should no longer have the TPC column on the right. Press the update key and everything will be saved and there should be no more error on start up. If there is a problem with the Dismiss button or anything taking to long, just power down and reboot the HMI and try it again.

244 XT-70 Control Panel 244 On the 17.2 and greater software there is going to be a greater initial delay on boot up with this screen. One of the new features is the pile sensor names and being able to set the records up in any desired sequence. Also the number of parameters up to twenty five in the record can be set. All this information has to be loaded for each of the XT panels that will be displayed on the HMI. Each one of the panels may have different sensor names and record sequences. It can take up to ten seconds per panel to load this information. Clicking on the Graph button allows the selection of a beginning and ending date. The default will give records from midnight. The format of the records is all determined by the csv file.

245 XT-70 Control Panel 245 XT Panel and the ER-110 EPR APP 030 EPR (Electronic Pressure Regulator): The EPR valve is normally used with multiple evaporators at different temperatures using one rack type condenser unit. The EPR has a lot of similarities to using suction control on a screw compressor or VFD compressor. Each allow the control of the suction pressure. In the case of the EPR, it is powwible that the control signal could pull the suction pressure very low in an attempt to pull down a room quickly. The problem is that the EEV may not be able to supply enough refrigerant and the superheat of the coil could go quite high. Once the superheat of the coil goes above 12 degrees, the efficiency of the coil gets very low. The ER-110 can compensate for this in a number of ways. In each case the suction pressure needs to be raised so that the superheat can be brought down. This app note will also cover the floating suction setpoint feature of the ER card. Theory: On a conventional system the temperature controller would output a 0-20ma signal based on the temperature difference between the Setpoint and room temp. This output would drive the EPR valve and in a direct correlation. For a 20 ma signal the EPR would be wide open providing the lowest possible suction pressure and disregard the superheat. The ER card looks at the temperature controller output signal and converts it to a pressure range. The ER card will create a Floating Suction Setpoint based on a number of other values. The EPR valve is driven by a PID loop to maintain this Floating Suction Setpoint (FSP). How It Works: The idea is to use the XT temperature Setpoint and a number of other parameters to calculate the ideal suction pressure. The first calculation is to determine the lowest temperature needed to maintain the XT setpoint. This is done by subtracting the Coil DT from the XT Setpoint. Each time the XT panel updates the refrigeration parameters, it passes its temperature setpoint. Example: XT Setpoint = 55 degrees F. Coil DT = 8 degrees F = 47 degrees F = 79 psi using R22 This is the highest pressure in the range. Range = 15 psi = 64 psi. This is the lowest pressure in the range. For a XT signal of 0 to 100 percent the FSP would vary from 79 to 64 psi.

246 XT-70 Control Panel 246 As the XT setpoint changes, the range will also change. It may still be possible at times to pull to hard on the suction and have high superheat on the evaporator suction. An example would be if you had product at 60 degrees and had a panel setpoint of 38 degrees. Doing the math: Coil DT = = 30 degrees = 55 psi Range = = 40psi suction pressure at 100% cooling demand. Sixty degree product would produce approximately 80 psi suction at 10 degree superheat. In this example, it would be very difficult for the EEV to supply enough refrigerant to keep the superheat on the evaporator at an efficient level. The SH_Diff setting is used to raise the suction pressure in this case. A setting of 3 degrees would start to increment the FSP as soon as the superheat was greater than the superheat setpoint plus 3 degrees. It would increment the FSP one psi every four minutes until the superheat dropped below the superheat setpoint. Using the terminal screen on Xbase you can watch the pressure offset value to determine how this is working.

247 XT-70 Control Panel 247 Theory XT Panel Return Heat Aux Control APP 031 In older storages when the outside air drops below the storage inside temperature condensate may form on the inside of the building. Turning on heaters in the return air may help this condition. The output to turn on this heater is either Aux 1 or Aux 2 on the XT control panel. The configuration byte for each of the Aux 1 or Aux 2 outputs will determine which one will be used. Two E2 parameters C_H_TEMP and C_H_TIME control when the heater will turn on and off. IF OUTSIDE AIR IS LESS THAN C_H_TEMP FOR C_H_TIME AND FANS RUN- NING THEN TURN ON AUX HEAT. This feature can be turned on and off using the Aux switch or remotely using the virtual aux switch. Wiring J11 J15 J18 J EVAP PUMP 120VAC MAG STARTER HUMID 1 120VAC PUMP RELAY HUMID 2 120VAC PUMP RELAY RETURN AIR HEATER 120VAC MAG STARTER OL OL OR J23 J25 J AUX 1 AUX 2 CAVITY 120VAC MAG STARTER OL Use either the Aux 1 or Aux 2 output and wire it in with the Heat contactor. If you are using a second heater for the condensation, then wire to that contactor. SYSTEM NEUTRAL

248 XT-70 Control Panel 248 Setup Determine which Aux 1 or Aux 2 switch to use and then set the Aux config byte to 5. This example shows Aux 1 being setup for the condensate heat.

249 XT-70 Control Panel 249 Theory 2009 XT Purge Control APP 032 This application note will describe each of the seven purge cycles of the XT-70 panel. 0 = No Purge cycles 1 = Time Purge, no ARL or CO2 2 = ARL (Ambient Reverse Loading), no CO2 or Time Purge 3 = ARL & CO2, no Time Purge 4 = ERV (Energy Recovery Ventilation) no CO2 5 = ERV with CO2 6 = Time Purge / Cooling Purge with CO2 sensor Application: Purge_cnfg = 0 No Purge: Fresh air doors only open in the Cooling Mode to control temperature. To use this configuration, set the following E2 parameters: Purge_Cnfg = 0 Purge_cnfg = 1 Timed Purge: The Time Purge cycle is used when a CO2 sensor is not available for purge initiation. Four parameters must be set to initiate the time purge. In the above example if the outside air is less than 40 degrees initiate a purge cycle for 15 minutes every 6 hours and set the fans

250 XT-70 Control Panel 250 at 85%. Once the purge is over the fans will go to the previous setting. If the XT panel is in Refrigeration or a Timed run the XT would pulse the fresh air doors open to the Max Door setting for the length of the purge. If the XT panel is in Cooling and the Heat Switch is in Auto, the XT panel will turn the Return air heaters on for the duration of the purge. To use this configuration, set the following E2 parameters: Purge_Cnfg = 1 Purge_cnfg = 2 ARL: (Ambient Reverse Loading) This purge cycle uses the fresh air doors to false load the refrigeration when you have minimum loading and the refrigeration wants to cycle on and off. When the Refrigeration output drops below the minimum Refrig_Level setting, the XT panel will slowly pulse the Fresh Air doors in a Heat PID mode to bring in warm fresh air to keep the Refrigeration system running. The Refrigeration system will run at the minimum setting and the doors will modulate in a heat mode to control temperature. The doors can only open to the Max Door Setting. The ARL mode will not only keep the refrigeration running, but will purge the storage by bringing in fresh air after long runs of refrigeration. The ARL function is primarily used in the spring when the refrigeration load is light. The Outside air temperature must be above the start temperature for the ARL to become active. Under some conditions it may be necessary to raise the start temperature to ensure the outside air is warm enough. This can be done using the OSA Diff setting. To protect against the OSA not being warm enough, the parameter LC (low cutout) is used. This is in 1/10ths of a degree and would have a default of 5. To use this configuration, set the following E2 parameters: Purge_Cnfg = 2 Ref_Level (ROL) default setting = 30% ROL_Diff default setting = 5% Low_Cutout default setting = 5 tenths of a degree Max_Door default setting = 20%

251 XT-70 Control Panel 251 ROL_Start_Dly default setting = 10 minutes Set the following Main Flash parameters: OSA DIFF this parameter is used to adjust the Start Temp. A suggested value for running ARL would be +5 degrees. Purge_cnfg = 3 ARL / CO2: (Ambient Reverse Loading with a CO2 Sensor) This configuration uses the same logic as the ARL purge_cnfg = 2. In addition to the ARL, this configuration uses a CO2 sensor to trigger a purge and monitor the CO2 levels during the ARL cycle. The ARL is active only during the Refrigeration cycle, but the CO2 purge can take place either in Cooling or Refrigeration. For the CO2 purge to become active, the CO2 must be greater than the CO2 SP. If the system is in Cooling and the Heat Switch is in Auto, then the Return air heater will turn on and force the fresh air doors open to purge the system. The heaters must be sized as to not raise the return air more than 3 degrees. The doors should open somewhere between 20 to 30%. If the system is running in Refrigeration, the CO2 purge will become active when the CO2 level is greater than the CO2 SP. When this happens the doors will slowly open and the Refrigeration will continue to maintain temperature. Once the CO2 level has dropped below the Setpoint minus the CO2_Diff, the doors will slowly close. To use this configuration, set the following E2 parameters: Purge_Cnfg = 3 Ref_Level (ROL) default setting = 30 % ROL_Diff default setting = 5 % Low_Cutout default setting = 5 tenths of a degree Max_Door default setting = 20 % ROL_Start_Dly CO2_Diff CO2_RAS default setting = 10 minutes default setting = 200 ppm default setting = 5 tenths of a degree

252 XT-70 Control Panel 252 Set the following Main Flash parameters: OSA DIFF this parameter is used to adjust the Start Temp. A suggested value for running ARL would be +5 degrees. CO2 SP this is the CO2 Setpoint. A suggested value would be 2000 ppm. Purge_cnfg = 4 ERV: (Energy Recovery Ventilator) The ERV purge uses a ventilator that will bring in fresh air. This configuration operates without a CO2 sensor, so it must trigger strictly on Time. The Aux 1 switch must be set to control the ventilator and must be in Auto. Four parameters must be set to initiate the ERV purge. Example: (Buttons are main flash parameter that need to be set) If the outside air is less than 40 degrees, initiate a purge cycle for 15 minutes every 6 hours with fans at 85%. The fans will return to previous setting after purge. If the XT panel is in Refrigeration or a Timed Run, the XT will turn the ventilator on. This purge does not activate if the panel is in Cooling. To use this configuration, set the following E2 parameters: Purge_Cnfg = 4 Aux 1_Config = 1 Purge_cnfg = 5 ERV / CO2: (Energy Recovery Ventilator with CO2 Sensor) The ERV purge uses a ventilator

253 XT-70 Control Panel 253 that will bring in fresh air. This configuration operates with a CO2 sensor. This purge will work in either a Time or Refrigeration mode. The Aux 1 switch must be configured to control the ventilator and be set to Auto. If the CO2 level is greater than the CO2 SP, then the ventilator will be turned on. The ventilator will turn off when the CO2 level is below the CO2 SP - CO2 Diff. To use this configuration, set the following E2 parameters: Purge_Cnfg = 5 Aux 1_Config = 1 CO2_Diff default setting = 200 ppm Set the following Main Flash parameters: CO2 SP this is the CO2 Setpoint. A suggested value would be 2000 ppm. Purge_cnfg = 6 Timed / CO2 Purge: This parameter is used when you do not have refrigeration but desire to recirculate the air when there is no cooling air available. A CO2 sensor is required and will be used to trigger the purge cycle. If you are in Cooling mode and the CO2 level is greater than the CO2 SP, the purge cycle will be activated. The Heat switch must be in Auto and the Return air heaters will then be turned on. The heaters must be sized as to not raise the return air more than 3 degrees. The doors should open somewhere between 20 to 30 %. If the system is running in Timed Run mode, then the purge will be triggered by both time and CO2. Example: (Buttons are main flash parameter that need to be set) If outside air is less than 40 degrees, initiate a purge cycle for 15 minutes every 6 hours and run the fans at 85%. If the XT panel is in cooling, the return air heaters will be turned on for

254 XT-70 Control Panel 254 the duration of the purge cycle. In a Timed Run the fresh air doors would be open to the Max Door setting. To use this configuration, set the following E2 parameters: Purge_Cnfg = 6 Max_Door default setting = 20 % Set the following Main flash parameters: CO2 SP this is the CO2 Setpoint. A suggested value would be 2000 ppm.

255 XT-70 Control Panel 255 Theory: TP LINK Router Setup APP 033 The purpose of a router is to interface the internet to a number of inside devices. The router has two sides, the inside or LAN (local area network) and the outside or WAN (wide area network). The LAN IP number for BTU devices are broken down into the following blocks: XT-70 control panel to HMI to Router Tranzeo Wireless to The WAN is composed of the following: Public Static IP Subnet mask Gateway DNS 1 DNS 2 When requesting an internet connection, make sure to document the above numbers. If the internet connection from the provider is wireless make sure the unit is setup as a Bridge only. Sometimes the provider will set them up as a router or other devices and they will not work with the XT router. The XT panels are being shipped with an internal TP LINK router instead of the switch. The routers being shipped have had the router portion turned off so it acts as just a switch. To use the router reset it to factory defaults or enable the wireless section. Since the WAN is composed of one Static IP and the LAN could have many IP s and ports are used to route WAN request and data to each of the LAN devices. The XT panel uses an individual port for each panel starting at When the router sees WAN data coming in it will use the attached port number to route to the correct LAN ip address. This app note will specifically cover the TP LINK router. There are many different types of routers and all have a similar setup. Setup:

256 XT-70 Control Panel 256 If you need to reset the router, power the unit down and press and hold the reset while powering up. Continue to hold the reset button in for fifteen seconds and the router should reset to factory defaults. Plug an Ethernet cable any of the 1 to 4 jacks and into your lap top. Open your web browser and type in The user name, password dialog box will appear. The default user name is admin and the password is also admin. If you have previously changed it, use the new user name and password. The TP_LINK will come up with the basic settings. Click on the Network link and then on the LAN link. This will show the inside or LAN settings. In most cases no changes should be needed.

257 XT-70 Control Panel 257 Next click on the WAN link under the Network link. The default setting for the WAN is Dynamic IP. For BTU applications it needs to be set for Static IP. Click on the drop down and select Static IP. Once you select Static IP a new screen will appear to enter the WAN numbers.

258 XT-70 Control Panel 258 Enter the static IP address provide by the internet provider. Also enter the Subnet Mask, Default Gateway, primary DNS and secondary DNS. Click save when done. Click on the Wireless link and then on the Wireless settings link. Make sure the setup is as shown and the Enable Wireless Router is checked. Click on the DHCP link and change the starting address to Next click on Save.

259 XT-70 Control Panel 259 Click on Forwarding and then on Virtual Servers. Next click on the Add New button. Type in the LAN address for the panel and the port number. The first panel should be and port Click on Save. If there is more than one panel, click on Add and add the second panel which typically would be and port 4002.

260 XT-70 Control Panel 260 The user name and password should be changed from the default to the BTU standard. Click on the Advanced Settings link and then on Security. Type in the new user name and password and then click on Save. The router should now be setup and ready to go.

261 XT-70 Control Panel 261 Theory: XT Panel Setup APP 034 This application note will explain how to setup the XT panel to send text messages and e- mails. The XT panel has the ability to send a text message or on a selected mode change or alarm. Setup: The setup of the XT panel must be done thru the web interface. Go on line with the panel and then click on the configuration button. Next select the tab. SMTP Server: (Simple Mail Transfer Protocol) SMTP is an internet standard for electronic mail transmission across internet protocol. The SMTP server address must come from the ISP that is providing the internet connection. You do not need an address to use this service. In the above example saddle mountain wireless was the provider for this XT panel. A phone call to the provider asking for the SMTP server address was all that was needed. In this case the address was mail.smwireless.net A mail server must come from the provided being used to supply the internet. You can not send using a different mail server than the service being used. In this case no username or password was required. SMTP Port #: The default port is 25. This should work in most cases. The internet provider will have this information.

262 XT-70 Control Panel 262 Username & Password: A username and password are sometimes needed to connect to a SMTP server. Generally these credentials are the same as the username and password for the ISP account and are required at the discretion of the administrator of the SMTP server. The best is to talk with the ISP about this. Remember the panel does not receive just send. Most time if a username and password is required, it would be the same as setup for the account. Panel s address: The panels address does not need to necessarily be from the ISP, it could be a goggle or hotmail account. Most ISP accounts include a free address and this would be the preferred panel address. Create a address that will identify the system and incorporate the username and password for the account. address 1: Enter the desired address for the panel to send to. If it is desired to text message, then use the appropriate address. Each cell phone provider will use the cell phone number at some unique address. Example for Verizon phone The format can be found on the internet for the different cell phone services. address 2: Same as above. Up to four address can be used. To trigger an or text message the desired modes must be selected. Click on the Op Alerts tab and select the desired modes to trigger the alert. Click on Save Settings to save. Click on Secondary alerts.

263 XT-70 Control Panel 263 On the Secondary Alerts, check the desired modes to trigger an alert. Click on Save Settings to save. Go back to the tab. Click on the Test Settings to test the alert function. Summary: First call the ISP and get the SMTP Server address. Second set up a address for the panel and get a username and password if needed.

264 XT-70 Control Panel 264 THEORY Staging a Scroll & a VFD Recip Compressor APP 035 The original system has a 3 ton scroll compressor with no staging. Additional refrigeration was needed for expansion and it was decided to go with a 14 ton compressor with a VFD on it. The problem is that with the VFD running at min frequency it still has 6 ton capacity. If the new VFD compressor is C1 and the old scroll is C2, the staging needs to be as follows: C2 on first C1 on second with C2 off C1 on third with C2 on C1 will run the CR-110 VSC software with a profile of VFD Comp and a PID mode of Comp Freq. The C2 compressor will run with the CR-110 conventional software with a profile of Basic Refrig and no PID mode. The C1 VSC software allows outputs 7 & 8 to be programmed as stages for other compressors. These stage outputs have an off percentage and an on percentage. This percentage is not the percentage from the control panel but rather the PID percentage from the suction control. This is the same percentage that drives the VFD. Thus you can turn the stage on when the VFD reaches 90% and then keep it on until the VFD backs down to say 50%. In this case, the CR-110 scroll compressor needs an input that will force the compressor into standby. Input 6 is normally the 0-20ma input from the panel when running in the input mode of ma signal. This input is only used on Card # 1: all other cards do not use this input. A change has been made so that when this input is shorted on any cards greater than # 1, it will force the card into a standby condition. If the compressor is running, it will pump down, short cycle and then go into standby. If the compressor is already in standby, it will just keep it in this condition. For this particular case, we will use two contacts in series. One contact will be a normally open contact that will close when ever compressor C1 is running. The second contact will be a normally closed contact that will open when Stage 1 output 7 is on for C1. The result will be C2 will be held in standby anytime C1 is running, except when Stage 1 is active. C2 s LLS will be set to go on at 10% and off at 5%. C1 s LLS will be set to go on at 30% and off at 20%. A normal stage up sequence would be for C2 to start, then C1 would start and C2 would shut off. When C1 s VFD reached 90%, both C1 and C2 would run. To stage down C1 VFD would have to drop below 50% and then C2 would shut off. If the output drops below 20%, C1 would turn off and C2 would start.

265 XT-70 Control Panel 265 C1 Wiring Diagram Analog Inputs For Card 1, the analog inputs are standard. Digital Outputs For Card 1, output 7 is used to control a sequence relay for compressor 2.

266 XT-70 Control Panel 266 C2 Wiring Diagram Analog Inputs For Card 2, the only change is input 6. Two contacts, C-5 and CPR1 are connected in series across input 6. When this circuit is made it will force C2 into standby condition. CPR1 is the compressor 1 run relay. C-5 is the Stage 1 relay from card 1. CPR1 will keep C2 from running when compressor C1 is on. Once C1 VFD reaches 90%, C-5 will pickup and allow C2 to run. Software Configuration In this application, two different inf Xbase files are used. C1 uses the VFD Compressor and C2 uses the basic CR-110 file. C1 Config

267 XT-70 Control Panel 267 Compressor rotation is shut off by setting the Rotation to zero. The Compressors must be set to two for the communications to be passed on to C2. C1 Config ST 1 is output 7 and is used to control the staging for C2. C1 Config C1 Config Suc SP is the highest suction pressure that would be needed and would correspond to 0% output from the panel. Suc span would be the total span for 100% output from the panel. With a Suc SP of 60 psi and a Suc span of 20, a 100% signal would give a floating suction SP of 40 psi. C1 Config

268 XT-70 Control Panel 268 C2 Configuration using Xbase CR-110 inf C2 Config C2 Config C2 Config

269 XT-70 Control Panel 269 C2 Config C2 Config

270 XT-70 Control Panel 270 THEORY Staging VFD Compressors using Gorman Panel APP 036 This system is a retrofit with to reciprocating compressors. The Gorman control panel has two relay outputs with no analog for refrigeration. Currently the panel turned just turned both compressor on or off. At this point it was not in the budget to replace the panel. The new update will use a VFD on the first compressor. The second compressor will be fitted with a CR- 110 card also. Compressor 1 will use a sensor on input 5 to control temperature. The temperature Setpoint will be set on Compressor 1 CR card. The two compressor are parallel, C1 is used to pump down. OPERATION The Gorman panel will supply a dry contact to input 6 of CR 1 to start the Refrigeration mode. CR 1 will generate a PID output to the VFD based on the error between the temperature Setpoint and the temperature on input 5. CR 1 will be running the VSC software and has two settings for outputs 7 and 8. These settings are based off of the PID output percentage and are used to stage the second compressor. A normally closed contact from output 7 will keep compressor 2 in standby until it energies. A typical setting would be to energize output 7 at 95% output and turn it off at 30% output. This would allow C1 to ramp up to 95% and then turn on C2. Once C2 is turned on C1 would ramp down to control temperature. C1 Analog Inputs

271 XT-70 Control Panel 271 C1 Digital Outputs C1 Analog Output

272 XT-70 Control Panel 272 C2 Analog Inputs C2 Digital Outputs

273 XT-70 Control Panel 273 Software Configuration In this application, two different software files are used. C1 uses the VSC software and C2 uses the basic CR-110 file. C1 Config Choose the correct pressure transducer. C1 and C2 are parallel compressors. C1 will pump down so do not check the parallel. Input mode needs to be Setpoint. This will use input 5 and the Setpoint setting to control temperature. Make sure that the rotation is set to zero and the compressors set to two. C1 Config ST 1 Off and ST 2 On will control the staging of C2. The percentage is controlled off of the PID output not the cooling demand. C1 Config

274 XT-70 Control Panel 274 C1 Config C1 Config SP is degrees F and is the temperature Setpoint for controlling temperature using the sensor on input 5. The PID Mode must be set to SP. The PID parameters will control the response of the PID output that goes to the VFD. Compressor 2 uses the basic CR-110 software. The profile is Basic Refig and the input mode is MA Signal. The input mode is used to just pass the refrig demand dry contact from the Gorman panel on C1 to C2. C2 Config This is a parallel compressor so make sure the Parallel check box is selected. C2 should not pump down.

275 XT-70 Control Panel 275 C2 Config C2 Config C2 Config No PID mode is used for C2. The Setpoint is not used on C2 also. C2 Config

276 XT-70 Control Panel 276 ER-110 Independent Valve Operation APP 037 THEORY There is a new version of software for the ER-110. ER-110 Independent EEV ver 2.68 This is a different hex file than the normal ER-110 and is available on the web site. This new software allows the two EEV valves to operate totally independent of each other. One can be in standby and the other could be in Refrigeration. OPERATION MODES LED MODES VALVE A VALVE B 0 Standby A Standby B 1 Refrig A Standby B 2 SP sensor fail A Standby B 3 ST sensor fail A Standby B 4 Standby A Refrig B 5 Refrig A Refrig B 6 SP sensor fail A Refrig B 7 ST sensor fail A Refrig B 8 Standby A SP sensor fail B 9 Refrig A SP sensor fail B 10 SP sensor fail A SP sensor fail B 11 ST sensor fail A SP sensor fail B 12 Standby A ST sensor fail B 13 Refrig A ST sensor fail B 14 SP sensor fail A ST sensor fail B 15 ST sensor fail A ST sensor fail B Xbase This application requires a special inf file for Xbase. The name of the file is ER-110INDEEV.inf and is available on the web site.

277 XT-70 Control Panel 277 Sensor Wiring: R28 R51 Resistors R28 and R51 are located directly behind each of the suction transducers. These resistors are only used if using as temperature inputs. It is a good idea to cut these two resistors out of the circuit. This is particularly true if using only one transducer for both inputs. If the card is controlling two independent systems then each system will need its own pressure and temperature sensor. Input 5 is used for LLSV proving on system one and input 7 is used on system 2. Connecting two cards with one transducer Above shows how to connect two cards with one transducer. If using a common power supply for both cards, make sure the power wires are wired exactly the same on both cards.

278 XT-70 Control Panel 278 Xbase Independent Valve Setup The Xbase independent valve setup requires a special inf file. The file is available on the web site and is ER-110INDEEV.inf

279 XT-70 Control Panel 279 V2 EV SH SP is a new parameter for the independent valve. It is the superheat setpoint for valve 2. This setpoint can automatically change according to the superheat of the compressor. V2 Max SP is the max value the superheat setpoint could automatically change to. V2 Min SP is the minimum value the superheat setpoint could automatically change to. V2 Comp # this is the compressor number for which V2 is associated with.

280 XT-70 Control Panel 280 Max SP and Min SP are referring to valve 1. The Comp # and Evap SH SP is also for valve 1.

281 XT-70 Control Panel 281 Application: Sweet Potato Storage Operation APP 038 This application note will cover two types of storages. First are the conventional storages with fresh air doors, such as a conventional potato storage. The second will be storages that have no fresh air doors, but have roof vents, intake fans and exhaust fans. In both cases, the Aux 2 switch will turn the Cure or Warming mode on. The Aux2_Config needs to be set to 188. To activate the Cure or Warming mode, the time clock must be set to all Blue. Aux2_Config must be set to 188 The warming mode is only used when trying to cure or warm up the product. During this time the time clock should be set to all blue and the Aux 2 switch should be set to Auto. Once the cure cycle is complete, the Aux 2 switch should be turned off. With all of the time clock in Blue and the Aux 2 in Auto, the system will either run in Warming or Cooling. If the Outside air is less than the Start temperature then the system will run in Cooling. If the Outside air is greater than the Start temperature then the system will run in Warming. When the Aux 2 switch is off, then the system will run in Cooling only.

282 XT-70 Control Panel 282 Purge Cycles During Cure with a CO2 Sensor: Sweet potatos initially will give off a large amount of CO2. A typical setpoint would be 85 degrees during cure. If the product is brought in cooler than 85 degrees and the outside air is less than 85, heat will be needed. During this time of heating, the CO2 will need to be purged. If a CO2 sensor is being used, purge config 7 would be the ideal purge cycle. Cold Purge Mode = Refrig yes no ARL Purge 7 Return CO2 > CO2 SP no CO2 < CO2 SP-Diff no yes yes Purge Off Clear MCR Timer Mode = Cooling yes Low Dev no Pulse Fresh Air Door to Max position no yes Close door 5% Mode = Time yes no Mode = Warming yes High Dev no Pulse Fresh Air Door to Max position no yes Return Close door 5% If the system is running in Cooling and the CO2 level exceeds the CO2 Setpoint, the fresh air doors will be pulsed open to the Max door setting. If during this opening of the fresh air doors, the plenum temperature drops below the Low Dev setting, the doors will be closed 5% until the plenum rises. If the system is running in Warming and the CO2 level exceeds the CO2 Setpoint, the fresh air doors will be pulsed open to the Max door setting. During this operation, the plenum temperature will be monitored. If the Plenum temperature rises above the High Dev setting the doors will be closed 5% every update until the temperature goes below. If the Heat switch is on the heat will come on if the plenum temperature drops below the SP minus the heat diff. This purge would typically be used without heat.

283 XT-70 Control Panel 283 Purge Cycles During Refrigeration: Purge 7 will also allow the system to purge CO2 during refrigeration. The ARL (ambient reverse loading) is also available in purge 7. The ARL will use the fresh air doors and ambient air to reverse load the refrigeration coils if the refrigeration level is very low and about to shut off. To disable the ARL, set the ROL E2 parameter to zero. If the CO2 level rises above the CO2 setpoint, the fresh air doors will gradually open to purge the CO2. Once the CO2 level drops below the CO2 Setpoint minus the CO2 differential, the doors will slowly close. CO2 > CO2 SP yes RUN PID HEAT MODE & CO2 PURGE SP = SP + CO2 PLEN RISE no CO2 < CO2SP - DIFF yes MODE = CO2 yes Door = 0 % no RUN PID HEAT MODE & CO2 PURGE SP = SP - CO2 PLEN RISE no no yes Purge Cycle During Standby: If refrigeration is not available and the ambient air becomes too warm, the system will go into Standby. If the CO2 level is above the CO2 Setpoint, a forced Cooling cycle will begin. The fresh air doors will only open to the Max Open setting. Once the CO2 drops below the differential setting, the MCR (minimum cooling run) will clear and the system will go back to Standby. MAIN LOOP Mode = Standby no yes Time Clock = Cooling Only no yes CO2 > CO2 SP no yes Force Cooling RETURN

284 XT-70 Control Panel 284 Purge Cycles During Cure without a CO2 sensor: Without a CO2 sensor, a purge must be activated by time only. This purge currently requires heat. The purge config would need to be set to 1. This is Time only with no CO2 sensor. When the purge config is set to 1, the above parameters will show on the Miscellaneous screen. These parameters will initiate a purge cycle according to the settings. To disable the time purge, set the parameters to 0. To do a purge in the Cooling mode the heat switch must be in Auto. In Timed or Refrig, the system will pulse the fresh air doors to Max Open for the length of the cycle. In theory, this will only occur when there is no cooling air available, thus the air being brought in will be warmer than the pile. Time Purge Back to Start ZZ Hours = 0 no RUN Hours > ZZ yes Mode = Cooling no Mode = Timed no Mode = Refrig no yes no yes yes yes Mode = Cooling yes Mode = Cooling yes OSA < XX yes Heat Switch Auto yes OSA < XX yes no no no no no Door Closed Door Closed Heat on for YY minutes Pulse Fresh Air Doors to Max Open for XX minutes When the CO2 purge is triggered in the Cooling mode, it will be because the OSA is cold and the fresh air doors are only slightly cracked. The return air heaters will cause the air to warm by 3 to 4 degrees, causing the fresh air doors to open and the fans to speed up to purge the storage.

285 XT-70 Control Panel 285 From Cure to Ramp Down & Purging: Once the Cure cycle is done it is time to ramp down to the desired holding temperature. The Aux 2 switch should be set to off once the cure cycle is complete. The time clock needs to be set for the desired operation. If refrigeration is available, the time clock should be set to green. This will allow the system to run in either Cooling or Refrigeration. If refrigeration is not available, the system would run in either Cooling or Timed. In a Timed run, the fresh air doors would be closed and the fans would run at a minimum level to circulate the air. The ramp mode is setup by setting the target to the desired long term storage temperature. In this example, the Setpoint will be ramped down.1 degrees every 6 hours of Cooling. The ramp will shut off when the final Target temperature of 50 degrees is reached. Note - anytime the Setpoint is changed from the main screen, the Target will be reset to the Setpoint and the ramp will turned off. The outside air control can be referenced to Setpoint or any of the pile sensors. As an example, the temperature setpoint is 72 and the North West pile sensor, selected as the reference, is 85. With the OSA Diff set to zero, the system will start bringing in fresh air when the outside air temp is below 85 degrees. If the outside air gets below the 72 degrees, the doors will start to close and control temperature. This allows the system to bring in air cooler than the pile but warmer than the setpoint. This will greatly enhance the cooling run time available. Once the pile is down to the long term storage setpoint, the reference should be changed to Setpoint.

286 XT-70 Control Panel 286 The purge config after the cure cycle will depend on if there is refrigeration, heat and a CO2 sensor. Without a CO2 sensor, purge config 1 is the only choice. It is triggered by elapsed time and must have heat to purge when in the cooling mode. See previous page for explanation of purge config 1. With a CO2 sensor and no refrigeration, purge config 7 would work best. This purge will work with or without heat. See previous page for explanation of purge config 7. With a CO2 sensor and refrigeration, purge config 3 is the best purge cycle. Purge config 3 needs some additional setup. For sweet potatoe, we do not want to use ARL (ambient reverse loading). These are the parameters that should be set. The values shown are the suggested values. For more information on each of these values, see the operators manual. In this configuration, the system will only purge if the CO2 rises above the CO2 Setpoint. In Cooling mode, the return air heater will be turned on, raising the return temperature by 3 or 4 degrees. This will cause the fresh air doors to open and purge the CO2. This should only happen during cold temperatures when the doors are just barely open. In refrigeration, when the CO2 exceeds the setpoint the fresh air doors will gradually open up to the max doors setting. As soon as the CO2 drops below the CO2 Setpoint minus the CO2 Diff, the doors will gradually go closed.

287 XT-70 Control Panel 287 Using Exhaust & Intake Fans: This will describe how to set the panel up when dealing with retrofit buildings, that do not have fresh air doors. These buildings have roof vents where air is drawn in, goes down through the pile and is exhausted out through the side walls with fans. These fans have VFD to control the speed of the fans. The temperature control is achieved by speeding up and slowing down the exhaust fans. When the exhaust fans reach a certain speed, there is the option to turn on the intake fans to help supplement the roof vents. For this type of control, the door config must be set to 4. The door time is an adjustable parameter that will determine how fast the exhaust fans speed up and slow down. Since there are no actual fresh air doors, a virtual door position is created using the Door Time parameter. This parameter is in seconds and is used to calculate the door position as shown on the main screen. Normally, the door is positioned by pulsing the open and closed relays. The door position can be calculated by keeping track of the open and closed pulses. The Door Time parameter would be the amount of time it would take the door to fully open. For this application, we use the same calculations but without an actual door. Thus, the Door open position will represent the virtual position from 0 to 100%. This percentage will then be outputted to the exhaust fans in the exact percentage. Example - if the Door Open was reading 45%, the Exhaust fans would be running at 45%. A problem occurs when the plenum temperature is below the temperature setpoint and the PID continues to lower the fan speed to zero. During normal operation the exhaust fan should continue to run at a minimum speed. The Cooling button is the Max fan speed. The door position can go to 100%, but the fan will go no higher than this percentage. The MIN button on the left controls the minimum speed of the fan when the Door Open is zero. For example, if this is set at 20%, the exhaust fan can not slow down to less than 20%. The Timed button is the percentage at which the intake fans will start. The Aux 1 switch needs to be in Auto for the intake fans to run.

288 XT-70 Control Panel 288 The PID loop will try to control temperature by varying the speed of the exhaust fans from the Min setting to the Cooling setting. The Door Open position will vary from 0 to 100 percent but the exhaust fans will vary only between Min and Cooling percentages. Purge Cycle using Exhaust & Intake Fans: Purge config 7 is best suited to this type of building. Purge 7 requires a CO2 sensor and will purge without any heat. See previous page for explanation of purge 7 or Cold Purge. In this case instead of the fresh air doors opening up to the max door setting, the exhaust fans will speed up to the max open setting. Once the CO2 has dropped to below CO2 Setpoint minus C02_diff, the exhaust fans will drop down in speed. The intake fans will only be used when the exhaust fans reach a high enough speed that the roof vents can no longer provide enough air. The Aux 1 switch controls the intake fans. If the switch is in auto, the intake fans will start when the exhaust fans reach a given percentage.

289 XT-70 Control Panel 289 Application: Zbase Programming Interface APP 039 This application note will cover installation and operation of BTU s new programming interface Zbase. Zbase was developed to replace Xbase and will be able to communicate with any of the BTU product line. Zbase is completely driven by a Excel csv spread sheet file. The program can be configured and custom made for different products. Installation: Download the Zbase Installer file off of the tech site. Double click on the Zbase Installer.msi file to install. Updates will be done with a new install file. Updates will now remove any of the existing files. Operation: When Zbase is first opened, it comes up unformatted. The entire layout of Zbase is controlled by a csv file. The current csv file should have been loaded when installed. Click on the Type dropdown and select the latest XT Micro csv file.

290 XT-70 Control Panel 290 The Zbase program can be used for any of the BTU product line. Clicking on the Type dropdown and choosing the corresponding csv file will configure Zbase for the type of device. Zbase can have programmable boxes, drop downs and push buttons. This app note will use the XT Micro for all examples. Communications: Zbase can communicate using either a serial connection or through UDP via Ethernet. Use the drop down to choose the desired type. Set the desire Network and Unit numbers.

291 XT-70 Control Panel 291 For this example, the XT Micro is #02 and is connected to the internet using a TPC touch screen. The IP address is and the port is The Communications Timeout is the length of time (in seconds) between the request and the response before an error will occur. If using RS-485 wireless links or using a slow Ethernet connection, this time may need to be extended. This example shows the setup for the XT Micro #02 using a serial connection. When serial is selected, use the drop downs to select the proper Com port and Baud Rate. Saving Setup: Once the Type is selected and the Communications parameters are selected, the Save As command can be used to save the file. Click on File and then Save as NEW Unit. Enter a name that describes the complex and unit number and type.

292 XT-70 Control Panel 292 Any number of units can be saved and then selected using the Name drop down. Changes can be made and saved using the Save command. Zbase Operation: Once connected to the XT-Micro either by serial or UDP, click on the Get all Data to load all tabs. To update only the current tab, click on Get Tab Data. Make changes to the desired parameter and then click on the Program Tab Update.

293 XT-70 Control Panel 293 Save Current Settings: To save the current values to a default file, first load all parameters using the Get All Data button. Then click on the Configure tab and then on Save CURRENT Values as a DEFAULT File. The default file will have a def extension. Note - the default file must match the parameter in the Type dropdown when loading. To open a default file, click on the Configure tab and then on Load Default Parameters. Select the desired file and open. Once the file is open, the Program All Data button can be used to program all data.

294 XT-70 Control Panel 294 Terminal: The terminal tab will issue a WW string command to display a current update. The update time can be changed if desired. The default setting is 10 seconds. Zbase has the ability to create and save a Function Key File. This allows for special commands to be entered and saved. To use the function keys, click on the Enable Command Buttons. Click on the dropdown and select XT MICRO.

295 XT-70 Control Panel 295 Each of the function keys can be programmed with different commands. This example will request the CR string for the given XT Micro. To edit these commands, click on Configure and then Edit Function Key Settings. To create a new file, click on New Function Key Settings. Type the Description and then the Command, without the check sum. Clicking on the CR 02 button will request the CR string. If the communications are working correctly, the XT Micro 02 will respond with the above string. A manual command can be entered without the checksum. Click on Send Command to send the request. To reset panel 02, type in <RA02>. Remote Stop <EX024444FF>. Remote Start <EX F>.

296 XT-70 Control Panel 296 Application: CR-110 VSC (VFD & SCREW) Profiles and Settings APP 040 This application note will explain the different profiles and PID modes for the VSC CR-110 software. Profile: None - this profile is not used. Basic Screw - this profile is for a normal Screw compressor without a VFD. The 0-20ma or 0-10vdc output is not used. VFD Screw - this profile is for using a VFD on a Screw compressor. The 0-20ma or 0-10vdc output is used to stage the VFD. VFD Compressor - this profile is for using a VFD on a reciprocating type compressor. The 0-20ma or 0-10vdc output is used to stage the VFD. Input Mode: Ma Signal - this mode uses a 0-20 or 4-20ma signal from an external source. This will determine the refrigeration demand. Setpoint - this mode uses a Setpoint and a temperature sensor on input 5 to control temperature. The PID loop will generate the refrigeration demand signal based on the difference between the Setpoint and the room sensor. This requires the PID mode to be set to Setpoint. Pulse - this uses a open and close pulse from a IVI panel to produce the refrigeration demand signal. Setpoint C - this is the same as the Setpoint mode except that the room temperature and Setpoint are in centigrade.

297 XT-70 Control Panel 297 Signal: This is the type of input signal to the CR card. 4-20ma will span 0% at 4ma and 100% at 20ma. 0-20ma will span 0% at 0ma and 100% at 20ma. Gas Type: Currently the following gas types are available. R-22 R-410a R-507 R-134a R-12 R-404a R-407c Condenser Mode: Fixed Head Pressure - uses the Control Point setting and Cond Fan Diff to cycle the condenser fans off and on. Balanced Head Pressure - control will float the head pressure depending on the ambient air conditions. The lowest pressure that the system will float to is the System Drop plus the suction pressure. Balanced PID pressure - control will produce a 4-20ma signal for a VFD drive on the condenser fans. The Setpoint would be the System Drop plus the Suction pressure. With this selected the PID mode should be set to none.

298 XT-70 Control Panel 298 PID Mode: None - no PID loop is used. Condenser Fan - The PID loop is used to control the speed of the condenser fan using a VFD. If the condenser mode is set to Fixed Head Pressure it will control to the condenser fan SP. If the condenser mode is set to balanced head press or balanced PID it will control to the condenser fan SP plus the system drop. 2 Comp VFD - This mode is used when there is two compressors both with VFD s. It will stage the two compressors up and down to match the load exactly according to the input signal. Manual - will output a 4-20ma signal equal to the man out setting. Setpoint - will use the PID loop to control the temperature to the SP using input 5 as the room sensor. VFD FSP - VFD Floating Setpoint. The VFD output will be based off of the FSP calculation. The FSP is determined from refrigeration demand, Suction Setpoint and the range. See app note 19 for more detail. VFD Linear - produces a linear output based on refrigeration demand. The Span L and Span U and min output is used in the calculation. Percent Output to the VFD = ((Rd - SL) / (SH - SL)) * (100 - Min) + Min The operation of the VFD will be from Min to 100 percent. Using the Span L and Span U the VFD can be setup to operate any where in the 0-100% refrigeration demand. Screw Linear - The output of the PID to the VFD is equal to the refrigeration demand. Screw FSP - Screw Floating Setpoint. The load and unload pulses to the screw will be based off of the FSP calculation. See app note 19 for more detail.

299 XT-70 Control Panel 299 Application: Using a Belimo Actuator for Exhaust Door Control APP 041 This application note will show how to hook up a Belimo Actuator for an Exhaust Door Control. The actuator will use the 0-10vdc signal from the SDX card. The actual voltage is 2-10vdc which is what the Belimo requires. A additional 24vac transformer will be required both to drive the actuator and also for the isolated supply on the SDX. When wiring the actuator it is very important to make sure the common on the transformer is connected to pin one on the actuator and pin 1 on the SDX ISO power input. The same transformer powers both the actuator and the isolated output on the SDX. Input 3 on the actuator is the 2-10vdc input. The 2-10 vdc can be adjusted using Xbase. OUTPUT V I G INPUT 12vdc OPEN CLOSE 4-20ISO 0-10V V I G 18vac 24vac ISO Main power supply for doors Control power supply

300 XT-70 Control Panel 300 Application: How to Program a XT Micro APP 042 The XT Micro has a different microprocessor than the XT panel. It uses the hockey puck programmer, but a different setup. Program Steps: Power the XT Micro off and plug in the hockey puck to J9. Power the hockey puck up and open the Microsoft MPLab program. Click on the Configure tap and then on Select Device. For the XT Micro select the PIC18F8723 processor. For the CR- 110, ER-110, SDX and XT-70 select the PIC18F452 processor. Note - anytime you change processors you will get this message wanting to download a new operating system. Click on OK.

301 XT-70 Control Panel 301 Note - when viewing the EEPROM with the 8723 processor you will see the address shown as three digits. The XT Micro has a lot larger E2 memory and if programming for the first time would advice to use a MCH file. A MCH file is a complete E2 file for a given application. If the processor is already running then you can do a read and get all the latest E2 settings from the processor. Using a MCH file: To use an existing MCH file, right click on the address 000. Click on Import Table. Select the correct file and click on Open. The E2 address should now be populated. E2. This is helpful if you are customizing units. Select the correct program and program the chip. The E2 memory file can also be exported using the same procedure once you have read the

302 XT-70 Control Panel 302 Appendix A (Installation and Use of the Microchip ICD2 Programmer): This Programmer is commonly referred to as the puck programmer, primarily because it looks like a hockey puck. It can be purchased from Digikey - part number - DV ND It costs about $ It is used to program the PIC 18 series Microchip microprocessors The following is a step by step process to install the software that comes with the programmer. Before installation - DO NOT CONNECT ICD2 to PC computer. Start: Double-click on the setup.exe file. At Welcome screen, click next Click I Accept then next Make sure Complete is checked, then click on Next At Choose Destination Directory window, click Next At the Copying Files window, click Next. After copying the files, several windows will pop up, asking if you want to view the installation instructions. Click No on all of them. One window may only have OK as a choice. Choose OK to close. Click Finish. Close the Document Viewer program. In Windows Explorer, go to C\Program Files\MPLAB IDE\Utilities \MPUsbIRU Double-click on MPUsbIRU.exe Check ICD 2 and click on Pre-Install. When it says Done in the lower box, click Close. Click No when asked to save the log.

303 XT-70 Control Panel 303 With nothing else running, plug in the ICD2 into the USB port DO NOT HAVE ICD2 PLUGGED INTO CIRCUIT BOARD A Found New Hardware wizard will start - click Next. A message may come up asking if it is okay to install the driver. Click Yes. Click Finish Repeat process when the next Found New Hardware window comes up. BEFORE STARTING MPLAB: Plug the ICD2 into the device to be programmed and power up the device. Start MPLAB IDE MPLAB defaults to the PIC 18F452. If you are programming a different chip, click configure on the menu bar, then select device. Change the drop down box to the desired chip - then click OK Import the hex file by clicking on File > Import.. Browse to the location of the hex file, select the hex file, the click open. Next, enable the programmer. On the menu bar, click Programmer > Select Programmer > MPLAB ICD2 A wizard starts up, click next Make sure USB is selected, then click next Make sure target has own power supply is selected, click next Check the MPLAB IDE automatically connects to the MPLAB ICD2 box, then click next. Click Next on the next screen

304 XT-70 Control Panel 304 Click Finish Click OK when asked about downloading new operating system. At the FYI window, click OK MPLAB will download the operating system. When finished, you should see the message MPLAB ICD2 ready in the output window. To program a chip, click on Programmer > Program on the menu bar. When the output window reads Programming succeeded, MPLAB ICD2 ready, shut down MPLAB and disconnect the ICD2 from the device. Default the device, and cycle the power. Quick steps for programming a device 1) Connect the ICD2 to the device to be programmed and power up the device. 2) Start MPLAB IBE 3) Select the ICD2 programmer 3) View the E2 Memory 4) Read the E2 Memory 5) Import the Hex file 6) Program device 7) Shut down MPLAB IDE 8) Disconnect ICD2 9) Default the device, and cycle power.

305 XT-70 Control Panel 305 Application: Two VFD Compressor Staging APP 043 This application will explain some new software for the CR-110. The software is the CR-110 VSC ver 1.28 or later. This address the use of two compressor the same size, each one with the VFD. The example used here is for two 25hp compressors. Each compressor can be run from 50 to 100%. This new software will provide a linear increase or decrease in refrigeration demand from SL to 100%. In this example SL = 20%. Rdemand is the output of the XT panel. Staging: Rdemand Lead % Lag Rdemand Lead % Lag Rdemand Lead % Lag

306 XT-70 Control Panel 306 SETUP: The Profile needs to be set to VFD Comp. The PID Mode must be set to 2 Comp VFD, this will enable the specific staging. The Rotation should be set to zero if no rotation is desired, other wise set to desired minutes. Max Horsepower is the max horsepower for one compressor. Min Horsepower is the horsepower when the compressor is running at the minimum setting. The LLS setting can vary depending if the compressors are set for rotation and if the value of the offset. See the control tab. Span L is the lower setting of the range. Span U is not used and the value is fixed at 100%.

307 XT-70 Control Panel 307 The Output Offset will affect where the LLS turn on and off. If this is set to zero then the LLS for each compressor will turn on and off with the exact setting and the value of the Rdemand. With the offset at 40% the Lag compressor will operate on the signal (Rdemand - 40%). The Lead compressor will operate on Rdemand. Example - Lead and Lag compressors LLS set to off at 5% and on at 15%. The lead compressors LLS will turn on as soon as the Rdemand signal is equal to or greater than 15%. The LLS will turn off as soon as the Rdemand signal is equal to or less than 5%. The Lag compressors LLS will turn on as soon as the Rdemand signal is equal to or greater than 40% + 15% or 55%. The Lag compressors LLS will turn off as soon as the Rdemand signal is equal to or less than 40% + 5% or 45%. The offset and LLS setting can be adjust to make the compressors start and stop as desired. RHP is the required horsepower. In this case 186 is 18.6 hp for the Rdemand signal. Comp 1 VFD out is the output for compressor 1. Comp 2 VFD out is the output for compressor 2.

308 XT-70 Control Panel 308 C1 = Compressor 1 C2 = Compressor 2 U = Unit (minimum possible hp) M = Max Compressor HP TU = total units to meet refrig demand RHP = Required HP to meet refrig demand SL = Span Low percent THP = Total HP available Rd = Refrigeration demand percentage Lead = lead compressor Lag = lead compressor Two VFD Compressor Staging Rev C C1 VFD = 25 HP C2 VFD = 25 HP U = 12.5 HP START RETURN Rd > SL yes no Lead = 0 Lag = 0 RHP = (THP - U)/(100 - SL) * (Rd - SL) + U TU = RHP / U TU <= 2 no yes Lead VFD % = TU*U*100 / M Lag VFD % = 0 TU <= 3 no yes Lead VFD % = U*100 / M Lag VFD % = (TU-1)*U*100 / M TU <= 4 no yes Lead VFD % = (TU-2)*U*100 / M Lag VFD % = 2*U*100 / M Lead VFD % = 100 Lag VFD % = 100 RETURN

309 XT-70 Control Panel 309 HUMIDITY READING FIELD NOTE PROBLEM: It has been brought to our attention that on the new rev B XT main cards, that the humidity readings will not go above 97 percent. This problem does not exist on the original XT main cards. The original cards used some 1/2 watt dropping resistors, for the 4-20ma current from the transducers. If the circuit got shorted, it will overheat the resistors and in time damage the circuit. The Rev B cards uses 5 watt resistors and some other protection that can with stand a long term short circuit. The problem is that the original resistors were 205 ohm, and the Rev B resistors are 200 ohm. The 5 watt resistors were only available in 200 ohm. Originally 205 ohm was use to provide max signal to the A2D. The difference in the resistors produce a 3 % error at the top of the scale. SOLUTION: The solution is quite simple, and involves the scaling for the math routine. The only issue is to distinguish between and original board and the Rev B board. The P1 Analog software V 1.88 and higher will correct the math issue for the Rev B board. The software defaults to a the Rev B board. If you are going to use the V1.88 or higher on a old board, you will need to clear EE memory location $3D. The easiest way to do this is to do it when you program the chip with your hockey puck. The next rev on the HMI will add this config byte and allow you to do it from the HMI, much like the door config byte. USING THE HOCKEY PUCK TO SET $3D: Remember that you only need to do this if you are going to update a original card to V1.88 or higher on the P1 analog chip. The standard procedure is to do a read on the EE, before you import the new program. EE memory address $3D Typical default would be $FF. If you have an original board, double click on the $3D and change it to 00 and the press enter. Now when you program the P1 chip it will be set to 00 and do the math for a 205 ohm resistor. The Rev B board will look for any value other than 0 to do the math converstion.