EMERSON EXD-HP1 2 Controller with ModBus Communication Capability Instruction Manual

EMERSON EXD-HP1 2 Controller with ModBus Communication Capability

Product Information

Specifications

• Power supply: AC 24V
• Power consumption: EXD-HP1: 15VA, EXD-HP2: 20VA
• Plug-in connector: Removable screw terminals wire size 0.14…1.5 mm2
• Protection class: IP20
• Digital Inputs: Potential free contacts (free from voltage)
• Temperature sensors: ECP-P30
• Pressure sensors: PT5N
• Output alarm relay: SPDT contact 24V AC 1 Amp inductive load; 24V AC/DC 4 Amp resistive load
• Stepper motor output: Coil: EXM-125/EXL-125 or EXN-125 Valves: EXM/EXL-… or EXN-…
• Type of action: 1B
• Rated impulse voltage: 0.5kV
• Pollution Degree: 2

Product Usage Instructions

Mounting
The EXD-HP1/2 controller can be mounted on a standard DIN rail. Ensure that the controller is equipped with core cable ends or metallic protective sleeves when connecting wires. When connecting the wires of EXM/EXL or EXN valves, follow the colour coding as listed below:

Interfacing and Communication
If Modbus communication is not being used, it is necessary to establish interfaces between the EXD-HP1/2 controller and the upper-level system controller. The external digital input should be operated in the function system’s compressor/demand. Ensure that necessary precautions are in place to protect the system.

Operating Conditions
The digital input status for the compressor is as follows:

• Compressor starts/run: closed (Start)
• Compressor stops: open (Stop)

Note:
Connecting any EXD-HP1/2 inputs to the supply voltage will permanently damage the EXD-HP1/2.

Electrical Connection and Wiring
When making electrical connections and wiring, follow these instructions:

• Use a class II category transformer for a 24VAC power supply.
• Do not ground the 24VAC lines.
• It is recommended to use individual transformers for the EXD-HP1/2 controller and third-party controllers to avoid possible interference or grounding problems in the power supply.
• Strip the wire insulation approximately 7 mm at the end.
• Insert the wires into the terminal block and tighten the screws securely.
• Ensure that the wires are properly connected and there are no loose connections.

Display/Keypad Unit (LEDs and Button Functions)
The display/keypad unit of the EXD-HP1/2 controller has the following LED indicators and button functions:

• ON: Data display
• ON: alarm
• ON: ModBus
• Circuit 1

FAQ (Frequently Asked Questions)

• Q: Can the EXD-HP1/2 controller be used with flammable refrigerants?
  A: No, the EXD-HP1/2 controller has a potential ignition source and does not comply with ATEX requirements. It should only be installed in a non-explosive environment. For flammable refrigerants, use valves and accessories that are approved for such applications.

• Q: How should I dispose of the EXD-HP1/2 controller once it reaches the end of its life?
  A: The EXD-HP1/2 controller should not be disposed of as commercial waste. It is the user’s responsibility to pass it to a designated collection point for safe recycling of Waste Electrical and Electronic Equipment (WEEE directive 2019/19/EU). For further information, contact your local environmental recycling centre.

General information

EXD-HP1/2 are stand-alone superheat and or economizer controllers. EXD-HP1 is intended for the operation of one EXM/EXL or EXN valve whereas EXD-HP2 is designed for the operation of two independent EXM/EXL or two EXN valves.

Note:
It is possible to use only Circuit 1 from EXD-HP2. In this case, circuit 2 must be disabled (C2 parameter) and the sensors and the valve for the second circuit are not needed.

ModBus communication is described in a Technical Bulletin and it is not covered by this document.

Technical Data

resistive load
Activated/energized:| During normal operation (no alarm condition)
Deactivated/de-energized:| During alarm condition or power supply is OFF
Stepper motor output| Coil: EXM-125/EXL-125 or EXN-125

Valves: EXM/EXL-… or EXN-…

Type of action| 1B
Rated impulse voltage| 0.5kV
Pollution Degree| 2
Mounting:| For standard DIN rail
Marking|
Dimensions (mm)

Warning -Flammable refrigerants:
EXD-HP1/2 has a potential ignition source and does not comply with ATEX requirements. Installation only in non-explosive environments. For flammable refrigerants only use valves and accessories approved for it!

Safety instructions

• Read operating instructions thoroughly. Failure to comply can result in device failure, system damage or personal injury.
• It is intended for use by persons having the appropriate knowledge and skill.
• Before installation or service disconnect all voltages from the system and device.
• Do not operate the system before all cable connections are completed.
• Do not apply voltage to the controller before the completion of wiring.
• Entire electrical connections have to comply with local regulations.
• Inputs are not isolated, potential free contacts need to be used.
• Disposal: Electrical and electronic waste must NOT be disposed of with other commercial waste. Instead, it is the user’s responsibility to pass it to a designated collection point for the safe recycling of Waste Electrical and Electronic Equipment (WEEE directive 2019/19/EU). For further information, contact your local environmental recycling centre.

Electrical connection and wiring

• Refer to the electrical wiring diagram for electrical connections.
• Note: Keep controller and sensor wiring well separated from supply power cables. The minimum recommended distance is 30mm.
• EXM-125, EXL-125 or EXN-125 coils are supplied with fixed cable and JST terminal block at the cable end. Cut the wires close to the terminal block. Remove the wire insulation approximately 7 mm at the end. It is recommended that the wires end to be equipped with core cable ends or metallic protective sleeve. When connecting the wires of EXM/EXL or EXN, consider the colour coding as follows:
  EXD| Terminal| EXM/L-125 wire color| EXN-125 wire color
  ---|---|---|---
  EXD- HP1| 6             BR

7             BL

8             OR

9             YE

10          WH

| Brown Blue Orange

Yellow White

| Red Blue Orange

Yellow White

EXD- HP2| 30          BR

31          BL

32           OR

33          YE

34          WH

| Brown Blue Orange Yellow White| Red Blue Orange Yellow White

• The digital input DI1 (EXD-HP1) and DI1/D12 (EXD-HP1/2) are the interfaces between EXD-HP1/2 and the upper-level system controller if the Modbus communication has not been used. The external digital shall be operated in the function system’s compressor/demand.
• If the output relays are not utilized, the user must ensure appropriate safety precautions are in place to protect the system.

Note:
Connecting any EXD-HP1/2 inputs to the supply voltage will permanently damage the EXD-HP1/2.

Wiring base board (EXD-HP 1/2):

Note:

• The base board is for the function of superheat control or Economizer control.
• Alarm relay, dry contact. The relay coil is not energized during alarm conditions or power off.
• Hot gas discharge sensor input is mandatory only for the economizer control function.

Warning:
Use a class II category transformer for a 24VAC power supply. Do not ground the 24VAC lines. We recommend using individual transformers for the EXD-HP1/2 controller and for third-party controllers to avoid possible interference or grounding problems in the power supply.

Wiring: Upper board (EXD- HP 2):

Note:

• The upper board is only for the function of superheat control.
• The upper board does not need to be wired if the circuit 2 is disabled.

Preparation for Start-up

• Vacuum the entire refrigeration circuit.
• Warning: Electrical Control Valves EXM/EXL or EXN are delivered in partially open position. Do not charge the system with refrigerant before the closure of the valve.
• Apply supply voltage 24V to EXD-HP1/2 while the digital input (DI1/DI2) is OFF(open). The valve will be driven to a close position.
• After the closure of the valve, start to charge the system with refrigerant.

Setup of parameters

(need to be checked/modified before start-up)

• Make sure that digital input (DI1/DI2) is off (open). Turn the power supply ON.
• Four main parameters Password (H5), type of function (1uE), refrigerant type (1u0/2u0) and pressure sensor type (1uP/2uP) can be set only when digital input DI1/DI2 is off (open) while the power supply is ON (24V). This feature is for added safety to prevent accidental damage to compressors and other system components.
• Once the main parameters have been selected/saved the EXD-HP1/2 is ready for startup. All other parameters can be modified at any time during operation or standby if it is necessary.

Display/keypad unit

Display/keypad unit (LEDs and button functions)

Procedure for parameter modification:
The parameters can be accessed via the 4-button keypad. The configuration parameters are protected by a numerical password. The default password is “12”. To select the parameter configuration:

• Press the button for more than 5 seconds, A flashing “0” is displayed
• Press until “12” is displayed; (password)
• Press to confirm the password
• Press or to show the code of the parameter that has to be changed
• Press to display the selected parameter value
• Press or to increase or decrease the value
• Press to temporarily confirm the new value and display its code
• Repeat the procedure from the beginning “press or to show…”

To exit and save the new settings:

• Press to confirm the new values and exit the parameters modification procedure.

To exit without modifying/saving any parameters:

• Do not press any button for at least 60 seconds (TIME OUT).

Reset all parameters to factory setting:

• Make sure that digital input (DI1/DI2) is Off (open).
• Press and together for more than 5 seconds.
• A flashing “0” is displayed.
• Press or until the password is displayed (Factory setting = 12).
• If the password was changed, select the new password.
• Press to confirm the password
• Factory settings are applied

Note:
In standard mode, the actual superheat is shown on the display. In the case of liquid injection and economizer function this change to discharge temperature.

• To display other data of circuit 1 of EXD-HP1/2 or 2 of EXD-HP2:
  • Press and together for 3 seconds to show data from Circuit 1
  • Press and together for 3 seconds to show data from Circuit 2
• To display data of each circuit: Press the button for 1 second until the index number according to the below table appears. Release the button and the next variable data will appear. By repeating above procedure, variable data can be displayed in a sequence as Measured superheat (K) → Measured suction pressure (bar) → Valve position (%) → Measured suction gas temperature (°C) → Calculated saturated temperature (°C) → Measured discharge temperature (°C) (if economizer function is selected) →REPEATING….

Note

1. Discharge temp. is available only if the economizer function is selected.
2. After 30 minutes, the display reverts to index 0.

Manual alarm reset/clearing functional alarms (except hardware errors):
Press and together for 5 seconds. When the clearing is done, a “CL” message appears for 2 seconds.

Manual mode operation

Press and together for 5 seconds to access to manual mode operation.

List of parameters in scrolling sequence by pressing the button

Code| Parameter description and choices| Min| Max| Factory setting| Field setting
---|---|---|---|---|---
1Ho| Manual mode operation; circuit 1| 0| 1| 0|
0 = off;      1 = on
1HP| Valve opening (%)| 0| 100| 0|
2Ho| Manual mode operation; circuit 2| 0| 1| 0|
0 = off       1 = on
2HP| Valve opening (%)| 0| 100| 0|

Note:
During manual operation, functional alarms such as low superheat are disabled. It is recommended to monitor the system operation when the controller is operated manually. Manual operation is intended for the service or temporary operation of the valve at a specific condition. After achieving the required operation, set the parameters 1Ho and 2Ho at 0 so the controller automatically operates the valve(s) according to its setpoint(s).

List Of Parameters

List of parameters in scrolling sequence by pressing button:

Code| Parameter description and choices| Min| Max| Factory setting
---|---|---|---|---
H5| Password| 1| 1999| 12
Adr| ModBus address| 1| 127| 1
br| Modbus baudrate| 0| 1| 1
PAr| Modbus parity| 0| 1| 0
-C2| Circuit 2 of EXD-HP2 enabled| 0| 1| 0
0 = Enabled;| 1 = Disabled|
-uC| Units conversion| 0| 1| 0
0 = °C, K, bar;                 1 = F, psig

This Parameter affects only the display. Internally the units are always SI- based.

HP-| Display mode| 0| 2| 1
0 = No display| 1 = Circuit 1| 2 = Circuit 2 (only EXD-HP2)
Parameters Circuit 1

1uE| Function| 0| 1| 1
0 = Superheat control

1 = Economizer control (Only for R410A/R407C/R32)

1u4| Superheat control mode| 0| 4| 0
0 = Standard control coil heat exchanger 1 = Slow control coil heat exchanger

2 = fixed PID

3 = fast control plate heat exchanger (not for 1uE = 1) 4 = Standard plate heat exchanger (not for 1uE = 1)

1u0| Refrigerant| 0| 15| 2
0 = R22         1 = R134a      2 = R410A     3 = R32         4 = R407C

5 = R290      6 = R448A     7 = R449A     8 = R452A     9 = R454A

10 = R454B 11 = R454C 12 = R513A  13 = R452B 14 = R1234ze

15 = R1234yf *

*) EXN not permitted

* _) Warning -Flammable refrigerants:_ EXD-HP1/2 has a potential ignition source and does not comply with ATEX requirements. Installation only in non-explosive environments. For flammable refrigerants only use valves and accessories approved for it!**

1uP| Installed pressure sensor type| 0| 3| 2
0 = PT5N-07…

2 = PT5N-30…

| 1 = PT5N-18…

3 = PT5N-10P-FLR

|  |  |  |
1uu| Start valve opening (%)| 10| 100| 20
1u9| Start opening duration (second)| 1| 30| 5
1uL| Low superheat alarm function| 0| 2| 1
0 = disable (for flooded evaporator) 2 = enable manual reset| 1 = enable auto reset|
1u5| Superheat set-point (K)

If 1uL = 1 or 2 (enabled auto or manual reset) If 1uL = 0 (disabled)

| ****

3

0.5

| ****

30

30

| ****

6

6

1u2| MOP function| 0| 1| 1
0 = disable| 1 = enable|  |  |  |
1u3| MOP set-point (°C) saturation temperature Factory setting according to selected refrigerant

(1u0). The default value can be changed

| see MOP table
Code| Parameter description and choices| Min| Max| Factory setting
---|---|---|---|---
1P9| Low pressure alarm mode circuit 1| 0| 2| 0
0 = disabled                                        1 = enabled auto reset 2 = enabled manual reset
1PA| Low pressure alarm cut-out circuit 1| -0.8| 17.7| 0
1Pb| Low pressure alarm delay circuit 1| 5| 199| 5
1Pd| Low-pressure alarm cut-in circuit 1| 0.5| 18| 0.5
1P4| Freeze protection alarm function| 0| 2| 0
0 = disabled,                    1 = enabled auto-reset, 2 = enabled manual reset
1P2| Freeze alarm cut-out circuit 1| -20| 5| 0
1P5| Freeze protection alarm delay, sec.| 5| 199| 30
1P-| Superheat control circuit 1 fixed PID (Kp factor) Display 1/10K| 0.1| 10| 1.0
1i-| Superheat control circuit 1 fixed PID (Ti factor)| 1| 350| 100
1d-| Superheat control circuit 1 fixed PID (Td factor) Display 1/10K| 0.1| 30| 3.0
1EC| Hot gas temperature sensor source| 0| 1| 0
0 = ECP-P30

1 = Via Modbus input

1PE| Economizer control circuit 1 fixed PID (Kp factor)      Display 1/10K| 0.1| 10| 2.0
1iE| The economizer control circuit 1 fixed PID (Ti factor)| 1| 350| 100
1dE| Economizer control circuit 1 fixed PID (Td factor)      Display 1/10K| 0.1| 30| 1.0
1uH| High superheat alarm mode circuit 1

0 = disabled                1 = enabled auto-reset

| 0| 1| 0
1uA| High superheat alarm setpoint circuit 1| 16| 40| 30
1ud| High superheat alarm delay circuit 1| 1| 15| 3
1E2| Positive correction of measured Hotgas temperature.| 0| 10| 0
Parameters Circuit 2 (only EXD-HP2)
Code| Parameter description and choices| Min| Max| Factory setting
2u4| Superheat control mode| 0| 4| 0
0 = Standard control coil heat exchanger 1 = Slow control coil heat exchanger

2 = fixed PID

3 = fast control plate heat exchanger 4 = Standard plate heat exchanger

2u0| System Refrigerant| 0| 5| 2
0 = R22         1 = R134a      2 = R410A     3 = R32         4 = R407C

5 = R290      6 = R448A     7 = R449A     8 = R452A     9 = R454A

10 = R454B 11 = R454C 12 = R513A  13 = R452B 14 = R1234ze

15 = R1234yf *

*) EXN not permitted

* _)_ Warning -Flammable refrigerants: EXD-HP1/2 has a potential ignition source and does not comply with ATEX requirements. Installation only in non-explosive environments. For flammable refrigerants only use valves and accessories approved for it!**

2uP| Installed pressure sensor type (When DI2 is off)| 0| 3| 1
0 = PT5N-07…          1 = PT5N-18…

2 = PT5N-30…          3 = PT5N-10P-FLR

2uu| Start valve opening (%)| 10| 100| 20
2u9| Start opening duration (second)| 1| 30| 5
2uL| Low superheat alarm function| 0| 2| 1
0 = disable (for flooded evaporator)              1 = enable auto reset 2 = enable manual reset
2u5| Superheat set-point (K)

If 2uL = 1 or 2 (enabled auto or manual reset) If 2uL = 0 (disabled)

| ****

3

0.5

| ****

30

30

| ****

6

6

2u2| MOP function| 0| 1| 1
0 = disable                          1 = enable
2u3| MOP set-point (°C) saturation temperature Factory setting according to selected refrigerant (2u0). The default value can be changed| see MOP table

2P9

| Low-pressure alarm mode circuit 2| 0| 2| 0
0 = disabled                     1 = enabled auto reset 2 = enabled manual reset
2PA| Low-pressure alarm cut-out (bar) circuit 2| -0.8| 17.7| 0
2Pb| Low-pressure alarm delay (sec) circuit 2| 5| 199| 5
2Pd| Low-pressure alarm cut-in (bar) circuit 2| 0.5| 18| 0.5
2P4| Freeze protection alarm function| 0| 2| 0
0 = disable,                      1 = enable auto-reset, 2 = enable manual reset
Code| Parameter description and choices| Min| Max| Factory setting
---|---|---|---|---
2P2| Freeze alarm cut-out circuit 2| -20| 5| 0
2P5| Freeze protection alarm delay, sec.| 5| 199| 30
2P-| Superheat control circuit 2

(Kp factor), fixed PID Display 1/10K

| 0.1| 10| 1.0
2i-| Superheat control circuit 2 (Ti factor), fixed PID| 1| 350| 100
2d-| Superheat control circuit 2 (Td factor), fixed PID       – Display 1/10K| 0.1| 30| 3.0
2uH| High superheat alarm mode circuit 2| 0| 1| 0
0 = disabled                1 = enabled auto-reset
2uA| High superheat alarm setpoint (K) circuit 2| 16| 40| 30
2ud| High superheat alarm delay (Min) circuit 2| 1| 15| 3
Selection for both circuits and discharge temperature control

Code| Parameter description and choices| Min| Max| Factory setting
Et| Valve type| 0| 1| 0
0 = EXM / EXL         1 = EXN
Note: EXD-HP2 can drive two similar valves i.e. both valves must be either EXM/EXL or EXN.
1E3| Discharge Temperature Setpoint Start Setpoint| 70| 140| 85
1E4| Discharge Temperature Control band| 2| 25| 20
1E5| Discharge Temperature limit| 100| 150| 120

MOP table (°C)

Refrigerant| Min.| Max.| Factory setting| Refrigerant| Min.| Max.| Factory setting
---|---|---|---|---|---|---|---
R22| -40| +50| +15| R452A| -45| +66| +15
R134a| -40| +66| +15| R454A| -57| +66| +10
R410A| -40| +45| +15| R454B| -40| +45| +18
R32| -40| +30| +15| R454C| -66| +48| +17
R407C| -40| +48/| +15| R513A| -57| +66| +13
R290| -40| +50| +15| R452B| -45| +66| +25
R448A| -57| +66| +12| R1234ze| -57| +66| +24
R449A| -57| +66| +12| R1234yf| -52| +66| +15

Control (valve) start-up behavior

(Parameter 1uu/2uu and 1u9/2u9)

Upload/download Key: Function
For serial production of systems/units, the upload/download key allows the transmission of configured parameters among a range of identical systems.

Uploading procedure:
(storing configured parameters in key)

• Insert the key while the first (reference) controller is ON and press the button; the “uPL” message appears followed by the “End” message for 5 seconds.
• Note: If the “Err” message is displayed for failed programming, repeat the above procedure.

Downloading procedure:
(configured parameters from key to other controllers)

• Turn off the power to the new controller
• Insert a loaded Key (with stored data from the reference controller) into the new controller and turn on the power supply.
• The stored parameters of the key will be downloaded automatically into the new controller memory; The “doL” message appears followed by an “End” message for 5 seconds.
• The new controller with the new loaded parameters setting will start to operate after the “End” message disappears.
• Remove the key.
• Note: If the “Err” message is displayed for failed programming, repeat the above procedure.

Error/Alarm handling

Alarm code| Description| Related parameter| Alarm relay| Valve| What to do?| Requires manual reset after resolving alarm
---|---|---|---|---|---|---
1E0/2E0| Pressure sensor 1/2 error| –| Triggered| Fully close| Check the wiring connection and measure the signal 4 to 20 mA| No
1E1/2E0| Temperature sensor 1/2 error| –| Triggered| Fully close| Check the wiring connection and measure the resistance of the sensor| No
1Ed| Discharge hot gas temperature sensor 3 error| –| Triggered| Operating| Check the wiring connection and measure the resistance of the sensor| No
1Π- /2Π-| EXM/EXL or EXN

electrical connection error

| –| Triggered| –| Check the wiring connection and measure the resistance of the winding| No
1Ad| Discharge hot gas temperature above the limit|  | Triggered| Operating| Check valve opening/ check liquid flow for flash gas free/check discharge hot gas temperature sensor| No
1AF/2AF|

Freeze protection

| 1P4/2P4: 1| Triggered| Fully close| Check the system for causes of low pressure such as insufficient load on the evaporator| No
1AF/2AF

blinking

| 1P4/2P4: 2| Triggered| Fully close| Yes
1AL/2AL| Low superheat (<0,5K)| 1uL/2uL: 1| Triggered| Fully close| Check the wiring connection and operation of the valve| No
1AL/2AL blinking| 1uL/2uL: 2| Triggered| Fully close| Yes
1AH/2AH| High superheat| 1uH/2uH: 1| Triggered| Operating| Check the system| No
1AP/2AP|

Low pressure

| 1P9/2P9: 1| Triggered| Operating| Check the system for causes of low pressure such as refrigerant loss| No
1AP/2AP blinking| 1P9/2P9: 2| Triggered| Operating| Yes
Err| Failed uploading/downloading| –| –| –| Repeat the procedure for uploading/downloading| No

Note:
When multiple alarms occur, the highest priority alarm is displayed until being cleared, then the next highest alarm is displayed until all alarms are cleared. Only then will parameters be shown again.

Emerson Climate Technologies GmbH

• Am Borsigturm 31 I 13507 Berlin I Germany
• www.climate.emerson.com/en-gb.

References

• Copeland is Engineered for Sustainability | Copeland GB
• Manual-Hub.com – Free PDF manuals!

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