Danfoss 080Z0130, 080Z0139 User guide

Design Guide

Controller for evaporator control

AK-CC 750 - 080Z0130 & 080Z0139

ADAP-KOOL® Refrigeration control systems

Contents

1. Introduction ............................................................................. 3

Application .................................................................................................. 3

Principles...................................................................................................... 4

2. Design of a controller ..............................................................7

Module survey ........................................................................................... 8

Common data for modules .................................................................10

Controller ...........................................................................................12

Extension module AK-XM 101A .................................................14

Extension module AK-XM 102A / AK-XM 102B .....................16

Extension module AK-XM 204A / AK-XM 204B .....................18

Extension module AK-XM 205A / AK-XM 205B .....................20

Extension module AK-OB 101A..................................................22

Display module EKA 163B / EKA 164B ..................................... 23

Transformer module AK-PS 075 / 150 ...................................... 24

Case Power module ........................................................................25

Preface to design ....................................................................................26

Functions ............................................................................................26

Connections ...................................................................................... 27

Limitations ......................................................................................... 27

Design of a evaporator control ..........................................................28

Procedure: ..........................................................................................28

Sketch .................................................................................................. 28

Evaporator and refrigerator appliance functions ................28

Connections ...................................................................................... 30

Planning table .................................................................................. 31

Length .................................................................................................32

Linking of modules ......................................................................... 32

Determine the connection points ............................................33

Connection diagram ...................................................................... 34

Supply voltage ................................................................................. 35

Ordering ..................................................................................................... 36

3. Mounting and wiring .............................................................37

Mounting ................................................................................................... 38

Mounting of extension module on the basic module ....... 38

Wiring .......................................................................................................... 39

4. Conguration and operation ................................................41

Conguration ...........................................................................................43

Connect PC ........................................................................................ 43

Authorization .................................................................................... 44

Unlock the conguration of the controllers ..........................45

System setup ....................................................................................46

Set plant type ................................................................................... 47

Denition of thermostat ............................................................... 48

Denition of sections .....................................................................49

Denition of defrost functions ................................................... 50

Denition of common functions ............................................... 51

Conguration of inputs and outputs .......................................53

Set alarm priorities..........................................................................55

Lock conguration ..........................................................................57

Check conguration .......................................................................58

Check of connections ............................................................................ 59

Check of settings.....................................................................................60

Installation in network .......................................................................... 63

First start of control ................................................................................64

Start the control ............................................................................... 65

Setup logs .......................................................................................... 66

Manual defrost ......................................................................................... 67

5. Regulating functions .............................................................69

Introduction ..............................................................................................70

Thermostat function .............................................................................. 71

Temperature alarms ............................................................................... 75

Common functions ................................................................................ 76

Liquid injection ........................................................................................78

Defrost ........................................................................................................ 79

Miscellaneous ..........................................................................................84

Information ............................................................................................... 86

Alarm texts ................................................................................................ 88

Appendix - Recommended connection ......................................... 90

Info

AK-CC 750 - 080Z0130 and 080Z0139 are US-versions of the standard AK-CC 750 controller. Main changes:

• Temperature in °F

• Pressure in PSI

• Other quick setup

• Separate controls are removed

• No stepper valve connections

• 080Z0130 = LON TP 78

• 080Z0139 = LON RS 485

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Software: 080Z0130: 6.0x 084Z0139: 6.1x

1. Introduction

Application

AK-CC 750 controllers are complete regulating units which together with valves and sensors constitute complete evaporator controls for refrigeration appliances and freezing rooms within commercial refrigeration. Generally speaking they replace all other automatic controls containing, inter alia, day and night thermostats, defrost, fan control, rail heat control, alarm functions, light control, thermo valve control, solenoid valve, etc. The controller is equipped with data communication and is operated via a PC. In addition to evaporator control the controller can give signals to other controllers about the operating condition, e.g. forced closing of expansion valves, alarm signals and alarm messages.

Advantages

• Control of 1 to 4 evaporator sections

• Adaptive superheat control ensures optimum evaporator usage in all operational circumstances.

• Electronic injection with AKV valve

• Traditional temperature regulation using on/o or modulating control of solenoid valve for both DX and indirect brine system.

• Weighted thermostat and alarm thermostat

• Defrost on demand based on evaporator capacity

• Appliance cleaning function

• Light control using door switch or network signal depending on day/night operation

• Rail heat pulsing depending on day/night operation or dew point

• Monitoring of door alarm and control of light/refrigeration depending on location of door switch.

• Log function for registration of historical parameter values and alarm modes.

Control

The controller’s main function is to control the evaporator so that the system constantly operates with the most energy-friendly refrigeration. A specic function for registration of the need for defrost will adapt the number of defrosts so that no energy is wasted on unnecessary defrosts and subsequent cooling-down cycles.

Adaptive defrosting

The AK-CC 750 includes an adaptive defrosting function. By using the AKV valve as mass ow sensor for the supply of refrigerant, the controller can monitor ice formation on the evaporator. If the load is too large for the standard defrost programme, the controller initiates additional automatic defrost cycles to eliminate the need for expensive service calls due to iced-up evaporators.

Evaporator control of one, two, three or four evaporators

Control of cool or frost room

Control of cool or frost appliance

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Principles

The great advantage of this series of controllers is that it can be extended as the size of the plant is increased. It has been developed for refrigeration control systems, but not for any specic application – variation is created through the read-in software and the way you choose to dene the connections. It is the same modules that are used for each regulation and the composition can be changed, as required. With these modules (building blocks) it is possible to create a multitude of various kinds of regulations. But it is you who must help adjusting the regulation to the actual needs – these instructions will assist you to nd your way through all the open questions so that the

regulation can be dened and the connections made.

Controller

Top part

Advantages

• The controller’s size can “grow” as systems grow

• The software can be set for one or more regulations

• Several regulations with the same components

• Extension-friendly when systems requirements are changed

• Flexible concept:

- Controller series with common construction

- One principle – many regulation uses

- Modules are selected for the actual connection requirements

- The same modules are used from regulation to regulation

Extension modules

Bottom part

The controller is the cornerstone of the regulation. The module has inputs and outputs capable of handling small systems.

• The bottom part – and hence the terminals – are the same for all controller types.

• The top part is the intelligence with software. This unit will vary according to controller type. But it will always be supplied together with the bottom part.

• In addition to the software the top part is provided with connection for data communication and address setting.

Examples

A regulation with few connections can be performed with the controller module alone

If the system grows and more functions have to be controlled, the regulation can be extended. With extra modules more signals can be received and more relays cut in and out – how many of them – and which – is determined by the relevant application.

If there are many connections one or more extension modules have to be mounted

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Direct connection

Setup and operation of an AK controller must be accomplished via the “AK-Service Tool” software program.

The programme is installed on a PC, and setup and operation of the various functions are carried out via the controller’s menu displays.

Displays

The menu displays are dynamic, so that dierent settings in one menu will result in dierent setting possibilities in other menus.

A simple application with few connections will give a setup with few settings. A corresponding application with many connections will give a setup with many settings. From the overview display there is access to further displays for the regulation. At the bottom of the display there is access to a number of general functions, such as “time table”, “manual operation”, “log function”, “alarms”, and “service” (conguration).

Network linking

The controller can be linked up into a network together with other controllers in an ADAP-KOOL® refrigeration control system. AK-SC 255, 355 or SM850 can be used as a system unit. After initial setup, operation can be performed from control system. 080Z0130 is equiped with LON TP 78 080Z0139 is equiped with LON RS 485.

Users

The controller comes supplied with several languages, one of which can be selected and employed by the user. If there are several users, they may each have their choice of language. All users must be assigned a user prole which either gives access to full operation or gradually limits the operation to the lowest level that only allows you “to see”.

External display

An external display can be tted in order for P0 (Suction) and Pc (Condensing) readings to be displayed. In AK-CC 750 up to 4 displays can be mounted.

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Light-emitting diodes

A number of light-emitting diodes makes it possible to follow the signals that are received and transmitted by the controller.

Log

From the log function you can dene the measurements you wish to be shown. The collected values can be printed, or you may export them to a le. You can open the le in Excel or import in AKM. (The Log function is only available via AK-ST 500.)

If you are in a service situation you can show measurements in a trend function. The measurements are then made real-time and displayed instantly.

■ Power

■ Comm

■ DO1 ■ Status

■ DO2 ■ Service Tool

■ DO3 ■ LON

■ DO4 ■ Alarm

■ DO5

■ DO6

■ DO7

■ DO8 ■ Service Pin

Slow ash = OK Quick ash = answer from gateway/ installed in network Constantly ON = error Constantly OFF = error

Flash = active alarm/not cancelled Constant ON = Active alarm/cancelled

(In 084Z0139 the alarm LED is moved to position 5.)

Alarm

The display gives you an overview of all active alarms. If you wish to conrm that you have seen the alarm you can cross it o in the acknowledge eld. If you want to know more about a current alarm you can click on it and obtain an information display on the screen.

A corresponding display exists for all earlier alarms. Here you can upload information if you need further details about the alarm history.

Adaptive defrost

AK-CC 750 is equipped with an adaptive defrost function. By using an AKV valve as mass ow sensor for the supply of refrigerant the control can monitor ice formation on the evaporator. Function can cancel planned defrosts which are not necessary, and on its own initiative start a defrost if the evaporator is about to be blocked by rime and ice.

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2. Design of a controller

This section describes how the controller is designed.

The controller in the system is based on a uniform connection platform where any deviations from regulation to regulation is determined by the used top part with a specic software and by which input and output signals the relevant application will require. If it is an application with few connections, the controller module (top part with belonging bottom part) may be sucient. If it is an application with many connections it will be necessary to use the controller module plus one or more extension modules.

This section will give you a survey of possible connections plus assistance in selecting the modules required by your actual application.

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Module survey

• Controller module – capable of handling minor plant requirements.

• Extension modules. When the numbers of evaporators becomes greater and additional inputs or outputs are required, modules can be attached to the controller. A plug on the side of the module will transmit the supply voltage and data communication between the modules.

• Top part The upper part of the controller module contains the intelligence. This is the unit where the regulation is dened and where data communication is connected to other controllers in a bigger network.

• Connection types There are various types of inputs and outputs. One type may, for example, receive signals from sensors and switches, another may receive a voltage signal, and a third type may be outputs with relays etc. The individual types are shown in the table below.

Extension module with additional analog inputs

External display for appliance temperature etc.

• Optional connection When a regulation is planned (set up) it will generate a need for a number of connections distributed on the mentioned types. This connection must then be made on either the controller module or an extension module. The only thing to be observed is that the types must not be mixed (an analog input signal must for instance not be connected to a digital input).

• Programming of connections The controller must know where you connect the individual input and output signals. This takes place in a later conguration where each individual connection is dened based on the following principle:

- to which module

- at which point (”terminals”)

- what is connected (e.g. pressure transmitter/type/

pressure range)

Extension module with additional relay outputs and additional analog inputs.

Bottom part

Controller with analog inputs and relay outputs.

Top part

The module with additional relay outputs is also available in a version where the top part is provided with change-over switches so that the relays can be overridden.

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1. Controller

Type Function Application

AK-CC 750 Controller for evaporator control Refrigeration appliances control

2. Extension modules and survey of inputs and outputs

Type Analog

inputs

For sensors, pressure transmitters etc.

Controller 11 4 4 - - -

Extension modules

AK-XM 101A 8

AK-XM 102A 8

AK-XM 102B 8

AK-XM 204A 8

AK-XM 204B 8 x

AK-XM 205A 8 8

AK-XM 205B 8 8 x

On/O outputs On/o supply voltage

Relay (SPDT)

Solid state Low voltage

(DI signal)

(max. 80 V)

High voltage (max. 260 V)

Module with switches

For override of relay outputs

3. AK operation and accessories

Type Function Application

Operation

AK-ST 500 Software for operation of AK controllers AK-operation

- Cable between PC and AK controller AK - Com port

- Cable between PC and AK controller AK - USB

Accessories Transformer module 230 V / 115 V to 24 V

AK-PS 075 18 VA, 24 V d.c.

AK-PS 150 36 VA, 24 V d.c.

Accessories External display that can be connected to the controller module. For showing, say, the refrigeration appliances

EKA 163B Display

EKA 164B Display with operation buttons

- Cable between display and controller

Accessories Real time clock for use in controllers that require a clock function, but are not wired with data communication.

AK-OB 101A Real time clock with battery backup. To be mounted in an AK controller

Cable between zero modem cable and AK controller / Cable between PDA cable and AK controller

AK - RS 232

Supply for controller

Length = 6.5 ft

Length = 19.5 ft

On the following pages there is data specic to each module.

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Common data for modules

Supply voltage 24 V d.c. / a.c. +/- 20%

Power consumption AK-__ (controller) 8 VA

AK-XM 101, 102, 103 2 VA

AK-XM 204, 205 5 VA

Analog inputs Pt 1000 ohm /0°C Resolution: 0.1°C

PTC 1000 ohm /0°C

Pressure transmitter type AKS 32R / AKS 2050 / AKS 32 (1-5 V)

Voltage signal 0-10 V

Contact function (On/O ) On at R < 20 ohm

On/o supply voltage inputs Low voltage

Relay outputs SPDT

Solid state outputs Can be used for loads that are cut in and

0 / 80 V a.c./d.c.

High voltage 0 / 260 V a.c.

AC-1 (ohmic) 4 A

AC-15 (inductive) 3 A

U Min. 24 V

out frequently, e.g. : rail heat, fans and AKV valve

Accuracy: +/- 0.5°C (between -58°F and +122°F)

Resolution:1 mV Accuracy +/- 10 mV Max. connection of 5 pressure transmitters on one module

O at R > 2K ohm (Gold -plated contacts not necessary)

O: U < 2 V On: U > 10 V

O: U < 24 V On: U > 80 V

Max. 230 V Low and high voltage must not be connected to the same output group

Max. 240 V a.c. , Min. 48 V a.c. Max. 0.5 A, Leak < 1 mA Max. 1 AKV

Ambient temperature During transport -40 to 158°F

During operation -4 to 131°F ,

0 to 95% RH (non condensing) No shock inuences / vibrations

Enclosure Material PC / ABS

Density IP10 , VBG 4

Mounting For mounting on panel wall or DIN rail

Weight with screw terminals modules in100- / 200- / controller-series Ca. 7 oz / 17 oz / 21 oz

Approvals EU low voltage directive and EMC require-

ments are complied with

UL 873,

The mentioned data applies to all modules. If data is specic, this is mentioned together with the module in question.

LVD tested according to EN 60730 EMC tested Immunity according to EN 61000-6-2 Emission according to EN 61000-6-3

UL le number: E166834

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Dimensions

The module dimension is 72 mm (2.83 in). Modules in the 100-series consist of one module Modules in the 200-series consist of two modules Controllers consist of three modules The length of an aggregate unit = n x 72 + 8 mm (n x 2.83 + 0.32 in).

AK-CC 750 - 080Z0130 & 080Z0139 RS8GM222 © Danfoss 10-2014 11

Controller

Function

There are several controllers in the series. The function is determined by the programmed software, but outwardly the controllers are identical – they all have the same connection possibilities: 11 analog inputs for sensors, pressure transmitters, voltage signals

and contact signals.

8 digital outputs, with 4 Solid state outputs and 4 relay outputs

Supply voltage

24 V a.c. or d.c. to be connected to the controller. The 24 V must not be retransmitted and used by other controllers as it is not galvanically separated from inputs and outputs. In other words, you must use a transformer for each controller. Class II is required. The terminals must not be earthed. The supply voltage to any extension modules is transmitted via the plug on the right-hand side. The size of the transformer is determined by the power requirement of the total number of modules.

The supply voltage to a pressure transmitter can be taken either from the 5 V output or from the 12 V output depending on transmitter type.

Data communication

If the controller is to be included in a system, communication must take place via the LON connection. The installation has to be made as mentioned in the separate instructions for LON communication.

TP 78 or RS 485

Address setting

When the controller is connected to a system unit, the controller’s address must be set between 1 and 200.

Scan function

When the controller is connected to the data communication cable the system unit must have knowledge of the new controller. This is obtained by the scan function in the system unit. The LED “Status” will ash fast when the system unit sends an acceptance message.

Operation

The conguration operation of the controller must take place from the software programme “Service Tool”. The program must be installed on a PC, and the PC must be connected to the controller via the network plug on the front of the unit.

Light-emitting diodes

There are two rows with LED’s. They mean: Left row:

• Voltage supply to the controller

• Communication active with the bottom PC board (red = error)

• Status of outputs DO1 to DO8

Right row:

• Software status (slow ash = OK)

• Communication with Service Tool

• Communication on LON

• Alarm when LED ashes

- 3 LED’s that are not used

• “Service Pin” switch has been activated

Address

■ Power

■ Comm

■ DO1 ■ Status

■ DO2 ■ Service Tool

■ DO3 ■ LON

■ DO4 ■ Alarm

■ DO5

■ DO6

■ DO7

■ DO8 ■ Service Pin

Keep the safety distance!

Low and high voltage must not be connected to the same output group

Slow ash = OK Quick ash = answer from gateway Installation in network Constantly ON = error Constantly OFF = error

Flash = active alarm/not cancelled Constant ON = Active alarm/cancelled

(In 084Z0139 the alarm LED is moved to position 5.)

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Point

Point 1 2 3 4 5 6 7 8 9 10 11

Type AI1 AI2 AI3 AI4 AI5 AI6 AI7 AI8 AI9 AI10 AI11

Terminal 15: 12 V Terminal 16: 5 V

Terminal 27: 12 V Terminal 28: 5 V

Analog inputs on 1 - 11

Solid state outputs on 12 - 15

Relay or AKV coil fx 230 V a.c.

Signal Signal

Pt 1000 ohm/0°C

S2, S3 S4, S5 Saux

AKS 32R AKS 2050

3: Brown

2: Blue

1: Black

P0 Pc Paux

AKS 32

3: Brown

2: Black

1: Red

...

On/O Ext.

Main switch

Day/ Night

Door Defrost

AKV

Fan Alarm Light Rail heat Defrost Night blind Valves Compressor

20-23*)

24 and 25 not used at evaporator control

type

Pt 1000

AKS 32R AKS 2050

-1 - xx bar

AKS 32

-1 - zz bar

0 - 5 V 0 - 10 V

Active at:

Closed

Open

Active at:

O

Point 12 13 14 15 16 17 18 19

Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 9 - 10

6 (AI 6) 11 - 12

7 (AI 7) 13 - 14

8 (AI 8) 19 - 20

9 (AI 9) 21 - 22

10 (AI 10) 23 - 24

11 (AI 11) 25 - 26

12 (DO 1) 31 - 32

13 (DO 2) 33 - 34

14 (DO 3) 35 - 36

15 (DO 4) 37 - 38

16 (DO 5) 39 - 40- 41

17 (DO6) 42 - 43 - 44

18 (DO7) 45 - 46 - 47

19 (DO8) 48 - 49 - 50

Terminal 17, 18, 29, 30: (Cable screen)

Relay outputs on 16 - 19

*) 20 - 23: See Case power module

Terminal

Signal type /

Active at

AK-CC 750 - 080Z0130 & 080Z0139 RS8GM222 © Danfoss 10-2014 13

Extension module AK-XM 101A

Function

The module contains 8 analog inputs for sensors, pressure transmitters, voltage signals and contact signals.

Supply voltage

The supply voltage to the module comes from the previous module in the row.

Supply voltage to a pressure transmitter can be taken from either the 5 V output or the 12 V output depending on transmitter type.

Light-emitting diodes

Only the two top LED’s are used. They indicate the following:

• Voltage supply to the module

• Communication with the controller is active (red = error)

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Point

Point 1 2 3 4

Type AI1 AI2 AI3 AI4

Terminal 9: 12 V Terminal 10: 5 V

Pt 1000 ohm/0°C

AKS 32R AKS 2050

AKS 32

At the top the signal input is the left of the two terminals.

At the bottom the signal input is the right of the two terminals.

3: Brown

2: Blue

1: Black

3: Brown

2: Black

1: Red

Signal Signal

type

S2 S3 S4

Pt 1000

S5 Saux

AKS 32R

P0 Pc Paux

AKS 2050

-1 - xx bar

AKS 32

-1 - zz bar

Terminal 15: 5 V Terminal 16: 12 V

Terminal

11, 12, 13, 14:

(Cable screen)

Point 5 6 7 8

Type AI5 AI6 AI7 AI8

On/O

...

Ext. Main switch Day/ Night Door Defrost

0 - 5 V 0 - 10 V

Active at:

Closed

Open

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 17 - 18

6 (AI 6) 19 - 20

7 (AI 7) 21 - 22

8 (AI 8) 23 - 24

Terminal

Signal type /

Active at

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Extension module AK-XM 102A / AK-XM 102B

Function

The module contains 8 inputs for on/o voltage signals.

Signal

AK-XM 102A is for low voltage signals. AK-XM 102B is for high voltage signals.

Supply voltage

The supply voltage to the module comes from the previous module in the row.

Light-emitting diodes

They indicate:

• Voltage supply to the module

• Communication with the controller is active (red = error)

• Status of the individual inputs 1 to 8 (when lit = voltage)

AK-XM 102A

Max. 24 V

On/O: On: DI > 10 V a.c. O: DI < 2 V a.c.

AK-XM 102B

Max. 230 V

On/O: On: DI > 80 V a.c. O: DI < 24 V a.c.

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Point

Point 1 2 3 4

Type DI1 DI2 DI3 DI4

Point 5 6 7 8

Type DI5 DI6 DI7 DI8

Signal Active at

AK-XM 102A: Max. 24 V AK-XM 102B: Max. 230 V

Ext. Main switch

Day/ Night

Door Defrost

Closed

(voltage on)

Open

(voltage o)

Signal Module Point Terminal Active at

1 (DI 1) 1 - 2

2 (DI 2) 3 - 4

3 (DI 3) 5 - 6

4 (DI 4) 7 - 8

5 (DI 5) 9 - 10

6 (DI 6) 11 - 12

7 (DI 7) 13 - 14

8 (DI 8) 15 - 16

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Extension module AK-XM 204A / AK-XM 204B

Function

The module contains 8 relay outputs.

Supply voltage

The supply voltage to the module comes from the previous module in the row.

AK-XM 204B only Override of relay

Eight change-over switches at the front make it possible to override the relay’s function. Either to position OFF or ON. In position Auto the controller carries out the control.

Light-emitting diodes

There are two rows with LED’s. They indicate the following: Left row:

• Voltage supply to the controller

• Communication active with the bottom PC board (red = error)

• Status of outputs DO1 to DO8

Right row: (AK-XM 204B only):

• Override of relays ON = override OFF = no override

AK-XM 204A AK-XM 204B

Fuses

Behind the upper part there is a fuse for each output.

Max. 230 V

AC-1: max. 4 A (ohmic) AC-15: max. 3 A (Inductive)

AK-XM 204B Override of relay

Keep the safety distance!

Low and high voltage must not be connected to the same output group

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Point

Signal Active at

Fan Alarm Light Railheat Defrost Night blind Valve Compressor

O

Point 1 2 3 4 5 6 7 8

Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

Signal Module Point Terminal Active at

1 (DO 1) 25 - 27

2 (DO 2) 28 - 30

3 (DO 3) 31 - 33

4 (DO 4) 34 -36

5 (DO 5) 37 - 39

6 (DO 6) 40 - 41 - 42

7 (DO 7) 43 - 44 - 45

8 (DO 8) 46 - 47 - 48

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Extension module AK-XM 205A / AK-XM 205B

Function

The module contains: 8 analog inputs for sensors, pressure transmitters, voltage signals

and contact signals.

8 relay outputs.

Supply voltage

The supply voltage to the module comes from the previous module in the row.

AK-XM 205B only Override of relay

Eight change-over switches at the front make it possible to override the relay’s function. Either to position OFF or ON. In position Auto the controller carries out the control.

Light-emitting diodes

There are two rows with LED’s. They mean: Left row:

• Voltage supply to the controller

• Communication active with the bottom PC board (red = error)

• Status of outputs DO1 to DO8

Right row: (AK-XM 205B only):

• Override of relays ON = override OFF = no override

AK-XM 205A AK-XM 205B

max. 10 V

Fuses

Behind the upper part there is a fuse for each output.

Max. 230 V

AC-1: max. 4 A (ohmic) AC-15: max. 3 A (Inductive)

AK-XM 205B Override of relay

Keep the safety distance!

Low and high voltage must not be connected to the same output group

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Point

Pt 1000 ohm/0°C

Signal Signal

type

S2, S3 S4,

Pt 1000

S5 Saux

Point 1 2 3 4 5 6 7 8

Type AI1 AI2 AI3 AI4 AI5 AI6 AI7 AI8

Terminal 9: 12 V Terminal 10: 5 V

Terminal 21: 12 V Terminal 22: 5 V

Terminal 11, 12, 23, 24 :

(Cable screen)

Point 9 10 11 12 13 14 15 16

Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

AKS 32R AKS 2050

AKS 32

On/O

3: Brown

2: Blue

1: Black

3: Brown

2: Black

1: Red

P0 Pc Paux

...

Ext. Main switch Day/ Night Door Defrost

Fan Alarm Light Antisweat Defrost Night blind Valve Compr.

AKS 32R AKS 2050

-1 - xx bar

AKS 32

-1 - zz bar

0 - 5 V 0 - 10 V

Active at:

Closed

Open

Active at:

O

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 13 - 14

6 (AI 6) 15 - 16

7 (AI 7) 17 - 18

8 (AI 8) 19 -20

9 (DO 1) 25 - 26 - 27

10 (DO 2) 28 - 29 - 30

11 (DO 3) 31 - 30 - 33

12 (DO 4) 34 - 35 - 36

13 (DO 5) 37 - 36 - 39

14 (DO6) 40 - 41 - 42

15 (DO7) 43 - 44 - 45

16 (DO8) 46 - 47 - 48

Terminal

Signal type /

Active at

Extension module AK-OB 101A

Function

The module is a real time clock module with battery backup.

The module can be used in controllers that are not linked up in a data communication unit together with other controllers. The module is used here if the controller needs battery backup for the following functions

• Clock function

• Fixed times for day/night change-over

• Fixed defrost times

• Saving of alarm log in case of power failure

• Saving of temperature log in case of power failure

Connection

The module is provided with plug connection.

Placing

The module is placed on the PC board inside the top part.

Point

No point for a clock module to be dened – just connect it.

Working life of the battery

The working life of the battery is several years – even if there are frequent power failures. An alarm is generated when the battery has to be replaced. After the alarm there are still several months of operating hours left in the battery.

Display module EKA 163B / EKA 164B

Function

Display of important measurements from the controller, e.g. appliance temperature. Setting of the individual functions can be performed by using the display with control buttons. It is the controller used that determines the measurements and settings that can occur.

Connection

The extension module is connected to the controller module via a cable with plug connections. You have to use one cable per module. The cable is supplied in various lengths.

Both types of display (with or without control buttons) can be connected to either display output A, B, C and D. When the controller starts up, the display will show the output that is connected.

- - 1 = output A

- - 2 = output B etc.

EKA 163B EKA 164B

Placing

The extension module can be placed at a distance of up to 15 m from the controller module.

Point

No point has to be dened for a display module – you simply connect it.

Transformer module AK-PS 075 / 150

Function

24 V supply for controller.

Supply voltage

230 V a.c or 115 V a.c. (from 100 V a.c. to 240 V a.c.)

Placing

On DIN-rail

Eect

Type Output tension Output current Power

AK-PS 075 24 V d.c. 0.75 A 18 VA

AK-PS 150 24 V d.c.

(adjustable)

1.5 A 36 VA

Dimension

Type High Width

AK-PS 075 90 mm 36 mm

AK-PS 150 90 mm 54 mm

Supply to a controller

Connections

AK-PS 075

AK-PS 150

Case Power module

If the AK-CC 750 must be connected to an existing Case Power Module, it must be done as follows: Connect the Case Power module via the 8-pin Molex connector.

AK-CC 750 are using the following points:

Point 20 21 22 23

Type ASH Light Def Fan

Relay output:

• Anti Sweat Heater

• Light

• Defrost

• Fan

Preface to design

Be aware of the following when the number of extension modules is being planned. A signal may have to be changed, so that an additional module may be avoided.

• An ON/OFF signal can be received in two ways. Either as a contact signal on an analog input or as voltage on a low or highvoltage module.

• An ON/OFF output signal can be given in two ways. Either with a relay switch or with solid state. The primary dierence is the permitted load and that the relay switch contains a cutout switch.

Mentioned below is a number of functions and connections that may have to be considered when a regulation has to be planned. There are more functions in the controller than the ones mentioned here, but those mentioned have been included in order that the need for connections can be established.

Functions

Clock function

Clock function and change-over between summer time and winter time are contained in the controller. The clock is zeroset when there is power failure. The clock’s setting is maintained if the controller is linked up in a network with a gateway, a system manager or a clock module can be mounted in the controller.

Start/stop of regulation

Regulation can be started and stopped via the software. External start/stop can also be connected.

Alarm function

If the alarm is to be sent to a signal transmitter, a relay output will have to be used.

Extra temperature sensors and pressure sensors

If additional measurements have to be carried out beyond the regulation, sensors can be connected to the analog inputs.

Forced control

The software contains a forced control option. If an extension module with relay outputs is used, the module’s top part can be with change-over switches – switches that can override the individual relays into either OFF or ON position.

Data communication

The controller module has terminals for LON data communication. The requirements to the installation are described in a separate document. Literature number RC8AC.

Connections

In principle there are the following types of connections:

Analog inputs ”AI”

This signal must be connected to two terminals. Signals can be received from the following sources:

• Temperature signal from Pt 1000 ohm temperature sensor

• Contact signal where the input is shortcircuited or ”opened”, respectively

• Voltage signal from 0 to 10 V

• Signal from pressure transmitter AKS 32, AKS 32R or AKS 2050. The supply voltage is supplied from the module’s terminal board where there is both a 5 V supply and a 12 V supply. When programming the pressure transmitter’s pressure range must be set.

ON/OFF voltage inputs ”DI”

This signal must be connected to two terminals.

• The signal must have two levels, either 0 V or ”voltage” on the input. There are two dierent extension modules for this signal type:

- low-voltage signals, e.g. 24 V

- high-voltage signals, e.g. 115 V

ON/OFF output signals ”DO”

There are two types, as follows:

• Relay outputs All relay outputs are with change-over relay so that the required function can be obtained when the controller is without voltage.

• Solid state outputs Primarily for AKV valves which connect quickly. But output can cut an external relay in and out, as with a relay output. The output is only found on the controller module.

When programming the function must be set:

• Active when the output is activated

• Active when the output is not activated.

When programming the function must be set:

• Active when the input is without voltage

• Active when voltage is applied to the input.

Limitations

As the system is very exible regarding the number of connected units you must check whether your selection complies with the few limitations there are. The complexity of the controller is determined by the software, the size of the processor, and the size of the memory. It provides the controller with a certain number of connections from which data can be downloaded, and others where coupling with relays can be performed.

The controller is not made for use on plate heat exchanger.

✔ The sum of connections cannot exceed 80.

✔ The number of extension modules must be limited so that the

total power will not exceed 32 VA (including controller).

✔ No more than 5 pressure transmitters may be connected to one

controller module.

✔ No more than 5 pressure transmitters may be connected to one

extension module.

Design of a evaporator control

Procedure:

1. Make a sketch of the system in question

2. Check that the controller’s functions cover the required application

3. Consider the connections to be made

4. Use the planning table. / Note down the number of connections ./ add up

5. Are there enough connections on the controller module? – If not, can they be obtained by changing an ON/OFF input signal from voltage signal to contact signal, or will an extension module be required?

6. Decide which extension modules are to be used

7. Check that the limitations are observed

8. Calculate the total length of modules

9. The modules are linked together

10. The connection sites are established

11. Draw a connection diagram or a key diagram

12. Size of supply voltage/transformer

Follow these 12 steps

Sketch

Make a sketch of the system in question.

Evaporator and refrigerator appliance functions

Application

Control of cold room or freezing room x

Control of refrigeration or freezing appliances x

Regulation of evaporators 1 - 4

Thermostat function

Common thermostat function for all sections x

Thermostat function for each section x

On/o thermostat with AKV or solenoid valve x

Modulating thermostat with AKV valve x

Change between two thermostat references (thermostat band) x

Day/night switch x

Displacement of reference via analog input signal x

Thermostat sensor before or after evaporator x

Thermostat sensor both before and after the evaporator (weighted thermostat)

Alarm thermostat (weighted) x

Common functions

Fan control (pulsation) x

Rail heat control (pulsation) x

Compressor control. Relay active when refrigeration is demanded x

Appliance cleaning function x

Appliance shut down x

Door contact function x

Light function x

Night blind X

Forced closing x

Alarm output x

Start / stop of regulation x

Product sensor with alarm function 4

AK-CC

750

Liquid injection

Control of AKV valves 4

Control of solenoid valves 4

Superheat regulation wit P0 and S2 measurement x

MOP control x

Refrigerant choice x

Defrost function

Electrical defrost 4

Warm Brine defrost, Hot gas defrost x

Smelt function x

Drip tray heat X

Adaptive defrost x

Defrost stop on temperature or time x

Coordinated defrost via network x

Miscellaneous

Alarm priorities x

Sensor correction x

Option for connection of separate display 4

System signals via data communication

Signal for P0-optimasation x

Night setback x

Inject ON-signal (forced closing) x

Light control x

Coordinated defrost x

Forced cooling x

Day/night signal for raising the reference

The built-in week diagram can be used for raising the thermostat reference, but it is also possible to use an external ON/OFF signal or a signal via the network.

Product sensors

Each appliance section has a separate product sensor which can be used for monitoring/registering the temperature.

Appliance cleaning function

A switch function with pulse pressure will activate the function whereupon refrigeration will be stopped. The fans continue operating. ”Later”: Next push on the switch will stop the fans. ”Still later”: Next push on the switch will restart refrigeration. When a display is mounted at the appliance the various situations may be followed by the readout: Normal operation: Appliance temperature 1st push: Fan 2nd push: OFF 3rd push: Appliance temperature

Appliance shut down

Signal about shutdown can be received via data communication or from a contact on a On/O input.

Door switch function

In freezing and coldrooms the door switch is used for switching the light on and o, for starting and stopping the refrigeration, and for sounding the alarm if the door has been open for a long time

Light function

The light function can be activated by the door switch, the internal time diagram or a signal via the network.

A bit more about the functions

Common thermostat

The thermostat temperature can be either a weighting of the S3 and S4 sensors in section A. Alternatively, the thermostat temperature can be a minimum value, a maximum value or an average value of all S3 or S4 sensors for the refrigeration sections used.

Modulating thermostat

AKV:

The function can only be used on central plant.

The opening degree of the valve is adjusted so that an accurate, constant temperature is maintained. .

Solenoid valve:

This function can be used on both central systems and on indirect refrigeration appliances. The valve's duty cycle is adapted so that optimum temperature regulation is achieved on the basis of a specic time period. The valve's duty cycle is desynchronised so that an even load is achieved across the entire system

Changeover between two thermostat references

The function is used for appliances where contents are frequently changed and where a dierent thermostat reference is required. Changeover between the two references can take place by means of a switch function.

Defrost sensor S5

On long evaporators it may be necessary to mount two sensors in order to ensure the correct defrost of the evaporator. The sensors are for example named S5A-1 and S5A-2.

“Inject ON” override function

The function closes expansion valves on the evaporator control when all compressors are stopped. The function can take place via the data communication, or it may be wired via a relay output.

Adaptive defrost

The function requires signals from S3 and S4 as well as from condensing pressure Pc. The expansion valve must furthermore be type AKV. The function cannot be used in combination with pulsation of fans.

If you want to know more about the functions, go to chapter 5.

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