Danfoss AK-CC 460 User guide

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User Guide

Controller for SemiPlugin appliance

AK-CC 460

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Contents

Introduction .........................................................................................................2

Applications .........................................................................................................3

Survey of functions ......................................................................................... 10

Operation ........................................................................................................... 21

Introduction

Application

Complete refrigeration appliance control for SemiPlugin refrigeration appliances.

- Where condensation heat is removed using brine

- Flammable refrigerants supported

- The total amount of refrigerant can be distributed across more circuits

- Variable speed compressor control

Advantages

• Energy optimisation of the whole refrigeration appliance

• One controller for several diﬀerent refrigeration appliances

• Integrated display at the front of the controller

• Built-in data communication

• Built-in clock function with power reserve

Menu survey ...................................................................................................... 22

Connections ...................................................................................................... 26

Data ...................................................................................................................... 28

Ordering ............................................................................................................. 29

Principle

The temperature in the appliance is registered by one or two temperature sensors which are located in the air ﬂow before the evaporator (S3) or after the evaporator (S4) respectively. A setting for thermostat, alarm thermostat and display reading determines the inﬂuence the two sensor values should have for each individual function. In addition product sensor S6, which can be optionally placed in the appliance, can be used to register the temperature near the required product in a certain place within the appliance. The temperature of the evaporator is registered with the S5 sensor which can be used as a defrosting sensor. In addition to the output for the compressors, the controller has 5 relay outputs for dedicated applications.

Functions

• Day/night thermostat

• Product sensor S6 with separate alarm limits

• Switch between thermostat settings via digital input

• Start of defrost via schedule, digital input or network

• Natural or electric defrost

• Stop of defrost on time and/or temperature

• Coordination of defrost across several controls

• Pulsing of fans when thermostat is satisﬁed

• Case cleaning function for documentation of HACCP procedure

• Rail heat control via day/night load or dew point

• Door function

• Control of two compressors or one variable speed compressor

• Control of night blinds and light

• Factory calibration that will guarantee a better measuring

accuracy than stated in the standard EN ISO 23953-2 without subsequent calibration (Pt 1000 ohm sensor)

• Integrated MODBUS communication with the option of

mounting a LonWorks or DANBUSS

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Applications

The controller supports the following 3 control modes:

- Sequential On/Oﬀ control of 2 compressors.

Output 1 will form the base load, and output 2 will connect a

lower capacity so that the variation of the cabinet temperature is kept to a minimum.

The compressors are coupled sequentially. Compressor 1 is ﬁrst

in and last out.

- Cyclic On/Oﬀ control of 2 compressors.

Here the compressors must be of equal size, and they are

coupled cyclic.

The runtimes are equalized.

- Variable speed control of one compressor

Here one compressor output is used together with the analogue

0 – 10 V signal.

Enables a very precise control of the cabinet temperature.

Control with two compressors

When the controller calls for refrigeration, compressor 1 will be cutin to the circuit ﬁrst. After the delay time, compressor 2 will be coupled to the circuit. When the temperature has reached the middle of the diﬀerential, compressor 2 will be cut out. Compressor 1 will continue until the temperature has reached the cut-out value. Then it will cut out. When the temperature again reaches the middle of the diﬀerential, compressor 1 will be cutin to the circuit again. If compressor 1 cannot maintain the temperature within the differential, compressor 2 will also be cutin to the circuit. The compressor's settings for ”Min On time” and ”Min Oﬀ time” will always have top priority during normal regulation. But if one of the override functions is activated, the ”Min On time” will be disregarded.

With cyclic control the compressor with the lowest runtime will be started ﬁrst. If one of the compressors has been running continuously for two hours, the compressors will be alternated to assure runtime equalization.

Variable speed control

Here the compressor will be started when the controller requests cooling. The analogue output will then be used to control the speed so that the temperature is kept very accurate at the reference. The actual reference is the set cut-out temperature plus half the set diﬀerence.

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Temperature control

Temperature monitoring

Just as it is possible for the thermostat, the alarm monitoring can be set with a weighting between S3 and S4 so that you can decide how much the two sensor values should inﬂuence the alarm monitoring. Minimum and maximum limits can be set for alarm temperature and time delays. A longer time delay can be set for high temperature alarms after defrosting, appliance cleaning or start-up.

Thermostat bands

Thermostat bands can be used beneﬁcially for appliances where diﬀerent product types are stored which require diﬀerent temperature conditions. It is possible to change between the two diﬀerent thermostat bands via a contact signal on a digital input. Separate thermostat and alarm limits can be set for each thermostat band – also for the product sensor.

Night setback of thermostat value

In refrigeration appliances there may be big load diﬀerences between the shop’s opening and closing hours, especially if night lids/blinds are used. The thermostat reference may be raised here without it having any eﬀect on the product temperature. Change-over between day and night operation can take place, as follows:

• via an external switch signal.

• via a signal from the data communication system.

Product sensor

A separate optional product sensor S6, which may be placed in the appliance, can also be used and which can register and monitor the temperature in the warmest part of the appliance. There are separate alarm limits and time delays for the product sensor.

S7 brine sensor

The temperature at the brine inlet is monitored by the S7 temperature sensor. If the temperature gets higher than the set value, the controller will reduce the cooling capacity, so that the load on the heat exchanger is reduced. For two-compressor operation, compressor 2 will be taken out of operation.

With variable speed control the compressor speed will be reduced to the value deﬁned by parameter "c93".

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Appliance cleaning

This function makes it easy for the shop’s staﬀ to carry out a cleaning of the appliance according to a standard procedure. Appliance cleaning is activated via a signal – as a rule via a key switch placed on the appliance. Appliance cleaning is carried out via three phases: 1 - at the ﬁrst activation the refrigeration is stopped, but the fans

keep on operating in order to defrost the evaporators. ”Fan” is shown on the display.

2 - at the second activation the fans are also stopped and the

appliance can now be cleaned. ”OFF” is shown on the display.

3 - At the third activation refrigeration is recommenced. The

display will show the actual appliance temperature (o97 setting).

Documentation When appliance cleaning is activated a cleaning alarm is transmitted to the normal alarm recipient. A later processing of these alarms will document that the appliance has been cleaned as often as planned.

Alarm monitoring

There are no temperature alarms during appliance cleaning.

- + + °C

1 ÷ + Fan

2 ÷ ÷ Oﬀ

3 + + °C

Defrost

Depending on the application you may choose between the following defrost methods: Natural: Here the fans are kept operating during the defrost Electric: The heating element is activated

Defrost sequence

1) Defrost

2) Waiting position after defrost

3) Drip oﬀ

4) Delay of fan

Start of defrost

A defrost can be started in diﬀerent ways Interval: Defrost is started at ﬁxed time intervals, say, every

eighth hour. An interval must ALWAYS be set to a "higher" value than the period set between two defrostings when a schedule or network signal is used.

Refrigeration time: Defrost is started at ﬁxed refrigeration time

intervals, in other words, a low need for refrigeration will ”postpone” the defrost

Schedule: Here defrost can be started at ﬁxed times of the

day and night. However, max. 6 times Contact: Defrost is started with a contact signal on a digital input Network: The signal for defrost is received from a system unit via the data communication Manual: An extra defrost can be activated from the controller’s

lower-most button All the mentioned methods can be used at random – if any of them is activated a defrost will be started.

Stop of defrost

Defrosting can be stopped by either:

• Time

• Temperature (with time as safety).

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Coordinated defrost

There are two ways in which coordinated defrost can be arranged. Either with wire connections between the controllers or via data communication

Wire connections The digital input DI2 is connected between the current controllers. When one controller starts a defrost all the other controllers will follow suit and likewise start a defrost. After the defrost the individual controllers will move into waiting position. When all are in waiting position there will be a change-over to refrigeration.

Coordination via data communication Here the system unit handles the coordination. The controllers are gathered in defrosting groups and the system unit ensures that defrosting is started in the group according to a weekly schedule. When a controller has completed defrosting, it sends a message to the system unit and then goes into a waiting position. When every controller in the group is in a waiting position, refrigeration is again permitted in all the individual controllers.

Defrost on demand

Based on refrigeration time When the aggregate refrigeration time has passed a ﬁxed time, a defrost will be started.

Max. 10

System manager

Melting function

This function will stop the air ﬂow in the evaporator from being reduced by frost created by uninterrupted operation for a long time. The function is activated if the thermostat temperature has remained in the range between -5°C and +10°C for a longer period than the set melting interval. The refrigeration will then be stopped for the set melting period. The frost will be melted so that the air ﬂow and hence the evaporator’s capacity will be greatly improved.

Real-time clock

The controller has a built-in real-time clock which can be used to start defrosts. This clock has a power reserve of four hours. If the controller is equipped with data communication, the clock will automatically be updated from the system unit.

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0 – 10

c46

c47

c48

80G437

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Railheat

It is possible to pulse-control the power to the rail heat in order to save energy. Pulse control can either be controlled according to day/night load or dew point.

Pulse control according to day and night

Various ON periods can be set for day and night operation. A period time is set as well as the percentage part of the period in which the rail heat is ON.

Pulse control according to dew point

In order to use this function a system manager of the type AK-SM is required which can measure dew point and distribute the current dew point to the appliance controllers. For this the rail heat’s ON period is controlled from the current dew point. Two dew point values are set in the appliance control:

• One where the eﬀect must be max. i.e.100%. (o87)

• One where the eﬀect must be min. (o86). At a dew point which is equal to or lower than the value in 086, the eﬀect will be the value indicated in o88. In the area between the two dew point values the controller will manage the power to be supplied to the rail heat.

During defrosting

During defrosting the rail heat will be controlled by the setting in "d27" (Oﬀ, On or pulsing).

Fan

Pulse control

To obtain energy savings it is possible to pulse control the power supply to the evaporator fans. Pulse control can be accomplished in one of the following ways:

- during the thermostat’s cutout period (cold room)

- during night operation and during the thermostat’s cutout pe-

riod (appliance with night lid /blind)

Rail heat

Dew point

A period of time is set as well as the percentage of this period of time where the fans have to be operating.

Cutout of fans during plant breakdowns

If the refrigeration in a breakdown situation stops, the temperature in the refrigeration appliance may rise as a result of the power supply from fans. In order to prevent this situation the controller can stop the fans if the temperature at S5 exceeds a set limit value.

Variable speed compressor control

The variable speed compressor control is using these 3 settings:

- Start speed - c47. After starting the compressor, this speed will

be maintained for 10 seconds. Hereafter the speed can vary between min. and max speed

- Max. speed – c48. The max allowed speed for the compressor

- Min. speed – c46. At low requested capacity, the set minimum

speed will be maintained until the compressor is cut out.

Note: the voltage on the analogue output is scaled for the maximum frequency range from min. speed to 100 Hz, meaning that if the max. speed is set lower than 100 Hz, the max. output voltage will be below 10 V.

10 V

V Max.

V Start

V Min.

Active voltage range

Fmin

Fstart

Fmax

Danfoss

100 Hz

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Light function

The function can be used for controlling the light in a refrigeration appliance or in a coldroom. It can also be used for controlling a motorised night blind.

The light function can be deﬁned in three ways:

- the light is controlled via a signal from a door contact. Together

with this function a time delay can be set so that the light is kept on for 2 minutes after the door has been closed.

- the light is controlled via the day/night function

- the light is controlled via the data communication from a system

unit. Here there are two operational options if data communication should fail:

- The light can go ON

- The light can stay in its current mode.

The light load must be connected to the NC switch on the relay. This ensures that the light remains on in the appliance if power to the controller should fail. The light is switched oﬀ when "r12" (Main switch) is set to oﬀ (see o98).

Night blind

Motorised night blind can be controlled automatically from the controller. The night blinds will follow the status of the light function. When the light is switched on, the night blinds opens and when the light is switched oﬀ, the night blinds close again. When the night blinds are closed, it is possible to open them and switch on the light using a switch signal on the digital input. If this input is activated, the night blinds will open and the refrigeration appliance can be ﬁlled with new products. If the input is activated again, the blinds close again. A night blind is open and light is switch on when the appliance cleaning function is activated. A setting can deﬁne that the night blind is open when "r12" (Main switch) is set to oﬀ (see o98). When the night blind rolls down, the fans can be stopped so that the air circulation does not interrupt the positioning of the blind. The desired stop time must be set in P65. The motor for the night blinds must be connected to the same relay as the light function.

Digital inputs

There are two digital inputs DI1 and DI2 with contact function and one digital input DI3 with high voltage signal. DI1 and DI2 input can be used for the following functions:

- Retransmission of contacts position via data communication

- Door contact function with alarm

- Starting a defrost

- Main switch - start/stop of cooling

- Night setback

- Thermostat bands switch

- General alarm monitoring

- Case cleaning

- Override of night blinds

- Case shut down

- Coordinated defrost (DI2 only)

DI3 is predeﬁned as input from the safety circuit for the compressors. When the voltage on the input is interrupted, the compressors will stop, and the alarm "A97 - Comp.Safety" will be activated.

Door contact

The door contact function can via the digital inputs be deﬁned for two diﬀerent applications:

Alarm monitoring

The controller monitors the door contact and delivers an alarm message if the door has been opened for a longer period than the set alarm delay.

Alarm monitoring and stop of refrigeration

When the door is opened the refrigeration is stopped and the fan are stopped and light switch on. If the door remains open for a longer time than the set restart time, refrigeration will be resumed. This will ensure that refrigeration is maintained even if the door is left open or if the door contact should be defective. If the door remains open for a longer period than the set alarm delay an alarm will also be triggered.

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Data communication

The controller has ﬁxed built-in MODBUS data communication.

If there is a requirement for a diﬀerent form of data communication, a Lon RS 485 or DANBUSS module can be inserted in the controller. The connection must then be to terminal RS 485.

(To use a Lon RS 485 module and gateway type AKA 245 the Gateway software must be Version 6.20 or higher.)

Display

The controller has one plug for a display. Here display type EKA 163B or EKA 164B (max. length 15 m) can be connected. EKA 163B is a display for readings. EKA 164B is both for readings and operation. The connection between display and controller is with a cable which has a plug at both ends.

If the distance between display and controller is greater than 15 m, the connection must take another form.

! Address o03 > 0

An extra module must also be mounted in the controller if data communication is used. The built-in MODBUS data communication is used so that the display connection and the data communication to the other controllers must take place via a module. The module can be: Lon RS 485, DANBUSS or MODBUS. When a display is to be connected to the built-in MODBUS, the display can advantageously be changed to a type with screw terminals. I.e. the type EKA 163A or EKA 164A. If connection of two displays is required, one must be connected to the plug (max. 15 m) and the other must then be connected to the ﬁxed data communication. The controllers address must be set higher than 0 in order for the display to be able to communicate with the controller.

Important

All connections to the data communication MODBUS, DANBUSS and RS 485 must comply with the requirements for data communication cables. See literature: RC8AC.

AK-CC 450/550 AK-CC 460

Override

The controller contains a number of functions which can be used together with the override function in the master gateway/system manager.

Function via data communication Function in gateway/system manager Used parameters in AK-CC 460

Start of defrosting Defrost control / Time schedule / Defrost group --- Def start

Coordinated defrost Defrost control / Defrost group --- HoldAfterDef / - - - DefrostState

Prevent defrost start --- Disable Def

Day/Night schedule Day/Night control / Time schedule / Light zone --- Night setback

Light control Day/Night control / Time schedule o39 light Remote

Railheat link to dew point / Enhanced railheat --- Dew point

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Survey of functions

Function Para-

meter

Normal display

Normally the temperature value from one of the two thermostat sensors S3 or S4 or a mixture of the two measurements is displayed. In o17 the ratio is determined. If the S6 temperature is to be shown, this must be deﬁned in setting o97.

Thermostat Thermostat control Set point

Regulation is based on the set value plus a displacement, if applicable. The value is set via a push on the centre button. The set value can be locked or limited to a range with the settings in r02 and r 03. The reference at any time can be seen in "u91 Cutout temp".

Diﬀerential

When the temperature is higher than the reference + the set diﬀerential, the compressor relay will be cut in. It will cut out again when the temperature comes down to the set reference.

Ref. Dif.

Setpoint limitation

The controller’s setting range for the setpoint may be narrowed down, so that much too high or much too low values are not set accidentally - with resulting damages.

To avoid a too high setting of the setpoint, the max. allowable reference value may be lowered.

To avoid a too low setting of the setpoint, the min. allowable reference value may be increased.

Correction of the display’s temperature

If the temperature at the products and the temperature received by the controller are not identical, an oﬀset adjustment of the display temperature can be carried out.

Temperature unit

Set here if the controller is to show temperature values in °C or in °F.

Parameter by operation via data communication

Display air (u56)

Cutout °C

r01 Diﬀerential

r02 Max cutout °C

r03 Min cutout °C

r04 Disp. Adj. K

r05 Temp. unit

°C=0. / °F=1 (Only °C on AKM, whatever the setting)

Correction of signal from S4

Compensation possibility due to long sensor cable

Correction of signal from S3

Compensation possibility due to long sensor cable

Start / stop of refrigeration

With this setting refrigeration can be started, stopped or a manual override of the outputs can be allowed. (For manual control the value is set at -1. Then the valve outlet and the relay outlets can be force-controlled by the respective reading parameters (u58, etc.). Here the read value can be overwritten.) Start / stop of refrigeration can also be accomplished with the external switch function connected to a DI input. Stopped refrigeration will give a ”Standby alarm”.

Night setback value

The thermostat’s reference will be the setpoint plus this value when the controller changes over to night operation. (Select a negative value if there is to be cold accumulation.)

Thermostat function

Here it is shown how the thermostat is operating. 1 = ON/OFF thermostat. The application mode (o61) is set to 1 or 3. The diﬀerence is deﬁned by parameter r01 2 = Modulating thermostat. The application mode (o61) is set to 2, and the temperature reference is cut-out plus half the diﬀerence set in r01. Note that when a modulating thermostat is used, it is not recommended to set the diﬀerence lower than 2 K.

Selection of thermostat sensor S4% during day operation

Here you deﬁne the sensor the thermostat is to use for its control function. S3, S4, or a combination of them. With the setting 0%, only S3 is used (Sin). With 100%, only S4.

Melt function

Only for control of refrigeration (-5 to +10°C). The function ensures that the evaporator will not be blocked by frost. Here you set how often the function is to stop the refrigeration and hence transform the frost to water (or ice if there is too much frost).

r09 Adjust S4

r10 Adjust S3

r12 Main Switch

1: Start 0: Stop

-1: Manual control of outputs allowed

r13 Night oﬀset

r14 Therm. mode

r15 Ther. S4 %

r16 MeltInterval

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Melt period

Here you set how long an on-going melt function is to last. Set point 2

The thermostat’s cutout value when the thermostat band 2 is activated via a digital input.

Correction of signal from S6

Compensation possibility due to long sensor cable

Selection of thermostat sensor S4% during night operation

Here you deﬁne the sensor the thermostat is to use for its control function. S3, S4, or a combination of them. With the setting 0%, only S3 is used (Sin). With 100%, only S4.

The temperature limit for the S4 temperature

If a lower temperature is registered, refrigeration will be stopped. Refrigeration is resumed when the S4 temperature is measured at 2 K above the cut-out value. The function is not used if the setting is set to -50 °C, or if it is set to a value that is higher than the thermostat’s cut-out value.

Alarm Alarm settings

The controller can give an alarm in diﬀerent situations. When there is an alarm all the lightemitting diodes (LED) will ﬂash on the controller front panel, and the alarm relay will cut in.

Alarm delay (short alarm delay on air temperature) If the upper or the lower alarm limit values are exceeded, a timer function will commence. The alarm will not become active until the set time delay has been passed. The time delay is set in minutes.

Time delay for door alarm

The time delay is set in minutes. The door function is deﬁned in o02 or o37.

Time delay for cooling (long alarm delay) This time delay is used during start-up, during defrost, immediately after a defrost. There will be change-over to the normal time delay (A03) when the temperature has dropped below the set upper alarm limit. The time delay is set in minutes.

Upper alarm limit

Here you set when the alarm for high temperature is to start. The limit value is set in °C (absolute value). The limit value will be raised during night operation. The value is the same as the one set for night setback, but will only be raised if the value is positive.

Lower alarm limit

Here you set when the alarm for low temperature is to start. The limit value is set in °C (absolute value).

Upper alarm limit for thermostat 2 (Thermostat band 2)

(Same function as for thermostat 1)

Lower alarm limit for thermostat 2 (Thermostat band 2)

(Same function as for thermostat 1)

Upper alarm limit for S6 temperature at thermostat 1 A22 HighLim1 S6 Lower alarm limit for S6 temperature at thermostat 1 A23 LowLim1 S6 Upper alarm limit for S6 temperature at thermostat 2 (Thermostat band 2) A24 HighLim2 S6 Lower alarm limit for S6 temperature at thermostat 2 (Thermostat band 2) A25 LowLim2 S6 S6 temperature alarm delay

The alarm is activated if one of the relevant alarm limits A22, A23, A24 or A25 is exceeded. The time delay is set in minutes. Alarms will not activate when the setting is set to the maximum value.

Delay of a DI1 alarm

A cut-out/cut-in input will result in alarm when the time delay has been passed. The function is deﬁned in o02.

Delay of a DI2 alarm A cut-out/cut-in input will result in alarm when the time delay has been passed. The function is deﬁned in o37

Signal to the alarm thermostat Here you have to deﬁne the ratio between the sensors which the alarm thermostat has to use. S3, S4 or a combination of the two. With setting 0% only S3 is used. With 100% only S4 is used

r17 Melt period

r21 Cutout2 temp

r59 Adjust S6

r61 Ther.S4% Ngt

r98 S4MinLimit

Night setbck (start of nightsignal. 0=Day, 1=Night)

CaseShutDown (Case shut down without alarm)

With data communication the importance of the individual alarms can be deﬁned. Setting is carried out in the “Alarm destinations” menu. (Gateway + AKM)

A03 Alarm delay

A04 DoorOpen del

A12 Pulldown del

A13 HighLim Air

A14 LowLim Air

A20 HighLim2 Air

A21 LowLim2 Air

A26 Al. Delay S6

A27 AI.Delay DI1

A28 AI.Delay DI2

A36 Alarm S4%

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Time delay on S6 (product sensor) for pull-down (long alarm delay) This time delay is used for start-up, during defrosting, immediately after a defrost and after an appliance clean. A change is carried out to standard time delay (A26) when the temperature has reached below the set upper alarm limit. The time delay is set in minutes.

Hot brine alarm

If the S7 brine temperature gets higher than the set value, an alarm will be delivered. If two compressors are in use, compressor 2 will be stopped for as long as the temperature is too high.

Brine alarm diﬀerential

The alarm is cleared, and operation of compressor 2 allowed again when the S7 temperature is lower than "A76" minus the diﬀerential.

Compressor Compressor control

The compressor relay works in conjunction with the thermostat. When the thermostat calls for refrigeration the compressor relay (relays) will be operated. In Application mode 2 it is only the "Compressor 2" relay that is used as start signal. The capacity is controlled via the 0 - 10 V output.

Running times

To prevent irregular operation, values can be set for the time the compressor is to run once it has been started. And for how long it at least has to be stopped. The running times are not observed when defrosts start.

Min. ON-time (in minutes) c01 Min. On time Min. OFF-time (in minutes) c02 Min. Oﬀ time

Time delay for couplings of two compressors

Settings indicate the time that has to elapse from the ﬁrst relay cuts in and until the next relay has to cut in.

VSD min Speed

Minimum allowed compressor speed

VSD start speed

The requested start speed for the compressor (must be set to a higher value than “VSD min speed”). After start this speed is maintained for 10 seconds before variation is possible

VSD max speed

The maximum allowed compressor speed

Kp factor

For the PI control of the variable speed compressor

Tn factor

For the PI control of the variable speed compressor Compressor on-time at sensor error

Output "Compressor 1" only. ("Compressor 2" is oﬀ.) Compressor oﬀ-time at sensor error

Output "Compressor 1"

VSD speed at sensor error

The ﬁxed speed at which the compressor will run during error on the control sensor

Slope rate

Limitation on how fast the compressor speed can change is set in Hz / second

Kp max factor

Max value for Kp at great deviation from the temperature setpoint for the PI control of the variable speed compressor

The LED on the controller’s front will show whether refrigeration is in progress Comp Relay / Comp2 Relay

A52 PullD del.S6

A76 MaxS7BrineT.

A77 S7Brine Diﬀ

Reset alarm Ctrl. Error (EKC error)

c05 Step delay

c46 CompMinSpeed

c47 CompStrSpeed

c48 CompMaxSpeed

c82 Comp Kp

c83 Comp Tn sec

c86 CmpOn T Err

c87 CmpOﬀ Err

c93 CmpEmrgSpeed

c96 MaxSlopeRate

n95 Cmp Kp Max

Here you can read the status of the compressor relay.

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Defrost Defrost control

The controller contains a timer function that is zeroset after each defrost start. The timer function will start a defrost if/when the interval time is passed. The timer function starts when voltage is connected to the controller, but it is displaced the ﬁrst time by the setting in d05. If there is power failure the timer value will be saved and continue from here when the power returns. This timer function can be used as a simple way of starting defrosts, but it will always act as safety defrost if one of the subsequent defrost starts is not received. The controller also contains a real-time clock. By means of settings of this clock and times for the required defrost times, defrost can be started at ﬁxed times of the day. Defrost start can also be accomplished via data communication, via contact signals or manual start-up. All starting methods will function in the controller. The diﬀerent functions have to be set, so that multiple defrosts are avoided.. Defrost can be accomplished with electricity. The actual defrost will be stopped based on time or temperature with a signal from a temperature sensor.

Defrost method

Here you set whether defrost is to be accomplished with electricity or (none). During defrost the defrost relay will be cut in.

d01 Def. method

0 = none 1 = El

Defrost stop temperature

The defrost is stopped at a given temperature which is measured with a sensor (the sensor is deﬁned in d10). The temperature value is set.

Interval between defrost starts

The function is zeroset and will start the timer function at each defrost start. When the time has expired the function will start a defrost. The function is used as a simple defrost start, or it may be used as a safeguard if the normal signal fails to appear. If master/slave defrost without clock function or without data communication is used, the interval time will be used as max. time between defrosts. If a defrost start via data communication does not take place, the interval time will be used as max. time between defrosts. When there is defrost with clock function or data communication, the interval time must be set for a somewhat longer period of time than the planned one, as the interval time will otherwise start a defrost which a little later will be followed by the planned one. In connection with power failure the interval time will be maintained, and when the power returns the interval time will continue from the maintained value. The interval time is not active when set to 0.

Max. defrost duration

This setting is a safety time so that the defrost will be stopped if there has not already been a stop based on temperature or via coordinated defrost.

Time staggering for defrost cutins during start-up

The function is only relevant if you have several refrigeration appliances or groups where you want the defrost to be staggered in relation to one another. The function is furthermore only relevant if you have chosen defrost with interval start (d03). The function delays the interval time d03 by the set number of minutes, but it only does it once, and this at the very ﬁrst defrost taking place when voltage is connected to the controller. The function will be active after each and every power failure.

Drip-oﬀ time

Here you set the time that is to elapse from a defrost and until the compressor is to start again. (The time when water drips oﬀ the evaporator).

d02 Def. Stop Temp

d03 Def Interval

(0=oﬀ)

d04 Max Def. time

d05 Time Stagg.

d06 DripOﬀ time

Delay of fan start after defrost

Here you set the time that is to elapse from compressor start after a defrost and until the fan may start again. (The time when water is “tied” to the evaporator).

Fan start temperature

The fan may also be started a little earlier than mentioned under “Delay of fan start after defrost”, if the defrost sensor S5 registers a lower value than the one set here.

Fan cut in during defrost

Here you can set whether fan is to operate during defrost. 0: Stopped 1 and 2: Running (stopped during "fan delay")

d07 FanStartDel

d08 FanStartTemp

d09 FanDuringDef

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Defrost sensor Here you deﬁne the defrost sensor. 0: None, defrost is based on time 1: S5 2: S4 3: S5 + S6

Pumpdown delay

Set the time where the evaporator is emptied of refrigerant prior to the defrost.

Defrost on demand – aggregate refrigeration time

Set here is the refrigeration time allowed without defrosts. If the time is passed, a defrost will be started. With setting = 0 the function is cut out.

Deﬁne rail heat during defrost: 0: Oﬀ 1: On 2: Pulsing

Max. duration of -d- on the display

Controls the display of "-d-" after defrosting so that "-d-" is displayed until the temperature is okay, the delay in question has expired, or a temperature alarm has been delivered.

If you wish to see the temperature at the defrost sensor, push the controller’s lowermost button. (May be changed to another function in o92.)

If you wish to start an extra defrost, push the controller’s lowermost button for four seconds. You can stop an ongoing defrost in the same way

Fan Fan control Fan stop temperature

The function stops the fans in an error situation, so that they will not provide heat to the appliance. If the defrost sensor registers a higher temperature than the one set here, the fans will be stopped. There will be re-start at 2 K below the setting. The function is not active during a defrost or start-up after a defrost. With setting +50°C the function is interrupted.

Pulse operation of fan

0: No pulse operation 1: Pulse operation when the thermostat does not call for refrigeration 2: Pulse operation when the thermostat does not call for refrigeration, but only during night operation

Pulse operation period for fan

Here the overall pulse time is set. The sum of ON-to and OFF time.

ON time for fan

Here the % part of the period the fans are to be in operation is set. The LED on the controller’s front will indicate whether a defrost is going on. Fan Relay

Internal defrosting schedule/clock function

(Not used if an external defrosting schedule is used via data communication.) Up to six individual times can be set for the defrost start throughout the day.

d10 DefStopSens.

d16 Pump dwn del.

d18 MaxTherRunT

d27 Railh. at def.

d40 Disp. d del.

Defrost temp.

Def Start Here you can start a manual defrost

Hold After Def Shows ON when the controller is operating with coordinated defrost via data communication.

Disable def. Defrost in progress can be stopped

Defrost State Status on defrost 1= shows ongoing defrost

F04 FanStopTemp.

F05 FanPulseMode

F06 Fan cycle

F07 Fan ON %

Here you can read the fan relay status, or force-control the relay in “Manual control” mode.

Defrost start, hour setting t01-t06

Defrost start, minute setting (1 and 11 belong together, etc.) When all t01 to t16 equal 0 the clock will not start defrosts.

Real-time clock:: Setting the clock is only necessary when there is no data communication. In the event of a power failure of less than four hours, the clock function will be saved.

t11-t16

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Clock: Hour setting t07

Clock: Minute setting t08

Clock: Date setting t45

Clock: Month setting t46

Clock: Year setting t47

Miscellaneous Miscellaneous Delay of output signal at start-up

When start-up after a power failure the controller’s functions can be delayed so that overloading of the electricity supply network is avoided. Here you can set the time delay.

Digital input signal - DI1

The controller has a digital input 1 which can be used for one of the following functions: Oﬀ: The input is not used

1) Status display of a contact function

2) Door function. When the input is open it signals that the door is open. The refrigeration and the fans are stopped and light switched on. When the time setting in “A04” is passed, an alarm will be given. The refrigeration will be resumed when time in o89 has passed.

3) Door alarm. When the input is open it signals that the door is open and light on. When the time setting in “A04” is passed, there will be alarm.

4) Defrost. The function is started with a pulse signal. The controller will register when the DI input is activated. The controller will then start a defrost cycle.

5) Main switch. Regulation is carried out when the input is closed, and regulation is stopped when the input is put in pos. OFF.

6) Night operation. When the input is closed, there will be regulation for night operation.

7) Thermostat band changeover. Switch to thermostat 2 (r21) when input is closed.

8) Separate alarm function. Alarm will be given when the input is closed.

9) Separate alarm function. Alarm will be given when the input is opened.

10) Case cleaning. The function is started with a pulse signal. See also description on page

11) Not used

12) Night blinds. Pulse signal activates the night blinds.

13,14) Not used

15) Case Shutdown when input is closed.

If the controller is built into a network with data communication, it must have an address, and the master gateway of the data communication must then know this address.

o01 DelayOfOutp.

o02 DI 1 Conﬁg.

Deﬁnition takes place with the numerical value shown to the left.

(0 = oﬀ)

DI state (Measurement) The DI input’s present status is shown here. ON or OFF.

Address

The address is set between 0 and 240, depending on the system unit and the selected data communication. If the system unit is gateway type AKA 245, the version must be 6.20 or higher.

Service pin (LON only)

The address is sent to the gateway when the menu is set in pos. ON IMPORTANT: Before you set o04, you MUST set o61. Otherwise you will be transmitting incorrect data. (The function is not used when the data communication is MODBUS or DANBUSS)

Access code 1 (Access to all settings)

If the settings in the controller are to be protected with an access code you can set a numerical value between 0 and 100. If not, you can cancel the function with setting 0. (99 will always give you access).

Local readout of Software version o08 SW version

Network frequency

Set the mains supply frequency (50 / 60 Hz). The value is used for variable speed compressor control.

Max. standby time after coordinated defrost When a controller has completed a defrost it will wait for a signal which tells that the refrigeration may be resumed. If this signal fails to appear for one reason or another, the controller will itself start the refrigeration when this standby time has elapsed.

Select signal for the display S4%

Here you deﬁne the signal to be shown by the display. S3, S4, or a combination of the two. With setting 0% only S3 is used. With 100% only S4.

o03

o04

o05 Acc. code

o12 Net Freq

o16 Max HoldTime

o17 Disp. S4%

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Digital input signal - D2

The controller has a digital input 2 which can be used for one of the following functions: Oﬀ: The input is not used.

1) Status display of a contact function

2) Door function. When the input is open it signals that the door is open. The refrigeration and the fans are stopped. When the time setting in “A04” is passed, an alarm will be given. The refrigeration will be resumed when time in o89 has passed.

3) Door alarm. When the input is open it signals that the door is open. When the time setting in “A04” is passed an alarm will be given.

4) Defrost. The function is started with a pulse signal. The controller will register when the DI input is activated. The controller will then start a defrost cycle. If the signal is to be received by several controllers (coordnated defrost) it is important that ALL connections are mounted the same way (DI to DI and GND to GND).

5) Main switch. Regulation is carried out when the input is closed, and regulation is stopped when the input is put in pos. OFF.

6) Night operation. When the input is closed there will be regulation for night operation.

7) Thermostat band changeover. Switch to thermostat 2 (r21) when the input is closed

8) Separate alarm function. Alarm will be given when the input is closed.

9) Separate alarm function. Alarm will be given when the input is opened.

10) Case cleaning. The function is started with a pulse signal.

See also description on page 5.

11) Not used

12) Night blinds. Pulse signal activates the night blinds.

13) The input is used for coordinated defrost in conjunction with other controllers of the same type

14) Not used

15) Case Shutdown when input is closed.

Conﬁguration of light function

1) Light is controlled via day/night status

2) Light is controlled via data communication and "Light remote o39"

3) Light is controlled by door contact, deﬁned in either o02 or o37 where the setting is

selected to either 2 or 3. When the door is opened the relay will cut in. When the door is closed again there will be a time delay of two minutes before the light is switched oﬀ.

4) As "2" but if there are any 15-minute network errors, the light will switch on and the

night blind will open.

Activation of light relay

The light relay can be activated here, but only if deﬁned in o38 with setting 2.

Rail heat during day operation

The ON period is set as a percentage of the time

Rail heat during night operation

The ON period is set as a percentage of the time

Rail heat cycle

The period of time for the aggregate ON time + OFF time is set in minutes

Case cleaning

The status of the function can be followed here or the function can be started manually. 0 = Normal operation (no cleaning) 1 = Cleaning with fans operating. All other outputs are Oﬀ. 2 = Cleaning with stopped fans. All outputs are Oﬀ. If the function is controlled by a signal at the DI1 or DI2 input, the relevant status can be seen here in the menu.

Selection of application

The controller can be deﬁned in various ways. Here you select which of the 3 application modes is used: 1: Two compressors – sequential mode 2: One compressor – variable speed controlled 3: Two compressors – cyclic mode

This menu can only be set when regulation is stopped, i.e. “r12” is set to 0.

Access code 2 (Access to adjustments)

There is access to adjustments of values, but not to conﬁguration settings. If the settings in the controller are to be protected with an access code you can set a numerical value between 0 and 100. If not, you can cancel the function with setting 0. If the function is used, access code 1 (o05) must also be used.

Save as factory setting

With this setting you save the controller’s actual settings as a new basic setting (the earlier factory settings are overwritten).

o37 DI2 conﬁg.

o38 Light conﬁg

o39 Light remote

o41 Railh.ON day%

o42 Railh.ON ngt%

o43 Railh. cycle

o46 Case clean

o61 Appl. Mode

o64 Acc. code 2

o67 -

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Rail heat control

The rail heat can be controlled in several ways: 0: The function is not used 1: Pulse control is used with a timer function following the day/night operation (o41 and o42) 2: Pulse control is used with a dew point function. This function requires that a signal is received about the dew point value. The value is measured by a system manager and sent to the controller via the data communication.

Dew point value where the rail heat is minimum

This function is discussed earlier in the manual.

Dew point value where the rail heat is maximum

This function is discussed earlier in the manual.

Lowest permitted rail heat eﬀect

Here the % part of the eﬀect to be achieved when the dew point value is minimum.

Start of refrigeration when door is open

If the door has been left open, refrigeration must be started after a set time. That time can be set here. (DI conﬁg = 2)

Alternative display

A reading can be displayed on the controller or on the display by pressing the lower button. This reading is set from the factory so that the defrosting stop temperature is displayed. A diﬀerent setting will give the following reading: 1: (Defrost stop temperature = factory setting) 2: S6 temperature

Display of temperature during normal operation

1: Air temperature. Weighted S3 + S4 2: Product temperature S6

Light and night blind deﬁnition

0: Light is switched oﬀ and night blind is open when the main switch is oﬀ 1: Light and night blind is independent of main switch.

Conﬁguration of the alarm relay

The alarm relay will be activated upon an alarm signal from the following groups: 1 - High temperature alarms 2 - Low temperature alarms 4 - Sensor error 8 - Digital input is activated for alarm 16 - Defrost alarms 32 - Miscellaneous The groups that are to activate the alarm relay must be set by using a numerical value which is the sum of the groups that must be activated. (E.g. a value of 5 will activate all high temperature alarms and all sensor errors. 0 will cancel the relay function)

Fan pause while the night blinds are rolling down.

Here it is possible to set a pause time for the fans so that the night blinds can roll down into the correct position unobstructed.

o85 Railh. mode

o86 DewP Min lim

o87 DewP Max lim

o88 Rail Min ON%

o89 DoorInjStart

o92 Displ menu 2

o97 Disp. Ctrl.

o98 Light MS = Oﬀ

P41 Al.Rel. Conf.

P65 BlindFanStop

Service Service

Temperature measured with S5 sensor u09 S5 temp. Status on DI1 input. on/1=closed u10 DI1 status Read the duration of the ongoing defrost or the duration of the last completed defrost. u11 Defrost time Temperature measured with S3 sensor u12 S3 air temp Status at the day-/night operation (night operation: on/oﬀ) u13 Night Cond. Temperature measured with S4 sensor u16 S4 air temp Thermostat temperature u17 Ther. air Read the ongoing cutin time for the thermostat or the duration of the last completed

cutin Read the temperature at the S6 sensor u36 S6 temp Status on DI2 input. on/1=closed Readout of the actual compressor capacity in % Air temperature. Weighted S3 +S4 Measured temperature for alarm thermostat

u18 Ther runtime

u37 DI2 status u52 CompCap % u56 Display air u57 Alarm air

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Status on relay for cooling Status on relay for fan Status on relay for defrost Status on relay for railheat Status on relay for alarm Status on relay for light Status on relay for compressor 2

Readout of the actual rail heat eﬀect in %

Readout of which thermostat used for regulation: 1= Thermostat 1, 2= Thermostat 2

Status on input DI3 (on/1 = 230 V)

Readout of the actual cutin value for the thermostat

Readout of the actual cut out value for the thermostat

Temperature measured by S7 brine sensor

Readout of the voltage signal on the analogue output

Forced control

If you need to force-control an output, you should set r12 to -1 (manual mode). You should then select the relevant relay function, e.g. u58. Go to the function by pressing the middle button. Select On.

u58 Comp1/LLSV u59 Fan relay u60 Def. relay u61 Railh. relay u62 Alarm relay u63 Light relay u67 Comp2 relay u85 Rail DutyC %

u86 Ther. band

u87 DI3 status

u90 Cutin temp.

u91 Cutout temp.

u98 S7 temp.

U44 AO_1 Volt

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Operating status (Measurement)

The controller goes through some regulating situations where it is just waiting for the next point of the regulation. To make these “why is nothing happening” situations visible, you can see an operating status on the display. Push brieﬂy (1s) the upper button. If there is a status code, it will be shown on the display. The individual status codes have the following meanings:

Normal regulation S0 0 Waiting for end of the coordinated defrost S1 1 When the compressor is operating it must run for at least x minutes. S2 2 When the compressor is stopped, it must remain stopped for at least x minutes. S3 3 The evaporator drips oﬀ and waits for the time to run out S4 4 Refrigeration stopped by main switch. Either with r12 or a DI-input S10 10 Refrigeration stopped by thermostat S11 11 Refrigeration has been stopped by the S4 limit S12 12 Defrost sequence. Defrost in progress S14 14 Defrost sequence. Fan delay — water attaches to the evaporator S15 15 Door is open. DI input is open S17 17 Melt function in progress. Refrigeration is interrupted S18 18 Modulating thermostat control S19 19 Emergency cooling due to sensor error *) S20 20 Manual control of outputs S25 25 Case cleaning S29 29 Delay on outputs during start-up S32 32 Case shutdown S45 45

Ctrl. state: (Shown in all menu displays)

Other displays:

The defrost temperature cannot be displayed. There is stop based on time non Defrost in progress / First cooling after defrost -dPassword required. Set password PS Regulation is stopped via main switch OFF

*) Emergency cooling will take eﬀect when there is lack of signal from a deﬁned S3 or S4 sensor. The regulation will continue with a

registered average cutin frequency. There are two registered values – one for day operation and one for night operation.

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Fault message

In an error situation the LED’s on the front will ﬂash and the alarm relay will be activated. If you push the top button in this situation you can see the alarm report in the display. There are two kinds of error reports - it can either be an alarm occurring during the daily operation, or there may be a defect in the installation. A-alarms will not become visible until the set time delay has expired. E-alarms, on the other hand, will become visible the moment the error occurs. (An A alarm will not be visible as long as there is an active E alarm). Here are the messages that may appear:

Code / Alarm text via data communication

A1/--- High t.alarm

A2/--- Low t. alarm

A4/--- Door alarm

A5/--- Max hold time

A13/--- High temp S6 Temperature alarm. High S6 1

A14/--- Low temp S6 Temperature alarm. Low S6 2

A15/--- DI1 alarm DI1 alarm 8

A16/--- DI2 alarm DI2 alarm 8

A45/--- Standby mode Standby position (stopped refrigeration via r12 or DI input) -

A59/--- Case clean Case cleaning. Signal from DI input -

A97/--- Comp. Safety Compressor safety. Signal from DI3 input is interrupted 8

AA3/--- High brine temp. High brine temperature alarm 8

E1/--- Ctrl. error Faults in the controller 32

E6/--- RTC error Check clock 32

E25/--- S3 error Error on S3 sensor 4

E26/--- S4 error Error on S4 sensor 4

E27/--- S5 error Error on S5 sensor 4

E28/--- S6 error Error on S6 sensor 4

E50/--- S7 error Error on S7 sensor 4

--- Max Def.Time Defrost stopped based on time instead of, as wanted, on temperature 16

Data communication

The importance of individual alarms can be deﬁned with a setting. The setting must be carried out in the group "Alarm destinations"

Settings from System manager AK-SM 720 High 1 X Middle 2 X Low 3 X Log only Disabled

Description Alarm relay groups

High temperature alarm

Low temperature alarm

Door alarm

The ”o16” function is activated during a coordinated defrost

Settings from AKM (AKM destination)

Send via Network

(P41)

(not in AK-SM 800 serie)

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Operation

Controller/Display

The values will be shown with three digits, and with a setting you can determine whether the temperature is to be shown in °C or in °F.

Light-emitting diodes (LED) on front panel

The LED’s on the front panel will light up when the relevant relay is activated.

= Refrigeration = Defrost = Fan running

The light-emitting diodes will ﬂash when there is an alarm. In this situation you can download the error code to the display and cancel/accept the alarm by giving the top button a brief push.

The buttons

When you want to change a setting, the upper and the lower buttons will give you a higher or lower value depending on the button you are pushing. But before you change the value, you must have access to the menu. You obtain this by pushing the upper button for a couple of seconds - you will then enter the column with parameter codes. Find the parameter code you want to change and push the middle button until value for the parameter is shown. When you have changed the value, save the new value by once more pushing the middle button.

Get a good start

With the following procedure you can start regulation very quickly:

1 Open parameter r12 and stop the regulation (in a new and not

previously set unit, r12 will already be set to 0 which means stopped regulation.)

2 Select electrical connection based on the drawings on page 26

3 Open parameter o61 and set the electric connection number in

4 Open parameter r12 and start the regulation

5 Go through the survey of factory settings. Make any necessary

changes in the respective parameters.

6 For network. Set the address in o03

7 Send address to system unit:

• MODBUS: Activate scan function in system unit

• If another data communication card is used in the controller:

- LON RS485: Activate the function o04

Examples

Set menu

1. Push the upper button until a parameter r01 is shown

2. Push the upper or the lower button and ﬁnd that parameter you want to change

3. Push the middle button until the parameter value is shown

4. Push the upper or the lower button and select the new value

5. Push the middle button again to set the value.

Cutout alarm relay / receipt alarm/see alarm code

• A short press of the upper button

If there are several alarm codes they are found in a rolling stack. Push the uppermost or lowermost button to scan the rolling stack.

Set temperature

1. Push the middle button until the temperature value is shown

2. Push the upper or the lower button and select the new value

3. Push the middle button again to conclude the setting.

Reading the temperature at defrost sensor (Or product sensor, if selected in o92.)

• A short press of the lower button

Manual start or stop of a defrost

• Push the lower button for four seconds.

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Menu survey

Parameter Wiring diagram

Function Code 1 & 3

Normal operation

Temperature (setpoint)

- - - 1 1 -50 °C 50 °C 2

Thermostat

Diﬀerential

Max. limitation of setpoint setting

Min. limitation of setpoint setting

Adjustment of temperature indication

Temperature unit (°C/°F)

Correction of the signal from S4

Correction of the signal from S3

Manual service, stop regulation, start regulation (-1, 0, 1)

Displacement of reference during night operation

Deﬁne thermostat function 1=ON/OFF

r01 1 1 0.1 K 20 K 2

r02 1 1 -49 °C 50 °C 50

r03 1 1 -50 °C 49 °C -50

r04 1 1 -10 10 0

r05 1 1 0/°C 1/F 0/°C

r09 1 1 -10 K 10 K 0

r10 1 1 -10 K 10 K 0

r12 1 1 -1 1 0

r13 1 1 -50 K 50 K 0

r14 1 2 — — —

2=Modulating

Deﬁnition and weighting, if applicable, of thermostat sensors - S4% (100%=S4, 0%=S3)

Time between melt periods

Duration of melt periods

Temperature setting for thermostat band 2 . As diﬀerential use r01

Correction of the signal from S6 r59 1 1 -10 K 10 K 0

Deﬁnition and weighting, if applicable, of thermostat sensors when night

r15 1 1 0 % 100 % 100

r16 1 1 0 hrs 10 hrs 1

r17 1 1 0 min. 30 min. 5

r21 1 1 -50 °C 50 °C 2

r61 1 1 0 % 100 % 100

cover is on. (100%=S4, 0%=S3)

S4 min. limit. Frost protection. Cooling is stopped.

r98 1 1 -50 °C 20 °C -50 °C

Alarms

Delay for temperature alarm

Delay for door alarm

Delay for temperature alarm after defrost

High alarm limit for thermostat 1

Low alarm limit for thermostat 1

High alarm limit for thermostat 2

Low alarm limit for thermostat 2

High alarm limit for sensor S6 at thermostat 1

Low alarm limit for sensor S6 at thermostat 1

High alarm limit for sensor S6 at thermostat 2

Low alarm limit for sensor S6 at thermostat 2

S6 alarm time delay With setting = 240 the S6 alarm will be omitted

Alarm time delay or signal on the DI1 input

Alarm time delay or signal on the DI2 input

Signal for alarm thermostat. S4% (100%=S4, 0%=S3)

Delay for S6 (product sensor alarm) after defrost

Alarm limit for max. S7 brine temperature

Diﬀerential for S7 brine alarm

A03 1 1 0 min. 240 min. 30

A04 1 1 0 min. 240 min. 60

A12 1 1 0 min. 240 min. 90

A13 1 1 -50 °C 50 °C 8

A14 1 1 -50 °C 50 °C -30

A20 1 1 -50 °C 50 °C 8

A21 1 1 -50 °C 50 °C -30

A22 1 1 -50 °C 50 °C 8

A23 1 1 -50 °C 50 °C -30

A24 1 1 -50 °C 50 °C 8

A25 1 1 -50 °C 50 °C -30

A26 1 1 0 min. 240 min. 240

A27 1 1 0 min. 240 min. 30

A28 1 1 0 min. 240 min. 30

A36 1 1 0 % 100 % 100

A52 1 1 0 min. 240 min. 90

A76 1 1 -50 °C 50 °C 8°C

A77 1 1 0.1 K 10 K 3.0 K

Compressor

Min. ON-time

Min. OFF-time

Time delay for cutin of comp.2

Min. speed for compressor

Start speed for compressor. Must be set higher than Min. speed

Max. speed for compressor

Kp factor for compressor PI control

Tn for compressor PI control

c01 1 1 0 min. 30 min. 0

c02 1 1 0 min. 30 min. 0

c05 1 0 sec 999 sec 5

c46 1 25 Hz 70 Hz 30

c47 1 30 Hz 70 Hz 50

c48 1 50 Hz 100 Hz 100

c82 1 3 30 20

c83 1 30 sec 360 sec 60

Min.

value

Max.

value

Factory

setting

SW = 1.2x

Actual

setting

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User Guide | Controller for SemiPlugin appliance, AK-CC 460

Continued code Wiring diagram Min. Max. Fac. Actual

Comp. on time when sensor fault

Comp. oﬀ time when sensor fault

Emergency speed for compressor if sensor error

Max. slope rate (max allowed speed change per second)

Max. proportional factor (Kp) for PI control

Defrost

Defrost method: 0=Oﬀ, 1= EL

Defrost stop temperature

Interval between defrost starts

Max. defrost duration

Displacement of time on cutin of defrost at start-up

Drip oﬀ time

Delay for fan start after defrost

Fan start temperature

Fan cutin during defrost 0: stopped 1 and 2: Running

Defrost sensor: 0 =Stop on time, 1=S5, 2=S4, 3=S5 and S6 d10 1 1 0 3 0

Pump down delay

Max. aggregate refrigeration time between two defrosts

Rail heat during defrost 0: oﬀ 1: on 2: Pulsing

Max. duration of -d- in display

Fan

Fan stop temperature (S5)

Pulse operation on fans: 0=No pulse operation, 1=At thermostat cuts out only, 2= Only at thermostat cut outs during night operation

Period time for fan pulsation (on-time + oﬀ-time)

On-time in % of period time

Real time clock

Six start times for defrost. Setting of hours. 0=OFF

Six start times for defrost. Setting of minutes. 0=OFF

Clock - Setting of hours

Clock - Setting of minute

Clock - Setting of date

Clock - Setting of month

Clock - Setting of year

Miscellaneous

Delay of output signals after power failure

Input signal on DI1. Function: 0=not used. 1=status on DI1. 2=door function with alarm when open. 3=door alarm when open. 4=defrost start (pulse-signal). 5=ext.main switch. 6=night operation 7=Thermostat band changeover (activate r21). 8=alarm function when closed. 9=alarm function when open. 10=case cleaning (pulse signal).

12=night cover. 15=application shutdown

Network address (0= oﬀ)

On/Oﬀ switch (Service Pin message) IMPORTANT! o61 must be set prior to o04

(used at LON 485 only)

Access code 1 (all settings)

Software Version

Setting of mains supply frequency

Max hold time after coordinated defrost

c86 1 0 min 240 min 15

c87 1 0 min 240 min 30

c93 1 25 Hz 100 Hz 60

c96 1 0.1 Hz/s 5 Hz/s 1

n95 1 5 50 20

d01 1 1 0/Oﬀ 1/EL 1/EL

d02 1 1 0 °C 50 °C 6

d03 1 1 0 hrs/Oﬀ 240 hrs 8

d04 1 1 0 min. 360 min. 45

d05 1 1 0 min. 240 min. 0

d06 1 1 0 min. 60 min. 0

d07 1 1 0 min. 60 min. 0

d08 1 1 -50 °C 0 °C -5

d09 1 1 0 2 1

d16 1 1 0 min. 60 min. 0

d18 1 1 0 hrs 48 hrs 0/OFF

d27 1 1 0 2 2

d40 1 1 5 min. 240 min. 30 min.

F04 1 1 -50 °C 50 °C 50

F05 1 1 0 2 0

F06 1 1 1 min. 30 min. 5

F07 1 1 0 % 100 % 100

t01 -

1 1 0 hrs 23 hrs 0

t06

t11 -

1 1 0 min. 59 min. 0

t16

t07 1 1 0 hrs 23 hrs 0

t08 1 1 0 min. 59 min. 0

t45 1 1 1 day 31 day 1

t46 1 1 1 mon. 12 mon. 1

t47 1 1 0 year 99 year 0

o01 1 1 0 sec 600 sec 5

o02 1 1 0 15 0

o03 1 1 0 240 0

o04 1 1 0/Oﬀ 1/On 0/Oﬀ

o05 1 1 0 100 0

o08 1 1

o12 1 50 Hz 60 Hz 50

o16 1 1 0 min. 360 min. 20

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Continued code Wiring diagram Min. Max. Fac. Actual

Select signal for display view. S4% (100%=S4, 0%=S3)

Input signal on DI2. Function: (0=not used. 1=status on DI2. 2=door function with alarm when open. 3=door alarm when open. 4=defrost start (pulse-signal). 5=ext. main switch 6=night operation 7=Thermostat band changeover (activate r21). 8=alarm function when closed. 9=alarm function when open. 10=case cleaning (pulse signal). 12=night cover, 13=coordinated defrost). 15=application shutdown

Conﬁguration of light function: 1=Light follows day /night operation,

2=Light control via data communication via ‘o39’, 3=Light control with a DI-input, 4=As "2", but light switch on and night cover will open if the network cut out for more than 15 minutes.

Activation of light relay (only if o38=2) On=light

Rail heat On time during day operations

Rail heat On time during night operations

Rail heat period time (On time + Oﬀ time)

Case cleaning. 0=no case cleaning. 1=Fans only. 2=All output Oﬀ.

Selection of Application mode. See overview on page 26. 1 = Two compressor sequential mode 2 = One compressor with variable speed control 3 = Two compressors cyclic mode

Access code 2 (partial access)

Replace the controllers factory settings with the present settings

Rail heat control 0=not used, 1=pulse control with timer function (o41 and o42), 2=pulse control with dew point function

Dew point value where the rail heat is minimum

Dew point value where the rail heat is 100% on

Lowest permitted rail heat eﬀect in %

Time delay from "open door” refrigeration is started

Deﬁnition of readings on lower button: 1=defrost stop temperature, 2=S6 temperature

Display of temperature 1= u56 Air temperature 2= u36 product temperature

Light and night blinds deﬁned 0: Light is switch oﬀ and night blind is open when the main switch is oﬀ 1: Light and night blind is independent of main switch

Conﬁguration of alarm relay The alarm relay will be activated upon an alarm signal from the following groups: 1 - High temperature alarms 2 - Low temperature alarms 4 - Sensor error 8 - Digital input is activated for alarm 16 - Defrost alarms 32 - Miscellaneous The groups that are to activate the alarm relay must be set by using a numerical value which is the sum of the groups that must be activated. (E.g. a value of 5 will activate all high temperature alarms and all sensor errors). 0 = Cancel relay function

Stop time for fans while the night blinds are rolling down P65 1 1

o17 1 1 0 % 100 % 100

o37 1 1 0 15 0

o38 1 1 1 4 1

o39 1 1 0/Oﬀ 1/On 0/Oﬀ

o41 1 1 0 % 100 % 100

o42 1 1 0 % 100 % 100

o43 1 1 6 min. 60 min. 10

*** o46 1 1 0 2 0

* o61 1 1 1 3 1

*** o64 1 1 0 100 0

o67 1 1 0/Oﬀ 1/On 0/Oﬀ

o85 1 1 0 2 0

o86 1 1 -10 °C 50 °C 8

o87 1 1 -9 °C 50 °C 17

o88 1 1 0 % 100 % 30

o89 1 1 0 min. 240 min. 30

o92 1 1 1 2 1

o97 1 1 1 2 1

o98 1 1 0 1 0

P41 1 1

0 63 47

0 min. 5 min. 0 min.

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Service

Temperature measured with S5 sensor

Status on DI1 input. on/1=closed

Actual defrost time (minutes)

Temperature measured with S3 sensor

Status on night operation (on or oﬀ) 1=on

Temperature measured with S4 sensor

Thermostat temperature

Run time of thermostat (cooling time) in minutes

Temperature measured with S6 sensor (product temperature)

Status on DI2 output. on/1=closed

Readout of the actual compressor capacity in %

Air temperature. Weighted S3 + S4(o17)

Measured temperature for alarm thermostat Weighted S3+S4 (A36)

Status on relay for compressor 1

Status on relay for fan

Status on relay for defrost

Status on relay for rail heat

Status on relay for alarm

Status on relay for light

Status on relay for compressor 2

Readout of the actual rail heat eﬀect

1: Thermostat 1 operating, 2: Thermostat 2 operating

Status on high voltage input DI3

Readout of thermostats actual cut in value

Readout of thermostats actual cut out value

Readout the brine temperature S7 u98 1 1

Readout of the voltage signal on the analogue output U44 1

*) Can only be set when regulation is stopped (r12=0) **) Can be controlled manually, but only when r12=-1 ***) With access code 2 the access to these menus will be limited

u09 1 1

u10 1 1

u11 1 1

u12 1 1

u13 1 1

u16 1 1

u17 1 1

u18 1 1

u36 1 1

u37 1 1

u52 1

u56 1 1

u57 1 1

** u58 1

** u59 1 1

** u60 1 1

** u61 1 1

** u62 1 1

** u63 1 1

** u67 1 1

u85 1 1

u86 1 1

u87 1 1

u90 1 1

u91 1 1

Forced control

Factory setting

If you need to return to the factory-set values, it can be done in this way:

- Cut out the supply voltage to the controller

- Keep upper and lower button depressed at the same time as you reconnect the supply voltage

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Connections

Appplication 1 and 3

Appplication 2

Application DO1 DO2 DO3 DO4 DO5 DO6 DO7 DI1 DI2 DI3 AI1 AI2 AI3 AI4 AI5 AI6 AO

1 and 3

DI1 DI2

DO1 DO2 DO3 DO4 DO5 DO6 DO7

In application1, the compressors are controlled sequentially. Compressor 1 is ﬁrst in and last out. In application 3, the compressors are controlled cyclically.

DI1 DI2 AO

• • •

S7 S3 S4 S5 S6

S7 S3 S4 S5 S6 0-10V

DO2 DO3 DO4 DO5 DO6 DO7 D13

DI1

Digital input signal. The deﬁned function is active when the input is short-circuited/ opened. The function is deﬁned in o02.

DI2

Digital input signal. The deﬁned function is active when the input is short-circuited/ opened. The function is deﬁned in o37.

Analogue output (only application 2) 0 - 10 V signal for variable speed compressor control.

S7, S3, S4, S5, S6

Pt 1000 ohm

S7, brine sensor, should be placed at the cold inlet to the heat exchanger S3, air sensor, placed in the warm air before the evaporator S4, air sensor, placed in the cold air after the evaporator

(the need for either S3 or S4 can be deselected in the conﬁguration)

S5, defrost sensor, placed on the evaporator S6, product sensor

EKA Display

If there is be external reading/operation of the controller, display type EKA 163B or EKA 164B can be connected.

RS485 (terminal 51, 52, 53)

For data communication, but only if a data communication module is inserted in the controller. The module can be a LON RS485, DANBUSS or a MODBUS. Terminal 51 = screen Terminal 52 = A (A+) Terminal 53 = B (B-) (For LON RS485 and gateway type AKA 245 the gateway must be version 6.20 or higher.)

RJ45

For data communication, but only if a TCP/IP module is inserted in the controller. (OEM)

MODBUS

For data communication. Terminal 56 = screen Terminal 57 = A+ Terminal 58 = B(Alternatively the terminals can be connected to an external display type EKA 163A or 164A, but then they cannot be used for data communication. Any data communication must then be carried out by one of the other methods.)

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Supply voltage

230 V AC

DO1

Compressor 1 (only application 1 and 3)

Connection of relay for compressor. The coil must be a 230 V AC coil.

DO2

Alarm

There is a connection between terminal 7 and 8 in alarm situations and when the controller is without power.

DO3

Compressor 2,

There is connection between terminal 10 and 11 when the compressor must be active In application 2 this output is used for compressor start signal

DO4

Defrost

There is connection between terminal 12 and 14 when defrosting takes place.

DO5

Fan

There is connection between terminal 15 and 16 when the fan is on.

DO6

Light relay

There is connection between terminal 17 and 18 when the light must be on. If night blinds are used, they should be connected here.

DI3

Digital input signal.

Compressors safety circuit (OK at 230V) The signal must have a voltage of 0 / 230 V AC.

Data communication

If data communication is used, it is important that the installation of the data communication cable is performed correctly. See separate literature No. RC8AC…

Electric noise

Cables for sensors, DI inputs and data communication must be kept separate from other electric cables:

- Use separate cable trays

- Keep a distance between cables of at least 10 cm

- Long cables at the DI input should be avoided

Installation considerations

Accidental damage, poor installation, or site conditions, can give rise to malfunctions of the control system, and ultimately lead to a plant breakdown. Every possible safeguard is incorporated into our products to prevent this. However, a wrong installation, for example, could still present problems. Electronic controls are no substitute for normal, good engineering practice. Danfoss wil not be responsible for any goods, or plant components, damaged as a result of the above defects. It is the installer's responsibility to check the installation thoroughly, and to ﬁt the necessary safety devices. Special reference is made to the necessity of signals to the controller when the compressor is stopped and to the need of liquid receivers before the compressors. Your local Danfoss agent will be pleased to assist with further advice, etc.

DO7

Rail heat

There is connection between terminal 20 and 21, when the rail heat is active.

Coordinated defrost via cable connections

Coordinated defrost via data communication

Max. 10

The following controllers can be connected up in this way: EKC 204A, AK-CC 210, AK-CC 250, AK-CC 450, AK-CC 460, AK-CC 550,

Refrigeration is resumed when all controllers have “released” the signal for defrost.

The setting of controllers to coordinate their defrosting takes place in the gateway/system manager.

Refrigeration is resumed when all controllers have “released” the signal for defrost.

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Data

Supply voltage 230 V AC +10/-15 %. 5 VA, 50/60 Hz

Sensors

Accuracy

Display LED, 3-digits

External display EKA 163B or 164B. (any EKA 163A or 164A)

Digital inputs DI1, DI2

Digital input DI3 230 V AC

Electrical connection cable

Solid state output

Analogue output

Relays*

Environments

Density IP 20

Mounting DIN-rail or wall

Weight 0.4 Kg

Data communication

Power reserve for the clock

Approvals

* DO3 and DO4 are 16 A relays. DO2, DO5, DO6 and DO7 are 8 A relays. Max. load must be observed.

S3, S4, S5, S6, S7 Pt 1000 ohm

Measuring range -60 – 120 °C

Controller

Pt 1000 sensor

Signal from contact functions Requirements to contacts: Gold plating Cable length must be max. 15 m Use auxiliary relays when the cable is longer

Max.1.5 mm2 multi-core cable

DO1 (for coil)

DO3, DO4 4 (3) A

DO2, DO5, DO6, DO7

0 – 55 °C, During operations

-40 – 70 °C, During transport 20 - 80% Rh, not condensed No shock inﬂuence / vibrations

Fixed / Build-in MODBUS

Extension options

The controller cannot be hooked up with a monitoring unit type m2.

4 hours

EU Low Voltage Directive and EMC demands re CEmarking complied with LVD tested acc. EN 60730-1 and EN 60730-2-9, A1, A2 EMC tested acc. EN 61000-6-2 and EN 61000-6-3 Relays are tested acc. to IEC 60079-15

±1 K below -35 °C ±0.5 K between -35 – 25 °C ±1 K above +25°C

±0.3 K at 0°C ±0.005 K per grad

Max. 240 V AC , Min. 28 V AC Max. 0.5 A Leak < 1 mA Max. 1 pcs. coil

0 – 10 V signal for variable speed control

CE (250 V AC)

IBExU approved

4 (3) A

LON RS485

DANBUSS

TCP/IP (OEM)

MODBUS

User Guide | Controller for SemiPlugin appliance, AK-CC 460

Ordering

Type Function Code no.

AK-CC 460

EKA 175

EKA 178B Data communication module MODBUS 084B8571

EKA 176 Data communication module DANBUSS + Gateway 084B8583

EKA 176A Data communication module DANBUSS + AK-PI 200 084B8591

EKA 163B External display with plug for direct connection 084B8574

EKA 164B

EKA 163A External display with screw terminals 084B8562

EKA 164A External display with operation buttons and screw terminals 084B8563

Case controller with MODBUS data communication

Data communication module LON RS 485

External display with operation buttons and plug for direct connections

084B8016

084B8579

084B8575

Examples of order

Installation Data communication Connection Code no.

MODBUS 084B8016 (AK-CC 460)

LON 084B8016

DANBUSS 084B8016

MODBUS 084B8016

LON / DANBUSS 084B8016

L < 15 m

MODBUS / LON / DANBUSS 084B8016

084B8579

084B8583

084B8574 (Display) 084B7299 (Cable, 6 m)

084B8574 (Display) 084B7299 (Cable, 6 m) 084Bxxxx (Data module)

084B8562 (Display) 084Bxxxx (Data module)

L > 15 m

Danfoss AK-CC 460 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual