Danfoss AK-CC 525A Installation guide

Instructions

AK-CC 525A

115 V

Identication

Principle

Dimensions

084B8017

Connections

AKV info !!

S2:

Insulate sensor
Fühler isolieren
Capteur isolés
Isolér føleren
Sensores aislados

115 V a.c. spole
115 V a.c. coil
115 V a.c. Spule
115 V c.a. Bobine
115 V c.a. Bobina
115 V c.a. Bobine

AK-CC 525A

Additional information: English Manual RS8HB... www.danfoss.com

RI8RZ102 06-2016

Data communication

Important All connections to the data communication MODBUS and RS 485 must comply

with the requirements for data communication cables. See literature: RC8AC.

System manager
/ Gateway

Display EKA 163 / 164

L < 15 m

L > 15 m

AK-SM....

AKA 245 version 6.20+ /
AK-SM...

! Address: o03 > 0

2 Instructions RI8RZ102 © Danfoss 06/2016 AK-CC 525A

Connections

DI1 DI2

DO1 DO2 DO3 DO4 DO5 DO6 DI3
(od) (ALA) (CoP) (dEF) (FAn) (Lgt)
(rHt)

DI1

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

DI2

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

Pressure transmitter

AKS 32R

Connect to terminal 30, 31 and 32.
(Used cable 060G1034: Black=30, Blue=31, Brown=32)
The signal from one pressure transmitter can be received by up
to 10 controllers. But only if there are no signicant pressure
decreases between the evaporators to be controlled.

S2

Pt 1000 ohm sensor

S3, S4, S5

Pt 1000 ohm sensor or PTC 1000 ohm sensor. All have to be of the
same type.

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
conguration)

S5, defrost sensor, placed on the evaporator.

EKA Display

If there is 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.)

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.)

Supply voltage

115 V a.c., 50/60 Hz

DO1

Connection of expansion valve type AKV or AKVA. The coil must
be a 115 V a.c. coil.

DO2

Alarm

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

DO3

Refrigeration / Railheat

There is connection between terminal 10 and 11 when the
function must be active.

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

There is connection between terminal 17 and 18 when the light
must be on.

DI3

Digital input signal.
The signal must have a voltage of 0 / 115 V a.c..
The function is dened in o84.

AK-CC 525A Instructions RI8RZ102 © Danfoss 06/2016 3

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 will 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 t 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.

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 550A,

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.

4 Instructions RI8RZ102 © Danfoss 06/2016 AK-CC 525A

Operation (only external)

External 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)

The LED’s on the external display will light up when the relevant
relay is activated.
o = Refrigeration

o = Defrost
o = Fan running

The light-emitting diodes will ash when there is an alarm.
In this situation you can download the error code to the display
and cancel/sign for 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 buttons until value for the parameter
is shown. When you have changed the value, save the new value
by once more pushing the middle button.

Examples

Set menu

1. Push the upper button until a parameter "cfg" is shown

2. Push the upper, middle or the lower button and nd 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 freeze the value.

Get a good start

With the following procedure you can start regulation very quick­ly:

cFg (System settings)
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 the min. range for the pressure transmitter (o20)

3 Select the max. range for the pressure transmitter (o21)

4 Select refrigerant (o30)

5 Factory setting for DO3 = Rail heat. It can be changed (o61)

6 Now select one of the preset settings from the table

Auxiliary schedule for
settings (quick-setup)

Preset settings (o62) 1 2 3 4 5 6

Temperature (SP)

Max. temp. setting (r02)

Min. temp. setting (r03)

Sensor signal for thermo­stat. S4% (r15)
Alarm limit high (A13)

Alarm limit low (A14)

Sensor signal for alarm
funct.S4% (A36)
Interval between defrost
(d03)
Defrost sensor: 0=time,
1=S5, 2=S4 (d10)
DI1 cong. (o02)

Sensor signal for display
view S4% (017)

Case Room

Defrost stop on Defrost stop on

time S5 time S5

2°C -2°C -28°C 4°C 0°C -22°C

6°C 4°C -22°C 8°C 5°C -20°C

0°C -4°C -30°C 0°C -2°C -24°C

100% 0%

8°C 6°C -15°C 10°C 8°C -15°C

-5°C -5°C -30°C 0°C 0°C -30°C

0% 100% 0%

6 h 6h 12h 8h 8h 6h

0 1 1 0 1 1

- Door function (=2)

0%

7 Open parameter o62 and set the number for the array of preset-

tings. The few selected settings will now be transferred to the
menu.

8 For network. Set the address in o03

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

9 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

stack.

10 Open parameter r12 and start the regulation

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.

(Menu groups)
11 Go through the survey of factory settings. The values in the

grey cells are changed according to your choice of settings.
Make any necessary changes in the respective parameters.

Reading the temperature at defrost sensor

• A short press of the lower button

Manuel start or stop of a defrost

• Push the lower button for four seconds.

AK-CC 525A Instructions RI8RZ102 © Danfoss 06/2016 5

Menu overview

Password

Temperature PS cFg

in

out

r-

Conguration

➞

➞

➞

Service

od

ALA S2 o30 Refrigerant type

Service

System settings

r12 Main switch

PE

o20 Min. transmitter range

tE o21 Max. transmitter range

A-- rHt / CoP S3 o61 Relay DO3 function

c-- dEF S4 o62 Preset settings

d-- FAn S5 o03 Modbus address

f-- Lgt di1 o04 Service pin (for LON only)

n-- ESc

Menu groups

r12 = service (-1)

Read output status. /

Override output when



Read input status

di2 ESc



o-- Return di3 Return

t-- ESc

See also the following pages.



u-- Return

ESc



Return

Close each group by pressing ESc (Return)

Parameter / Function Code DO3 function

Normal operation

Temperature (setpoint) - - - -50°C 50°C 2
Thermostat r-­Temperature (setpoint) r00 -50°C 50°C 2
Dierential r01 0.1 K 20 K 2
Max. limitation of setpoint setting r02 -49°C 50°C 50
Min. limitation of setpoint setting r03 -50°C 49°C -50
Adjustment of temperature indication r04 -10 K 10 K 0
Temperature unit (°C/°F) r05 0/°C 1/F 0/°C
Correction of the signal from S4 r09 -10 K 10 K 0
Correction of the signal from S3 r10 -10 K 10 K 0
Manual service, stop regulation, start regulation (-1, 0, 1) r12 -1 1 0
Displacement of reference during night operation r13 -50 K 50 K 0
Dene thermostat function

1=ON/OFF, 2=Modulating
Denition and weighting, if applicable, of thermostat sensors - S4% (100%=S4, 0%=S3) r15 0 % 100 % 100
Time between melt periods r16 0 hrs 10 hrs 1
Duration of melt periods r17 0 min. 30 min. 5
Thermostat displacement when signal on DI input r40 -50 K 50 K 0
Alarms A--

Delay for temperature alarm A03 0 min. 240 min. 30
Delay for door alarm A04 0 min. 240 min. 60
Delay for temperature alarm after defrost A12 0 min. 240 min. 90
High alarm limit for thermostat A13 -50°C 50°C 8
Low alarm limit for thermostat A14 -50°C 50°C -30
Alarm time delay or signal on the DI1 input A27 0 min. 240 min. 30
Alarm time delay or signal on the DI2 input A28 0 min. 240 min. 30
Signal for alarm thermostat. S4% (100%=S4, 0%=S3) A36 0 % 100 % 100
Compressor c-­Min. ON-time c01 0 min. 30 min. 0
Min. OFF-time c02 0 min. 30 min. 0
Defrost d-­Defrost method: 0=o, 1= EL, 2=Gas d01 0/o 2/gAs 1/EL
Defrost stop temperature d02 0°C 50°C 6
Interval between defrost starts d03 0 hrs/O 240 hrs 8
Max. defrost duration d04 0 min. 360 min. 45
Displacement of time on cutin of defrost at start-up d05 0 min. 240 min. 0

r14 1 2 1

(o61=)

1

CoP2rHt

Min.­value

Max.­value

Factory

setting

SW = 1.5x

Actual

setting

6 Instructions RI8RZ102 © Danfoss 06/2016 AK-CC 525A

Drip o time d06 0 min. 60 min. 0
Delay for fan start after defrost d07 0 min. 60 min. 0
Fan start temperature d08 -50 °C 0 °C -5
Fan cutin during defrost

d09 0 2 1
0: Stopped
1: Running (stopped during "fan delay")
2: Running during pump down and defrost

Defrost sensor: 0 =Stop on time, 1=S5, 2=S4 d10 0 2 0
Pump down delay d16 0 min. 60 min. 0
Max. aggregate refrigeration time between two defrosts d18 0 hrs 48 hrs 0/OFF
Rail heat during defrost

d27 0 2 2
0=o. 1=on. 2=Pulsating

Max. duration of -d- in display

d40

5 min. 240 min. 30 min.

Fan F-­Fan stop temperature (S5) F04 -50°C 50°C 50
Pulse operation on fans: 0=No pulse operation, 1=At thermostat cuts out only, 2=

F05 0 2 0
Only at thermostat cut outs during night operation

Period time for fan pulsation (on-time + o-time) F06 1 min. 30 min. 5
On-time in % of period time F07 0 % 100 % 100
Injection control function n-­Max. value of superheat reference n09 2°C 20°C 12
Min. value of superheat reference n10 2°C 20°C 3
MOP temperature. O if MOP temp. = 15.0 °C n11 -50°C 15°C 15
Period time of AKV pulsation

n13 3 sec 6 sec 6
Only for trained personnel

Miscellaneous o-­Delay of output signals after start-up o01 0 sec 600 sec 5
Input signal on DI1. Function:

o02 0 15 0
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 oset (activate r40). 8=alarm function when closed. 9=alarm function
when open. 15=case shut down

Network address (0 = o) o03 0 240 0
On/O switch (Service Pin message)

o04 0/O 1/On 0/O
IMPORTANT! o61 must be set prior to o04
(used at LON 485 and DANBUSS only)

Access code 1 (all settings) o05 0 100 0
Used sensor type for S3, S4 and S5: 0=Pt1000, 1=Ptc1000, o06 0/Pt 1/Ptc 0/Pt

Readout of software version o08

Max hold time after coordinated defrost o16 0 min. 360 min. 20
Select signal for display view. S4% (100%=S4, 0%=S3) o17 0 % 100 % 100
Pressure transmitter working range – min. value * o20 -1 bar 5 bar -1
Pressure transmitter working range – max. value * o21 6 bar 200 bar 12
Refrigerant setting:

* o30 0 42 0
1=R12. 2=R22. 3=R134a. 4=R502. 5=R717. 6=R13. 7=R13b1. 8=R23. 9=R500.
10=R503. 11=R114. 12=R142b. 13=User dened. 14=R32. 15=R227. 16=R401A.
17=R507. 18=R402A. 19=R404A. 20=R407C. 21=R407A. 22=R407B. 23=R410A.
24=R170. 25=R290. 26=R600. 27=R600a. 28=R744. 29=R1270. 30=R417A. 31=R422A.
32=R413A. 33=R422D. 34=R427A. 35=R438A. 36=R513A(XP10). 37=R407F. 38=R1234ze.
39=R1234yf. 40=R448A. 41=R449A. 42=R452A.

Input signal on DI2. Function:

o37 0 15 0
(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 oset (activate r40). 8=alarm function when closed. 9=alarm function
when open. 13=coordinated defrost). 15=case shut down

Conguration of light function: 1=Light follows day /night operation, 2=Light control

o38 1 4 1
via data communication via ‘o39’, 3=Light control with a DI-input, 4=As "2", but light
switch on if the network cut out for more than 15 minutes.

Activation of light relay (only if o38=2) On=light o39 0/O 1/On 0/O

Rail heat On time during day operations

Rail heat On time during night operations

Rail heat period time (On time + O time)

Selection of DO3 function.: 1=Cooling. 2=Rail heat

o41

o42

o43

0 % 100 % 100

0 % 100 % 100

6 min. 60 min. 10

o61 1 2 0 2 2
Download a set of predetermined settings. * o62 0 6 0
Access code 2 (partial access) *** o64 0 100 0
Replace the controllers factory settings with the present settings o67 0/O 1/On 0/O
Input signal on DI3. Function: (high voltage input)

o84 0 15 0
(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 oset (activate r40). 14=Refrigeration stopped (forced closing)). 15=case
shut down

AK-CC 525A Instructions RI8RZ102 © Danfoss 06/2016 7

Rail heat control:

o85 0 1 0

0=not used, 1=pulse control with timer function (o41 and o42),
Time delay from "open door” refrigeration is started o89 0 min. 240 min. 30
Fan operation at stopped cooling (forced closing):

o90 0 3 1
0= Stopped (defrost allowed)
1= Running (defrost allowed)
2= Stopped (defrost not allowed)
3= Running (defrost not allowed)

Light and night blinds dened

o98 0 1 0

0: Light is switch o and night blind is open when the main switch is o
1: Light and night blind is independent of main switch

Conguration of alarm relay

P41 0 127 111

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 enabled for alarm
16 - Defrosting alarms
32 - Miscellaneous
64 - Injection alarms
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 error and will

cancel the relay function).
Real time clock t-­Six start times for defrost.

Setting of hours.

t01 ­t06

0 hrs 23 hrs 0

0=OFF
Six start times for defrost.

Setting of minutes.

t11 ­t16

0 min. 59 min. 0

0=OFF
Clock - Setting of hours t07 0 hrs 23 hrs 0
Clock - Setting of minute t08 0 min. 59 min. 0
Clock - Setting of date t45 1 day 31 day 1
Clock - Setting of month t46 1 mon. 12 mon. 1
Clock - Setting of year t47 0 year 99 year 0
Service u-­Temperature measured with S5 sensor u09
Status on DI1 input. on/1=closed u10
Actual defrost time (minutes) u11
Temperature measured with S3 sensor u12
Status on night operation (on or o) 1=on u13
Temperature measured with S4 sensor u16
Thermostat temperature u17
Run time of thermostat (cooling time) in minutes u18
Temperature of evaporator outlet temp. (S2) u20
Superheat across evaporator u21
Reference of superheat control u22
Opening degree of AKV valve ** u23
Evaporating pressure Po (relative) u25
Evaporator temperature To (Calculated) u26
Status on DI2 output. on/1=closed u37
Display air temperature. Weighted S3 and S4 u56
Measured temperature for alarm thermostat u57

Status on relay for cooling

** u58
Status on relay for fan ** u59
Status on relay for defrost ** u60

Status on relay for railheat

** u61
Status on relay for alarm ** u62
Status on relay for light ** u63
Readout of the actual rail heat eect u85
Status on high voltage input DI3 u87
Readout of thermostats actual cut in value u90
Readout of thermostats actual cut out value u91

*) 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

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

8 Instructions RI8RZ102 © Danfoss 06/2016 AK-CC 525A

Fault message

In an error situation the LED’s on the front will ash 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 High temperature alarm

A2/--- Low t. alarm Low temperature alarm

A4/--- Door alarm Door alarm

A5/--- Max hold time The ”o16” function is activated during

A10/--- Inject prob. Control problem

A11/--- No Rfg. sel. No refrigerant selected

A15/--- DI1 alarm DI1 alarm

A16/--- DI2 alarm DI2 alarm

A45/--- Standby
mode

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

E6/--- RTC error Check clock

E20/--- Pe error Error on pressure transmitter Pe

E24/--- S2 error Error on S2 sensor 4

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

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

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

---/--- Max Def.Time Defrost stopped based on time in-

Description

a coordinated defrost

Standby position (stopped refrigera­tion via r12 or DI input)

stead of, as wanted, on temperature

Alarm relay
groups (P41)

1

2

8

16

64

64

8

8

-

32

32

64

16

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 briey (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.

When the compressor is stopped, it must remain stopped
for at least x minutes.

The evaporator drips o and waits for the time to run out S4 4

Refrigeration stopped by main switch. Either with r12 or
a DI-input

Refrigeration stopped by thermostat S11 11

Defrost sequence. Defrost in progress S14 14

Defrost sequence. Fan delay — water attaches to the
evaporator

Refrigeration stopped due to open ON input or stopped
regulation

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

Regulation problem in the injections function S21 21

Start-up phase 2. Evaporator being charged S22 22

Adaptive control S23 23

Start-up phase 1. Signal reliability from sensors is
controlled

Manual control of outputs S25 25

No refrigerant selected S26 26

Delay on outputs during start-up S32 32

Case shutdown S45 45

Other displays:

The defrost temperature cannot be displayed. There is
stop based on time

Defrost in progress / First cooling after defrost -d-

Password required. Set password PS

Regulation is stopped via main switch OFF

S2 2

S3 3

S10 10

S15 15

S16 16

S24 24

non

Ctrl. state:
(Shown in all
menu displays)

*) Emergency cooling will take eect when there is lack of signal from a dened S3

or S4 sensor or signal from the pressure transmitter is outside signal range. The
regulation will continue with a registered average cutin frequency. There are
two registered values – one for day operation and one for night operation.

Data communication

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

Settings from
System manager

Settings from
AKM (AKM destination)

Log Alarm relay Send via

Non High Low-High

Network
High 1 X X X X
Middle 2 X X X
Low 3 X X X
Log only X
Disabled

AK-CC 525A Instructions RI8RZ102 © Danfoss 06/2016 9

10 Instructions RI8RZ102 © Danfoss 06/2016 AK-CC 525A

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