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AK-CC55 Compact
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Table of contents
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Danfoss AK-CC55 Compact User guide

User Guide
Case/room controller (EEV) Type AK-CC55 Compact
SW Ver. 2.0x
For refrigeration appliances and cold storage rooms.
AK-CC55 Compact

Contents

Introduction 5
Portfolio overview 6
Connectivity 7
Controller functionality 9
Functions 9
Defrost 12
Fans 13
Rail heat 15
Fan 16
Night blind 17
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AK-CC55 Compact
Display 19
Override 19
Applications 21
Product identication 25
Data communication 26
AKV info 26
External solid state relay for rail heat 27
AKS 32R info 27
Coordinated defrost via cable connections 27
External display AK-UI55 28
Connections 28
Operation 30
Parameter groups when operating via display 32
Get a good start 32
AK-UI55 display menu (SW ver. 2.0x) 34
Thermostat 34
Defrost 35
Fan control 35
Control 38
DO cong and manual 38
Service 39
Operation via AK-UI55 Bluetooth 41
AK-CC55 Connect menu (SW ver. 2.0x) 42
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AK-CC55 Compact
Start / Stop 42
Conguration 42
Fan control 49
Advanced 52
Operating status 55
Product specication 56
Electrical specications 56
Sensor and measuring data 56
Input and output relay specications 56
Function data 57
Environmental conditions 57
Dimensions 57
Certicates, declarations, and approvals 58
Online support 60
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Danfoss
84B3281
S5
S3
S4
S2
P
AKV
AK-CC55 Compact

Introduction

Application
Refrigeration appliance control with great exibility to adapt to refrigeration appliances and cold storage rooms.
Advantages:
• Control of Thermostatic Expansion Valve (TEV) and Electronic Expansion valve(EEV) applications
• Quick set-up with predened settings
• Easy conguration and service using a mobile app with Bluetooth
• Adaptive Minimum Stable Superheat (MSS) control is performed with lowest possible superheat
• Allows the suction pressure to be raised several degrees
• Adaptive Liquid Control (ALC) can be performed with superheat down to 0 degrees on transcritical CO2 systems with liquid ejectors
Principle
The temperature in the appliance is registered by one or two temperature sensors which are located in the air ow before the evaporator (S3) or after the evaporator (S4) respectively. A setting for thermostat, alarm thermostat and display reading determines the inuence the two sensor values should have for each individual function.
The temperature of the evaporator is registered with the S5 sensor which can be used as a defrosting sensor.
In addition to the output of the electronic AKV injection valve, the controller has relay outputs which are dened by the application setting
Figure 1: AK-CC55 with evaporator, AKV valve and sensor positions
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AK-CC55 Compact
AK-CC55 Single Coil
AK-CC55 Single Coil UI
AK-CC55 Multi Coil
Product image
Valve
1 x TXV or AKV
1 x AKV
1 x AKV
3 x AKV
Digital Output3554
Digital input
1 (2)
3 (2)
3 (2)
3 (2)
Analogue Output1111
Analogue Input
5 (4)
6 (7)
6 (7)
6 (7)
Display
1 remote
2 remote
1 remote + 1 Integrated
2 remote
Comm. module
Modbus
Modbus
Modbus
Modbus
Optional comm. module
LON module
LON module
LON module
Application
AK-CC55 Compact
AK-CC55 Single Coil
AK-CC55 Single Coil UI
AK-CC55 Multi Coil
AKV - application (electrically operated expansion valve)
xxx
0 – 10 V to control external stepper driver
x
TXV - application (thermostatic expansion valve + solenoid valve or compressor)
x
Remote hot gas - application
x
One valve, one evaporator, one refrigeration section
xxx
One valve, one evaporator, two refrigeration sections
x
One valve and two evaporators, two refrigeration sections
x
Two valves and two evaporators (same refrigeration section)
x
Three valves and three evaporators (same refrigeration section)
x
Custom conguration of relay outputs
x
x
Two compressorsxx
Heating functionxx
Control of air humidity
x
x
Adaptive superheat
xxx
Adaptive liquid control (zero superheat control for transcritical CO2 systems with liquid ejectors)
xxx
Adaptive defrosting
x
Product sensor
x
RS485 Lon, option (AK-OB55)
x
x
AK-CC55 Compact

Portfolio overview

The AK-CC55 portfolio contains four controllers with dierent functionalities and application settings, as outlined in the table.
Table 1: AK-CC55 Portfolio

Function overview

Table 2: AK-CC55 function overview by type
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Danfoss
84B8235
Compact
System Manager
AKA 245: LON units only and max 250 controller parameters
Multi Coil
KoolProg
Single Coil UI
AK-UI Info
AK-UI Set
AK-UI Bluetooth
Bluetooth
AK-CC55 Connect
Smart Device (IOS
or Android)
Modbus
LON/ TCP/IP (SNMP)
Display Bus
Modbus
LON/ TCP/IP (SNMP)
Modbus
Case Controller Remote Display Service App

AK-CC55 Compact

Connectivity

The diagram outlines the connectivity options presented by AK-CC55 for the design of system functionality.
Figure 2: Connectivity

Data communication

The AK-CC55 Compact controller has built-in MODBUS data communication only.
AK-CC55 Compact
Compact version for controlling one evaporator.
An application mode setting will congure inputs and outputs for the desired use. There are nine applications to choose from.
Regulation is performed using a TXV in combination with a liquid line solenoid valve, controlling a compressor or an AKV expansion valve.
AK-CC55 Compact is without display, and can be extended with one external display (see Figure 3 and Figure 4):
Figure 3: AK-CC55 Compact Figure 4: AK-CC55 Compact with external display.

External display

There are three versions available with dierent functions:
• AK-UI55 Info: Temperature display.
• AK-UI55 Set: Temperature display with control buttons on the front.
• AK-UI55 Bluetooth: Temperature display with Bluetooth communication, for use with AK-CC55 Connect Mobile app.
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AK-CC55 Compact
Figure 5: AK-UI55 Info Figure 6: AK-UI55 Set Figure 7: AK-UI55 Bluetooth
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Danfoss
84B3281
S5
S3
S4
S2
P
AKV
AK-CC55 Compact

Controller functionality

Functions

• Day/night thermostat with ON/OFF or modulating principle.
• Switch between thermostat settings via digital input.
• Adaptive superheat control.
• Modulating PWM control of brine valve
• Start of defrost via schedule, digital input, network or setting display.
• Natural, electric, simple hot gas, or warm brine defrost.
• Stop of defrost on time and/or temperature.
• Coordination of defrosting among several controllers in a line-up.
• Pulsing or ECO control of fans when thermostat is satised.
• Appliance cleaning function for documentation of HACCP procedure.
• Rail heat control via day/night load or dew point.
• Door function.
• Control of two compressors.
• Control of night blinds.
• Light control.
• Heat thermostat.
• High accuracy inputs:
◦ to guarantee a better measuring accuracy than stated in the standard EN ISO 23953-2 without subsequent
calibration (Pt1000 ohm sensor).
• Integrated MODBUS communication

Liquid injection by use of AKV

Liquid injection in the evaporator is controlled by an electronic injection valve of the type AKV. The valve operates as both expansion valve and solenoid valve. The controller opens and closes the valve based on sensor readings. The function contains an adaptive algorithm which independently adjusts the valve’s opening so that the evaporator constantly supplies optimum amount of refrigerant.
Superheat is measured via:
Pressure sensor Pe and temperature sensor S2. By using a pressure sensor and temperature sensor, a correct measurement of superheat is achieved under all conditions which ensures a very robust and precise control. The signal from one pressure transmitter can be shared by max. 10 controllers, but only if there is no signicant pressure dierence between the evaporators in question.
Figure 8: Liquid injection function with AKV valve
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Dry expansion (MSS Control)
Adaptive liquid control (ALC)
S4
S5
S3
Danfoss
84B3267
AK-CC55 Compact
There are two parallel settings for superheat:
• Dry expansion, which does not allow liquid ow on the outlet of the evaporator.
• Adaptive liquid control in transcritical CO2 systems, which allows liquid ow. This type of control requires that the controller receives an on/o signal from (for example) a suction accumulator in the suction line. A level switch in the tank will register when the liquid level exceeds the max. level. When this happens, the controller will switch to dry expansion, and then back to liquid control when the liquid level has dropped. The function is dened in setting o02, o37 or o84.
The function can also be activated via data communication from a system unit. If the adaptive liquid control signal is lost, the controller will automatically switch back to dry expansion.
Table 3: Liquid injection
WARNING:
Accidental actuation may allow liquid throughput to the compressor. It is the installer’s responsibility to ensure that signal loss to the controller will not result in liquid throughput to the compressor. Danfoss accepts no
responsibility for damage resulting from inadequate installation.

Thermostatic expansion valve control

In the compact version the refrigeration (injection) can be controlled either by starting/stopping a compressor or by opening/closing a solenoid valve in the liquid line.
Figure 9: AK-CC55 Compact with evaporator, solenoid valve, expansion valve and sensor positions
Brine control
When changing from ON/OFF control to modulating control in TXV applications, a solenoid valve can be PWM controlled with a set period time from 30 – 900 sec. A number of additional brine control parameters are available in the injection control menu. When brine control is enabled, a dedicated brine defrost can also be set up in order to force open the brine valve while defrosting.
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ON/OFF control
Modulating control
AK-CC55 Compact

Temperature control

The temperature in the appliance is registered by one or two temperature sensors which are located in the return air before the evaporator (S3) or after the evaporator (S4) respectively. A setting for the thermostat, night thermostat, alarm thermostat and display reading determines how much the two sensor values should inuence each individual function, e.g. 50% of S4 will produce an equal value from both sensors.
The actual temperature control can take place in two ways:
1.
As an ordinary ON/OFF regulation with a dierential, or
2.
As a modulating control where the temperature variation will not be nearly as high as in ON/OFF control.
There is, however, a limit to the use of a modulating control as it can only be used in remote cabinets. It is not recommended to use modulating thermostat control in low temperature applications. In applications with one evaporator and one compressor, the thermostat function with ON/OFF control should be selected. In remote cabinets, the thermostat function may either be selected for ON/OFF control or modulating control.
Table 4: Control methods

Temperature monitoring

Just as 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 inuence 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 alarm. This time delay is active for pull-down, after defrosting, appliance cleaning and start-up.

Thermostat bands

Thermostat bands can be used benecially for appliances where dierent product types are stored, which requires dierent temperature conditions. It is possible to change between the two dierent 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.
Figure 10: Thermostat band function with two dierent band settings

Night setback of thermostat value

In refrigeration appliances there may be big load dierences 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 eect on the product temperature.
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-++°C1÷+
Fan2÷÷O3++°C
AK-CC55 Compact
Change-over between day and night operation can take place as follows:
• via an external switch connected to a digital input.
• via a signal from the data communication system.
Figure 11: Thermostat band function with Night setback

Appliance cleaning

This function makes it easy for the shop’s sta to carry out a cleaning of the appliance according to a standard procedure. Appliance cleaning is activated via a pulse signal – as a rule via a key switch placed on the appliance or via the AK-CC55 Connect mobile app.
Appliance cleaning is carried out via three phases:
1.
At the rst 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.
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.
There are no temperature alarms during appliance cleaning.
Table 5: Appliance cleaning function

Appliance shutdown

The function closes the AKV valve and all outputs are switched o. The cooling appliance is stopped like the “Main switch”, but this happens without an “A45 standby alarm”. The function can be enabled by a switch on the DI input or via a setting through data communication.

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
• Hot gas: Simple hot gas defrost can be selected in application modes where a compressor is controlled. The compressor unit will operate during defrosting
• Brine defrost: The brine valve is forced open while defrosting (only possible when selecting modulating control in TXV applications)
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AK-CC55 Compact

Start of defrost

A defrost can be started in dierent ways:
Interval:
Defrost is started at xed time intervals like e.g. 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.
Week schedule:
Here defrost can be started at xed times of the day and night. However, max. 6 defrosts per day.
Contact:
Defrost is started with a contact signal on a digital input.
Figure 12: Defrost start
Network:
The defrost start signal is received from a system manager via data communication.
Max. thermostat runtime:
When the aggregate time has passed a preset value, a defrost will be initiated.
Manual:
An extra defrost can be activated from the defrost button on the AK-UI55 Set display via the app, or via the parameter setting. All the mentioned methods can be used in parallel – if just one of them is activated, a defrost will be started.

Stop of defrost

Defrosting can be stopped by either:
• Time
• Temperature (with time as safety)

Compressor run during hot gas defrost

If the defrosting method is set to “Gas,” the compressor will be “On” during the defrost cycle. (Only for application situations that include a compressor output).

Fans

The fans can be stopped or operated during defrosting. They can also run and then be stopped at a set temperature. The temperature signal is obtained from the defrost stop sensor.

Defrost sequence

1.
Pump down
2.
Defrost
3.
Waiting position after defrost
4.
Drip o
5.
Delay of fan

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 days.
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System manager
Max 10.
Danfoss
84B8268
AK-CC55 Compact
If the controller is equipped with data communication, the clock will automatically be updated from a Danfoss system manager.

Coordinated defrost

There are two ways in which coordinated defrost can be arranged.
Figure 13: Coordinated defrost options
Either with wire connections between the controllers or via data communication:
Wire connections
The digital input DI2 must be congured for coordinated defrost and wiring must be connected between the relevant 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 manager handles the coordination. The controllers are gathered in defrosting groups and the system manager 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 manager 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.

Melt function

This function will prevent the air ow 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 during the set melting period. The frost will be melted so that the air ow and hence the evaporator’s capacity will be greatly improved.

Control of two compressors (only with custom set-up)

Two compressor steps can be controlled cyclic or sequentially. At cyclic control, two compressors must be of the same size, while in sequential control compressor step 1 can be larger than step 2.
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AK-CC55 Compact
Figure 14: Control of two compressors.
Cyclic control
When the controller demands refrigeration, it will rst cut in the compressor with the shortest operating time. After the time delay, the second compressor will be cut in.
When the temperature has dropped to ”the middle of the dierential”, the compressor with the longest operation time will be cut out.
The running compressor 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 dierential, a compressor will again be started.
If one compressor cannot maintain the temperature within the dierential, the second compressor will also be started.
If one of the compressors has run on its own for two hours, the compressors will be changed over so that operational time is balanced.
The two compressors must be of a type that can start up against a high pressure.
The compressor's settings for ”Min. On time” and ”Min. O time” will always have top priority during normal regulation. But if one of the override functions is activated, like e.g. defrost, door open function, case shutdown, forced closing, the ”Min. On time” will be disregarded.
Sequential control
Compressor steps are controlled in the same manner as described for cyclic control, but compressor step 1 will always be started rst and cut out as the last one. No time equalization is available in sequential control mode.

Rail heat

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 dewpoint.
Relay or analogue output
A relay output can be used when long cycle times are permitted. If fast pulsing is required, the AO1/PWM output can be used. The output must be connected to an external power solid state relay. The cycle time must be congured for the relay output in o43 or for analogue output in P82.
Pulse control according to day and night
Various ON periods can be set for day and night operation. A cycle time is set as well as the percentage part of the period in which the rail heat is ON.
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AK-CC55 Compact
Figure 15: Rail heat control, day/night load.
Pulse control according to dewpoint
In order to use this function, a system manager of the type AK-SM is required which can measure ambient temperature and humidity to calculate dewpoint and distribute to the appliance controllers. For this the rail heat’s ON period is controlled according to the distributed dewpoint.
Two dewpoint values are set in the appliance control:
• One where the eect must be max. i.e. 100%. (o87)
• One where the eect must be min. (o86)
At a dewpoint which is equal to or lower than the value in 086, the eect will be the value indicated in o88. In the area between the two dewpoint values, the controller will manage the power to be supplied to the rail heat.
Figure 16: Rail heat control, dewpoint
During defrosting
During defrosting rail heat will be active, as selected in setting d27.
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 cut-out period (cold room)
• during night operation and during the thermostat’s cut-out period (appliance with night blinds) (The function is not actual when r14=2, i.e. modulating regulation).
A period of time is set as well as the percentage of this period of time where the fans have to be operating.
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AK-CC55 Compact
Figure 17: Fan cycle time
Cut-out of fans during plant breakdowns
If the refrigeration in a breakdown situation stops, the temperature in the cold room may rise quickly as a result of the emission of heat from large fans. In order to prevent this situation, the controller can stop the fans if the temperature at S5 exceeds a set limit value. The fans will start running again when the S5 temperature has dropped 2K below the set limit. (The function can also be used as a type of MOP function. Here the load on the compressors is limited until the S5 temperature has fallen below the congured value).
ECO operations (only with custom set-up)
Reduced fan speed is permitted when the night blind is down. (Fan with changeover between high and low speed). ECO operation is not permitted if the heat function is activated.

Light function

The function can be used for controlling the light in a refrigeration appliance or in a cold room. It can also be used for controlling a motorised night blind.
The light function can be dened in several ways:
• The light is controlled via a signal from a door contact. The light is kept on for a set time after the door has been closed.
• The light is controlled via the day/night function
• The light is controlled via a DI input
• The light is controlled via the data communication from a system manager. 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 terminals on the relay. This ensures that the light remains ON in the appliance if power to the controller should fail.
A setting denes how light is controlled when regulation is stopped via r12 Main switch = OFF (see o98). The light is switched o when the appliance cleaning function is activated.

Night blind

Motorised night blinds 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 open, and when the light is switched o, the night blinds close again. When the night blinds are closed, it is possible to open them using a switch signal on the digital input. If this pulse signal is activated, the night blinds will open and the refrigeration appliance can be lled with new products. If the pulse signal is activated again, the blinds close.
When the night blind function is used, the thermostat function can control with dierent weighting between the S3 and S4 sensors. A weighting during day operation and another when the blind is closed.
A night blind is opened when the appliance cleaning function is activated.
A setting can dene that the night blind is opened when "r12" (Main switch) is set to o (see o98).
When the night blind rolls down, the fan will be stopped for the set time. The night blind can thereby roll down to the correct position.
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Danfoss
84B8269
A
r01
r01
t
º C
r62
B
C
ABC
Refrigeration
Neutral zone
Heat
Function
Input / Settings menu
Setting
DI1
DI2
o02
o37
None++
0
DI Status++
1
Door function++
2
Door alarm++
3
Defrost start++
4
Main switch++
5
Night setback++
6
Thermostat band++
7
Alarm at closed++
8
Alarm at open++
9
Case cleaning++
10
Forced cooling++
11
Open blinds++
12
Coordinated defrost
+
13
Forced closing++
14
Shutdown++
15
Light control++
16
Leak detection++
20
Adaptive liquid control
++21
AK-CC55 Compact

Heating function (only with custom set-up)

The heating function is used to prevent the temperature from becoming too low, e.g. in a cold room, etc. The limit for when the heating function cuts o is set as an oset value below the current cut-out limit for the refrigeration thermostat. This ensures that refrigeration and heating do not occur simultaneously. The dierence for the heating thermostat has the same value as for the refrigeration thermostat. To prevent that the heating thermostat cuts in during short-term drops in air temperature, a time delay can be set for when to change from refrigeration to heating.
Figure 18: Heating function

Digital inputs

There are two digital inputs, DI1 and DI2, with dry contact function, and one digital input DI3 with high voltage signal.
They can be used for the following functions:
Table 6: Function table and DI settings
Example: If DI1 is to be used to start a defrost, o02 must be set to 4.
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