Danfoss AK-CH 650A User guide

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Design Guide

Capacity controller for water chiller with two suction groups

AK-CH 650A

ADAP-KOOL® Refrigeration control systems

Contents

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

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

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

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

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

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

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

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

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

Extension module AK-XM 103A .................................................18

Extension module AK-XM 204A / AK-XM 204B .....................20

Extension module AK-XM 205A / AK-XM 205B .....................22

Extension module AK-OB 110 ....................................................24

Extension module AK-OB 101A..................................................25

Extension module EKA 163B / EKA 164B ................................ 26

Power supply module AK-PS 075 / 150 ...................................27

Preface to design ....................................................................................28

Functions ............................................................................................28

Connections ...................................................................................... 29

Limitations ......................................................................................... 29

Design of a compressor and condenser control .........................30

Procedure: ..........................................................................................30

Sketch .................................................................................................. 30

Compressor and condenser functions ....................................30

Connections ...................................................................................... 31

Planning table .................................................................................. 33

Length .................................................................................................34

Linking of modules ......................................................................... 34

Determine the connection points ............................................35

Connection diagram ...................................................................... 36

Supply voltage ................................................................................. 37

Ordering ..................................................................................................... 38

3. Mounting and wiring .............................................................39

Mounting ................................................................................................... 40

Mounting of analog output module ........................................ 40

Mounting of extension module on the basic module ....... 41

Wiring .......................................................................................................... 42

4. Conguration and operation ................................................45

Conguration ...........................................................................................47

Connect PC ........................................................................................ 47

Authorization .................................................................................... 48

System setup ....................................................................................50

Set plant type ................................................................................... 51

Set control of compressors ..........................................................52

Setup control of condenser .........................................................55

Setup Display .................................................................................... 57

Setup defrost .................................................................................... 58

Setup general alarm inputs ......................................................... 59

Setup separate thermostat functions ...................................... 60

Setup separate voltage functions ............................................. 61

Conguration of inputs and outputs .......................................62

Set alarm priorities..........................................................................64

Lock conguration ..........................................................................66

Check conguration .......................................................................67

Check of connections ............................................................................ 69

Check of settings.....................................................................................71

Schedule function .................................................................................. 73

Installation in network .......................................................................... 74

First start of control ................................................................................75

Check alarms ..................................................................................... 75

Start the control ............................................................................... 76

Manual capacity control ............................................................... 77

Manual defrost ......................................................................................... 78

5. Regulating functions .............................................................79

Suction groups ........................................................................................80

Capacity control of compressors ...............................................80

Reference for compressor control ..................................... 81

Capacity distribution .............................................................. 82

Power pack types – compressor combinations ............82

Load shedding ..........................................................................85

Injection in evaporators ........................................................ 85

Defrost .................................................................................................86

Safety functions ............................................................................... 87

Pump control ....................................................................................89

Condenser ................................................................................................. 90

Capacity control of condenser ...................................................90

Reference for condensing pressure ..........................................91

Capacity distribution ..................................................................... 92

Step regulation ........................................................................................92

Speed regulation ....................................................................................92

Condenser couplings .....................................................................93

Safety functions for condenser .................................................. 93

External condenser control .........................................................94

General monitoring functions ...........................................................95

Miscellaneous ..........................................................................................96

Appendix A - Alarm texts ...................................................................100

Appendix B - Recommended connection ...................................102

2 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

1. Introduction

Application

AK-CH 650A is a water chiller control for capacity control of max. 8 compressors in two groups and capacity control of one air-cooled condensers on indirect refrigeration systems within commercial refrigeration. In addition to capacity control, the controller can control pumps etc.

SW = 1.8

The controller uses the following signals for control/monitoring: S4 Charge temperature (control signal) S3 Return temperature P0.1, P0.2 Suction pressure Pc Condensing pressure Sc3 Ambient temperature S4.1, S4.2 Frost protection Flow switch Frost protection / pump change Sd.1, Sd.2 Discharge gas temperature (monitoring) Ss.1, Ss.2 Suction gas temperature (reading)

Compressor capacity is controlled by charge temperature S4 and by suction pressure P0 as frost protection. Condenser capacity is controlled by condensing pressure Pc or, alternatively, temperature sensor S7.

If the system has a condenser for each suction group, the condenser capacity must be externally regulated, e.g. by two AK-PC 530 units. If the system has dry coolers and heat recovery, it must be externally regulated, e.g. by an AK-PC 420. A couple of examples are shown in the section on condenser regulation.

Among the dierent functions are:

- Capacity control of up to 8 compressors (2x4 pcs.)

- Max. 3 unloaders/compressor

- Speed control of two compressors

- Up to 6 safety inputs for each compressor

- Capacity limitation to minimize consumption peaks

- Twin pump control with automatic operating time equalisation

- Speed control of twin pump

- Start/stop signal for injection in evaporator

- Defrost control with time or temperature stop (Applicance

controls)

- Safety monitoring of high pressure / low pressure / pressure

temperature

- Frost protection

- Capacity control of up to 8 fans

- Floating condenser reference with regard to outside temperature

- Heat recovery function

- Fan capacity with regard to Step coupling, speed regulation or a

combination

- Safety monitoring of fans

- Alarm signals can be generated directly from the controller and

via data communication

- Alarms are shown with texts so that the cause of the alarm is

easy to see.

- Plus some completely separate functions that are totally inde-

pendent of the regulation – such as alarm inputs, thermostats, pressostat and voltage inputs.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 3

Principles

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

Controller

Top part

Advantages

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

• The software can be set for one or more regulations

• Several regulations with the same components

• Extension-friendly when systems requirements are changed

• Flexible concept:

- Controller series with common construction

- One principle – many regulation uses

- modules are selected for the actual connection requirements

- The same modules are used from regulation to regulation

Extension modules

Bottom part

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

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

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

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

Examples

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

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

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

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Direct connection

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

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

Displays

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

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

Network linking

The controller can be linked up into a network together with other controllers in an ADAP-KOOL® refrigeration control system. After the setup operation can be performed at a distance with, say, our software program type AKM.

Users

The controller comes supplied with several languages, one of which can be selected and employed by the user. If there are several users, they may each have their choice of language. All users must be assigned a user prole which either gives access to full operation or gradually limits the operation to the lowest level that only allows you “to see”. Language selection is part of the service tool settings. If the language selection is not available in the service tool for the current regulator, English texts will be displayed.

External display

An external display can be tted in order for brine temperature, P0 (Suction) and Pc (Condensing) readings to be displayed. A total of 4 displays can be tted and with one setting it is possible to choose between the following readings: S4, S3, P01, P02, S4.1, S4.2, Cond. regulation sensor, Pc1, Pc2, Sd1, Sd2, Ss1, Ss2.

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Light-emitting diodes

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

Log

From the log function you can dene the measurements you wish to be shown. The collected values can be printed, or you may export them to a le. You can open the le in Excel.

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

■ Power

■ Comm

■ DO1 ■ Status

■ DO2 ■ Service Tool

■ DO3 ■ LON

■ DO4

■ DO5 ■ Alarm

■ DO6

■ DO7

■ DO8 ■ Service Pin

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

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

Alarm

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

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

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2. Design of a controller

This section describes how the controller is designed.

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

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

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Module survey

• Controller module – capable of handling minor plant requirements.

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

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

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

Extension module with additional analog inputs

External display for suction pressure etc.

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

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

- to which module

- at which point (”terminals”)

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

pressure range)

Extension module with additional relay outputs and additional analog inputs.

Controller with analog inputs and relay outputs.

Top part

Extension module with 2x analog output signals

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

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1. Controller

Type Function Application

AK-CH 650A Controller for capacity control of compressors and condensers Water chiller control for two suction groups

2. Extension modules and survey of inputs and outputs

Type Analog

inputs

For sensors, pressure transmitters etc.

Controller 11 4 4 - - - -

Extension modules

AK-XM 101A 8

AK-XM 102A 8

AK-XM 102B 8

AK-XM 103A 4 4

AK-XM 204A 8

AK-XM 204B 8 x

AK-XM 205A 8 8

AK-XM 205B 8 8 x

The following extension module can be placed on the PC board in the controller module. There is only room for one module.

AK-OB 110 2

On/O outputs On/o supply voltage

Relay (SPDT)

Solid state Low voltage

(DI signal)

(max. 80 V)

High voltage (max. 260 V)

Analog outputs

0-10 V d.c. For override of

Module with switches

relay outputs

3. AK operation and accessories

Type Function Application

Operation

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

- Cable between PC and AK controller AK - Com port

- Cable between zero modem cable and AK controller AK - RS 232

Cable between PC and AK controller AK - USB port

Accessories Power supply module 230 V / 115 V to 24 V

AK-PS 075 18 VA

AK-PS 150 36 VA

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

EKA 163B Display

EKA 164B Display with operation buttons

- Cable between display and controller

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

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

Supply for controller

Length = 2 m

Length = 6 m

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

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 9

Common data for modules

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

Power consumption AK-__ (controller) 8 VA

AK-XM 101, 102 2 VA

AK-XM 204, 205 5 VA

Analoge indgange Pt 1000 ohm /0°C Resolution: 0.1°C

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

Other pressure transmitter: Ratiometric signal Min. and Max. pressure must be set

Voltage signal 0-10 V

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

On/o supply voltage inputs Low voltage

Relay outputs SPDT

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

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

High voltage 0 / 260 V a.c.

AC-1 (ohmic) 4 A

AC-15 (inductive) 3 A

U Min. 24 V

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

Accuracy: +/- 0.5°C

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

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

O: U < 2 V On: U > 10 V

O: U < 24 V On: U > 80 V

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

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

Ambient temperature During transport -40 to 70°C

During operation -20 to 55°C ,

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

Enclosure Material PC / ABS

Class IP10 , VBG 4

Mounting For mounting on panel wall or DIN rail

Weight with screw terminals modules in100- / 200- / controller-series Ca. 200 g / 500 g / 600 g

Approvals EU low voltage directive and EMC require-

ments are complied with

UL 873,

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

Capacitive load

The relays cannot be used for the direct connection of capacitive loads such as LEDs and on/o control of EC motors. All loads with a switch mode power supply must be connected with a suitable contactor or similar.

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

UL le number: E166834 for XM modules UL le number: E31024 for CH modules

10 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Dimensions

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

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 11

Controller

Function

There are several controllers in the series. The function is determined by the programmed software, but outwardly the controllers are identical – they all have the same connection possibilities:

11 analog inputs for sensors, pressure transmitters, voltage signals

and contact signals.

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

Supply voltage

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

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

Data communication

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

Address setting

When the controller is connected to a gateway type AKA 245, the controller’s address must be set between 1 and 119.

Service PIN

When the controller is connected to the data communication cable the gateway must have knowledge of the new controller. This is obtained by pushing the key PIN. The LED “Status” will ash when the gateway sends an acceptance message.

Operation

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

Light-emitting diodes

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

• Voltage supply to the controller

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

• Status of outputs DO1 to DO8

Right row:

• Software status (slow ash = OK)

• Communication with Service Tool

• Communication on LON

• Alarm when LED ashes

- 3 LED’s that are not used

• “Service Pin” switch has been activated

Address

■ Power

■ Comm

■ DO1 ■ Status

■ DO2 ■ Service Tool

■ DO3 ■ LON

■ DO4

■ DO5 ■ Alarm

■ DO6

■ DO7

■ DO8 ■ Service Pin

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

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

Keep the safety distance!

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

A small module (option board) can be placed on the bottom part of the controller. The module is described later in the document.

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Point

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

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

Terminal 15: 12 V Terminal 16: 5 V

Terminal 27: 12 V Terminal 28: 5 V

Analog inputs on 1 - 11

Solid state outputs on 12 - 15

Relay or AKV coil fx 230 V a.c.

Signal Signal

Pt 1000 ohm/0°C

S1 S2 Saux1 Saux2 SSA SdA

AKS 32R

3: Brown

2: Blue

1: Black

P0A P0B PcA

AKS 32

3: Brown

2: Black

1: Red

PcB

...

On/O Ext.

Main switch

Day/ Night

Door

AKV

AKV Comp 1 Comp 2 Fan 1 Alarm Light Rail heat Defrost

Option Board

Please see the signal on the page with the module.

24 and 25 used only when "Option board tted"

type

Pt 1000

AKS 32R / AKS 2050

-1 - xx bar

AKS 32

-1 - zz bar

0 - 5 V 0 - 10 V

Active at:

Closed

Open

Active at:

O

Point 12 13 14 15 16 17 18 19

Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 9 - 10

6 (AI 6) 11 - 12

7 (AI 7) 13 - 14

8 (AI 8) 19 - 20

9 (AI 9) 21 - 22

10 (AI 10) 23 - 24

11 (AI 11) 25 - 26

12 (DO 1) 31 - 32

13 (DO 2) 33 - 34

14 (DO 3) 35 - 36

15 (DO 4) 37 - 38

16 (DO 5) 39 - 40 - 41

17 (DO6) 42 -43 - 44

18 (DO7) 45 - 46- 47

19 (DO8) 48 - 49 -50

24 -

25 -

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

Relay outputs on 16 - 19

Terminal

Signal type /

Active at

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 13

Extension module AK-XM 101A

Function

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

Supply voltage

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

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

Light-emitting diodes

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

• Voltage supply to the module

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

14 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Point

Point 1 2 3 4

Type AI1 AI2 AI3 AI4

Terminal 9: 12 V Terminal 10: 5 V

Pt 1000 ohm/0°C

AKS 32R

AKS 32

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

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

3: Brown

2: Blue

1: Black

3: Brown

2: Black

1: Red

Signal Signal

type

S1 S2 Saux1

Pt 1000 Saux2 SsA SdA

AKS 32R / P0A P0B

AKS 2050

-1 - xx bar PcA PcB

AKS 32

-1 - zz bar

Terminal 15: 5 V Terminal 16: 12 V

Terminal

11, 12, 13, 14:

(Cable screen)

Point 5 6 7 8

Type AI5 AI6 AI7 AI8

...

On/O Ext.

Main switch

Day/ Night

Door

0 - 5 V 0 - 10 V

Active at:

Closed

Open

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 17 - 18

6 (AI 6) 19 - 20

7 (AI 7) 21 - 22

8 (AI 8) 23 - 24

Terminal

Signal type /

Active at

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 15

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

Function

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

Signal

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

Supply voltage

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

Light-emitting diodes

They indicate:

• Voltage supply to the module

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

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

AK-XM 102A

Max. 24 V

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

AK-XM 102B

Max. 230 V

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

16 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Point

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

Signal Active at

Ext. Main switch

Day/ Night

Comp. safety 1

Comp. safety 2

Closed

(voltage on)

Open

(voltage o)

Point 1 2 3 4

Type DI1 DI2 DI3 DI4

Point 5 6 7 8

Type DI5 DI6 DI7 DI8

Signal Module Point Terminal Active at

1 (DI 1) 1 - 2

2 (DI 2) 3 - 4

3 (DI 3) 5 - 6

4 (DI 4) 7 - 8

5 (DI 5) 9 - 10

6 (DI 6) 11 - 12

7 (DI 7) 13 - 14

8 (DI 8) 15 - 16

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Extension module AK-XM 103A

Function

The module contains: 4 analog inputs for sensors, pressure transmitters, voltage signals

and contact signals. 4 analog voltage outputs 0 - 10 V

Supply voltage

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

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

Galvanic isolation

The inputs are galvanically separated from the outputs. The outputs AO1 and AO2 are galvanically separated from AO3 and AO4.

Light-emitting diodes

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

• Voltage supply to the module

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

Max. load

I < 2.5 mA R > 4 kΩ

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Point

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

Point 1 2 3 4

Type AI1 AI2 AI3 AI4

Terminal 9: 12 V Terminal 10: 5 V

Terminal 11, 12: (Cable screen)

Pt 1000 ohm/0°C

AKS 32R

AKS 32

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

3: Brown

2: Blue

1: Black

3: Brown

2: Black

1: Red

Signal Signal

type

S1 S2 Saux SsA

Pt 1000

SdA Shr Stw Sgc

P0A P0B PcA

AKS 32R / AKS 2050

-1 - xx bar PcB Paux Pgc

AKS 32

-1 - zz bar Prec

Galvanic isolation: AI 1-4 ≠ AO 1-2 ≠ AO 3-4

Point 5 6 7 8

Type AI5 AI6 AI7 AI8

...

On/O Ext.

Main switch Day/ Night

Door Level switch

0 - 5 V 0 - 10 V

Active at:

Closed

Open

0-10 V

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AO 1) 17 - 18

6 (AO 2) 19 - 20

7 (AO 3) 21 - 22

8 (AO 4) 23 - 24

Terminal

Signal type /

Active at

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 19

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

Function

The module contains 8 relay outputs.

Supply voltage

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

AK-XM 204B only Override of relay

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

Light-emitting diodes

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

• Voltage supply to the controller

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

• Status of outputs DO1 to DO8

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

• Override of relays ON = override OFF = no override

AK-XM 204A AK-XM 204B

Fuses

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

Max. 230 V

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

AK-XM 204B Override of relay

Keep the safety distance!

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

20 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Point

Signal Active at

Comp. 1

Comp. 2

Fan 1

Alarm

O

Point 1 2 3 4 5 6 7 8

Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

Signal Module Point Terminal Active at

1 (DO 1) 25 -26 - 27

2 (DO 2) 28 - 27 - 30

3 (DO 3) 31 - 32 - 33

4 (DO 4) 34 - 35 -36

5 (DO 5) 37 - 38 - 39

6 (DO 6) 40 - 41 - 42

7 (DO 7) 43 - 44 - 45

8 (DO 8) 46 - 47 - 48

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 21

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

Function

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

and contact signals.

8 relay outputs.

Supply voltage

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

AK-XM 205B only Override of relay

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

Light-emitting diodes

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

• Voltage supply to the controller

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

• Status of outputs DO1 to DO8

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

• Override of relays ON = override OFF = no override

AK-XM 205A AK-XM 205B

max. 10 V

Fuses

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

Max. 230 V

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

AK-XM 205B Override of relay

Keep the safety distance!

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

22 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Point

Pt 1000 ohm/0°C

Signal Signal

type

S1 S2 Saux1

Pt 1000

Saux2 SsA SdA

Point 1 2 3 4 5 6 7 8

Type AI1 AI2 AI3 AI4 AI5 AI6 AI7 AI8

Terminal 9: 12 V Terminal 10: 5 V

Terminal 21: 12 V Terminal 22: 5 V

Terminal 11, 12, 23, 24 :

(Cable screen)

Point 9 10 11 12 13 14 15 16

Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8

AKS 32R

AKS 32

On/O

3: Brown

2: Blue

1: Black

3: Brown

2: Black

1: Red

P0A P0B PcA PcB

...

Ext. Main switch

Day/ Night

Door

Comp 1 Comp 2 Fan 1 Alarm Light Rail heat Defrost

AKS 32R / AKS 2050

-1 - xx bar

AKS 32

-1 - zz bar

0 - 5 V 0 - 10 V

Active at:

Closed

Open

Active at:

O

Signal Module Point

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 13 - 14

6 (AI 6) 15 - 16

7 (AI 7) 17 - 18

8 (AI 8) 19 -20

9 (DO 1) 25 - 26 - 27

10 (DO 2) 28 - 29 - 30

11 (DO 3) 31 - 32 - 33

12 (DO 4) 34 - 35 - 36

13 (DO 5) 37 - 38 - 39

14 (DO6) 40 - 41 - 42

15 (DO7) 43 - 44 - 45

16 (DO8) 46 - 47 - 48

Terminal

Signal type /

Active at

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 23

Extension module AK-OB 110

Function

The module contains two analog voltage outputs of 0 – 10 V.

Supply voltage

The supply voltage to the module comes from the controller module.

Placing

The module is placed on the PC board in the controller module.

Point

The two outputs have points 24 and 25. They are shown on the earlier page where the controller is also mentioned.

Max. load I < 2,5 mA R > 4 kohm

AO 0 - 10 V

Module

Point 24 25

Type AO1 AO2

AO2

AO1

24 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Extension module AK-OB 101A

Function

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

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

• Clock function

• Fixed times for day/night change-over

• Fixed defrost times

• Saving of alarm log in case of power failure

• Saving of temperature log in case of power failure

Connection

The module is provided with plug connection.

Placing

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

Point

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

Working life of the battery

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

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 25

Extension module EKA 163B / EKA 164B

Function

Display of important measurements from the controller, e.g. brine

temperature, suction pressure or condensing pressure.

Setting of the individual functions can be performed by using the display with control buttons. It is the controller used that determines the measurements and settings that can occur.

Connection

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

Both types of display (with or without control buttons) can be connected to either display output A, B, C or D.

When the controller starts up, the display will show the output that is connected.

- - 1 = output A

- - 2 = output B etc.

EKA 163B EKA 164B

Placing

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

Point

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

Module

Point - -

Type - -

26 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Power supply module AK-PS 075 / 150

Function

24 V supply for controller.

Supply voltage

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

Placing

On DIN-rail

Eect

Type Output tension Output current Power

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

AK-PS 150 24 V d.c.

(adjustable)

1.5 A 36 VA

Dimension

Type High Width

AK-PS 075 90 mm 36 mm

AK-PS 150 90 mm 54 mm

Supply to a controller

Connections

AK-PS 075

AK-PS 150

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 27

Preface to design

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

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

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

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

Functions

Clock function

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

Start/stop of regulation

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

Alarm function

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

Extra temperature sensors and pressure sensors

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

Forced control

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

Data communication

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

28 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Connections

In principle there are the following types of connections:

Analog inputs ”AI”

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

sources:

• Temperature signal from Pt 1000 ohm temperature sensor

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

• Voltage signal from 0 to 10 V

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

transmitter’s pressure range must be set.

ON/OFF voltage inputs ”DI”

This signal must be connected to two terminals.

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

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

- high-voltage signals, e.g. 230 V

ON/OFF output signals ”DO”

There are two types, as follows:

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

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

When programming the function must be set:

• Active when the output is activated

• Active when the output is not activated.

Analog output signal ”AO”

This signal is to be used if a control signal is to be transmitted to an external unit, e.g. a frequency converter. When programming the signal range must be dened: 0-5 V, 1-5 V, 0-10 V or 2-10 V. Or conversely 5-0 V, 5-1 V, 10-0 V or 10-2 V.

When programming the function must be set:

• Active when the input is without voltage

• Active when voltage is applied to the input.

Limitations

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

✔ The sum of connections cannot exceed 80.

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

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

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

controller module.

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

extension module.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 29

Design of a compressor and condenser control

Procedure:

1. Make a sketch of the system in question

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

3. Consider the connections to be made

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

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

6. Decide which extension modules are to be used

7. Check that the limitations are observed

8. Calculate the total length of modules

8. The modules are linked together

10. The connection sites are established

11. Draw a connection diagram or a key diagram

12. Size of supply voltage/transformer

Follow these 12 steps

Sketch

Make a sketch of the actual plant.

Compressor and condenser functions

AK-CH 650A

Application

Regulation of two compressor groups x

Regulation of a condenser group x

Both compressor groups and condenser group x

Pumpe control x

Regulation of compressor capacity

PI-regulation x

Max. number of compressors 8

Max. number of unloaders each compressor 3

Identical compressor capacities x

Dierent compressor capacities x

Speed regulation of rst compressor i each group x

Run time equalisation within each group x

Min. restart time x

Min. On-time x

Liquid injection in evaporator x

Load shedding (Capacity limitation) x

Brine temperature reference

Override via P0 optimisation x

Override via “night setback” x

Override via "0 -10 V signal" x

Speed regulation of pumps x

Regulation of condenser capacity

Step regulation x

Max. number of steps 8

Speed regulation x

30 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Step and speed regulation x

Speed regulation on rst step x

Limitation of speed during night operation x

Heat recovery function via thermostat function x

Heat recovery function via DI signal x

A bit more abot the functions

Compressor

Regulation of up to 8 compressors. Up to three unloaders per compressor. Compressor No. 1 in each group can be speed-regulated.

Condenser pressure reference

Floating condensing pressure reference x

Setting of reference for heat recovery function x

Safety functions

Preventing the temperature from dropping below the accepted limit at S4.1 and S4.2.

Min. suction pressure x

Max. suction pressure x

Max. condensing pressure x

Max. discharge gas temperature x

Min. / Max. superheat x

Safety monitoring of compressors x

Common high pressure monitoring of compressors x

Safety monitoring of condenser fans x

General alarm functions with time delay 10

Frost protection x

Miscellaneous

Extra sensors 7

Option for connection of separate display 2

Separate thermostat functions 5

Separate pressostat functions 5

Separate voltage measurements 5

Condenser

Regulation of up to 8 condenser steps. Fans can be speed-regulated. Either all on one signal or only the rst fan of several. Relay outputs and solid state outputs may be used, as desired.

Speed regulation of condenser fans

The function requires an analog output module. A relay output may be used for start/stop of the speed regulation. The fans may also be cut in and out by relay outputs.

Safety circuit

If signals are to be received from one or more parts of a safety circuit, each signal must be connected to an ON/OFF input.

Day/night signal for raising the suction pressure

The clock function can be used, but an external ON/OFF signal may be used instead. If the “P0 optimisation” function is used, no signal will be given concerning the raising of the suction pressure. The P0 optimisation will see to this.

Separate thermostat and pressure control functions

A number of thermostats can be used according to your wishes. The function requires a sensor signal and a relay output. In the controller there are settings for cutin and cutout values. An associated alarm function may also be used.

Separate voltage measurements

A number of voltage measurements can be used according to your wishes. The signal can for example be 0-10 V. The function requires a voltage signal and a relay output. In the controller there are settings for cutin and cutout values. An associated alarm function may also be used.

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

Connections

Here is a survey of the possible connections. The texts can be read in context with the table in point 4.

Analog inputs

Temperature sensors

• S4 and S3 (regulation sensors for brine temperature) Must always be used.

• S4.1, S4.2 (frost protection sensor)

• Ss1, Ss2 (suction gas temperature)

The measurement is reserved, but the connection can be deleted.

• Sd1, Sd2 (discharge gas temperature) The measurement is reserved, but the connection can be deleted.

• Sc3 (outdoor temperature) To be used when regulation is performed with oating condenser reference.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 31

• S7 (Hot brine return temperature)) This must be used when the control sensor for the condenser has been selected as S7.

• Saux (1-4), Extra temperature sensors, if applicable Up to four additional sensors for monitoring and data collection may be connected. These sensors can be used for general thermostat functions.

• Shrec (heat recovery thermostat)

Must be used when heat recovery is controlled via a thermostat function.

Pressure transmitters

• P01. P02 Suction Pressure Must always be used

• Pc (Pc1, Pc2) Condensing Pressure

Must always be used in connection with compressor and condenser regulation

• Paux (1-3)

Up to 3 extra pressure transmitters can be connected for monitoring and data collection.

These sensors can be used for general pressure switch functions. A pressure transmitter type AKS 32 or AKS 32R can supply signals to a maximum of ve controllers.

Voltage signal

• Ext. reference

Used when overriding signal is received from another control.

• Volt indputs (1-5)

Up to 5 extra voltage signals can be connected for monitoring and data collection. These signals can be used for general voltage input functions.

On/O-inputs

Contact function (on an analog input) or voltage signal (on an extension module)

• Frost protection

• Flow switch or pressure dierence for pump monitoring

• Start of defrost

• Up to 6 signals from each compressors safety circuits

• Signal from the condenser fans’ safety circuit

• Any signal from the frequency converter’s safety circuit (comp.

and/or fans)

• External start/stop of regulation

• External start stop of heat recovery

• Up to 2 Inputs for capacity limitation

• External day/night signal (raise/lower the suction pressure reference). The function is not used if the “P0 optimisation” function is used.

• DI alarm (1-10) inputs.

Up to 10 extra on/o signals for general alarm monitoring and data collection can be connected.

On/o-outputs

Relay outputs

• Compressors (1-8)

• Unloaders (max. 3/compressor)

• Fan motor (1-8)

• Start/stop of liquid injection in evaporator

• Defrost output

• Start/stop of heat recovery

• Start/stop of twin pumps (1-2)

• Start/stop of speed control (1-2) (comp. / fans / pumps)

• Alarm relay

• General functions from thermostats (1-5), pressostats (1-5) and

voltage inputs (1-5).

Solid state outputs

The solid state outputs on the controller module may be used for the same functions as those mentioned under “relay outputs”. (The output will always be “OFF” when the controller has a power failure).

Analog outputs

• Speed regulation of the condenser’s fans.

• Speed regulation of compressors.

• Speed regulation of pumps

Example

Compressor group:

• Refrigerant R404A

• 4 compressors (15 kW)

• Safety monitoring of each compressor

• Capacity limitation of compressors via contact signal (load shedding)

• Injection signal to heat exchanger

• S4 setting 2°C

Air cooled condenser:

• 4 fans, step regulation

• Pc regulates based on outdoor temperature sensor Sc3

Pumps + defrost:

• start/stop of 2 pumps

• Speed regulation of pumps

• Monitoring via ow switch (contact signal)

• Output for defrost

Fan in plant room

• Thermostat control of fan in engine room (sensor + output)

Safety functions:

• Monitoring of S4, P0, Pc, Sd and superheat in suction line

• P0 min. = -10°C

• Pc max. = 50°C

• Sd max. = 120°C

• SH min. = 5°C, SH max. = 35°C

Other:

• Alarm output used

• External main switch used (contact signal)

Data from this example is used on the next page. The result is that the following modules should be used:

• AK-CH 650A basic module

• AK-XM 102A digital input module

• AK-XM 205A relay module

• AK-OB 110 analog output module

32 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Planning table

The table helps you establish whether there are enough

inputs and outputs on the basic controller. If there are not enough of them, the controller must be extended by one or more of the mentioned extension modules.

Note down the connections you will require and add them up

Analog inputs

Temperature sensors, S3, S4, S4.1, S4.2, Ss1, Ss2, Sd1, Sd2, S7

Outdoor temperature sensor, Sc3 1

Extra temperature sensor / separate thermostats

Pressure transmitters, P01, P02, Pc, separate pressostats

0-10 V signal from other regulation, separate signals

Heat recovery via thermostat

On/o inputs

Safety circuits, frost protection

Safety circuits, Oil pressure

Safety circuits, comp. Motor protection /Motor temp.

Safety circuits, comp. High pres. thermostat

Safety circuits, comp. High pres. pressostat

Safety circuits, general for each compressor

Safety circuits, condenser fans

Safety circuits, VSD, comp. / cond./pump

Defrost start External start/stop 1

Night setback of suction pressure

Flow switch 1

Separate alarm functions

Heat recovery via DI

Capacity limitations 1

On/o outputs

Compressors (motors)

Unloaders

Fan motors

Alarm relay

Pumps

Defrost output

Separate thermostat and pressostat functions and voltage measurements

Heat recovery function

Liquid injection in evaporators

Analog control signal, 0-10 V

Frequency converter compressor / condenser / pump 1

Analog input signal

Example

On/o voltage signal

Example

On/o voltage signal

Example

On/O output signal

Example

Analog output 0-10 V

Example

1 3 P = Max. 5 / module

contact 24 V 230 V

4 1 2

Limitations

The example:

None of the 3 limitations are exceeded => OK

Sum of connections for the regulation

Number of connections on a controller module

Missing connections, if applicable

The missing connections to be supplied by one or more extension modules:

AK-XM 101A (8 analog inputs)

AK-XM 102A (8 digital low voltage inputs)

AK-XM 102B (8 digital high voltage outputs)

AK-XM 103A (4 analog inputs + 4 analog outp.) ___ pcs. á 2 VA = __

AK-XM 204A / B (8 relay outputs)

AK-XM 205A / B (8 analog inputs + 8 relay outp.)

AK_OB 110 (2 analog outputs)

15 0 5 15 1 Sum = max. 80

11 11 0 0 0 0 8 8 0 0

4 - 5 7 1

Sum of power

___ pcs. á 2 VA = __

1 1

___ pcs. á 2 VA = __

___ pcs. á 5 VA = __

___ pcs. á 0 VA = 0

1 pcs. á 8 VA = 8

Sum =

Sum = max. 32 VA

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 33

Length

If you use many extension modules the controller’s length will grow accordingly. The row of modules is a complete unit which cannot be broken.

The module dimension is 72 mm. Modules in the 100-series consist of one module Modules in the 200-series consist of two modules

The controller consist of three modules The length of an aggregate unit = n x 72 + 8

or in an other way:

Module Type Number at Length

Controller module 1 x 224 = 224 mm Extension module 200-series _ x 144 = ___ mm Extension module 100-series _ x 72 = ___ mm

Total length = ___ mm

Linking of modules

Start with the controller module and then mount the selected extension modules. The sequence is of no importance.

However, you must not change the sequence, i.e. rearrange the modules, after you have made the setup where the controller is told which connections are found on which modules and on

which terminals.

The modules are attached to one another and kept together by a connection which at the same time transmits the supply voltage and the internal data communication to the next module.

Example continued: Controller module + 1 extension module in 200-series + 1 extension module in 100-series = 224 + 144 + 72 = 440 mm.

Mounting and removal must always be performed when there is no voltage.

The protective cap mounted on the controller’s plug connection must be moved to the last vacant plug connection so that the plug will be protected against short-circuit and dirt.

When the regulation has started the controller will all the time check whether there is connection to the connected modules. This status can be followed by the light-emitting diode.

When the two catches for the DIN rail mounting are in open position the module can be pushed into place on the DIN rail – no matter where in the row the module is found. Removal is likewise carried out with the two catches in the open position.

34 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Determine the connection points

All connections must be programmed with module and point, so in principle it does not matter where the connections are made, as

long as it takes place on a correct type of input or output.

• The controller is the rst module, the next one is 2, etc.

• A point is the two or three terminals belonging to an input or output (e.g. two terminals for a sensor and three terminals for a relay).

The preparation of the connection diagram and the subsequent programming (conguration) should take place at the present time. It is most easily accomplished by lling in the connection

survey for the relevant modules. Principle:

Name On module On Point Function

fx Compressor 1 x x Close fx Compressor 2 x x Close fx Alarm relay x x NC fx Main switch x x Close fx P0 x x AKS 32R 1-6 bar

The connection survey from the controller and any extension modules are uploaded from the paragraph "Module survey. E.g. controller module:

Signal Module Point Terminal

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

- Columns 1, 2, 3 and 5 are used for the programming.

- Columns 2 and 4 are used for the connection diagram.

Signal type /

Active at

Module Point

Mind the numbering. The right-hand part of the controller module may look like a separate module. But it isn’t.

Hint In appendix B, 16 general installation types are illustrated. If your installation is nearly similar to one of those illustrated, you can advantageously use the given connection points.

Example continued:

Signal Module Point Terminal

Brine return temperature S3

Brine supply temperature S4

Brine frost protection S4.1

Brine frost protection S4.2

Suction gas temperature -Ss1

Suction gas temperature - Ss2

Condensing pressure - Pc

Discharge temperature - Sd1

Discharge temperature - Sd2

Suction pressure - P01

Suction pressure - P02

Compressor 1 / (groupA no. 1)

Compressor 2 / (group B no. 1)

Compressor 3 / (groupA no. 2)

Compressor 4 / (groupB no. 2)

Liq. injec. in evaporator 1

Liq. injec. in evaporator 2

Pump 1

Pump 2

Speed control of pumps

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

4 (AI 4) 7 - 8

5 (AI 5) 9 - 10

6 (AI 6) 11 - 12

7 (AI 7) 13 - 14

8 (AI 8) 19 - 20

9 (AI 9) 21 - 22

10 (AI 10) 23 - 24

11 (AI 11) 25 - 26

12 (DO 1) 31 - 32

13 (DO 2) 33 - 34

14 (DO 3) 35 - 36

15 (DO 4) 37 - 38

16 (DO 5) 39-40-41

17 (DO6) 42-43-44

18 (DO7) 45-46-47

19 (DO8) 48-49-50

24 -

25 -

Signal type /

Active at

Pt 1000

AKS32-34

Pt 1000

AKS32-12

0-10 V

Signal

Out door temperature Sc3

Thermostat sensor in plant room Saux

External Main switch 3 (AI 3) 5 - 6 ON

Flow switch, brine 8 (AI 8) 19 - 20 OFF

Fan 1 9 (DO 1) 25-26-27 On

Fan 2 10 (DO 2) 28-29-30 On

Fan 3 11 (DO 3) 31-32-33 On

Fan 4 12 (DO 4) 34-35-36 On

Defrost 13 (DO 5) 37-38-39 On

Alarm 15 (DO 7) 43-44-45 OFF

Signal Module Point Terminal Active at

Compressor 1 Gen. Safety

Compressor 2 Gen. Safety 2 (DI 2) 3 - 4 Open

Compressor 3 Gen. Safety 3 (DI 3) 5 - 6 Open

Compressor 4 Gen. Safety 4 (DI 4) 7 - 8 Open

Capacity limitation 6 (DI 6) 11 - 12 Closed

Mod-

ule

Point Terminal Active at

1 (AI 1) 1 - 2 Pt 1000

2 (AI 2) 3 - 4 Pt 1000

14 (DO 6) 40-41-42

8 (DO 8) 46-47-48

1 (DI 1) 1 - 2 Open

5 (DI 5) 9 - 10

7 (DI 7) 13 - 14

8 (DI 8) 15 - 16

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 35

Connection diagram

Drawings of the individual modules may be ordered from Danfoss. Format = dwg and dxf.

You may then yourself write the module number in the circle and draw the individual connections.

Example continued:

Comp. 1 Gen. safety

External Main Switch

Pack 1, comp. 1

Pack 2, comp. 1

Pack 1, comp. 2

Pack 2, comp. 2

Frequency converter

Pumpen ow switch

Room fan

Comp. 2 Gen. safety

Consumption limitation

Comp. 3 Gen. safety

Comp. 4 Gen. safety

Liquid injection in evaporator

36 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Supply voltage

Supply voltage is only connected to the controller module. The supply to the other modules is transmitted via the plug between the modules. The supply must be 24 V +/-20%. One transformer must be used for each controller. The transformer must be a class II. The 24 V must not be shared by other controllers or units. The analog inputs and outputs are not galvanically separated from the supply.

The + and – 24V input must not be earthed.

Example continued:

Controller module 8 VA + 1 extension module in 200-series 5 VA + 1 extension module in 100-series 2 VA

------

Transformer size (least) 15 VA

Transformer size

The power consumption grows with the number of modules used:

Module Type Number á Eect

Controller 1 x 8 = 8 VA Extension module 200-series _ x 5 = __ VA Extension module 100-series _ x 2 = __ VA Total ___ VA

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 37

Ordering

1. Controller

Type Function Application Language Code no.

English, German, French, Dutch, Italian

English, Danish, Finnish 080Z0138

080Z0136

AK-CH 650A

Controller for capacity control of compressors and condensers

Water chiller with two suction groups

2. Extension modules and survey for inputs and outputs

Type Analog

inputs

For sensors, pressure transmitters etc.

Controller 11 4 4 - - - - -

Extension modules

AK-XM 101A 8 080Z0007

AK-XM 102A 8 080Z0008 x

AK-XM 102B 8 080Z0013

AK-XM 103A 4 4 080Z0032

AK-XM 204A 8 080Z0011

AK-XM 204B 8 x 080Z0018

AK-XM 205A 8 8 080Z0010 x

AK-XM 205B 8 8 x 080Z0017

The following extension module can be placed on the PC board in the controller module. There is only room for one module.

AK-OB 110 2 080Z0251 x

On/O outputs On/o supply voltage

Relay (SPDT)

Solid state Low voltage

(DI signal)

(max. 80 V)

High voltage (max. 260 V)

Analog outputs

0-10 V d.c. For over-

module with switches

ride of relay outputs

Code no.

With screw terminals

continued

Example

3. AK operation and accessories

Type Function Application Code no.

Operation

AK-ST 500 Software for operation of AK controllers AK-operation 080Z0161 x

- Cable between PC and AK controller AK - Com port 080Z0262 x

- Cable between zero modem cable and AK controller AK - RS 232 080Z0261

- Cable between PC and AK controller AK - USB port 080Z0264

Accessories Power supply module 230 V / 115 V to 24 V

AK-PS 075 18 VA

AK-PS 150 36 VA 080Z0054

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

EKA 163B Display 084B8574

EKA 164B Display with operation buttons 084B8575

- Cable between display and controller

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

AK-OB 101A Real time clock with battery backup. To be mounted in an AK controller 080Z0252

Supply for controller

Length = 2 m 084B7298

Length = 6 m 084B7299

080Z0053 x

Example

continued

38 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

3. Mounting and wiring

This section describes how the controller:

• Is tted

• Is connected

We have decided to work on the basis of the example we went through previously, i.e. the following modules:

• AK-CH 650A controller module

• AK-XM 205A relay module

• AK-XM 102A digital input module

• AK-OB 110 analog output module

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 39

Mounting

Mounting of analog output module

1. Lift the top part o the basic module

The basic module must not be connected to voltage.

Press in the plate on the left-hand side of the light-emitting diodes and the plate on the right-hand side for the red address changers. Lift the top part o the basic module.

The analog extension module will supply a signal to the variable frequency drive.

2. Mount the extension module in the basic module

3. Put the top part back on the basic module

There are two outputs, but we only use one in the example.

40 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Mounting and wiring - continued

Mounting of extension module on the basic module

1. Move the protective cap

Remove the protective cap from the connection plug on the right-hand side of the basic module. Place the cap on the connection plug to the right of the extension module that is to be mounted on the extreme right-hand side of the AK assembly.

2. Assemble the extension module and the basic

module

The basic module must not be connected to voltage.

In our example two extension modules are to be tted to the basic module. We have chosen to t the module with relays directly on the basic module and then the module with input signals. The sequence is thus:

All the subsequent settings that aect the two extension modules are determined by this sequence.

When the two snap catches for the DIN rail mounting are in the open position, the module can be pushed into place on the DIN rail – regardless of where the module is on the row. Disassembly is thus done with the two snap catches in the open position.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 41

Mounting and wiring - continued

Wiring

Decide during planning which function is to be connected and where this will be.

1. Connect input and outputs

Here are the tables for the example:

Signal Module Point

Brine return temperature S3

Brine supply temperature S4

Brine frost protection S4.1

Brine frost protection S4.2 4 (AI 4) 7 - 8 Pt 1000

Suction gas temperature - Ss1 5 (AI 5) 9 - 10 Pt 1000

Suction gas temperature - Ss2 6 (AI 6) 11 - 12 Pt 1000

Condenser pressure - Pc 7 (AI 7) 13 - 14 AKS32-34

Discharge gas temperature

- Sd1

Discharge gas temperature

- Sd2

Suction pressure - P01 10 (AI 10) 23 - 24 AKS32-12

Suction pressure - P02 11 (AI 11) 25 - 26 AKS32-12

Compressor 1 (group A no. 1) 12 (DO 1) 31 - 32 ON

Compressor 2 (group B no. 1) 13 (DO 2) 33 - 34 ON

Compressor 3 (group A no. 2) 14 (DO 3) 35 - 36 ON

Compressor 4 (group B no. 2) 15 (DO 4) 37 - 38 ON

Liquid injec. in evaporator 1 16 (DO 5) 39-40-41 ON

Liquid injec. in evaporator 2 17 (DO6) 42-43-44 ON

Pump 1 18 (DO7) 45-46-47 ON

Pump 2 19 (DO8) 48-49-50 ON

Speed control of pumps 24 - 0-10 V

1 (AI 1) 1 - 2

2 (AI 2) 3 - 4

3 (AI 3) 5 - 6

8 (AI 8) 19 - 20 Pt 1000

9 (AI 9) 21 - 22 Pt 1000

Terminal

25 -

Signal type /

Active at

Pt 1000

The function of the switch functions can be seen in the last column.

There are AKS 32 pressure transmitters for several pressure ranges. Here there are two dierent ones. One up to 12 bar and one up to 34 bar.

Signal Module Point Terminal Active at

Out door temperature Sc3

Thermostat sensor in plant room Saux

External main switch 3 (AI 3) 5 - 6 ON

Flow switch, brine 8 (AI 8) 19 - 20 OFF

Fan 1 9 (DO 1) 25-26-27 On

Fan 2 10 (DO 2) 28-29-30 On

Fan 3 11 (DO 3) 31-32-33 On

Fan 4 12 (DO 4) 34-35-36 On

Defrost 13 (DO 5) 37-38-39 On

Fan in plant room 14 (DO 6) 40-41-42

Alarm 15 (DO 7) 43-44-45 OFF

Signal Module Point Terminal Active at

Compressor 1 Gen. safety

Compressor 2 Gen. safety 2 (DI 2) 3 - 4 Open

Compressor 3 Gen. safety 3 (DI 3) 5 - 6 Open

Compressor 4 Gen. safety 4 (DI 4) 7 - 8 Open

Consumption limitation 6 (DI 6) 11 - 12 Closed

1 (AI 1) 1 - 2 Pt 1000

2 (AI 2) 3 - 4 Pt 1000

8 (DO 8) 46-47-48

1 (DI 1) 1 - 2 Open

5 (DI 5) 9 - 10

7 (DI 7) 13 - 14

8 (DI 8) 15 - 16

42 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Mounting and wiring - continued

The connections for the example can be seen here.

Warning Keep signal cables separate from cables with high voltage.

The screen on the pressure transmitter cables must only be connected at the end of the controller.

Comp. 1 Gen. safety

Comp. 3 Gen. safety

Comp. 2 Gen. safety

External main switch

Pump ow switch

Comp. 4 Gen. safety

evaporators

Pack 1, comp. 1

Frequency converter

Pack 2, domp. 1

Pack 2, comp. 2

Pack 1, domp. 2

Liquid injection in

2. Connect LON communication network

The installation of the data communication must comply with the requirements set out in document RC8AC.

3. Connect supply voltage

Is 24 V, and the supply must not be used by other controllers or devices. The terminals must not be earthed.

4. Follow light-emitting diodes

When the supply voltage is connected the controller will go through an internal check. The controller will be ready in just under one minute when the light-emitting diode ”Status” starts ashing slowly.

5. When there is a network

Set the address and activate the Service Pin.

Internal communication between the modules: Quick ash = error Constantly On = error

■ Power

■ Comm

■ DO1 ■ Status

■ DO2 ■ Service Tool

■ DO3 ■ LON

■ DO4

■ DO5 ■ Alarm

■ DO6

■ DO7

■ DO8 ■ Service Pin

Status on output 1-8

Room Fan

Slow ash = OK Quick ash = answer from gateway in 10 min. after network installation Constantly ON = error Constantly OFF = error

External communication

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

Network installation

Consumption limit

6. The controller is now ready to be congured.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 43

44 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

4. Conguration and operation

This section describes how the controller:

• Is congured

• Is operated

We have decided to work on the basis of the example we went through previously, i.e. compressor control with 4 compressors and condenser control with 4 fans. The example is shown overleaf.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 45

Refrigerating plant example

We have decided to describe the setup by means of an example comprising a two evaporators and a condenser.

The example is the same as the one given in the "Design" section, i.e. the controller is an AK-CH 650A + extension modules.

Compressor pack:

• Refrigerant R404A

• 4 x compressors (15 kW)

• Safety monitoring of each compressor

• Capacity limitation of compressors via contact signal (load shedding)

• Injection signal to heat exchanger

• S4 setting 2°C

Air cooled condenser:

• 4 fans, step regulation

• Pc regulates based on outdoor temperature Sc3

Pumps + defrost:

• Start/stop of 2 twin pumps

• Speed regulation of pumps

• Monitoring via ow switch (contact signal)

• Output for defrost

Fan i plant room:

• Thermostat control of fan in plant room (sensor + output)

Safety functions:

• Monitoring of S4, P0, Pc, Sd and superheat on suction line

• P0 min. = -10°C

• Pc max. = 50°C

• Sd max. = 120°C

• SH min. = 5°C, SH max = 35°C

Other:

• Alarm output used

• External main switch used (contact signal)

There is also an internal main switch as a setting. Both must be “ON” before any adjustment is made.

For the example shown we use the following modules:

• AK-CH 650A basic module

• AK-XM 102A digital input module

• AK-XM 205A relay module

• AK-OB 110 analog output module

46 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

The modules used are selected in the design phase.

Conguration

Connect PC

PC with the program “Service Tool” is connected to the controller.

The controller must be switched on rst and the LED “Status” must ash before the Service Tool programme is started.

Start Service Tool programme

For connecting and operating the "AK service tool" software, please see the manual for the software.

The rst time the Service Tool is connected to a new version of a controller the start-up of the Service Tool will take longer than usual while information is retrieved from the controller. Time can be followed on the bar at the bottom of the display.

Select the name SUPV and key in the access code.

When the controller is supplied the SUPV access code is 123. When you are logged into the controller an overview of it will always appear.

In this case the overview is empty. This is because the controller has not yet been set up. The red alarm bell at the bottom right tells you that there is an active alarm in the controller. In our case the alarm is due to the fact that the time in the controller has not yet been set.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 47

Conguration - continued

Authorization

1. Go to Conguration menu

Press the orange setup button with the spanner at the bottom of the display.

2. Select Authorization

3. Change setting for the user ‘SUPV‘

When the controller is supplied it has been set with standard authorization for dierent user interfaces. This setting should be changed and adapted to the plant. The changes can be made now or later.

You will use this button again and again whenever you want to get to this display. On the left-hand side are all the functions not shown yet. There will be more here the further into the setup we go.

Press the line Authorization to get to the user setup display.

4. Select user name and access code

5. Carry out a new login with the user name and then access code

Mark the line with the user name SUPV.

Press the button Change

This is where you can select the supervisor for the specic system and a corresponding access code for this person.

The controller will utilize the same language that is selected in the service tool but only if the controller contains this language. If the language is not contained in the controller, the settings and readings will be shown in English.

To activate the new settings you must carry out a new login to the controller with the new user name and the relevant access code. You will access the login display by pressing the padlock at the top left corner of the display.

48 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

Unlock the conguration of the controllers

1. Go to Conguration menu

2. Select Lock/Unlock conguration

The controller can only be congured when it is unlocked. It can only be adjusted when it is locked.

Changes to the input and output settings are only activated once the controller is "Locked".

The values can be changed when it is locked, but only for those settings that do not aect the conguration.

3. Select Conguration lock

Press the blue eld with the text Locked

4. Select Unlocked

Select Unlocked.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 49

Conguration - continued

System setup

1. Go to Conguration menu

2. Select System setup

3. Set system settings

All system settings can be changed by pressing in the blue eld with the setting and then indicating the value of the required setting.

In the rst eld you enter a name for what the controller will be controlling.

When the time is set the PC’s time can be transferred to the controller. When the controller is connected to a network, date and time will automatically be set by the system unit in the network. This also applies to change-over Daylight saving.

50 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

Set plant type

1. Go to Conguration menu

2. Select plant type

Press the line Select plant type.

3. Set plant type

Quick setup consists of a number of settings that are all based on a system with two evaporators and one condenser.

When the installation type is to be congured, it can be done in two ways: Either one of these two (we chose to use the lowest).

The higher of the two settings gives

a choice between a number of pre-

dened combinations, which at the

same time determine the connec-

tion points.

At the end of the manual there is

an overview of the options and

connection points.

4. Set Common functions

In our example the plant contins of two evaporators and a condenser. We therefore select the plant type Two evap. + one cond.

The controller can control one condenser group, but not two. Two groups must be controlled separately. Here we opt to let the controller control the condenser group. Set to Yes .

Further settings: External main switch to Yes Use Alarm output to High. (At ”High” the relay is only activated for high-priority alarms).

After conguration of this func-

tion, the controller will shut

down and restart. After the

restart, a large number of set-

tings will have been made.

These include the connec-

tion points. Continue with

the settings and check the

values.

If you change some of

the settings, the new

values will come into

force.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 51

Conguration - continued

Set control of compressors

1. Go to Conguration menu

2. Select Suction group

3. Set values for the reference

Press the +-button to go on to the next page

4. Set values for capacity control

The conguration menu in the Service Tool has changed now. It

shows the possible settings for the selected plant type.

In our example we select the settings:

- Set point = 2°C The settings are shown here in the display.

There are several pages, one after the other. The black bar in this eld tells you which of the pages is currently displayed. Move between the pages using the + and - buttons.

In our example we select:

- 4 compressors

- S4 as signal to the regulation

- Refrigerant = R404A The settings are shown here in the display.

If you want to know more about the dierent conguration options, they are listed below. The number refers to the number and picture in the column on the left.

3 - Reference mode

Displacement of suction pressure as a function of external signals 0: Reference = set reference + night oset + oset from external 0-10 V signal 1: Reference = set reference + oset from P0 optimization + Night displacement Set point ( -80 to +30°C) Setting of required suction pressure in °C

Oset via Ext. Ref

Select whether a 0-10V external reference override signal is required Oset at max input (-100 to +100 °C) Displacement of reference at max. Ext. Ref. signal Oset at min input (-100 to +100 °C) Displacement of reference at min. Ext. Ref signal Oset lter (10 - 1800 Sec) Filter for displacement of reference, higher value results in slower displacement

Night select via DI

Select whether a digital input is required for activation of night operation. Night operation can alternatively be controlled via internal weekly schedule or from the system manager via data communication Night Oset (-25 to +25 K) Displacement of the brine temperature during night operation (set in Kelvin)

Oset via S3

The reference selection must be displaced by a signal from S3. (The function is only relevant when the controller's sensor is set to S4. If it is set to S3, the oset function will lapse.)

Tref S3 oset

Set the S3 temperature where it is not to be oset.

K1 S3 oset

Set the size of the change to be made in the reference when the S3 temperature deviates 1 degree from the setting. (-10 to 10 K) Max reference (-50 to +80 °C) Max. permissible brine reference Min reference (-80 to +25 °C) Min. permissible brine reference.

4 - Compressor application

Select the compressor application required No. of compressors Set number of compressors

No. of unloaders

Set number of unloader valves

Regulation sensor

Select either S3 or S4

P0 Refrigerant

Select refrigerant type

Po refrigerant factors K1, K2, K3

Only used if “Po refrigerant type” is set to custom (contact Danfoss for information)

Injection evaporator 1 (2)

If the function is selected, injection can be coordinated with compressor operation: No Synchronisation Synchronisation: Here is the signal on, if just one compressor is in operation. VSD min speed (0.5 – 60.0 Hz) Minimum allowed speed before stop of Variable Speed drive (Low load condition)

52 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

Press the +-button to go on to the next page

5. Set values for capacity of the compressors

Press the +-button to go on to the next page

6. Set values for main step and any unloaders

In our example we select:

- 4 compressors of 15 kW

In our example there are no unloaders and hence no changes.

VSD start speed (20.0 – 60.0 Hz) Minimum speed for start of Variable speed drive (Must be set higher than “VSD Min. Speed Hz”) VSD max speed (40.0 – 120.0 Hz) Highest permissible speed for the compressor motor

VSD safety monitoring

Select this if input for monitoring of the frequency converter is required. Start delay rst compressor (5-600 sec.) To ensure brine ow before startup, a delay before start of the rst compressor can be entered.

Load shed limits

Select how many load shedding inputs are required

Load shed limit 1

Set max capacity limit for load shed input 1

Load shed limit 2

Set max capacity limit for load shed input 2

Override limit for S4 (S3)

Any load below the limit value is freely permitted. If the S4 (S3) exceeds the value, a time delay is started. If the time delay expires, the load limit is cancelled

Override delay 1

Max. time for capacity limit, if S4 (S3) is too high

Override delay 2

Max. time for capacity limit, if S4 (S3) is too high

Advanced control settings

Select whether the advanced capacity control settings should be visible

Amplication factor for PI regulation (0.1 – 10.0) Min. capacity change (0 – 100 %) Minimum change in requested capacity that will result in cut in/out of compressors. Initial start time (15 – 900 s) The time after start-up where the cut-in capacity is limited to the rst compressor step.

Unloading mode

Select whether one or two capacity controlled compressors are allowed to be unloaded at the same time at decreasing capacity

Press the +-button to go on to the next page

7. Set values for safe operation

Press the +-button to go on to the next page

In our example we select the

settings shown in the display

5 - Compressors

In this screen the capacity distribution between the compressors is dened. Capacities that need to be set depend upon the “compressor application” and “Step control mode” that has been selected. Nominal capacity (0.0 – 100000.0 kW) Set the nominal capacity for the compressor in question. For compressors with variable speed drive the nominal capacity must be set for the mains frequency (50/60 Hz)

Unloader

Number of unload valves for each compressor (0-3)

6 - Readout of capacity distribution

The settings are made in the earlier displays. Main step 0 - 100%.

Unload

Readout of the capacity on every unloading

7 - Safety Emergency cap. day

The desired cut-in capacity for daily use in the case of emergency operations resulting from error in the suction pressure sensor/ media temperature sensor.

Emergency cap. night

The desired cut-in capacity for night operations in the case of emergency operations resulting from error in the suction pressure sensor/ media temperature sensor.

Sd max limit

Max. value for discharge gas temperature 10 K below the limit, the compressor capacity should be reduced and the entire condenser capacity will be cutin. If the limit is exceeded, the entire compressor capacity will be cutout

Pc Max limit

Maximum value for the condenser pressure in °C

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 53

Conguration - continued

8. Set monitoring of compressor

Press the +-button to go on to the next page

9. Set operation time for compressor

Press the +-button to go on to the next page

10. Set times for safety cutouts

Press the +-button to go on to the next page

11. Set Misc. function

Press the +-button to go on to the next page

In our example we use:

- Frost protection (ow switch)

- One general safety monitoring unit for each compressor

(The remaining options could have been selected if specic safety controls for each compressor had been required)

Set min. OFF-time for the compressor relay Set min. ON-time for the compressor relay Set how often the compressor is allowed to start

The settings only apply to the relay that cuts the compressor motor in and out. They do not apply to unloaders.

If the restrictions overlap, the controller will use the longest restriction time.

In our example we do use

Alarm monitoring of the S4

temperature.

3 K below the limit, the compressor capacity reduced. If the limit is exceeded, the entire compressor capacity will be cutout.

P0 Min limit

Minimum value for the suction pressure in °C If the limit is reduced, the respective compressor capacity will be cutout. P0 min delay at start-up (0-600 sec) Low pressure cut-out can be delayed for cut-out to be avoided.

P0 max alarm

Issues an alarm when the delay time has expired

P0 max delay

Delay time for P0 max. alarm

S4 Min limit

Cut-out limit. If S4.1 or S4.2 measures a value lower than the set one, the respective compressor group will cut out.

Safety restart time

Common time delay before restarting the compressor. (Applicable to the functions: "Sd max. limit", Pc max. limit" and "P0 min. limit and S4 min limit).

8 - Compressor safety Frost protection

Choose whether an overall, joint DI-security inlet for all compressors is desired. If the alarm is activated, all compressors will be disengaged.

Oil pressure etc

Dene here whether this type of protection should be connected. For "General", there is a signal from each compressor.

9 - Minimum operation times

Congure the operation times here so "unnecessary operation" can be avoided. Restart time is the time interval between two consecutive starts.

10 - Safety timer Cutout delay

The time delay resulting from drop-out of automated safety measures and until the compressor-error is reported. This setting is common for all safety inputs for the relevant compressor.

Restart delay

Minimum time that a compressor should be OK after a safety cut-out. After this interval it can start again.

11 - Misc. functions Alarm monitoring S4

Alarm option in the case of too high and too low S4 Dierent time delays are connected

12 - Pumps No of pumps (0, 1 or 2) Cold pump control

Pump operation is dened here: 0: No pumps in operation 1: Only pump 1 in operation 2: Only pump 2 in operation 3: Both in operation 4: Operating time equalisation. Start before stop 5: Operating time equalisation. Stop before start

Pump cycle time

Operating time before changeover to the second pump (1-500h)

Pump switch time

Overlapping time, where both pumps are in operation with "start before stop" or break time with "stop before start" (0-600 sec)

Pump alarm delay

Delay from drop out of ow switch to alarm.

Variable pump speed

Yes: Speed controlled by a 0-10 V signal. No: Pump controlled on/o

Speed factor for pump

0.1-1: Non-linear correlation (the higher the value, the higher the output voltage at the same compressor capacity).

Min. pump speed

Set the desired frequency. The same value must be set in the frequency converter.

Max. pump speed

Set the desired frequency. The same value must be set in the frequency converter.

54 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

12. Setting pump functions

Setup control of condenser

1. Go to Conguration menu

2. Select Condenser

3. Set control mode and reference

In our example the condenser pressure is controlled on the basis of the outdoor temperature (oating reference). The settings shown here in the display.

3 - PC reference Control sensor

Pc: The condensing pressure PC is used for regulation S7: Media temperature is used for regulation

Reference Mode

Choice of condenser pressure reference Fixed setting: Used if a permanent reference is required = “Setting” Floating: Used if the reference is changed as a function of Sc3 the external temperature signal, the congured "Dimensioning tm K"/"Minimum tm K" and the actual cut in compressor capacity.

Setpoint

Setting of desired condensing pressure in °C

Min. tm

Minimum average temperature dierence between Sc3 air and Pc condensing temperature with no load.

Dimensioning tm

Dimensioning average temperature dierential between Sc3 air and Pc condensing temperature at maximum load (tm dierence at max load, typically 8-15 K).

Min reference

Min. permitted condenser pressure reference

Max reference

Max. permitted condenser pressure reference

Heat recovery mode

Choice of method for heat recovery No: Heat recovery not used Thermostat: Heat recovery operated from thermostat Digital input: Heat recovery operated from signal on a digital input.

Heat recovery relay

Choose whether an output is required that should be activated during heat recovery.

Heat recovery ref

Reference for the condensing pressure, when heat recovery is activated.

Heat recovery ramp down

Congure how quickly the reference for the condenser pressure should be ramped down to normal level after heat recovery. Congure in Kelvin per minute.

Heat recovery cutout

Temperature value where the thermostat cuts-out the heat recovery.

Heat recovery cutin

Temperature value where the thermostat cuts-out the heat recovery.

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 55

Conguration - continued

Press the +-button to go on to the next page

4. Set values for capacity regulation

Used in our example are four stepcontrolled fans. The settings shown here in the display.

For your information the function ”Monitor fan safety” will require an input signal from each fan.

4 - Capacity control No of fans

Set number of fans.

Monitoring fan safety

Safety monitoring of fans. A digital input is used to monitor each fan.

Capacity control mode

Select control mode for condenser Step: Fans are step-connected via relay outputs Step/speed: The fan capacity is controlled via a combination of speed control and step coupling Speed: The fan capacity is controlled via speed control (frequency converter) Speed control on rst step, rest=step

Control type

Choice of control strategy P-band: The fan capacity is regulated via P-band control. The P band is congured as "Proportional band Xp" PI-Control: The fan capacity is regulated by the PI controller.

Capacity curve

Choice of capacity curve type Linear: The same amplication in the entire area Square: Square curve shape, which gives higher amplication at higher loads. Continued

VSD start speed

Minimum speed for start of speed control (Must be congured higher than "VSD Min. Speed %")

VSD min Speed

Minimum speed whereby speed control is cut-out (low load).

Proportional band Xp

Proportional band for P/PI controller

Integration time Tn

Integration time for PI controller

VSD safety monit.

Choice of safety monitoring of frequency converter. A digital inlet is used for monitoring the frequency converter.

Capacity limit at night

Setting of maximum capacity limit during night operations. Can be used to limit fan speed at night in order to limit the noise level.

56 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

Setup Display

1. Go to Conguration menu

2. Select Display setup

3. Dene which readings are to be shown for the individual outputs

In our example, separate displays are not used. The setting is included here for information.

3 - Display setup

Display

The following can be read for the four outputs.. S4 S3 P01 P02 S4.1 S4.2 Cond. control sensor Pc1 Pc2 Sd1 Sd2 Ss1 Ss2

Unit readout

Choose whether readings are to be in SI units (°C and bar) or (US-units °F and psi)

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 57

Conguration - continued

Setup defrost

1. Go to Conguration menu

2. Select Defrost

3. Dene the required defrost functions

When no input is used to start a defrost cycle, this allows use of a schedule where the defrost startup times are specied. The schedule is located under the daily user interface. See page 72.

3 - Defrost functions Defrost function

Select whether defrost control is to be used

Defrost start via DI

Select whether a DI input to start the defrost cycle is to be used. . If not, this allows a defrost schedule to be attached to the "daily user interface"..

Defrost stop

Select a defrost stop procedure. By time. / By S3 temperature. By S4 temperature

Defrost stop temp.

Value setting (-5 to 60)

Max. defrost time

Max. permitted defrost time Refrigeration will always start once this time has passed.

Drip delay

Time after defrost end, where the water is dripping from the refrigeration surfaces.

Defrost outputs

Select whether an output is to be activated during defrosting..

Comp.operation during defrost

Select whether the compressors are to run during defrosting.

58 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

Setup general alarm inputs

1. Go to Conguration menu

2. Select General alarm inputs

3. Dene the required alarm functions

In our example we have no general alarm inputs. The image is included for guidance. One alarm function is shown. The name of the alarm function and the alarm text can be dened as desired.

3 - General alarm input

This function can be used to monitor all kinds of digital signals.

No. of inputs

Set the number of digital alarm inputs

Adjust for each input

• Name

• Delay time for DI alarm (common value for all)

• Alarm text

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 59

Conguration - continued

Setup separate thermostat functions

1. Go to Conguration menu

2. Select Thermostats

3. Dene the required thermostat function

In our example we select one thermostat

function for monitoring the plant room

temperature.

We have subsequently entered a name for the

function.

3 - Thermostats

The general thermostats can be used to monitor the temperature sensors that are used, as well as 4 extra temperature sensors. Each thermostat has a separate outlet to control external automation.

No. of thermostats

Set the number of general thermostats. For each thermostat adjust

• Name

• Which of the sensors is used Actual temp. Temperature measurement on the sensor that is attached to the thermostat

Actual state

Actual status on the thermostat outlet

Cut out temp.

Cut-out value for the thermostat

Cut in temp.

Cut-in value for the thermostat

High alarm limit

Alarm delay high

Time delay for high alarm

Alarm text high

Indicate alarm text for the high alarm

Low alarm limit

Alarm delay low

Time delay for low alarm

Alarm text low

Indicate alarm text for low alarm

3b - Pressostats

There are similar settings for up to 3 pressure

Via the +- button you can move to similar settings for the pressure control functions. (Not used in the example)

switch functions.

60 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

Setup separate voltage functions

1. Go to Conguration menu

2. Select General Voltage inputs

(In our example we do not use this function).

3. Dene the required names

and values attached to the signal

In our example we do not use this function, so the display has been included for your information only. The name of the function may be xx and further down in the display the alarm texts may be entered.

The values ”Min. and Max. Readout” are your settings representing the lower and upper values of the voltage range. 2V and 10V, for example. (The voltage range is selected during the I/O setup).

For each voltage input dened the controller will reserve a relay output in the I/O setup. It is not necessary to dene this relay if all you require is an alarm message via the data communication.

3 - Voltage inputs

The general volt inlet can be used to monitor external voltage signals. Each volt inlet has a separate outlet to control external automatic controls.

No. of voltage inp.

Set the number of general voltage inputs, specify 1-5:

Name Actual value

= read-out of the measurement

Actual state

= read-out of outlet status Min. readout State read-out values at minimum voltage signal

Max. readout

State read-out values at maximum voltage signal

Cutout

Cut-out value for outlet

Cutin

Cut-in value for outlet

Cutout delay

Time delay for cut-out

Cut in delay

Time delay for cut-in

Limit alarm high

High alarm limit

Alarm delay high

Time delay for high alarm Alarm text high Set alarm text for high alarm Limit alarm low Low alarm limit

Alarm delay low

Time delay for low alarm Alarm text low Indicate alarm text for low alarm

AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 61

Conguration - continued

Conguration of inputs and outputs

1. Go to Conguration menu

2. Select I/O conguration

3. Conguration of Digital outputs

The following displays will depend on the earlier denitions. The displays will show which connections the earlier settings will require. The tables are the same as shown earlier.

• Digital outputs

• Digital inputs

• Analog outputs

• Analog inputs

Load Output Module Point Active at

Compressor 1 (group A no. 1) DO1 1 12 ON

Compressor 2 (group B no. 1) DO2 1 13 ON

Compressor 3 (group A no.2) DO3 1 14 ON

Compressor 4 (group B no. 2) DO4 1 15 ON

Liq. Injec. evap. 1 DO5 1 16

Liq.injec. evap. 2 DO6 1 17 ON

Pump 1 DO7 1 18 ON

Pump 2 DO8 1 19 ON

Fan 1 DO1 2 10 ON

Fan 2 DO2 2 11 ON

Fan 3 DO3 2 12 ON

Fan 4 DO4 2 13 ON

Defrost DO5 2 9 ON

Fan in plant room DO6 2 14 ON

Alarm DO7 2 15 OFF !!!

!!! The alarm is inverted so that there will be an alarm if the supply

voltage to the controller fails.

We set up the controller’s digital outputs by keying in which module and point on this module each one of these has been connected to.

We furthermore select for each output whether the load is to be active

when the output is in pos. ON or OFF.

Function Input Module Point Active at

External main switch AI3 2 3 Closed

Flow switch, brine AI8 2 8 Open

3 - Outputs

The possible functions are the following: Pack 1 Comp. 1-4 Unloader 1-1, 1-2, 1-3 Pack 2 Comp. 2-4 Cold pump 1 Cold pump 2 Injec in evaporator Defrost Fan 1 / VSD Fan 2 - 8 Heat recovery Alarm Thermostat 1 - 5 Pressostat 1 - 5 Voltage input 1 - 5

4 - Digital inputs

The possible functions are the following: Ext. Main switch Night setback Load shed 1 Load shed 2 Frost protection All compressors: Pack X Comp x Oil pressure safety Over current safety Motor protect. safety Disch. temp. safety Disch. press. safety General safety VSD comp_. error 1-2 Flow switch (cold) Fan 1 protection

Fan 2......8 protection

VSD Cond. protection Heat recovery DI Alarm 1

DI Alarm 2.....10

Defrost

Press the +-button to go on to the next page

4. Setup On/o input functions

Press the +-button to go on to the next page

Compressor 1 Gen. Safety DI1 3 1 Open

Compressor 2 Gen. Safety DI2 3 2 Open

Compressor 3 Gen. Safety DI3 3 3 Open

Compressor 4 Gen. Safety DI4 3 4 Open

Capacity limitation DI6 3 6 Closed

We set up the controller’s digital input functions by keying in which module and point on this module each one of these has been connected to. We furthermore select for each output whether the function is to be active when the output is in pos. Closed or Open. Open has been selected here for all the safety circuits. This means that the controller will receive signal under normal operation and register it as a fault if the signal is interrupted. The pump's ow switch is used here for frost protection. This means that all compressors stop in the event of insucient ow. The bottom setting for the pump's ow switch is set here to 0-0, but it will give incorrect information in the daily user display. This can be corrected by repeating the threading to an available input, and then dening this instead of 0-0.

62 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A

Conguration - continued

5. Conguration of Analog

outputs

Press the +-button to go on to the next page

6. Conguration of Analog Input signals

Function Output Module Point Ty pe

Speed control of pumps AO1 1 24 0-10 V

We set up the analog outputs for control of the compressor speed.

Sensor Input Module Point Type

Brine return temp. S3 AI1 1 1 Pt 1000

Brine supply temp. S4 AI2 1 2 Pt 1000

Brine frost protection S4.1 AI3 1 3 Pt 1000

Brine frost protection S4.2 AI4 1 4 Pt 1000

Suction gas temperature - Ss1 AI5 1 5 Pt 1000

Suction gas temperature - Ss2 AI6 1 6 Pt 1000

Condenser pressure - Pc AI7 1 7 AKS32-34

Discharge gas temperature

- Sd1

Discharge gas temperature

- Sd2

Suction pressure- P01 AI10 1 10 AKS32-12

Suction pressure- P02 AI11 1 11 AKS32-12

Outdoor temp. Sc3 AI1 2 1 Pt 1000

Thermostat sensor in plant

room Saux

AI8 1 8 Pt 1000

AI9 1 9

AI2 2 2 Pt 1000

Pt 1000

We set up the analog inputs for the sensors.

5 - Analog outputs

The possible signals are the following: 0 – 10 V 2 – 10 V 0 – 5 V 1 – 5 V 10 – 0 V 10 – 2 V 5 – 0 V 5 – 1 V Select for:

• Speed control comp.

• Speed control fans.

• Speed control pumps

6 - Analog inputs

The possible signals are the following: Temperature sensors:

• Pt1000

• PTC 1000

Pressure transmitters:

• AKS 32, -1 – 6 bar

• AKS 32R, -1 – 6 Bar

• AKS 32, - 1 – 9 Bar

• AKS 32R, -1 – 9 Bar

• AKS 32, - 1 – 12 Bar

• AKS 32R, -1 – 12 Bar

• AKS 32, - 1 – 20 Bar

• AKS 32R, -1 – 20 Bar

• AKS 32, - 1 – 34 Bar

• AKS 32R, -1 – 34 Bar

• AKS 32, - 1 – 50 Bar

• AKS 32R, -1 – 50 Bar

• AKS 2050, -1 – 59 Bar

• AKS 2050, -1 – 99 Bar

• AKS 2050, -1 – 159 Bar

• User dened (only ratiometric, min. and max value of the pressure range must be set)

Voltage signals for reference displacement:

• 0 – 5 V,

• 0 -10 V

S4, S4.1, S4.2 Brine supply S3 Brine return P01, P02 suction pressure Ss1, Ss2 suction gas Sd1, Sd2 disch gas Pc, Pc1, Pc2 cond. press. S7 warm brine Sc3 air on Ext. Ref. Signal Heat recovery Saux 1 - 4 Paux 1 - 3 Voltage input 1 - 5

• 0 -5 V,

• 0 -10 V,

• 1 – 5 V,

• 2 – 10 V

Conguration - continued

Set alarm priorities

1. Go to Conguration menu

2. Select Alarm priorities

Very many functions have an alarm connected.

Your choice of functions and settings has connected all the relevant alarms that are current. They will be shown with text in the three pictures.

All alarms that can occur can be set for a given order of priority:

• ”High” is the most important one

• ”Log only” has lowest priority

• ”Disconnected” gives no action The interdependence between setting and action can be seen in the table.

Setting

High X X X X 1

Medium X X X 2

Low X X X 3

Log only X

Disconnected

See also alarm text

Log Alarm relays selection Net-

Non High Low - High

work

AKM dest.

3. Set priorities for Suction group

Press the +-button to go on to the next page

4. Set alarm priorities for condenser

The rst alarms for the suction groups are shown here. Further down in the display the priorities for the compressors’ safety circuits are set.

In our example we select the settings shown here in the display

Press the +-button to go on to the next page

Conguration - continued

5. Set alarm priorities for thermostat and extra Digital signals

In our example we select the settings shown here in the display

Conguration - continued

Lock conguration

1. Go to Conguration menu

2. Select Lock/Unlock conguration

3. Lock Conguration

Press in the eld against Conguration lock.

Select Locked.

The controller will now make a comparison of selected functions and dene inputs and outputs. The result can be seen in the next section where the setup is controlled.

The setup of the controller has now been locked. If you subsequently want to make any changes in the controller’s setup, remember rst to unlock the conguration.

Conguration - continued

Check conguration

1. Go to Conguration menu

2. Select I/O conguration

3. Check conguration of Digital Outputs

This control requires that the setup is locked

(All input and output settings only become active once the setup is locked.)

An error has occurred, if you see the following:

The setup of the digital outputs appears as it is supposed to according to the wiring made.

A 0 – 0 next to a dened function. If a setting has reverted to 0-0, you must control the setup again. This may be due to the following:

• A selection has been made of a combination of module number and point number that does not exist.

• The selected point number on the selected module had been set up for something dierent.

The error is corrected by setting up the output correctly.

Remember that the setup must be unlocked before you can change module and point numbers..

Press the +-button to go on to the next page

4. Check conguration of Digital Inputs

Press the +-button to go on to the next page

5. Check conguration of Analog Outputs

The setup of the digital inputs appears as it is supposed to according to the wiring made.

The settings are shown on a RED background. If a setting has turned red, you must control the setup again. This may be due to the following:

• The input or the output has been set up; but the setup has later been changed so that it should no longer be applied.

The problem is corrected by setting module

number to 0 and point number to 0.

Remember that the setup must be unlocked before you can change module and point numbers.

Press the +-button to go on to the next page

Conguration - continued

6. Check conguration of Analog Inputs

The selected module and point numbers for Sc3 Air on are shown in a red eld instead of a blue one. This is due to the fact that this input has been set up, but that the setup has later been changed so that the outdoor temperature sensor Sc3 is no longer to be used. For instance by changing the Pc reference selection for condenser A from Floating to Fixed setting. The problem is corrected by setting Sc3 air on to module number 0 and point number 0. (IN THIS EXAMPLE WE RETAIN SETTINGS 2 AND 1. The wrong setting has only been shown for your information). Remember that the setup must be unlocked before you can change module and point numbers.

Check of connections

1. Go to Conguration menu

2. Select I/O status and manual

3. Check Digital Outputs

Before the control is started we check that all inputs and outputs have been connected as expected.

This controls requires that the setup is locked

By means of the manual control of each output it can be checked whether the output has been correctly connected.

AUTO The output is controlled by the controller

MAN OFF The output is forced to pos. OFF

MAN ON The output is forced to pos ON

Press the +-button to go on to the next page

4. Check Digital Inputs

Press the +-button to go on to the next page

Cut out the safety circuit for compressor 1. Check that LED DI1 on the extension module (module 3) goes out. Check that the value of the alarm for the safety monitoring of compressor 1 changes to ON. The remaining digital inputs are checked in the same way.

Check of connections - continued

5. Check Analog outputs

6. Put the control of the output voltage back to automatic

Set Control of output voltage to manual Press in the Mode eld.

Select MAN.

Press in the Value eld

Select for example 50%.

Press OK.

On the output you can now measure the expected value: In this example 5 volts

Example of the connection between a dened output signal and a manual set value.

Denition Setting

0 % 50 % 100 %

0 - 10 V 0 V 5 V 10 V

1 - 10 V 1 V 5.5 V 10 V

0 - 5 V 0 V 2.5 V 5 V

2 - 5 V 2 V 3.5 V 5 V

Press the +-button to go on to the next page

7. Check Analog inputs

Check that all sensors show sensible values.

In our case we have no value for the most sensors. This may be due to the following:

• The sensor has not been connected.

• The sensor is short-circuited.

• The point or module number has not been set up correctly.

• The conguration is not locked.

Check of settings

1. Go to the overview

2. Select suction group

3. Move on through all the individual displays for the suction group

Before the control starts, we check that all the settings are as they should be.

The overview display will now show one line for each of the general functions. Behind each icon there is a number of displays with the dierent settings. It is all these settings that have to be checked.

Change displays with the +- button. Remember the settings at the bottom of the pages – the ones that can only be seen via the ”Scroll bar”.

4. Safety limits

5. Go back to the overview

The last page contains safety limits and restart times.

6. Select condenser group

7. Move on through all the individual displays for the condenser group

Check of settings - contiuned

Change displays with the +- button. Remember the settings at the bottom of the pages – the ones that can only be seen via the ”Scroll bar”.

8. Safety limits

The last page contains safety limits and restart times.

9. Go back to the overview and Move on to the defrost function

Check the settings.

10. Go back to the overview and Move on to the thermostat group

Check the settings.

11. Go back to the overview and on to the general

alarm inputs

In the example, the defrost schedule has been set to two defrosts a day.

Check the settings.

12. The controller setup has been completed.

Schedule function

1. Go to Conguration menu

2. Select schedule

3. Setup schedule

Before regulation is started we will set the schedule function for the night setback of the S4 temperature. In other cases where the controller is installed in a network with one system unit, this setting may be made in the system unit which will then transmit a day/night signal to the controller.

Press a weekday and set the time for the day period.

Continue with the other days.

A complete weekly sequence is shown in the display.

Installation in network

1. Set the address (here, for example 3)

Turn the right-hand address switch so that the arrow will point at 3. The arrow of the two other address switches must point at 0.

2. Push the Service Pin

Press down the service pin and keep it down until the Service Pin LED lights up.

The controller has to be remote-monitored via a network. In this net-

work we assign address number 3 to the controller.

The same address must not be used by more than one controller in the

same network.

Requirement to the system unit

The system unit must be a gateway type AKA 245 with software version

6.0 or higher. It is capable of handling up to 119 AK controllers.

3. Wait for answer from the system unit

Depending on the size of the network it may be up to one minute before the controller receives an answer as to whether it has been installed in the network. When it has been installed the Status LED will start to ash faster than normal (once every half second). It will continue with this for about 10 minutes

4. Carry out new login via Service Tool

If the Service Tool was connected to the controller while you installed it in the network, you must carry out a new login to the controller via the Service Tool.

If there is no answer from the system unit

If the Status LED does not start ashing faster than normal, the controller has not been installed in the network. The reason for this may be one of the following:

The controller has been assigned an address out of range

Address 0 cannot be used.

If the system unit in the network is an AKA 243B Gateway only the addresses between 1 and 10 can be used.

The selected address is already being used by another controller or unit in the network:

The address setting must be changed to another (vacant) address.

The wiring has not been carried out correctly. The termination has not been carried out correctly.

The data communication requirements are described in the document: ”Data communication connections to ADAP-KOOL® Refrigeration Controls” RC8AC.

First start of control

Check alarms

1. Go to the overview

Press the blue overview button with the compressor and condenser at the bottom left of the display.

2. Go to the Alarm list

Press the blue button with the alarm bell at the bottom of the display.

3. Check active alarms

In our case, we have a series of alarms. We will tidy them up so that we only have those that are relevant.

4. Remove cancelled alarm from the alarm list

Press the red cross to remove cancelled alarms from the alarm list.

5. Check active alarm again

In our case an active alarm remains because the control has stopped. This alarm must be active when control has not started. We are now ready for the startup of control.

Please note that active plant alarms are automatically cancelled when the main switch is in pos. OFF. If active alarms appear when the control is started the reason for these should be found and remedied.

First start of control - continued

Start the control

1. Go to Start/Stop display

Press the blue manual control button at the bottom of the display.

2. Start control

Press in the eld against Main switch. Select ON.

The controller will now start controlling the pumps, compressors and the fans.

Note: Control does not start until both the internal and external switch are “ ON ”.

Manual capacity control

1. Go to overview

2. Select suction group

Press the suction group button for the suction group that is to be controlled manually.

Press the +-button to go on to the next page

3. Set capacity control to manual

If you need to manually adjust the capacity of the compressors, you can use the following procedure:

Press the blue eld against Control mode Select MAN.

4. Set capacity in percent

Press in the blue eld against Manual capacity.

Set the capacity to the required percentage. Press OK.

Manual defrost

1. Go to Conguration menu

2. Select defrost

3. Start defrost

If you want to perform a manual defrost, this can be done via the following operation.

5. Regulating functions

This section describes how the dierent functions work

Suction groups

Capacity control of compressors

PI-control and control zones

AK-CH 650A can control up to 8 compressors with up to 3 unloader valves each. The rst compressor in each group can be equipped with speed regulation.

The calculation of the requested compressor capacity takes place on the basis of a PI control, but the set up is carried out in the same way as for a neutral zone controller which is divided into 5 dierent control zones as shown in below sketch.

Brine temperature

The width of some of the zones can be set via the settings “+ Zone K”, “NZ K” and “- Zone K”. Furthermore it is possible to adjust zone timers which is equal to the Tn integration time for the PI controller whenever the suction pressure is in the zone in question (please see sketch above).

By setting a zone timer to a higher value will make the PI controller slower in this zone and by setting the zone timer lower will make the PI controller faster in this zone.

The amplication factor Kp is adjusted as parameter ”Kp S4” In the neutral zone the controller is only allowed to increase or decrease the capacity by means of speed control and/or switching of unloader valves. In the other zones the controller is also allowed to increase/ decrease capacity by means of starting and stopping compressors.

The last compressor is only allowed to be stopped when the brine temperature is in the “- Zone” or “- - Zone”

At start-up the refrigeration system must have time to be stable before the PI controller takes over the control. For this purpose at start-up of a plant a limitation is made of the capacity so that only the rst capacity step will cutin after a set period (to be set via "runtime rst step").

Requested capacity

The readout “Requested capacity” is the output from the PI controller and it shows the actual requested compressor capacity by the PI controller. The rate of change in the requested capacity depends upon in which zone the brine temperature is and whether the brine temperature is stable or whether it is constantly changing.

The Integrator is looking at the deviation between the set point and the current temperature only and increases/reduces the requested capacity correspondingly. The amplication factor Kp on the other hand only looks at the temporary temperature changes.

In the “+ Zone” and “++ Zone” the controller will normally increase the requested capacity as the temperature is above the set point. But if the temperature is decreasing very fast the requested capacity might decrease also in these zones.

In the “- Zone” and “-- Zone” the controller will normally decrease the requested capacity as the temperature is below the set point. But if the temperature is increasing very fast the requested capacity might increase also in these zones.

Change capacity

The controller will cutin or cutout capacity based on these basic rules:

Increase capacity: The capacity distributor will start extra compressor capacity as soon as the requested capacity has increased to a value, which allows the next compressor step to start. Referring to below example - a compressor step is added as soon as there is “Room” for this compressor step below the requested capacity curve.

Decrease capacity: The capacity distributor will stop compressor capacity as soon as the requested capacity has decreased to a value, which allows the next compressor to stop. Referring to below example - a compressor step is stopped as soon as there is no more “Room” for this compressor step above the requested capacity curve.

Example: 4 compressor of equal size (two in each group) - The capacity curve will look like this

Odd number is from group 1. Equal number is from group 2

Cut-out of the last compressor stage: Normally, the last compressor step will only be cut-out when the required capacity is 0% and the suction pressure is at "-Zone" or in "—Zone"

Reference for compressor control

Regulating sensor

The regulating sensor can be set at S4 or S3. By setting the regulating sensor to S4, the S3 temperature can be included in the regulation with an oset function. (Frost protection must be performed by the sensors S4.1 and S4.2).

The Reference

The reference for the regulation can be dened in 2 ways: Either Ref = P0 setting + P0 optimisation + Night displacement or Ref = setting + night displacement + Ext. Ref + S3 oset

Setting

A basic value for the brine temperature is set.

P0 optimization

This function displaces the reference so that regulation will not take place with a lower brine temperature than required. The function cooperates with controllers on the individual refrigeration appliances and network system manager. The system manager obtains data from the individual appliance sections and adapts the brine temperature to the optimum energy level. The function is described in the manual for the system manager. With this function you can read which appliance is most heavily loaded at the moment as well as the displacement allowed for the brine temperature reference.

Night displacement

The function is used to change the suction pressure reference for night time operation as an energy saving function. With this function the reference can be displaced by up to 25 K in positive or negative direction. (When you displace to a higher temperature, a positive value is set). Displacement can be activated in three ways:

• Signal on an input

• From a system managers override function

• Internal time schedule The “night displacement” function can not be used when regulation with the override function “P0-optimisation” is performed. (Here the override function will itself adapt the brine temperature to the max. permissible). The function can be used if a short change in the brine temperature (e.g. up to 15 min.) is needed. Here the P0 optimisation will not be able to compensate for the modication.

Ext. Ref. - Override with a 0 - 10 V signal

When a voltage signal is connected to the controller the reference can be displaced. In the setup it is dened how big a displacement is to take place at max. signal (10 V).

S3 oset

(Only if the regulating sensor is set to S4.) With this function it is possible to delay the reference, based on a measured S3 temperature. The sensor can be located, for example, in the return temperature of the brine or in the store premises. This allows a reference to be achieved that is adjusted to the current load. In the case of an error on the S3 sensor, the contribution to the reference is omitted.

The oset is calculated on the basis of the following expression: S3 oset = K1 (S3 temp. – TrefS3Oset.), where K1 is a multiplication factor and "TrefS3Oset" is the S3 temperature that does not give reference oset.

For example:

- The reference temperature of the brine is to be oset based on the shop temperature

- At 18°C no reference oset is required, i.e. S3 ref = 18

- For each increase of 1°C in shop temperature, a reduction in reference of 0.5K is required, i.e. K1 = -0.5

- The contribution to the reference therefore becomes: -0.5 x ("S3 temp" - 18)

Limitation of reference

To safeguard yourself against a too high or too low regulation reference, a limitation of the reference must be set.

S4 (S3) ref

Max.

Min.

Forced operation of the compressor capacity

A forced operation of the capacity can be carried out which disregards the normal regulation. Depending on the selected form of forced operation, the safety functions will be cancelled.

Forced operation via overload of requested capacity The control is set to manual and the desired capacity is set in % of the possible compressor capacity.

Forced operation via overload of digital outlets The individual outputs can be set to MAN ON or MAN OFF in the software. The control function disregards this but an alarm is sent out that the outlet is being overridden.

Forced operation via change-over switches

If the forced operation is done with the switch-over on the front of an expansion model, this is not registered by the control function and no alarm is sounded. The controller continues to run and couples with the other relays.

Capacity distribution

Power pack types – compressor combinations

Cyclic operation is used to regulate each group.

All compressors should be of the same type and size. The capacity is connected in alternating fashion between the two groups: 1: First in group A 2: First in group B 3: Second in group A 4: Second in group B etc.

The compressor cuts-in and cuts-out in accordance with the "First In First Out" principle (FIFO) to equalise operating hours between the compressors. Speed-regulated compressors will always be cut in rst, and the variable capacity is used to ll capacity gaps between the subsequent steps. When there is one compressor with relief valves, it will always cut in as the rst.

Timer restrictions and safety cut outs If a compressor is prevented from starting because it is “hanging” on the restart timer or is safety cut out, this step is replaced by another compressor.

The controller is able to control power packs with up to 8 compressors of various types:

- Two speed controlled compressors

- Capacity controlled reciprocating compressors with up to 3 unloader valves

- Single step compressors – reciprocating or scroll

The chart below shows the compressor combination which the controller is capable of controlling.

Group A Group B Description

*1) The one-step compressors must be the same size. *2) For compressors with unload valves, it is generally true that they must have the

same size, the same number of unload valves (max 3) and the same sized main steps. If compressors with unload valves are combined with one-step compres-

sors, all compressors should be the same size. (The rst two or all are with unload valves) *3) Speed-regulated compressors can have dierent sizes in relation to subsequent

compressors. Speed-regulated compressors must have the same frequency range.

One-step compressors. *1

A compressor with an unload valve, combined with one-step compressors. *2

All compressors with unload valves. *2

A speed-regulated compressor combined with one-step compressors. *1 and *3

Operating time equalisation The operating hour equalizing is carried out between compressors of the same type with the same total capacity.

-At the dierent startups the compressor with the lowest number of operating hours will be started rst.

- At the dierent stops the compressor with the highest number of operating hours will be stopped rst.

- For compressors with several steps, the operating time equalizing is carried out between the compressors’ main steps.

Example of cut-in order

Capacity-regulated compressors with unload valves

"Unloader control mode" determines how the capacity distributor should handle these compressors.

Unloader control mode = 1 Here the capacity distributor allows only one of the compressors to be unloaded at a time. The advantage of this setting is that it avoids operating with several compressors unloaded, which is not energy ecient.

For example: Two capacity-regulated compressors of 20 kW, each with 2 unload valves, cyclical coupling pattern.

• For decreasing capacity, the compressor with the most operating hours is unloaded (C1).

• When C1 is completely unloaded, it is cut-out before compressor C2 is unloaded.

Speed control compressors:

The controller is able to use speed control on the st compressor in each group. The variable part of the speed controlled compressor is used to ll in capacity gaps of the following compressor steps.

General regarding handling: An output is connected to the frequency converter’s ON/OFF input and at the same time an analog output ”AO” is connected to the frequency converter’s analog input. The ON/OFF signal will start and stop the frequency converter and the analog signal will indicate the speed. It is only the compressors dened as compressor 1 and 2 that can be speed controlled.

Unloader control mode = 2

Here the capacity distributor allows two compressors to be unloaded while capacity is decreasing. The advantage of this setting is it reduces the number of compressor start/stops.

For example: Two capacity-regulated compressors of 20 kW, each with 2 unload valves, cyclical coupling pattern.

• For decreasing capacity, the compressor with the most operating hours is unloaded (C1).

• When C1 is completely unloaded, compressor C2 with one-step is unloaded before C1 is cut out.

When the step is in operation it will consist of a xed capacity and a variable capacity. The xed capacity will be the one that corresponding to the mentioned min. speed and the variable one will lie between the min. and max. speed. To obtain the best regulation the variable capacity must be bigger than the subsequent capacity steps it has to cover during the regulation. If there are major short-term variations in the plant’s capacity requirement it will increase the demand for variable capacity.

This is how you cut the step in and out:

Cutin The speed-controlled compressors will always be the rst to start and the last to stop. The frequency converter will be started when a capacity requirement corresponding to the mentioned ”Start speed” arises (the relay output for compressor 1 changes to ON and the analog output is supplied with a voltage corresponding to this speed). It is now up to the frequency converter to bring the speed up to ”Start speed”. The capacity step will now be cut in and the required capacity determined by the controller. The start speed always ought to be set so high that a fast lubrication of the compressor is obtained during the start.

Controlling – increasing capacity If the need for capacity becomes larger than “Max. Speed” then the subsequent compressor step will be cut-in. At the same time, the speed on the capacity step will be reduced so the capacity is reduced with a size that corresponds to exactly the cut-in compressor step. Thereby a completely "frictionless" transition is achieved without capacity holes (refer also to sketch).

1 1+2 1+2 1+2 +3 +3+4

As mentioned before the variable part of the speed capacity should be bigger than the capacity of the following one-step compressor steps in order to achieve a capacity curve without “holes”.

The precondition for using this regulating method is that both compressors have the same frequency range.

Controlling – decreasing capacity If the capacity requirement becomes less than “Min. speed” then the subsequent compressor step will be cut-out. At the same time, the speed on the capacity step is increased so the capacity is increased with a size that corresponds to exactly the cut-out compressor step.

Cut-out The capacity step will be cut-out when the compressor has reached “Min. Speed” and the requested capacity has dropped to 1%.

Timer restriction on the speed controlled compressors If a speed controlled compressor is not allowed to start due to a timer restriction, no other compressor is allowed to start. When the timer restriction has expired the speed controlled compressor will start.

Safety cutout on speed controlled compressors If a speed controlled compressor is cutout on safety other compressors are allowed to start. As soon as the speed controlled compressor is ready to start it will be the rst compressor to start.

Compressor timers

Time delays for cutins and cutouts

To protect the compressor against frequent restarts three time delays can be put in.

- A minimum time to run from a compressor’s startup and until it may be restarted.

- A minimum time (ON-time) for the compressor to operate before it may be stopped again.

- A minimum OFF time to run from a compressor stops and until it

may be restarted

When unloaders are cut in and out, the time delays will not be used.

Overriding of load shedding: To avoid load shedding leading to temperature problems for the chilled products, an overriding function is tted.

A overriding limit is set for the regulation temperature as well as a delay time for each digital inlet.

If the temperature during load shedding exceeds the set overriding limit and the attached delay times for the two digital inlets expire then load shedding overrides the signals so that the compressor capacity can be increased until the temperature is again under the normal reference value. The load shedding can then be activated again.

Timer

The operating time of a compressor motor is registered continuously. You can read out:

- operating time for the previous 24-hour period

- total operating time since the timer was last set to zero-set.

Coupling counter

The number of relay cutins and cutouts is registered continuously. The number of starts can be read out here:

- Number during the previous 24-hour period

- Total number since the counter was last set to zero-set.

Load shedding

On some installations there is the desire to limit the cut-in compressor capacity so that one can limit the total electrical load in the store for periods.

There are 1 or 2 digital inlets available for this purpose.

For each digital inlet a limit value is attached for the maximum allowable cut-in compressor capacity so that one can carry out the capacity limitation in 2 steps.

Alarm: When a load shedding digital inlet is activated, an alarm will be activated to inform that the normal control has been bypassed. This alarm can however be suppressed if so desired.

Injection in evaporators

The controller can emit a start/stop signal for liquid injection in the evaporator of each group.

The function can be connected with compressor operation so that the uid injection is synchronised with compressor start/stop Here the injection signal comes ON when the rst compressor is started and goes OFF when the last compressor cuts out.

When a digital inlet is activated, the maximum allowable compressor capacity is limited to the set limit. This means that if the actual compressor capacity upon activation of the digital inlet is higher than this limit, then so much compressor capacity is cut-out that it will then be on or under the set maximum limit value for this digital inlet.

When both load-shedding signals are active, the lowest limit value for the capacity will be the one that is applicable.

Defrost

The controller can perform a central defrost of the entire cold brine circuit. When a defrost is commenced, the compressors stop (selectable), and the pumps continue to circulate the cold brine. Defrost can be stopped by time, or when the cold brine has reached a set temperature. After defrost has been stopped, it is possible to specify a drip delay time before the compressors restart.

There is the option for the defrost function to use an output for activation of external automatic controls.

Defrost start

Defrost can be started in several ways.

- Manual defrost After activation, the setting automatically returns to OFF once defrost has been completed.

- External contact signal Defrost start is performed with a signal on a DI input. The signal must be a pulse signal of at least 3 seconds' duration. Defrost starts when the signal changes from OFF to ON.

- Internal schedule Defrost is started via a weekly program set in the controller. The times are related to the controller's clock function. Up to 8 defrosts per day can be set.

- Network signal Defrost can be started via a signal from the network (system manager).

Start after defrost

It is possible to input a drip delay after defrost, so that any water droplets can drip o the evaporators before refrigeration is restarted. This ensures that the evaporator is as free as possible of water on refrigeration restart.

Defrost output

It is possible to dene a defrost output to control external automatic controls during defrost. The output will be activated during defrost itself, but deactivated during any drip delay that might be input.

Compressors

It is possible to dene whether normal compressor capacity control is to be active during defrost or not.

Pumps

Pump control will always be active during defrost.

Status

It is possible to read o the following status values for defrost:

- Defrost status (ON/OFF)

- Current temp. at defrosting sensor

- Duration of defrost in progress or last completed defrost

- Average duration of the last 10 defrosts.

Defrost stop

The following types of defrost stop can be selected:

Stop by temperature with time as security

Here the temperature of the cold brine is measured. Once the temperature is equal to the set stop temperature, defrost is stopped. Stopping defrost by S4 or S3 temperature may be selected. If the defrost time exceeds the set max. defrost time, defrost is stopped. This happens even if the temperature for defrost stop has not been reached. At the same time as defrost is stopped, the alarm message "Defrost time has been exceeded" is output. The alarm is automatically acknowledged after 5 min.

Stop by time

Here a permanent defrost time is set. Once this time has elapsed, defrost is stopped.

Manual stop

A defrost in progress can be stopped manually by activating the "Stop defrost" function.

Safety functions

Signal from the compressor’s safety controls

The controller can monitor the status of each compressor’s safety circuit. The signal is taken directly from the safety circuit and connected to an input. (The safety circuit must stop the compressor without involving the controller). If the safety circuit is cut out the controller will cut out all output relays for the compressor in question and give an alarm. Regulation will continue with the other compressors.

General safety circuit

If a low-pressure switch is placed in the safety circuit it must be placed at the end of the circuit. It must not cut out the DI signals. (There is a risk that the regulation will become locked and that it will not start again). This also applies to the example below.

If an alarm is needed which also monitors the low-pressure thermostat, a “general alarm” can be dened (an alarm that does not aect the control). See the following section “General monitoring functions”.

Extended safety circuit Instead of a general monitoring of the safety circuit this monitoring function can be extended. In this way a detailed alarm message is issued which tells you which part of the safety circuit has dropped out. The sequence of the safety circuit must be established as shown, but not all of them need necessarily be used.

Oil pressure cutout

Overload current cut-out

Motor temperature cutout

Discharge temp. cutout

Output pressure cut-out

General protection

Common safety circuit- Frost protection with ow switch A common safety signal can also be received from the whole suction group. All compressors will be cut out when the safety signal cuts out.

Time delays with safety cut-out: In connection with safety monitoring of a compressor it is possible to dene two delay times:

Cut-out delay time: Delay time from alarm signal from the safety circuit until the compressor outlet cuts out (note that the delay time is common to all security inlets for the compressor concerned)

Safety re-start time: The minimum time a compressor must be OK after a safety cut-out until it may start again.

Monitoring of max. discharge gas temperature (Sd1, Sd2)

The function promptly cuts out all compressor steps in the group if the discharge temperature becomes higher than permitted. A message alert. The cutout limit is common for both groups and can be dened in the range from 0 to +195°C.

The alarm is cancelled and renewed cutin of compressor steps is permitted when the delay time prior to restart has been passed. (see later)

Monitoring of min. suction pressure (P01, P02)

The function promptly cuts out all compressor steps in the group if the suction pressure becomes lower than the permitted value. The cutout limit is common for both groups and can be dened in the range from -120 to +30°C. At cutout the the alarm function is activated:

The alarm is cancelled and renewed cutin of compressor steps is

permitted when the following conditions are met:

- the pressure (temperature) is above the cutout limit

- the time delay has elapsed (see later).

(On startup of the rst compressor it is possible to delay the function so that cut-out can be avoided.)

Alarm at max. suction pressure

An alarm is issued if the value is exceeded, but the regulation continues.

Monitoring of max. condensing pressure (Pc,Pc1, Pc2)

(Pc is used for a common condenser; if separate condensers are used for each group, Pc1 and Pc2 are used.) The function cuts out all compressor steps in the group if the condensing pressure becomes higher than permitted. The cutout limit is common for both groups and can be dened in the range from –30 to +100°C. The condensing pressure is measured with pressure transmitter Pc, Pc1, Pc2.

At common condensor (Pc) the function takes eect at a value which is 3 K below the set value. At this time 33% of the compressor capacity is cut out (but min. one step). This is repeated every 30 seconds. The alarm function is activated.

If the temperature (pressure) rises to the set limit value, the following will happen:

- all compressor steps will immediately be cut out

- the condenser capacity will remain cut in

The alarm will be cancelled and renewed cutin of compressor steps is permitted when the following conditions are met:

- the temperature (pressure) falls to 3 K below the limit value

- the time delay for restart has been passed.

Common condenser (Pc) If the limit value is exceeded, all compressors will cut out. An alarm will be issued.

Time delay

There is a joint time delay for “Monitoring of max. discharge gas temperature” and “Min. suction pressure” and monitoring of max. condensing pressure Pc. After a cutout, regulation cannot be recommenced until the time delay has been passed.

Frost protection

The temperature of the evaporator are measured by sensors S4.1 and S4.2. Common limit value "S4 min. Limit" has to be set. If measured lower temperatures, all compressors in the group stopped immediately. The pump operation continues. Re-engagement of the compressors is not permitted as long as the temperature is below the value limit.

Startup procedure

The controller contains functions that ensure the proper interaction of pumps, compressors and injection on startup.

Pumps

On startup, the pumps must accelerate a large brine mass to normal ow rate before the compressors are allowed to start. In the controller there is an adjustable delay time, "Comp. Wait s", which must expire before the rst compressor can start.

Capacity limit

If too much compressor capacity is connected in the startup situation, there is a risk that the compressors will drop out at low pressure. To prevent this situation, a capacity limit is input on startup of the system, so only the rst capacity step is engaged in a set time period (set via "operation time rst step").

S4 Alarm thermostat

The function is used to emit an alarm if the S4 brine temperature becomes critical. Alarm limits and delay times can be set for high and low temperature. An alarm is emitted if the set limit is exceeded, but only after the delay time has expired. There are no alarms when refrigeration has been stopped due to the main switch being set to O.

Alarm limits

The alarm limits for high and low S4 temperature are set as absolute values in °C. The alarm limits are not aected during night operation or on external reference displacement via a voltage signal.

Time delays

Three time delays are set:

• At too low a temperature

• At too high a temperature during normal control

• At too high a temperature during pull-down

- After activation of an internal or external main switch

- During defrosting

- After a power failure The time delay during pull-down applies until the S4 temperature drops below the upper alarm limit

S4 status information

To be able to assess how well the system is operating, the following can be read:

• Min, Max and average S4 temperature for the last 24 hours

• Operation time outside alarm limits within the last 24 hours, as a

percentage

Example

Delay on P0 min cut-out

As further protection against cut-out at low pressure during startup, it is possible to delay the "P0 Min" cut-out. The delay time can be set via "P0 Min. delay".

Curve 1: Pull-down phase (1): The time delay is passed. The alarm becomes active. Curve 2: Normal control where the temperature becomes too high (2): The time delay is passed. The alarm becomes active. Curve 3: The temperature becomes too low (3): The time delay is passed. The alarm becomes active.

Pump control

The controller can control and monitor one or two pumps that circulate the brine. If two pumps are used, and operating time equalisation is selected, the controller can also perform a changeover between the two pumps if operating alarms occur.

Activity in the case of operating alarm Pump selection is performed using the following setting: 0: Both pumps are stopped 1: Pump 1 is started up 2: Pump 2 is started up 3: Both pumps are started up 4: Automatic changeover between the pumps is permitted. Start before stop. 5: Automatic changeover between the pumps is permitted. Stop before start.

(This function is used when both pumps are controlled in shifts by

the same frequency converter.)

Automatic changeover between the pumps (only for setting = 4 and 5)

Start before stop

case where there is no ow. Depending on whether pump changeover neutralises the alarm situation or not, the following occurs:

1) Pump changeover neutralises the alarm situation before the alarm delay expires. If pump changeover neutralises the alarm situation, the nonfaulty pump, now in operation, will run until the normal cycle time has expired. After that, there is changeover again to the "faulty pump", as it is assumed to have been repaired. At the same time, the alarm situation is reset (the alarm is acknowledged). If the faulty pump has not been repaired, this will still trigger an alarm and still result in changeover to the pump that is not faulty. This is repeated until conditions are returned to normal.

2) Pump changeover does not neutralise the alarm situation before the alarm delay expires. If the alarm, on the other hand, is active after pump changeover, the controller will also emit an alarm for the second pump. At the same time, both pump outputs are activated in an attempt to create enough ow for the alarm situation to be neutralised. From now on, the controller will have both pump outputs activated until the normal cycle time has expired, after which the alarm situation is reset and pump changeover to one pump is performed again.

Separate alarm priorities can be set for drop out of one pump and for drop out of both pumps. See the Alarms and Messages section.

Stop before start

Using this setting there can be alternation between the two pumps so that a type of operating time equalisation is achieved. The period between the pump changeovers can be set as "PumpCycle". On changeover to the second pump, the rst one will remain in operation for the "PumpDel" time. It will then stop. At stop before start "PumpDel" will be the break time for changeover.

Pump monitoring The controller monitors pump operation via the "Flowswitch" safety input. The signal can originate, for instance, from a pressure dierence pressure switch or a ow switch. Here too, set an alarm delay time that applies during startup and on pump changeover. The delay time is to ensure that on startup/pump changeover, no error is signalled for a pump before brine ow has been established.

If a ow switch is used to stop the compressors, it must be connected to the compressors' "frost protection" safety function.

The special case of operating time equalisation If the pumps are running with automatic operating time equalisation, the controller can perform a changeover of the pumps in a

Alarm handling

Pump alarms are suppressed/acknowledged when normal pump changeover is performed after the cycle time has expired. Pump alarms can also be suppressed by setting pump selection to the "faulty" pump - if the ow switch is OK, the alarm will be acknowledged/suppressed as a result.

Variable pump speed

The controller can supply a 0-10 V signal, which indicates the desired speed of the pump. The signal is connected to a frequency converter.

Speed factor The desired characteristic is dened by a factor that the output signal must have in relation to the cut-in compressor capacity. The relationship is linear at a factor = 0.

Cut in compressor capacity

Min. and Max. frequency to be set for both the controller and the frequency converter.

Condenser

The controller can control a condenser that is common to the two suction groups. If there is a condenser for each suction group, the condensers must be controlled by another device.

Capacity control of the condenser can be accomplished via step regulation or speed control of the fans.

• Step regulation The controller can control up to 8 condenser steps that are cut in and out sequentially.

• Speed control The analog output voltage is connected to a speed control. All fans will now be controlled from 0 to max. capacity. If an ON/ OFF signal is required it can be obtained from a relay output. Regulation can be carried out based on one of the following principles:

- all fans operate at the same speed

- Only the necessary number of fans is cut in.

- Combination with one fan speed regulated and the rest step regulated

Capacity control of condenser

The cut-in condenser capacity is controlled by the condenser pressure’s actual value and depends on whether the pressure is rising or falling. Regulation is performed by a PI controller which may however be changed into a P controller if the design of the plant necessitates this.

PI regulation

The controller cuts in capacity in such a way that the deviation between the actual condensing pressure and the reference value becomes as small as possible.

P regulation

The controller cuts in capacity that depends on the deviation between the actual condensing pressure and the reference value. The proportional band Xp indicates the deviation at 100% condenser capacity.

This means that the capacity controller requires more amplication at high capacities than at low capacities. Consequently, the capacity controller for condenser regulation functions with an arc-shaped capacity curve so that amplication is optimal at both high and low capacities. On some units, compensation is already made for the "problem" described above, by binary connection of the condenser fans: i.e. a few fans are connected at low capacity and many fans at high capacity, for example 1-2-4-8 etc. In this case, the non-linear amplication is already compensated for, and there is no need for an arc-shaped capacity curve.

It is therefore possible to choose on the controller whether you require an arc-shaped or a linear capacity curve to manage the condenser capacity.

Capacity curve = Linear / Power

Capacity curve = Power Capacity curve = Linear

Regulating sensor selection

The capacity distributor can either regulate from the condenser pressure PC or from the average temperature S7.

Cap. Ctrl sensor = Pc /S7

If the regulation sensor is selected for media temperature S7, then Pc is still used as the safety function for high condenser pressure and will therefore ensure cut-out of the compressor capacity when condenser pressure is too high.

Handling sensor errors:

Cap. Ctrl. Sensor = Pc If Pc is used as the regulation sensor, an error in the signal will result in a cut-in of 100% condenser capacity, but the compressor regulation will remain normal.

Cap Ctrl. Sensor = S7 If S7 is used as the regulation sensor, an error in this sensor will result in further regulation that follows the Pc signal, but in accordance with a reference that is 5K over the actual reference. If there is an error on both S7 and Pc, 100% condenser capacity cuts-in, but the compressor regulation remains normal.

Capacity curve

On air-cooled condensers, the rst capacity step will always give comparatively more capacity than the subsequent capacity steps. The increase in capacity produced by each extra step decreases gradually as more and more steps are cut in.

Reference for condensing pressure

The reference for the regulation can be dened in two ways. Either as a xed reference or as a reference that varies according to the outdoor temperature.

Fixed reference

The reference for the condensing pressure is set in °C.

Floating reference

This function allows the condensing pressure’s reference value to vary according to the outdoor temperature within a dened area.

PI regulation The reference is based on:

- the outdoor temperature measured with Sc3 sensor

- The minimum temperature dierence between the air temperature and the condensing temperature at 0% compressor capacity.

- the condenser’s dimensioned temperature dierence between the air temperature and the condensing temperature at 100% compressor capacity (Dim tmK)

- how large a part of the compressor capacity has been cut in.

Pc ref

2. Use of a thermostat for the function. This function can be used with advantage where the heat recovery is used to warm up a water tank. A temperature sensor is used to activate/deactivate the heat recovery function. When the temperature sensor becomes lower than the set cut in limit, the heat recovery function is activated and the reference for the condenser temperature will be raised to a set value and simultaneously the chosen relay outlet is used to activate a solenoid valve which leads the warm gas through the heat exchanger in the water tank. When the temperature in the tank has reached the set value, the heat recovery is cut-out again.

In both cases it applies that when the heat recovery function is de-activated, the reference for the condensing temperature will then decline slowly in accordance with the set rate in Kelvin/ minute.

The minimum temperature dierence (min tm) at low load should be set at approximately 6 K as this will eliminate the risk that all fans will be running when no compressors are running. Set the dimensioned dierence (dim tm) at max. load (e.g. 15 K).

The controller will now contribute with a value to the reference which depends on how large a part of the compressor capacity has been cut in.

P-regultion With P regulation the reference will be three degrees above the measured outdoor temperature. The proportional band Xp indicates the deviation with 100% condenser capacity.

Heat recovery function

The heat recovery function can be used on the installation when you want to make use of warm gas for heating purposes. When the function is activated the reference for the condenser temperature will be raised to a set value and the attached relay outlet is used to activate a solenoid valve. The function can be activated in two ways:

Limitation of the reference

To safeguard yourself against a too high or too low regulation reference, a limitation of the reference must be set.

PcRef

Max

Min

Forced operation of condenser capacity

Forced operation of the capacity can be arranged where the normal regulation is ignored.

The safety functions are cancelled during forced operation.

Forced operation via setting The regulation is set to Manual. The capacity is set in percent of the regulated capacity.

Forced operation of relays If the forced operation is carried out with the switches at the front of an extension module, the safety function will register any exceeding of values and transmit alarms, if required, but the controller cannot cut the relays in or out in this situation.

1. A digital input signal is received In this instance, the heat recovery function is activated via an external signal from, for example a building management system. When the function is activated the reference for the condenser temperature will be raised to a set value and the attached relay outlet is used to activate a solenoid valve.

Capacity distribution

Step regulation

Cutins and cutouts are carried out sequentially. The last cut-in unit will be cut out rst.

Speed regulation

When an analog output is used the fans can be speed regulated, e.g. with a frequency converter type AKD.

Speed regulation + step regulation

Start Min.

The controller starts the frequency converter and the rst fan when the capacity requirement corresponds to the set starting speed. The controller cuts in several fans step by step as the capacity requirement grows and then adapts the speed to the new situation. The controller cuts out fans when the capacity requirement becomes lower than the set minimum speed.

Joint speed regulation

The analog output voltage is connected to the speed regulation. All fans will now be regulated from 0 to max. capacity. If an ON/ OFF signal is required for the frequency converter, so that the fans can be stopped completely, a relay output can be dened.

Start Min.

The controller starts the frequency converter when the capacity requirement corresponds to the set starting speed. The controller stops the frequency converter when the capacity requirement becomes lower than the set minimum speed.

In the conguration of the controller’s outputs it will be the output “FanA1”” that will start and stop the frequency converter.

Speed regulation of rst fan + step regulation of the rest

The controller starts the frequency converter and increases the speed of the rst fan. If additional capacity is required, the next fan cuts in at the same time as the rst fan switches to minimum speed. From here, the rst fan can increase speed again, etc.

Capacity limitation during night operation

The function is used to reduce the noise from the fans to a minimum. It is primarily used in conjunction with a speed control, but it will also be active when steps are cut in and out. The setting is arranged as a percentage of the max. capacity.

The limitation will be disregarded when safety functions Sd max. and Pc max. take eect.

Condenser couplings

Coupling of condenser steps

There are no time delays in connection with cutin and cutout of condenser steps beyond the time delay inherent in the PI/Pregulation.

Timer

The operating time of a fan motor is registered continuously. You can read out:

- operating time for the previous 24-hour period

- total operating time since the timer was last set to zero-set.

Safety functions for condenser

Signal from fan and frequency converter’s safety controls

The controller can receive signals on the status of each individual condenser step’s safety circuit. The signal is obtained directly from the safety circuit and connected to a “DI” input. If the safety circuit is cut out the controller will give alarm. Regulation continues with the remaining steps.

The ancillary relay outlet is not cut-out. The reason for this is that the fan are often connected in pairs but with one safety circuit. With fault on the one fan, the other will continue to operate.

Coupling counter

The number of couplings is registered continuously. Here the number of starts can be read out:

- number during the previous 24-hour period

- total number since the counter was last set to zero-set.

External condenser control

If each suction circuit has its own condenser, each condenser must be controlled separately by its own separate capacity controller, e.g. an AK-PC 530.

Example

If the condenser side requires a complete control of a dry cooler circuit, AK-CH 650A can be combined with a dry cooler control, type AK-PC 420.

Example

General monitoring functions

General alarm inputs (10 units) An input can be used for monitoring an external signal.

The individual signal can be adapted to the relevant use as it is possible to give the alarm function a name and to indicate your own alarm text. A time delay can be set for the alarm.

General thermostat functions (5 units) The function may freely be used for alarm monitoring of the plant temperatures or for ON/OFF thermostat control. An example could be thermostat control of the fan in the compressor compartment.

The thermostat can either use one of the sensors used by the regulation (Ss_, Sd_, Sc3, S3, S4_, S7, Shrec) or an independent sensor (Saux1, Saux2, Saux3, Saux4). Cutin and cutout limits are set for the thermostat. Coupling of the thermostat’s output will be based on the actual sensor temperature. Alarm limits can be set for low and high temperature, respectively, including separate alarm delays. The individual thermostat function can be adapted to the relevant application as it is possible to give the thermostat a name and to indicate alarm texts.

General voltage input with ancillary relay (5 units) 5 general voltage inputs are accessible for monitoring of various voltage measurements of the installation. Examples are monitoring of a leak detector, moisture measurement measurement and level signal - all with ancillary alarm functions. The voltage inputs can be used to monitor standard voltage signals (0-5V, 1-5V, 2-10V or 0-10V). If required, one can also use 0-20mA or 4-20mA if external resistance is placed at the inlet to adjust the signal to the voltage. A relay outlet can be attached to the monitoring so that one can control external units.

For each inlet, the following can be set/read out:

- Freely denable name

- Selection of signal type (0-5V, 1-5V, 2-10V, or 0-10V)

- Scaling of read-out so it corresponds to measuring unit

- High and low alarm limit including delay times

- Freely denable alarm text

- Attach a relay output with cut in and cut-out limits including delay times

General pressure control functions (5 units) The function may freely be used for alarm monitoring of plant pressure or for ON/OFF pressure control regulation.

The pressure control can either use one of the sensors used by the control function (Po_, Pc_) or an independent sensor (Paux1, Paux2, Paux3). Cutin and cutout limits are set for the pressure control. Coupling of the pressure control’s output will be based on the actual pressure. Alarm limits can be set for low and high pressure, respectively, including separate alarm delays. The individual pressure control function can be adapted to the relevant application as it is possible to give the pressure control a name and indicate alarm texts.

Miscellaneous

Main switch

The main switch is used to stop and start the controlling function.

The switch-over has 2 positions:

- Normal controlling state (Setting = ON)

- Control stopped. (Setting = OFF)

In addition, one can also choose to use a digital input as an external main switch.

If the switch-over or the external main switch is set at OFF, all the control’s functions are inactive and an alarm is generated to draw attention to this – all other alarms cease.

Refrigerant

Before regulation can be commenced, the refrigerant must be dened. You can select one of the following refrigerants:

1 R12 11 R114 21 R407A 31 R422A

2 R22 12 R142b 22 R407B 32 R413A

3 R134a 13 User dened 23 R410A 33 R422D

4 R502 14 R32 24 R170 34 R427A

5 R717 15 R227 25 R290 35 R438A

6 R13 16 R401A 26 R600 36 R513A

7 R13b1 17 R507 27 R600a 37 R407F

8 R23 18 R402A 28 R744

9 R500 19 R404A 29 R1270

10 R503 20 R407C 30 R417A

The refrigerant can only be changed if the “Main switch” is set at “stopped control”.

Warning: Incorrect selction of refrigerant can cause damage to the compressor.

Sensor failure

If lack of signal from one of the connected temperature sensors or pressure transmitters is registered an alarm will be given.

• When there is a S4 and P0 error regulation will continue with xx% cut-in capacity during day operation and xx% cut-in capacity during night operation – but minimum one step. (The values can be set).

• In the case of an S3 or S4 error, control continues by emergency cooling in which values from the other sensors are used.

• When there is a Pc error all compressors will be cut out.

• In the event of a Pc1 or Pc2 error, the appertaining compressor group is cut out.

• When there is an error on the Sd sensor the safety monitoring of

the discharge gas temperature will be discontinued.

• When there is an error on the Ss sensor the monitoring of the

superheat on the suction line will be discontinued.

• When there is an error on the outdoor temperature sensor Sc3 the regulation with variable condensing pressure reference cannot be carried out. Instead you use the PC ref. min. value as reference.

• S7 error: See page 90. NB: An incorrect sensor must be in order for 10 minutes before the

sensor alarm deactivates.

Sensor calibration:

The input signal from all connected sensors can be corrected. A correction will only be necessary if the sensor cable is long and has a small cross-sectional area. All displays and functions will reect the corrected value.

Clock function

The controller contains a clock function. The clock function is used only to change between day/night. The year, month, date, hour and minutes must be set.

Note: If the controller is not equipped with a RTC module (AK-OB 101A) the clock must be reset after each mains voltage outage. If the controller is connected to an installation with an AKAgateway or an AK system manager, this will automatically reset the clock function.

Alarms and messages

In connection with the controller’s functions, there are a number of alarms and messages that become visible in cases of fault or erroneous operation.

Alarm history:

The controller contains an alarm history (log) that contains all active alarms as well as the last 40 historical alarms. In the alarm history you can see when the alarm began and when it stopped. In addition, one can see the priority of each alarm as well as when the alarm has been acknowledged and by which user.

Alarm priority:

Dierentiation is made between important and not-so-important information. The importance – or priority – is set for some alarms whilst others can be changed voluntarily (this change can only be done with attachment of AK-ST service tool software to the system and settings must be made in each individual controller).

The setting decides which sorting / action must be carried out when an alarm is sounded.

• “High” is the most important

• “Log only” is the lowest

• “Interrupted” results in no action

Alarm relay

One can also choose whether one requires an alarm output on the controller as a local alarm indication. For this alarm relay it is possible to dene on which alarm priority it must react to – one can choose between the following:

• “Non” – no alarm relay is used

• “High’ – Alarm relay is activated only with alarms with high priority

• “Low - High’ – Alarm relay is activated only with alarms with “low” priority, “medium” or “high” priority.

The relationship between alarm priority and action appears in the schedule below.

Setting Log Alarm relay Send

High X X X X 1 Medium X X X 2 Low X X X 3 Log only X Interrupted

Non High Low-High

Network

AKM des-

tination

Alarm acknowledgement If the controller is connected to a network with an AKA gateway or an AK system manager as alarm receiver, these will automatically acknowledge the alarms that are sent to them.

If the controller on the other hand is not included in a network, the user must acknowledge all alarms.

Alarm LED The alarm LED on the front of the controller indicates the controller’s alarm status.

Blinking: There is an active alarm or an unacknowledged alarm. Fixed light: There is an active alarm that has been acknowledged. Switched o: There are no active alarms and no unacknowledged alarms.

IO Status and manual

The function is used in connection with installation, servicing and fault-nding on the equipment. With the help of the function, the connected outputs are controlled.

Forced operation via network

The controller contains settings that can be operated from the gateway’s forced operation function via data communication.

When the forced operation function asks about one change, all the connected controllers on this network will be set simultaneously. There are the following options:

- Change to night operation

- Forced closure of injection valves (Injection ON)

- Optimising of suction pressure (Po)

Operating AKM / Service tool

The setup of the controller itself can only be carried out via AK-ST 500 service tool software. The operation is described in tters on site guide.

If the controller is included in a network with an AKA gateway one can subsequently carry out the daily operation of the controller via AKM system software, i.e. one can see and change daily readouts/settings.

Note: AKM system software does not provide access to all conguration settings of the controller. The settings/read-outs that may be made appear in the AKM menu operation (see also Literature overview).

Authorisation / Passwords

The controller can be operated with System software type AKM and service tool software AK-ST 500.

Both methods of operation provide the possibility for access to several levels according to the user’s insight into the various functions.

Measurements The status of all inlets and outlets can be read and controlled here.

Forced operation One can carry out an override of all outlets here to control whether these are correctly attached.

Note: There is no monitoring when the outlets are overridden.

Logging/registration of parameters

As a tool for documentation and fault-nding, the controller provides the possibility of logging of parameter data in the internal memory.

Via AK-ST 500 service tool software one can:

a) Select up to 10 parameter values the controller will

continuously register

b) State how often they must be registered

The controller has a limited memory but as a rule of thumb, the 10 parameters can be saved, which are registered every 10 minutes for 2 days.

Via AK-ST 500 one can subsequently read the historical values in the form of graph presentations.

System software type AKM: The various users are dened here with initials and key word. Access is then opened to exactly the functions that the user may operate. The operation is described in the AKM manual.

Service tool software AK-ST 500: The operation is described in tters on site guide.

When a user is created, the following must be stated: a) State a user name b) State a password c) Select user level d) Select units – either US (e.g. °F and PSI) or Danfoss SI (°C and Bar) e) Select language

Access is given to four user levels.

1) DFLT – Default user – Access without use of password See daily settings and read-outs.

2) Daily – Daily user Set selected functions and carry out acknowledgement of alarms.

3) SERV – Service user All settings in the menu system except for creation of new users

4) SUPV – Supervisor user All settings including the creation of new users.

Display of brine temperature and condensing pressure

One to four separate displays can be connected to the controller. Connection is accomplished by means of wires with plug connections. The display may be placed in a control box front, for example. When a display is connected, it will show the value for what is indicated in the conguration: fx.

- Brine regulation sensor

- P01, P02

- S3

- S4, S4.1 3), S4.2

- Ss1, Ss2

- Sd1, Sd2

- Condensors regulation sensor

- Pc, Pc1, Pc2

- S7

1) - 4)

= factory set display outlet

u48 Actual regulation status on condenser

0: Power up 1: Stopped 2: Manuel 3: Alarm 4: Restart 5: Standby 10: Full loaded

11: Running u49 Cut in condenser capacity in % x x u50 R eference for condenser capacity in % x x u51 Actual regulation status on suction group

0: Power up

1: Stopped

2: Manuel

3: Alarm

4: Restart

5: Standby

10: Full loaded

11: Running u52 Cut in compressor capacity in % x x u53 R eference for compressor capacity x x u54 S d discharge gas temperature in °C x x u55 Ss Suc tion gas temperature in °C x x u98 Actual temperature for S7 media sensor x x U01 Actual Pc1 condensing pressure in °C x x U29 Actual Pc2 condensing pressure in °C x x U30 Actual Suction pressure P01 in °C x x U31 Actual Suction pressure P02 in °C x x U32 Actual brine supply S4.1 in °C x x U33 Actual brine supply S4.2 in °C x x

AL1 Alarm suction pressure x x AL2 Alarm condenser x x

x x

When a display with control buttons is chosen, a simple operation via a menu system can be performed in addition to the display of brine temperature and condensing pressure.

No. Function Cond. Suc-

d02 Defrost stop temperature x x x d04 Max defrost time (safety time at stop on temperature) x x x d06 Drip delay. Time before cooling starts after defrost x x x o30 R efrigerant setting x x x o57 Capacit y setting for condenser

0: MAN, 1: OFF, 2: AUTO 058 Manual setting of condenser capacity x x o59 Capacit y setting for suction group

0: MAN, 1: OFF, 2: AUTO o60 M anual setting of suction capacity x x o62 S elect of predened conguration

This setting will give a selection of predened combina-

tions which at the same time establish the connections

points.. At the end of the manual an overview of options

and connection points is shown. After the conguration

of this function the controller will shut down and restart o93 Lock of conguration

It is only possible to select a predened conguration or

change refrigerant when the conguration lock is open.

0 = Conguration open

1 = Conguration locked P31 Pump status

0=stopped. 1=pump 1 running. 2=pump 2 running.

3=both pumps running P35 Selection of pump control

0=both pumps are stopped. 1=only pump 1 must run.

2=only pump 2 must run. 3=both pumps must run.

4= equalization of operation time (start before stop).

5=equalization of operation time (stop before start) r12 Main switch

0: Controller stopped

1: Regulating r23 Set point suction pressure

Setting of required brine temperature in °C r24 Suction pressure reference

Actual reference temperature for brine regulation r28 Set point condenser

Setting of required condenser pressure in °C r29 Condenser reference

Actual reference for temperature for condenser capacity u09 Temperature at defrost sensor x x x u11 D efrost time or duration of last defrost x x x u12 S3 temperature x x x u16 Actual media temperature measured with S4 x x u44 S c3 out door temperature in °C x x

x x

x x x

x x

tion

x x

Pack

If you want to see one of the values in the menu list under "function" you should use the buttons in the following way:

1. Press on the upper button until a parameter is shown

2.Press on the upper or lower button and nd the parameter you want to read

3. Press on the middle button until the value of the parameter is displayed.

After a short time, the display will return automatically to the "Read out display".

Secondary display The following readings can be displayed by pressing the bottom button on the display: For display A: Condenser's regulating sensor For display B: Compressor's regulating sensor. For display C: S4.1 brine temperature For display D: S4.2 brine temperature

Light-emitting diodes on the controller

Internal communication between the modules: Quick ash = error Constantly On = error

Status of output 1-8

Slow ash = OK Quick ash = answer from gateway

■ Power

■ Comm

■ DO1 ■ Status

■ DO2 ■ Service Tool

■ DO3 ■ LON

■ DO4

■ DO5 ■ Alarm

■ DO6

■ DO7

■ DO8 ■ Service Pin

remains on for 10 mins after network registration Constantly ON = error Constantly OFF = error

External communication

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

Network installation

Appendix A - Alarm texts

Settings Priority

(factory)

Suction group

Control mode Low Manual comp. cap. Control_ Manual control of compressors

Low suction pressure P0_ Low Low pressure P0_ Minimum safety limit for suction pressure P0 has been exceeded

High suction pressure P0_ High High pressure P0_ High alarm limit for P0 has been exceeded

High S4_ temperature High High S4_ temp. High S4 temperature

Low S4_ temperature Medium Low S4_ temp. Low S4 temperature

Load shedding Medium Load Shed active Load shedding has been activated

P0_/S4_ sensor error High

Misc. sensor error High

Pump alarm Medium

Cold pump 1&2 alarm High

Frost protection High Anti freeze safety cutout All compressors have been cut out on common safety input

All compressors

Pack 1 Comp. 1 safety Pack 2 Comp. 1 safety Medium

VSD safety Medium

English alarm texts Description

P0_ sensor error Pressure transmitter signal from P0 is defective

S4_ sensor error Temperature signal from S4 media temp. sensor defective

S3 sensor error Temperature signal from S3 media temp. sensor defective

Ss_ sensor error Temperature signal from Ss suction gas temp. is defective

Sd_ sensor error Temperature signal from Sd discharge gas temp. is defective

Sc3 sensor error Temperature signal from Sc3 air on condenser defective

Heat recovery sensor error Temperature signal from Shrec heat recovery thermostat defective

Saux1 sensor error Signal from extra Temp. sensor Saux1 is defective

Saux2 sensor error Signal from extra Temp. sensor Saux2 is defective

Saux3 sensor error Signal from extra Temp. sensor Saux3 is defective

Saux4 sensor error Signal from extra Temp. sensor Saux4 is defective

Cold pump 1 alarm Cold pump 1 is defective

Cold pump 2 alarm Cold pump 2 is defective

Cold pump 1&2 alarm Both cold pump 1 and 2 are defective

Comp. X oil pressure cut out Compressor no. x has been cut out on oil pressure safety

Comp. x over current cut out Compressor no. x has been cut out on over current safety

Comp. 1 motor prot. cut out Compressor no. x has been cut out on motor protection safety

Comp. 1 disch. Temp cut out Compressor no. x has been cut out on discharge temperature safety

Comp. 1 disch. Press. Cut out Compressor no. x has been cut out on discharge pressure safety

Comp. 1 General safety cut out

Comp. 1 VSD safety error Variable speed drive for comp. x has been cut out on safety

Compressor no. x has been cut out on general safety

Condenser

Control mode low Manual cond. cap. Control Manual control of condenser

High Pc_/Sd_ temp. High

Pc_/S7 Sensor error High

Fan/VSD safety Medium

High disch. temp. Sd_ Safety limit for discharge temperature has been exceeded

High pressure Pc_ High safety limit for condensing pressure Pc has been exceeded

Pc_ sensor error Pressure transmitter signal from Pc is defective

S7 sensor error Temperature signal for S7 media temperature sensor is defective

Fan Alarm 1 Fan no. X is reported defective via safety input

Fan VSD alarm Variable speed drive for condenser fans has been cut out on safety

Danfoss AK-CH 650A User guide

Specifications and Main Features

Frequently Asked Questions

User Manual