Danfoss AK-CH 650A User guide
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. Conguration and operation ................................................45
Conguration ...........................................................................................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
Conguration of inputs and outputs .......................................62
Set alarm priorities..........................................................................64
Lock conguration ..........................................................................66
Check conguration .......................................................................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 dierent 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
specic application – variation is created through the read-in
software and the way you choose to dene 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 dened 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
4 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A
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 dierent settings in one
menu will result in dierent 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” (conguration).
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 prole 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.
AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 5
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 dene 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 conrm 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.
6 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A
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 specic 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 sucient.
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.
AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 7
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 dened 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 conguration where each individual connection is dened 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.
8 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A
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 specic 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 inuences / 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 specic, 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.
PIN
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 conguration 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.
12 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A
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
S
Pt 1000 ohm/0°C
S1
S2
Saux1
Saux2
SSA
SdA
P
AKS 32R
3: Brown
2: Blue
1: Black
P0A
P0B
PcA
AKS 32
3: Brown
2: Black
1: Red
PcB
U
...
On/O Ext.
Main
switch
Day/
Night
Door
DO
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:
On
/
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
1
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
S
Pt 1000 ohm/0°C
P
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
U
...
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
DI
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
AK-CH 650A Capacity controller RS8GK302 © Danfoss 08-2015 17
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
18 Capacity controller RS8GK302 © Danfoss 08-2015 AK-CH 650A
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)
S
Pt 1000 ohm/0°C
P
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
U
...
On/O Ext.
Main
switch
Day/
Night
Door
Level
switch
AO
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
DO
Signal Active at
Comp. 1
Comp. 2
Fan 1
Alarm
On
/
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
S
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
P
AKS 32R
AKS 32
U
On/O
DO
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:
on
/
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
AO 0 - 10 V
Module
Point 24 25
Type AO1 AO2
1
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 dened – 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 dened for a display module – you simply connect it.
Module
Point - -
Type - -
1
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
Eect
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 dierence 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 dierent 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 dened: 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
1
Sketch
Make a sketch of the actual plant.
2
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
Dierent 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
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