Danfoss AK-PC 781A User guide
User guide
Capacity controller
with recovery function
AK-PC 781A
ADAP-KOOL® Refrigeration control systems
Manual
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-XM 208C ................................................24
Extension module AK-OB 110 ....................................................26
Extension module EKA 163B / EKA 164B / EKA 166 ............ 27
Graphic display MMIGRS2 ............................................................27
Power supply module AK-PS 075 / 150 / 250 ........................28
Communication module AK-CM 102 .......................................29
Preface to design ....................................................................................30
Functions ............................................................................................30
Connections ...................................................................................... 31
Limitations ......................................................................................... 31
Design of a compressor and condenser control .........................32
Procedure: ..........................................................................................32
Sketch .................................................................................................. 32
Compressor and condenser functions ....................................32
Connections ...................................................................................... 33
Planning table .................................................................................. 35
Length .................................................................................................36
Linking of modules ......................................................................... 36
Determine the connection points ............................................37
Connection diagram ...................................................................... 38
Supply voltage ................................................................................ 40
Ordering ..................................................................................................... 41
3. Mounting and wiring .............................................................43
Mounting ................................................................................................... 44
Mounting of analog output module ........................................ 44
Mounting of extension module on the basic module ....... 45
Wiring .......................................................................................................... 46
4. Configuration and operation ................................................49
Configuration ...........................................................................................50
Connect PC ........................................................................................ 50
Authorization .................................................................................... 52
Unlock the configuration of the controllers ..........................53
System setup ....................................................................................54
Set plant type ................................................................................... 55
Set control of compressors ..........................................................56
Set oil management ....................................................................... 60
Setup control of condenser fans ...............................................62
Setup control of high pressure ...................................................64
Setup control of receiver pressure ............................................65
Setup control of heat recovery.................................................. 66
Setup Display .................................................................................... 69
Setup Functions for General purpose ......................................70
Separate thermostats .................................................................... 71
Separate pressostats ......................................................................71
Separate voltage signals ...............................................................72
Separate alarm inputs ...................................................................72
Separate PI functions ..................................................................... 73
Configuration of inputs and outputs .......................................74
Set alarm priorities..........................................................................76
Lock configuration ..........................................................................78
Check configuration .......................................................................79
Check of connections ............................................................................ 81
Check of settings.....................................................................................83
Schedule function .................................................................................. 85
Installation in network .......................................................................... 86
First start of control ................................................................................87
Start the control ...............................................................................88
Manual capacity control ............................................................... 89
5. Regulating functions .............................................................91
Suction group ..........................................................................................92
Controlling sensor selection .......................................................92
Reference ...........................................................................................93
Capacity control of compressors ...............................................94
Capacity distribution methods ........................................... 96
Power pack types – compressor combinations ............97
Compressor timers ................................................................101
Compressor with variable capacity .................................101
Load shedding ........................................................................102
Injection signal to heat exchanger control ..................103
Injection ON ............................................................................103
Liquid injection in common suction line ......................104
Safety functions .....................................................................104
Oil management............................................................................106
Condenser ...............................................................................................108
Capacity control of condenser .................................................108
Reference for condensing pressure ........................................108
Capacity distribution ...................................................................110
Step regulation ......................................................................................110
Speed regulation ..................................................................................110
Condenser couplings ...................................................................111
Safety functions for condenser ................................................111
EC motor ...........................................................................................111
CO2 transcritical system and heat recovery ........................112
Circuit for heat recovery or hot tap water ....................113
Circuit for recovery for heating.........................................114
Circuits for control of CO2 gas pressure ........................117
Receiver control .....................................................................119
Parallel compression ............................................................120
General monitoring functions .........................................................122
Miscellaneous ........................................................................................124
Appendix A – Compressor combinations and coupling pat-
terns ...........................................................................................................128
Appendix B - Alarm texts ...................................................................134
Appendix C - Recommended connection ...................................136
2 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
Application
1. Introduction
SW = 1.4x
AK-PC 781A is complete regulating units for capacity control of
compressors and condensers in refrigeration systems. The controller is with oil management, heat recovery function and CO2
gas pressure control.
In addition to capacity control the controllers can give signals to
other controllers about the operating condition, e.g. forced closing of expansion valves, alarm signals and alarm messages.
The controller’s main function is to control compressors and
condensers so that operation all the time takes place at the
energy-optimum pressure conditions. Both suction pressure
and condensing pressure are controlled by signals from pressure
transmitters.
Capacity control can be carried out by suction pressure P0, media
temperature S4 or separate control pressure Pctrl (for cascade).
Among the different functions are:
- Capacity control of up to 10 compressors
- Up to 3 unloaders for each compressor
- Oil management. Either shared or individual for all of the compressor's oil valves. Receiver pressure control.
- Speed control of one or two compressors
- Up to 6 safety inputs for each compressor
- Option for capacity limitation to minimize consumption peaks
- When the compressor does not start, signals can be transmitted
to other controllers so that the electronic expansion valves will
be closed
- Regulation of liquid injection into suction line
- Start/stop of liquid injection in heat exchanger (cascade)
- MT/LT - coordination between controllers in cascade control
- Safety monitoring of high pressure / low pressure / discharge
temperature
- Capacity control of up to 8 fans
- Floating reference with regard to outside temperature
- Heat recovery function
- CO2 gas cooler control and receiver control
- Parallel compression on transcritical CO2 system
- Step coupling, speed regulation or a combination
- Safety monitoring of fans
- The status of the outputs and inputs is shown by means of lightemitting diodes on the front panel
- Alarm signals can be generated 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 independent of the regulation – such as alarm, thermostat ,pressure
and PI-regulating functions.
Examples
Traditional capacity control
Booster control with 2 controls
(For pure booster control without MT cooling, the intermediate pressure
must be connected to the receiver to prevent Pmin and Pmax cut-outs
during the start-up).
Heat recovery functions, controlling the condensing pressure and
receiver pressure of a CO2 plant
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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 specific
application – variation is created through the read-in software and
the way you choose to define 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 find your way through all the questions so that the regulation
can be defined 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 RS8HE202 © Danfoss 2017-07 AK-PC 781A
Direct connection
Setup and operation of an AK controller must be accomplished via
the “AK-Service Tool” software program.
The program 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 different settings in one
menu will result in different 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” (configuration).
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 profile 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 fitted in order for P0 (Suction) and Pc
(Condensing) readings to be displayed.
A total of 4 displays can be fitted and with one setting it is possible to choose between the following readings: suction pressure,
suction pressure in temperature, Pctrl, S4, Ss, Sd, condenser pressure, condenser pressure in temperature, S7 gas cooler temperature, hot tap water at heat recovery and heat exchanger temperature at heat recovery.
A graphical display with control buttons can also be fitted.
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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 define the measurements you wish
to be shown.
The collected values can be printed, or you may export them to a
file. You can open the file in Excel.
If you are in a service situation you can show measurements in a
trend function. The measurements are then made real-time and
displayed instantly.
■ Power
■ Comm
■ DO1 ■ Status
■ DO2 ■ Service Tool
■ DO3 ■ LON
■ DO4 ■ I/O Extension
■ DO5 ■ Alarm
■ DO6
■ DO7 ■ Display
■ DO8 ■ Service Pin
Slow flash = OK
Quick flash = 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 confirm that you have seen the alarm you can cross it off in the
acknowledge field.
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.
Trouble-shooting
The controller contains a function that continuously follows
a number of measurements and deals with them. The result
indicates whether the function is OK or whether an error may be
expected within a given period of time (“the trip down the roller
coaster has started”). At this time an alarm is transmitted about
the situation – no error has appeared as yet, but it will come.
One example may be slow clogging-up of a condenser. When the
alarm comes the capacity has been reduced, but the situation is
not serious. There will be time to plan a service call.
Alarm
Error
6 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
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 specific 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 sufficient.
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 ap-
plication.
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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 defined 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
• 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 configuration where each individual connection is defined 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.
External display for
suction pressure etc.
Bottom part
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.
If the row of modules needs to
be interrupted due to length or
external positioning, a communication module should be used.
8 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
1. Controller
Type Function Application
AK-PC 781A
Controller for capacity control of compressors and condensers
10 compressors with up to 3 unloaders, 8 fans, max. 120 inputs/outputs
Compressor / Condenser / Both/
Oil management / Heat recovery / CO2 gas
pressure
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
AK-XM 208C 8 4
On/Off outputs On/off 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 valves
Stepper
output
with step
control
Module with
switches
For override of
relay outputs
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
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 USB A-B (Standard IT cable)
Accessories Power supply module 230 V / 115 V to 24 V d.c.
AK-PS 075 18 VA
Supply for controllerAK-PS 150 36 VA
AK-PS 250 60 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
EKA 166 Display with operation buttons and LED for function cut in
MMIGRS2 Graphic display with operation
-
Accessories Communication modules for controllers where modules cannot be connected continuously
AK-CM 102 Communication module
Cable between EKA display and controller Length = 2 m, 6 m
Cable between graphic display and controller Length = 1.5 m, 3.0 m
Data communication for external extension
modules
On the following pages there is data specific to each module.
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 9
Common data for modules
Supply voltage 24 V d.c./a.c. +/- 20%
Power consumption AK-__ (controller) 8 VA
AK-XM 101, 102, 103, 107, AK-CM 102 2 VA
AK-XM 204, 205, 208 5 VA
Analog inputs Pt 1000 ohm /0°C Resolution: 0.1°C
Pressure transmitter type AKS 32R / AKS
2050
MBS 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/Off ) On at R < 20 ohm
On/off supply voltage inputs Low voltage
Relay outputs
SPDT
Solid state outputs Can be used for loads that are cut in and
Stepper outputs Used for valves with stepper input 20-500 step/s
Ambient temperature During transport -40 to 70°C
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. :
Oil valves, fans and AKV valves
Accuracy: +/- 0.5°C
+/- 0.5°C between -50°C and +50°C
+/- 1°C between -100°C and -50°C
+/- 1°C between +50°C and +130°C
Resolution:1 mV
Accuracy +/- 10 mV
Max. connection of 5 pressure transmitters on one module
Off at R > 2K ohm
(Gold -plated contacts not necessary)
Off: U < 2 V
On: U > 10 V
Off: 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
Separate supply to stepper outputs : 24 a.c./d.c. / 13 VA
During operation -20 to 55°C ,
0 to 95% RH (non condensing)
No shock influences / vibrations
Enclosure Material PC / ABS
Class IP10 , VBG 4
Mounting For mounting on panel wall or DIN rail
Weight with screw terminals Modules in 100- / 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 specific, this is mentioned together with the module in question.
LVD tested according to EN 60730
EMC tested
Immunity according to EN 61000-6-2
Emission according to EN 61000-6-3
UL file number: E166834 for XM and CM-modules
UL file number: E31024 for PC-modules
10 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
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-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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. (If it is a
system manager AK-SM .., then 1-999).
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 flash
when the gateway sends an acceptance message.
Operation
The configuration operation of the controller must take place
from the software program “Service Tool”. The program must be
installed on a PC, and the PC must be connected to the controller
via the USB-B 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 flash = OK)
• Communication with Service Tool
• Communication on LON
• Communication with AK-CM 102
• Alarm when LED flashes
- 1 LED that is not used
• Communication with display on RJ11 plug
• “Service Pin” switch has been activated
Address
■ Power
■ Comm
■ DO1 ■ Status
■ DO2 ■ Service Tool
■ DO3 ■ LON
■ DO4 ■ I/O Extension
■ DO5 ■ Alarm
■ DO6
■ DO7 ■ Display
■ DO8 ■ Service Pin
Slow flash = OK
Quick flash = 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 RS8HE202 © Danfoss 2017-07 AK-PC 781A
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
S1
S2
Pt 1000 ohm/0°C
Saux_
SsA
SdA
Shr
Stw
Sgc
P
AKS 32R
3: Brown
2: Blue
1: Black
P0A
P0B
PcA
PcB
AKS 32
3: Brown
2: Black
1: Red
Paux
Pgc
Prec
U
...
On/Off Ext.
Main
switch
Day/
Night
Door
Level
switch
DO
AKV
AKV
Comp 1
Comp 2
Fan 1
Alarm
Light
Rail heat
Defrost
Solenoid
valve
Option Board
Please see the signal
on the page with the
module.
24 and 25 used
only when "Option board fitted"
type
Pt 1000
AKS 32R /
AKS 2050
MBS 8250
-1 - xx bar
AKS 32
-1 - zz bar
0 - 5 V
0 - 10 V
Active at:
Closed
/
Open
Active at:
On
/
Off
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 -
Relay outputs on
16 - 19
Terminal
Terminal
17, 18, 29, 30:
(Cable screen)
Signal type /
Active at
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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 RS8HE202 © Danfoss 2017-07 AK-PC 781A
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
Saux
SsA
Pt 1000
SdA
Shr
Stw
Sgc
P0A
P0B
PcA
PcB
AKS 32R /
AKS 2050
MBS 8250
-1 - xx bar
Paux
Pgc
Prec
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/Off
...
Ext.
Main
switch
Day/
Night
Door
Level
switch
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-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 15
Extension module AK-XM 102A / AK-XM 102B
Function
The module contains 8 inputs for on/off 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/Off:
On: DI > 10 V a.c.
Off: DI < 2 V a.c.
AK-XM 102B
Max. 230 V
On/Off:
On: DI > 80 V a.c.
Off: DI < 24 V a.c.
16 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
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
Level
switch
Closed
(voltage on)
/
Open
(voltage off)
Point 1 2 3 4
Type DI1 DI2 DI3 DI4
Point 5 6 7 8
Type DI5 DI6 DI7 DI8
(The module can not register a pulse signal from e.g. a
reset function.)
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-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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 of 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 outlets.
The outlets 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 RS8HE202 © Danfoss 2017-07 AK-PC 781A
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
Saux
SsA
Pt 1000
SdA
Shr
Stw
Sgc
P0A
P0B
PcA
PcB
Paux
Pgc
Prec
AKS 32R /
AKS 2050
MBS 8250
-1 - xx bar
AKS 32
-1 - zz bar
Terminal
11, 12:
(Cable screen)
Galvanic isolation:
AI 1-4 ≠ AO 1-2 ≠ AO 3-4
Point 5 6 7 8
Type AO1 AO2 AO3 AO4
U
...
On/Off 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 Terminal Signal type /Active at
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
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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 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 204B only):
• Override of relays
ON = override
OFF = no override
Fuses
Behind the upper part there is a fuse for each output.
AK-XM 204A AK-XM 204B
Max. 230 V
AC-1: max. 4 A (ohmic)
AC-15: max. 3 A (Inductive)
Keep the safety distance!
Low and high voltage
must not be connected to
the same output group
AK-XM 204B
Override of relay
Note
If the changeovers are used to override the compressor operation,
it is necessary to wire a safety relay into the circuit for oil management. Without this safety relay, the controller will fail to stop the
compressor if it should run out of oil. See Regulating functions.
20 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
Point
DO
Signal Active at
Comp. 1
Comp. 2
Fan 1
Alarm
Solenoid
valve
On
/
Off
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 - 27
2 (DO 2) 28 - 30
3 (DO 3) 31 - 33
4 (DO 4) 34 -36
5 (DO 5) 37 - 39
6 (DO 6) 40 - 41 - 42
7 (DO 7) 43 - 44 - 45
8 (DO 8) 46 - 47 - 48
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 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.
Note
If the changeovers are used to override the compressor operation,
it is necessary to wire a safety relay into the circuit for oil management. Without this safety relay, the controller will fail to stop the
compressor if it should run out of oil. See Regulating functions.
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 RS8HE202 © Danfoss 2017-07 AK-PC 781A
Point
S
Pt 1000 ohm/0°C
P
AKS 32R
AKS 32
U
On/Off
DO
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
PcB
Paux
Pgc
Prec
AKS 32R /
AKS 2050
MBS 8250
-1 - xx bar
AKS 32
-1 - zz bar
0 - 5 V
...
Ext. Main
switch
Day/
Night
Door
0 - 10 V
Active at:
Closed
Open
Level
switch
Comp 1
Active at:
Comp 2
Fan 1
on
Alarm
Light
Rail heat
Off
Defrost
Solenoid
valve
Point 1 2 3 4 5 6 7 8
Type AI1 AI2 AI3 AI4 AI5 AI6 AI7 AI8
Point 9 10 11 12 13 14 15 16
Type DO1 DO2 DO3 DO4 DO5 DO6 DO7 DO8
Signal Module Point
/
/
Terminal 9: 12 V
Terminal 10: 5 V
Terminal 21: 12 V
Terminal 22: 5 V
Terminal 11, 12, 23, 24 :
(Cable screen)
Terminal
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 - 30 - 33
12 (DO 4) 34 - 35 - 36
13 (DO 5) 37 - 36 - 39
14 (DO6) 40 - 41 - 42
15 (DO7) 43 - 44 - 45
16 (DO8) 46 - 47 - 48
Signal type /
Active at
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 23
Extension module AK-XM 208C
Function
The module contains:
8 analog inputs for sensors, pressure transmitters, voltage signals
and contact signals.
4 outputs for stepper motors.
Supply voltage
The supply voltage to the module comes from the previous module in the row. Here supplied with 5 VA.
The supply voltage to the valves must be from a separate supply,
which must be galvanically separated from the supply for the
control range.
(Power requirements: 7.8 VA for controller + xx VA per valve).
A UPS may be necessary if the valves need to open/close during a
power failure.
Light-emitting diodes
There is one row with LED’s. It indicate the following:
• Voltage supply to the module
• Communication active with the bottom PC board (red = error)
• Step1 to step4 OPEN: Green = Open
• Step1 to step4 CLOSE: Green = Close
• Red flash = Error on motor or connection
Separate voltage
supply is required
24 V ac./d.c. fx. 13 VA
max. 10 V
Output:
24 V d.c.
20-500 step/s
Max phase current = 800 mA RMS
∑ P
= max. 21 VA
out
Valve data
Type P
ETS 12.5 - ETS 400
KVS 15 - KVS 42
CCMT 2 - CCMT 8
CCM 10 - CCM 40
CCMT 16 - CCMT 42 5.1 VA
1.3 VA
Power supply to AK-XM 208C:
Fx: 7.8 + (4 x 1.3) = 13 VA AK-PS 075
Fx: 7.8 + (4 x 5.1) = 28.2 VA AK-PS 150
24 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
Point
CCMT
Step /
Terminal
ETS
CCM / CCMT
KVS 15
KVS 42-54
Point 1 2 3 4 5 6 7 8
Type AI1 AI2 AI3 AI4 AI5 AI6 AI7 AI8
Terminal 17: 12 V
Terminal 18: 5 V
Terminal 19, 20:
(Cable screen)
Point 9 10 11 12
Step 1 2 3 4
Type AO
1 25 26 27 28
2 29 30 31 32
3 33 34 35 36
4 37 38 39 40
White Black Red Green
White Black Green Red
Valve Module Step Terminal
1 (point 9) 25 - 28
2 (point 10) 29 - 32
3 (point 11) 33 - 36
4 (point 12) 37 - 40
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 25
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
26 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
Extension module EKA 163B / EKA 164B / EKA 166
Function
Display of important measurements from the controller, e.g. ap-
pliance 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 and D.
Ex.
A: P0. Suction pressure in °C.
B: Pc. Condensing pressure in °C.
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 defined for a display module – you simply connect it.
Graphic display MMIGRS2
Function
Setting and display of values in the controller.
Connection
The display connects to the controller via a cable with RJ11 plug
connections.
Supply voltage
Received from the controller via cable and RJ11 connector.
Termination
The display must be terminated. Mount a connection between the
terminals H and R.
(AK-PC 781A is terminated internally.)
EKA 166
Placing
The display can be placed at a distance of up to 3 m from the
controller.
Point / Address
No point has to be defined for a display – you simply connect it.
However, the address must be verified. See the instructions accompanying the controller.
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 27
Power supply module AK-PS 075 / 150 / 250
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
Effect
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
AK-PS 250 24 V d.c. (adjustable) 2.5 A 60 VA
Dimension
Type High Width
AK-PS 075 90 mm 36 mm
AK-PS 150 90 mm 54 mm
AK-PS 250 90 mm 72 mm
Connections
Class II
Supply to a controller
AK-PS 075
AK-PS 150
AK-PS 250
28 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
Communication module AK-CM 102
Function
The module is a new communication module, meaning the row of
extension modules can be interrupted.
The module communicates with the regulator via data communication and forwards information between the controller and the
connected extension modules.
Connection
Communication module and controller fitted with RJ 45 plug connectors.
Nothing else should be connected to this data communication; a
maximum of 5 communication modules can be connected to one
controller.
The communication module can be used only with controllers of
the type AK-PC 781A.
Communication cable
One metre of the following is enclosed:
ANSI/TIA 568 B/C CAT5 UTP cable w/ RJ45 connectors.
Positioning
Max. 30 m from the controller
(The total length of the communication cables is 30 m)
Max. 32 VA
Supply voltage
24 volt AC or DC should be connected to the communication
module.
The 24 V can be sourced from the same supply that supplies the
controller. (The supply for the communication module is galvanically separated from the connected extension modules).
The terminals must not be earthed.
The power consumption is determined by the power consumption of the total number of modules.
The controller strand load must not exceed 32 VA.
Each AK-CM 102 strand load must not exceed 20 VA.
Point
Connection points on the I/O modules should be defined as if the
modules were an extension of each other.
Address
The address for the first communication module should be set to
1. Any second module should be set to 2. A maximum of 5 modules can be addressed.
Termination
The termination switch on the final communication module
should be set to ON.
The controller should permanently be set to = ON.
Warning
Additional modules may only be installed following the installation of the final module. (Here following module no. 11; see the
sketch.)
After configuration, the address must not be changed.
Max. 20 VA
Max. 20 VA
AK-PC 781A Capacity controller RS8HE202 © Danfoss 2017-07 29
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 difference is the permitted load and that the relay switch contains a cutout switch.
Mentioned below are 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 setting is maintained for at least 12 hours at a power
failure.
The clock setting is kept updated if the controller is linked up in a
network with a system manager.
Start/stop of regulation
Regulation can be started and stopped via the software. External
start/stop can also be connected.
Warning
The function stops all regulation, including any high-pressure
regulation.
Excess pressure can lead to a loss of charge.
Start/stop of compressors
External start/stop can be connected.
Alarm function
If the alarm is to be sent to a signal transmitter, a relay output will
have to be used.
I'm alive function
A relay can be reserved which is pulled during normal regulation.
The relay will be released if the regulation stops with the main
switch or if the controller fails.
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.
Wiring should be done with a safety relay. See Regulating functions.
Data communication
The controller module has terminals for LON data communication.
The requirements to the installation are described in a separate
document.
30 Capacity controller RS8HE202 © Danfoss 2017-07 AK-PC 781A
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