Danfoss AK-PC 783A User guide

Design Guide

Capacity controller with
cascade control

AK-PC 783A

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-XM 208C ................................................24

Extension module AK-OB 110 ....................................................26

Extension module EKA 163B / EKA 164B ............................... 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 suction group MT ................................................56

Set control of suction group LT .................................................. 60

Set oil management ....................................................................... 63

Setup control of condenser fans ...............................................65

Set control of cascade heat exchanger ..................................67

Setup control of heat recovery.................................................. 68

Setup control of pump function ............................................... 68

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

The capacity from the digital scroll compressor ........102

Cascade control .....................................................................103

Load shedding ........................................................................104

Injection ON ............................................................................105

Liquid injection in suction line .........................................105

Safety functions .............................................................................106

Oil management............................................................................108

Pump control ..................................................................................110

Condenser ...............................................................................................112

Capacity control of condenser .................................................112

Reference for condensing pressure ........................................112

Capacity distribution ...................................................................114

EC motor ...........................................................................................114

Step regulation ......................................................................................114

Speed regulation ..................................................................................114

Condenser couplings ...................................................................115

Safety functions for condenser ................................................115

General monitoring functions .........................................................116

Miscellaneous ........................................................................................118

Appendix A – Compressor combinations and coupling pat-

terns ...........................................................................................................122

Appendix B - Alarm texts ...................................................................128

2 Capacity controller RS8HN102 © Danfoss 2017-11 AK-PC 783A

1. Introduction

Application

AK-PC 783A is complete regulating units for capacity control of
compressors and condensers in refrigeration plants with cascade
function.
The controller controls the high-pressure circuit, low-pressure
circuit and cascade circuit.
The controller is with oil management, simple heat recovery func­tion and coordination between the high-pressure control and
low-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 is carried out by suction pressure P0 on the two
circuits.
Cascade control is performed in accordance with the two tem­perature sensors, Scasc2 and Scasc3.

Among the different functions are:

- Capacity control of up to 12 compressors
(Max. 6 on each circuits or 7 MT + 5 LT or 8 MT + 4 LT)

- Up to 3 unloaders for each compressor

- Up to 3 screw compressors

- Digital scroll compressor

- Oil equalisation function on MT circuit

- Oil management. Either shared or individual for all of the com­pressor's oil valves in the LT circuit. 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

- Control of liquid injection into suction line

- Control of liquid injection into screw compressor

- Control of liquid injection in heat exchanger (cascade)

- Control of two cascade circuits in parallel

- Safety monitoring of high pressure / low pressure / discharge
temperature

- Capacity control of up to 8 fans on the condenser

- Floating reference with regard to outside temperature

- Heat recovery function

- Step coupling, speed regulation or a combination

- Control of CO2 pump system

- Safety monitoring of fans

- Control of fans with EC motors

- 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.

SW = 1.1x

AK-PC 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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, S4, Ss, Sd, condenser pressure,
condenser pressure in temperature, S7 media temperature etc.
A graphical display with control buttons can also be fitted.

AK-PC 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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

application.

AK-PC 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

1. Controller

Type Function Application

AK-PC 783A

Controller for capacity control of compressors and condensers
12 compressors with up to 3 unloaders, 8 fans, max. 160 inputs/outputs

Compressor MT and LT/ Condenser MT/Cascade.
Oil management / Heat recovery.

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 — USB-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

MMIGRS2 Graphic display with operation buttons

-

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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
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

During operation -20 to 55°C ,

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 d.c.

0 to 95% RH (non condensing)
No shock influences / vibrations

Enclosure Material PC / ABS

Density 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 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 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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

S2
Saux_
SsLT
SdMT
Shr
Stw
Scasc

P

AKS 32R

3: Brown

2: Blue

1: Black

P0LT
P0MT
Pc LT

AKS 32

3: Brown

2: Black

1: Red

PcMT
Paux

U

...

On/Off Ext.

Main
switch
Day/
Night
Door
Level
switch

DO

AKV

AKV

PWM
Comp 1
Comp 2
Fan 1
Alarm
Light
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 -

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

Relay outputs on
16 - 19

Terminal

Signal type /

Active at

AK-PC 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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

S2
Saux
SsLT

Pt 1000
SdMT
Shr
Stw
Sscac

AKS 32R /

P0LT
P0MT
Pc LT
PcMT
Paux

AKS 2050 /

MBS 8250

-1 - xx bar

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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

S2
Saux
Ss

Pt 1000
Sd
Shr
Stw
Scasc

AKS 32R /

P0LT
P0MT
Pc LT
PcMT
Paux

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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

S2
Saux
Ss

Pt 1000
Sd
Shr
Stw
Scasc

AKS 32R /

P0MT
P0LT
PcMT
Pc LT
Paux
Prec

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

Active at:

Comp 1
Comp 2

on
Fan 1
Alarm
Light

Off

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 a.c./d.c. / fx. 13 VA

max. 10 V

Valve data

Type P

ETS 12.5 - ETS 400
KVS 15 - KVS 42
CCMT 2 - CCMT 8
CCM 10 - CCM 40
CTR 20

CCMT 16 - CCMT 42 5.1 VA

1.3 VA

Output:

24 V d.c.

20-500 step/s

Max phase current = 800 mA RMS

∑ P

= max. 21 VA

out

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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

Point

CCMT

Step /
Terminal

ETS
CCM / CCMT
CTR
KVS

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

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

Extension module EKA 163B / EKA 164B

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 783A is terminated internally.)

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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 RS8HN102 © Danfoss 2017-11 AK-PC 783A

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.

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 783A Capacity controller RS8HN102 © Danfoss 2017-11 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.
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 RS8HN102 © Danfoss 2017-11 AK-PC 783A