Danfoss OPTYMA Control AK-RC 101 Operation And Maintenance Manual

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MAKING MODERN LIVING POSSIBLE

OPTYMATM Control

Single-phase AK-RC 101

Operation and Maintenance Guide

Table of contents Page

General .....................................................................................................................................................................................................3

Description .........................................................................................................................................................................................3

Applications .......................................................................................................................................................................................3

Main characteristics ........................................................................................................................................................................3

Overall dimensions ............................................................................................................................................................................3

Identication data ..............................................................................................................................................................................4

Installation .............................................................................................................................................................................................4

Important information for the installer ...................................................................................................................................4

Standard assembly kit ....................................................................................................................................................................4

Installing the unit .............................................................................................................................................................................5

Functions ................................................................................................................................................................................................7

Technical characteristics of OPTYMATM Control, single-phase ......................................................................................7

Control panel ........................................................................................................................................................................................8

Front keypad ......................................................................................................................................................................................8

LED Display.........................................................................................................................................................................................9

Symbols used ....................................................................................................................................................................................9

Setting and displaying the set points .......................................................................................................................................9

Level 1 - Programming (User Level)........................................................................................................................................ 10

List of Level 1 variables (User Level) ....................................................................................................................................... 10

Level 2 - Programming (Installer Level).................................................................................................................................11

List of Level 2 variables (Installer Level) ................................................................................................................................ 11

Switching on the OPTYMATM Control single-phase .......................................................................................................... 12

Compressor activation/deactivation conditions ............................................................................................................... 12

Manual defrosting ........................................................................................................................................................................ 12

Hot-gas defrosting ....................................................................................................................................................................... 13

Pump-down function .................................................................................................................................................................. 13

Password function ........................................................................................................................................................................ 13

Alarm relay .......................................................................................................................................................................................... 14

Trouble shooting / Alarm list ...................................................................................................................................................... 15

Connection diagrams ..................................................................................................................................................................... 16

Parts list ................................................................................................................................................................................................ 18

Ordering ............................................................................................................................................................................................... 19

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General

Description

The OPTYMATM Control single-phase is a new control panel for cold rooms with a single-phase compressor up to 2 HP, specially designed for safety, protection, control and ease of installation. It allows the user to control all the components on a refrigeration system: compressor, evaporator fans, defrosting elements, room light and thermostatholder.

Main characteristics

- Direct control of defrosting elements, evaporator fans, room light with outputs directly connectable to the various units.

- Automatic fuse protect the refrigeration unit.

- Stylish ABS housing with transparent cover for access to the automatic fuse, all with an IP65 protection rating so that panel can be used outside the room.

Overall dimensions

Applications

- Complete management of single-phase static or ventilated refrigeration systems up to 2 HP, with o-cycle or electrical defrosting and with direct or pump-down compressor stop.

- Control of single-phase evaporator unit only with solenoid valve or remote condensing unit.

- LED indicators and large display show system status.

- User-friendly keypad.

- Display resolution to 0.1 °C.

- Modbus data communication that can be connected to an ADAP-KOOL® system unit.

Dimensions in mm.

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Identication data

The unit described in this manual has an ID label on the side showing all the relevant identication data:

• Name of Manufacturer

• Type and code number

• Product name

• Power supply

• Serial number (10 digits)

• Date (Day/Month/Year)

Installation

Important information for the installer. Installation to be done by authorised person only!

1. Install the device in places where the protection rating is observed and try not to damage the housing when drilling holes for wire penetrations

2. Do not use multi-polar cables which have wires connected to inductive/power loads and signalling wires (e.g. sensors and digital inputs).

3. Do not t power supply wiring and signal wiring

(sensors and digital inputs) in the same raceways or ducts.

4. Minimise the length of connector wires so that

wiring does not twist into a spiral shape as this could have a detrimental eect on the electronics.

Standard assembly kit

For the purposes of assembly and use, the electronic OPTYMATM Control single-phase unit comes with:

• Three rubber washers, to be tted between the

xing screws and the housing back panel

• One user’s manual.

• Two temperature sensors

5. Fit a general protection fuse before the electronic controller.

6. All wiring must be of a diameter suitable for relevant power levels.

7. If a sensor extension is required, the wires must have a diameter of at least 1 mm2.

8. If data communication is used, it is important that the data communication cable is correctly installed. See separate literature, no. RC8AC...

9. If data communication is used, the alarm relay cannot be used.

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Installing the unit

Lift the transparent cover. Remove the screw cover on the right-hand side of the housing.

Undo the 4 xing screws at the front of the housing.

Open the front of the housing, lift it and slide the two hinges out as far as they will go.

Press on the sides of the hinges to remove them from their seats and then remove the front panel completely.

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Use the three existing holes to x the housing back panel to the wall: use three screws of a suitable length for the thickness of the wall on which the panel will be mounted. Fit a rubber washer (supplied) between each screw and the housing back panel.

Hook the front panel back up to the lower part of the housing by inserting the two hinges in their seats and, bending them, rotate downwards 180° to gain access to the electronic board.

If Modbus data communication is connected, see the JUMPER setting on page 14, preferably before all the wiring is connected.

NOTE ! Make all the electrical connections as illustrated in the diagram for the corresponding model (see drawing on page 16). To eect correct electrical connection and maintain the protection rating, use appropriate wire/ raceway grips to ensure a good seal. Route the wiring inside the unit in as tidy a fashion as possible: be especially careful to keep power wires away from signal wires. Use clips to hold wires in place.

Close the front panel, making sure that all the wires are inside the housing and that the housing seal sits in its seat properly. Tighten the front panel using the 4 screws, making sure the O-rings on the head of each screw are used. Power up the panel and carry out thorough reading/programming of all the parameters.

NOTE ! Be careful not to over-tighten the closure screws as this could warp the housing and compromise proper operation of the membrane-type keypad. Install short-circuit overload safety devices on all the power cables connected to the OPTYMATM Control so as to prevent damage to the device. Work and/or maintenance must be carried out on the unit ONLY after disconnecting the panel from the power supply and from any inductive/power loads: doing so allows the worker to do his job safely.

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Functions

OPTYMATM Control single-phase:

- Display and adjustment of cold room temperature setting to 0.1 °C

- Display of evaporator temperature from para meter

- System control activation/deactivation

- System warnings (probe/sensor errors, minimum and maximum temperature warnings, compressor shutdown)

- Evaporator fans control

- Automatic and manual defrost (static, heating element, cycle inversion)

- Direct control of compressor unit up to 2 HP

- Room light, via panel key or door switch

- Alarms/auxiliary relay

- Defrosting, lights and alarms can be operated via data communication.

Technical characteristics of OPTYMATM Control single-phase

Power supply

Voltage 230 V~ ± 10% 50Hz / 60Hz

Power consumption (electronics only) ~ 7 VA

Cold room conditions

Operating temperature -5 to 50°C

Storage temperature -10 to 70°C

Relative humidity Less than 90% -

General characteristics

Type of sensors EKS 221, code no.: 084N3210

Resolution 0.1 °K

Sensor read precision ± 0.5 °K

Read range -45…+45 °C

Digital inputs

Requirements to contact Gold plating

OPTYMATM Control single-phase - Output characteristics - max. applicable load (230 V AC)

Compressor 1500W (AC3)

Defrost 3000W (AC1)

Fans 500W (AC3)

Room light 800W (AC1)

Alarm contact (non-powered contact) 100W

General electrical protection Automatic fuse 16A

Dimensions

Dimensions 168 mm x 97 mm x 262 mm (HxPxL)

Insulation / mechanical characteristics

Housing protection rating IP65

Housing material Self-extinguishing ABS

Type of insulation Class II

Not condensed. No shock inuence/vibration.

Id=300 mA Disconnecting power 4.5 kA

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Control Panel

Front keypad

AUXILIARY RELAY CONTROL

(on the version with alarm relay controls the relay manual if parameter AU=1)

UP / MUTE WARNING BUZZER

STAND BY

(The LED ashes if the system shuts down)

Room temperature SETTING / SET key

DOWN / MANUAL DEFROST

ROOM LIGHT

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LED Display

1. Cold room temperature / parameters

2. Stand-by (ashes on stand-by). Outputs are de-

activated

3. Room light (ashes if door switch activated)

4. Cold (indicates activation of compressor)

5. Fans

6. Defrosting

7. Auxiliary

8. Alarm/warning

General

To enhance safety and simplify the operator’s work, the OPTYMATM Control has two programming levels; the rst level (Level 1) is used to congure

It is not possible to access the Level 2 programming directly from Level 1: you must exit the programming

mode rst. the frequently-modied SETPOINT parameters. The second programming level (Level 2) is for general parameter programming of the various controller work modes.

Symbols used

For practical purposes the following symbols are used:

• (▲) the UP key is used to increase values and mute the alarm.

• (▼) the DOWN key is used to decrease values and force defrosting.

Setting and displaying the setpoints

1. Press the SET key to display the current SETPOINT (temperature)

2. Hold down the SET key and press the (▲) or (▼) keys to modify the SETPOINT.

Release the SET key to return to cold room temperature display: the new setting will be saved automatically.

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Level 1 - Programming (User Level)

To gain access to the Level 1 conguration menu proceed as follows:

When conguration values have been set, you can exit the menu by pressing the (▲) and (▼) keys simultaneously for a few seconds until the

1. Press the (▲) and (▼) keys simultaneously and

cold room temperature reappears. keep them pressed for a few seconds until the rst programming variable appears on the display.

5. The new settings are saved automatically when

you exit the conguration menu.

2. Release the (▲) and (▼) keys.

3. Select the variable to be modied using the (▲) and (▼) key.

4. When the variable has been selected it is possible to:

• display the setting by pressing the SET key

• modify the setting by pressing the SET key together with the (▲) and (▼) key.

List of Level 1 variables (User Level)

Variables Explanation Value Default

r0 Dierential above main SETPOINT*

* SETPOINT see page 9

d0 Defrost interval (hours) 0 - 24 hours 4 hours

d2 End-of-defrost setpoint.

Defrosting will not take place if the temperature detected by the defrost sensor is greater than d2 (If the sensor is faulty defrosting is timed)

d3 Max defrost duration (minutes) 1 - 240 min 25 min

d7 Drip duration (minutes)

At the end of defrost, the compressor and fans remain at standstill for time d7 and the defrost LED on the front panel ashes.

F5 Fan pause after defrost (minutes)

Allows fans to be kept at standstill for time F5 after dripping. This time begins at the end of dripping. If no dripping has been set, the fan pause starts directly at the end of defrost.

A1 Minimum temperature alarm

Allows user to dene a minimum temperature for the room being refrigerated. Below value A1 an alarm trips: the alarm LED ashes, the displayed temperature ashes and the buzzer sounds to indicate the problem.

A2 Maximum temperature alarm

Allows user to dene a maximum temperature for the room being refrigerated. Above value A2 an alarm trips: the alarm LED ashes, the displayed temperature ashes and the buzzer sounds to indicate the problem.

tEu Evaporator sensor temperature display Displays

0.2 - 10 K 2K

-35 - 45 °C 15°C

0 - 10 min 0 min

- -45°C

- +45°C

evaporator temperature (displays nothing if dE =1)

read only

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Level 2 - Programming (Installer Level)

To access the second programming level press the UP (▲) and DOWN (▼) keys and the LIGHT key simultaneously for a few seconds.

2. View the setting by pressing the SET key.

3. Modify the setting by holding the SET key down and pressing the (▲) or (▼) key.

4. When conguration settings have been completed you can exit the menu by pressing the

When the rst programming variable appears the system automatically goes to stand-by.

(▲) and (▼) keys simultaneously and keep them pressed until the room temperature reappears.

5. Changes are saved automatically when you exit

1. Select the variable to be modied by pressing the UP (▲) and DOWN (▼) keys. When the parameter has been selected it is

the conguration menu.

6. Press the STAND-BY key to enable electronic

control.

possible to:

List of Level 2 variables (Installer Level)

Variables Explanation Value Default

AC Door switch status 0 = normally open

F3 Fan status with compressor o 0 = fans run continuously

F4 Fan pause during defrost 0 = fans run during defrost

dE Sensor presence

If the evaporator sensor is disabled defrosts are carried out cyclically with period d0: defrosting ends when an external device trips and closes the remote defrost contact or when time d3 expires.

d1 Defrost type, cycle inversion (hot gas) or with

heater elements

bdr Modbus baudrate

(Danfoss System unit =19200 baud)

Ad Modbus address 1 ... 247

Ald Minimum and maximum temperature

Signalling and alarm display delay

C1 Minimum time between shutdown and

subsequent switching on of the compressor.

CAL Correction of sensor signal -10…+10 0

Pc Compressor protection contact status 0 = NO

doC Compressor safety time for door switch: when

the door is opened the evaporator fans shut down and the compressor will continue working for time doC, after which it will shut down.

tdo Restart time, if the door remains open 0... 240 min. (0=no function) 0

Fst FAN shutdown TEMPERATURE

The fans will stop if the temperature value read by the evaporator sensor exceeds this value.

1 = normally closed

1 = fans only run when compressor is working

1 = fans do not run during defrost

0 = evaporator sensor present 1 = no evaporator sensor

1 = hot gas 0 = electric

0=300. 1=600. 2=1200. 3=2400. 4=4800. 5=9600. 6=14400. 7=19200. 8=38400 baud.

(+ setting: AU must be set to 7) (+ move jumper: see page 14)

1…240 min 120 min

0…15 min 0 min

1 = NC

0…5 minutes 0

-45…+45°C +45°C

0 = NO

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Continued...

Variables Explanation Value Default

Fd Fan dierential below Fst 0…+10K 2K

LSE Min. limit of set point setting -45...HSE -45°C

HSE Max. limit of set point setting 45... LSE 45°C

tA NO – NC alarm relay switching 0 = activates when alarm is on

AU Auxiliary/alarm relay control 0 = alarm relay

StA Temp. setting for aux. relay -45…+45°C 0

In1 Man in cold room alarm

Select input INP1 on the board as compressor protection alarm or as man-in-room alarm (contact NC).

P1 Password type of protection

( active when PA does not equal 0)

PA Password

(see P1 for the type of protection)

reL Software release The version can be read -

1 = deactivates when alarm is on

1 = manual auxiliary relay controlled via AUX key 2 = automatic auxiliary relay managed by StA temp. setting with 2°C dierential 3 = not used 4 = pump-down function (see 5.15) 5 = free voltage contact for condensing unit (AUX relay and compressor relay in parallel) 6 = Relay used to control a heating

element in the crankcase. The relay is on when the compressor is stopped.

7 = The relay function is cancelled

and data communication is permitted

0 = compressor protection 1 = man-in-room alarm

0 = display set point only 1 = display set point, AUX, light access 2 = access to programming not permitted 3 = access to second level programming not permitted

0...999 0 = not active

Switching on the OPTYMATM Control single-phase

After wiring the electronic controller correctly,

immediately emit a beep and all the LEDs will come on simultaneously for a few seconds.

connect 230 V a.c.; the display panel will

Compressor activation/deactivation conditions

The OPTYMATM Control single-phase activates the compressor when cold room temperature exceeds

Manual defrosting

To defrost just press the dedicated key (see page 8) to activate the elements relay. Defrosting will not take place if the end-of-defrost temperature setting (d2) is lower than the temperature detected by the

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setting+dierential (r0); it deactivates the compressor when the cold room temperature is lower than the setting.

evaporator sensor. Defrosting ends when the endof-defrost temperature (d2) or maximum defrost time (d3) is reached. When using data communication, the defrost cycle can be started from the system unit.

Hot-gas defrosting

Set parameter d1 =1 to defrost in cycle inversion mode. The compressor relay and defrost relay are activated throughout the defrost phase. To ensure proper control of the system the installer must use the defrost output: this must allow

opening of the cycle inversion solenoid valve and closure of the liquid solenoid valve. For capillary systems (without thermostat valve) the cycle inversion solenoid valve can be controlled via the defrost relay control.

Pump-down function

Pump-down function is activated when parameter AU=4 (for version with AUX/Alarm relay only). Connect pump-down pressostat on the digital input INP-1.

Password function

The protection function is activated when parameter PA is set to a value other than 0. See parameter P1 for the dierent protection types. When PA is set, protection starts after two

The compressor is directly controlled by pressostat. Connect evaporator solenoid valve on the AUX relay. The solenoid is controlled directly by the thermostat.

minutes of inactivity. 000 appears on the display. Use the up/down keys to change the number, and the set key to conrm it. If you have forgotten your password, use the universal number 100.

Alarm relay

Factory setting = The relay functions as an alarm relay. When using data communication, a JUMPER must be moved. See the following:

1. Open the front of the housing as described on page 5: rotate it downwards 180° to gain access to the electronic board.

2. Undo the 6 CPU board xing screws: remove the board from the front part of the housing in ABS.

3. Remove the jumper from JUMPER JP2.

4. Insert the jumper in JUMPER JP2 in position: 3-2: to select data communication (2-1: is the alarm relay position).

Trouble shooting / Alarm list

In the event of any anomalies the OPTYMATM Control warns the operator by displaying alarm codes and

panel. If an alarm is tripped the display will show one of the following messages.

sounding the warning buzzer inside the control

Alarm code Possible cause Solution

E0 Cold room temperature sensor not working

E1 Defrost sensor not working properly

E2 Eeprom alarm

E8 Man-in-room alarm • Reset the alarm input inside the cold room

Ec Compressor protection tripped (e.g. thermal

Ed Open door - alarm (Open door and tdo-time

Temperature shown on display is ashing

properly

(In this case defrosts will last time d3)

An EEPROM memory alarm has been detected (All outputs except the alarm one are deactivated)

protection or max pressure switch) (All outputs except the alarm one – where applicable – are deactivated)

has expired)

Minimum or maximum temperature alarm.

The temperature inside the cold room has exceeded the min. or max. temperature alarm setting (see variables A1 and A2, user programming level)

• Check that cold room temperature sensor is working properly

• If the problem persists replace the sensor

• Check that defrost sensor is working properly

• If the problems persists replace the sensor

• Switch unit o and then back on again

• Check that compressor is working properly

• Check compressor absorption

• If the problem persists contact the technical assistance

Check door / door contact

• Check that the compressor is working properly.

• Sensor not reading temperature properly or compressor start/stop control not working.

Connection diagram

Power

Supply

230Vac

Modbus

Defrost probe

Ambient probe

Common probe

Common dig. input

Door Limit Switch

Comp. Protection

Danfoss

80Z679.10

17 18

15 16 14

Common

12 11

8 7

6 5 4

23 1

B A

How to connect the OPTYMATM Control single-phase to OPTYMATM condensing unit

Danfoss 80Z681.10

Danfoss

Common dig. input

Door Limit Switch

Comp. Protection

Common probe

Ambient probe

Modbus

Defrost probe

Power Supply 230Vac

12NL

15 16

OPTYMATM Condensing unit

2 34567

17 18

Condenser

fan

Compressor

How to connect the OPTYMATM Control single-phase to OPTYMA PLUSTM and SlimPack condensing unit

Common dig. input

Door Limit Switch

Comp. Protection

2 34567

Modbus

Common probe

Ambient probe

Defrost probe

Power Supply 230Vac

Connect Compr. Relay output to room thermostat input terminals of OptymaPlus / SlimPack (remove bridge before): Term. 3-4 Optyma SlimPack Term. 4-5 OptymaPlus Evo.2 H1 - H3 Term. 5-6 OptymaPlus Evo.2 H4 Term. 6-7 OptymaPlus Evo.2 230V-3Phase Term. 24-25 OptymaPlus new Generation (DI1 of OptymaPlus Controller)

15 16

17 18

80Z682.

Parts list

1 Housing back panel in ABS

2 Housing front panel in ABS

3 Front cover in transparent polycabonate

4 Front panel opening hinge

5 Front panel closure screws

6 Board xing screws

7 Automatic fuse/ Cut out switch

8 CPU board

9 Polycarbonate screw cover

10 Terminal for earth connections

Ordering

Type

OPTYMATM Control single-phase (2 HP) including two sensors

Code no.

080Z3200

Sensor EKS 221 (spare part) 084N3210

Notes

Danfoss OPTYMA Control AK-RC 101 Operation And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual