Capacity Controller AK-PC 351 Manual

Capacity Controller
AK-PC 351
Manual
Introduction
Application
The controller is used for capacity regulation of compressors
and condensers in small refrigeration applications. A maximum of
4 compressors and one condenser can be regulated. For example:
• One suction group + one condenser group, max. 6 steps total
• One compressor group, max. 4 steps
• One condenser group, max. 4 steps
Advantages
• Energy savings via:
- Optimisation of suction pressure
- Night set back
- Floating condensing pressure
Input and output
There are a limited number of available inputs and outputs.
For each signal type, though, the following can be connected:
• Analogue inputs, max. 4 pcs.
Signal from 2 pressure transmitters and 2 temperature sensors
• Digital inputs, max. 8 pcs.
Signal from automatic safety control, external start stop, night
signal, general alarm.
• Relay outputs, max. 5 pcs.
Connection of compressors, condenser fans, alarm relay
• Solid state outputs, max. 1 pcs.
Control of bypass on a digital scroll or for controlling unloader
on a stream compressor. If the output is not used for this function, it can be used as ordinary relay output
• Analogue outputs, max. 2 pcs.
Speed control of compressors and condenser fans.
Operation
The daily operation can be set up directly on the controller.
During set-up, the display images will be adjusted so that only
the relevant images are opened for additional setting and
end-user operation.
The operation is password protected, and three levels of
access can be granted.
The controller contains several languages. Select the preferred
language at start-up.
Data communication
The controller has built-in Modbus data communication, and it
can be connected to an AK-SM 800 type system device.
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Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
Suction Group
Compressor types
The following types of compressor combinations can be used for
regulation:
• Single-step compressors
• Speed controlled compressor together with single-step
• Digital scroll compressor together with single-step
• Stream 4 cylinder compressor together with single-step
• Compressors with an equal number of unloaders.
Capacity regulation
The cut-in capacity is controlled by signals from the connected
pressure transmitter/temperature sensor and the set reference.
Set a neutral zone around the reference .
In the neutral zone, the regulating compressor controls the
capacity so that pressure can be maintained. When it can no
longer maintain the pressure within the neutral zone, the controller will cut out or cut in the next compressor in the sequence.
When further capacity is either cut out or cut in, the capacity
from the regulating compressor will be modified accordingly
to maintain the pressure within the neutral zone (only where
the compressor has variable capacity).
– When the pressure is higher than the “reference + a half neutral
zone”, cut-in of the next compressor (arrow up) is permitted.
– When the pressure is lower than the “reference - a half neutral
zone”, cut-out of a compressor (arrow down) is permitted.
– When the pressure is within the neutral zone, the process
will continue with the currently activated compressors.
Control sensor
Normally, a suction group is controlled based on a signal from
the Po pressure transmitter.
If control on a brine, the S4 sensor must be the control sensor.
An external, low-pressure thermostat can be connected to DI7 for
frost protection.
The reference
At set or variable reference can be used for regulation. For
example, the variable reference can be used for a night time
increase or Po optimisation. Enter a set point here so that a
contribution from the Po optimisation or night time increase
is added. This contribution can raise or lower the reference,
as determined by the momentary cooling need.
To limit the reference from values that are too high or too low, set
a max. and min. limit.
AK-PC 351
Po ref.
Max.
Min.
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Condenser
Fan control
The fans can be controlled incrementally using the controller’s
relays, or they can be speed-controlled via the controller’s
analogue output.
Speed control can be via a frequency VLT-type transformer.
If the fans have EC motors, the 0-10 V signal can be used directly.
Control
Regulation is carried out based on a signal from the Pc pressure
transmitter or an S7 media temperature sensor. The signal is compared with the regulation reference.
The regulation reference can originate from one or more of the
following functions:
• Fixed reference
• Variable reference, which follows the outdoor temperature.
When the outdoor temperature drops, the reference will drop
by a corresponding amount.
This variable reference requires the installation of an Sc3
outdoor temperature sensor. The sensor must be positioned
so that it registers the correct outdoor temperature. In other
words, it must be shielded from direct sunlight and located
near the airway of the condenser.
This regulation requires setting a min. and max. reference,
so that the regulation process is kept within the given limits.
Max. ref.
Min. ref.
Media temperature
If controlling a media temperature, the control sensor
must be set to S7. This temperature sensor must be located
in the desired medium.
High-pressure monitoring can occur with an external,
high-pressure pressure switch on DI8.
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Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
Safety functions
Min./max. suction pressure Po
The suction pressure is recorded continuously.
If the measured value falls below the set minimum limit,
the compressors will immediately cut out.
If it exceeds the max. value, an alarm will be generated once
the time delay has elapsed.
Max. condensing pressure Pc
If the condensing pressure reaches the upper permissible value,
the controller will connect all condenser fans to keep the pressure
down. At the same time, a portion of the compressor capacity will
be disconnected. If the pressure remains near the threshold value,
even more compressors will be disconnected.
All compressors will be disconnected immediately if the threshold
value is exceeded.
LP switch
On/off signal on a DI7 input
If a signal is received, all compressors will immediately be stopped.
HP switch
On/off signal on a DI8 input
If a signal is received, all compressors will immediately be stopped.
Fan capacity will increase depending on how much the
Pc measurement exceeds the reference.
AK-PC 351
Max. discharge gas temperature Sd for digital scroll / stream
Temperature sensor on an AI input.
A signal can be received from a Pt 1000 Ohm sensor on the pressure pipe.
If the temperature nears the set max. temperature, the capacity of
the compressor will be increased so that the compressor can cool
down itself.
The compressors will be stopped if the temperature nears the set
max. temperature value.
Sensor failure
If lack of signal from one of the connected temperature sensors or
pressure transmitters is registered an alarm will be given.
• In the event of a Po error (S4 error), regulation will continue with
a set capacity in daytime operation (e.g. 50%), and a set capacity
in night operation (e.g. 25%), but with a minimum of one step.
• In the event of a Pc error, the condenser capacity that
corresponds to how much compressor capacity is connected
will cut in. Compressor regulation will remain normal.
• When there is an error on the Sd sensor the safety monitoring of
the discharge gas temperature will be discontinued.
• In the event of an error on the outdoor temperature sensor,
Sc3, the permanent setting value will be used as a reference.
NB: A faulty sensor must be OK within 10 minutes before a sensor
alarm is cancelled.
General DI alarm
On/off signal on a DI8 input
If the input is used as general alarm input alarm text and delay
times can be connected.
Alarm and text will appear when the delay time has elapsed.
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Display overview
End-user overview
The images in this daily user interface will depend on how the set-up is made. They will illustrate what is regulated.
For example: One suction group, one condenser group, or a combination. See examples below:
1 suction
groupe
1 condenser
group
1 suction group
and
1 condenser
group
Press "Enter" 
to get to the overview
When an alarm is sent from the controller,
you must advance to this
display to see the
alarm text.
Select a line and
press "Enter" 
Status = either 1 suction group or 1 condenser group or Parameters
6
Both suction group and condenser group
Access to the menus requires password.
Level 1: Only view (100)
Level 2: Change values (200)
Level 3: Change configuration (300).
Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
Set-up overview
There are two ways in which the controller can be set up. Select the one that is easiest for you: either “Wizard” or a review of “all
parameters”.
Start screen upon delivery
Press “Enter” 
Operating principles
1. Select position using arrow keys
2. Select using “Enter” 
3. Use the “X” to return
Hold “Enter”  down for 2 seconds to come to password entry
The default password upon
delivery is 300. Use the arrow
keys to set the password. End
by pressing “Enter” 
Wizard
Here you will be led through a series of settings, after
which the controller will be ready for start.
Image 1 of 22 is displayed here.
Select a set-up method. End
by pressing “Enter” 
Main Menu
The first setting is the
Plant type
The following options are available here:
• Comp. + Cond. = suction group and condenser
• Condenser = ondenser only
• Compressor = suction group only
• None
When the Plant type has
been selected, it will allow several settings to be
made.
For example:
Continue to the next
menus.
All settings are explained
on the pages that follow
AK-PC 351
Manual RS8GZ102 © Danfoss 06-2014
7
Menu
SW: 1.0x
Start/stop
Main switch
Main switch
Start and stop regulating here.
The configuration settings will require that regulating is stopped.
If you try to enter a configuration setting when regulating has started, the controller will
ask if regulating should be stopped.
When all settings have been made and the main switch is set to “ON”, the controller will
enable the display of the various measurements. Regulation will start. (If an external main
switch has been defined, it must also be “ON” before regulating starts.)
Extern Main swich
External main switch
On DI6 an external switch can be connected which can be used to start and stop regulating.
If a switch is not connected, the input must be shorted.
Both the internal and external main switch must be ON before regulating starts.
On / Off
Plant type
Select Plant type
Plant settings:
The following must be regulated:
• Compressor group
• Condenser group
• One compressor group + One condenser group
Refrigerant type
Refrigerant setting
Before refrigeration is started, the refrigerant must be defined. You may choose between
the following refrigerants:
R12, R22, R134a, R502, R717, R13, R13b1, R23, R500, R503, R114, R142b, user defined,
R32, R227, R401A, R507, R402A, R404A, R407C, R407A, R407B, R410A, R170, R290, R600,
R600a, R744, R1270, R417A, R422A, R413A, R422D, R427A, R438A, XP10, R407F.
Warning: Wrong selection of refrigerant may cause damage to the compressor.
Other refrigerants: Here Setting "user defined" is selected and then three factors - fac1, fac2
and fac3 and temperature glide (if necessary).
Unit of setpoints
Define reference settings and readings for saturation temperature or pressure
Select pressure or saturation temperature.
(Can be set during initial set-up and must not be subsequently changed.)
Temp. / press
Fac: Saturated
Mains frequency
Frequency
Set the net frequency
50 Hz / 60 Hz
Fac: 50 Hz
Alarm output
Alarm relay
Define an alarm relay here that will be activated in the event of an alarm.
1. Select the alarm priority that will activate the relay
• No relay
• Critical alarms
• Critical and serious alarms
• All alarms
Select whether the relay will be active (pulled) when the alarm is ON, or when it is OFF.
(If all relays are used to start/stop compressors and condenser fans, it will not be possible to
use an alarm relay.)
DO-demand
Fac: None
Fac: None
Fac: No relay
Suction
Control status
8
Regulation status
Control status
Read the status of the control circuit here e.g.:
No comp=no capacity available (error). Normal=regulation. Alarm comp=alarm situation where the compressor not starts. ON timer=await timer function. Start timer= await
timer function. Normal ctrl=regulation in neutral zone. Inj. ON delay=await time delay,
Cascade=slave or master. 1st comp. del=await first compressor timer. Pump down=suction
down until the set limit before compressor stops. Sensor error=emergency cooling due to
defective signal. Load shed=power limitation function is active. Sd High=temperature monitoring effect the regulation. Pc High= temperature monitoring effect the regulation. Manual
ctrl=manuel operation. Main switch off=regulation stops.
Actuel zone
You will be able to see how the regulation is in relation to the reference here:
P0 error: No regulation
- Zone: The desired pressure is below the neutral zone
NZ: The pressure is in the neutral zone
+ Zone: The desired pressure is above the neutral zone
Control temp. /
Control pres.
The current value of the regulation sensor can be read here
Reference
The total regulation reference can be read here
Running capacity
Here the connected capacity can be read as a % of total capacity
Requested capacity
Here the preferred connected capacity can be read as a % of total capacity
Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
No. of running comp.
The number of compressors in operation can be read here
Po Pressure
The measured pressure for the Po pressure transmitter can be read here
To Saturated temp.
The measured Po pressure converted to temperature can be read here
S4 media temp.
The measured S4 sensors actual value can be read here
MC Po offset
The size of a reference displacement on Po required from the system unit
(suction pressure optimisation function) can be read here
Pc Pressure
The measured pressure for pressure transmitter Pc can be read here
Tc Saturated temp.
The measured Pc pressure converted to temperature can be read here
Day / Night status
The status of the day/night function can be read here
LP switch
The measured status on the connected low pressure switch can be read here
HP switch
The measured status on the connected high pressure switch can be read here
Injection ON
The status of the injection ON signal sent via the system unit to the evaporator controllers
can be read here
MC Night Setback
The status of the night increase signal received from the system device can be read here
Control settings
Control mode
Regulation type
The regulation is normally set to “Auto”, but it can be changed to “Off” or “Manual”.
When setting to “Manual”, a forced capacity setting can subsequently be entered in %.
MAN / OFF / AUTO
Fac: AUTO
Min: 0 %
Max: 100%
Setpoint
Enter the set point for the regulation (regulation reference = set point + different offsets) here
An offset can originate from a night increase signal or from an override function on the
system device.
Min: -80°C (-1.0 bar)
Max: 30°C (50 bar)
Fac: -15°C (3.5 bar)
Neutral zone
Set the neutral zone around the reference here. Also see the illustration on page 3.
Min: 0,1 K (0.1 bar)
Max: 20 K (5.0 bar)
Fac: 6 K (0.4 bar)
Night offset
If necessary, set the value by which the reference will be raised at night.
Keep the setting at 0 if regulating with Po optimisation from a system device.
Min: -25 K (-5.0 bar)
Max: 25 K (5.0 bar)
Fac: 0 K (0.0 bar)
Max Reference
Set the highest permissible regulation reference here
Min: -50°C (-1.0 bar)
Max: 80°C (50.0 bar)
Fac: 80°C (40.0 bar)
Min Reference
Set the lowest permissible regulation reference here
Min: -80°C (-1.0 bar)
Max: 25°C (40.0 bar)
Fac: -80°C (-1.0 bar)
PI control selection
Set how quickly the PI regulation must react here: 1 = slowly, 10 = very quickly.
(For “Custom” setting 0, the special settings options will open, i.e. Kp, Tn and time settings
around the neutral zone. These options are only for trained staff.)
Min: 0 (custom)
Max: 10
Fac: 5
First step runtime
At start-up, the cooling system must have time to cool down before PI regulation takes over
the regulation role and can cut in the next compressor step.
Set the time before the next compressor may be started here.
Min: 0 s
Max: 300 s
Fac: 120 s
Pump down
Pump-down function
To avoid too many compressor starts/stops at a low load, it is possible to define a pumpdown function for the last compressor. In this case, the compressor will only be cut out when
the current suction pressure is down at the set “Pump-down limit Po”.
(The setting must be greater than the safety limit for low suction pressure “Po Min Limit”.)
Yes /No
Fac: No
Emergency cap. day
Emergency capacity in the event of a malfunction of the regulation sensor (suction pressure
sensor)
Set the desired capacity that will apply during daytime operation.
Min: 0 %
Max: 100%
Fac: 50%
Emergency cap. night
Emergency capacity in the event of a malfunction of the regulation sensor (suction pressure
sensor)
Set the desired capacity that will apply during night operation.
Min: 0 %
Max: 100%
Fac: 25%
Comp. start delay
Delay of compressor start after forced closing of expansion valves (at the end of a forced
close signal)
The delay will result in the system device receiving a start signal for all the evaporator controls involved before the first compressor is started.
Min: 0 s
Max: 180 s
Fac: 30 s
Injection OFF delay
Delay of the forced closing of expansion valves, if the controller calls for cut in of compressors, but the compressors are in a locked situation and therefore cannot start.
Min: 0 s
Max: 300 s
Fac: 120 s
Configuration
Control sensor
AK-PC 351
Regulation settings
Min: -80°C (-1.0 bar)
Max: 30°C (50.0 bar)
Facb: -40°C (0.3 bar)
Configuration
Select the regulating sensor for the suction circuit:
• Pressure transmitter Po - Ratiometric (AKS 32R), 1-5V (AKS 32), 0-20mA, 4-20mA (AKS 33)
• Temperature sensor S4 (brine regulation). (Pt 1000 ohm)
Manual RS8GZ102 © Danfoss 06-2014
AI-demand
Po / S4
Fac: Po ratiometric
9
Compressor mode
Set the type of compressor to be used for regulation:
None;
1 single, 2 single, 3 single, 4 single
1 speed, 2 speed, 3 speed, 4 speed,
1 digital, 2 digital, 3 digital
1 stream, 2 stream, 3 stream
1x1 unload, 1x2 unload, 1x3 unload, 2x1 unload
DO-demand /
AO-demand
Fac:
2 digital
Application
Single step
Speed on the
first. Then single
step
Digital scroll
(stream) on the
first. Then single
step
Compressors
with unloader
10
Po sensor max range
Pressure transmitter working range
Set pressure transmitters upper value. Set in relative pressure.
Min: -1 bar
Max: 159 bar
Fac: 12 bar
Po sensor min range
Pressure transmitter working range
Set pressure transmitters lower value.. Set in relative pressure.
Min: -1 bar
Max: 159 bar
Fac: -1 bar
Lead comp. size
Set the nominal compressor capacity for the first compressor (it is defined under
“Compressor mode”)
That is, the capacity of either a “Digital scroll”, “Stream”, “Variable speed”
Min: 1 kW
Max: 100 kW
Fac: 1 kW
Comp. size
Set the nominal compressor capacity of the other compressors
For single-step only: All are of the same size, including the first.
For unloader all: All are of the same size, including the first.
Min: 1 kW
Max: 100 kW
Fac: 1 kW
VSD Min. speed
For speed
Min. speed for speed regulated compressor
Min: 10 Hz
Max: 60 Hz
Fac: 30 Hz
VSD Start speed
For speed
Minimum speed at which the compressor will start (must be set to a higher value than
“VSD Min. speed”)
Min: 20 Hz
Max: 60 Hz
Fac: 45 Hz
VSD Max speed
For speed
Highest permitted speed for compressor
Min: 40 Hz
Max: 120 Hz
Fac: 60 Hz
PWM period time
For “Scroll” and “Stream”
Set the period time for the bypass valve (on time + off time)
Min: 10 s
Max: 40 s
Fac: 20 s
PWM Min cycle
For scroll
Minimum capacity in the time period (without a minimum capacity the compressor
will not be cooled)
Min: 10%
Max: 50%
Fac: 10%
PWM start cycle
For scroll
Start capacity: the compressor will only start when the capacity requirement reaches
the value
Min: 10%
Max: 60%
Fac: 30%
Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
PWM Max cycle
For scroll
Limitation of capacity during time period. There is no limit if the setting in 100%.
Min: 60%
Max: 100%
Fac: 100%
Comp. 1 Sd temp.
For “Scroll” and “Stream”
Define whether the controller should monitor the discharge gas temperature Sd from a
digital scroll or a stream compressor (NTC 86K or Pt 1000 Ohm).
AI-demand
For scroll and Stream and yes to “Comp.1 Sd temp”
Set the maximum Sd temperature
Min: 0°C
Max: 195°C
Fac: 125°C
Comp. 1 Sd max.
Compressor timers
Compressor timers
Lead comp. Min ON
Min. On-time for first compressor
Set a forced On-time here during which the compressor will remain in operation before it
can be switched off again. The setting is to prevent incorrect operation.
To prevent a compressor breakdown, the setting must be made in accordance with the
requirements of the compressor supplier.
Min: 0 min
Max: 60 min
Fac: 0 min
Lead comp. Min OFF
Min. Off-time for first compressor
Set the forced Off-time during which the compressor must be off before it can be switched
on again. The setting is to prevent incorrect operation.
Min: 0 min.
Max: 30 min
Fac: 0 min
Lead comp. Restart
Min. period of time for re-starting the first compressor.
Set the forced Off-time during which the compressor must be off before it can be switched
on again. The setting is to prevent incorrect operation.
To prevent a compressor breakdown, the setting must be made in accordance with the
requirements of the compressor supplier.
Min: 1 min.
Max: 60 min
Fac: 4 min
Lead comp. Safety
delay
Delay time before compressor no. 1 cut out for reasons of safety
The time begins when a signal is received on the safety input for the compressor
Min: 1 min.
Max: 10 min
Fac: 1 min
Comp. Min ON
Min. On-time for remaining compressors
Set a forced On-time here during which the compressor will remain in operation before it
can be switched off again. The setting is to prevent incorrect operation.
Min: 0 min.
Max: 60 min
Fac: 0 min
Comp. Min OFF
Min. Off-time for remaining compressors
Set the forced Off-time during which the compressor must be off before it can be switched
on again. The setting is to prevent incorrect operation.
Min: 0 min.
Max: 30 min
Fac: 0 min
Comp. Restart
Min. period of time for restarting remaining compressors
Set the forced Off-time during which the compressor must be off before it can be
switched on again. The setting is to prevent incorrect operation.
Min: 1 min.
Max: 60 min
Fac: 4 min
Comp. Safety delay
Delay time before compressors cut out for reasons of safety
The time begins when a signal is received on the safety input for the compressor
Min: 1 min.
Max: 10 min
Fac: 0 min
Compressor status
Compressor status
Comp. 1 Sd gas
Read the Sd temperature of the compressor here.
Comp. 1 status
Read the operating status for compressor 1 here. The following information may appear:
Power up=startup. Off= compressor stoppt. Manual ctrl=compressor manual controlled.
Cut out on safety=stoppt due to signal on DI-input. Restart timer=await timeout of time
delay. Ready=ready to start. Min OFF timer=await time out of time delay. Min. ON timer=await
timout of time delay. Full load=compressor works 100%. Running=compressor running.
Disabled=stoppt due to service
Comp. 2....
The same function for the remaining compressors
Compressor capacity
Compressor capacity
Comp. 1 cap
Read the connected capacity of the compressor (0-100%) here
Comp. 2......
The same function for the remaining compressors
Compressor runhours
Compressor run hours
Reset runtime
Reset all of the hour counters and start counters for the subsequent compressors here.
Comp.1 Runtime L
Read the total operating time of the compressor (in hours) here
Comp.2.....
The same function for the remaining compressors
Compressor service
AK-PC 351
No / Yes
Fac: No
Compressor service
Comp.1 out of service
The compressor can be taken out of operation, so that the controller regulates without this
compressor.
No = Normal regulation
Yes = Regulating is carried out without this compressor, and no alarms are generated by it.
Comp.2.....
The same function for the remaining compressors
Manual RS8GZ102 © Danfoss 06-2014
Yes /No
Fac: No
11
Condenser
Control status
Here you can read the status of the condenser circuit, e.g.:
• Main switch = OFF
• Capacity control is ready
• Capacity control is in normal run mode
• Capacity control is set in manual control mode
• Capacity forced to 100% due to High Pc/High Sd prevention functions
• Capacity forced to 100% due to external HP switch/HP safety/Sd safety limit violation
Control temp./press
The current value of the regulation sensor can be read here
Reference
The total regulation reference can be read here
Running capacity
Here the connected capacity can be read as a % of total capacity
Requested capacity
Here the preferred connected capacity can be read as a % of total capacity
No. of running fans
The number of fans in operation can be read here
Tc Saturated temp.
The measured Pc pressure converted to temperature can be read here
Pc Pressure
The measured pressure for pressure transmitter Pc can be read here
S7 Media
Here the measured media temperature with sensor S7 can be read (only if S7 has been
selected as the regulation sensor during “Fan configuration”)
Sc3 air on cond.
The measured outdoor temperature with sensor Sc3 can be read here
HP safety switch
The status of the HP safety switch can be read here
Day / Night status
Here the status of the day /night function can be read
Control settings
Control settings
Control mode
Regulation type
The regulation is normally set to “Auto”, but it can be changed to “Off” or “Manual”.
When setting to “Manual”, capacity can then be forced set in %.
MAN / OFF / AUTO
Fac: AUTO
Min: 0 %
Max: 100%
Setpoint
Enter the set point for the condenser regulation here.
Also set a value if regulating with a fluid reference (set point value used in the event of an
outside temperature sensor error).
Min: -25°C (-1.0 bar)
Max: 90°C (159 bar)
Fac: 35°C (15.0 bar)
Sc3 offset
Temperature offset for regulation with fluid reference.
Regulation reference = Sc3 measurement + Sc3 offset
Min: 0 K
Max: 20 K
Fac: 6 K
Min. reference
Set the lowest permissible regulation reference here
Min: -25°C (-1.0 bar)
Max: 100°C (159 bar)
Fac: 10°C (5.0 bar)
Max. reference
Set the highest permissible regulation reference here
Min: -25°C (-1.0 bar)
Max: 100°C (159 bar)
Fac: 50°C (35.0 bar)
Gain factor Kp
Amplification factor for PI regulation
If the Kp value is lowered, regulation runs more smoothly
Min: 1
Max: 30
Fac: 10
Integration time Tn
Integration time for PI regulation
If the Tn value is increased, regulation will run more smoothly
Min: 30 s
Max: 240 s
Fac: 180 s
Fan configuration
Configuration of fans
Select the regulating sensor for the condensor circuit:
• Pressure transmitter Po - Ratiometric (AKS 32R), 1-5V (AKS 32), 0-20mA, 4-20mA (AKS 33)
• Temperature sensor S7 (Pt 1000 ohm)
AI-demand
Pc sensor max range
Pressure transmitter working range
Set pressure transmitters upper value. Set ini relative pressure.
Min: -1 bar
Max: 159 bar
Fac: 34 bar
Pc sensor min range
Pressure transmitter working range
Set pressure transmitters lower value.. Set ini relative pressure
Min: -1 bar
Max: 159 bar
Fac: -1 bar
Reference mode
Set the reference for regulation here
• Fixed reference; the reference here will be the defined set point
• Variable reference; the reference here will follow the outside temperature, which is measured with Sc3.
AI-demand
Control sensor
12
Regulation status
Control status
Manual RS8GZ102 © Danfoss 06-2014
Pc / S7
Fac: Pc
Setpoint / Floating
Fac: Setpoint
AK-PC 351
Configuration of fans:
Fan speed & DO: Speed controled fans via AO2 and start/stop via DO output.
Fan speed: Speed controlled fans via AO2
4 Fan step: step-by-step . Start/stop via 4 pcs. DO outputs
3 Fan step: step-by-step . Start/stop via 3 pcs. DO outputs
2 Fan step: step-by-step . Start/stop via 2 pcs. DO outputs
1 Fan step: step-by-step . Start/stop via 1 pcs. DO outputs
Not used
For step-by-step connection, the fans cut in and out sequentially (e.g. 123-321).
DO-demand
AO-demand
Control type
Normally, PI-regulation is used, but this can be changed to a P-regulation if the design of the
system necessitates this.
• PI Ctrl: Regulation is carried out here with as little deviation between the reference and
measurement as possible.
• P-band ctrl: Capacity is cut in here after proportional regulation.
P / PI
Fac: PI
VSD Start speed
Set the start speed of the frequency converter here.
The value must be higher than the VSD min. speed value.
Min: 0%
Max: 40%
Fac: 20%
VSD Min speed
Set the minimum speed of the frequency converter here.
If lower capacity is required, this minimum speed should be maintained untill the required
capacity reach 0%. Hereafter all fans stops completely
Min: 0%
Max: 40%
Fac: 10%
Fan mode
Fan status
Fac: Fan speed&DO
Fan status
Fan speed
Here a reading of the actually condenser fan capacity in % (speed control)
Fan 1 status
The status of Step 1 (step 1 or relay for frequency transformer) is indicated here
Fan 2.....
The status of Step 2, 3, etc. is indicated here
Safety monitoring
Po/S4 Min limit
Safety limits for min. Po
If a low value is registered, all compressors will cut out
Min: -120°C (-1.0 bar)
Max: 30°C (159 bar)
Fac: -40°C (0.5 bar)
Po/S4 Max alarm
Alarm limit for high Po
If a high value is registered, an alarm will be generated
Min: -30°C (-1.0 bar)
Max: 100°C (159 bar)
Fac: 100°C (5.0 bar)
Po/S4 Max delay
Delay time for issuing a Po max. alarm
Min: 0 min.
Max: 240 min.
Fac: 5 min.
Pc max limit
Safety limit for max. Pc
If Pc exceeds the value set here minus 3 K, the entire condenser capacity will cut in,
and compressor capacity will be reduced by 1/3 for every 30 seconds.
If Pc exceeds the threshold value, the entire compressor capacity will immediately cut out,
and an alarm will be generated when the delay time expires.
Min: -1 bar
Max: 159 bar
Fac: 40 bar
Tc Max limit
Safety limit for max. Tc
The setting for PC max. limit, converted to temperature, can be read here.
-
S7 max limit
Safety limit for S7
If S7 exceeds the value set here minus 3 K, the entire condenser capacity will cut in,
and compressor capacity will be reduced by 1/3 for every 30 seconds.
If S7 exceeds the threshold value, the entire compressor capacity will immediately cut out,
and an alarm will be generated when the delay time expires.
Min: -50°C
Max: 100°C
Fac: 100°C
Pc/S7 Max delay
Time delay for Pc max. alarm
The alarm will only be generated when the time delay has elapsed.
Min: 0 min.
Max: 240 min.
Fac: 0 min.
Safety restart time
Delayed start-up following safety cut-out
If a safety cut-out has occurred due to “Pc max. limit” or “Po min. limit”,
the compressors must be kept stopped for a defined period of time. The amount of
time can be set here.
Min: 0 min.
Max: 60 min.
Fac: 1 min.
Sensor alarm reset
Reset alarm after sensor error
When a sensor error has occurred, an O.K. signal must be registered within a specified
number of minutes before the controller resets the alarm. The regulation will be resumed
as soon as the sensor signal is O.K.
Min: 0 min.
Max: 30 min.
Fac: 10 min.
AK-PC 351
Manual RS8GZ102 © Danfoss 06-2014
13
General functions
Digital input
DI7 config
DI8 config
Digital input
There are two general digital inputs that can be used by the controller.
The DI7 input can be set to:
• Not used
• Receive night signal. The signal will raise the suction pressure with set offset.
• Register signal from an LP switch. The signal will cause the controller to stop all compressors.
DI-demand
The DI8 input can be set to:
• Not used
• Register signal from an HP switch. The signal will start an override of the fan capacity, and
the compressor capacity will cut.
• Registering a general alarm.
An alarm text can be connected along with a general alarm. This text can be seen in the
display and can be sent to a system device.
DI-demand
Night / LP switch
Fac: Not used
General / HP switch
Fac: Not used
DI8 Alarm tekst
The following alarm texts can be selected when DI8 is selected for generel alarm:
Generel alarm, Low pressure, High pressure, High temp, Low temp, Oil level, Oil temp, Liquid
level, Leak, Inverter fault.
DI8 Alarm delay
Delay time for the DI8 alarm
Min: 0 min.
Max: 360 min.
Fab: 5 min.
Select views on the display
-
Language
Choose from the following languages:
English, Danish, German, Spanish, Italian, Portuguese, Russian, Polish, Czech, Turkish, Croatioa, Serbian or Hungarian
Fac: UK English
Engineering units
Device
Select SI or Imperial (when setting the compressor capacity with U.S. values).
SI / Imperial
Fac: SI
Pressure units
Pressure unit (All pressure readings and settings are in relative pressure.)
Select bar or PSIG
Bar / PSIG
Fac: bar
Temperature units
Temperature unit
Select °C or °F.
°C / °F
Fac: °C
Screen saver time
Screen saver time
If no buttons have been pushed for a specific period of time, the light in the display will be
minimised.
The light level will be restored upon renewed activity.
Min: 1 min.
Max: 60 min.
Fac: 1 min.
User logout time
Log-off time
If buttons have not been pressed within a specified period of time, the screen will return to
the overview display. Afterwards, the user will have to log on again.
If the time is changed, the new time will apply the next time the user logs in.
If you log out here without waiting for the time-out period to elapse, go to the "Home" display and hold down the “X” button for 3 seconds.
Min: 1 min.
Max: 60 min.
Fac: 2 min.
System
Display
Password
Password level 1
Password level 2
Password level 3
Network
Fac: 100
Fac: 200
Fac: 300
Network
-
Modbus Address
Set the address of the controller here if it is connected to a system device via data communication.
Min: 0
Max: 199
Fac: 0
Baudrate
The controller only communicates with system devices that have this baud rate, e.g. AK-SM
850. The value must not be changed
Fac: 384
Serial mode
The value must not be changed
Fac: 8E1
Reset to factory
14
Access code
The settings in the controller can be protected with three levels of access codes.
Level 1: Only see
Level 2: Adjusting installer level
Level 3: Configuration of system settings (configuration menu)
The access code is a number between 001 and 999.
Return to factory settings
If this function is set to “YES”, all settings will be returned to factory default settings, and the
alarm list will be cleared.
Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
I/O configuration
Here you can see which outputs and inputs your settings have established.
The connection points shown cannot be changed, but the analog input measurements can be adjusted.
Digital outputs
1:
2:
3:
.
6:
On/off outputs
The outputs are set up automatically in the following order:
a) If a PWM output is needed, place it on DO6
b) Compressors and unloader valves from DO1 and above
c) Next, fans
d) Alarm
(One output can be on or off with an activated relay.)
On
Off
Digital inputs
1:
2:
3:
..
8:
On/off inputs
The following connection points are fixed and cannot be changed:
DI1-4 = Safety input for the respective compressor. DI5 = Safety input for fans. DI6 = External
start/stop. DI7 = Night signal or LP switch. DI8 = General alarm or HP switch.
(The function can be active when the input is connected or disconnected.)
On
Off
Analog outputs
1:
2:
Analog outputs
AO1 can be used to control the speed of a compressor.
AO2 can be used to control the speed of fans.
When a function is chosen, the output signal will be 0-10 V.
Analog inputs
1:
2:
3:
4:
.
Analog inputs
The inputs are automatically set up
AI1: Sc3 outdoor temperature sensor, Pt 1000 ohm
AI2: Sd discharge sensor, Pt 1,000 ohm or NTC 86K ohm
AI3: S4 temperature sensor, Pt 1000 ohm or Po pressure transmitter: See the type. See sensor’s lower pressure. See the sensor’s upper pressure.
AI4: S7 temperature sensor Pt 1000 ohm or Pc pressure transmitter: See the type. See sensor’s
lower pressure. See the sensor’s upper pressure.
(A type AKS 2050 pressure transmitter, for high pressure, emits a signal as an AKS 32R.)
All measurements can be calibrated if necessary.
I/O Status
Digital outputs
1:
.
6:
Status of on/off outputs
Here you can see if the function is on or off.
(PWM for a digital scroll must be connected to DO6. The pulsing signal will be able to be seen
as an alternating on/off signal)
Digital inputs
1:
.
8:
Status of on/off inputs
Here you can see the status of the input signal.
Analogue outputs
1:
2:
Status of analogue outputs
Here you can see the size of the output signals as a % of max. signal.
Analog inputs
1:
.
4:
Status of analogue inputs
Here you can see pressure and temperature values received by the controller.
The values include calibration
I/O Summary
DO: Max 6, Used:__
DI: Max 8, Used:__
AO: Max 2, Used:__
AI: Max 4, Used:__
Inputs and outputs used
Here you can see how many of the different inputs and outputs are available.
You can also compare this amount with how many have been configured.
If too many have been defined, an exclamation mark (!) will appear.
I/O Manual control
Digital outputs
Manual control of a relay output
Under normal regulation, the function of the relay will be in “Auto”.
In the event of an override, the function will be switched to either “On” or “Off”.
Remember to switch to “Auto” when the override is to be completed.
Auto / On / Off
Analog outputs
Manual control of analogue output
During normal regulation, the function of the output will be “Auto”.
In the event of an override, the function must first be changed to “Manual”,
after which the output signal can be changed from 0-100%.
Remember to switch to “Auto” when the override is to be completed.
Auto / Man
AK-PC 351
Manual RS8GZ102 © Danfoss 06-2014
0-100%
15
Alarm priorities
General
Standby mode:
Sensor error:
Refrigerant:
Output in MANUAL:
General alarm;
Suction group
Low pressure:
High pressure:
Compressor safety:
Alarm priorities
The controller will issue an alarm notification if a specific incident occurs.
Each incident is set to indicate the importance of each alarm, but it is possible to modify the
importance of each. Choose from between the following priority levels:
Critical: Important alarms that require a high level of attention.
Severe: Alarms of intermediate importance
Normal: No important alarms
Disable: Alarms set to this priority level will be cancelled.
Factory setting for the alarm can be seen on bottom of this page
Critical
Servere
Normal
Disable
Condenser
High pressure:
Fan safety:
Setup Wizard
Setup Wizard
This wizard will lead you through the necessary settings, i.e. a total of approximately
20 to 25 display screens, depending on what is selected along the way.
The selection will also result in a connection to a given input and output. You yourself
will see this connection in the IO configuration menu. If applicable, see page 17.
Alarm list
Alarm text
Reason
Priority
setting
Default
value
General alarms
Standby mode (Main sw. OFF)
Alarm when control is stopped by internal or external Main Switch (DI input "Main Switch")
Po sensor error
Pressure transmitter signal from Po defective
Standby mode
Normal
S4 sensor error
Temperature signal from S4 media temp. sensor defective
Sd sensor error
Temperature signal from Sd discharge gas temp. Sd defective
Pc sensor error
Pressure transmitter signal from Pc defective
S7 sensor error
Temperature signal from S7 media sensor on condenser defective
Sensor error
Normal
Sc3 sensor error
Temperature signal from Sc3 air on condenser defective
Sd Comp. 1 sensor error
Temperature signal from "Sd comp. 1" discharge gas temp. on digital scroll/Stream compressor is
defective
Refrigerant not selected
Output in manual mode
Alarm if no refrigerant has been selected
Refrigerant not set
Normal
An output is set in manual mode
Output in MAN mode
Normal
IO configuration error
Not all inputs and outout functions have been assigned to hardware Inputs or outputs*
(can not be set)
Normal
GA - "Alarm text"
Alarm on general alarm input DI 8 (DI input "Gen. Alarm" - alarm text depend upon configured text)
General alarm
Normal
Low pressure Po
Normal
High pressure Po
Critical
Compressor safety
Normal
High pressure Pc
Critical
Fan safety
Normal
Suction alarms
Po/S4 Low suction pressure
Minimum safety limit for suction pressure Po has been violated
LP safety switch cut out
Low safety limit for external low pressure switch has been violated (DI 7 input)
Po/S4 High suction pressure
High alarm limit for Po has been exceeded
Comp. 1 High disch. temp
Safety limit for discharge temperature of digital scroll/Stream compressor has been exceeded
Compressor 1-4 safety cut out
Compressor no. 1-4 has been cut out on general safety input (DI input "Comp.1-4 safety")
Condenser alarms
Pc/S7 High condensing
pressure
High prevention safety limit for condensing pressure Pc has been violated (3K below safety limit)
HP safety switch cutout
High safety limit for external high pressure switch has been violated (DI 8 input)
Common fan safety cut out
A Fan is reported defective via common safety input (DI input "Fan safety")
* The alarm "IO configuration error" is activated if not all IO functions have been assigned to a hardware Input or output.
The reason is that too many functions have been selected via the configuration of the controller.
Go to the menu point "Main menu => IO status => IO summary".
In this screen you can see if you have configured too many functions of a certain type - indicated by an exclamation mark " ! "
Please refer to the screen example, were too many DO functions have been configured.
Solve the problem by adapting the DO functions to the max. No of DO outputs.
Sensor alarms
Sensor alarms shut off automatically when the sensor has been O.K. for 10 minutes.
If you have corrected the sensor error and want to perform a manual, forced removal of the alarm, go to the “Alarm detail display”
Press and hold the “X” key for 2 seconds here.
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Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
Connections when using Setup Wizard
Digital outputs (DO1-DO6):
If you have used the Setup Wizard
for the configuration, the controller will automatically assign the
outputs in accordance with the
following prioritised order:
• PWM outputs for digital scroll or
Stream compressor will be located on solid state outputs DO6
• Compressor start and unloaders
• Fans
• Alarm
Digital inputs (DI1-DI8) are established on the following inputs:
Analog outputs (AO3-AO4) are established on the following outputs:
Analog inputs (AI1-AI4) are established on the following inputs:
DI1-4: Compressor safety input
DI5: Fan safety input
DI6: External Main switch (Start/
Stop)
DI7: LP safety switch or Night
status
DI8: HP safety switch or General
alarm input
AO1: Compressor speed control
AO2: Condenser speed control
AI1: Sc3 outside temperature
AI2: Sd discharge gas temperature
AI3: Po suction pressure or S4
media temperature
AI4: Pc condensation pressure or
S7 media temperature
The assignment of functions on the respective inputs and outputs can be regulated
in “IO configuration”. Here is an example of 3 compressors and 2 fans:
In this image you can see how
many outputs and inputs your
settings have provided.
AK-PC 351
Manual RS8GZ102 © Danfoss 06-2014
17
Connections
Connection, lower level
Connection, upper level
All 24 V or
all 230 V a.c.
Warning
The supply voltage of AI may
not share the signal with
other controllers.
Supply Voltage.
24 V a.c. or 24 V d.c.
DO - Digital outputs, 6 pcs. DO1 - DO6
DO6 is solid state relay.
The relays are de-rated to the specified values.
If an alarm relay is defined, it will be driven under normal operation and it will drop in the event of alarms and insufficient
power to the controller.
DO
DO1-DO5
DO6
I Max.
5A
(2)
0.5 A
min. 50 mA
Ioff < 1.5 mA
U
All 24 V or
all 230 V AC
Pressure transmitters
• Ratiometric: 10-90% of supply, AKS 32R / AKS 2050
• Signal: 1-5 V, AKS 32
• Current: 0-20 mA / 4-20 mA, AKS 33 (supply = 12 V)
DI - Digital switch inputs, 8 pcs. DI1 - DI8
The connection may be a shut-down or interruption function.
Select what is to be activated during configuration.
DI1-4: Safety circuits, compressor 1, 2, 3 and 4
DI5: Safety circuits, condenser fans
DI6: External Main Switch
DI7: Night signal or LP switch
DI8 General alarm or HP switch
AKS 32R
10-90% ratiometric
AKS 32
1-5 V
AKS 33
0-20mA
4-20mA
18
AI - Analogue inputs, 4 pcs. AI1 - AI4
AI1- Sc3: Pt 1000 ohm, AKS 11 or AKS 21.
AI2 - Sd compressor 1: NTC 86K ohm @ 25°C, from digital scroll
or Pt 1000 ohm
AI3: Presure transmitter Po or temperature sensor S4, Pt 1000
ohm
AI4: Pressure transmitter Pc or temperature sensor S7, Pt 1000
ohm
AO - Analogue output, 2 pcs. AO1 - AO2
Must be used when using a frequency converter or EC motors.
Obtain 0-10 volts from terminals COM and AO1 (compressor),
respectively COM and AO2 (fans).
Modbus
It is important that the installation of the data communication
cable be done correctly. Cf. separate literature No. RC8AC.
Remember termination at the bus termination.
Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
The capacity from the digital scroll compressor
Only DO6
The capacity is divided into period times as "PWM per". 100% capacity is delivered when cooling takes place for the whole period. An off
time is required by the bypass valve within the period and an on time is also permitted. There is "no cooling" when the valve is on.
The controller itself calculates the capacity needed and will then vary it according to the cut-in time of the capacity control valve.
A limit is introduced if low capacity is needed so that the cooling does not go below 10%. This is because the compressor can cool itself.
This value can be increased if necessary.
The capacity can similarly be limited so that the compressor cannot deliver 100% capacity. It is not normally necessary to limit this max.
capacity.
Sd monitoring
When regulating with Sd monitoring, the controller will increase capacity if the temperature nears the Sd limit. This will result in better
cooling of the digital scroll compressor.
Refrigeration
No refrigeration
Stream compressor
The PWM signal can also be used to control one stream compressor with one unloader valve.
The compressor capacity is distributed by up to 50% for one relay and the remaining 50-100% for the unloader. The unloader is connected to DO6.
Sd can be monitored like a scroll compressor.
Injection off
The electronic expansion valves in the cooling appliances must be closed when all the compressors are prevented from starting.
As a result, the evaporators will not be filled with fluid that can be led to a compressor when the regulation process restarts.
The function can be prompted via data communication.
AK-PC 351
Manual RS8GZ102 © Danfoss 06-2014
19
Mounting /Dimensions
Data
Supply voltage
4 analog Input
8 digital input
Relay output to
capacity control
2 Voltage outputs
Display output
Data communication
Environments
Density
Weight
Mounting
Connection terminals
Approvals
24 V a.c. +/-15% 50/60 Hz, 17 VA
24 V d.c. (20-60 V), 17 VA
Pressure meauring:
Ratiometric pressure transmitter type AKS 32R
1-5 volt pressure transmitter type AKS 32
0-20 (4-20) mA pressure transmitter type AKS 33
Temperature measurement
Pt 1000 ohm/0°C
NTC - 86K from digital scroll / stream
From contact function
E.g. to:
Start/stop of regulation
Monitoring of safety circuits
General alarm function
AC-1: 5 A (ohmic)
5 pcs. SPDT (5A)
AC-15: 2 A (inductive)
1 pcs. Solid State.
Imax. = 0.5A
PWM for scroll Imin. = 50 mA.
unload
Leak<1.5 mA
0-10 V d.c. Ri = 1kohm
For type MMIGRS2
Modbus
for AK-SM 800
-20 - 60°C, During operations
-40 - 70°C, During transport
For DIN rail mounting only (IP 20)
20 - 80% Rh, not condensed
No shock influence / vibrations
IP 20
0,2 kg
DIN-rail
max. 2.5 mm2 multi core
EU Low Voltage Directive and EMC demands re
CE-marking complied with
LVD tested acc. EN 60730-1 and EN 60730-2-9
EMC-tested acc. EN61000-6-2 and 3
Pressure transmitter / temperature sensor
Kindly refer to catalogue RK0YG...
20
Manual RS8GZ102 © Danfoss 06-2014
AK-PC 351
Ordering
Type
AK-PC 351
AK-PC 351
Function
Capacity controller
Operation
With buttons and display
Manual RS8GZ102 © Danfoss 06-2014
Supply voltage
24 V
Code no.
080G0289
21
List of literature
Installation guide for extended operation RC8AC
Here you can see how a data communication connection to ADAP-KOOL® Refrigeration control systems can be established.
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alternations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respecitve companies. Danfoss and Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
22
Manual RS8GZ102 © Danfoss 06-2014
ADAP-KOOL®
Installation considerations
Accidental damage, poor installation, or site conditions, can give
rise to malfunctions of the control system, and ultimately lead to a
plant breakdown.
Every possible safeguard is incorporated into our products to
prevent this. However, a wrong installation, for example, could still
present problems. Electronic controls are no substitute for normal,
good engineering practice.
Danfoss will not be responsible for any goods, or plant components, damaged as a result of the above defects. It is the installer's
responsibility to check the installation thoroughly, and to fit the
necessary safety devices.
Special reference is made to the necessity of signals to the controller when the compressor is stopped and to the need of liquid
receivers before the compressors.
Your local Danfoss agent will be pleased to assist with further
advice, etc.
AK-PC 351
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