Danfoss ADAP-KOOL AK-CT 200A User manual

User guide

ADAP-KOOL®Refrigeration control systems

Controller tray for refrigeration

appliance control with TEV

AK-CT 200A + AK-CT 450A

AK-CT 450A

2 User Guide RS8GR602 © Danfoss 2016-10 AK-CT 450A

Introduction

Application

Complete refrigeration appliance control with great exibility to

adapt to all types of refrigeration appliances and cold storage

rooms.

• For refrigeration with brine

• For use with a thermostatic expansion valve (TEV)

Advantages

• Optimised for installation by manufacturer

• Electricity-controlled and voltage controlled relay connections

• Loads requiring electricity can be connected directly

• Overcurrent limitation

• Energy optimisation of the whole refrigeration appliance

• One controller for several dierent refrigeration appliances

• Quick set-up with predened settings

• Built-in data communication

• Built-in clock function with power reserve

Principle

The temperature in the appliance is registered by one or two

temperature sensors which are located in the air ow before the

evaporator (S3) or after the evaporator (S4) respectively.

A setting for thermostat, alarm thermostat and display reading

determines the inuence the two sensor values should have for

each individual function.

In addition product sensor S6, which can be optionally placed in

the appliance, can be used to register the temperature near the

required product in a certain place within the appliance.

The temperature of the evaporator is registered with the S5 sensor

which can be used as a defrosting sensor.

In addition to the output for the solenoid valve type EVR the con-

troller has 9 relay outputs which are dened by the use selected –

the individual usage options are described in detail on page 12

Functions

• Day/night thermostat with ON/OFF or modulating principle

• Product sensor S6 with separate alarm limits

• Switch between thermostat settings via digital input

• Start of defrost via schedule, digital input or network

• Natural, electric, hot gas defrost or brine defrost

• Stop of defrost on time and/or temperature

• Coordination of defrosting among several controls

• Pulsing of fans when thermostat is satised

• Case cleaning function for documentation of HACCP procedure

• Rail heat control via day/night load or dew point

• Door function

• Control of two compressors

• Control of night blinds

• Light control

• Heat thermostat

• Integrated MODBUS communication with the option of

mounting a LonWorks communication card

Appliance examples

Contents

Introduction ....................................................................................................... 2

Operation ............................................................................................................ 4

Applications .....................................................................................................12

Connections .....................................................................................................17

Survey of functions........................................................................................19

Operation ..........................................................................................................32

Menu survey.....................................................................................................33

Ordering ............................................................................................................39

Data.....................................................................................................................40

AK-CT 450A User Guide RS8GR602 © Danfoss 2016-10 3

Applications

Here is an overview of the controller’s usage options.

• Standard appliance or cooling room with one valve,

one evaporator and one cooling section.

• Refrigeration appliance with one valve, two evaporators

and two cooling sections (each with its own temperature-

measuring function).

• Refrigeration device with one valve, one evaporator and

two cooling sections.

A setting will congure input and outputs so that the controller’s

operation interface is directed at the selected application.

The current settings for the respective uses can be found

on page 34.

Installation benets

The controller is designed to provide a number of advantages

when installed by the refrigeration appliance manufacturer,

such as:

High relay load

Load connection/disconnection is controlled by a voltage

measurement and a current measurement, so that the relay’s

switch function can operate under optimal conditions.

The controller can then connect loads of up to 16 A, without

the use of auxiliary relays.

Spring clamps

All cable connections are made using plugs with spring switches.

This allows for fast and easy installation.

Parallel power point

Several of the outlets have double or triple connections points,

so the use of external loop clips is not usually necessary.

Structure of the controller

The controller consists of hardware type AK-CT 200A and a

software identity code AK-CT 450A.

This software identity code is delivered in a separate plug

and must be placed in an RJ45 plug in the hardware. It is rst

necessary to mount the plug when conguring the controller.

4 User Guide RS8GR602 © Danfoss 2016-10 AK-CT 450A

Operation

Cooling

Regulation can be performed on the basis of the following princi-

ples:

Direct expansion

The temperature is controlled either through the starting/stop-

ping of a compressor or through the opening/closing of a sole-

noid valve in the liquid line.

Brine

Here, the temperature is controlled by opening/closing a solenoid

valve/motor valve in the brine supply.

Temperature control

The temperature in the appliance is registered by one or two

temperature sensors which are located in the air ow before the

evaporator (S3) or after the evaporator (S4) respectively. A setting

for the thermostat, alarm thermostat and display reading deter-

mines how much the two sensor values should inuence each

individual function, e.g. 50% will produce an equal value from

both sensors.

Various weightings can be set for day and night operation.

The actual temperature control can take place in two ways: as an

ordinary ON/OFF regulation with a dierential, or as a modulat-

ing control where the temperature variation will not be nearly as

great as in ON/OFF control. There is however a limit to the use of

a modulating control as it can only be used in DX central plant or

brine system.

In principle, regulation in this system is the same as described

above, but is now performed with a PI function. This results in

reduced uctuation of the regulated air temperature with stable

loads, giving a more constant air humidity.

The function gives a constant temperature regulation with a tem-

perature value, which lies half-way between the on and o values

of the thermostat.

The operating parameters of the PI regulation are automatically

optimised via the preset on and o values and the degree of

opening of the valve.

The dierential aects the amplication of the regulator and can

therefore not be set to less than 2K in order to ensure regulation

stability.

In a decentralised plant the thermostat function with ON/OFF

control should be selected.

In a central plant the thermostat function may either be selected

for ON/OFF control or modulating control.

Temperature monitoring

Just as is possible for the thermostat, the alarm monitoring can

be set with a weighting between S3 and S4 so that you can decide

how much the two sensor values should inuence the alarm

monitoring. Minimum and maximum limits can be set for alarm

temperature and time delays. A longer time delay can be set

for high temperature alarms after defrosting, appliance cleaning

or start-up.

Modulating

On /O

AK-CT 450A User Guide RS8GR602 © Danfoss 2016-10 5

Thermostat bands

Thermostat bands can be used benecially for appliances where

dierent product types are stored which require dierent tem-

perature conditions. It is possible to change between the two

dierent thermostat bands via a contact signal on a digital input.

Separate thermostat and alarm limits can be set for each thermo-

stat band – also for the product sensor.

Night setback of thermostat value

In refrigeration appliances there may be big load dierences

between the shop’s opening and closing hours, especially if night

lids/blinds are used. The thermostat reference may be raised here

without it having any eect on the product temperature.

Change-over between day and night operation can take place,

as follows:

• via an external switch signal.

• via a signal from the data communication system.

Product sensor

A separate product sensor S6, which may be placed in the

appliance, can also be used and which can register and monitor

the temperature in the warmest part of the appliance. There are

separate alarm limits and time delays for the product sensor.

Appliance cleaning

This function makes it easy for the shop’s sta to carry out a

cleaning of the appliance according to a standard procedure.

Appliance cleaning is activated via a signal – as a rule via a key

switch placed on the appliance.

Appliance cleaning is carried out via three phases:

1 - at the rst activation the refrigeration is stopped, but the fans

keep on operating in order to defrost the evaporators. ”Fan” is

shown on the display.

2 - at the second activation the fans are also stopped and the

appliance can now be cleaned. ”OFF” is shown on the display.

3 - At the third activation refrigeration is recommenced.

The display will show the actual appliance temperature,

(o97 setting).

When appliance cleaning is activated a cleaning alarm is

transmitted to the normal alarm recipient. A later processing

of these alarms will document that the appliance has been

cleaned as often as planned.

Alarm monitoring

There are no temperature alarms during appliance cleaning.

Appliance shut-down

The function closes the solenoid valve and all outputs are

switched o.

The cooling appliance is stopped like the“Main switch”, but this

happens without an “A45 standby alarm”.

The function can be enabled by a switch on the DI input or via

a setting through data communication.

- + + °C

1 ÷ + Fan

2 ÷ ÷ O

3 + + °C

6 User Guide RS8GR602 © Danfoss 2016-10 AK-CT 450A

Hot gas application

Defrost

Depending on the application you may choose between the

following defrost methods:

Electric: The heating element is activated

Hotgas: Here the solenoid valves are controlled so that the

hotgas can ow through the evaporator

Brine: Here, the solenoid/motor valve is opened on the supply

pipe, so that hot brine can be fed through.

Natural: Here the fans are kept operating during the defrost

Defrost sequence

1) Pump down

2) Defrost

3) Waiting position after defrost

4) Draining (drain delay. Hotgas only)

5) Drip o

6) Delay of fan

Hot gas defrost (application 7 only)

This type of connection can be used on systems with hotgas

defrost, but only in small systems in, say, supermarkets – the

functional content has not been adapted to systems with large

charges.

Must not be used together with PMLX and GPLX valves, unless

a time delay relay is installed, which ensures that the PMLX/GPLX

valve is closed completely before the hotgas is turned on.

Drip tray heating element

It is possible to control a heating element in the drip tray for

hot gas defrosting. When defrosting is commenced, the heating

element is activated. The heating element remains activated until

a set time after defrosting has ended by time or temperature.

Start of defrost

A defrost can be started in dierent ways

Interval: Defrost is started at xed time intervals, say, every

eighth hour. An interval must ALWAYS be set to

a "higher" value than the period set between two

defrostings when a schedule or network signal is used.

Refrigeration time: Defrost is started at xed refrigeration time

intervals, in other words, a low need for refrigeration will

”postpone” the defrost

Schedule: Here defrost can be started at xed times of the

day and night. However, max. 6 times

Contact: Defrost is started with a contact signal on a digital input

Network: The signal for defrost is received from a system unit

via the data communication

Manual: An extra defrost can be activated from the controller’s

lower-most button

All the mentioned methods can be used at random – if just of

them is activated a defrost will be started.

Stop of defrost

Defrosting can be stopped by either:

• Time

• Temperature (with time as safety).

AK-CT 450A User Guide RS8GR602 © Danfoss 2016-10 7

Coordinated defrost

There are two ways in which coordinated defrost can be arranged.

Either with wire connections between the controllers or via data

communication

Wire connections

The digital input DI2 is connected between the current controllers.

When one controller starts a defrost all the other controllers will

follow suit and likewise start a defrost. After the defrost the indi-

vidual controllers will move into waiting position. When all are in

waiting position there will be a change-over to refrigeration.

Coordination via data communication

Here the system unit handles the coordination.

The controllers are gathered in defrosting groups and the system

unit ensures that defrosting is started in the group according to a

weekly schedule.

When a controller has completed defrosting, it sends a message

to the system unit and then goes into a waiting position. When

every controller in the group is in a waiting position, refrigeration

is again permitted in all the individual controllers.

Defrost based on refrigeration time

When the aggregate refrigeration time has passed a xed time,

a defrost will be started.

Min. time between defrosts

There is a 2 hours minimum time between defrosts.

This avoids that planned defrosts in accordance with the weekly

schedule are carried out immediately after a defrost on demand

has been carried out. The time applies from when a Defrost based

on refrigeration time has been completed to when a planned

defrost is again permitted. Defrost based on refrigeration time will

not start defrosting with a shorter interval than the 2 hours either.

System manager

Melting function

This function will stop the air ow in the evaporator from being re-

duced by frost created by uninterrupted operation for a long time.

The function is activated if the thermostat temperature has

remained in the range between -5°C and +10°C for a longer

period than the set melting interval. The refrigeration will then be

stopped during the set melting period. The frost will be melted

so that the air ow and hence the evaporator’s capacity will be

greatly improved.

Real-time clock

The controller has a built-in real-time clock which can be used

to start defrosts. This clock has a power reserve of more than 24

hours.

If the controller is equipped with data communication, the clock

will automatically be updated from the system unit.

Max. 10 pcs.

8 User Guide RS8GR602 © Danfoss 2016-10 AK-CT 450A

Control of two compressors (application 8)

The two compressors must be of the same size.

When the controller demands refrigeration it will rst cut in

the compressor with the shortest operating time. After the time

delay the second compressor will be cut in.

When the temperature has dropped to ”the middle of the

dierential”, the compressor with the longest operation time

will be cut out.

The running compressor will continue until the temperature

has reached the cutout value. Then it will cut out. When the

temperature again reaches the middle of the dierential,

a compressor will again be started.

If one compressor cannot maintain the temperature within the

dierential, the second compressor will also be started.

If one of the compressors has run on its own for two hours,

the compressors will be changed over so that operational time

is balanced.

The two compressors must be of a type that can start up against

a high pressure.

The compressors’s settings for ”Min On time” and ”Min O time”

will always have top priority during normal regulation. But if one

of the override functions is activated, the ”Min On time” will be

disregarded.

Railheat

It is possible to pulse-control the power to the rail heat in order

to save energy. Pulse control can either be controlled according

to day/night load or dew point.

Pulse control according to day and night

Various ON periods can be set for day and night operation.

A period time is set as well as the percentage part of the period

in which the rail heat is ON.

Pulse control according to dew point

In order to use this function a system manager of the type AK-SM

is required which can measure dew point and distribute the

current dew point to the appliance controllers. For this the rail

heat’s ON period is controlled from the current dew point.

Two dew point values are set in the appliance control:

• One where the eect must be max. i.e.100%. (o87)

• One where the eect must be min. (o86).

At a dew point which is equal to or lower than the value in 086,

the eect will be the value indicated in o88.

In the area between the two dew point values the controller will

manage the power to be supplied to the rail heat.

During defrosting

The rail heating will be active during defrosting (as selected

in setting d27).

Dew point

Rail heat

AK-CT 450A User Guide RS8GR602 © Danfoss 2016-10 9

Fan

Pulse control

To obtain energy savings it is possible to pulse control the power

supply to the fans at the evaporators.

Pulse control can be accomplished in one of the following ways:

- during the thermostat’s cutout period (cold room)

- during night operation and during the thermostat’s cutout

period (appliance with night lid)

A period of time is set as well as the percentage of this period of

time where the fans have to be operating.

Cutout of fans during plant breakdowns

If the refrigeration in a breakdown situation stops, the

temperature in the cold room may rise quickly as a result of the

power supply from large fans. In order to prevent this situation the

controller can stop the fans if the temperature at S5 exceeds a set

limit value.

Fan pause

When the setting P65 is set to a value greater than 0, the fans will

stop while the night blind is rolling down.

Eco-mode

When the night blind is down, the fan speed can be reduced.

Eco-mode is not allowed if the heating function has been

activated.

When Eco-mode is enabled, relay DO8 will be activated.

Light function

The function can be used for controlling the light in a refrigeration

appliance or in a cold room. It can also be used for controlling

a motorised night blind.

The light function can be dened in more than one way:

- The light is controlled via a signal from a door contact.

The light will remain on for 2 minutes after the door has been

shut.

- The light is controlled via the day/night function.

- The light is controlled via the data communication from

a system unit.

Here there are two operational options if data communication

should fail:

- The light can go ON.

- The light can stay in its current mode.

•Two signals, both of which can be on before the light goes on.

One can be a DI contact signal at the appliance (fx DI3) and the

other can be via data communication or a voltage signal.

Voltage signal must be activated on DI7.

The light is switched o when "r12" (Main switch) is set to o

(see o98).

The light is switched o when the appliance cleaning function

is activated.

If an override of the light is desired, this can be done via pulse

pressure on a DI input + setting = 19.

Extra light (light 2)

Light 2 can also be activated by one DI input, e.g. DI4.

It can also be controlled with two signals. For two signals,

the second signal must be sent with a voltage signal on DI8.

Period time

Light 2

(extra light)

controlled by

DI8 and fx DI4.

Light 1

controlled by

DI7

and fx DI3.

Override of light 1

10 User Guide RS8GR602 © Danfoss 2016-10 AK-CT 450A

Night blind

Motorised night blind can be controlled automatically from

the controller. The night blinds will follow the status of the light

function. When the light is switched on, the night blinds opens

and when the light is switched o, the night blinds close again.

When the night blinds are closed, it is possible to open them

using a pulse signal on the digital input. If this input is activated,

the night blinds will open and the refrigeration appliance can

be lled with new products. If the input is activated again,

the blinds close again.

If the activation is omitted, the blind will close automatically

when the delay time expires. A setting is used to dene whether

the light is to be on or o when the night blind is up.

When the night blind function is used, the thermostat function

can control with dierent weighting between the S3 and S4

sensors. A weighting during day operation and another when

the blind is closed.

A night blind is open when the appliance cleaning function

is activated.

A setting can dene that the night blind is open when "r12"

(Main switch) is set to o (see o98).

Digital inputs

There are six digital inputs with contact function and two digital

inputs with high voltage signal.

They can be used for the following functions:

- Retransmission of contacts position via data communication

- Door contact function with alarm

- Starting or cancelling a defrost cycle

- Main switch - start/stop of cooling

- Night setback

- Thermostat bands switch

- General alarm monitoring

- Case cleaning

- Forced cooling

- Override of night blinds

- Coordinated defrost (DI2 only)

- Forced closing of valve

- Appliance shutdown

- Light, Extra light, Override light

Forced closing

The solenoid valve can be closed with an external signal

( "Forced closing").

If a defrost cycle is in progress, the forced closing status will not

be re-established until the defrost is completed. Otherwise,

the defrost cycle will be stopped immediately when the signal

is received. The function can be dened in o90. The signal can

be received from the DI3-input or via the data communication.

During a forced closing the fans can be dened to be stopped

or in operation.

Door contact

The door contact function can via the digital inputs be dened

for two dierent applications:

Alarm monitoring

The controller monitors the door contact and delivers an alarm

message if the door has been opened for a longer period than

the set alarm delay.

Alarm monitoring and stop of refrigeration

When the door is opened the refrigeration is stopped, i.e. the

injection, the compressor and the fan are stopped and light

switch on.

If the door remains open for a longer time than the set restart

time, refrigeration will be resumed. This will ensure that

refrigeration is maintained even if the door is left open or

if the door contact should be defective. If the door remains

open for a longer period than the set alarm delay an alarm

will also be triggered.

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