Danfoss AK-PC 782B IP Communication Enabled User Guide

Danfoss AK-PC 782B IP Communication Enabled

AK-PC 782B ST500 overview layout

Alarm = Red alarm bell when alarm is present
Value = Controlling sensor actual value
Ref. = Target set point
Act.% = Percent active capably or valve open %
Status = Condition of control sequence

AK-PC 782B wiring & addressing overview

1. Represents board number assigned in pack controller using ST500
2. Represents communications module address to identify order of CM102’s In the I/O extension loop. Has no relation to AK-PC 782B dial addresses.

AK-PC 782B analog input verification

Open ST500, press , then select “sensor calibration”

If there are issues with readings, first verify MOD/PT assignments.

AK-PC 782B point numbering layout.
The AK-PC 782B, as well as all modules connected to the pack controller, follow point numbering from top-left to bottom-right as shown below.

AK-PC 782B analog input configuration

Open ST500, press , then select “I/O configuration”

If MOD/PT assignments are accurate, verify sensor wiring Transducers should be AKS2050-59 or AKS2050-159 only

Danfoss temperature sensors are not polarity sensitive one wire to input (–), the other wire to input (+)

AK-PC 782B digital input verification

Open ST500, press , then select “I/O status and manual”. Press the “+” icon to move to “Digital Inputs” page.

If issues are present, verify MOD/PT assignments and “Active at” selection.

AK-PC 782B digital output verification

Open ST500, press , then select “I/O status and manual”

AK-PC 782B output input verification

Open ST500, press , then select “I/O status and manual”. Press the “+” icon to move to “analog outputs” page

If issues are present, verify MOD/PT assignments and “Type” selection.

AK-PC 782B stepper valve wiring

Valves with integrated actuators example: CCM-40

| TERMINAL ON XM 208C
---|---
VALVE #| 1| 25| 26| 27| 28
2| 29| 30| 31| 32
3| 33| 34| 35| 36
4| 37| 38| 39| 40
ETS|

WHITE

|

BLACK

|

RED

|

GREEN

CCM/CCMT
CTR
KVS 15
KVS 42-54

Valves with external ICAD actuators example: ICMTS-20

ICAD 600A/1200A quick start

Note!
Cross tighten all 3 screws to ensure equal tightening. Max 3 Nm torque.

Please observe cable voltage drop Distance between the applied DC transformer and the ICAD terminal box may cause a voltage drop. Cross section of cables and  size of DC transformer must be calculated so that the voltage at all time at the ICAD terminal box*, both during standstill and during operation of ICAD, is within this range:

• Uninterruptable Power Supply

Prefabricated ICAD cable length Code number| 1.Sm 027H0426| 3m 027H0438| 10m 027H0427| 1S m 027H043S
---|---|---|---|---
Voltage !CAD terminal
(600N l 200A) (V DC]| Min.| 21| 22| 23| 24
Max.| 26.4

• Do not measure inside the ICAD itself

Programming the ICAD

Note:
If the keypad is not operated within 20 seconds; time out will automatically exit programming mode.

• Decrease value
• Edit / Enter
• Increase value

Valve size setup (mandatory)

When powering up the ICAD, A1 will flash in the display

• Hold down for 2 seconds to enter programming mode

• Press and go to parameter 10. Press

• Press until you reach 11 (password). Press

• Press until you reach parameter 26 Press

• Press or to select ICM size or CVE. Press

  1. ICM 20 with ICAD 600A
  2. ICM 25 with ICAD 600A
  3. ICM 32 with ICAD 600A
  4. ICM 40 with ICAD 1200A
  5. ICM 50 with ICAD 1200A
  6. ICM 65 with ICAD 1200A
  7. ICM 100 with ICAD 1200A
  8. ICM 125 with ICAD 1200A
  9. ICM 150 with ICAD 1200A
  10. CVE pilot with ICAD 1200A

• ICM/CVE & ICAD is now calibrating

• Hold down for 2 seconds to exit programming mode

Valve label ID:

NOTE !
If media temperature is lower than -30 °C (-22 °F) it is mandatory to set parameter i30 an i31.
See separate document attached in ICAD box: document number AN285243155312

Changing analogue input signal (optional)

• Hold down for 2 seconds to enter programming mode

• Press until you reach parameter 03. Press

• Press  or to select analogue input signal

  1. 1: 0 – 20 mA
  2. 2: 4 – 20 mA*
  3. 3: 0 – 10 V
  4. 4: 2 – 10 V

• default factory setting

  • Press

  • Hold down for 2 seconds to exit programming mode

  • If A3 alarm occurs the analogue input signal is out of range

Factory reset of ICAD

Disconnect power 1
Press down and 2
simultaneously while reconnecting power 1
Release and   2

Note:
If factory reset has been performed the ICAD will start flashing A1 in the display.

AK-PC 782B high pressure valve settings

Open ST500, press , then select “Setpoint management”. Press the “+” icon to move to “HP control” page.

Pc max. limit MT = maximum allowable gas cooler psi. If pressure reaches pc max. limit MT minus Pgc
max. limit P-band, fans ramp to 100% and entire compressor capacity cuts off.
Example: 1450 psi – 50 psi = 1400 psi. If GC psi reaches 1400 psi, fans go to 100% and compressors are staged down until GC psi gets below pgc max. setting of 1350 psi. Pc max. Limit IT = same functionality as Pc max. limit MT
Pgc max. = maximum allowable gas cooler psi. Fan speed is used to maintain this setting. If fans alone do not reduce psi, the above setting is reached and compressors cut off
Pgc max. limit P-band = this value is subtracted from Pc max. limit setting to allow compressors to deactivate prior to reaching Pc max. limit setting Pgc min. = Minimum allowable gas cooler psi. (Low ambient setting)
Min. Tm = condenser fan speed setting for differential between Sc3 air probe and Sgc gas cooler outlet probe. (This is the temperature delta setting for floating).
Dimensioning TM = similar to min. Tm setting. When all compressors are active the pack uses this setting in lieu of min. TM.

AK-PC 782B high ejector control settings

Open ST500, press , then select “Setpoint management”. Press the “+” icon to move to “HP control” page.

Control mode = auto means the pack controller is staging the ejectors. Man is mainly used for testing purposes and allows the user to define a percentage from 0 – 100 (remember to change this setting back to auto! The man settings remain forever).
Pgc neutral zone = this setting straddles Pgc max. Setting to determine when to activate and deactivate ejector stages. This prevents excessive cycling of ejector solenoids.
Example: Pgc max. = 1350 psi, Pgc neutral zone = 43 psi, ejectors staging will increase at 1371 psi and decrease at 1329 psi
Ejector 1 cycle = total number of time that ejector 1 has been activated since the last time the pack controller was power cycled.
Cycle rate: an ejector valve should not disconnect more than once/minute over. An average of 24 hours. The setting Pgc neutral zone described above can be used to slow down ejector cycling. Increasing Pgc neutral zone reduces number of cycles
Wiring note: ejectors solenoids wire to solid state relay outputs. General operation: ejectors operate in a similar fashion as condenser fans. As the gas cooler psi increases, additional ejectors will activate. When the gas cooler psi decreases, ejectors will de-activate. The pack controller will stage ejectors in random order when needed to keep the cycle counts relatively close to each other.

AK-PC 782B receiver bypass valve settings

Open ST500, press , then select “Setpoint management”. Press the “+” icon to move to “receiver control” page

P rec ref. Mode = leave this as fixed SP
Enable Delta P min = leave this as No
P rec max. = maximum allowable receiver pressure. Also P rec max P band Hi setting
P rec max P band = this value is subtracted from P rec max. Setting to arrive at P rec max P band Lo setting. once value is reached valve to drive to 100% open
P rec max P band Lo = safety value if reached will cause valve to open 100%
P rec setpoint = this setting defines the target receiver pressure
P rec min P band Hi = this value equals P rec min. Setting plus P rec min P band. Once this value is reached the valve will drive to the 100% closed position
P rec min P band = this value is added to P rec min. To close the receiver valve Prior to reaching P rec min. setting
P rec min. = going below this value will generate a low receiver pressure alarm

AK-PC 782B low temp suction group settings

Open ST500, press , then select “Setpoint management”. Press the “+” icon to move to “LT control” page

Neutral zone band = this setting straddles to setpoint setting to determine when to activate and de active compressor stages. Inverter is used to stay within neutral zone.
Example: to setpoint = -13.0 °F, neutral zone band = 5.0 °F, compressor staging will increase at 15.5 °F and decrease at 10.5 °F
Night offset = a digital input can be used to increase to setpoint during non- trading hours to reduce system energy usage
To setpoint = this setting defines the target suction temperature
To max. alarm = going above this setting will generate a high temperature alarm
Max. reference = maximum value of the pressure transducer
Min. reference = minimum value of the pressure transducer
Pump down = if this value is reached the compressors will be cut off
To min. Limit = if this setting is reached all compressor activity is lock off. This differs from pump down setting in that to min. Limit also disables the receiver valve

AK-PC 782B medium temp suction group settings

Open ST500, press , then select “Setpoint management”. Press the “+” icon to move to “MT control” page.

Neutral zone band = this setting straddles to setpoint setting to determine when to activate and de active compressor stages. Inverter is used to stay within neutral zone.
Example: to setpoint = -13.0 °F, neutral zone band = 5.0 °F, compressor staging will increase at 15.5 °F and decrease at 10.5 °F
Night offset = a digital input can be used to increase to setpoint during non- trading hours to reduce system energy usage
To setpoint = this setting defines the target suction temperature
To max. Alarm = going above this setting will generate a high temperature alarm
Max reference = maximum value of the pressure transducer
Min reference = minimum value of the pressure transducer
Pump down = if this value is reached the compressors will be cut off.
To min. Limit = if this setting is reached all compressor activity is lock off. This differs from pump down setting in that to min. Limit also disables the receiver valve.

AK-PC 782B IT (parallel compression) suction group settings

Open ST500, press , then select “Setpoint management”. Press the “+” icon to move to “MT control” page.

Operation note: initial settings for when the it suction group is activated are located In the receiver control section of ST500. It is here that you define at what V rec % the IT suction group is activated.
IT smart start enable = the pack control can automatically calculate ideal IT start V rec OD if this option is set to Yes. Otherwise the user defines IT start V rec OD.
IT start V rec OD = this is the % that V rec has to be open before the receiver gas load is shifted to the IT compressor group.
IT start delay filter = once V rec reaches it start v record, the number of seconds defined must expire
before the IT suction group activates. Basically an ON delay for IT group.
IT end delay = OFF delay for IT group before switching control back to V rec
IT Comp. Sg c min. = the gas cooler outlet temp must be above this value for the IT suction group to activate. This ensures enough load to the group to keep it running.

AK-PC 782B oil reservoir setup

Open ST500, press , then select “Oil management”

There are three options for the oil Reservoir level switch:
None = a level switch is defined and the input has a physical jumper that remains in place. The emptying sequence repeats indefinitely as defined by the settings shown on the next page.

Only high = the level switch indicates the Reservoir is full and starts the emptying sequence. Once the level drops below the switch the sequence stops until the high level switch is activated again.

Low & High = the emptying sequence starts when the high level switch activates and continues until the low level switch is activated.

Open ST500, press , then select “Oil management”. Press the “+” icon to move to next page

Separator = select the number of oil reservoirs
Level switch = 1 /Full seq. is used for both none and only High. Low & high is selected on systems with both a high and low level switch on the oil reservoir.
Repeat oil return cycle = time between emptying sequences
No oil Sep. alarm delay = alarm delay if high-level never activates
No of periods = times oil pulse valve should open during emptying sequence
Period time = time between valve openings
Open time nominal = time valve is open during the period
Example: based on the settings above, when the emptying sequence starts it will pulse the oil reservoir dump valve for 15 seconds every four minutes.

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• Climate Solutions
• danfoss.com
• +45 7488 2222

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References

• Engineering Tomorrow | Danfoss

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