AKO-16523 Temperature Controller for Cold Rooms User Manual

AKO-16523 Temperature Controller for Cold Rooms User Manual

AKO Electromecánica thanks and congratulates you for purchasing our product, in whose development and manufacture the most innovative technology has been used, as well as strict production and quality control processes.

Our commitment to satisfy our customers and our continuous efforts to improve every day can be seen in the various quality certifications we have obtained.

This is a high performance, high technology product. The operation and final performance of the equipment depend on proper planning, installation, configuration and commissioning. Read this manual carefully before installation, and always follow its instructions.

Only qualified personnel should install or perform technical assistance on this product.
This product is designed to be used in the applications described in the product manual. AKO Electromecánica gives no guarantee of its operation in any use not foreseen in the manual, and is not responsible for any damage resulting from improper use, configuration, installation or commissioning.

It is the responsibility of the installer and the customer to comply with and ensure others comply with all regulations applicable to installations incorporating our products. AKO Electromecánica is not responsible for any damage caused by non-compliance with regulations.

Follow strictly the instructions given in this manual.

To maximise the service life of our equipment, these recommendations should be followed:
Do not expose electronic equipment to dust, dirt, water, rain, humidity, high temperatures, chemicals or corrosive substances of any sort.
Do not submit the equipment to blows or vibrations nor try to manipulate it differently from shown in the manual.
Never exceed the specifications and limitations indicated in the manual.
Always respect the specified ambient working and storage conditions.
During and after installation, avoid leaving loose, broken, unprotected or damaged wiring, since they might constitute a risk for the equipment and its users.
AKO Electromecánica reserves the right to make any non-metrology modification to the documentation or the equipment without previous notice

Versions and references

Warnings

• If the equipment is used without adhering to the manufacturer’s instructions, the device safety requirements could be compromised. Only probes supplied by AKO must be used for the unit to operate correctly. 2 -From -40 ºC to +20 °C, if the NTC probe is extended to 1000 m with at least a 0.5 mm cable, the maximum deviation will be 0.25 ºC (cable for probe extension ref. AKO-15586. Earth the cable mesh at one end only).
• Only NTC type probes supplied by AKO must be used for the appliance to operate correctly.
• It must be installed in a place protected from vibrations, water and corrosive gases, where the ambient temperature does not exceed the value indicated in the technical data.
• For the reading to be correct, the probe must be used in a place without thermal influences apart from the temperature you want to measure or control.
• IP65 protection degree is only valid with the protection cover closed.
• The IP65 protection degree is only valid if the cables enter the device through a tube for electric conduits + gland with IP65 or above. The size of the glands must be suitable for the diameter of the tube used.
• Do not spray the unit directly with high-pressure hoses, as this could damage it.

Maintenance

Clean the surface of the unit with a soft cloth, water and soap.
Do not use abrasive detergents, petrol, alcohol or solvents, as this might damage the unit.

Description

Keypad

STAND-BY
To stop the controlled stop process and force the step to Stand-by, press the Stand-by key again for 3 seconds.

Installation

Wiring

  Always disconnect the power supply to do the wiring.
The probes and their cables must NEVER be installed in a conduit together with power, control or power supply cables.
For disconnection, the power supply circuit must be equipped with at least a 2 A, 230 V switch, located near the device. The power supply cable shall be of the H05VV-F or NYM 1×16/3 type. The cross-section to be used
2 will depend on the local regulations in force, but must never be less than 1.5 mm .
2 Cables for relay or contactor outputs must have a cross-section of 2.5 mm and allow working temperatures equal to or over 70 °C and must be installed with as little bending as possible.
The 120/230 V~ wiring area must be kept clear of any other external element.
The wiring to be undertaken depends on the option selected in the initial configuration wizard (see p. 8). Use the appropriate diagram based on the option selected.
Check the available options on the diagram sheet included with your device.
The AKO-16523D model has a contactor which allows for the connection of three- phase defrost resistors, a three phase compressor or three-phase fans, according to your installation’s requirements. Check how to connect it on the diagram sheet included with your device.

IMPORTANT:

• The AUXILIARY relays are programmable, and their operation depends on the configuration.
• The function of the digital inputs depends on the configuration.
• The recommended currents and powers are the maximum working currents and powers.

Initial configuration (wizard)

  If options 2, 5, 7, 9 or 12 are chosen, check the configuration of parameter I11 according to the pressure switch type used. (See diagram included with the device).

Operation

Messages

Pump down function

This function foresees problems in the compressor caused by movements of coolant, using a stop/start technique for the installation, controlled via the liquid solenoid, the low pressure switch and the compressor itself.
This function is only available for In{ options 2, 5, 7, 9 and 12 and requires the connection of a low pressure switch in digital input 1. (I10=7)

STOP
When the temperature in probe S1 reaches the set point (SP) value, the COOL relay deactivates, closing the liquid solenoid.
Because the compressor continues to operate, pressure in the evaporator quickly drops. Upon reaching a given value, the low pressure switch activates, changing the status of digital input 1, which stops the compressor (relay AUX 1).

This manoeuvre isolates all of the coolant in the high-pressure line, far from the compressor crankcase, preventing serious faults upon start-up.

Should the low pressure switch fail, the controller stops the compressor once the safety interval defined in C20 has elapsed, displaying the message “Pd” (an informative message that does not affect the unit’s operation).

If C20 time is 0 (default value), the compressor will not stop until the low pressure switch is activated, but it will display the “Pd” message after 15 minutes.

START
When the temperature in probe S1 reaches the set point value plus the differential (SP+C1), the COOL relay activates, opening the liquid solenoid. This increases the pressure in the evaporator, deactivating the low pressure switch, which turns the compressor on.

If, some time (determined by C19) after the liquid solenoid is opened (COOL relay set to ON), the low pressure switch does not deactivate, the controller will once again close the solenoid (COOL relay set to OFF) and the “LP” message will be displayed. This manoeuvre will be repeated every 2 minutes, indefinitely, until the pressure switch is deactivated and the installation reverts to its normal operation.

If C19 time is 0 (default value), the solenoid will remain open until the low pressure switch deactivates, but it will display the “LP” message after 5 minutes.

STAND-BY
If the pump down function is active, a certain amount of time may elapse between starting the standby function and the controller stopping; this is because certain installation control phases cannot be interrupted.

To force the stop of the controller, press the Stand-by key again for 3 seconds.

Continuous cycle mode

Set Point change mode

This allows for quick alternation between two working temperatures in the cold room store, modifying the Set Point in line with the value indicated in parameter C12. The aforementioned value may be negative or positive, which allows for the Set Point to be reduced or increased. If it is configured in 0, the mode is disabled.
It is activated in three possible ways:

• By means of an external switch connected to one of the digital inputs. The digital input should be configured as “Set Point change (I10 or I20=4). Activation through this method cancels any other activation and can only be deactivated using the same method.
• By means of the AKONet application. This requires the device to be connected to a Modbus network (see p. 28).
• By means of the CAMM module and the AKO CAMM tool application.

EXAMPLE:

Compressor protection timing

Management of door frame resistor (only devices with 5 relays)
If the Set Point is equal to or below -4°C and the relay AUX 2 has been configured as “door frame resistor” (o10=4), the resistor is activated (relay ON) when the temperature of the cold room drops below -3°C, and is deactivated (relay OFF) when 0°C is reached.

Defrost
Types of defrost
There are 5 possible defrost types, depending on the option selected in the wizard (Inl):

Electric (InI=1, 2 and 3) (d7=0)
Defrost is performed through electrical resistors, supplying the evaporator with heat. The operation of fans in this mode depends on parameter F3; the compressor and solenoid are stopped.

By air (InI=4, 5 and 6) (d7=1)
Usually used in positive cold rooms (> 3°C), since the inside temperature of the cold room is sufficient to melt evaporator ice. By default, the fans are activated so that air may circulate through the evaporator; to stop them, change parameter F3 to 0. The compressor and solenoid are stopped.

Static (InI=11, 12 and 13)
In this type of installation, there are no evaporator fans and defrost is performed by stopping cold production.

Hot gas (InI=7 and 8) (d7=2)
The hot gas from compressor discharge is used to melt evaporator ice and, to this end, two valves are necessary:
one at the condenser input (A) (SSV relay) and another between the compressor output and the evaporator input (B) (DEF relay).

During the process, the liquid solenoid valve (C) and the condenser input valve are closed and the evaporator input valve is opened, forcing hot gas to pass through the latter and melting the ice.

Optionally, a high pressure switch (D) can be added to control the solenoid valve (digital input D2, l20=9) during the defrost process using hot gas. If the pressure decreases, the solenoid opens to allow liquid into the tank; when the pressure rises again, the solenoid closes.

Reversed cycle (InI=9 y 10) (d7=3)
A 4-way valve is used to invert the installation cycle, using the evaporator as a condenser to melt the ice formed.
The process begins by stopping cold production (if it is active). If Pump Down is active, defrost begins once the manoeuvre is complete.
Next, the 4-way valve is activated (DEF relay ON), alongside the solenoid (COOL relay ON) and the compressor (AUX 1 ON), and the defrost process begins. D1 time begins to be counted after the COOL relay is activated.

When defrost is complete, the manoeuvre can be stopped in two possible ways:

• Pump down active (Inl=9): The solenoid closes (COOL relay OFF) and the 4-way valve returns to its initial position (DEF relay OFF) whilst the compressor continues to operate (AUX 1 relay ON), until the low pressure switch activates, stopping the compressor (AUX 1 relay OFF), starting the drip time.
• Without Pump Down (Inl=10): The solenoid closes (COOL relay OFF) and the 4-way valve returns to its initial position (DEF relay OFF) and the compressor stops (AUX 1 relay OFF), starting the drip time.

Defrost control

Alarm delays
These delays prevent certain alarms from being shown, to allow the installation to recover its normal operation after certain events.

• Delays in start-up (A3): This delays the activation of the temperature alarms upon receiving power (at start-up or after a power supply failure) or when exiting Stand-by mode. This allows for the installation to start up avoiding alarms.
• Delay after a defrost (A4): This delays the activation of the temperature alarms when a defrost completes.
• Delay to minimum and maximum temperature alarm (A5): This delays the activation of the maximum (A1) and minimum (A2) temperature alarms, from when the temperature in probe 1 reaches the programmed value.
• Delay to activation of external alarm (A6): This delays the activation of the external alarm, from when the digital input becomes active.
• Delay to deactivation of external alarm (A7): This delays the deactivation of the external alarm, from when the digital input becomes active.
• Delay to open door alarm (A12): This delays the activation of the alarm upon detecting that the door is open.

Configuration of alarm relay
Should any relay have been configured as an alarm relay, parameter A9 allows for the relay status to be defined when an alarm is triggered:
A9=0 Relay active (ON) in the event of an alarm (OFF without alarm)
A9=1 Relay inactive (OFF) in the event of an alarm (ON without alarm)

Operation of the auxiliary relays
Depending on the controller model, it may have 1 or 2 auxiliary relays. The function of these relays is configurable through the parameters menu.

AUX 1 relay

• Deactivated (o00=0): It does not carry out any function.
• Compressors / crankcase resistor (o00=1): Controls compressor operation. When the compressor is not in operation, it powers the crankcase resistor. This function can only be selected via the initial wizard (In{).
• Light (o00=2): This regulates the operation of cold room light (see p. 20).
• Virtual control (o00=3): The relay can be remotely activated and deactivated by means of AKONet software.
• Alarm (o00=4): This activates the relay every time that an alarm occurs (Only in devices with 4 relays) (see p. 19).

AUX 2 relay (only devices with 5 relays)

• Deactivated (o10=0): It does not carry out any function.
• Alarm (o10=1): This activates the relay every time that an alarm occurs (see p. 19).
• Light (o10=2): This regulates the operation of cold room light (see p. 20).
• Virtual control (o10=3): The relay can be remotely activated and deactivated by means of AKONet software.
• Door frame resistor (o10=4): This controls the operation of the cold room’s door frame resistor (see p.13).
• Defrost 2º evaporator (o10=5): This controls the defrost resistors of a second evaporator (see p. 16).
• Same as solenoid status (o10=6): Imitates solenoid status: active if the solenoid is in ON mode, inactive if the solenoid is in OFF mode.
• Same as unit status (o10=7): Indicates the unit’s status: active if the unit is in ON mode, inactive if the unit is in Stand-by mode.

Configuration

Condensed programming menu
This allows for the most-used parameters to be quickly configured. Press the SET key for 3 seconds to access it.

Condensed programming menu

Parameters

Extended programming menu
Use the extended programming menu to configure all of the unit’s parameters in order to adapt it to your installation requirements. Press the SET key for 6 seconds to access it.

Extended programming menu

Parameters

According to wizard.
†It can only be modified using the configuration wizard (InI).

• According to wizard.

Connectivity

The controllers are equipped with a port for connection of RS485 (MODBUS) data, which allows for remote management of these using a AKO-5010, AKO-5025, AKO-5041 or AKO-5051 gateway.

The MODBUS address is factory-set and is indicated on the rating plate located on the left side of the controller. This address must be different for each unit within the same network. The address can be changed using parameter b20. Once modified, the old address indicated on the plate will not be valid.

Technical specifications

• The AKO-15586H extension cable has an impedance of maximum cable distance 0.0172 Ohms* mm /m.

Accessories

AKO-58500 CAMM Module

Together with the application for mobile devices, this module provides the unit with multiple functionalities:

• Data logging
• Logging of configuration changes
• Remote configuration
• Clock functions in real time
• Activity summaries
• Logging of events and alerts
• Remote control of functions

AKO ELECTROMECÁNICA , S.A.L.
Avda. Roquetes, 30-38
08812 • Sant Pere de Ribes.
Barcelona • Spain.

www.ako.com

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