Design Guide Capacity controller for small CO2 refrigeration system AK-PC 772 ADAP-KOOL® Refrigeration control systems Contents 1. Introduction .............................................................................3 Setup control of receiver pressure ............................................66 Application ..................................................................................................3 Setup control of heat recovery..................................................67 Principles......................................................................................................4 Setup Display ....................................................................................68 2. Design of a controller ..............................................................7 Setup Functions for General purpose ......................................69 Module survey ...........................................................................................8 Separate thermostat...............................................................70 Common data for modules .................................................................10 Separate pressostat ................................................................70 Controller ...........................................................................................12 Separate voltage signal .........................................................71 Extension module AK-XM 101A .................................................14 Separate alarm inputs ............................................................71 Extension module AK-XM 102A / AK-XM 102B .....................16 Separate PI function ...............................................................72 Extension module AK-XM 103A .................................................18 Configuration of inputs and outputs .......................................73 Extension module AK-XM 204A / AK-XM 204B .....................20 Set alarm priorities..........................................................................75 Extension module AK-XM 205A / AK-XM 205B .....................22 Lock configuration ..........................................................................77 Extension module AK-XM 208C ................................................24 Check configuration .......................................................................78 Extension module AK-OB 110 ....................................................26 Check of connections ............................................................................80 Extension module AK-OB 101A..................................................27 Check of settings.....................................................................................82 Extension module EKA 163B / EKA 164B / EKA 166 ............28 Schedule function ..................................................................................84 Graphic display AK-MMI ...............................................................28 Installation in network ..........................................................................85 Power supply module AK-PS 075 / 150 / 250 ........................29 First start of control ................................................................................86 Communication module AK-CM 102 .......................................30 Start the control ...............................................................................87 Preface to design ....................................................................................32 Manual capacity control ...............................................................88 Functions ............................................................................................32 5. Regulating functions .............................................................89 Connections ......................................................................................33 Suction groups ........................................................................................90 Limitations .........................................................................................33 Controlling sensor...........................................................................90 Design of a compressor and condenser control .........................34 Reference ...........................................................................................90 Procedure: ..........................................................................................34 Capacity control of compressors ...............................................91 Sketch ..................................................................................................34 Capacity distribution methods ...........................................92 Compressor and condenser functions ....................................34 Power pack types – compressor combinations ............93 Connections ......................................................................................35 The capacity from the digital scroll compressor ..........97 Planning table ..................................................................................37 Extra refrigeration capacity (“extra compressor”) .......97 Length .................................................................................................38 Compressor timers ..................................................................97 Linking of modules .........................................................................38 Simpel oil equalisation ..........................................................97 Determine the connection points ............................................39 Load shedding ..........................................................................98 Connection diagram ......................................................................40 Injection ON ..............................................................................98 Supply voltage ................................................................................42 Liquid injection in suction line ...........................................99 Ordering .....................................................................................................43 Safety functions ...............................................................................99 3. Mounting and wiring .............................................................45 Condenser ...............................................................................................101 Mounting ...................................................................................................46 Capacity control of condenser .................................................101 Mounting of analog output module ........................................46 Reference for condensing pressure ........................................101 Mounting of extension module on the basic module .......47 Heat recovery .................................................................................102 Wiring ..........................................................................................................48 Capacity distribution ...................................................................104 4. Configuration and operation ................................................51 Step regulation .......................................................................104 Configuration ...........................................................................................52 Speed regulation ...................................................................104 Connect PC ........................................................................................52 Condenser couplings ...........................................................105 Authorization ....................................................................................54 Safety functions for condenser ........................................105 Unlock the configuration of the controllers ..........................55 EC motor ...........................................................................................105 System setup ....................................................................................56 Circuits for control of CO2 gas pressure ................................106 Set plant type ...................................................................................57 Receiver control .............................................................................107 Set control of MT compressors ...................................................58 Parallel compression ............................................................108 Set control of LT compressors .....................................................61 General monitoring functions .........................................................112 Set oil management .......................................................................62 Miscellaneous ........................................................................................114 Setup control of condenser fans ...............................................63 Appendix - Alarm texts .......................................................................118 Setup control of high pressure ...................................................65 2 Capacity controller RS8GU202 © Danfoss 2015-03 AK-PC 772 1. Introduction Application AK-PC 772 is complete regulating units for capacity control of compressors and gas cooler in a small CO2 refrigeration systems. Either as a compressor and condenser control on MT or as a booster system. The controller is with oil management, heat recovery function and CO2 gas pressure control. In addition to capacity control the controllers can give signals to other controllers about the operating condition, e.g. forced clos- ing of expansion valves, alarm signals and alarm messages. The controller’s main function is to control compressors and gas cooler so that operation all the time takes place at the energy- optimum pressure conditions. Both suction pressure and gas pressure are controlled by signals from pressure transmitters and temperature sensors. Among the different functions are: - Capacity control of up to 3 compressors on high pressure (2 if also regulating with parallel compressor). - Capacity control of up to 2 compressors on low pressure - Up to 3 unloaders for each compressor - Oil equalisation. - Speed control of one or two compressors - Up to 6 safety inputs for each compressor - Option for capacity limitation to minimize consumption peaks - When the compressor does not start, signals can be transmitted to other controllers so that the electronic expansion valves will be closed - Control of liquid injection into suction line - MT/LT - coordination between the high and low-pressure controllers - Safety monitoring of high pressure / low pressure / discharge temperature - Capacity control of up to 4 fans - Floating reference with regard to outside temperature - Heat recovery function - CO2 gas cooler control and receiver control - Parallel compression on transcritical CO2 system - Step coupling, speed regulation or a combination - Safety monitoring of fans - The status of the outputs and inputs is shown by means of light- emitting diodes on the front panel - Alarm signals can be generated via data communication - Alarms are shown with texts so that the cause of the alarm is easy to see. - Plus some completely separate functions that are totally inde- pendent of the regulation – such as alarm, thermostat, pressure and PI-regulating functions. SW=1.1x AK-PC 772 Capacity controller RS8GU202 © Danfoss 2015-03 3 Principles The great advantage of this series of controllers is that it can be Advantages extended as the size of the plant is increased. It has been devel- • The controller’s size can “grow” as systems grow oped for refrigeration control systems, but not for any specific • The software can be set for one or more regulations application – variation is created through the read-in software and • Several regulations with the same components the way you choose to define the connections. • Extension-friendly when systems requirements are changed It is the same modules that are used for each regulation and the • Flexible concept: composition can be changed, as required. With these modules - Controller series with common construction (building blocks) it is possible to create a multitude of various - One principle – many regulation uses kinds of regulations. But it is you who must help adjusting the - modules are selected for the actual connection requirements regulation to the actual needs – these instructions will assist you - The same modules are used from regulation to regulation. to find your way through all the questions so that the regulation can be defined and the connections made. Controller Extension modules Top part Bottom part The controller is the cornerstone of the regulation. The module has inputs and If the system grows and more functions have to be controlled, the regulation can be outputs capable of handling small systems. extended. • The bottom part – and hence the terminals – are the same for all controller types. With extra modules more signals can be received and more relays cut in and out – • The top part contains the intelligence with software. This unit will vary according how many of them – and which – is determined by the relevant application. to controller type. But it will always be supplied together with the bottom part. • In addition to the software the top part is provided with connections for data communication and address setting. Examples A regulation with few connections can If there are many connections one or more exten- be performed with the controller module sion modules have to be mounted alone 4 Capacity controller RS8GU202 © Danfoss 2015-03 AK-PC 772 Direct connection Setup and operation of an AK controller must be accomplished via the “AK-Service Tool” software program. The program is installed on a PC, and setup and operation of the various functions are carried out via the controller’s menu displays. Displays The menu displays are dynamic, so that different settings in one menu will result in different setting possibilities in other menus. A simple application with few connections will give a setup with few settings. A corresponding application with many connections will give a setup with many settings. From the overview display there is access to further displays for the compressor regulation and the condenser regulation. At the bottom of the display there is access to a number of general functions, such as “time table”, “manual operation”, “log function”, “alarms”, and “service” (configuration). Network linking The controller can be linked up into a network together with other controllers in an ADAP-KOOL® refrigeration control system. After the setup operation can be performed at a distance with, say, our software program type AKM. Users The controller comes supplied with several languages, one of which can be selected and employed by the user. If there are sev- eral users, they may each have their choice of language. All users must be assigned a user profile which either gives access to full operation or gradually limits the operation to the lowest level that only allows you “to see”. Language selection is part of the service tool settings. If the language selection is not available in the service tool for the current regulator, English texts will be displayed. External display An external display can be fitted in order for P0 (Suction) and Pc (Condensing) readings to be displayed. A total of 4 displays can be fitted and with one setting it is pos- sible to choose between the following readings: suction pressure, suction pressure in temperature, Ss, Sd, condenser pressure, con- denser pressure in temperature, gas cooler temperature, etc. A graphical display with control buttons can also be fitted. AK-PC 772 Capacity controller RS8GU202 © Danfoss 2015-03 5 Light-emitting diodes A number of light-emitting diodes makes it possible to follow the Slow flash = OK signals that are received and transmitted by the controller. ■ Power Quick flash = answer from gateway ■ Comm Constantly ON = error ■ DO1 ■ Status Constantly OFF = error ■ DO2 ■ Service Tool ■ DO3 ■ LON ■ DO4 ■ I/O Extension ■ DO5 ■ Alarm Flash = active alarm/not cancelled ■ DO6 Constant ON = Active alarm/cancelled ■ DO7 ■ DO8 ■ Service Pin Log From the log function you can define the measurements you wish to be shown. The collected values can be printed, or you may export them to a file. You can open the file in Excel. If you are in a service situation you can show measurements in a trend function. The measurements are then made real-time and displayed instantly. Alarm The display gives you an overview of all active alarms. If you wish to confirm that you have seen the alarm you can cross it off in the acknowledge field. If you want to know more about a current alarm you can click on it and obtain an information display on the screen. A corresponding display exists for all earlier alarms. Here you can upload information if you need further details about the alarm history. 6 Capacity controller RS8GU202 © Danfoss 2015-03 AK-PC 772 2. Design of a controller This section describes how the controller is designed. The controller in the system is based on a uniform connection platform where any deviations from regulation to regulation is determined by the used top part with a specific software and by which input and output signals the relevant application will require. If it is an application with few connections, the controller module (top part with belonging bottom part) may be sufficient. If it is an application with many connections it will be necessary to use the controller module plus one or more extension modules. This section will give you a survey of possible connections plus assistance in selecting the modules required by your actual ap- plication. AK-PC 772 Capacity controller RS8GU202 © Danfoss 2015-03 7 Module survey • Controller module – capable of handling minor plant require- • Optional connection ments. When a regulation is planned (set up) it will generate a need for a number of connections distributed on the mentioned types. • Extension modules. When the complexity becomes greater This connection must then be made on either the controller and additional inputs or outputs are required, modules can be module or an extension module. The only thing to be observed attached to the controller. A plug on the side of the module will is that the types must not be mixed (an analog input signal must transmit the supply voltage and data communication between for instance not be connected to a digital input). the modules. • Programming of connections • Top part The controller must know where you connect the individual The upper part of the controller module contains the intelli- input and output signals. This takes place in a later configura- gence. This is the unit where the regulation is defined and where tion where each individual connection is defined based on the data communication is connected to other controllers in a big- following principle: ger network. - to which module - at which point (”terminals”) • Connection types - what is connected (e.g. pressure transmitter/type/ There are various types of inputs and outputs. One type may, for pressure range). example, receive signals from sensors and switches, another may receive a voltage signal, and a third type may be outputs with relays etc. The individual types are shown in the table below. Extension module with addi- tional relay outputs and additional analog inputs. Extension module with ad- ditional analog inputs External display for suction pressure etc. Bottom part Controller with analog inputs and relay outputs. Top part The module with additional relay outputs is also available in a version where the top part is provided with change-over switches so that the relays can be overridden. Extension module with 2x analog output signals If the row of modules needs to be interrupted due to length or external positioning, a communi- cation module should be used. 8 Capacity controller RS8GU202 © Danfoss 2015-03 AK-PC 772 1. Controller Type Function Application Controller for capacity control of a small CO2 plant with booster. Compressor / Condenser / Both/ AK-PC 772 A maximum of 3 compressors for high pressure, 2 for low pressure, Heat recovery / CO2 gas pressure 4 fans and a maximum of 120 inputs/outputs 2. Extension modules and survey of inputs and outputs Type Analog On/Off outputs On/off supply voltage Analog Stepper Module with inputs (DI signal) outputs output switches For sensors, pres- Relay Solid state Low voltage High voltage 0-10 V d.c. For valves For override of sure transmitters (SPDT) (max. 80 V) (max. 260 V) with step relay outputs etc. control Controller 11 4 4 - - - - Extension modules AK-XM 101A 8 AK-XM 102A 8 AK-XM 102B 8 AK-XM 103A 4 4 AK-XM 204A 8 AK-XM 204B 8 x AK-XM 205A 8 8 AK-XM 205B 8 8 x AK-XM 208C 8 4 The following extension module can be placed on the PC board in the controller module. There is only room for one module. AK-OB 110 2 3. AK operation and accessories Type Function Application Operation AK-ST 500 Software for operation of AK controllers AK-operation - Cable between PC and AK controller AK - Com port Cable between zero modem cable and AK controller / - AK - RS 232 Cable between PDA cable and AK controller - Cable between PC and AK controller AK - USB Accessories Power supply module 230 V / 115 V to 24 V d.c. AK-PS 075 18 VA AK-PS 150 36 VA Supply for controller AK-PS 250 60 VA Accessories External display that can be connected to the controller module. For showing, say, the suction pressure EKA 163B Display EKA 164B Display with operation buttons EKA 166 Display with operation buttons and LED for function cut in AK-MMI Graphic display with operation Cable between display and controller Length = 2 m, 6 m - Cable between graphic display and controller Length = 1.5 m, 3.0 m Accessories Real time clock for use in controllers that require a clock function, but are not wired with data communication. AK-OB 101A Real time clock with battery backup. To be mounted in an AK controller Accessories Communication modules for controllers where modules cannot be connected continuously Data communication for external extension AK-CM 102 Communication module modules On the following pages there is data specific to each module. AK-PC 772 Capacity controller RS8GU202 © Danfoss 2015-03 9 Common data for modules Supply voltage 24 V d.c./a.c. +/- 20% Power consumption AK-__ (controller) 8 VA AK-XM 101, 102, 107, AK-CM 102 2 VA AK-XM 204, 205, 208 5 VA Analog inputs Pt 1000 ohm /0°C Resolution: 0.1°C Accuracy: +/- 0.5°C Pressure transmitter type AKS 32R / AKS Resolution:1 mV 2050 Accuracy +/- 10 mV AKS 32 (1-5 V) Max. connection of 5 pressure transmitters on one module Other pressure transmitter: Ratiometric signal Min. and Max. pressure must be set Voltage signal 0-10 V Contact function (On/Off) On at R < 20 ohm Off at R > 2K ohm (Gold -plated contacts not necessary) On/off supply voltage inputs Low voltage Off: U < 2 V 0 / 80 V a.c./d.c. On: U > 10 V High voltage Off: U < 24 V 0 / 260 V a.c. On: U > 80 V Relay outputs AC-1 (ohmic) 4 A SPDT AC-15 (inductive) 3 A U Min. 24 V Max. 230 V Low and high voltage must not be connected to the same output group Solid state outputs Can be used for loads that are cut in and Max. 240 V a.c. , Min. 48 V a.c. out frequently, e.g. : Max. 0,5 A, Oil valves, fans and AKV valves Leak < 1 mA Max. 1 AKV Stepper outputs Used for valves with stepper input 20-500 step/s Separate supply to stepper outputs : 24 a.c./d.c. / 13 VA Ambient temperature During transport -40 to 70°C During operation -20 to 55°C , 0 to 95% RH (non condensing) No shock influences / vibrations Enclosure Material PC / ABS Density IP10 , VBG 4 Mounting For mounting on panel wall or DIN rail Weight with screw terminals Modules in 100- / 200- / controller-series Ca. 200 g / 500 g / 600 g Approvals EU low voltage directive and EMC require- LVD tested according to EN 60730 ments are complied with EMC tested Immunity according to EN 61000-6-2 Emission according to EN 61000-6-3 UL file number: E166834 for XM and CM-modules UL 873, UL file number: E31024 for PC-modules The mentioned data applies to all modules. If data is specific, this is mentioned together with the module in question. 10 Capacity controller RS8GU202 © Danfoss 2015-03 AK-PC 772