Danfoss ADAP-KOOL® AK2 Input – Output Modules
Contents
1. 55368 5C NO NC 6C NO NC 7C NO NC NO NC NC Wire to normally closed load Toit aa MAX OUTPUT RATINGS load open 1 4 HP 120 240VAC 5A RESISTIVE 24VDC OR 250VAC C Wireto Tor wie power FUSED SB 250 There are eight status LEDs one for each output point A status LED represents the state of the relay and not necessarily the state of the device wired to that point If the LED is ON the relay is energized With the LED ON then a device wired through normally closed NC contacts is OFF because the normally closed contacts are open Refrigeration compressors for example are wired through normally closed NC contacts so that if power to the control system fails and all the relays are de energized the control circuits for the compressors will be closed and the compressors will run Override switches have logic in line with that of the status LEDs When an override switch is put in the ON position the corresponding relay is continuously energized the LED will come ON and any device wired through the normally closed NC contacts is forced OFF If the same point were to have a device wired through it s normally open NO contacts instead the LED would be ON and the device forced ON When an override switch is2. m POWER m 1 m2 m3 COMM ERROR AK2 XM 102B No 08020029 Extension 8DIH U Ny P T 18 Compatible valves Disconnect power from the lineup Mounting CAUTION Connecting leads from EEPR valves Recording board and point information Connecting valve power Installing an AK2 XM 208B EEPR stepper motor output module The AK2 XM 208B EEPR stepper motor output module provides 4 bipolar outputs for control of stepper motor EEPR valves supplied by Danfoss and certain other manufacturers see table below This module is compatible with Danfoss AK2 SC 255 and AKC 55 system controllers The AK2 XM 208B EEPR stepper moter output module can be supplied in two 1 without terminal blocks 2 with Phoenix type terminal blocks Electrical data is found in the speci fications toward the end of this manual The AK2 XM 208B output module is compatible with the following stepper moter EEPR valves Danfoss Alco Sporlan KVS 15 22 ESR 12 12V CDS 8 12V KVS 28 35 ESR 12 24V CDS9 12V KVS 42 54 ESR 20 12V CDS 16 17 12V ESR 20 24V Before installing any new module disconnect power from the lineup s communication module Do not reconnect power until by following these instructions the installation including the final inspection has been completed Mount the AK2
3. m a a aaa S 000000 ik 5 DGN OL LOANNOD J 5 26 ata TT SW s u eae ss t m 1X3N OL 193NNOO 4 1 8 WANVW 3HL NI SNOLVOLIO3dS 318V9 MOTIOI MHOML3N M03 SINY NOLLO3NNOO 4 Addressing Network connection Power connection Inspection of the installed Make sure to follow all the steps in the instructions that follow 0902 Z Z 1 m POWER r Im oll 1 m ERROR P STATUS 1 MSTATUS2 mSTATUS3 mRESET H m SERVICE pm f I AK2 CM 104A L No 08020061 RCO TP 78 Using the rotary ID switches shown at lower right in the illustration set the communication module s unique address from 001 099 Any number can be used as long as it is not used on any other communication module in the system Using 20 24 AWG shielded stranded twisted pair cable connect the communications mod ule to one of the I O network terminal blocks on the host Rack Controller communica tions module can also be connected in a daisy chain to the network terminals of another node on the Rack Controller s I O network There is no need to observe any particular polarity with the A and B wi
4. 0 to 95 RH non condensing M Storage Temperature 15 Z 40 F to 158 F 40 to 70 C 0 to 95 RH non condensing eae AK2 XM 102A LH LI TR DIGITAL Extension 8DIL INPUT 29 Specifications AK2 XM 102A digital input module high voltage 3 Digital inputs 8 Input rating 95 260 VAC lt 144 x Power supply 18 36 VDC 0 7W sup plied by communication d PRESS i module Um 2 i Power required to communication module al h gt 0 8W 24 VDC 1 0 VA 24 VAC Operating temperature K 4 F to 131 F 20 to 55 C M 4 0 to 90 RH non condensing EIL m 4 F to 104 F 20 to 40 C HJ 0 to 95 RH non condensing nl e I HF O 24 Storage Temperature i 48 916 40 F to 158 F 40 to 70 C W 2 0 to 95 RH non condensing Vom Mee Ar UT DIGITAL Extension 8DIL INPUT 30 Specifications AK2 XM 208B bipolar stepper output module POWER AK2 XM 2088 Bipolar stepper outputs 4 Input rating 95 260 Vac Power supply 18 36 Vdc 0 7 W supplied by communication module Power required to communication module 0 8 W 24 1 0 VA 24 Vac Power supplied by module to
5. When a Danfoss IOPS is used it can be located up to 50 feet from the communications module it is powering Use 16 or 18 AWG wire when connecting power to the communications module Fuses Mounting modules DIN rail mounting Screw mounting Fuses are reached by removing the module cover Except for the fuses there are no user adjustments or user serviceable parts in the modules and when modules are in service the covers should always be in place All AK2 modules offer two mounting options DIN rail mounting and screw mounting All of the modules in a lineup must be mounted in the same way For DIN rail mounting first mount the rail with a minimum of 2 1 4 inches clearanceon each side Open the first module s red tabs by using a small screwdriver as shown in the drawings below until the tabs snap open Then position the module by slipping it over the rail hold it in place and press the red tabs The module will be securely mounted To mount the second and subsequent modules on a DIN rail open the red tabs as shown below Position the new module so that the connectors are engaged and gently push the module toward the rail until it is seated Then press the red tabs to release them and lock the module in place When mounting on a flat surface with screws mount the communications module first using the screw slots Then connect the first extension module and secure it is advisable to connect the modules first then position t
6. 8 Sensor excitation 5 12 VDC 100 mA Excitation fusing auto reset 200 mA Power supply 18 36 VDC 1 1W supplied by communication module Power required to communication module 1 3W 24 VDC 1 5 VA 24 VAC Operating temperature 4 F to 131 F 20 to 55 C 0 to 95 RH non condensing Storage Temperature 40 F to 158 F 40 to 70 C 0 to 95 RH non condensing Universal Inputs a Voltage Resolution 1 Accuracy 20 4 0 4 VDC Temp Coeff 0 4 mV C Accuracy 20 C 10 mV 4 10 VDC Temp Coeff 1 4 mV C b Resistive Resolution 0 1Q Accuracy 1 2Q 10 400Q 0 40 400 1500 1 20 1500 23000 2 00 2300 25000 0 02Q C 10 15000 0 04Q C 1500 23002 Temp Coeff c Dry contact Contact cleansing current 120 mA for 0 1 msec Steady state current 10 mA Closed when contact resistance lt 200 Q d Ratiometric sensor 28 Specifications AK2 XM 102A digital input module low voltage 2 77 UL file number E166834 27 Low voltage digital inputs 8 F a Input rating 9 80 Vac or Power supply 18 36 Vdc 0 7 W supplied by communication module Power required to communication module n 0 8 W 24 Vdc j 1 0 VA 24 Vac 8 Operating temperature im 4 F to 131 F 20 to 55 C comes 0 to 90 RH non condensing saan alll _ 4 F to 104 F 20 to 40 C
7. 80V AC or DC Mounting Mount the module by connecting it to a communications module or to an existing lineup Mounting instructions are supplied with the module and are also given in the section of this manual about the communications module CAUTION All safety precautions normally used when wiring control systems and high voltage equipment should be observed Disconnect power from the communications module before wiring any extension modules in its lineup Digital inputs The module s 8 digital inputs connect to the terminals at the top and bottom of the module enclosure Connecting digital inputs Connect digital inputs as shown on the facing page Recording input information For each set of terminals on the digital input module record the unique two digit address of the lineup s communication module the single digit location of the module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal number point number to which the input is wired Also record a description of the input wired to the terminal e g oil fail A1 A form is provided with each new module for this purpose You will need this information when configuring the host controller Inspection of the installed low voltage digital When a low voltage digital input module is ready for operation you should be able to observe input module the following 1 The module is securely mounted to DIN rail or to a flat
8. The module s 8 digital inputs connect to the terminals on the top and bottom of the mod ule enclosure Connecting Digital inputs Connect digital inputs as shown on the facing page Recording input information For each set of terminals on the digital input module record the unique two digit address of the lineup s communication module the single digit location of the module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal number point number to which the input is wired Also record a description of the input wired to the terminal e g compressor A1 A form is provided with each new module for this purpose You will need this information when configuring the host controller Inspection of the installed Low voltage digital When a high voltage digital input module is ready for operation you should be able to observe input module the following 1 The module is securely mounted to DIN rail or to a flat surface 2 Connection has been made to a communication module or to another module that is already connected to a communication module Power has been reconnected to the communication module The POWER LED is ON The COMM ERROR LED is OFF The status LEDs 1 through 8 correctly reflect the operating status of the equipment being monitored OQ Un 17 POSITIVE 80 260 VAC NEGATIVE 80 260 VAC
9. XM 208B module by connecting it to communications module or to an existing lineup Mounting instructions are supplied with the module and are also given in the earlier section of this manual about the communications module All safety precautions normally used when wiring control systems and high voltage equipment should be observed Disconnect power from the communications module before wiring any extension modules in its lineup Observe the cautions stated above There are connectors for four valves on each module Terminal blocks can be removed for making easy connection of wire leads from valves Each compatible EEPR valve has four leads red white black and either green or blue Re move the terminal block from an unused valve position on the module Connect the valve leads to the terminal block in accordance with the wiring diagram on page 21 If no KVS cable filter is installed make sure that no valve is more than 30 feet from the module With a KVS cable filter installed valves can be up to 100 feet 30 meters from the AK2 XM208B module Mount the filter module within one foot of the AK2 XM208B For each EEPR control module record the unique two digit address of the lineup s commu nication module the single digit location of the EEPR module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal number point number to which each EEPR valves leads are wired Also record a
10. each end of each module The connector holds the modules together and makes the electrical connections between them All power and network connections are made through the module connectors with only the communica tions module in each lineup having a power cable and a network cable to the system s I O network Each module has a black cover with an identification label There are fuses in the communi cations modules and in modules that have digital outputs The fuses are reached by remov ing the module cover Except for the fuses there are no user adjustments or user service able parts in the modules and when modules are in service the covers should always be in place The types of AK2 I O modules are the following Module name Description Inputs and outputs provided Power AK2 CM 101A communications module AK2 XM 204A digital output module 8 relay outputs 3 0 W 3 7 VA AK2 XM 205A universal analog input amp digital output module 8 relay out 8 universal inputs 3 9 W 4 8 VA AK2 XM 101A universal input module 8 universal analog inputs 1 3 W 1 5 VA AK2 XM 102A digital input module low voltage 8 digital inputs 9 80Vac or Vdc 1W 1 25 VA AK2 XM 102B digital input module high voltage 8 digital inputs 80 260Vac 0 8W 1 0 VA AK2 XM 107A pulse input module 8 pulse inputs 1W 1 25 VA AK2 XM 208B Bipolar stepper output module 4 bipolar stepper outputs 0 8 W 1 0 VA Stepper module requires a second separate 24 Vac power sou
11. hour the communications module performs a check with all the extension modules in its lineup During this check less than 1 4 second the ERROR LED on the communica tions module will light This is normal and does not indicate any malfunction Installing an AK2 XM 204 digital output module Fuses Mounting CAUTION Connecting loads Recording digital output information Inspection of the installed digital output module The AK2 XM 204 digital output module provides 8 fused digital outputs each output can be wired to normally open NO or normally closed NC relay contacts This module is available with or without override switches and can be supplied in three terminal block variations 1 without terminal blocks 2 with Phoenix type terminal blocks and 3 with Euromate type terminal blocks Electrical data is found in the specifications toward the end of this manual Fuses are reached by removing the module cover Except for the fuses there are no user adjustments or user serviceable parts in the modules and when modules are in service the covers should always be in place Mount the module by connecting it to a communications module or to an existing lineup Mounting instructions are supplied with the module and are also given in the section of this manual about the communications module All safety precautions normally used when wiring control systems and high voltage equipment should be observed Disconnect pow
12. operate valves 13 VA 12 or 24 Vdc brand dependent Operating temperature 4 F to 131 F 20 to 55 C 0 to 90 RH non condensing 4 F to 104 F 20 to 40 C 0 to 95 RH non condensing Storage Temperature 40 F to 158 F 40 to 70 C 0 to 95 RH non condensing 31 Code numbers for ordering 08020005 AK2 XM 205A EXT MODULE 8AI 8DO 08020006 AK2 XM 204A EXT MODULE 8DO 08020007 AK2 XM 101A EXT MODULE 08020008 AK2 XM 102A EXT MODULE 8DI LOW VOLTAGE 08020009 2 102B EXT MODULE HIGH VOLTAGE 08020010 AK2 XM 205A EXT MODULE 8AI 8DO 08070011 2 204A EXT MODULE 8DO 08020012 AK2 XM 102A EXT MODULE 80 08070013 2 1028 EXT MODULE 8DI HIGH VOLTAGE 08020015 2 205B EXT MODULE 8AI 8DO 08070016 AK2 XM 204B EXT MODULE 8DO 08020017 2 205B EXT MODULE 8AI 8DO 08020018 2 204B EXT MODULE 8DO 08020020 2 107A PULSE COUNTER MODULE 08020022 AK2 XM 2088 STEPPER VALVE MODULE 08020052 POWER SUPPLY FOR I O 56 VA IPOS 08020061 POWER SUPPLY FOR AK2 CM 101A COMM TP 78AK2 CM 101A COMM 32 Whats the difference between EuroMate amp Standard style connectors Euromate typically used in the Americas market has larger screw terminals suitibale to secure up to 12 AWG gauge wiring EuroMate Terminals 1 m POWER 22 3 ADAP KOOL 7 AK2 X
13. put in the OFF position the corresponding relay is continuously de energized the LED will be OFF and any device wired through the normally closed NC contacts is forced ON If the same point were to have a device wired through it s normally open NO contacts instead the LED would be OFF and the device forced OFF Mounting CAUTION Digital outputs Connecting loads Recording digital input information Universal analog inputs Compatible sensors Connecting analog inputs 4 20mA inputs Installing an AK2 XM 205A Combination Digital Output and Universal Analog Input Module The AK2 XM 205A combination digital output and analog input module provides 8 fused digital outputs and 8 universal analog inputs Each output load can be wired through normally open NO or normally closed NC relay contacts This module is available with or without override switches and with two types of terminals both of which can be seen in the illustration that follows Excitation voltages for inputs are furnished at 5V and 12V Mount the module by connecting it to a communications module or to an existing lineup Mounting instructions are supplied with the module and are also given in the section of this manual about the communications module All safety precautions normally used when wiring control systems and high voltage equipment should be observed Disconnect power from the communications module before wiring any extension modules in i
14. surface 2 The module is connected to a communication module or to an existing lineup 3 Power has been reconnected to the communication module 4 The POWER LED is ON 5 The COMM ERROR LED is OFF 6 The status LEDs 1 through 8 correctly reflect the operating status of the equipment be ing monitored 15 9 80 POSITIVE 9 80 VDC 9 80 VAC NEGATIVE DC GND gt L7 H m m POWER r m COMM ERROR D m2 i m3 Jt ms m7 C m8 DIGITAL INPUT ADAP KOOL AK2 XM 102A No 08020028 Extension 8DIL 16 Installing an AK2 XM 102A High Voltage Digital Input Module The AK2 XM 102A half width high voltage digital input module provides 8 digital inputs rated at 80 to 260V AC Mounting Mount the module by connecting it to a communications module or to an existing lineup Mounting instructions are supplied with the module and are also given in the section of this manual about the communications module CAUTION All safety precautions normally used when wiring control systems and high voltage equipment should be observed Disconnect power from the communications module before wiring any extension modules in its lineup Digital inputs
15. that module Connect analog inputs as shown on the facing page Resistive sensors with two wires are connected like the temperature sensor shown at left and sensors requiring an excitation voltage are connected like the pressure transducer shown at right When connecting a sensor with a 4 20 mA output place a 250 Ohm 1 4 Watt precision resistor across the input terminals to be used um TEMP BROWN AND WHITE LEADS NO POLARITY TEMPERATURE SENSOR NO POLARITY PRESSURE TRANSDUCER AKS 11 AKS 32 CONNECT LEADS TO BLACK GND SIG AND GND WHITE SIG RED 12V SHIELD SHLD 5 OUTDOOR RH SENSOR EMHS 4 TERMINAL GND 9 TERMINAL SIG TERMINAL 12V 5 INDOOR RH WITH TEMP SENSOR E EMHS 3 Qoooo00000000000 0000000 RH Lx lt El H TERMINAL SIG 1 V TERMINAL 12V POWER OVERRIDE E TEMP T1 AND T2 NO POLARITY fni CONNECT TO SIG AND GND rr mCOMM ERROR OvR1 T E ret mi mi OVR2 mi m2 m2 OVR3 T P one NS OUTDOOR PHOTO WITH TEMP SENSOR PHOTO OD 1 m4 OVR5 S ni OR DC m6 m6 ADAP KOO OVR7 al 12VAC OR EXTERNALLY SUPPLIED goo 2 2058 PHOTO OUT SIG SIG 5 PHOTO OUT GND GND me we No 08020030 o auro on lm RELAY OVERRIDE E
16. this purpose You will need this information when configuring the host controller TEMPERATURE SENSOR NO POLARITY PRESSURE TRANSDUCER AKS 11 AKS 32 BLACK GND WHITE SIG RED 12V SHIELD SHLD CONNECT LEADS TO SIG AND GND OUTDOOR RH SENSOR EMHS 4 TERMINAL GND 9 TERMINAL SIG TERMINAL 12V INDOOR RH WITH TEMP SENSOR EMHS 3 RH G TERMINAL GND H TERMINAL SIG V TERMINAL 12V TEMP T1 AND T2 NO POLARITY m POWER CONNECT TO SIG AND GND COMM ERROR OUTDOOR PHOTO WITH TEMP SENSOR PHOTO OD 1 PHOTO 12Vdc PROVIDED FROM 12V TERMINAL PHOTO OUT SIG SIG PHOTO OUT GND GND AK2 XM 101A No 08020027 Extension TEMP BROWN AND WHITE LEADS NO POLARITY CONNECT LEADS TO SIG AND GND Inspection of the installed universal analog input When a universal analog input module is ready for operation you should be able to ob serve module the following 1 The module is securely mounted to DIN rail or to a flat surface 2 The module is connected to a communication module or to an existing lineup 3 Power has been reconnected to the communication module 4 The POWER LED is ON 5 The COMM ERROR LED is OFF 14 Installing an AK2 XM 102A Low Voltage Digital Input Module Illustration of the module is on the next page The AK2 XM 102A half width low voltage digital input module provides 8 digital inputs rated at 9 to
17. 2 VDC 100 mA i Excitation fusing auto reset 200 mA Power supply 18 36 VDC 3 6W supplied by 22022202220022002200020202 communications module r Power required to communications module ig a 3 9W 24 VDC _ om ne H 4 8 VA 24 VAC Operating temperature 4 F to 131 F 20 to 55 C 0 to 95 RH non condensing Storage Temperature 40 F to 158 F 40 to 70 C 0 to 95 RH non condensing RELAY OVERRIDE 4 Universal Inputs a Voltage Resolution 1 Accuracy 9 20 4 mV 0 4 VDC Temp Coeff 0 4 mV C Accuracy 20 C 10 mV 4 10 VDC Temp Coeff 1 4 mV C b Resistive Resolution 20 10 21 20 10 4000 0 40 400 1500 1 2Q 1500 23002 2 00 9 2300 25002 Temp Coeff 0 02Q C 10 15000 0 04Q C 1500 23000 c Dry contact Contact cleansing current 120 mA for 0 1 msec Steady state current 10 mA Closed when contact resistance lt 200Q d Ratiometric sensor 27 Specifications AK2 XM 101A analog input module 1 cj m power COMM ERROR Hm Lj 3 1 a f ADAP KOOL H 2 101 FIM 4 Extension 8 sf TL 2000000 UE TETUR 185399 UL file number E166834 Universal inputs
18. M 102A u mB 08020028 1 4 DIGITAL Extension J Standard Terminals 222222222202 POWER un yen f ADAP KOOL L H AK2 XM 101A No 08020027 a T i Extension BAL s 7 AL 33 ADAP KOOL Refrigeration Control Systems is a trademark of Danfoss A S www danfoss com Danfoss Inc Refrigeration amp Air Conditioning Division 7941 Corporate Drive Baltimore MD 21236 Tel 410 931 8250 Fax 410 931 8256 www danfoss com North_America Danfoss shall not be responsible for any errors in catalogs brochures or other printed material Danfoss reserves the right to alter its products at any time without notice provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved Copyright 2006 Danfoss Inc DKRCE PI R1 A2 22 520 1912
19. MAKING MODERN LIVING POSSIBLE ADAP KOOL AK2 Input Output Modules For AK2 SC255 and AKC 55 Systems SC255 DANFOSS ELECTRONIC CONTROLS amp SENSORS USER MANUAL Table of Contents Installing AKZ Modules eene cii eret erectae ete tetra er aaa chad ere a pp 3 20 MIMO WCU OM CAL LOIN EE ETOILE 3 Power supply Mounting modules DIN rail mounting Screw MOUNTING 4 Installinig acommunications 4 5 Cabling requirements 78 55 systems I U U u u p 4 Other transceiver types x i nico icti m n piene to ure a Er b en S Te et e p 4 Addresssing Network connections Power connection Installer s final inspection Error and status p 7 Installing an AK2 XM 204 digital output module pp 8 9 Connecting loddi u aus C p 8 Installers Anal tiere e usadas p 8 Installing an AK2 XM 205A Combination Digital Output and Universal Analog Mod le 5 rte iter testosterone L R i pp 10 12 Digital OU tS nu
20. P1 KIT requires CTP KIT requires CTP KIT 30 to 97 F 30 to 97 F Connect analog inputs as shown on the facing page Resistive sensors with two wires are connected like the temperature sensor shown at left and sensors requiring an excitation voltage are connected like the pressure transducer shown at right When connecting a sensor with a 4 20mA output place a 250 ohm 1 4 watt precision resis tor across the input terminals to be used When sensor cables have a required shield connect the shield to one of the two terminals labeled SHLD at the end of each half of the terminal strip Connect one side of a dry contact digital input pair to one of the terminals labeled A A1 A2 etc and connect the other to one of the A A1 A2 etc terminals for excita tion Remember to record that the input is a DI rather than an Al This information will be 13 important when configuring the input at the host controller Recording sensor For each set of terminals on the universal analog input module record the unique two digit information address of the lineup s communication module the single digit location of the I O module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal number point number to which the sensor is wired Also record a description of the sensor e g suction pressure compressor A1 A form is provided with each new module for
21. Type Fixture Name User Def Enter user defined name Circuit Monitor box door Num case box sensors Temperature control 7 E Target 35 0 F Type of defrost Notice that once EEPR is selected the following Target line no longer shows a value often called a range or dead band since no dead band is required for a a modulating valve like a stepper EEPR Enter the target temperature Page down to the next page and specify defrost if any If there is an entry other than None you will have to select a condition Open Closed for the valve during defrost Return to the configuration menu select Board amp Points and choose the icon for variable outputs It is the fourth from left of the icons at the bottom of the screen The screen that appears looks like the one at left below Enter the board amp point information module ad dress In the sample screen the address is 01 1 1 Yours will very likely be different Now select Setup and press ENTER and the screen at right below will appear 1 12 06 13 01 54 enar NEN Board amp Points A Variable Outputs Stepper Setup Bd Pt Range Max Steps 4100 Step rate 300 sec Max Steps Step hysteresis 0 Overdrive at init 10 Manual failsafe 0 4 Max phase current Max holding current 0 SORT On The settings in the Stepper Setup screen are determined by the type of valve that is be ing configured and are given in the fol
22. aditional IO boards require three character ad dresses as detailed in chapter 4 of your User Manual or Reference Manual and AK2 points require the four character addresses described here If any other number of characters is entered the entry will be rejected and zeros will appear 25 Specifications AK2 CM 101A communications module 15 NEM 52 ol GH UL file number E166834 Input voltage 18 36 VDC 24 VAC 20 H Input power 50 W 60 VA S e Input fusing 3 15 A SB 250 VAC Power Output voltage 18 36 VDC ES Output power capacity up to 45 W M IO module capacity up to 10 FSH oll 5 Power consumption 0 8 W 24 VDC IQ TE 1 0 VA 24 VDC J ra Sm E An Operating temperature ri 4 F to 131 F 0 to 95 RH non condensing N Extension 8AI J 1 Storage Temperature 40 F to 158 F 0 to 95 RH non condensing Compatible with 24V battery backup systems 26 Specifications AK2 XM 204A digital output module AK2 XM 205A combination digital output amp analog input module UL file number E166834 General purpose relays 8 form C Universal inputs 8 Relay rating 1 4 hp 120 240 VAC 5 Aresistive E 24 Vdc or 240VAC Device limit outputs 20A Relay fusing 5A 250 VAC Sensor excitation 5 or 1
23. connected to the communication module 4 The POWER LED is ON 5 The COMM ERROR LED is OFF 6 The status LEDs are ON for each point whose output relay is energized and OFF for each point whose output relay is de energized 7 The override LEDs reflect the status of the override switches The LED should be OFF for each switch in the center AUTO position The LED should be ON for each switch in the left OFF or right ON position PRESS CU E QoO0o00Q00000Q00900004Q024Q0 00 00 0 0 Kit A2 AR AG MUN HV shd ABE AG ABE ATH AT MUN shd h RELAY m POWER OVERRIDE COMM ERROR m OVR2 2 m2 OVRS m3 ova m4 m4 OVRS 5 m5 ov m m6 1 7 2 2058 8 No 08020030 OFF AUTO ON lt RELAY OVERRIDE Extension Status LEDs relay states and override switches 225252102 NO NC 2 NO NC NO NC 4C NO NC
24. ded on the reverse side of the form for the digital outputs for this purpose You will need this information when configuring the host controller Inspection of the installed combination module When a combination module is ready for operation you should be able to observe the fol lowing 1 The module is securely mounted to DIN rail or to a flat surface 2 The module is connected to a communication module or to an existing lineup 3 Power has been reconnected to the communication module 4 The POWER LED is ON 5 The COMM ERROR LED is OFF 6 The status LEDs reflect the status of the output relays The LED should be lit for each point whose relay is energized 7 The override LEDs reflect the status of the override switches The LED should be OFF for each switch in the center AUTO position The LED should be ON for each switch in the left OFF or right ON position 12 Installing an AK2 XM 101A Universal Analog Input Module Mounting CAUTION Universal Analog inputs Compatible sensors Sensor name AKS 11 AKS 12 AKS 21 THERM 3 DPS100 AKS 32 100 AKS 32 200 AKS 32 500 CT 12 CT 13 14 15 53 PHOTO OD 1 ComTrol CTTS ECI TP 1 TP 2 CPC 501 1121 Connecting analog inputs 4 20mA inputs Shielded cable Dry contact inputs The AK2 XM 101A half width analog input module provides 8 analog inputs for sensors and dry contact digital inputs Excitation voltages for inputs are furnished a
25. description of the valve wired to the terminal e g circuit B 4 or meat cases system 22 You will need this information when configuring the host controller for the new valve s Power to operate controlled EEPR stepper motors is provided through the AK2 XM 208B Connect 24V AC from a separate external Danfoss IOPS power supply to the power termi nals on the AK2 XM 208B module An external IOPS 56 VA can supply up to 16 valves us ing 4 AK2 XM 208B modules Set the output of the power supply according to valve chart 19 Reconnect power to the communications module When all connections are made and after replacing the module terminal blocks if necessary reconnect power to the communications module The AK2 XM 208B is now ready to configure Inspection of the installed digital output module When physical installation of AK2 XM 208B stepper EEPR control module is complete you should be able to observe the following 1 The module is securely mounted to DIN rail or to a flat surface The module is connected to a communication module or to an existing lineup Power has been reconnected to the communication module The POWER LED is ON The COMM LED is off It may blink initially until communication with the host controller is established If steady on seek support from Danfoss The status LEDs should remain are ON for each point whose output relay is energized and OFF for each point whose output relay is de
26. energized 12 or 24v Valve Dependent See Chart QUTPUT VOLTAGE SELECT SET JUMPERS W3 amp W4 FOR 12 OR 24 VOLTS SEE DETAIL BELOW OL 1110 JO OL O z 08020022 d 6334355 87383940 q 7 Y 0 y SUPPLY VOLTAGE SELECT SET JUMPERS Wi amp We ooo FOR 115 OR 230 VOLTS WP SEE DETAIL BELOW Class 1 Wiring Bipolar stepper output module AK2 XM 2088 Part No 08020022 Power Supply uv QOO 56VA Part No 08020052 5566 FA NN Unit shipped for 230 VAC supply Wiring Reference Chart Cable Part 08482238 Be ee 29 30 31 32 37 38 39 Filter KVS 15 34 white KVS 42 54 White Black C SpodancDpS White Black Red Green Alco ESR White Black Red Blue 20 Configuring a Danfoss controller for an AK2 XM 208A EEPR stepper motor output module After installation of the hardware host controller software must be configured for the type of valve to be controlled and for operational settings Use the procedure that follows From the controller s Main Menu select Configuration From the Configuration Menu select Refrigeration From the Refrigeration Menu select the rack with the EEPR val
27. er from the communications module before wiring any extension modules in its lineup Observe the cautions stated above Terminal blocks can be removed from the module for making connections Connections to the module are in groups of three as shown in the illustration Each group has a C common screw numbered from 1 to 8 an NO normally open screw and an NC normally closed screw Wire each load to the module using a numbered group of 3 termi nal screws Connect each load to common and to either NO or NC contacts For each digital output module record the unique two digit address of the lineup s com munication module the single digit location of the module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal num ber point number to which the controlled load is wired Also record a description of the point wired to the terminal e g compressor A1 A form is provided with each new I O module for this purpose You will need this information when configuring the host controller When all connections are made and after replacing the terminal block if necessary recon nect power to the communications module When a digital output module is ready for operation you should be able to observe the following 1 The module is securely mounted to DIN rail or to a flat surface 2 The module is connected to a communication module or to an existing lineup 3 Power has been re
28. he entire lineup of modules and mark the screw holes After drilling the holes mount with panhead screws or bolts Installing a communications module Cabling requirements Other transceiver types A communications module has one of three types of transceiver TP78 EIA 485 or FTT The ADAP KOOL I O network uses the TP78 protocol and communications modules with TP78 transceivers code number 080Z0061 are required No other type of communica tions module will function in an ADAP KOOL network Use 20 to 24 AWG stranded twisted shielded Belden 9841 9464 9461 8762 8761 or equivalent Place a terminator across the network terminals on the last communications module on any cable run from an ADAP KOOL Rack Controller Use the drawing on the facing page for reference while wiring your control system When Danfoss I O is used with non Danfoss systems the communications module is avail able with two other transceiver types Those types and their cabling requirements are FTT transceiver Code number 080Z0062 Use 16 AWG stranded twisted Belden 85102 or equivalent Do not use shielded cable with this transceiver EIA 485 transceiver Code number 08070063 Use 20 to 24 AWG stranded twisted shielded Belden 9841 9464 9461 8762 8761 or equivalent FINGON TINON p pom NO 15 1 3HL SI INGON SNOLLVOINDWWOO SIHL 31 NMOHS SV MOLVNIWH3L V S rca p d B H rie
29. lowing table Manual failsafe is explained in the text following the table The sample has most of the data for a Danfoss KVS 42 or 54 taken taken from the table The table also contains information for other manufacturers valves 22 Valve Type Step rate Overdrive Max phase Max holding Power Supply at init Current current Voltage Danfoss KVS 15 amp 22 4100 300 sec Danfoss KVS 28 amp 35 5540 300 sec 100mA Danfoss KVS 42 amp 54 3810 150 sec 100mA Alco ESR 12 12v 5000r800 50 sec fo ESR 12 24v 501 800 50 Jo AlcoESR20 12v so sos o For Alco valves the Max steps value depends on the date code of the individual valve Valves manu factured before 2001 have max 500 steps Also consult Alco technical documentation for details Manufacturers may change valve specifications without notice Always check the settings in the following table against information provided with each new valve by its manufacturer or contact the manufacturer s application Engineering department for the information The fields in the EEPR Setup screen are as follows Max steps 0 to 10000 The number of steps that corresponds with 10096 opening of the valve Step rate 0 to 500 sec The rate at which the valve motor must be driven Step hysteresis 0 to 127 When a gear driven valve is at any given position driving a number of steps to a new position reversing direction and then driving back
30. mines the position as a percentage of full open that the valve will default to should communications fail between the Rack Controllerand the communications module for the 2 208B s lineup or between the communications module and the AK2 XM 208B 0 to 1000 mA Limits the current and thus the power dissipation in the valve Take care to set the value to the valve manufacturer s specification The module resolves the programmed value to the nearest 10 mA 0 to 7096 The percentage of Max phase current required by some stepper valves to hold the valve at its most recently achieved position The module resolves the programmed value to the nearest 1096 List box Closed Open the position the valve should maintain during defrost The AK2 XM 208A requires Board amp Points configuration as an analog output board in ac cordance with the information in the following section under What s different 24 Configuring other AK2 I O Modules in an AK2 SC 255 or AKC 55 System What s different Configuration of points on AK2 modules is almost exactly the same as for other points in systems based an ADAP KOOL Rack Controller Consult the Rack Controller s User Manual or Reference Manual There is one difference in configuration When entering the board and point information for an AK2 point there are five characters to enter That is why you recorded for each point a the communications module address 2 digits from 01 t
31. n terrent n nnum inerte datae eicit p 10 Universal analog inputs LO u tro stet Ee Oen REB au Se Hid na heap s eR nen p 10 4 20 W eUI DER E EET DO m p 10 Dry contact u a p 11 Installers final inspection ees Installing an AK2 XM 101A Universal Analog Input Module Universal analog inputs Compatible 50 13 SEPAN p 13 Dry contact k em p 13 Installers fimal 14 Installing 2 101A Low Voltage Digital Input Module 15 16 Explanatio Nep nre eis tired 15 Installer s final inspection and 5 15 16 Installing an AK2 XM 101A High Voltage Digital Input Module reete pp 17 18 Explanatio gua uscite 17 Installer s final inspection and ilUStratiON sssssesscssscssseecssecesseecsscccssccesnccessecessecss
32. o 99 the leftmost switch is not used and remains set to zero b thel O module position 1 digit from 1 to 9 C the point number 1 digits from 1 to 8 note that on combination modules there are two sets of points digital outputs and universal analog inputs each set numbered from 1 to 8 one set is entered in the digital output board amp point screen and the other in the sen sor input board amp point screen Board lt Points T Sensor Inputs Name Bcast Bd Pt Type Inside Temp No 01 1 1 PT1000 Disch Press C No 02 1 1 532 500 Dropleg Temp C No 02 1 2 PT1000 Inlet Temp C No 02 1 3 PT1000 Suction Temp CA No 02 1 4 PT1000 Suction Pres CA No 02 1 5 532 200 Oil Press CAL No 02 1 6 532 200 Outside Temp No 1000 SORT On PG DN for more MN To make an entry in the board amp point screen you will need the address information you recorded while installing the individual I O modules On the Board amp Points screen enter for each point the two digit communications module address first A hyphen automatically appears Then enter the single digit position num ber for the extension module then the two digit point number The point number can be entered as 01 or as 1 but the entry will always display as in the screen shown above Either three character configuration or four character board amp point numbers will be accepted by the Rack Controller because tr
33. rce Dan foss IOPS for valve drive power See installation section of this manual AK2 module names contain information about their use and size A module containing the letters CM is a communications module One containing the letters is an exten sion module The last grouping of 3 or 4 characters in the name specifies the exact type of module The first digit of the last group indicates the width of the module 1for a half width module and 2 for a full width module The remainder indicates the exact nature of the module The AK2 CM 101A communications module is available with 3 types of Echelon transceiver TP78 EIA 485 and FTT The TP78 protocol is required for AK2 SC255 and AKC 55 systems Each physically separate lineup of I O modules requires a communications module In locating the communications module remember that the total length of all cable runs from either type of ADAP KOOL Rack Controller including stubs is limited to 5000 feet A single communications module will support up to 9 modules Use only a galvanically isolated class 2 power supply It is recommended that one of the 24 Vac Danfoss IOPS supplies be used either the 30 VA or 56 VA version depending on the total VA demand of the extension modules in the lineup Part numbers for ordering IOPS power supplies are given on the last page of this manual In selecting a power supply be certain to check the total power requirements in VA using the table above
34. res when making network connections Connect the shield to the terminals marked shield at both ends of every TP78 communi cations cable If the communications module is the last unit on the cable run place a network termina tor across its A and B terminals Network terminators are supplied with every Danfoss Rack Controller across each set of NETWORK terminals If you are rebuilding an I O run you should find a terminator across the A B terminals of the last node on the network With main power to the communications module interrupted connect the 24V terminals and ground of the power supply to the three corresponding terminals of the communica tions module Make sure to use a supply with a VA rating adequate for the modules being connected Module power ratings are given on page 3 Wiring of the communications module is now complete Communication module When a communication module is ready for operation you should be able to observe the following proceding clockwise around the module from the power terminal strip 1 Power connections have been made 2 Address switches have been set to a valid unique address from 001 to 099 3 Connection has been made to an I O network terminal of the Rack Controller at the NETWORK terminals or to the network terminals of another node on the I O 4 If this module is the last node I O cable run make sure that it is terminated by using one of the terminators supplied with
35. secsssccssscessseesseecsssccssecesseecsnseesneeesneeesee Installing an AK2 XM208B EEPR Stepper Motor Output Configuring an AK2 XM208B EEPR Stepper Motor Output Module special requirements Configuring AK2 I O Modules an AKC 55 System important information for all modules What s different Board Point entries Specifications of AK2 Modules rin nete titii titii Rte tem ree te qhasusqaqa qahaq ani AK2 CM 101A communications module u u u u p 26 AK2 XM 204A digital output module 2 205A combination Al DO module p 27 AK2 XM 101A Analog Input p 28 AK2 XM 102A low voltage digital input module p 29 AK2 XM 102B high voltage digital input module U eese p 30 AK2 XM 208B bipolar stepper output 31 Code numbers ordering for AK2 modules p 32 Installing AK2 Modules Fuses Communications Power supply The AK2 series of I O modules form lineups with each lineup having a single user ad dressed communications module and up to nine self addressing I O modules of any assortment These lineups become groups of nodes in supermarket control and monitor ing systems based on Danfoss AK2 SC 255 and AKC 55 Rack Controllers The modules are physically linked by means of connectors at
36. t 5V and 12V Mount the module by connecting it to a communications module or to an existing lineup Mounting instructions are supplied with the module and are also given in the section of this manual about the communications module All safety precautions normally used when wiring control systems and high voltage equipment should be observed Disconnect power from the communications module before wiring any extension modules in its lineup The module s 8 analog inputs connect to the terminals on the top and bottom of the mod ule enclosure Each input can be either an analog or a dry contact digital input High and low voltage input modules are separately available for sensing the presence or absence of current flows e g compressor contactors The following types of sensors can be connected to the module Sensor type Temperature sensor Temperature sensor Temperature sensor Temperature sensor Dewpoint sensor Pressure transducer Pressure transducer Pressure transducer Current transducer Current transducer Humidity sensor with AKS 11 temperature sensor Indoor outdoor photo sensor Temperature sensor Temperature sensor Temperature sensor Temperature sensor Sensor range Remarks 58 to 212 F 94 to 320 F 70 to 356 F requires VR5 1 interface board 0 to 100 F 0 100 psig 0 200 psig 0 500 psig 0 25 0 50 or 0 75 A 0 100 0 150 or 0 200 A 10 95 RH 32 to 120 F 0 to 300 foot candles requires CTP KIT requires T
37. the rack controller The terminator should be placed across the A and B terminals at the network connection on the communication module 5 If functioning is normal the first five status LED states shown below under Error LED OFF will occur in order The module will go through these states any time power is interrupted and reapplied Software configuration of I O points is done from the rack controller or from a PC and is covered in the section titled Configuration Error and Status LEDs The Error and Status LEDs indicate the following conditions when there is power to a com munications module on the I O network and a lineup of I O modules is connected Error LED OFF Status LEDs ON Meaning 1 briefly Powering up 2 Local bus initialized waiting for host acknowledgement 3 Connection to host established Receiving configuration 1 2 3 briefly Communications module configured 1 blinking 2 3 Running all modules operational Error LED blinking 1 blinking 2 3 on Running one or more modules offline Error LED ON Status LEDs ON Description Possible cause 1 Automatic address No working modules found assignment failed Module limit exceeded 2 Unable to retrieve self Software error in one or more identification record modules from one or more modules 3 Upper memory buffer Maximum number of input boundary exceeded points 80 exceeded 1 2 3 Host communication Host rack controller is offline timeout Every
38. the same number of steps the valve may not return to the position it started from This phenomenon occurs because of backlash in the gear train To compensate hysteresis is programmed and works like this When a valve is driven open to a target position the controller will over drive the valve by the hysteresis amount then drive back in the closing direction by the same hysteresis amount The effect is that regardless of the net change in valve position either more open or more closed the last real direction for valve travel will also be in the closed direction The hysteresis adjustment ensures that the valve train is always pre loaded in the same direction ensuring repeatability of valve position Overdrive at init 0 to 3196 Stepper motor valves do not usually include a feedback mechanism to determine the actual mechanical position of the valve Valve manufacturers however design their valves to be overdriven at complete closure without damage The Overdrive at init value gives the additional amount as a percentage of Max steps that the valve should be driven closed whenever we initialize the valve Valve initialization occurs auto matically whenever the Rack Controller is reset whenever the AK2 XM 208B stepper motor EEPR control module is reset and whenever the associated refrigeration circuit defrosts 23 Manual failsafe Max phase current Max holding current Valve in defrost Configuration 0 to 100 Deter
39. ts lineup Loads are connected as described in the previous section for digital output modules Connections to the module are in groups of three as shown in the illustration Each group has a C common screw numbered from 1 to 8 an NO normally open screw and an NC normally closed screw Wire each load to be controlled to the module using a numbered group of 3 terminal screws Connect each load to common and to either NO or NC con tacts For each digital output on the combination module record the unique two digit address of the lineup s communication cation module the single digit location of the I O module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal number point number to which the controlled load is wired Also record a description of the point wired to the terminal e g compressor A1 A form is provided with each new I O module for this purpose You will need this information when configur ing the host controller The module s 8 analog inputs connect to the terminals opposite the relay output terminals Each input can be either an analog or a dry contact digital input High and low voltage input modules are separately available for sensing the presence or absence of current flows e g compressor contactors Sensor types that can be used with this module are the same as for the AK2 XM 101A ana log input module and will be found in the next section which covers
40. ve you want to configure From the Configure Rack Menu select the suction group The Evaporator configuration screen will appear note There may be many evaporators For the purposes of this explanation we have cre ated a suction group with a single circuit The Evaporator configuration screen appears at left below EEPR configuration is an option under circuit type 2 5 255 so leave that field as is and select gt Setup lt The screen at right will appear except that the cursor will be on the Fixture Type field 1 12 06 12 55 2 1 12 06 12 57 5 Configure Rack A Evaporators Configure Rack Circuit AA E Number of Circuits 1 Fixture Type Dewpoint method Fixture Name Humidity sensor to use Inside RH 1 Enter user defined name Auto defrost schedules Disabled Monitor box door Num case box sensors Temperature control Circuit AK2 SC255 Target 1 7 C Type of defrost Configure the fixture and sensor information as for any other circuit using the procedures given in chapter 1 of the AK2 SC 255 Rack Controller System Reference Manual Then move the cursor to the Temperature control field and press ENTER or left click A list box will open as shown at left below Move the cursor in the list box to EEPR and press ENTER or left click The screen will appear as at right below 21 Board amp Points Configuration 1 12 06 13 00 2 Configure Rack A Circuit 1 8 Fixture
41. xtension CONNECT LEADS TO SIG AND GND lt Di 000000000000 NC Wire to normally closed load 5C NO NC NO NC 7C NO NC NO NO Wire to normally open load C Wire to power for controlled load MAX OUTPUT RATINGS 1 4 HP 120 240VAC 5A RESISTIVE 24VDC OR 250VAC FUSED 5A SB 250VAC Shielded cable When sensor cables require a shield connect the shield to one of the two terminals labeled SHLD at the end of each half of the terminal strip Dry contact inputs Connect one side of a dry contact digital input pair to one of the terminals labeled A A1 A2 etc and connect the other to one of the A A1 A2 etc terminals for excita tion Remember to record that the input is a DI rather than an Al This information will be important when configuring the input at the host controller 11 Recording sensor For each analog on the combination module record the unique two digit address of the information lineup s communication module the single digit location of the module 1 for the module next to the communication module 2 for the next one and so on up to 9 and the terminal number point number to which the sensor is wired Also record a description of the sensor wired to the terminal e g suction pressure compressor A1 A form is provi
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