Danfoss OPTYMA Control AK-RC 101 Instruction Manual

OPTYMATM Control
Single-phase
AK-RC 101
MAKING MODERN LIVING POSSIBLE
Operation and Maintenance Guide

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General.....................................................................................................................................................................................................3
Description.........................................................................................................................................................................................3
Applications.......................................................................................................................................................................................3
Main characteristics ........................................................................................................................................................................3
Overall dimensions ............................................................................................................................................................................3
Identication data..............................................................................................................................................................................4
Installation.............................................................................................................................................................................................4
Important information for the installer ...................................................................................................................................4
Standard assembly kit....................................................................................................................................................................4
Installing the unit.............................................................................................................................................................................5
Functions ................................................................................................................................................................................................7
Technical characteristics of OPTYMATM Control, single-phase......................................................................................7
Control panel ........................................................................................................................................................................................8
Front keypad......................................................................................................................................................................................8
LED Display.........................................................................................................................................................................................9
General ................................................................................................................................................................................................9
Symbols used ....................................................................................................................................................................................9
Setting and displaying the set points.......................................................................................................................................9
Level 1 - Programming (User Level)........................................................................................................................................ 10
List of Level 1 variables (User Level)....................................................................................................................................... 10
Level 2 - Programming (Installer Level)................................................................................................................................. 11
List of Level 2 variables (Installer Level)................................................................................................................................ 11
Switching on the OPTYMATM Control single-phase .......................................................................................................... 12
Compressor activation/deactivation conditions............................................................................................................... 12
Manual defrosting ........................................................................................................................................................................ 12
Hot-gas defrosting ....................................................................................................................................................................... 13
Pump-down function.................................................................................................................................................................. 13
Password function........................................................................................................................................................................ 13
Alarm relay.......................................................................................................................................................................................... 14
Trouble shooting / Alarm list...................................................................................................................................................... 15
Connection diagrams..................................................................................................................................................................... 16
Parts list................................................................................................................................................................................................ 18
Ordering............................................................................................................................................................................................... 19
Table of contents Page

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 3
Description
The OPTYMATM Control single-phase is a new control
panel for cold rooms with a single-phase compressor
up to 2 HP, specially designed for safety, protection,
control and ease of installation.
It allows the user to control all the components on
a refrigeration system: compressor, evaporator fans,
defrosting elements, room light and thermostat-
holder.
Applications
- Complete management of single-phase static
or ventilated refrigeration systems up to 2 HP, with
o-cycle or electrical defrosting and with direct or
pump-down compressor stop.
- Control of single-phase evaporator unit only with
solenoid valve or remote condensing unit.
Main characteristics
- Direct control of defrosting elements, evaporator
fans, room light with outputs directly connectable
to the various units.
- Automatic fuse protect the refrigeration unit.
- Stylish ABS housing with transparent cover for
access to the automatic fuse, all with an IP65
protection rating so that panel can be used
outside the room.
- LED indicators and large display show system
status.
- User-friendly keypad.
- Display resolution to 0.1 °C.
- Modbus data communication that can be
connected to an ADAP-KOOL® system unit.
Overall dimensions
Dimensions in mm.
General

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The unit described in this manual has an ID label on
the side showing all the relevant identication data:
• Name of Manufacturer
• Type and code number
• Product name
• Power supply
• Serial number (10 digits)
• Date (Day/Month/Year)
Identication data
1. Install the device in places where the protection
rating is observed and try not to damage the
housing when drilling holes for wire penetrations
2. Do not use multi-polar cables which have
wires connected to inductive/power loads and
signalling wires (e.g. sensors and digital inputs).
3. Do not t power supply wiring and signal wiring
(sensors and digital inputs) in the same
raceways or ducts.
4. Minimise the length of connector wires so that
wiring does not twist into a spiral shape as this
could have a detrimental eect on the electronics.
Installation
5. Fit a general protection fuse before the electronic
controller.
6. All wiring must be of a diameter suitable for
relevant power levels.
7. If a sensor extension is required, the wires
must have a diameter of at least 1 mm2.
8. If data communication is used, it is important
that the data communication cable is correctly
installed. See separate literature, no. RC8AC...
9. If data communication is used, the alarm relay
cannot be used.
Important information for the installer.
Installation to be done by authorised person only!
For the purposes of assembly and use, the electronic
OPTYMATM Control single-phase unit comes with:
• Three rubber washers, to be tted between the
xing screws and the housing back panel
• One user’s manual.
• Two temperature sensors
Standard assembly kit

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 5
1.
Lift the transparent cover.
Remove the screw cover on the
right-hand side of the housing.
Installing the unit
2.
Undo the 4 xing screws at the
front of the housing.
3.
Open the front of the housing, lift
it and slide the two hinges out as
far as they will go.
4.
Press on the sides of the hinges
to remove them from their seats
and then remove the front panel
completely.

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5.
Use the three existing holes to
x the housing back panel to the
wall: use three screws of a suitable
length for the thickness of the
wall on which the panel will be
mounted. Fit a rubber washer
(supplied) between each screw
and the housing back panel.
6.
Hook the front panel back up to
the lower part of the housing by
inserting the two hinges in their
seats and, bending them, rotate
downwards 180° to gain access to
the electronic board.
NOTE !
Make all the electrical connections as illustrated in the diagram for the corresponding model (see
drawing on page 16).
To eect correct electrical connection and maintain the protection rating, use appropriate wire/
raceway grips to ensure a good seal.
Route the wiring inside the unit in as tidy a fashion as possible: be especially careful to keep power
wires away from signal wires. Use clips to hold wires in place.
7.
Close the front panel, making sure
that all the wires are inside the
housing and that the housing seal
sits in its seat properly.
Tighten the front panel using the 4
screws, making sure the O-rings on
the head of each screw are used.
Power up the panel and carry out
thorough reading/programming
of all the parameters.
NOTE !
Be careful not to over-tighten the closure screws as this could warp the housing and compromise
proper operation of the membrane-type keypad.
Install short-circuit overload safety devices on all the power cables connected to the OPTYMATM
Control so as to prevent damage to the device. Work and/or maintenance must be carried out on
the unit ONLY after disconnecting the panel from the power supply and from any inductive/power
loads: doing so allows the worker to do his job safely.
If Modbus data communication
is connected, see the JUMPER
setting on page 14, preferably
before all the wiring is connected.

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 7
- Display and adjustment of cold room temperature
setting to 0.1 °C
- Display of evaporator temperature from para-
meter
- System control activation/deactivation
- System warnings (probe/sensor errors, minimum
and maximum temperature warnings, compressor
shutdown)
Functions
- Evaporator fans control
- Automatic and manual defrost (static, heating
element, cycle inversion)
- Direct control of compressor unit up to 2 HP
- Room light, via panel key or door switch
- Alarms/auxiliary relay
- Defrosting, lights and alarms can be operated via
data communication.
OPTYMATM Control single-phase:
Technical characteristics of OPTYMATM Control single-phase
Power supply
Voltage 230 V~ ± 10% 50Hz / 60Hz
Power consumption (electronics only) ~ 7 VA
Cold room conditions
Operating temperature -5 to 50°C
Storage temperature -10 to 70°C
Relative humidity Less than 90% -
Not condensed. No shock inuence/vibration.
General characteristics
Type of sensors EKS 221, code no.: 084N3210
Resolution 0.1 °K
Sensor read precision ± 0.5 °K
Read range -45…+45 °C
Digital inputs
Requirements to contact Gold plating
OPTYMATM Control single-phase - Output characteristics - max. applicable load (230 V AC)
Compressor 1500W (AC3)
Defrost 3000W (AC1)
Fans 500W (AC3)
Room light 800W (AC1)
Alarm contact (non-powered contact) 100W
General electrical protection Automatic fuse 16A
Id=300 mA
Disconnecting power 4.5 kA
Dimensions
Dimensions 168 mm x 97 mm x 262 mm (HxPxL)
Insulation / mechanical characteristics
Housing protection rating IP65
Housing material Self-extinguishing ABS
Type of insulation Class II

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Control Panel
Front keypad
AUXILIARY RELAY CONTROL
(on the version with alarm relay controls the relay
manual if parameter AU=1)
UP / MUTE WARNING BUZZER
STAND BY
(The LED ashes if the system shuts down)
Room temperature SETTING / SET key
DOWN / MANUAL DEFROST
ROOM LIGHT

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 9
LED Display
1. Cold room temperature / parameters
2. Stand-by (ashes on stand-by). Outputs are de-
activated
3. Room light (ashes if door switch activated)
4. Cold (indicates activation of compressor)
5. Fans
6. Defrosting
7. Auxiliary
8. Alarm/warning
General
To enhance safety and simplify the operator’s work,
the OPTYMATM Control has two programming
levels; the rst level (Level 1) is used to congure
the frequently-modied SETPOINT parameters. The
second programming level (Level 2) is for general
parameter programming of the various controller
work modes.
It is not possible to access the Level 2 programming
directly from Level 1: you must exit the programming
mode rst.
Symbols used
For practical purposes the following symbols are used:
• (▲) the UP key is used to increase values and mute the alarm.
• (▼) the DOWN key is used to decrease values and force defrosting.
Setting and displaying the setpoints
1. Press the SET key to display the current SETPOINT
(temperature)
2. Hold down the SET key and press the (▲) or (▼)
keys to modify the SETPOINT.
Release the SET key to return to cold room
temperature display: the new setting will be saved
automatically.

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Level 1 - Programming (User Level)
To gain access to the Level 1 conguration menu
proceed as follows:
1. Press the (▲) and (▼) keys simultaneously and
keep them pressed for a few seconds until the
rst programming variable appears on the
display.
2. Release the (▲) and (▼) keys.
3. Select the variable to be modied using the (▲)
and (▼) key.
4. When the variable has been selected it is
possible to:
• display the setting by pressing the SET key
• modify the setting by pressing the SET key
together with the (▲) and (▼) key.
When conguration values have been set, you
can exit the menu by pressing the (▲) and (▼)
keys simultaneously for a few seconds until the
cold room temperature reappears.
5. The new settings are saved automatically when
you exit the conguration menu.
List of Level 1 variables (User Level)
Variables Explanation Value Default
r0 Dierential above main SETPOINT*
* SETPOINT see page 9
0.2 - 10 K 2K
d0 Defrost interval (hours) 0 - 24 hours 4 hours
d2 End-of-defrost setpoint.
Defrosting will not take place if the temperature detected by the defrost
sensor is greater than d2 (If the sensor is faulty defrosting is timed)
-35 - 45 °C 15°C
d3 Max defrost duration (minutes) 1 - 240 min 25 min
d7 Drip duration (minutes)
At the end of defrost, the compressor and fans remain at standstill for time
d7 and the defrost LED on the front panel ashes.
0 - 10 min 0 min
F5 Fan pause after defrost (minutes)
Allows fans to be kept at standstill for time F5 after dripping. This time
begins at the end of dripping. If no dripping has been set, the fan pause
starts directly at the end of defrost.
0 - 10 min 0 min
A1 Minimum temperature alarm
Allows user to dene a minimum temperature for the room being
refrigerated. Below value A1 an alarm trips: the alarm LED ashes, the
displayed temperature ashes and the buzzer sounds to indicate the
problem.
- -45°C
A2 Maximum temperature alarm
Allows user to dene a maximum temperature for the room being
refrigerated. Above value A2 an alarm trips: the alarm LED ashes, the
displayed temperature ashes and the buzzer sounds to indicate the
problem.
- +45°C
tEu Evaporator sensor temperature display Displays
evaporator
temperature
(displays
nothing if
dE =1)
read
only

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Level 2 - Programming (Installer Level)
To access the second programming level press the
UP (▲) and DOWN (▼) keys and the LIGHT key
simultaneously for a few seconds.
When the rst programming variable appears the
system automatically goes to stand-by.
1. Select the variable to be modied by pressing the
UP (▲) and DOWN (▼) keys.
When the parameter has been selected it is
possible to:
2. View the setting by pressing the SET key.
3. Modify the setting by holding the SET key down
and pressing the (▲) or (▼) key.
4. When conguration settings have been
completed you can exit the menu by pressing the
(▲) and (▼) keys simultaneously and keep them
pressed until the room temperature reappears.
5. Changes are saved automatically when you exit
the conguration menu.
6. Press the STAND-BY key to enable electronic
control.
List of Level 2 variables (Installer Level)
Variables Explanation Value Default
AC Door switch status 0 = normally open
1 = normally closed
0
F3 Fan status with compressor o 0 = fans run continuously
1 = fans only run when
compressor is working
1
F4 Fan pause during defrost 0 = fans run during defrost
1 = fans do not run during defrost
1
dE Sensor presence
If the evaporator sensor is disabled defrosts are
carried out cyclically with period d0: defrosting
ends when an external device trips and closes the
remote defrost contact or when time d3 expires.
0 = evaporator sensor present
1 = no evaporator sensor
0
d1 Defrost type, cycle inversion (hot gas) or with
heater elements
1 = hot gas
0 = electric
0
bdr Modbus baudrate
(Danfoss System unit =19200 baud)
0=300. 1=600. 2=1200. 3=2400.
4=4800. 5=9600. 6=14400.
7=19200. 8=38400 baud.
7
Ad Modbus address 1 ... 247
(+ setting: AU must be set to 7)
(+ move jumper: see page 14)
0
Ald Minimum and maximum temperature
Signalling and alarm display delay
1…240 min 120 min
C1 Minimum time between shutdown and
subsequent switching on of the compressor.
0…15 min 0 min
CAL Correction of sensor signal -10…+10 0
Pc Compressor protection contact status 0 = NO
1 = NC
0 = NO
doC Compressor safety time for door switch: when
the door is opened the evaporator fans shut down
and the compressor will continue working for time
doC, after which it will shut down.
0…5 minutes 0
tdo Restart time, if the door remains open 0... 240 min. (0=no function) 0
Fst FAN shutdown TEMPERATURE
The fans will stop if the temperature value read by
the evaporator sensor exceeds this value.
-45…+45°C +45°C

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Variables Explanation Value Default
Fd Fan dierential below Fst 0…+10K 2K
LSE Min. limit of set point setting -45...HSE -45°C
HSE Max. limit of set point setting 45... LSE 45°C
tA NO – NC alarm relay switching 0 = activates when alarm is on
1 = deactivates when alarm is on
1
AU Auxiliary/alarm relay control 0 = alarm relay
1 = manual auxiliary relay
controlled via AUX key
2 = automatic auxiliary relay
managed by StA temp. setting
with 2°C dierential
3 = not used
4 = pump-down function (see 5.15)
5 = free voltage contact for
condensing unit (AUX relay and
compressor relay in parallel)
6 = Relay used to control a heating
element in the crankcase.
The relay is on when the
compressor is stopped.
7 = The relay function is cancelled
and data communication is
permitted
0
StA Temp. setting for aux. relay -45…+45°C 0
In1 Man in cold room alarm
Select input INP1 on the board as compressor
protection alarm or as man-in-room alarm
(contact NC).
0 = compressor protection
1 = man-in-room alarm
0
P1 Password type of protection
( active when PA does not equal 0)
0 = display set point only
1 = display set point, AUX, light
access
2 = access to programming not
permitted
3 = access to second level
programming not permitted
3
PA Password
(see P1 for the type of protection)
0...999
0 = not active
0
reL Software release The version can be read -
Continued...
Switching on the OPTYMATM Control single-phase
After wiring the electronic controller correctly,
connect 230 V a.c.; the display panel will
immediately emit a beep and all the LEDs will come
on simultaneously for a few seconds.
Compressor activation/deactivation conditions
The OPTYMATM Control single-phase activates the
compressor when cold room temperature exceeds
setting+dierential (r0); it deactivates the
compressor when the cold room temperature is
lower than the setting.
Manual defrosting
To defrost just press the dedicated key (see page 8)
to activate the elements relay. Defrosting will not
take place if the end-of-defrost temperature setting
(d2) is lower than the temperature detected by the
evaporator sensor. Defrosting ends when the end-
of-defrost temperature (d2) or maximum defrost
time (d3) is reached.
When using data communication, the defrost cycle
can be started from the system unit.

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 13
Hot-gas defrosting
Set parameter d1 =1 to defrost in cycle inversion
mode.
The compressor relay and defrost relay are activated
throughout the defrost phase.
To ensure proper control of the system the installer
must use the defrost output: this must allow
opening of the cycle inversion solenoid valve and
closure of the liquid solenoid valve.
For capillary systems (without thermostat valve) the
cycle inversion solenoid valve can be controlled via
the defrost relay control.
Pump-down function
Pump-down function is activated when parameter
AU=4 (for version with AUX/Alarm relay only).
Connect pump-down pressostat on the digital input
INP-1.
The compressor is directly controlled by pressostat.
Connect evaporator solenoid valve on the AUX
relay. The solenoid is controlled directly by the
thermostat.
Password function
The protection function is activated when
parameter PA is set to a value other than 0.
See parameter P1 for the dierent protection types.
When PA is set, protection starts after two
minutes of inactivity. 000 appears on the display.
Use the up/down keys to change the number, and
the set key to conrm it. If you have forgotten your
password, use the universal number 100.

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1. Open the front of the housing as described
on page 5: rotate it downwards 180° to gain
access to the electronic board.
Alarm relay
2. Undo the 6 CPU board xing screws: remove the
board from the front part of the housing in ABS.
3. Remove the jumper from JUMPER JP2.
4. Insert the jumper in JUMPER JP2 in position:
3-2: to select data communication
(2-1: is the alarm relay position).
Factory setting = The relay functions as an alarm
relay.
When using data communication, a JUMPER must
be moved.
See the following:

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 15
In the event of any anomalies the OPTYMATM Control
warns the operator by displaying alarm codes and
sounding the warning buzzer inside the control
Trouble shooting / Alarm list
panel. If an alarm is tripped the display will show one
of the following messages.
Alarm code Possible cause Solution
E0 Cold room temperature sensor not working
properly
• Check that cold room temperature sensor is
working properly
• If the problem persists replace the sensor
E1 Defrost sensor not working properly
(In this case defrosts will last time d3)
• Check that defrost sensor is working
properly
• If the problems persists replace the sensor
E2 Eeprom alarm
An EEPROM memory alarm has been detected
(All outputs except the alarm one are
deactivated)
• Switch unit o and then back on again
E8 Man-in-room alarm • Reset the alarm input inside the cold room
Ec Compressor protection tripped (e.g. thermal
protection or max pressure switch)
(All outputs except the alarm one – where
applicable – are deactivated)
• Check that compressor is working properly
• Check compressor absorption
• If the problem persists contact the technical
assistance
Ed Open door - alarm (Open door and tdo-time
has expired)
Check door / door contact
Temperature
shown on
display is
ashing
Minimum or maximum temperature alarm.
The temperature inside the cold room has
exceeded the min. or max. temperature
alarm setting (see variables A1 and A2, user
programming level)
• Check that the compressor is working
properly.
• Sensor not reading temperature properly or
compressor start/stop control not working.

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Connection diagram
Comp. Protection
Door Limit Switch
Common dig. input
Defrost probe
Ambient probe
Common probe
Power
Supply
230Vac
Common
12345678910 11 12 13 14 15 16 17 18 19
Modbus A
B
A
B
Danfoss 80Z679.10

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 17
How to connect the OPTYMATM Control single-phase to OPTYMATM condensing unit
How to connect the OPTYMATM Control single-phase to OPTYMA PLUSTM and SlimPack condensing unit
Condenser
fan
Compressor
HP
OPTYMA
TM
Condensing unit
Comp. Protection
Door Limit Switch
Common dig. input
Defrost probe
Ambient probe
Common probe
Power
Supply
230Vac
12 3 45678910 11 12 13 14 15 16 17 18 19
Modbus
Danfoss
80Z681.10
A B
A B
12NL
P
Connect Compr. Relay output to room thermostat input terminals of
OptymaPlus / SlimPack (remove bridge before):
Term. 3-4 Optyma SlimPack
Term. 4-5 OptymaPlus Evo.2 H1 - H3
Term. 5-6 OptymaPlus Evo.2 H4
Term. 6-7 OptymaPlus Evo.2 230V-3Phase
Term. 24-25 OptymaPlus new Generation (DI1 of OptymaPlus Controller)
Comp. Protection
Door Limit Switch
Common dig. input
Defrost probe
Ambient probe
Common probe
Power
Supply
230Vac
12 3 45678910 11 12 13 14 15 16 17 18 19
Danfoss
80Z682.
11
Modbus A
B
A B

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Parts list
1Housing back panel in ABS
2Housing front panel in ABS
3Front cover in transparent polycabonate
4Front panel opening hinge
5Front panel closure screws
6Board xing screws
7Automatic fuse/ Cut out switch
8CPU board
9Polycarbonate screw cover
10 Terminal for earth connections

OPTYMATM Control single-phase AK-RC 101 RS8FD402 ©Danfoss A/S 2014/11 19
Ordering
Type Code no.
OPTYMATM Control single-phase (2 HP)
including two sensors 080Z3200
Sensor EKS 221 (spare part) 084N3210

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Notes