Danfoss ADAP-KOOL AKD 102 User manual

Contents
1 Introduction
3
1.1.2 Copyright, Limitation of Liability and Revision Rights 4
1.1.6 Type Code String 6
2 Safety
7
2.1.2 High Voltage Warning 7
2.1.5 Before Commencing Repair Work 8
2.1.6 Special Conditions 9
2.1.7 Safe Stop of the Frequency Converter 9
2.1.8 IT Mains 11
3 Application Guide
12
3.1.1 ADAP-KOOL
®
Drive Application Guide 12
3.1.2 Application Descriptions 17
4 Mechanical Installation
19
4.1 Before starting 19
4.1.2 Mechanical Dimensions 20
4.2 How to Install 23
5 Electrical Installation
25
5.1 How to Connect 25
5.1.2 Electrical Installation and Control Cables 26
5.1.5 Mains Wiring Overview 30
5.1.11 Motor Wiring Overview 36
5.1.19 How to Test Motor and Direction of Rotation 41
6 How to Operate the Frequency Converter
45
6.1.2 How to Operate the Graphical LCP (GLCP) 45
6.1.6 Tips and Tricks 52
7 How to Programme the Frequency Converter
54
7.1 How to Programme 54
7.2 Parameter list 80
7.2.1 0-** Operation and Display 81
7.2.2 1-** Load / Motor 83
7.2.3 2-** Brakes 84
7.2.4 3-** Reference / Ramps 85
7.2.5 4-** Limits / Warnings 86
7.2.6 5-** Digital In / Out 87
7.2.7 6-** Analog In / Out 89
Contents ADAP-KOOL
®
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MG.11.L4.02 - ADAP-KOOL
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7.2.8 8-** Communication and Options 91
7.2.9 11-** ADAP-KOOL LON 92
7.2.10 13-** Smart Logic Controller 93
7.2.11 14-** Special Functions 94
7.2.12 15-** FC Information 95
7.2.13 16-** Data Readouts 97
7.2.14 18-** Info & Readouts 99
7.2.15 20-** FC Closed Loop 100
7.2.16 21-** Ext. Closed Loop 101
7.2.17 22-** Application Functions 103
7.2.18 23-** Time Based Funtions 105
7.2.19 25-** Pack Controller 106
7.2.20 26-** Analog I / O Option MCB 109 107
7.2.21 28-** Compressor Functions 108
8 Troubleshooting
109
8.1.1 Warning/Alarm list 112
9 Specifications
116
9.1 General Specifications 116
9.2 Special Conditions 124
Index
128
Contents ADAP-KOOL
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Drive Operating Instructions
2 MG.11.L4.02 - ADAP-KOOL
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Drive

1Introduction
1.1 Introduction
The AKD 102 ADAP-KOOL Drive from Danfoss Food Retail has been designed with our refrigeration customers clearly in
mind. The drive is designed to make commissioning and installation a simple and easy task. The built in “wizard” set up
menu guides the installer through the set up of the drive in a clear and structured manner, and has been constructed with
reference to the industries refrigeration engineers, to ensure that the text and language used makes complete sense to the
installer.
The AKD 102 drive comes with a common user interface which covers all power ratings between 1.1- 250 kW. Thus ensuring
that once you have learnt how to commission one drive you understand how to commission them all. Included on this local
control panel is an “info” button which is essentially a built in drive instruction manual which help the user to both gain
information and also suggests other parameters which may need to be changed. The AKD 102 also features a built in “pack
controller” controlled via the drives own standard software. This allows the drive to control the lead compressor via variable
speed and the bringing on line of another 2 compressors in fixed speed mode. This leads to extremely efficient pack design
which also adds the energy efficiency of variable speed control. Using the drive in this way eliminates the need for an
external pack controller thus giving financial savings to the customer.
The drive can be supplied in either of two protection classes IP21(IP20 up to 7,5kW) or IP55 (IP66 on request); this insures
that our customers benefit from having the most robust of designs supplied directly from the factory, without the need for
additional cabinets in which to house the drive. The AKD also benefits from the inclusion of having built in RFI filters as
standard which means that the problems associated with radio interference and long cable runs are no problem for our
customers.
The modular construction of the AKD means that you only have to pay for what you need. Each AKD is manufactured only
when we receive a customer order and so is built exactly to customer specification with any chosen options added at this
stage. But by using this manufacturing and design philosophy it means that should options such as ADAP-KOOL Lon be
required at some future date they are a simple retrofit inside of the drive which can be done by anyone with extreme ease.
Warranty: Each AKD comes with 18 months warranty from date of manufacture or 12 months from date of documented
installation, whichever comes first thus ensuring that our Food Retail customers have complete peace of mind when
choosing AKD as their drive of choice.
1.1.1 Software Version and Approvals: ADAP-KOOL
®
Drive
ADAP-KOOL
®
Drive
Operating Instructions
Software version: 2.xx
This Operating Instructions can be used for all ADAP-KOOL
®
Drive frequency converters with software version 2.xx.
The software version number can be seen from parameter 15-43.
Introduction ADAP-KOOL
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1.1.2 Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to Danfoss. By accepting and using this manual the user agrees that the
information contained herein will be used solely for operating equipment from Danfoss or equipment from other vendors
provided that such equipment is intended for communication with Danfoss equipment over a serial communication link.
This publication is protected under the Copyright laws of Denmark and most other countries.
Danfoss does not warrant that a software program produced according to the guidelines provided in this manual will
function properly in every physical, hardware or software environment.
Although Danfoss has tested and reviewed the documentation within this manual, Danfoss makes no warranty or represen-
tation, neither expressed nor implied, with respect to this documentation, including its quality, performance, or fitness for a
particular purpose.
In no event shall Danfoss be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or
the inability to use information contained in this manual, even if advised of the possibility of such damages. In particular,
Danfoss is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue,
loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third
parties.
Danfoss reserves the right to revise this publication at any time and to make changes to its contents without prior notice or
any obligation to notify former or present users of such revisions or changes.
1.1.3 Available Literature
-Operating Instructions MG.11.Lx.yy provide the neccessary information for getting the drive up and running.
-Design Guide MG.11.Mx.yy entails all technical information about the drive and customer design and applications.
-Programming Guide MG.11.Nx.yy provides information on how to programme and includes complete parameter
descriptions.
-Operating Instructions AKD102 High Power, MG.11.Ox.yy
-Operating InstructionsAKD LonWorks, MG.11.Px.yy
x = Revision number
yy = Language code
Danfoss Drives technical literature is also available online at www.danfoss.com/BusinessAreas/DrivesSolutions/Documentations/
Technical+Documentation.htm.
Introduction ADAP-KOOL
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1.1.4 Abbreviations and Standards
Abbreviations: Terms: SI-units: I-P units:
aAcceleration m/s2ft/s2
AWG American wire gauge
Auto Tune Automatic Motor Tuning
°CCelsius
ICurrent AAmp
ILIM Current limit
Joule Energy J = Nm ft-lb, Btu
°FFahrenheit
FC Frequency Converter
f Frequency Hz Hz
kHz Kilohertz kHz kHz
LCP Local Control Panel
mA Milliampere
ms Millisecond
min Minute
MCT Motion Control Tool
M-TYPE Motor Type Dependent
Nm Newton Metres in-lbs
IM,N Nominal motor current
fM,N Nominal motor frequency
PM,N Nominal motor power
UM,N Nominal motor voltage
par. Parameter
PELV Protective Extra Low Voltage
Watt Power WBtu/hr, hp
Pascal Pressure Pa = N/m psi, psf, ft of water
IINV Rated Inverter Output Current
RPM Revolutions Per Minute
SR Size Related
TTemperature CF
tTime ss,hr
TLIM Torque limit
UVoltage V V
Table 1.1 Abbreviation and standards table.
1.1.5 Frequency Converter Identification
Below is an example of an identification label. This label is situated on the frequency converter and shows the type and
options fitted to the unit. See table 2.1 for details of how to read theType code string (T/C).
Illustration 1.1 This example shows an identification label.
NOTE
Please have T/C (type code) number and serial number ready before contacting Danfoss.
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1.1.6 Type Code String

Description Pos Possible choice
Product group & VLT Series 1-6 AKD102
Power rating 8-10 1.1 - 250 kW (P1K1 - P250)
Number of phases 11 Three phases (T)
Mains voltage 11-12 T 2: 200-240 VAC
T 4: 380-480 VAC
Enclosure 13-15
E20: IP20
E21: IP 21/NEMA Type 1
E55: IP 55/NEMA Type 12
E66: IP66
P21: IP21/NEMA Type 1 w/backplate
P55: IP55/NEMA Type 12 w/backplate
RFI filter 16-17
H1: RFI filter class A1/B
H2: RFI filter class A2
H4: RFI filter class A2/A1
Display 19 G: Graphical Local Control Panel (GLCP)
X: No Local Control Panel
Coating PCB 20 C: Coated PCB
Mains option 21 X: No Mains disconnect switch
1: With Mains disconnect switch (IP55 only)
Adaptation 22 Reserved
Adaptation 23 Reserved
Software release 24-27 Actual software
Software language 28
A options 29-30 AX: No options
AZ: MCA 107AKD LonWorks
B options 31-32
BX: No option
BK: MCB 101 General purpose I/O option
BP: MCB 105 Relay option
BO:MCB 109 Analog I/O option
C0 options MCO 33-34 CX: No options
C1 options 35 X: No options
C option software 36-37 XX: Standard software
D options 38-39 DX: No option
D0: DC back-up MCB107
Table 1.2 Type code description.
The various options are described further in the ADAP-KOOL
®
Drive AKD102 Design Guide, MG.11.Mx.yy.
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2Safety
2.1.1 Symbols
Symbols used in this manual:
NOTE
Indicates something to be noted by the reader.
CAUTION
Indicates a general warning.
WARNING
Indicates a high-voltage warning.
✮Indicates default setting
2.1.2 High Voltage Warning
WARNING
The voltage of the frequency converter and the MCO 101 option card is dangerous whenever it is connected to mains.
Incorrect installation of the motor or frequency converter may causedeath, serious injury or damage to the equipment.
Consequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety
regulations.
2.1.3 Safety Note
WARNING
The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor,
frequency converter or fieldbus may cause death, serious personal injury or damage to the equipment. Consequently, the
instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
Safety Regulations
1. The frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains
supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.
2. The [STOP/RESET] key on the LCP of the frequency converter does not disconnect the equipment from mains and
is thus not to be used as a safety switch.
3. Correct protective earthing of the equipment must be established, the user must be protected against supply
voltage, and the motor must be protected against overload in accordance with applicable national and local
regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is set by 1-90 Motor Thermal Protection. If this function is desired, set 1-90 Motor
Thermal Protection to data value [ETR trip] (default value) or data value [ETR warning]. Note: The function is
initialized at 1.16 x rated motor current and rated motor frequency. For the North American market: The ETR
functions provide class 20 motor overload protection in accordance with NEC.
6. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains.
Check that the mains supply has been disconnected and that the necessary time has passed before removing
motor and mains plugs.
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7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing (linking
of DC intermediate circuit) and external 24 V DC have been installed. Check that all voltage inputs have been
disconnected and that the necessary time has passed before commencing repair work.
Installation at high altitudes
WARNING
Installation at high altitude:
380 - 500 V, enclosure A, B and C: At altitudes above 2 km, please contact Danfoss regarding PELV.
380 - 500 V, enclosure D, E and F: At altitudes above 3 km, please contact Danfoss regarding PELV.
WARNING
Warning against Unintended Start
1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop,
while the frequency converter is connected to mains. If personal safety considerations make it necessary to ensure
that no unintended start occurs, these stop functions are not sufficient.
2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always
be activated; following which data can be modified.
3. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a
temporary overload or a fault in the supply mains or the motor connection ceases.
WARNING
Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC
intermediate circuit), as well as the motor connection for kinetic back up. Refer to the Operating Instructions for further
safety guidelines.
2.1.4 Caution
Caution
The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the
frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency converter:
Voltage Minimum Waiting Time
4 min. 15 min.
200 - 240 V 1.1 - 3.7 kW 5.5 - 45 kW
380 - 480 V 1.1 - 7.5 kW 11 - 90 kW
Be aware that there may be high voltage on the DC link even when the LEDs are turned off.
2.1.5 Before Commencing Repair Work
1. Disconnect the frequency converter from mains
2. Disconnect DC bus terminals 88 and 89
3. Wait at least the time mentioned in section General Warning above
4. Remove motor cable
Safety ADAP-KOOL
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2.1.6 Special Conditions
Electrical ratings:
The rating indicated on the nameplate (Illustration 2.1) of the frequency converter is based on a typical 3-phase mains
power supply, within the specified voltage, current and temperature range, which is expected to be used in most
applications.
The frequency converters also support other special applications, which affect the electrical ratings of the frequency
converter.
Special conditions which affect the electrical ratings might be:
□Single phase applications
□High temperature applications which require de-rating of the electrical ratings
□Marine applications with more severe environmental conditions.
Other applications might also affect the electrical ratings.
Consult the relevant clauses in these instructions and in the AKD102 Design Guide, MG.11.Mx.yy for information about the
electrical ratings.
Installation requirements:
The overall electrical safety of the frequency converter requires special installation considerations regarding:
□Fuses and circuit breakers for over-current and short-circuit protection
□Selection of power cables (mains, motor, brake, loadsharing and relay)
□Grid configuration (IT,TN, grounded leg, etc.)
□Safety of low-voltage ports (PELV conditions).
Consult the relevant clauses in these instructions and in the AKD102 Design Guide for information about the installation
requirements.
2.1.7 Safe Stop of the Frequency Converter
For versions fitted with a Safe Stop terminal 37 input, the frequency converter can perform the safety function Safe Torque
Off (As defined by draft CD IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe
Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried
out in order to determine whether the Safe Stop functionality and safety category are appropriate and sufficient. In order to
install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1, the related
information and instructions of the AKD102 Design Guide MG.11.MX.YY must be followed! The information and instructions of
the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!
Safety ADAP-KOOL
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130BA491
Illustration 2.1 This certificate also covers AKD102
Safety ADAP-KOOL
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2.1.8 IT Mains
WARNING
IT mains
Do not connect frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more
than 440 V for 400 V converters and 760 V for 690 V converters.
For 400 V IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth.
For 690 V IT mains and delta earth (grounded leg), mains voltage may exceed 760 V between phase and earth.
14-50 RFI Filter can be used to disconnect the internal RFI capacitors from the RFI filter to ground.
2.1.9 Disposal Instruction
Equipment containing electrical components must not be disposed of together with domestic waste.
It must be separately collected with electrical and electronic waste according to local and currently
valid legislation.
Safety ADAP-KOOL
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3ApplicationGuide
3.1.1 ADAP-KOOL
®
Drive Application Guide
The built in “wizard” menu guides the installer through the set up of the drive in a clear and structured manner, and has
been constructed with reference to the industries refrigeration engineers, to ensure that the text and language used makes
complete sense to the installer.
The ADAP-KOOL Drive AKD 102 will initially start up with the Application guide (each time until it has been run), thereafter
in the event of power failure the application guide is accessed through the Quick menu screen.
If “Cancel” is pressed, the AKD 102 will return to the status screen. An automatic timer will cancel the wizard after 5 min. of
inactivity (no buttons pressed). The wizard must be re-entered through the Quick Menu when it has been run once.
Answering the questions on the screens will take the user though a complete setup for the ADAP-KOOL Drive. Most
standard refrigeration applications can be setup by using this Application Guide. Advanced features must be accessed
though the menu structure (Quick Menu or Main Menu) in the drive.
The Application guide covers all standard settings for:
-Compressors
-Single fan and pump
-Condenser fans
After completing setup, choose to re-run wizard or start application
The Application Guide can be cancelled at any time by pressing “Back”. The Application Guide can be re-entered through
the Quick Menu. When re-entering the Application Guide, the user will be asked to keep previous changes to the factory
setup or to restore default values.
The ADAP-KOOL Drive AKD 102 will start up initially with
the Application guide thereafter in the event of power
failure the application guide is accessed through the Quick
menu screen.
The following screen will be presented:
If “Cancel” is pressed, the AKD 102 will return to the status
screen. An automatic timer will cancel the wizard after 5
min. of inactivity (no buttons pressed). The wizard must be
re-entered through the Quick Menu as described below.
If “OK” is pressed, the Application Guide will start with the
following screen:
This screen will automatically change to the first input
screen of the Application Guide:
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Answering the questions on the screens will take the user
though a complete setup for the ADAP-KOOL Drive. Most
standard refrigeration applications can be setup by using
this Application Guide. Advanced features must be
accessed though the menu structure (Quick Menu, Main
Menu etc.) in the drive.
The Application guide covers all standard settings for:
-Compressors
-Single fan and pump
-Condenser fans
Compressor pack setup
As an example, please see screens below for a compressor
pack setup:
Voltage and frequency setup
Current and nominal speed setup
Min. and max. frequency setup
Min. time between two starts
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Choose with/ without bypass valve
Select open or closed loop
NOTE
Internal / Closed loop : The AKD 102 will control the
application directly using the internal PID control within
the drive and needs an input from an external input such
as a temperature or other sensor which is wired directly
into the drive and controls from the sensor signal.
External / Open loop: The AKD 102 takes its control signal
from another controller (such as a pack controller) which
gives the drive e.g. 0-10v, 4-20 mA or ADAP-KOOL Lon.
The drive will change its speed depending upon this
reference signal.
Select sensor type
Settings for sensor
Info: 4-20 mA feedback chosen - please connect
accordingly
Info: Set switch accordingly
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Select unit and conversion from pressure
Select fixed or floating setpoint
Set setpoint
Set high/ low limit for setpoint
Set cut out/ in value
Choose pack control setup
Set number of compressors in pack
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Info: Connect accordingly
Info: Setup completed
After completing setup, choose to re-run wizard or start
application. Here we can select the following options:
•
Re-run wizard
•
Go to main menu
•
Go to status
•
Run AMA - Note this is a reduced AMA if
compressor application is selected and full AMA if
single fan and pump is selected.
•
If condenser fan is selected in application NO
AMA can be run.
•
Run application- this mode starts the drive in
either hand / local mode or via an external
control signal if open loop is selected in an earlier
screen
The Application Guide can be cancelled at any time by
pressing “Back”. The Application Guide can be re-entered
through the Quick Menu:
When re-entering the Application Guide, the user will be
asked to keep previous changes to the factory setup or to
restore default values.
NOTE
If the system requirement is to have the internal pack
controller for 3 compressors plus by-pass valve connected,
there is the need to specify AKD 102 with the extra relay
card (MCB105) mounted inside the drive.
The bypass valve must be programmed to operate from
one of the extra relay outputs on the MCB105 board.
This is needed because the standard relay outputs in the
AKD 102 are used to control the compressors in the pack.
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3.1.2 Application Descriptions
The AKD Wizard is structured into three basic applications:
•
Compressor
•
Multi condenser fan
•
Single fan and pump
These applications are then further expanded to allow control of the drive to be controlled via the drives own internal PID
controllers or from an external control signal.
Compressor
The wizard guides the user through the set up of a refrigeration compressor by asking him to input data about the
compressor and the refrigeration system on which the drive will be running. All terminology and units used within the
wizard are common refrigeration type and set up is thus completed in 10-15 easy steps using just two buttons of the drives
local control panel.
Illustration 3.1 Standard drawing of “Compressor with internal control”
Single or multiple fans or pumps
The wizard guides the user through the set up of a refrigeration condenser fan or pump by asking him to input data about
the condenser or pump and the refrigeration system on which the drive will be running. All terminology and units used
within the wizard are common refrigeration type and set up is thus completed in 10-15 easy steps using just two buttons of
the drives local control panel.
Illustration 3.2 Speed control using analogue reference (open loop) – single fan or pump / multiple fans or pumps in parallel
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Illustration 3.3 Pressure control in closed loop – stand alone system. single fan or pump / multiple fans or pumps in parallel
Compressor pack
Illustration 3.4 P
0
pressure transmitter
54
Illustration 3.5 How to connect the AKD102 and AKS33 for closed loop applications
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4 Mechanical Installation
4.1 Before starting
4.1.1 Checklist
When unpacking the frequency converter, ensure that the unit is undamaged and complete. Use the following table to
identify the packaging:
Enclosure type: A2
(IP 20-21)
A3
(IP 20-21)
A4/A5
(IP 55-66) B1 (IP 21-55-66) B2 (IP 21-55-66) C1 (IP 21-55-66)
C2
(IP 21-55-66)
Unit size (kW):
200-240 V 1.1-3.0 3.7 1.1-3.7 5.5-11/
5.5-11
15/
15-18.5
18.5-30/
22-30
37-45/
37-45
380-480 V 1.1-4.0 5.5-7.5 1.1-7.5 11-18.5/
11-18.5
22-30/
22-37
37-55/
45-55
75-90/
75-90
Table 4.1 Unpacking table
Please note that a selection of screwdrivers (phillips or cross-thread screwdriver and torx), a side-cutter, drill and knife is also
recommended to have handy for unpacking and mounting the frequency converter. The packaging for these enclosures
contains, as shown: Accessories bag(s), documentation and the unit. Depending on options fitted there may be one or two
bags and one or more booklets.
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4.1.2 Mechanical Dimensions
A2 A3 A4 A5 B1 B2 C1 C2
IP20/21 IP20/21 IP55/66 IP55/66 IP21/55/66 IP21/55/66 IP21/55/66 IP21/55/66
All measurements in mm.
* A5 in IP55/66 only
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