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User Guide | Optyma™ iCO2

14 | BC408445719305en-000101

2. Module controller

2.1 System Overview

Below is a topology over the system

System Manager

Condensing unit

AK-SM 800/800A

AK-CC55

Remote control assembly

Evaporator controllers

User interface

12VDC

Power Supply

12VDC

+12VDC

230VAC

Modbus RTU

230VAC

Modbus RTU

CO2 MODULE CONTROLLER
UNIVERSAL GATEWAY

INPUT 12 VDC

RS485-1

GND

A -

B -

GND

A -

B -

RS485-2

GND

A -

B -

RS485-3

PWR

RJ12

Module controller

assembly

Functions

• Control of connected condensing unit (CDU).

• Coordination of oil recovery.

• Communication with a Danfoss System Manager.

Condensing unit

The connected condensing unit is allowed to start when any of the evaporator controllers have a cooling demand.

Oil recovery

The controller coordinates oil recovery operation between the condensing unit and the evaporator controllers. During oil recovery the

expansion valves are opened and the speed of the compressor is increased.

Data communication

The controller is delivered with three interfaces for Modbus communication, each with their own function:

1. Communication with System Manager

This interface lets a Danfoss System Manager find both the connected condensing unit and all the connected evaporator controllers.

2. Communication with condensing unit

3. Communication with evaporator controllers

Important

All connections to the data communication must comply with the requirements for data communication cables.

See literature: Design guide RC8AC Data communication between ADAP-KOOL® Refrigeration Controls.

Note:

No direct possible link between System Manager and unit controller, you need to connect to Module controller

Содержание Optyma iCO2

Страница 1: ...Optyma iCO2 OP UPAC015COP04E User Guide danfoss com...

Страница 2: ...ing diagram 26 5 Servicing 27 5 1 Procedure and caution for commissioning 27 5 2 Installation and Commissioning check sheet 32 5 3 Request for maintenance and inspection 36 5 4 Warranty conditions of...

Страница 3: ...Note Protective control initiates an extraordinary operation in order to protect the product when it is expected that it may run out the allowable ranges for the refrigeration cycle devices and elect...

Страница 4: ...lay content High Low Receiving of line check command QO ROM version display WLMC or other Error display Exx Operation code display oPE X Compressor oil check operation display oil Ordinary channel dis...

Страница 5: ...p L 40 100 1 C C15 Tho R liquid feed pipe temp L 40 100 1 C C16 Tho S suction pipe temp L 40 100 1 C C18 CT1 CM1 current 0 50 1A C20 EEVG medium pressure receiver inlet electronic expansion valve 0 47...

Страница 6: ...ooling coil temp sensor 1 saturation pressure 0 8 5 0 1 bar C49 Suction superheat degree 1 0 50 0 1deg C51 Subcooling coil superheat degree 0 50 0 1deg C52 Under dome superheat degree 1 0 50 0 1deg C5...

Страница 7: ...20 1 P07 External input CNS2 function assignment 1 Default 0 20 1 Demand input 2 Quiet mode input 3 Spare 4 Compulsory oil return control input 5 Gas cooler fan snow control input 9 Multistage demand...

Страница 8: ...coil sensor broken wire Tho SC 7 time E37 7 Liquid feed pipe temp sensor broken wire Tho R E38 Continuous Once E38 Outdoor temp sensor broken wire Tho A E39 Continuous Once E39 1 Td sensor 1 broken w...

Страница 9: ...essure LP being detected by the low pressure sensor will become the set low pressure 2 Operation stop by decreased low pressure LP When the low pressure LP is lower than the preset stop pressure value...

Страница 10: ...peed drops Low pressure value Stop setting pressure 2 min elapsed Compressor stop Subcool coil electronic expansion valve OFF full closure Middle pressure receiver inlet electronic expansion valve OFF...

Страница 11: ...is restricted by the control PCB of condensing unit Restriction of frequency output Forcible frequency reduction Start value 23 A release value 22 A 22 A After 3 minutes 23 A Forcible frequency reduct...

Страница 12: ...le pressure MP from rising excessively at standstill If the detected middle pressure MP exceeds 70bar EEVSC is opened and EEVG is closed Control is end when middle pressure MP below 65bar or 180 secon...

Страница 13: ...aperture full open Initial aperture Ordinary control 45 sec 120 sec Stop aperture full open 45 sec Oil level switch OLS1 2 ON at low oil level Controlled at or above the specified value of discharge...

Страница 14: ...ave a cooling demand Oil recovery The controller coordinates oil recovery operation between the condensing unit and the evaporator controllers During oil recovery the expansion valves are opened and t...

Страница 15: ...ND A B Power supply to CDU Short circuit proof cable NSGAF U 1 8 3kV 2 x 1 5mm 1 2m in PVC sleeve Communication to CDU Twisted pair shielded cable UNITRONIC BUS LD 1 x 2 x 0 22 1 8m Modbus to evaporat...

Страница 16: ...le for this is included Connect this RS485 2 Modbus cable to terminal A and B of the condensing unit control panel Modbus interface terminal block Do not connect insulated shield to ground RS485 3 Mod...

Страница 17: ...nd connect the System Manager Modbus cable to the Module controller 2 Optional installation on the frontside only for 10HP unit just beside the CDU control panel holes to be drilled Procedure Remove C...

Страница 18: ...cable ties and should not touch the baseplate to avoid water ingress Power cable The communication cable and the power cable should not touch the baseplate Please wire the communication cable from th...

Страница 19: ...ntrol assembly 1 x Mounting bracket 4 x M4 screws 5 x Inox rivets 5 x Sheet metal screws Approvals EC Low Voltage Directive 2014 35 EU EN 60335 1 EMC 2014 30 EU EN 61000 6 2 and 6 3 2 5 Spare parts Pa...

Страница 20: ...le button again to freeze the value See alarm code A short press of the upper button If there are several alarm codes they are found in a rolling stack Push the uppermost or lowermost button to scan t...

Страница 21: ...28 For Danfoss Only SH Guard ALC Cut out limit for ALC control oil recovery r20 SH Start ALC Cut in limit for ALC control oil recovery r21 Oil ALC setpoint LBP AK CC55 parameter P87 P86 r22 SH Close A...

Страница 22: ...rs n01 Clear Network List Clears the list of evaporator controllers may be used when one or several controllers are removed proceed with a new network scan n01 after this n02 Service Read discharge pr...

Страница 23: ...controller 5 offline Communication lost with evap controller 5 See A01 A06 Evap controller 6 offline Communication lost with evap controller 6 See A01 A07 Evap controller 7 offline Communication lost...

Страница 24: ...dress Io02 0 240 0 Node 3 Address Io03 0 240 0 Node 4 Address Io04 0 240 0 Node 5 Address Io05 0 240 0 Node 6 Address Io06 0 240 0 Node 7 Address Io07 0 240 0 Node 8 Address Io08 0 240 0 Node 9 Addres...

Страница 25: ...y 20 Sight glass 21 Under dome temperature sensor 22 Injection inlet temperature sensor 23 Discharge pipe temperature sensor 24 Subcooling coil temperature sensor 25 Middle pressure receiver inlet tem...

Страница 26: ...al type switching J14 16 Spare L1 1 2 DC reactor L3 Reactor LED1 Main inspection red LED2 Main normal green LED3 Main service green LED4 6 7 segment LED function display LED7 9 7 segment LED data disp...

Страница 27: ...t the bottom of controller is turned OFF Remove the carton and the bracket before operation 5 Anti vibration shipping washers are not used on the compressor Since this product does not use anti vibrat...

Страница 28: ...nt from the table below Standard data OP UPAC015COP04E Outside temperature C Evaporation temperature C Compressor Rotating rate rps HP MP LP bar g Td C EEVG pulse EEVSC pulse EEVLB pulse Rated refrige...

Страница 29: ...essure set in r01 and the upper value of the target evaporation pressure set in r02 The target evaporation pressure is sent to the CDU from the module controller e g When r01 is set to 30 and r02 is s...

Страница 30: ...rted pressure setting value Low pressure setting OFF value Low pressure setting ON value Error pressure 5 19 38 7 bar 19 3 bar 13 3 bar Evaporation temperature Converted pressure setting value 5 0 bar...

Страница 31: ...y check When 7 segment display has shown Lo1 in place of 0 the operation is stopped because an oil shortage has been detected In this case turn the dipswitch SW 6 to OFF and replenish the oil Quantity...

Страница 32: ...ing unit installed level Check with level gauge Yes No Is the Condensing unit installed on a suitable base Check foundation strength Is the Condensing unit installed near any oil and or hazardous gase...

Страница 33: ...3 10 Is below dip switch setting of control board or interface board samw as below SW4 6 of control board Oil check operation mode select OFF SW5 7 of control board Airtight test mode select OFF SW3 4...

Страница 34: ...unit and load unit Refer 2 07 The distance between the farthest load unit and the condensing unit is 100m or less Follow the Maximun refrigerant charge quantity at the same time shown in 5 Leak detec...

Страница 35: ...arge g The operation starts at 90 of the calucated amount of the refrigeration Follow the refrigerant amount shown in the Instruction manual 10 Procedure and caution for commissioning 10 7 Check of ad...

Страница 36: ...or High middle low pressure vibration noise insulation resistance loose terminal 1 40 000 h Air side heat exchanger Gas cooler High middle low pressure fouled fin discharge temperature 1 8 years Solen...

Страница 37: ...n the wire connection of compressor R S T to prevent reverse phase When a part failed including compressor do not replace the while Condensing unit but replace defective part only When disposing the C...

Страница 38: ...sively larger or smaller capacity is selected for the cooling load Example Mistake in selection of expansion valve improper installation omission of solenoid valve in liquid line etc 2 Nonconformity i...

Страница 39: ...pressure sensor Bar 6 46 C28 PSM medium pressure sensor Bar 14 79 C29 Inverter current 1 A 23 C31 Pressure switch left end 1 C32 Oil level switch left end 1 1 C46 Medium Pressure satuation temp C C50...

Страница 40: ...ormation Cooler 2 Liquid feeding solenoid valve ON 1 OFF 0 Cooler 2 defrost status 3 u60 ON 1 OFF 0 Cooler 2 fan Operating 3 u59 ON 1 OFF 0 Cooler 3 Roomtemperature SV 3 r00 C 45 30 Cooler 3 Roomtempe...

Страница 41: ...at SV 3 u22 deg 5 Cooler7superheat PV 3 u21 deg 5 Cooler7 expansion valve opening duty 3 u23 0 100 Cooler7 information Cooler7 Liquid feeding solenoid valve ON 1 OFF 0 Cooler7 defrost status 3 u60 ON...

Страница 42: ...erant overcharged Does the high pressure error 7 segment display E40 or liquid back from the medium pressure receiver 7 segment display E43 occur Is the oil level maintained above the lower limit duri...

Страница 43: ...erature sensor error Injection inlet temperature sensor blown wire short circuit are detected Defective injection inlet temperature sensor connector disconnection or short circuit Replace E37 6 Subcoo...

Страница 44: ...igh pressure sensor error Stops with high pressure sensor blown wire output error detection Defective high pressure sensor connector disconnection or short circuit Replace E55 1 Under dome temperature...

Страница 45: ...100 or less a power cable may be connected to the signal cable terminal board Communication method is based on RS485 Connect signal cable to A B on the terminal board Signal cables has the polarity Co...

Страница 46: ...to the outside of control box 3 pcs Brown For compulsory oil return control input CNS3 Harnesses for external operation input CNS1 and demand input CNS2 are fixed in the control box with tapes JST XAP...

Страница 47: ...ut CNH Connector color Blue Error output CNY Connector color White 7 segment setting output CNZ1 Connector color Red 7 segment setting output CNZ2 Connector color Black 4 point relay Provided at site...

Страница 48: ...e customer to make rectification it is much easier to explain the Ask the customer to make rectification Check operation without any rectifications 2 Error detection method Check the power source volt...

Страница 49: ...ce the sensor Check the coil of solenoid valve or the sensor and replace it Replace the coil EEVLB Replace the EEVLB main body If there is no refrigerant in liquid line charge refrigerant additional C...

Страница 50: ...37 3 Tho M E37 4 Tho INJ1 E37 6 Tho SC E37 7 Tho R 2 According to the kinds of sensors from 1 to 7 time flash or keep flashing Temperature resistance characteristics Gas cooler temperature sensor Tho...

Страница 51: ...omalously low temperature resistance of outdoor air temperature sensor Tho A If the sensor detects anomalously low temperature for 20 seconds continuously after power ON Broken sensor harness or the i...

Страница 52: ...ol PCB of condensing unit Broken sensor harness or the internal wire of sensing section Check the molded section as well Disconnection of sensor harness connection connector Control PCB anomaly If the...

Страница 53: ...ter Fan motor anomaly Control PCB anomaly Disconnection of high pressure switch connector Breakage of high pressure switch harness Disconnection of connector Closed service valves High pressure sensor...

Страница 54: ...eration range check the voltage at connector If 400V is detected replace fan motor If 0V is detected replace control PCB After checking loose connection of connector or disconnection of wiring harness...

Страница 55: ...ocedure of E48 Restart operation under the operating conditions 30 minutes before error occurred as possible as you can Wait and see Replace compressor Replace power transistor Measure after confirmin...

Страница 56: ...y of inrush current suppression resistance When the communication between inverter PCB and control PCB is not established Note If the same error does not reappear continue to get data with Mente PC Er...

Страница 57: ...y of inrush current suppression resistance When the communication between inverter PCB and control PCB is not established When E45 is displayed on the 7 segment LED display All models From previous pa...

Страница 58: ...data with Mente PC Error code Remote control 7 segment display LED Green Red Condensing unit Keep flashing 1 Content E48 1 2 1 DC fan motor anomaly 1 2 Turn off the unit disconnect CNFAN1 CNFAN2 from...

Страница 59: ...on control PCB CNFAN1 connect CNFAN2 connector and CNFAN2 connects on CNFAN1 Is the faulty fan motor running No Which is FG signal 0V Yes Y es No Y es 5V Y es 3 2 5 4 4Is there a short circuit on the...

Страница 60: ...er source terminal GND Yellow Black 200k 10 FG Between 4pin and 2pin of power source terminal GND Blue Black 1M and over OVERC Between 5pin and 2pin of power source terminal GND Green Black 1M and ove...

Страница 61: ...Purge refrigerant and recharge refrigerant properly Refrigerant is leaking Specify the leak point and after rectifying the leak point recharge refrigerant properly Correct the connection Check the lo...

Страница 62: ...ature sensor Tho S1 Note E53 1 Suction pipe temperature sensor Tho S anomaly 3 Check several times to prove any poor connection Temperature resistance characteristics Suction pipe temperature sensor T...

Страница 63: ...e speci ed take a measure Replace control PCB Replace sensor Note From the viewpoint of safety pressure cannot be measured with pressure gauge during operation Please check pressure during stopping op...

Страница 64: ...k sensing value Compare the temperature shown in Mente PC data to the acutal temperature measured with thermometer Insert the connector securely Replace under dome temperature sensor Tho C1 Replace th...

Страница 65: ...tor temperature sensor Tho P1 Replace the control PCB of condensing unit Note 140 120 100 80 60 40 20 200 180 160 140 120 100 80 60 40 20 0 0 1 time flash All models Detection of anomalously low tempe...

Страница 66: ...bility that the liquid refrigerant is migrated in the compressor Wait for about one hour with keeping the power source and then restart operation In order to evaporate the liquid refrigerant migrated...

Страница 67: ...record it Check the power source voltage and correct it Is the capillary tube returning oil from oil separator clogged Does EEV actuate normally Replace the power cable If there is a problem on the t...

Страница 68: ...e can be specified take a measure Replace control PCB Replace sensor Note From the viewpoint of safety pressure cannot be measured with pressure gauge during operation Please check pressure during sto...

Страница 69: ...on or during stopping Replace control PCB Check the cause for occurring emergency stop It is better to have the data of 30 minutes before stopping for checking 2 Error detection method When the contac...

Страница 70: ...test version Or replace the ROM to the latest version one If it occurs 4 times within 15 minutes Control PCB anomaly Replace control PCB Software program version before rewritten was unmatched IC2 is...

Страница 71: ...stallation of condensing unit Do the pipings installed on site contact each other at some parts NO NO NO YES YES NO Note Condensing unit is not a cause If option parts is used check the secure connect...

Страница 72: ...not abnormal If it is unendurable sound for the customer please ask our distributor If some foreign matter like icicle is biting remove it In case of the installation in cold region installation of s...

Страница 73: ...s of the oil level sensor from the connector As the harness for the oil level sensor passes through the insulation disconnect the relay connector OSL1 2 where connected with another connectors from th...

Страница 74: ...cket Upper jacket Top cover Under dome temperature sensor Tho C1 Pipe Oil level switch OLS1 2 Lower jacket Upper jacket Top cover Crankcase heater CH1 3 Remove temperature sensors four places and cran...

Страница 75: ...sensors located backside to keep off harnesses from the brazing area Move aside 1 Remove the terminal cover 3 Remove the terminal block Remove EEV to keep the harnesses away 2 Use stubby screwdriver...

Страница 76: ...e if residual pressure is 0 bar In case anything goes wrong sudden brazing is dangerous We recommend dismounting the compressor by cutting off the pipes because the pipes are thicker and longer insert...

Страница 77: ...ew compressor Braze pipes after tightening fixing bolts three positions in total 3 Suction pipe 4 Discharge pipe 1 Gas injection pipe 2 Oil return pipe User Guide Optyma iCO2 Danfoss Climate Solutions...

Страница 78: ...Under dome temperature sensor sensors and crankcase heater Preparation work before mounting insulation 3 Mounting of insulation 4 Fitting discharge pipe and injection sensor etc back to the original p...

Страница 79: ...opening door Loosen 8 screws shown with white arrow Left side of control box 3 screws Inner left side of control box 3 screws Bottom side of control box 2 screws Be careful not to forget to loosen a...

Страница 80: ...1 to 3 enables easy access to the inverter PCB without disconnecting wires 3 Open the mounting board of first and second layer 2 Inverter PCB 2 At the bottom of control box This mounting board support...

Страница 81: ...B a Replacement work of power PCB on the second layer The second layer 1 Loosen 4 screws There are 4 screws at all corners of the first layer User Guide Optyma iCO2 Danfoss Climate Solutions 2023 01 L...

Страница 82: ...going to control PCB 3 Cut the tie up band 4 Disconnect the wire going to control PCB Disconnect CNB1 Disconnect CNX1 Cut the tie up band Disconnect CNDR Disconnect CNB1 connector Green and CNX1 conne...

Страница 83: ...low and CN18V connector Black at the upper center part of control PCB Check the detailed position of connector with the wiring diagram or control PCB drawing Following the process from 1 to 6 enables...

Страница 84: ...BC408445719305en 000101 Danfoss Climate Solutions 2023 01 LCA012A030...

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