AK SM 800 Commissioning Guide

Transcription

1 AK SM 800 Commissioning Guide AK-SM 800 step-by-step ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 1

2 Intro... 3 Connection to the system... 5 Software version... 7 Preferences wizard... 8 Users wizard Alarm levels and action setup Alarm handling Alarm routing System alarms Layout wizard Initial setup of AK2 controllers Upload of all controllers Controller copy wizard Setup of connected controllers Master control functions Defrost schedules Adaptive rail heat Calculation example on rail heat function Day/Night functions kwh-measurment Leak detectors Po-optimization AKC ON (injection ON) History setup 42 Graphical layout Full backup ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 2

3 Intro Purpose of this instruction is to guide you through the ADAP-KOOL AK-SM 800 commissioning. The guide is written as an example to a typical store setup. It is easy to follow the guide in a chronological order for good commissioning practice. This guide is neither a complete manual nor a commissioning tutorial for the ADAP-KOOL AK-SM 800-series. It must be complimented by individual product manuals and good engineering practice and automation knowledge. ADAP-KOOL Cool Thinking simplified system layout example AK-SM 800-series limitations ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 3

4 Preparing the individual controllers on the network Set controller LON/Modbus addresses (max.120) and choose the correct application (param. o61). In EKC-type controllers LON/Modbus address is given via parameter o03. In AK2-type controllers LON-bus address can be screwed form the dip-switches. Remember to make a power reset after changing the address. In MCX-type of controllers Modbus address is given via the menu. Go to System -> Network -> Modbus address Notice! - Each controller must have an individual address between 1 120! - AK-SM 800 MASTER has the address 0. - If more controllers (SM 8220=32/SM850=120) should be used an AK-SM 800 SLAVE unit must be Installed using address 1. - AK-CM 101C must have an address between 1 99 ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 4

5 Connection to the system Connection to the AK-SM 800 can be made basically in two different ways: - straight connection; set static IP for the AK-SM 800 and your PC (use crossed network cable). - using a router; set static IP for the AK-SM 800, the router DHCP server will give IP to your PC. AK-SM 800 static IP setup: -Press config button -Go to Comm -Give access. User: Supervisor, Password: Set IP setup. Press to reset the unit to restart of the unit with new IP settings ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 5

6 Note! Network ports and firewall settings: In AK-SM units, FTP service is a convenient way to download/upload files and updating database/code. Open FTP server ports to the public internet is not considered as a safe network practice. To avoid these issues, Danfoss strongly suggests FTP functionality in LAN network only. This would reduce the risk of open FTP ports and enhance network security. However, to make the FTP work on WAN side, it must have configured FTP server port opened and forwarded to the public internet. Access the unit by Store View Desktop program your web browser (faster) or via your web browser (basically a bit slower). Enter user name and password: ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 6

7 Software version Check AK-SM 800 software version under Info menu: Check Danfoss AK-SM 800 website for AK-SM 800, RMT & SVD updates. Make sure to use latest software versions! An update is recommended to be done with the MAI-file (and Bootloader-file if needed) by using a compatible USB stick: Note! When updating the unit, all previous settings are stored (settings, MIMIC, logs, etc.), but remember to make a full back up before update just in case! Note! If you want to reset the unit to factory settings, go to: Configuration -> System -> Clear Database ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 7

8 Preferences wizard Go to Configuration and run Preferences and run through each step: ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 8

9 Note! If you wan to use a weekly day/night schedule for the plant opening hours. Go to Configuration -> Time (Can be ued later for example for alarm routing.) ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 9

10 Users wizard Go to Configuration and run Users and run through each step: ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 10

11 Click on change Daily user and Service user access settings can be modified ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 11

12 Alarm levels and action setup Go to Configuration -> Control -> Refrigeration -> Choose Section -> Setup -> Alarms Give all alarms in each controller an alarm level and action number. Alarm level = information of the alarm, shown eg. in alarm list. Alarm action = alarm routing is done based on action number, can be set to trigger an alarm relay for example. Note! As alarm action default value is 1 for all alarms, it is easier to change the priority to something else on only the alarms we want to forward, eg. 8. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 12

13 Alarm handling Alarm routing Go to Configuration -> Control -> Alarms -> Alarm Routing In this example we ll make the simplest alarm routing setup where the unit s internal relay1and the front LED is triggered by alarm action 8. The alarm relay will be activated for 2 min and will stay active regardless of the actual alarm status which triggered. The front LED will be active until a user acknowledgement will satisfy the alarm, regardless of the actual alarm status which triggered. Double-click ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 13

14 Stop Conditions - these control the alarm output, such as relays, buzzer, LED, etc. Time - the amount of time that the alarm output will be active (minutes). This is regardless of the actual alarm status which triggered. Ack - a user acknowledgement will satisfy the alarm out,, regardless of the actual alarm status which triggered. Clear - the alarm output will stay 'On' until the alarm clears. Time/Rep - the alarm output will stay 'On' for the amount of time specified, but then a selected repeat interval of time is available. This will be activated until the alarm clear. Ack/Rep - the alarm output is satisfied upon a user acknowledgement, but a repeat time is now used so that until the alarm clears, the output will again turn 'On' Note! For further info on the alarm routing handling please refer to the manual. There are several possible configurations. Eg. send alarm, send XML-alarm, use additional relays on an extension module for different actions, etc. System alarms Go to Configuration -> Control -> Alarms -> System Configure system alarms (further info on the alarms please refer to manual) ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 14

15 Go to Configuration -> Control -> Alarms -> I/O comm Configure communication alarm to each controller and extension module. As the list depends on your system configuration it is important to go through each tab and define the alarm settings for each node. Note! Communication alarm must be treated seriously, as this is the only alarm the system can give if a controller is powered off/breaks down and the system risks high temperatures. Communication alarm is generated after 2 minutes for I/O modules and 10 minutes for generic devices = controllers. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 15

16 Layout wizard Go to Configuration and run Layout and run through each step: Enable only the used network bus for faster network scan. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 16

17 Scan network. Name you pack controllers, use network address in the name for easier identification later on. Name you case controllers, use network address in the name for easier identification later on. Drag and drop your case controllers to the belonging pack controller. Check your layout configuration before creating it by clicking Finish. Note! The defined layout is seen on different pages used later on in daily use. The intention of the layout setup is to give a user friendly overlook of the site. Select No compressor for controllers that don t belong to a real pack controller. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 17

18 Initial setup of AK2 controllers AK2 controller = As the AK-SM 800 only supports a limited number of parameters from each controller, AK2 controllers must be initially commissioned using Service Tool! This also applies to other network nodes and 3d party controllers that contain a large amount of parameters, e.g. FC103 drive. AK2 controllers can be accessed with Service Tool via AK-SM 800: Note! Alarm priorities that are set in AK2 controllers via ST affects only that specific controllers display and alarm relay output! Alarm priorities and actions for AK2-controllers for system alarm routing must also be set separetely in the AK-SM 800 for each AK2-controller! See alarm settings. AK2-controller alarm priorities set via ST is not the same as alarm priorities set in the AK-SM 800! ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 18

19 Upload of all controllers To make sure all data from controller are updated in the AK-SM 800 it is recommended to make an upload of all the controllers before making further controller setup. Go to Configuration -> Network Nodes -> Upload Select all controllers and Press to upload from selection After a successful upload the status changes from Unknown to Pass ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 19

20 Controller copy wizard The copy wizard is an easy/fast way to define and copy controller parameter, alarm and history settings. Only alarms and history settings can be done on AK2-controllers! Go to Configuration and run Copy and run through each step: ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 20

21 Choose the controller and parameters to copy from ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 21

22 You can also save settings to a file for later use. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 22

23 ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 23

24 Remember to check each individual controller parameter, alarm and history setting that the copy has been successfully changed to the selected devices. See next section Setup of connected controllers Also remember to start history collection from Configuration -> History -> Start History ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 24

25 Setup of connected controllers Note! you can also re-run the Copy Wizard to make changes on individual controllers. Parameter setup: Configuration -> Control Under Refrigeration tab you find the commonly used refrigeration controllers The Refrigeration part is divided in different sections: Suction = Pack Controllers (AK-PC ) Circuits = Case Controllers (AK-CC, EKC-thermostats ) Etc. Choose your section and go to Setup tab. Each controller can be selected in the left dropdown box. The controller main menus are found in the right dropdown box. Lines marked with a * in front of a parameter are updating the current value from the controller. Parameters can be changed by double-clicking on the value. Note! Individual controller parameters can also be easily accessed and changed via ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 25

26 Detail -> Status/Settings menu. Alarm priority/action: Configuration -> Control -> Refrigeration -> Suction/Circuit -> Setup -> Alarms Alarm history settings: Configuration -> History -> Controllers ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 26

27 Master control functions For detailed description of the master function please refer to the manual. Defrost schedules Go to Configuration -> Control -> Refrigeration -> Schedules Choose number of schedules and enable Schedules. Enable Schedule and choose schedule usage, description, control funct. and defrost times. On Controllers tab choose controllers belonging to the group. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 27

28 Under Schedules the defrost groups are shown. Note! Check individual controller defrost interval, schedule, adaptive defrost and coordinated defrost via DI settings and make sure your schedule defrost acts like planned. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 28

29 Adaptive rail heat In this example we use the Danfoss EMHS3-1 dew point sensor connected via AK-CM101C + AK-XM modules for adaptive rail heat control. Go to Configuration -> Control -> Refrigeration -> Rail Heat Use adaptive rail heat and chose Calc Dewpt ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 29

30 Go to Configuration -> Control -> Refrigeration -> Addresses -> Sensors Configure the EMHS3-1 Rail Hum and Temp input points (Address) and type. Address configuration principle. (Note! Point config. differs from AK2 config.) Note! Dew point is automatically transmitted to all connected controllers. Remember to check controller rail heat configuration in each controller. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 30

31 Calculation example on rail heat function Quick guid on how to see Hymidity and Temp readings on MISC overview page. Config. Misc items to be shown on Dashboard. Config. 2 sensor inputs ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 31

32 Make 2 calculations and clone Humidity and Temp values ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 32

33 Insert the cloned (Ca-xx) values as sensors ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 33

34 Day/Night functions In this example we are controlling selected case controllers lights from the day/night function according to a time schedule and DI-override connected to an extension module. Reserve an on/off input for the DI-override. Config. the DI-override input ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 34

35 Configure a schedule for the light control. Choose controllers for the group. Note! Remember to configure in each controller what the day/night info is used for. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 35

36 kwh-measurment In this example we are connecting a kwh-meter with pulse signal (1000 pulses/kwh) via AK-CM 101C + AK-XM 107A extension module. Config. number of kw meters. Config. input type ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 36

37 Config. name and pulses/kwh from the meter. Config. signal input point. kwh-meters are shown under energy. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 37

38 Leak detectors In this example we are connecting leak detectors with 0 10V signal. Config. number of leak detectors. Config. name and signal type. Config. refrigerant ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 38

39 Config. signal input and type. Config. leak detector warning / alarm limits, alarm level and action. Leak detectors are shown under misc. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 39

40 Po-optimization Pack controller Go to pack controller Settings page. Set Suction Opt. to Yes. Config. max. float value and if Po float is allowed to override the pack Po setpoint below setpoint. The values set here can be set extra high, as it is more important to configure the min/max Po reference in the pack controller parameters, that finlly limits the Po-reference. Po-Opt. load info. Case controller Go to pack controller Status/Setting page. Choose if the selected case controllers will participate in the Po-opt. float function. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 40

41 AKC ON (injection ON) If Injection ON control is to be used over the network see Evap shutdown when injection off settings in the Pack and Case controllers. Note! The case controller must see a signal within 15 minute period or it falls back to run mode. In case of communication error to the pack controller the case controllers will shut down for 15 minutes and start again to run after that. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 41

42 History setup Go to Configuration -> History Start by Auto Configure History at e.g. 30 min interval. Notice! you might have defined controller history logs via the Copy Wizard already. Check manually that all controller and system param. and interval times are as you wish. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 42

43 Remember to start History Note! If logs are to be used for HACCP-report, consider carefully the log settings for temperature and control status interval (EKC/REG/Ctrl state). Especially the control status log interval needs to be set short enough to capture defrost sequences for the report e.g. 2 min. Note! History memory can t be exactly calculated, but as a very rough calculation120 data points at 10 minutes interval would give 1 year of storage time. It is always most recommended to backup HACCP (temp) raw data. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 43

44 Different arrangements for temperature data backup and sufficient storage memory for authorities: - XML-send to Danfoss AK-EM Danfoss EDS service (Daily HACCP-report) - XML-integratin to 3d party database/service - Danfoss Store View program auto export history function - Manually save history data periodically ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 44

45 Graphical layout The graphical layout must be done using Danfoss RMT-tool. The AK-SM850 can support a total of 5 web graphic views (Jpeg s) for the web browser and 5 Viz (custom bit maps) for each SM800 local display. In addition to a graphical image, system parameters can be mapped to display current temperatures and status. This may serve as an easy means to display critical data on the local and web screens. If no graphic is loaded, a factory logo will be seen in the system view screen. The pictures can be drawn using Windows Paint. AK-SM local screen: 792x548 pixels 8 bit 240 colors Bit Map format (Workaround for Paint; save first to 24-bit bmp after that save to 256 color bmp) AK-SM WEB graphics: Jpeg format (used for AK-SM850 web browser) WEB and Local screen picture examples. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 45

46 Open a New Graphics Project Before proceeding, it is suggested that you have already created a folder on your PC which contains the graphic files for your project. In this folder, copy the BMP and JPEG files, as well as a copy of the database for this particular AK-SM850 There are two methods available: Offline or Online connection. Click on to open a new graphics project. The following Project Wizard is presented. Use the Browse button to navigate to the working folder for this project that contains your jpg and bmp files. The Project Name will automatically be assigned as the name of the selected directory. Therefore, you won t be able to change the Project Name here. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 46

47 Select the number of AK-SM850 units for this site. In this example 1 was chosen. If you wish to start the offline simulator of your AK-SM850 configuration for this site, place a check mark in the box to the right. In this example, this was left unchecked (typical when connecting to a live system). Click Next to continue. Selected 1 web graphics file in this example and path to containing folder on PC. Select your jpeg for the Web graphics Click Next to continue. Selected 1 screen graphics file in this example and path to containing folder on PC. Select your bitmap image(s) for the screen graphics. Click Next to continue ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 47

48 Summary of the Project information as entered. Click on the OK to proceed Current view is the Web Graphics FLP (jpeg) ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 48

49 Click on the box to the left (Select to View Screen Graphics file) and now you are shown the bit map (bmp) for the local AK-SM850 screen. Click on the download datapoints button AK-SM850 you are connected to. from the tool bar to retrieve data points from the All of the points configured in the AK-SM850 are now pulled back and listed here. Shown is the open list of analog sensor inputs. Click on each of the other data point types (e.g. devices) to present any points which may fall into those categories. Points from Devices would be parameters from EKC / AK-CC controllers, etc. ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 49

50 NOTE: When viewing the local screen graphic only data points from the target AK-SM850 will be shown. Only local data points from this unit can be mapped. When viewing the Web graphics window, you will see ALL AK-SM850 units (if connected). Under the Web graphics screen you may map ANY data point from ANY AK-SM850 controller. Save project when done ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 50

51 Download projects to the unit The project needs to be loaded from your PC into the AK- SM850 unit. Click on this icon from the tool bar to proceed. If you are not yet logged on, do so now. If you press F3 at the local AK-SM850 display, this site view will be present. Real-Time updating of configured data points is seen ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 51

52 Web Browser Graphic View Floor Plan ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 52

53 Full backup AK-SM 800 backup file (*.S55) contains all AK-SM 800 system settings. Graphic files are NOT included in this backup! The backup file (*.S55) also contains full backup of connected controllers. (Controller param. settings are stored both in the controller and AK-SM 800 and can be managed by the upload/download function) A separate backup must be done from AK2 controllers and other network nodes that contain a large amount of parameters, e.g. FC103 drive! AK2 controller backup (*.bck) must be done using Service Tool. Connect a compatible USB stick to the AK-SM 800 Flash Drive Detected menu pops up, select menu 4 = Save Database. A backup file (*.S55) is created = Year 2013 Month 2 Day 7 Time 10:41 Note! Remeber to include the RMT Graphic Project files and AK2 backup (*.bck), drives backup and other special controllers backup files into your complite backup folder of the site. Configured history log datapoints are stored but history data istself is not included in the backup file (*.S55). If you need to backup log history it can be exported/imported from History page: ADAP-KOOL Oy Danfoss Ab / Kylmäosasto 53