Recommended Installation guide...USCO.EI.RF0.A3.22.CT / 521U0185 Version 1.2 Revised recommendation to remove end of line terminators (at AK-SC255 and Com-Trol local bus) Added new

1DANFOSS NORTH AMERICA

Recommended Installation guideAK-SC255 Com-Trol local bus support

V1.2

MAKING MODERN LIVING POSSIBLE

2

Table of contents

Page 3 Introduction and document scope

Page 4 1.0 Intended application (Hardware / Software)

Page 5 2.0 Programming AK-SC255 Database

Page 6 3.0 Network wiring / power

Page 7 4.0 Appendix

Document historyUSCO.EI.RF0.A1.22.CT / 521U0185 Version 1.0USCO.EI.RF0.A2.22.CT / 521U0185 Version 1.1

Added additional information on extended address format Danfoss part numbers

USCO.EI.RF0.A3.22.CT / 521U0185 Version 1.2Revised recommendation to remove end of line terminators (at AK-SC255 and Com-Trol local bus) Added new figure to highlight ‘daisy chain’ communications formatModified figure 1 to better reflect daisy chain local bus layout

3

IntroductionThis document describes the main points concerning a Com-Trol to Danfoss AK-SC255 conversion process. Since January 2011 the Schneider Electric© group has formally granted Danfoss Inc the intellectual rights to it’s Com-Trol control products. Danfoss Inc is pleased to be the only official controls supplier which is recognized as the recommended replacement solution for your Com-Trol installation.

Document scopeThe scope of this document is intended to provide guidance when replacing Com-Trol 4k or 4K2e controllers for a Danfoss AK-SC255 on a existing Com-Trol local bus network. The Danfoss AK-SC255 is a comprehensive front end controller, capable of Refrigeration, Lighting and HVAC control and is used globally throughout the Food Retail market. Once the Danfoss AK-SC255 has been suitably installed it will provide many years of trouble free, efficient operation, in parallel with the existing Com-Trol local bus I/O boards.

This installation guide does not replace any existing documentation provided by Com-Trol, when working with Com-Trol equipment please refer to available Com-Trol documentation.

Prerequisite knowledge and experienceIt is expected that the service technician is already experienced and has a deep knowledge of the Danfoss AK-SC255 controller. Training is available from Danfoss upon request. In addition, knowledge about the actual site installation would be advanta-geous as many control changes may have occurred from the original configuration.

Figure 1 - Danfoss AK-SC255 used as Com-Trol 4k / 4k2e replacement (local bus)

• Ensure daisy chain communication wiring format• Remove ALL end of line terminator throughout network run• Twisted pair and shield cable• When connecting IO enclosures, you need to re-wire the

incoming 485 local bus network to the first I/O board, daisy chain the network though all installed boards, to maintain daisy chain wiring format.

Ethernet host network

4

1.0 Intended application (Hardware / Software)The following important points define the intended application scope for a Com-Trol (local bus) retro-fit installation. Please read these fundamental requirements before continuing.

• Recommended communications wire twisted pair, plus shield (See appendix section)• One Com-Trol 4K/4K2e should be replaced with one Danfoss AK-SC255 unit• The Danfoss AK-SC255 RS-485 (Modbus) port is used for communication to the Com-Trol I/O boards (figure 2). Host communication to other AK -SC255 and/or AK-SC255 Loggers must be done via the Ethernet port.• Only one local bus loop can be connected to the AK-SC255 (figure 1) - No star wiring configurations allowed• No terminators needed for Com-Trol local bus nor on the AK-SC255 RS485 Modbus port (see figure 2 below)• When using Danfoss AK I/O modules, terminators must be in place (Lonworks ports) • Observe power wiring rules (see section 3.0)• Existing system capacity for number of Com-Trol I/O boards (defined by Com-Trol documentation) must be maintained• AK-SC255 software version R2.153 and above must be used in order to provide Com-Trol support• The AK-SC255 being used in the application must have a valid Com-Trol license installed. If a license is required contact Danfoss Customer service on 410-931-8714 with the AK-SC255 MAC address

Power Connection(100 - 240 V a.c.)

LonWorks© Port(s)

RS485 Modbus port- Used for Com-Trol local bus(Remove factory terminator from connection block -

not required)

Alarm Relay

External Modem PortEthernet

Fuse (1 Amp) 30 V d.c.

Direct ConnectPort

Door latch

CPU Card

Battery Jumper circuit

Address Switch & JP3 JP4

Figure 2- AK-SC255 Internal port and connection layout

• Jumper 3 and Jumper 4 (JP3 JP4) - check that jumper pins are located on both pin sets. With JP3 and JP4 jumpers in place, this enables correct Com-Trol communication via RS485 port.

• Remove any terminator resistor found in the AK-SC255 RS485 Modbus communi-cation port (when used for Com-Trol local bus)

• Enable battery back up via Jumper 5 (JP5)

5

2.0 Programming AK-SC255 Database

One of the central tasks involved in retro-fitting the Com-Trol front end unit is the configuration of the AK-SC255 database that allows the Danfoss controller to fully replace the Com-Trol unit(s). Review the following section for guidance in creating the AK-SC255 database, which replaces the Com-Trol 4k/4K2e systems.

Using the Com-Trol Ezcom software, pull back and save the existing Com-Trol 4K or 4K2e controllers to be converted to the Danfoss AK-SC255

The Com-Trol files can be viewed with the Com-Trol Ezset software utility

Using the Danfoss AKA65 software service tool, create a blank database by using the simulate function. Ensure the correct version of simulated database is created to avoid compatibility issues on site (i.e. use the same version for the database pro-gramming that will be installed in the physical AK-SC255 unit) 3a Start configuration of the AK-SC255 database by setting the Legacy I/O type to COMTL (found in the Store Info / Preferences) Figure 3 3b Configure the Modbus channel under the Communications / I/O Network / Rescan Channels page. If Danfoss AK I/O boards are also to be used, ensure the channel ‘LonWorks’ is checked also. Figure 4 3c When assigning Com-Trol board points, first press F4 to convert the board-point type to the Com-Trol format. Figure 5

Relay configuration (table 1)

Sensor offsets used in Com-Trol controllers should be transferred to the AKA65 database

Com-Trol format (Ezset) Danfoss format (AKA65)

Relay Normal N-Closed

Invert N-Open

Digital Input Normal Open

Invert Closed

Table 1

1

2

3

4

5

Preferences screen(set Legacy I/O to COMTROL)

Sensor Configure screen(select from drop down type list)

Rescan screen(check Modbus)

Figure 3 Figure 4 Figure 5

new Com-Trol sensor selection

6

3.0 Network wiring / power It is important to ensure the network connections between the AK-SC255 and Com-Trol I/O devices are correctly made. A so called daisy chain format must be followed where the Dx + terminal on the AK-SC255 RS485 port connects to the + Data connection on the Com-Trol board. Dy - on the AK-SC255 must go to the - Data, and Shield must go to Common. Table 2 highlights the naming differences between Com-Trol and Danfoss.

Com-Trol I/O network format AK-SC255 RS485 Modbus port (used for Com-Trol I/O local bus)

+ Data Dx+

- Data Dy-

Figure 6 - Daisy chain network topology

Com-Trol I/O

Com-Trol I/O

Com-Trol I/O

AK-SC255

Figure 7- Com-Trol recommended wiring standard (extract from Com-Trol MCS-4xxx and 4K2e Install manual (F-27262-4)

Table 2 - Daisy chain network connections

Dx

+D

y -

Shie

ld

7

4.0 Appendix

Site Survey considerations

Location of Com-Trol 4k or 4ke - Note whether box mount or panel-mount.

Modem location (6k)

Danfoss Logger requirements?

Leak detector location and type

Note any HGM 300 units and number of zones

Document Com-Trol hardware copyright dates. Dates prior to 1999 MAY cause compatibility issues (see figure 8)

Determine optimum Ethernet switch location and Cat5 cable length

Danfoss highly recommends that all power, communications, grounding connections and termination resistors pertaining to the Com-Trol I/O boards are reviewed before conversion to the Danfoss AK 255.

Figure 8 - According to previously published Schneider Electric documentation a compatibility issue may occur with IO boards manufactured prior to 1999. The issue involves the local bus communications between the AK-SC255 and these older IO boards. When upgrading to a AK-SC255 be aware that it may be necessary to replace some of the IO boards.The boards that may need to be replaced can be identified by a copyright date prior to 1999 printed onthe printed circuit board. Typically only a few boards need to be replaced per installation.

Combining multiple Com-Trol front ends to AK-SC255 unitsThere may be site configurations where several Com-Trol controllers are being retro-fitted for a reduced number of AK-SC255 units. Typically one-to-one replacements will make for simplified retro-fit project, but it is possible to combine Com-Trol functionality in a reduced number of AK-SC255 controllers. The following points must be taken under consideration before commencing work

• I/O limitation (Com-Trol I/O addressing considerations)

-16 point analog input board = 2 addresses -8 channel stepper board = 2 addresses -If a 16 channel AI or ESB board is addressed as#3, address 4 is allotted for the 2nd half of that I/O board the next AI board will need to be addressed as #5 (same as Com-Trol)

Extended addressing switchWhen migrating one I/O network to another it is often required to readdress I/O in order to maintain unique addresses in one network run. Use the JU1 Extended addressing jumper to assign an address range beyond 16. Note, some Com-Trol I/O boards before 2003 may not have the address extender jumper, in this instance a newer I/O board is required

For addressing boards higher than 16, move jumper to position ‘32’. Only boards used with 4K2e controller are capable of addresses higher than 16. (Not all I/O boards have extended addressing)

8

Com-Trol Communications wiring standards Extract from Com-Trol Installation Manual (drawing 945004BH00a 08/30/08) Copyright T.A.C©

9

Recommended Installation guide - Com-Trol to Danfoss USCO.EI.RF0.A3.22.CT / 521U0185 ©Danfoss 09-11

www.danfoss.usADAP-KOOL® Refrigeration Control Systems is a trademark of Danfoss A/S, www.danfoss.com

Danfoss can accept no responsibility for possible errors in catalogs, brochures, or other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.