Danfoss AKS 4100,4100U Cable Version Installation Guide

Danfoss AKS 4100,4100U Cable Version

Instruction

1. 4-20 mA output displayed as bar graph and in percentage [%]
2. Measurement name (in this example, DISTANCE)
3. Device tag name
4. Measurement reading and unit
5. Device status (markers) Marker 1, 2 and 3 (Error)
   Hardware problem; the Signal Converter hardware is defective. Contact Danfoss. Marker 4 and 5 (Notification)
   Depending on the level, the marker is ON or OFF. Used for Danfoss service information only.
6. Keypad buttons
7. Flashing star indicating unit in operation.

• DISTANCE is a display option.
  If the display is set to “DISTANCE” the displayed value will be the distance from the Reference  point to the top surface of the liquid refrigerant (see fig. 5).
• LEVEL is display option.
  If the display is set to “LEVEL” then the value displayed will be:
  PROBE LENGTH (entered in QUICK SETUP)
  DISTANCE (see fig. 5).
• OUTPUT (%) is display option.
  Will represent the level of refrigerant,in percent, scaled (entered in QUICK SETUP) according to: SCALE 4 mA (0%), SCALE 20 mA (100%) (see fig. 5).
• OUTPUT I (mA) is display option.
  Will represent the level of refrigerant,in 4-20 milliampere, scaled (entered in QUICK SETUP) according to: SCALE 4 mA (4 mA), SCALE 20 mA (20 mA) (see fig. 5).

Please observe that AKS 4100/4100U is intended to always be installed in a standpipe (column/bypass/stilling well). A Standpipe is commonly used when:

• Servicing the AKS 4100
• There is highly conductive foam in the tank.
• The liquid is very turbulent or agitated.

Refrigerants

AKS 4100/4100U is designed specifically to measure liquid level in the most commonly used refrigerants, including R717(ammonia), HCFC, HFC and non corrosive gases/liquids.
AKS 4100/4100U can also be used with R744  (CO2) in the coaxial version. Please see the technical brochure for further details.

Basic data

AKS 4100/4100U is a passive 2-wired 4-20 mA sensor that is loop powered.

Supply Voltage
14-30 V d.c. Min/Max. value for a max. output of 22 mA at the terminal

Load
RL [Ω] ≤ ((Uext -14 V)/20 mA).

• Default (Error output set to 3.6 mA)
  RL [Ω] ≤ ((Uext -14 V)/22 mA).
• (Error output set to 22 mA)

Cable gland 

• Cable gland
• AKS 4100 PG 13, M20×1.5 ; (cable diameter:
• 6-8 mm (0.24-0.31in.)
• AKS 4100U ½ in. NPT
• Terminals (spring loaded)
• 0.5-1.5 mm2 (~20-15 AWG)
• Enclosure
• IP 67 (~NEMA type 4X)
• Refrigerant temperature
• –60°C/100°C (–76°F/212°F)

Refrigerants

The listed refrigerants are qualified and approved by Danfoss:

• R717 / NH3: –40°C / +50°C (–40°F / +122°F)
• R744 / CO2: –50°C / +15°C (–58°F / +59°F)
• HCFC:
• R22: –50°C / +48°C (–58°F / +118°F)
• HFC:
• R404A: –50°C/ +15°C (–58°F / +59°F)
• R410A: –50°C /+15°C (–58°F / +59°F)
• R134A –40°C /+50°C (–40°F /+122°F)
• (Further details in the Technical Brochure)

Ambient temperature

• –40°C / +80°C (–40°F / +175°F)
• For HMI : –20°C / +60°C (–4°F / +140°F)

Process pressure

• –1 barg / 100 barg (–14.5 psig / 1450 psig)
• Mechanical process connection with 5 m (197 in.)

Ø2 mm (0.08 in.) stainless cable:

• AKS 4100 G1 inch pipe thread.

Aluminium gasket included

• AKS 4100U ¾ in. NPT (Further details in the Technical Brochure)

Mechanical Installation

Preparations prior to Mechanical Installation Disassemble the Signal Converter from the Mechanical process connection (use 5´mm hex key, see fig. 6). Fit the red protection cover on top of the Mechanical process connection to protect it againt any moisture or dirt paticles.

Content supplied (fig. 1)

1. Signal Converter (with or without HMI)
2. Mechanical process connection with 5 m (197 in.) Ø2 mm (0.08 in.) stainless wire  Counterweight
3. Accessory bag comprising:  3 mm set screws.
4. Red cover to protect mechanical process connection  prior to mounting Signal converter. Setting label.

Note:
Stand pipe design guidelines:

The side connection pipes must NOT penetrate into the stand pipe (fig. 2a)

Recommended diameter of the side connection pipe: 0.5 x stand pipe diameter (e.g. if stand pipe has diameter DN100, the side connection must be diameter DN50 or smaller) (fig. 2a).
If above design guidelines for side connection are not fulfilled, one of the following options are recommended:

1. Increase Detection Delay. Parameter 2.3.6.
   We recommend to increase the Detection Delay (parameter 2.3.6) from the standard 0 mm to a value below the lowest point of the top side connection plus 50 mm (fig. 2a). Changing the Detection Delay (parameter 2.3.6) does not require changing the (0% ) 4mA and (100%)20mA settings in the AKS 4100/4100U Within the Detection Delay zone, no measuring will take place.
2. Exchange from Cable to Coaxial version.

The stand pipe must have the SAME diameter through out the entire length. If standpipe diameter differs in width (fig. 2b) the Cable version is not recommended. Coaxial version should be used.
Adjustment of the counterweight blades Allow 5 mm space between the guided blades and the inner wall of the pipe (see fig. 2c). Use side cutters to trim the guided blades to fit the actual standpipe diameter (see fig. 3).

Adjustment of the cable probe

Please observe that the stainless steel wire is not permanently creased or kinked.

Always use the reference point, at the Mechanical Process Connection (see fig. 4), as a starting point for all measuring to determine:

• Where to cut the cable.
• Probe length (see fig. 5)
• Scale 4 mA (see fig. 5)
• Scale 20 mA (see fig. 5)

Note the probe length, Scale 4 mA and Scale 20 mA for use later when programming the HMI  (Human Machine Interface) on the AKS  4100/4100U.

Follow these instructions and see fig. 4 & 5:

1. Measure the inner length of the Standpipe.
2. Preparation before cutting the cable Known data:
   Space below counterweight: 20 mm (0.8 in.) Steel wire insertion length in counterweight: 12 mm (0.5 in.) counterweight height: 33 mm (1.3 in.) Max Probe length =
   • Space below counterweight (20 mm (0.8 in.))
     The cable length =
     Max probe length
     + Steel wire insertion length in counterweight (12 mm (0.5 in.))
   • Counterweight height (33 mm (1.3 in.))
3. Measure out the cutting point of the cable. Measure from the reference point (fig. 4) and cut the cable.
4. Fit the counterweight on the cable and secure the two set screws with a 3 mm Allen Key (fig. 3).
5. Lower the counterweight down through the threaded hole. Make sure that the counterweight is gliding down through the pipe without any resistance and that the cable is straight (not touching the inner walls of the stand pibe or any incoming piping (see fig. 2a)).
6. Use a torque wrench to tighten the mechanical process connection (fig. 1, item 2) to 120 Nm (89 lb/ft).

Calculating the measuring range

• 4 mA setting for max. measuring range:
  • Max probe length
  • Counterweight height (33 mm (1.3 in.))
  • Bottom dead zone (see fig. 5)
• 20 mA setting for max. measuring range:
  Top dead zone (see fig. 5)

Example

Known data:

• Space below counterweight: 20 mm (0.8 in.)
• Steel wire insertion length in
• counterweight: 12 mm (0.5 in.)
• counterweight height: 33 mm (1.3 in.)

Preconditions:

• Factory setting is used
• Refrigerant = Ammonia
• Standpipe inner length = 3100 mm (122 in.)
• Max probe length =
• 3100 mm – 20 mm = 3080 mm
• (122 in. – 0.8 in. = 121.3 in.)

The cable length:

• Max probe length =
• + Steel wire insertion length in
• counterweight (12 mm (0.5 in.))
• – Counterweight height (33 mm (1.3 in.))
• 3080 mm + 12 mm – 33 mm = 3059 mm
• (121.3 in. + 0.5 in. – 1.3 in. = 120.4 in.)
• 4 mA Setting for Max. Measuring Range:
• Max probe length (3080 mm (121.3 in.))
• – Counterweight height (33 mm (1.3 in.))
• – Bottom dead zone (see fig. 5)
• (210 mm (8.3 in.)) = 2837 mm (111.7 in.)
• 20 mA Setting for Max. Measuring Range:
• = Top dead zone (see fig. 5) = 120 mm (4.7 in.)

How to mount the AKS 4100/4100U Converter

(see fig 6)

1. Unscrew the set screw with a 5 mm Hexagon key in the Signal converter.
2. Push the Signal Converter downwards tostop on the Mechanical process connection
3. Turn the Signal Converter to the wanted position and tighten the set screw with a 5 mm Hexagon key

Electrical installation/connection

Output terminals (fig. 7 and 8):

1. Current output –
2. Current output +
3. Grounding terminal

Electrical installation procedure

1. Use a 2.5 mm Allen wrench to loosen the cover stop.
2. Remove the terminal compartment cover from the housing.
3. Do not disconnect the wire from the terminal compartment cover. Put the terminal compartment cover adjacent to the housing.
4. Connect the wires to the device. Tighten the cable entry glands.
5. Attach the terminal compartment cover to the housing.
6. Use a 2.5 mm Allen wrench to tighten the cover stop.

Start up:

• Connect the converter to the power supply.
• Energize the converter.
• Devices with the HMI display option only:
• After 10 seconds the screen will display “Starting up”. After 20 seconds the screen will display the software version numbers. After 30 seconds the default screen (fig. 12) will appear.
• Precausions when changing from AKS 41/41U to AKS 4100/4100U

Note:

• AKS 41/41U supports both a.c. and d.c. supply whereas the AKS 4100/4100U is using d.c. supply only. Follow the instructions in fig. 9.
  
• Connecting to controller or PLC
• Follow the instructions in fig. 10 or 11.
  
• The current output will be set to 3.6 mA whenever the AKS 4100/4100 detects an error like Marker 1, 2 or 3 (see page 4).

Note:
The signal converter can be programmed with or without mechanical process connector assembled.

How to force mA output (all values below are only examples)

Optional Procedure

If the temperature condition in the stand pipe is known, a constant (dielectric constant of the refrigerant gas) can be entered (parameter 2.5.3 GAS EPS.R), in order to obtain lower Top and Bottom Dead Zone values (see fig. 5).

How to enter dielectric constant of refrigerant gas (all values below are only examples)

Saturated vapour dielectric constant (default value: 1.066)

Saturated vapour dielectric constant

How to change the language setting (Default: English)

Reset to factory setting]

• Go to SUPERVISOR menu (see page 7).
• Go to parameter 2.9.4 Reset Factory.
• Select RESET FACTORY YES
• Press 3 times to return to default screen.

Factory reset completed

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