Danfoss AK-SM 800A Series System Manager User Guide

1. Product Introduction

1.1 Product Introduction

The Danfoss System Manager AK-SM 800A series is an advanced refrigeration control system designed for the Food Retail market. It builds upon previous System Manager models with enhanced electronics, new operating system (Linux-based), and IT industry standard security protocols like HTTPS and WPA2 encryption. Key features include an enhanced touch screen UI/UX, a full HTML5 web browser (StoreView Browser 5 - SvB5), a new Utilities App supporting mobile devices, retro-fit readiness, extended history capacity, and secure Wi-Fi access.

Series Features (Model Dependent)

• Built-in standard IT security best practices and protocols (HTTPS, Secure e-mail, Encrypted data, secure software update packages).
• Full Web browser interface utilizing modern web technology (HTML5).
• Mobile-ready utilities for user-friendly tasks like software updates and backups.
• Refrigeration Control (centralized and de-centralized).
• Lighting Control (centralized and de-centralized).
• HVAC Control (centralized and de-centralized).
• Energy saving technology (built-in).
• Master Schedules (Central Defrost, Case lighting, Store / Outside Lighting, Night setback, Shutdown).
• Flexible Alarm Routing / output (e-mail, IP address, relay).
• Built-in field bus options (Modbus, LonWorks®, SNMP IP, CANbus - future update).
• Full color VGA Local touch screen.
• Built-in Buzzer & 2-tone LED for easy local alarm notification.
• Custom graphics for creating simple and clear graphic screens.
• Extended History logging for more data points.
• Alsense™ ready for digital services and reporting.

1.2 Specifications

Environmental Range: Operating temperature: -10 to 50 °C (14 to 122 °F) @ 95% RH (non-condensing). IP20.

Approvals: UL file: E31024 61B5 Class 2 or LPS in accordance with NEC. Enclosure rating type 1. FCC ID: X02SPB209A. IC ID: 8713A-SPB209A.

Electrical Range: Supply connections: Use 16 AWG or larger wires rated for at least 75 °C (167 °F). Copper conductors only. ~ 100 - 240 V AC 50/60 Hz, 12 W. Built-in alarm relay.

Contact Voltage: Up to 240 V. Load: AC-1 (Ohmic) Current rating: 5 Amp. AC-15 (inductive) Current rating: 3 Amp.

Size: Unit Width: 295 mm (11.6"), Unit Height: 235 mm (9.3"), Unit Depth: 65 mm (2.5"). Mounting holes Width: 246 mm (9.7"), Mounting holes Height: 175 mm (6.9").

LCD Touch Screen: Active TFT touch (thin-film transistor), SVGA 800 x 600.

LCD Touch Screen Cleaning: Use a soft lint-free cloth, dry or lightly dampened with mild soap cleaner or Ethanol (max 4% Ammonia). Avoid acidic/alkaline cleaners or organic chemicals like paint thinner, acetone, etc.

Declarations of Conformity: Regulation 2005/37/EC, EN 12830, EN 13485, HACCP 080R1215, CE, C-Tick, UL E31024.

WARNING: To avoid risk of injury from electric shock, ensure correct electrical isolation before working within the enclosure.

International Certifications: Este equipamento não tem direito à proteção contra interferência prejudicial e não pode causar interferência em sistemas devidamente autorizados. Para maiores informações, consulte o site da ANATEL - www.anatel.gov.br.

FCC Compliance Statement: This device complies with Part 15 of the FCC Rules. Operation is subject to two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received. CAUTION: Changes or modifications not expressly approved could void your authority to use this equipment.

Industry Canada Statement: This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to two conditions: (1) this device may not cause interference, and (2) this device must accept any interference. Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence.

EU Conformity Notice: Danfoss A/S declares that the radio equipment type AK-SM 800A is in compliance with Directive 2014/53/EU. Full text available at www.danfoss.com.

2. Installation and Start-up Configuration

2.1 Installation

Tools Needed: Bubble level, small slotted screwdriver, Torx 8 screwdriver, screwdriver for fixing, pen, larger slotted screwdriver.

Wall Mounting (Box): Attach screw to wall, mount AK-SM 800A, loosen/remove technician lid, level unit, mark and attach connector part with screws.

Wall Mounting (Wiring): Insert cables through rubber grommets, strip cables and wires, secure wires in connectors, strain relief cables.

Wall Mounting (Panel Recessed): Machine a hole of 280 x 220mm. Insert AK-SM 800A. From the backside, slide fasteners into housing and secure with screws. Remove technician lid and push cables inside housing.

2.2 Connections

The AK-SM 800A features various connections including USB 2.0 (x2), CANbus, Power, Alarm Relay 1 & 2, Ethernet (Eth0 for WAN, Eth1 for Field), MODBUS 1 & 2, and LON (RS485) or LON (TP78).

2.3 Network Topology

The AK-SM supports MODBUS and Lon RS485 connections. Follow standard topology guidelines for Lon RS485, including maximum cable length (1200m, use repeater for longer), twisted pair cables (with or without screen), and termination resistors (120 Ohm) on network ends. For MODBUS, use screened twisted pair cables, with repeaters for lengths over 1200m. MODBUS channels 1 and 2 are available, supporting unique node addressing for each device. MOD1 supports Danfoss and pre-coded devices, while MOD2 supports Danfoss and 3rd party devices with configurable scan address ranges.

2.3.1 Lon RS485 Topology

Devices are wired controller to controller without branches. Use 120 Ohm terminators on the last device and enable the Termination Switch on the AK-SM 800A. Screened wires must be looped from device to device and not connected to anything else. The AK-SM 880A (080Z4029) is available with a pre-installed LonWorks® TP78 option card for migration from older systems.

2.3.2 MODBUS Topology

Two Modbus channels are available. Both can be enabled simultaneously with unique node addressing. MOD1 is for Danfoss devices, MOD2 for Danfoss and 3rd party devices. Screened cables are required, with repeaters for lengths over 1200m. Termination is required on network ends. The System Manager can be in the middle of a network run with termination OFF. Modbus device addresses can range up to 199. Ensure correct baud rate configuration for repeaters (e.g., 19.2, 38.4).

2.4 First Time Startup

An initial wizard guides through basic settings: Language, Administrator setup (username/password - caution: no recovery by Danfoss), Date/Time/Format, System Units, Connector Notification, Network Setup, and Software Update notification. A system reset is required after completion. Local screen login requires valid credentials. A 'Forgot Credentials' option exists, but passwords are encrypted and not recoverable by Danfoss; a reset requires specific unit information and may involve technical support.

2.5 IP Configuration and Suggested Security Settings

Danfoss emphasizes security. The AK-SM 800A is designed for secure networks behind firewalls. Recommendations include: Do not connect to open/public networks, use strong passwords, enable HTTPS, and do not share credentials. Consult ISO/IEC 27002:2013 for guidance. The AK-SM 800A supports auto-negotiated 10/100 Ethernet speeds and full/half duplex. Key ports include: 5136 (UDP/SNMP), 1041 (UDP/PI-200), 443 (TCP/HTTPS), 80 (TCP/HTTP), 5003, 5005 (UDP/Host network communication).

3. Navigation and Use (Local Screen)

3.1 Log in Screen

Access to system information requires valid username and password. A 'show' checkbox aids credential input. Password reset procedures are detailed, emphasizing local screen access for security. For North America, Alsense™ can initiate resets.

3.2 Home Screen / Dashboard

The default screen after login. Users can configure Dashboard, Equipment, or Graphics as the home screen. The Dashboard provides access to functions via icons:

• USB Flash Drive: Access via USB icon (solid when detected). Menu options include Eject, Update Software, Export (Database, HACCP, Reports, etc.), and Import. Max USB size 32MB.
• AK-SM 800A Wi-Fi Access Point: If enabled, a Wi-Fi icon appears. Connect mobile devices or laptops for access to Utilities (mobile) or SvB5 (desktop). Wi-Fi is disabled by default and reverts to disabled upon reset.
• Info Button: Provides About (unit info, software version, MAC/IP), Licensing, Terms, and Connections details.
• Log out: Exits the system. Auto log-off occurs after 20 minutes of inactivity (configurable).

3.3 Home Screen – Menu Bar

The menu bar offers quick links. The 'grid button' opens a fly-in menu.

• Dashboard: Displays active alarms (count and list). Alarms can be acknowledged individually or in bulk. Options include Cleared, Service, Status, and Info screens. 'Top 5 alarming assets' provide insights. Enabled Energy Features are highlighted.
• Custom Screen: Allows display of up to 15 user-defined data points. Configured via Configuration -> System -> Custom Screen.
• Equipment: Lists installed equipment (Refrigeration, HVAC, Lighting, Misc.). Press '>' for device detail screens.
• Graphics: Displays loaded graphics. Configuration is done via Utilities.

4. Navigation and Use (SvB5 Browser)

The SvB5 (StoreView Browser 5) is the web browser interface providing full system access. It utilizes HTML5 and requires a supported browser (Chrome, Edge, Safari). Connections are encrypted via HTTPS, though browsers may show warnings for self-signed certificates.

4.1 StoreView Browser 5 (SvB5)

Provides full system access, including features not on the local screen (e.g., wizards). Access via HTTPS address. Supports Chrome, Edge, Safari. Self-signed certificates may trigger browser warnings.

4.2 AK-SM 800A Utilities

Accessed via the 'grid icon' in the browser interface. Utilities include Information (unit details, exportable as CSV), Diagnostic Log (for technical support), Software Update (local file or web connectivity), EDF Update, Graphic Editor, Export/Import Database, Cleared Alarm Log, and Browser Certificate management.

4.3 Utilities – Software Update

Keeps the AK-SM 800A updated with bug fixes, enhancements, and security patches. Updates can be via 'Local Stored File' (SPK package) or 'Web Connectivity'. Software packages have digital signatures for integrity. Power must not be interrupted during updates. All units in a host network must have the same software version.

4.4 Food Safety Logging (HACCP)

Facilitates food safety reports. Allows manual tagging of history data points as 'HACCP'. Supports up to 200 history points at a 15-minute sample rate. Reports can be generated locally or via browser (CSV/PDF export). Scheduled daily email exports are possible. Data is secured for 18 months.

4.5 File Menu

Includes Preferences, Refrigeration Report (exportable to PDF, CSV, Print), Download Report (unit info, configuration, alarms, etc.), and Log Out.

4.6 Dashboard

Provides a consolidated system view, showing configured AK-SM 800A units on a host network. Allows zooming into application panels. Access to individual units via configuration menu.

4.7 Managing Alarms

Active alarms are shown on the Dashboard. Clicking an alarm line provides details and options to Mute/Acknowledge. Global alarms are accessed via the Alarms tab. Service screen allows test alarms, suspending alarms, clearing logs, and configuring internal relays.

4.8 System View

Offers a graphical view of configured controls (Racks/Packs, evaporator circuits). Hovering over icons shows information. 'Show Detail' button reveals Status, Settings, and Manual Operation.

4.9 Device Detail

Provides detailed asset information and settings. Includes Application/device selection tree, Device Detail Menu, Device details and history plot, and Device Settings.

4.10 Schedule View

System-wide view of schedules (Shutdown, Defrost, Case Lights, Night Setback). Schedules can be viewed graphically or as text tables, and exported.

4.11 History (Logs)

Collects and records control parameters. Up to 8 data points can be viewed simultaneously. Toolbar functions include Export (hst, csv), Load History, Convert hst to csv, Load/Save history groups, Preferences, Show/Hide Grid, Reset Zoom, and Page controls. Data can be collected for specific time ranges.

4.12 AK-SM 800A Host Network Configuration

Supports up to 10 interconnected AK-SM 800A units for larger applications. Requires IP Ethernet connection for each unit. Primary device configuration involves setting the rotary switch to '0' and enabling 'Host Network' in Configuration -> Comm. Secondary devices are configured with unique rotary switch addresses. Network status can be verified locally.

4.13 Secondary Device Configuration

Set rotary address switch to a unique number (e.g., '1' for Secondary Address 1). Reset unit, verify Primary IP address in Configuration -> Comm, enable 'Host Network', and enter the total number of System Managers on the network.

4.14 Device Upload / Download

Upload: Retrieves field bus controller settings to sync with the AK-SM database. Used when replacing older controllers or synchronizing existing configurations.

Download: Sends controller settings from the AK-SM database to field bus controllers. Used for pre-programming devices before site installation.

4.15 Device Management

Controls the amount of active device files to conserve system memory. Device groups can be Enabled/Disabled. A limit of 1000 device selections applies. EDF files not packaged with the AK-SM are available from the Danfoss Support website.

5. Configuration

This section details commissioning and configuration steps, primarily via the web browser interface. It covers centralized (using I/O modules) and decentralized (using Pack/Case controllers) control methods.

5.1 Configuration Wizards

Web Wizards simplify initial setup:

• Preferences Wizard: Configures language, store names, units, time, date, daylight savings.
• Users Wizard: Creates/modifies users, user groups, and authorization levels (up to 22 users, 7 authorization types).
• Licensing Wizard: For entering new license functionality (future feature).
• Refrigeration Layout Wizard: Scans field bus nodes, addresses/names devices, and maps refrigeration devices into suction groups. Supports Danfoss Pack and Case controllers.

5.2 Copy Wizard

Speeds up commissioning by copying settings from a 'source' device to like-type devices. Can copy controller settings, alarm configurations, and history points. Supports saving/loading settings to/from a file. Note: Auto-polling is temporarily suspended during the wizard. Main switch of target devices is automatically turned off and on. Not fully compatible with Danfoss AK2 platform devices.

5.3 Configuration – Time

Configures system time, time zone, operating hours, daylight savings, and holidays. Operating hours can be referenced by relative schedules.

5.4 Configuration – System

System: Defines store/region names, unit preferences, authorization levels. Options include Home Screen selection, Idle timeout, Generic Device Write Errors, Offline Status Indicator, Clear Database. Up to 100 users can be configured. 'Require Strong Password' is recommended.

Users: Manages user accounts, permissions (Configuration, Authorization, Refrigeration, HVAC, Lighting, etc.), manual operations, and alarm configurations.

Licensing: View current license and MAC address.

System Report: Configures what aspects of the AK-SM 800A are included in reports.

Files: Manages Internet Files, Device Files (EDF), Device Management, and MCX Upgrade.

Custom Screen: Configures up to 15 points for the AK-SM 800A dashboard local screen.

5.5 Configuration – Comm

Configures IP network settings for two Ethernet connections (eth0 for WAN, eth1 for Field Bus). Options include Internet access, HTTPS/TLS usage, Header Authentication (for XML), DNS, DHCP, and Host Network configuration.

5.6 Configuration – Alarms

Manages alarm settings including Connections (email, remote, XML), Service (test alarms, suspend, clear logs), Alarm Routing (using an Alarm Action Matrix), Relays, System alarms, and Offline alarms.

5.7 Offline

Configures offline communication alarms for controllers and I/O modules. Allows association of alarms with calculations.

5.8 Control

Defines application areas (Refrigeration, HVAC, Lighting, Miscellaneous). Supports centralized (I/O) and decentralized (field bus) control. Configuration involves setting up Racks/Packs, suction groups, and associating controllers. Upload/Download functions synchronize controller settings with the AK-SM database. The Copy function allows settings transfer between similar devices.

5.9 Configuration – Network Nodes

Initiates network scans to detect controllers and I/O modules. Provides Node Overview, Scan Status, Configuration Status, Duplicates check, and Upload/Download tabs. Enhancements for Modbus include scan address range definition and support for 3rd party devices on Modbus channel 2.

5.10 Configuration – History (Inc HACCP points)

Allows collection and recording of control parameters. Up to 3000 points (plus 200 for HACCP) can be configured. Options include Auto Configure History, Clear History Configuration/Log, Start/Suspend History. History points can be set to Polled or Event Driven. A maximum of 45 history points per device is recommended.

5.11 Configuration – History

Detailed configuration of history points for Controllers, Relays, Sensors, On/Off Inputs, Variable Outputs, and other miscellaneous points. Supports standard (polled) and event-driven history collection.

6. Master Control Functions

Covers energy saving features, scheduling, and load shedding.

6.1 Rail Heat

Manages energy output to case trim heaters. Options include using Night Setback Schedules, AK I/O relays (controlled by calculated or direct dew point), or Adaptive Rail Heat control (using humidity/temperature sensors connected to AK-SM).

6.2 Schedules

Allows configuration of multiple schedules for Case Lighting, Night Setback, Shutdown, Defrost, and Coordinated Defrost. Schedules can be time-based, digital input-based, or a combination. Controllers can be associated with schedules.

6.3 Customized Control

Enables triggering on/off events based on user-configured control triggers (time schedule and/or digital input) to switch specific controller parameters.

6.4 Suction Pressure Optimization

Automatically optimizes suction pressure based on system load to save energy and reduce compressor wear. Identifies the 'Most Heavily Loaded' refrigeration point and adjusts suction pressure accordingly while maintaining temperature. Requires plant survey for optimal results.

6.5 Configuration of Suction Optimization

Enables suction optimization in Pack controller configuration. Allows setting maximum float pressure, post-defrost delay, and defining Po stop/alarm conditions.

6.6 Adaptive Liquid Management

The CO Adaptive Liquid Management (CALM) solution utilizes evaporator surface for energy savings in CO2 refrigeration systems. It requires compatible Case and Pack controllers. CALM can be enabled in the AK-SM 800A Series System Manager. Excludes specific case controllers by setting 'Adaptive Liquid Management' to 'No'. Returns to normal MSS control if CALM signals are not received or valid.

6.7 AKC ON (Evap shutdown when injection off)

Detects pack shutdown conditions and signals configured evaporator controllers to close their AKV valves, reducing the risk of liquid hammer or compressor damage upon restart. Must be configured per pack suction group.

6.8 Coordinated Adaptive Defrost

Allows case controllers to skip unnecessary defrost cycles based on real-time evaporator performance monitoring. Calculates ice build-up by comparing refrigerant mass flow and air flow. Defrost cycles can be coordinated across multiple case sections within a store.

7. Advanced Features and Configurations

7.1 Managers Override

Allows authorized users to place Lighting zones and/or HVAC units into an override state. Options include Timed Override, Interrupt enabled, Override all zones/units, and Bluetooth® Interface Override for securing wireless interfaces.

7.2 Light

Supports lighting schedules and control via Danfoss I/O modules or lighting panel communications. Configuration involves setting the number of lighting zones, photocell usage, and control parameters like trip level, delays, and minimum on/off times.

7.2.1 Lighting Configuration

Detailed configuration within the Light tab. Options include number of control relays, trip level percentage, pre/post delays, minimum on/off times, override switches, zone names, photocell selection (None, Inside, Outside, Skylight), control methods (Schd and photo, Schd or photo), and schedule types (Standard, Relative).

7.2.2 Addresses

Assigns AK I/O addresses (Board & Point) for lighting control components like relays and sensors.

7.2.3 Alarms

Configures alarm points for lighting control, linking them to alarm levels and actions defined in the central alarm routing page.

7.3 Dimming Control via AK I/O

Enables dimming of lighting controls using Danfoss AK I/O dimming systems. Requires specific configuration in the Light tab, including 'Schd and photo' control method and 'Skylight' selection for dimmer night setback. Defines minimum/maximum output levels and uses a dimming algorithm based on foot-candle readings.

7.4 HVAC Configuration

Supports HVAC control via centralized (AK I/O) or decentralized (field bus) methods. Configuration involves defining the number of HVAC units, phase loss monitors, humidity/dewpoint sensors, and selecting control types (AHU, RTU, or field bus controller). Detailed settings cover fan control, cooling/heating stages, freeze protection, night setback, and dehumidi cation.

7.5 Miscellaneous Configuration

Monitors and controls miscellaneous application areas using Danfoss AK I/O modules. Includes configuration for relays, sensors, on/off inputs, and variable outputs. Allows custom conversion factors for non-Danfoss sensors and alarm configuration for any miscellaneous point.

7.6 Energy

Details energy saving features and configurations, including energy measurement and load shedding.

7.7 Energy Measurement / Load Shed

Configuration related to energy measurement and load shedding capabilities.

7.8 Detail – Energy

Provides detailed information on energy-related functions.

7.9 Enterprise Load Shed (via Danfoss EDS Service)

Information on enterprise-level load shedding managed through Danfoss EDS Service.

7.10 Demand Limiting

Configuration for demand limiting features.

7.11 Boolean Logic / Calculations

Enables the creation of Boolean logic and calculations for advanced control strategies.

8. Device Support

Details support for various Danfoss control systems and tools.

8.1 Danfoss AKC Support (Via AK-PI 200)

Information on supporting Danfoss AKC controllers using the AK-PI 200 tool.

8.2 Service Tool Support

Information on support provided by the Service Tool.

8.3 CoreSense™ (MODBUS) Support

Details on CoreSense™ support over MODBUS.

8.4 Technical Data

General technical specifications.

8.5 Generic Capacity-A / B

Information on generic capacity parameters.

8.6 Specifications

Detailed specifications for the system.

9. Ordering

Information related to product ordering.

10. Document History

Details revisions and updates to the document.

11. Glossary of Terms

Definitions of key terms used throughout the document.