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BITZER ACP LINK

Original document

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Type list
BITZER ACP ammonia compressor packs with BITZER ACP LINK

(PLC software v1.1.0.0, CM-SW firmware 2.9.89.00, Electrical panel IO-module program version 1.05)

Skilled installer, Electrically skilled person

Eingewiesener Monteur, Elektrofachkraft

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Содержание ACP Link

Страница 1: ...2 Type list BITZER ACP ammonia compressor packs with BITZER ACP LINK PLC software v1 1 0 0 CM SW firmware 2 9 89 00 Electrical panel IO module program version 1 05 Skilled installer Electrically skil...

Страница 2: ...ing 15 6 1 Transport and storage 15 6 2 ACP LINK panel mounting 15 6 3 Electrical panel IO module M172 mounting 15 6 4 Economizer system module CM IO mounting optional 15 7 Electrical connection 16 7...

Страница 3: ...guration electrial panel IO module M172 33 9 7 Configuration variable speed drives VSD 34 Check of direction of rotation with VSD 34 Variable speed drive configuration WEG CFW11 for operation with ACP...

Страница 4: ...ol functions 74 12 5 Alarm warning and timer functions 78 13 Parameter and timer overview 80 13 1 Overview of parameters in ACP LINK PLC HMI 80 13 2 Overview of timers in ACP LINK 85 13 3 Overview of...

Страница 5: ...essor Packs have been built in accordance with state of the art methods and current regulations Particular importance was placed on user safety The notes given in the Operating Instructions SB 600 mus...

Страница 6: ...nel DANGER Life threatening voltages inside the electrical panel housing Contact can cause severe injury or death Never open electrical panel housing during operation Switch off the main switch and se...

Страница 7: ...f 5 8 4 Hz 9 8 mm s2 f 8 4 150 Hz Display Schneider HMIDT651 HMIG3U PLC Schneider TM251MESE Emergency power switch WEG BC01F Breakers Main 230V 120 Vac 13A PLC HMI M172 24 Vdc 6A OAHC oil sep 230 120...

Страница 8: ...C 5 95 RH non condensing Terminal blocks M172ASCTB42 M172 Performance 42 I Os screw terminal blocks Digital outputs 12 outputs CN6 CN14 1A 250V CN7 CN8 CN9 CN15 3A 250V Digital inputs 2 fast inputs 10...

Страница 9: ...230 Vac Schrack RT424730 1 pcs 1 W 120 Vac Schrack RT424615 Resistor for level control release ECO 1 pcs 69 0 k 4 5 Additional motor connection box The additional motor connection box is fixed to the...

Страница 10: ...10 CT 600 2 Type 300A 1A WEG 14498543 Type 750A 1A WEG 14289837 Type 1000A 1A PTC output See motor data sheet...

Страница 11: ...of the modules are connected to local sensors and actuators for the different main components ACP LINK panel with PLC and HMI The ACP LINK panel is the central component that handles the monitoring p...

Страница 12: ...essor and oil system module it monitors protects and operates the economizer system The module handles the liquid level control valve suction bypass and oil return valve Communication with ACP LINK pa...

Страница 13: ...ed in the different functions A set of signals including the status for all alarms and warnings are shared for communication to a SCADA system via Modbus TCP IP See section 15 for a complete list of a...

Страница 14: ...he allowed area Besides the capacity control different control functions are used to handle functions related to the external inputs like start permission alarms and digital feedback outputs The oil s...

Страница 15: ...ick on flange with the cables already installed on the ACP unit The connection may need to be established after placement of the unit and the ACP LINK panel Connection to the plant and electrical pane...

Страница 16: ...of the connectors primarily in the bottom of the panel Greyed out boxes are to be disregarded by the customer since they are internally connected NOTICE Compressor high pressure safety chain X8 0 1 2...

Страница 17: ...120 VAC O BK Screw terminals behind connector 5 L HP Safety Chain 230 120 VAC O GR 4 Internally connected Cable 5x1 0 BN BL GR BK GND Valid from 03 2019 3 2 N Customer supply 230 120 VAC I BL 6A 1 L B...

Страница 18: ...to 250V 1A CN13 AI9 Process temperature PT1000 default AI10 Auxilary temperature not used PT1000 default AI11 Remote setpoint 1 0 10V default AI12 Remote setpoint 3 External Capacity Limiter in Auto...

Страница 19: ...input from customer Supply from 24VDC over 2A Fuse Customer fuse DI1 Emergency stop input from customer safety chain COM_DI 24VDC Common CN2 AO4 Not used spare AO3 Speed setpoint Hz for VSD Comp 3 0 1...

Страница 20: ...iring and connection The Modbus RTU network is proprietary for the ACP LINK only and may not be connected to other devices The maximum cable distance between devices on the Modbus RTU network is 100 m...

Страница 21: ...CT 600 2 21 Modbus RTU Network overview with economizer ACP Link Panel...

Страница 22: ...t of the PLC Firmware update must be done on new PLC s and can also be required in relation to certain program updates Firmware update will remove all data and settings Backup configuration and settin...

Страница 23: ...MAIN_CONTROLLER1 4 If zipped take the zip file and extract directly onto a formatted SD card Fat32 Root folder shall contain two folders sys and usr The files will have this structure Copy them all Ct...

Страница 24: ...ow further the steps 3 and on in section 8 1 2 4 Follow procedure in section 8 1 4 to set IP addresses to unique values for each PLC and HMI Re configure IP addresses after program update Re configura...

Страница 25: ...eded Firmware update will remove all data and settings Backup configuration and settings before firmware update Update Schneider firmware ACP LINK panel HMI The Schneider HMI comes with firmware insta...

Страница 26: ...ommunication between PLC and HMI will resume 12 If the communication to the PLC does not resume it may be necessary to configure the IP address and or the PLC node name which the HMI looks for See sec...

Страница 27: ...y 15 to 20 sec to copy the data The yellow light will turn on while reading from the USB Stick and turns off when the process is finished 5 Power cycle the M172 electrical panel IO module turn off the...

Страница 28: ...r between PC and CM SW 01 or CM IO module connection CN 14 6 Select Connect BEST converter 7 Wait for connection to establish 8 Check Overview Firmware version Firmware version must be 2 8 82 00 or ne...

Страница 29: ...s recommended to power cycle the module after a software update reconnect to BEST after power cycle To power cycle remove connector CN1 for 5 10 seconds then reconnect NOTICE After a firmware update i...

Страница 30: ...10 11 about configuration and parameter settings 1 Set the communication setup Service Communication Setup Check that the number of available compressors equals the number of compressors on the ACP C...

Страница 31: ...e set the value roughly to 10 of the total swept volume of the ACP 2 Set the suction pressure low alarm and warning Param Plant page 2 Typically defined by the plant temperature level Assure where pos...

Страница 32: ...on 8 4 2 Alternatively use the Bluetooth connection to connect Default Bluetooth password 8670 3 If the CM SW 01 module is completely new Transfer Transfer default values to device This is done becaus...

Страница 33: ...may include changes to default values 3 Copy actual values to user values 4 Modify various values manually in the right column User Setting Use parameters from tables in section 0 for reference to se...

Страница 34: ...on of rotation with VSD Direction of rotation is imperative to check as the first thing before operating the compressor This can be done with a VSD set to operate at extremely low speed Configure the...

Страница 35: ...ion after configuration of the frequency inverter but before operation the compressor Operation in the wrong direction can damage the compressor See subsequent section on how to check direction of rot...

Страница 36: ...te datasheet See note2 Nominal Rated Speed 402 Motor specific Acc motor nameplate datasheet See note5 Motor Rated Frequency 403 Motor specific Acc motor nameplate datasheet See note5 Motor Rated Power...

Страница 37: ...n the PLC The files can be downloaded or uploaded to an SD card for further use or storage To save and upload files from the PLC to an SD card 1 It is possible to save three different configuration an...

Страница 38: ...n be done while the PLC is in operation 6 The SD LED will be blinking a few seconds Wait about 30 sec The SD LED should stop blinking and continue to be on 7 Take out the SD card 8 The rcp files have...

Страница 39: ...Yes and wait approximately 5 sec to copy the data 3 Remove the USB Stick and check in a PC that a file named 00PARAM DAT is on the USB Stick Store this file in a suitable location for future use To d...

Страница 40: ...is needed to read and convert the dat files on a PC 9 10 Configure communication with SCADA system over Modbus The ACP LINK PLC has a list of signals including status of the warnings and alarms access...

Страница 41: ...r shows the actual user level and a button to log in or out On the Home screen hot spots around the pictures for compressor and oil system act as links to the screens for those components In the top l...

Страница 42: ...1234 See also the section 10 12 to understand the extent of this user level and how the unit is being operated on a daily basis Service level access allows access to more screens and is used to setup...

Страница 43: ...es and minimum capacity to start The minimum nominal capacity levels of the compressors and the unit are used to decide whether to start or stop the operation of the unit or the single compressor in t...

Страница 44: ...st be delivered by the customer as an analog input to the electrical starter panel IO module see also section 11 1 When the unit is not running then the remote signal must exceed the level of the mini...

Страница 45: ...mum is wanted the user can change the starting priority number The number can be set between 1 and 9 the lower the number the higher the priority For optimum regulation handled by the built in algorit...

Страница 46: ...ed as the difference between the oil pressure after the filter and the suction pressure Oil system pressure drop is defined as the difference between the discharge pressure and the oil pressure after...

Страница 47: ...cause first Certain alarms from the compressor module CM SW 01 will always require manual reset or even a power cycle of the module Manual reset can be done with the Reset All button above the alarm t...

Страница 48: ...10 8 Trends screen The trend function can be used as a diagnostic tool by the user Predefined values are logged The user can access historical values by use of a calendar function and monitor live da...

Страница 49: ...d to allow planning of service and for diagnostic purposes About the program version of the PLC and the HMI are shown 10 10 Communication setup screen The configuration of network settings including t...

Страница 50: ...and status is shown in the right column Important for the communication to the HMI are the IP address for Ethernet 1 connection and the PLC node name The PLC and HMI must be on the same network and th...

Страница 51: ...he button with picture of the module in the right side of the screen similarly as for the compressor modules The user can monitor the status of the different inputs and outputs to from the module with...

Страница 52: ...y time to automatically reset an alarm after the conditions have returned to normal The values in line 5 6 and 7 function together to make up alarm handling Total current high warning and alarm Plant...

Страница 53: ...action can be set individually Operates in so called manual mode when PID regulator is not used all operation modes other than Auto Anti reset windup to avoid saturation or wind up in integral action...

Страница 54: ...the integral calculation will be normal Eco superheat low and high warning and alarm limit Economizer Page 1 Parameters to adjust the limits for surveillance of the economizer gas superheat Timer set...

Страница 55: ...ess point Find the name of the SSID and the wireless password illustrated on the Wifi device Connect the tablet to the WIFI access point 4 On the tablet setup a manual IP address for the network Make...

Страница 56: ...left key until the main menu is shown View I O s Select IOs on the main menu and then select one of the four types of input or output to be shown Use the up down keys to go through the pages Change S...

Страница 57: ...used and the signal resolution used in the ACP LINK In addition to the scale a calibration factor can be used if multiplication is needed for the sensor to match To modify a value select the desired i...

Страница 58: ...nal extension module The RS485 1 Modbus RTU parameters can also be changed however this is normally not necessary for use on ACP From the Settings screen page 2 select USB to download select Load Para...

Страница 59: ...alarm or ammonia detection alarm High no external alarm healthy low external alarm ACP unit will shut down after time delay adjustable when input is low DI 3 CN4 External start permission Signal from...

Страница 60: ...ncy inverter soft starter or motor must be connected here where available Default Low drive motor error High no drive motor error Optionally the inverse signal can be used by setting the related param...

Страница 61: ...he start permission chain for the high pressure compressor units DO 6 CN7 3 A 250 V Start request chiller pump Signal from ACP LINK to plant to request start of chiller water brine pump This output wi...

Страница 62: ...External suction temperature Optional signal from temperature sensor mounted in the common suction header line Temperature signal is used by ACP LINK to calculate and display suction gas superheat AI...

Страница 63: ...recorded by the ACP LINK but no further functionality related to this sensor is implemented yet AI 11 CN13 0 10V Remote setpoint 1 common Signal from plant to the ACP LINK for remote control of the ca...

Страница 64: ...with speed set point for motor drive on compressor no 1 Only required for operation with variable speed Must be connected to analog input for speed set point on the variable speed drive AO 2 CN2 0 10V...

Страница 65: ...8 69 0 2 Modbust TCP IP communication The ACP LINK PLC writes different signals to a group of addresses for use on SCADA systems see also section 9 10 0 3 Data processing Various new signals are calcu...

Страница 66: ...ble redundant signal will be used where possible 70 79 10 31 42 1 6 Redudancy CM IO Eco system optional Depending on type of warning from diagnosis for the CM IO Eco system a suitable redundant signal...

Страница 67: ...ter systems will not have alarm when no compressor is running 4 16 17 3 2 5 Pressure ratio high Surveillance for high pressure ratio A warning is issued when the warning limit is exceeded An alarm is...

Страница 68: ...h main oil filter pressure drop A warning is issued when the warning limit is exceeded An alarm is issued when the alarm limit is exceeded 9 72 73 2 10 Suction superheat low Surveillance for low sucti...

Страница 69: ...is exceeded An alarm is issued when the alarm limit is exceeded after timer delay The surveillance is timer delayed at start of first compressor 15 82 83 25 2 15 Oil temperature high Surveillance for...

Страница 70: ...issued when the alarm limit is exceeded or the warning limit is exceeded for the timer period 21 77 78 10 2 21 Motor current high Surveillance for high motor current A warning is issued when the warn...

Страница 71: ...ystem suction superheat A warning is issued when the warning limit is exceeded An alarm is issued when the alarm limit is exceeded Only active when at least one compressor is running with eco valve en...

Страница 72: ...or detects oil for the timer period only when at least one compressor is running 84 19 2 30 External emergency stop Surveillance of the digital emergency stop signal An alarm is issued when the digita...

Страница 73: ...back low Surveillance if CM IO and SP IO modules are online An alarm is issued when CM IO for oil system or SP IO starter panel module is not online An alarm is issued when CM IO for economizer system...

Страница 74: ...pressure drop over the oil filter in the oil line to the OS A95 compressor is too high The warning is surpressed during start of each compressor and at start of first compressor 97 98 99 79 25 36 2 42...

Страница 75: ...compressors The distribution tries to meet the required capacity as close as possible with the available compressors taking into account several factors best possible efficiency compressor regulation...

Страница 76: ...ressure cold brine both cooling mode discharge pressure and hot water both heating mode 66 88 137 3 9 External output shutdown and ready signal External digital output for shutdown is set when all com...

Страница 77: ...ere is a warning for low oil level 18 86 87 3 15 Oil separator oil return valve Coalescer oil return valve is opened when at least one compressor is running no compresser is starting and oil level in...

Страница 78: ...is closed when at least one compressor eco valve is open or when the economizer system is not active or not enabled 3 20 Eco system oil return valve Economizer oil return solenoid valve is opened whe...

Страница 79: ...dged by alarm handler Alarm can only be acknowledged if status is reset Most alarms will reset automatically Few alarms from CM SW 01 will always require manual reset or power cycle A certain number o...

Страница 80: ...1 PLC Ethernet 2 IP 0 0 0 0 Device network Subnet 0 0 0 0 Gateway 0 0 0 0 PLC Serial RS485 Node Modbus address 0 Data bit 8 Stop bit 1 Parity Even Baudrate 19200 HMI Ethernet 1 IP 192 168 1 101 Subnet...

Страница 81: ...16 Discharge pressure high warning Plant 2 28 0 bara 17 Discharge pressure high alarm Plant 2 28 0 bara 18 Pressure ratio high warning Plant 2 50 19 Pressure ratio high alarm Plant 2 50 20 Pressure d...

Страница 82: ...x for start up Comp Motor 1 25 50 CR min normal operation OS85 Comp Motor 1 50 51 CR min normal operation OS95 Comp Motor 1 25 52 CR max normal operation OS85 OS95 Comp Motor 1 100 53 Discharge temper...

Страница 83: ...A95 oil filter pressure drop high warning Oil System 1 1 2 bar 80 Oil temperature high warning Oil System 2 65 C 81 Oil temperature high alarm Oil System 2 70 C 82 Oil temperature low warning Oil Syst...

Страница 84: ...low limit cold brine PID 2 2 100 116 PID inner window I part cold brine PID 2 2 0 C 117 PID outer window I part cold brine PID 2 2 0 C 118 PID KP discharge pressure P PID 2 3 20 0 bar 119 PID TN disc...

Страница 85: ...imer 1 3600 6 Lubric press low warning time Timer 1 3600 7 Suct superheat low time to alarm Timer 1 30 8 Oil sep level low warning time Timer 1 10800 9 Oil sep coal high time to warning Timer 1 600 10...

Страница 86: ...the settings when using the motor start functions frequency inverter or soft starter on the CM SW 01 in the section MotorStart These operating modes require the use of the run feedback signal from th...

Страница 87: ...fault protection Input 2 OilFault2 OS A85 Yes OS A95 No Oil fault sensor2 type selection OilFault2 Pressure Input2 ignore time during startup OilFault2 30 Delay time until fault is set input 2 OilFaul...

Страница 88: ...90 Actual capacity at or above which ECO valve can be opened at minimum VI EcoValve OS A85 75 OS A95 100 Actual capacity at or above which ECO valve can be opened at maximum VI EcoValve OS A85 75 OS A...

Страница 89: ...onfig 230 115 depending on region Compressor serial number actual CompInfo Number as on name plate for oil separator or economizer Customer Location CompInfo Site description System name Compressor nu...

Страница 90: ...0 1000 PE 5000 5094 4 0 1379 signal out in 0 01 bara AI8 Discharge Pressure AKS 33 4 20mA PE 5000 0 5V rat 0 AKS 33 100 2600 PE 5000 5093 2 100 3300 PE 5000 5094 3 100 3447 signal out in 0 01 bara AI...

Страница 91: ...with KDC or related solenoid valves 7 Lubricating pressure low 2 7 Combination of 6 and 8 8 Oil system pressure drop high 2 8 Oil cooler pressurer drop high Valve s in oil system partly closed Main o...

Страница 92: ...ves to plant 19 Oil separator level high 2 18 Too much oil in oil separator Error in plant oil return system 20 Oil separator coalescer level high 2 19 Oil not returning or too slow from coalescer col...

Страница 93: ...gnal 1 1 Sensor or connection error 53 Sensor oil pressure after filter low signal 1 1 Sensor or connection error Low pressure due to evacuation 54 Sensor oil pressure after filter high signal 1 1 Sen...

Страница 94: ...Sensor or connection error 76 Sensor discharge temperature IO low signal 1 2 Sensor or connection error 77 Sensor discharge temperature IO high signal 1 2 Sensor or connection error 78 Sensor process...

Страница 95: ...quid temperature high signal 1 3 Sensor or connection error 97 98 99 Compressor 1 2 3 oil filter pressure drop high 2 41 Pressure drop over compressor oil filter high only OS A95 101 102 103 Compresso...

Страница 96: ...tart time 3 1 3 5 Compressor start to start timer active Compressor stop start may not be possible 191 192 193 Compressor 1 2 3 start priority zero 2 39 Start priority of compressor is zero in CTRL pa...

Страница 97: ...Read Only 2 28 54 HW 3 3V 2 28 55 HW User 5V 2 28 62 Sensor Motor Thermistor 2 28 68 Suction Pressure Low 2 28 Too little load too much capacity Suction stop valve s partly closed Wrong configuration...

Страница 98: ...2 28 92 Output Current Total Value Low 2 28 93 Output Current Total Value High 2 28 94 Sensor Suction Pressure Signal Low 2 28 Sensor or connection error 95 Sensor Suction Pressure Signal High 2 28 S...

Страница 99: ...4 Output Current Unloader High 2 28 115 Output Current Oil Inj Low 2 28 116 Output Current Oil Inj High 2 28 117 Output Current Liquid Inj Low 2 28 118 Output Current Liquid Inj High 2 28 119 Too many...

Страница 100: ...otor speed below minimum allowed 136 Motor Frequency High 2 28 Motor speed above maximum allowed 137 Oil Stop Valve 2 28 140 Output Current HW Trip 2 28 145 HW Sensor supply voltage 1 24V 2 28 146 HW...

Страница 101: ...2 28 Module system voltage not aligned with parameter for system voltage 208 Dev check eco enable 2 28 209 Dev check comp Type 2 28 Module compressor type not aligned with parameter for compressor typ...

Страница 102: ...0000 MW40000 X0 0 Not used MW40000 X1 1 Suction pressure low MW40000 X2 2 Suction pressure high MW40000 X3 3 Discharge pressure low MW40000 X4 4 Discharge pressure high MW40000 X5 5 Pressure ratio hig...

Страница 103: ...MW40016 X5 5 Pressure ratio high MW40016 X6 6 Pressure difference low MW40016 X7 7 Lubricating pressure low MW40016 X8 8 Oil system pressure drop high MW40016 X9 9 Main oil filter pressure drop high M...

Страница 104: ...setpoint for start MW40060 MW40061 14 Module status 0 stop 1 manual 2 auto 3 remote 4 service 5 remote ind MW40072 MW40073 20 Oil pressure before filter bara MW40074 MW40075 21 Oil pressure after filt...

Страница 105: ...MW40173 70 Compressor 1 status oil flow level switch MW40174 MW40175 71 Compressor 1 status oil pressure switch OS85 oil pressure OS95 bara MW40176 MW40177 72 Compressor 1 general alarm status MW40178...

Страница 106: ...ressor 3 discharge temperature C MW40238 MW40239 103 Compressor 3 discharge superheat C MW40240 MW40241 104 Compressor 3 drive shaft frequency Hz MW40242 MW40243 105 Compressor 3 motor current A MW402...

Страница 107: ...6 MW40307 137 M172 AI 3 Current motor 3 A MW40308 MW40309 138 M172 AI 4 External setpoint 2 MW40310 MW40311 139 M172 AI 5 Suction temperature C MW40312 MW40313 140 M172 AI 6 Discharge temperature C MW...

Страница 108: ...r 1 Hz MW40354 MW40355 161 M172 AO 2 Speed set motor 2 Hz MW40356 MW40357 162 M172 AO 3 Speed set motor 3 Hz MW40392 MW40393 180 PID regulator PV MW40394 MW40395 181 PID regulator SP MW40396 MW40397 1...

Страница 109: ...ine ungerade letzte Seite oder die Seite nach er letzten Seite 80060902 06 2020 Subject to change nderungen vorbehalten BITZER K hlmaschinenbau GmbH Peter Schaufler Platz 1 71065 Sindelfingen Germany...

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