BITZER ACP Link Datasheet

CT‐600‐2

BITZER ACP LINK

Original document

English ························································································································································· 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 skilled person

Eingewiesener Monteur, Elektrofachkraft

2 CT-600-2

Contents

1Introduction ................................................................................................................................................. 5

1.1Also observe the following technical documents ................................................................................ 5

2Safety .......................................................................................................................................................... 5

2.1Authorized staff ................................................................................................................................... 5

2.2Residual risks ..................................................................................................................................... 5

2.3Safety references ................................................................................................................................ 5

2.4General safety references .................................................................................................................. 6

3Required special tools ................................................................................................................................ 6

4Technical data ............................................................................................................................................ 7

4.1ACP LINK panel .................................................................................................................................. 7

4.2Electrical panel IO-module (M172) ..................................................................................................... 8

4.3Compressor module (CM-SW) ........................................................................................................... 8

4.4Oil separator and economizer system module (CM-IO) ..................................................................... 9

4.5Additional motor connection box ........................................................................................................ 9

5General description ................................................................................................................................... 11

5.1ACP LINK architecture ...................................................................................................................... 11

5.2ACP LINK HMI overview ................................................................................................................... 12

5.3ACP LINK main functions overview .................................................................................................. 13

6Mounting ................................................................................................................................................... 15

6.1Transport and storage ...................................................................................................................... 15

6.2ACP LINK panel mounting ................................................................................................................ 15

6.3Electrical panel IO-module (M172) mounting ................................................................................... 1 5 

6.4Economizer system module (CM-IO) mounting (optional) ............................................................... 15

7Electrical connection ................................................................................................................................. 16

7.1ACP LINK panel ................................................................................................................................ 16

7.2Electrical panel IO-module (M172) ................................................................................................... 18

7.3Compressor modules (CM-SW), additional motor boxes, oil separator module (CM-IO) ................ 19

7.4Economizer system module (CM-IO) ............................................................................................... 19

7.5Modbus RTU wiring and connection ................................................................................................. 20

8Software installation and update .............................................................................................................. 22

8.1ACP LINK panel PLC ........................................................................................................................ 22

Update Schneider firmware, ACP LINK panel PLC ...................................................................... 22

Update software, ACP LINK panel PLC ....................................................................................... 23

More than one ACP on a network, change PLC node-name ....................................................... 24

Re-configure IP-addresses after program update ........................................................................ 24

Contingency plan for problems with updating PLC program ........................................................ 25

8.2ACP LINK panel HMI ........................................................................................................................ 25

CT-600-2 3

Update Schneider firmware, ACP LINK panel HMI ...................................................................... 25

Update software, ACP LINK panel HMI ....................................................................................... 25

Procedure to change the PLC node name that the HMI looks for ............................................... 26

8.3Electrical panel IO-module (M172) ................................................................................................... 27

Step 1: update program with default configuration, electrical panel IO-module .......................... 27

Step 2: update configuration and parameters, electrical panel IO-module .................................. 27

8.4Compressor, oil and economizer system modules, CM-SW-01 & CM-IO ....................................... 27

9Configuration and setup ........................................................................................................................... 30

9.1Configuration ACP LINK panel, IP addresses and PLC name ........................................................ 30

9.2Configuration ACP LINK, basic setup .............................................................................................. 30

9.3Configuration ACP LINK panel, plant specific parameters............................................................... 31

9.4Configuration, compressor modules (CM-SW-01) ........................................................................... 32

9.5Configuration, oil and economizer system modules (CM-IO)........................................................... 33

9.6Configuration, 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 LINK .......................... 35

Speed set point settings in ACP LINK .......................................................................................... 36

Current calibration factor in ACP LINK ......................................................................................... 37

9.8Backup and restore of system configuration and settings................................................................ 37

ACP LINK panel PLC (M251) ....................................................................................................... 37

Compressor, oil and economizer system modules (CM-SW-01 & CM-IO) .................................. 38

Electrical panel IO-module (M172) ............................................................................................... 39

9.9Recovery of data logs ....................................................................................................................... 40

9.10Configure communication with SCADA system over Modbus ......................................................... 40

10ACP LINK, user guide .............................................................................................................................. 41

10.1Home screen (Home) ....................................................................................................................... 41

10.2User access (login) to ACP LINK panel HMI .................................................................................... 4 2 

10.3Control screen (CTRL) ..................................................................................................................... 42

Regulation / Select Operation Mode ............................................................................................ 43

State ............................................................................................................................................. 44

PID ................................................................................................................................................ 45

Compressors ................................................................................................................................ 45

10.4Compressor screen (Compr.) ........................................................................................................... 45

10.5Oil system screen (OilSys) ............................................................................................................... 46

10.6Economizer system screen (EcoSys) ............................................................................................... 47

10.7Alarms and warnings screen (Alarms) ............................................................................................. 47

10.8Trends screen ................................................................................................................................... 48

4 CT-600-2

10.9Service screen .................................................................................................................................. 49

10.10Communication setup screen ........................................................................................................... 49

10.11Parameters and timers screen (Param.) .......................................................................................... 51

10.12Daily use of ACP LINK ...................................................................................................................... 55

10.13Remote access to BITZER ACP LINK via Schneider App ............................................................... 55

10.14Remote access to ACP LINK via Schneider Webgate ..................................................................... 55

10.15Electrical panel IO-module HMI and keyboard ................................................................................. 56

11I/O overview .............................................................................................................................................. 59

11.1Electrical panel IO-module (M172) ................................................................................................... 59

12Function overview ..................................................................................................................................... 65

12.1Data handling functions .................................................................................................................... 65

12.2Diagnosis and redundancy functions ................................................................................................ 65

12.3Protection functions .......................................................................................................................... 66

12.4Control 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 parameters in CM-SW-01 – compressors .................................................................... 86

13.4Overview of parameters in CM-IO – oil and economizer system ..................................................... 89

13.5Overview of parameters in M172 – electrical panel I/O .................................................................... 89

14Alarms and warnings overview ................................................................................................................. 91

14.1Overview of alarms and warnings in ACP LINK PLC/HMI ............................................................... 91

14.2Overview of compressor specific alarms .......................................................................................... 96

15Modbus TCP/IP signal list ...................................................................................................................... 102

15.1List of alarms and addresses on Modbus TCP/IP .......................................................................... 102

15.2List of warnings and addresses on Modbus TCP/IP ...................................................................... 103

15.3List of data signals and addresses on Modbus TCP/IP .................................................................. 104

CT-600-2 5

1 Introduction

The BITZER Ammonia Compressor Packs (ACP) can be delivered with the BITZER ACP LINK. The system

consists of the main ACP LINK panel with HMI and individual electronic modules for the main components.

The ACP LINK handles all necessary protection and operation of the components on the ACP including the

interaction with the plant where it is part of.

This document describes the BITZER ACP LINK: installation, setup and software update, configuration,

parametrization and daily operation. The document also gives an overview of the different functions that the

system handles.

1.1 Also observe the following technical documents

 SB-600 Operating instructions – Ammonia Compressor Packs (ACP) – with open screw compressors

 ST-150 Technical Information – Compressor Module for Screw Compressors – CM-SW-01

 ACP wiring diagrams: “ACP 85 3C_Link.pdf“, “ACP 85 2C_Link.pdf“, “ACP 95 3C_Link.pdf“, “ACP 95

2C_Link.pdf“, “ACP 85 3C no eco_Link.pdf”, “ACP 85 2C no eco_Link.pdf”, “ACP 95 3C no eco_Link.pdf”,

“ACP 95 2C no eco_Link.pdf”, “Starter _panel_Standard_Link_M172 Controller.pdf”

2 Safety

The BITZER Ammonia Compressor 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 must be followed in addition to this Technical

Information.

Always keep all Instructions in the vicinity of the refrigeration system during the whole lifetime of the ACP.

2.1 Authorized staff

All work done on the compressors, variable speed drives (VSD), electronic accessories and on the

refrigeration systems may only be performed by qualified and authorized personnel who have been trained

and instructed accordingly. The local regulations and guidelines will apply with respect to the qualification and

expertise of the specialists.

2.2 Residual risks

Compressors and electronic accessories may present unavoidable residual risks. This is why any person

working on this device must carefully read this document.

The following regulations are mandatory:

 The relevant safety regulations and standards,

 General accepted safety rules,

 EU directives,

 National regulations.

Example standards: EN378, EN60204, EN60335, EN ISO14120, ISO5149, IEC60204, IEC60335, ASHRAE

15, NEC, UL-standards

2.3 Safety references

Safety references are instructions intended to prevent hazards. Safety references must be stringently

observed!

6 CT-600-2

NOTICE

Safety reference to avoid situations which may result in damage to a device or its equipment.

CAUTION

Safety reference to avoid a potentially hazardous situation which may result in minor or moderate

injury.

WARNING

Safety reference to avoid a potentially hazardous situation which could result in death or serious injury.

DANGER

Safety reference to avoid an imminently hazardous situation which may result in death or serious injury.

2.4 General safety references

The HMI Human Machine Interface on the ACP LINK may only be operated when the main ACP LINK panel,

CM-SW-01/CM-IO modules and starter panel are closed. In case it is necessary to open one of the panels or

modules or Motor Connection boxes for software updates or work on the electric or electronic components for

installation or service, then this may only be done by authorized staff.

When working on the electrical system and the ACP LINK panel

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 secure it against being switched on again.

Before switching on again, close the electrical panel housing.

When welding on the unit or plant

NOTICE

Risk of damage to electronic components.

Before welding on the ACP unit or connected piping and equipment: switch off the main switch and secure

it against being switched on again.

When welding on the ACP unit or connected piping and equipment: make sure that the welding ground

lead is connected properly and close to the welding spot.

3 Required special tools

1 SD-card recommended brand (Scandisk, Kingston, Schneider), preferred size 4 – 32 Gb.

2 USB-stick (USB type 1 or 2), recommended brand (Scandisk, Kingston), preferred size 4 Gb.

3 PC with SD-card slot and latest version of BEST SOFTWARE installed.

4 BEST interface converter (BITZER part no. 34431402).

5 HB Products programming cable (HB Products part no. HBxC-USB) and latest version of HB Tool

software (only for optional economizer system).

!

CT-600-2 7

4 Technical data

4.1 ACP LINK panel

The ACP LINK panel is to be mounted on a support on or close to the ACP unit

(see section 6.2). The panel is partly pre-wired by BITZER but must be finally

wired and connected on site by the customer (see section 7.1). See also section

13.1 and 13.2 for parameters settings.

Supplier WEG

Reference No. 31816777

Description BITZER ACP LINK panel

Dimensions H = 400mm, W = 400mm, D = 210mm

Color RAL 7035

Enclosure class IP54

Approvals UL/CSA/CE/IEC

Temp./humidity range Min. / max temperature: 0 / 55°C

Min. / max humidity: 10 – 90% (non-condensing)

Max. vibration levels According to EN/IEC 61131-2:

3.5 mm constant amplitude (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 Vac, 10A

Eco system: 230/120 Vac 10A

Compressor 1, 2, 3: 230/120 Vac, 4A

Schneider panel breakers Multi 9, C60SP, 1Pol, C3A

Schneider panel breakers Multi 9, C60SP, 2Pol, C4A, C6A, C10A, C13A

I/O Power supply, safety chain, start signal, communication to/from related modules

and plant.

Communication ports 2 x Modbus TCP/IP on PLC (for HMI, SCADA, Ethernet and Devices)

2 x Modbus TCP/IP on HMI (for PLC and Wifi access point)

1 x Modbus RTU (RS485)

Power supply 230 Vac / 120Vac, +10%/-15%, min. 16A

24 Vdc, +20%/-15%, min. 10A

Mounting Four M8 threaded holes, one in each corner of the back of the enclosure, for

mounting on a frame or support. Center distance between holes: 355mm.

8 CT-600-2

4.2 Electrical panel IO-module (M172)

The module is delivered loose and must be mounted in the electrical panel (see

section 6.3). For BITZER supplied electrical panels, the module is installed and partly

pre-wired. For customer supplied electrical panels, the module must be wired by the

customer (see section 7.2). See section 11.1 for detailed information about I/O

configuration of the electrical panel IO-module, as used on ACP and section 13.5 for

parameters and settings used on ACP.

Supplier Schneider Electric

Reference No. 31802062, TM172PDG42RI

Description M172 Performance 42 I/Os

Display Yes

Temp./humidity range -20-65°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 regular inputs, 24V, “- on COM”, “+ on DI”

Analog outputs 6 configurable outputs

4-20mA, current on/off, 0-10V, PWM

Analog inputs 12 configurable inputs (must be of equal type in pairs)

0-10V, 0-5V ratiometric, 0-20mA, 4-20mA, PT1000, NTC

Communication ports CAN expansion bus

2 x RS485

USB (type A) & USB (type min-B)

Ethernet

Power supply 24 Vdc, +20%/-15%, Type T fuse 2 A

Mounting 35 mm top section rail (DIN rail)

4.3 Compressor module (CM-SW)

The compressor modules are mounted on each compressor and are all pre-wired from the

factory.

Supplier BITZER

Reference No. OS.A 85: 34738808

OS.A 95: 34738806

Description See ST-150 for technical data on CM-SW module.

CT-600-2 9

4.4 Oil separator and economizer system module (CM-IO)

See ST-150 for technical data on CM-IO module (same as for CM-SW).

The oil separator module is mounted on the oil separator and is pre-wired from the factory.

The economizer system module is mounted on the economizer system and is partly pre-wired

from the factory.

Supplier BITZER

Reference No. OAHC65051A: 34738701

OAHC80051A: 34738702

OAHC100051A: 34738703

ECO SYS: 34738704

Description See ST-150 for technical data on CM-SW module.

Relays for heaters

(OAHC)

2 pcs 1 W, 12 A, 230 Vac (Schrack RT424730)

2 pcs 1 W, 120 Vac (Schrack RT424615)

Relay for level control

release (ECO)

1 pcs 1 W, 12 A, 230 Vac (Schrack RT424730)

1 pcs 1 W, 120 Vac (Schrack RT424615)

Resistor for level control

release (ECO)

1 pcs 69.0 kΩ

4.5 Additional motor connection box

The additional motor connection box is fixed to the

main connection box on the motor. The connections

to the compressor module are pre-wired from the factory.

Supplier WEG

Reference No.

Box for frame size W22 200: WEG 14859061

Box for frame size W22 225 up to 315SM: WEG 14509565

Box for frame size W22 315L: WEG 14509566

Box for frame size W22 355: WEG 14509608

Box for frame size W50 355 and 400: 14859065

Description Motor box for connection to compressor module (CM-SW)

Cable gland M20 (WEG 12008911)

IP class IP 67

Phase output 3 phases

Fuse holder WEG 14281692

Fuse 10x38 FF 690 Vac 1A (Mercen)

Current output

Current transformers:

0 .. 1 A, Bridge current transformer: 1 Ω resistance, 3W CPF3

Type 200A/1A

10 CT-600-2

Type 300A/1A (WEG 14498543)

Type 750A/1A (WEG 14289837)

Type 1000A/1A

PTC output See motor data sheet

CT-600-2 11

5 General description

5.1 ACP LINK architecture

The ACP LINK (see figure below) consists of the ACP LINK panel with HMI (Human Machine Interface) and

several electronic modules mounted directly on the main components (compressors, oil separator,

economizer), including one module in the external electrical panel. The connections between the ACP LINK

panel and the electrical panel handles power supply, safety chain and communication signals (Modbus

RTU). The compressor and oil system modules (CM-SW-01 and CM-IO) are only connected to the ACP

LINK panel. The connection to the plant and starter equipment is handled with digital and analog signals

from/to the ACP LINK panel and the IO-module in the electrical starter panel. There is also the possibility of

Modbus TCP/IP communication from the ACP LINK panel. Each 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, protection, operation and

communication of the entire ACP. The ACP LINK panel contains the PLC (Schneider Electric type M251), the

HMI (Schneider Electric type HMI3GU with 12.” HMIDT651 touch screen). The ACP LINK panel is connected

to the different compressor (CM-SW) and oil system (CM-IO) modules and the electrical panel IO-module

(M172) via the Modbus-RTU communication cable and power/signal cables.

The ACP LINK panel is prepared for Modbus TPC/IP communication with the superior plant control system.

The HMI is a touch-screen monitor for the normal user interface to the ACP. It is possible to access the HMI

remotely on a PC or mobile device (smart phone, tablet, etc.) via web-access or a local Wi-Fi.

The parameters of the system and the operation mode are adjusted on the HMI. Configuration is done via the

HMI.

ACPLinkPanel

12 CT-600-2

Compressor modules – CM-SW-01

The compressor module CM-SW-01 integrates the entire electronic periphery of the compressor. It monitors

essential operating parameters and protects the compressor and motor from operation under critical

conditions. The module operates the compressor depending on the capacity requirement of the ACP LINK

panel. It operates slide valve capacity, internal volume ratio (depending on compressor type), oil return and

economizer valve. The compressor module is connected to an additional motor connection box for specific

motor signals. Communication with ACP LINK panel is via Modbus-RTU and some digital signals.

Configuration is done via BEST software.

Oil system module – CM-IO

The oil system module CM-IO integrates the entire electronic periphery of the oil system. Similar to the

compressor module it monitors, protects and operates the oil system. The module operates oil heaters, oil

return from the coalescing filters and pilot valves for the operation of the pressure controlled discharge valve.

Communication with ACP LINK panel is via Modbus-RTU. Configuration is done via BEST software.

Electrical panel IO module – M172

The electrical panel IO module handles all the digital and analog in- and outputs to and from the electrical

panel and plant control system, such as external start permission, external alarm signal, digital run-status,

external sensors etc. The module functions as distributed IO for the electrical panel. The signals going into

the M172 are scaled on the module and communication with ACP LINK panel is via Modbus-RTU.

Configuration is done on the module itself (keys and display).

Economizer system module – CM-IO

The economizer system module CM-IO integrates the entire electronic periphery of the economizer system.

Similar to the compressor 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 panel is via Modbus-RTU. Configuration is done via BEST software.

5.2 ACP LINK HMI overview

The HMI contains several screens for the different types of operation and service that are to be handled by

the different users. The right side of each screen is always the same and contains buttons to switch between

the different screens. It is necessary to log on with user name and password in order to use the specific

functions on the different screens, such as to start/stop the unit, to manually reset alarms, to change

parameters, etc.

See further section 10 for more information on how to operate (and login to) the HMI. The bottom left of each

screen contains a button to go back to the previous screen.

Main screen

The main screen, “HOME” shows the overall operation of the ACP. The top left corner of the screen shows

the overall status of the ACP, indicated with different symbols. The main signals for the operating condition of

the system are shown in the top of the screen. Relevant data for the status of each compressor and the oil

system are shown with numbers and status lights.

Control screen

The control screen, “CTRL” shows the regulation mode and control status for the ACP. The information for

status and signals of the system are shown on the top of the screen (same as on the main screen). When

logged in to the system, the user can change the regulation mode on this screen. The screen also shows

information about the capacity distribution and status of the individual compressors.

Compressor, Oil system, Eco System

Detailed information for each main component on the ACP can be found on the specific screens for each

compressor, “Compr.”, the oil system, “OilSys” and optional economizer, “EcoSys”.

These screens only show information on different signals and status, but do not allow user interaction.

CT-600-2 13

Alarms & Warnings

The alarms & warnings screen “Alarms” shows a table with the active alarms. The top of the screen shows

buttons to see alarm history and active warnings. On the screen that shows the warnings there is a similar

button to go to the screen for the warning history. It is possible to manually reset alarms, when logged in to

the system.

Trends

The trends page “Trends” gives the user the possibility to see trend data for certain signals. The trend pages

show the actual value and some period back in time, but also offer the possibility to look further into historical

trend data.

Service

The service page “Service” is used to setup the communication between the modules, change language,

units, time, etc. The page also links to an event log, operating hours and information about the software

versions.

Parameters

The parameter page “Param.” is made up of different screens to set up all the relevant parameters and timer

values that are needed to configure and operate the system. The parameters and timers are collected in

different groups.

5.3 ACP LINK main functions overview

The many functions of the ACP LINK can be sorted in different groups:

I/O signals data processing

The different signals for sensor and actuators are communicated to the ACP LINK panel through a Modbus

RTU connection. Various other related signals that are not measured directly, are then derived to be used 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 all signals and register addresses, available

on Modbus TCP/IP.

Diagnosis and redundancy

A diagnosis of possible signal errors, primarily high/low values is performed and a warning will be issued if a

possible bad signal is detected. If a bad signal is diagnosed and there is an alternative signal available, then

the redundancy function will point the alternative signal to take over for the bad signal. The redundant signal

may be from another sensor or may also be a derived signal, possible of lower quality than the original

signal.

The intention of the diagnosis and redundancy functions is to assure continuous operation of the ACP, even

in case of sensor errors. It shall be possible to correct the defect, while the ACP can continue to operate.

Depending on the type of defect, operation may continue unrestricted, or limited in some way. In the latter

case a warning will indicate that.

Protections

The ACP LINK protects the ACP and its components from incorrect operation and shall prevent wear and

breakdown. The different protection functions test certain signals up against limits and will issue a warning

and or alarm if limits are exceeded. In some cases timers are incorporated in the protection algorithm. The

protection function itself will only issue a warning or an alarm. The counter action, such as to stop a

compressor, is handled through the alarm handling and control functions.

14 CT-600-2

Control and limitation

The control functions main objective is to regulate the operating mode and the capacity control of the

individual compressors. Different operating modes can be selected to define a requested capacity for the

ACP. A capacity distribution algorithm will find the optimum distribution of the requested capacity over the

available compressors, taking into account various parameters, such as compressor size, capacity regulation

type, running hours, start priority, etc. The starting and stopping of each compressor is handled through

separate control algorithms to assure correct unloaded start and unload after stop for the different

compressor types.

Limiter functions are used to limit the capacity for the ACP or individual compressors based on warnings

issued by the protection functions. A typical example would be low suction pressure or high motor current.

The limiter function will over-rule the request from the capacity regulation and limit the capacity to prevent an

alarm, that could stop the compressors. Some limiter functions will limit the total capacity of the ACP, other

limiters will limit the slide valve position of the individual compressors. The figure below shows the principle

of keeping the operating condition (To/Tc) within the dotted lines, i.e. when the suction pressure drops below

its low warning limit or the discharge pressure rises above its high limit, then the capacity will be reduced in

order to force the operating point back into the 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 system and economizer control

functions are also handled.

Handling of alarms, warnings and timers

Each warning, alarm and timer is evaluated to decide how to react. Warnings will not stop the operation, but

may trigger a limitation of the capacity. Warnings can also become alarms, if they are time limited. Warnings

are to be regarded as an information to the user, that the operation is limited, but still without direct risk of

damage. An alarm will always stop operation in some kind – ranging from closing the economizer valve,

stopping a single compressor, to shutting down the complete ACP.

Safety chain function

The safety chain is essentially, not a part of the control system, but the wiring of the safety chain is part of the

wiring of the ACP LINK. The safety chain is individual for each compressor and directly connected to the CM-

SW-01 module and will cut the start-signal in case the chain is broken.

The safety chain is a hard wired serial connection of different components to assure safe operation. The

safety chain on ACP consist of, but is not limited to, below parts:

 High pressure switch, connected to CM-SW-01 protects the system against high pressure.

 Emergency switch, mounted on the side of the ACP LINK panel – allows anyone to stop the unit in

case of emergency, activating the emergency switch will stop all compressors. The emergency

switch terminals must be connected directly to the electrical panel safety circuit in serial connections

with the existing local emergency stop system.

CT-600-2 15

6 Mounting

This section describes the transport, storage and mechanical installation of the components, mainly the ACP

LINK panel and IO-module (M172) in the electrical panel.

6.1 Transport and storage

The ACP LINK panel is delivered mounted on a separate frame. The HMI panel enclosure is of IP-Class

IP54 and must be stored accordingly. During transport, the ACP LINK panel and frame are transported

horizontally on the unit, the cable connection terminals are disconnected and must be assembled after

placement of the unit (see section 7).

6.2 ACP LINK panel mounting

The ACP LINK panel is attached to a separate frame with four 8mm bolts. The panel is prepared with M8

threaded holes in each corner.

The frame with the ACP LINK panel must be placed close to the ACP unit. The panel may not obstruct

access to the ACP unit. The predefined clamp-on attachment in the bottom of the panel is ready for the click-

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 panel must be fitted by

the customer (see section 7.1).

6.3 Electrical panel IO-module (M172) mounting

The electrical panel IO-module (M172) is shipped loose on systems where the starter panel is supplied by

the customer. The module M172 must be installed in the electrical panel and connected on-site (see section

7.2).

The M172 PLC is prepared for a DIN-rail attachment and must be placed with proper distance to the motor

cables etc. in the control voltage section of the electrical panel. Mounting instructions are supplied with the

module. See section 4.2 and section 11.1 for more information on technical data and I/O’s.

6.4 Economizer system module (CM-IO) mounting (optional)

The economizer system is shipped loose and must be installed and connected on-site. The module itself is

mounted to the support frame of the economizer system. The connection to the ACP LINK panel must be

fitted by the customer (see section 7.4).

16 CT-600-2

7 Electrical connection

The complete electrical installation of the electronic modules on the ACP unit itself is wired and configured

from the factory before delivery. The connections that must be made by the customer are described in the

terminal plans in the sub sections below. A separate section () describes the wiring of the serial bus

(Modbus RTU).

7.1 ACP LINK panel

The wiring to the ACP unit is prepared from the factory. If the ACP LINK panel is supplied loose, then this part

must be connected after placement of the ACP unit and the panel (see also section 6.2). The wires to/from the

ACP unit are packed together on the unit and come with numbered connectors, which correspond to the

terminals in the ACP LINK panel. These must be connected first, before making the other connections to and

from the plant. When all wiring is finished, the cable grommet can be mounted. The grommet (fitted to the

bottom of the panel) can be fully disassembled, so it can be mounted after the wiring is done. If any grommet

bores are unused, be sure to plug them.

The terminal plan for connection of the ACP LINK panel can be seen below. The terminal plan layout

corresponds to the placement 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 (X8.0/1/2.5) is a fail-safe signal from each compressor module,

available for further use by the customer. It is hardwired to the high pressure safety switch on each

compressor and a high signal equals a healthy safety switch. See also ST-150 for more information on

connection of the high pressure switch to the CM-SW module.

Compressor start signal to customer (X8.0/1/2.6) is the start request for each compressor, from the

control panel to the customer electrical panel. A high signal requests the corresponding motor/VSD to start.

The control system will receive feedback for running status from the phase surveillance on the CM-SW

module, which is connected to the additional motor box.

The power supply for each compressor is made individually to ensure reasonable fuses sizing, and to ensure

that no over voltage can occur in the event of wire break on neutral wire.

NOTICE

The power supply for each compressor is made individually to ensure reasonable fuse sizing, and to

ensure that no over voltage can occur in the event of wire break on neutral wire. The minimum fuse

rating of the power supplies shall be higher than the breakers and fuses inside the ACP LINK panel to

ensure selectivity.

!

CT-600-2 17

Terminal plan ACP LINK panel

Emergen

cystop

X9

4

Emerg.

stop

Emerg.stopreturn2



Dep.On

customerem.

stopcircuit



Emergencystop

customerelectricalpanel

3Emerg.stopreturn1 

2Emerg.stopsupply2 

1Emerg.stopsupply1 

       

Modbus,

SupplyM172

X8.3

624VDC‐ ForM172andECO

system(optional)

O3x1.0

(1,2+Gnd)>6AM172andCM‐IO‐ECOare

suppliedfromhere

524VDC+O

4  Notused     

3RS485+

ModbusRTU

 3x0.6

(ModbusRTU

standard)

NOTE:connectmodbusacc.

tosection

2RS485‐   

1RS485GS 

       

Compressor3

X8.2

6!LStartsignaltocustomer230/120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BN

       

Compressor2

X8.1

6!LStartsignaltocustomer230/120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BN

       

Compressor1

X8.0

6!LStartsignaltocustomer230/120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BN

       

Oil

res.

X5.2

2NTocustomer

(Optionaloilreservoir)



O

Dep.on

customer

NOTE:functionalitynot

implementedyet.

1L  

       

Eco

X5.1

4NEconomizersupply230/120VACO3x1.0

(1,2+Gnd)

NOTE:IfusingECO,connect

modbusacc.tosection

3L 

Oil

sep

2  Internallyconnected230/120VACO3x1.0

(1,2+Gnd)

 

1   

       

Customermain

supply

X5.0

6PE

Customersupply230/120VACI3x1.5

(1,2+Gnd)10



524VDC‐ 

424VDC+ 

3PE

Customersupply24VDCI3x1.5

(1,2+Gnd)16



2N 

1L 

       

Designation

Row

Terminal

Connection

Description

Voltage

Direction

Cable

Fusemin.

rating[A]

Note

18 CT-600-2

Terminal plan ACP LINK panel

7.2 Electrical panel IO-module (M172)

The M172 module for the electrical panel is supplied loose and to be installed by the customer (see also

section 6.3). The terminal plan below shows how to connect the module to the ACP LINK panel, the plant,

the optional eco system module and optional sensors. Section 11.1 gives an overview of the I/O signals and

further descriptions. For BITZER supplied electrical panels, the M172 module is installed and partly pre-

wired.

Terminal plan electrical panel I/O module (M172)

CN19

GNDRS485‐1GSFromACPHMI.Installedandcablesuppliedbycustomer(3x0,6ModbusRTUstandard,Belden3106Aor

equivalent).Terminatewith120Ωresistor

‐ RS485‐1‐

+RS485‐1+

  

CN15

DO11  Notused(spare)Upto250V,3A

DO10  Notused(spare)Upto250V,3A

DO9 EcosystemrunningUpto250V,3A

C91011 Common 



  

CN14

C12  Common 

DO12‐ Notused(spare)Upto250V,1A

DO12  Notused(spare)Up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mode0‐10Vdefault

GND Connecttoallvoltagesensorsand3‐wirecurrentsensors

5Vdc Usefor0‐5Vrat.(whereapplies)

24Vdc Useforcurrentsensors

  

CN12

COM‐DI24VDC‐  

DI9  Notused(spare) 

DI1024VDC+Drive/motorerror1

Contactinmotorordrive

DI1124VDC+Drive/motorerror2

DI1224VDC+Drive/motorerror3



 

CN11

GND  Common 

AO5+Notused(spare) 

AO6+Notused(spare) 

  

CN10

‐ 24VDC‐ Customersupplyfromtransformerinelectricalpanel,typeTfuse2A

+24VDC+Customersupplyfromtransformerinelectricalpanel,typeTfuse2A

  

CN9

C2RelayCommonforD02 

DO2RelayCommonalarmUpto250V,3A

C1RelayCommonforD01 

D01RelayShutdownUpto250V,3A

  

CN8

DO4RelayRunsignalUpto250V,3A

DO3RelayReadyforoperationUpto250V,3A

C34RelayCommon 

  

CN7

DO7RelayNotused(spare)Upto250V,3A

DO6RelayStartrequestchillerpumpUpto250V,3A

DO5RelayStartpermissionHP/LP(forboosteronly)Upto250V,3A

C567RelayCommon 

  

CT-600-2 19

CN6

C8RelayCommonUpto250V,1A

DO8‐ RelayStartsignalforoilpump(optionalcontactNC)

DO8RelayStartsignalmotoroilpump(standardcontactNO)

  

CN5

AI1+Motorcurrent10‐10Vdefault

AI2+Motorcurrent20‐10Vdefault

AI3+Motorcurrent30‐10Vdefault

AI4+Remotesetpoint20‐10Vdefault

AI5+ExternalsuctiontemperaturePT1000default

AI6+ExternaldischargetemperaturePT1000default

AI7+Externalsuctionpressure4‐20mAdefault

AI8+Commondischargepressure4‐20mAdefault

GND Connectedtoallvoltagesensorsand3‐wirecurrentsensors

5Vdc Usefor0‐5Vrat. 

24Vdc Useforcurrentsensors

  

CN4

DI8+PIDsetpoint2enable

Supplyfrom24VDC+

2AFuse

(Customerfuse)

DI7+Remoteeconomizerenable

DI6+Oilpumperrorsignal

DI5+Oilpumprunsignal

DI4+Currentlimiter(notused)

DI3+Externalstartpermission

COM_DI24VDC‐ Common– 

  

CN3

DI2+Externalalarm(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0‐10Vdefault

AO2+SpeedsetpointHzforVSDComp.20‐10Vdefault

AO1+SpeedsetpointHzforVSDComp.10‐10Vdefault

GNDCom 

  

CN1

GNDRS485‐2GS

Notused‐ RS485‐2‐

+RS485‐2+

  

Row

Ternimal

Connection

Description



Instruction

Voltage



Fuseinfo

(where

available)

Terminal plan electrical panel I/O module (M172)

7.3 Compressor modules (CM-SW), additional motor boxes, oil separator module (CM-IO)

The connections to the compressor modules, the additional motor boxes and the oil separator module are all

pre-wired and connected from the factory.

7.4 Economizer system module (CM-IO)

When using an economizer, it must be connected according to the terminal plan in section 7.1. The customer

must connect (cables supplied by customer) the economizer system module with the ACP LINK panel:

 Supply 230/115 VAC, connect to CN1

 Supply 24 VDC, connect to X54:DC- and X54:DC+

 Modbus RTU, connect to CN14

20 CT-600-2

NOTICE

Please observe the change in the Modbus connections, and connect according section . Remove the

120 Ω end resistor in the oil separator module (CM-IO) if one is present, and fit one in the Modbus RTU

connection on economizer system module.

7.5 Modbus RTU wiring 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. Modbus cable type

and installation must be carried out in accordance with IEC-norm. As example, Belden 3106A cable can be

used however other types of cable with equivalent characteristics can also be used.

Modbus RTU network overview without economizer

!

ACPLink

Panel

Page is loading ...

BITZER ACP Link Datasheet

BITZER ACP Link Datasheet

Other documents