Bitzer ACP Link Manual

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

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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
1Introduction
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”
2Safety
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.
3Required special tools
1SD-card recommended brand (Scandisk, Kingston, Schneider), preferred size 4 – 32 Gb.
2USB-stick (USB type 1 or 2), recommended brand (Scandisk, Kingston), preferred size 4 Gb.
3PC with SD-card slot and latest version of BEST SOFTWARE installed.
4BEST interface converter (BITZER part no. 34431402).
5HB 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
4Technical 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.

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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