Bitzer CM-SW-01 Manuel utilisateur

Compressor control module for the OSKA95103-K compressor

Original document

Preliminary v 1.0C

CM-SW-01

Electrical skilled installer

 
 
SG-150-1 
 
Table of contents 
 
Read this first! 4 
1 Reference guide 5 
2 Safety 5 
Definitions 6 
Functions 7 
1 Control functions 7 
2 Monitoring and diagnosis 7 
2.1 Motor temperature 7 
2.2 Discharge temperature 8 
2.3 Oil supply 8 
2.4 Short-cycling warning 8 
2.5 Application limits 9 
Datalog 11 
1.1 Alarms 11 
1.2 Events 11 
1.3 Datalog information 11 
1.4 Periodic data 11 
1.5 Statistics and counters 12 
1.6 Accumulated operation counters 12 
1.7 Capacity load 12 
1.8 Daily counters 12 
1.9 Runtime statistic 12 
1.10 Compressor start statistic 12 
Control of the CM-SW-01 13 
1 Commands and setpoint 13 
1.1 Command Start 13 
1.2 Setpoint –and speed changes 13 
2 Enable serial control 13 
3 Required signals to start the compressor 14 
3.1 Digital and analogue signals 14 
3.2 Serial control (Modbus) 14 
4 Control Word bit definitions 14 
4.1 Data valid bit 14 
5 Examples of Serial Control Word setups: 15 
6 Status Word bit definitions 15 
7 Setting the serial setpoint 16 
8 Serial Control Timeout Function 16 
I/O List for CM-SW-01 17 
Drawings 19 
Standards 20 
Alarm system 21 
1 Alarm severity types 21 
2 Fault reset types 21 
3 Alarm list 22 
Programming and monitoring 26 
1Introduction 26 
2Serial communication 26 
2.1 Modbus (RTU) configuration 26 
2.2 Data values, scaling and data types 27 
2.3 Reading and writing 32 bit values via Modbus 27 
2.4 Modbus function codes 27 
2.5 Modbus exception codes 27 
3Parameters 28 
3.1 Control –application 28 
4Status data 29 
4.1 Status –alarm 29 

SG-150-1 3

10.4.2 Status –compressor 32

10.4.3 Status –motor 34

10.4.4 Status –device 34

10.4.5 Status –IO 35

10.5Configuration data 35

10.5.1 Configuration –application 35

10.5.2 Configuration –compressor 36

10.5.3 Configuration –COM1 36

10.5.4 Logs –application 37

10.5.5 Info –compressor type 37

11. Trouble shooting 38

11.1Communications trouble shooting 38

11.2Status LEDs 39

11.3LED flashing patterns of the three operation status LEDs 40

4 SG-150-1

1. Read this first!

The contents of this manual are subject to change without further notice.

Lodam electronics holds the copyright to this reference guide. The user shall follow any instructions given in

this reference guide entirely and not only partly. Any non-following of this reference guide result in exclusion

of all warranties, guarantees, and liabilities.

Disposing of the parts of the CM-SW-01:

INFORMATION FOR USERS ON THE CORRECT HANDLING OF WASTE

ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE)

In reference to European Union directives and the related national legislation, please note that:

1. WEEE cannot be disposed of as municipal waste and such waste must be collected and disposed of

separately

2. The public or private waste collection systems defined by local legislation must be used. In addition,

the equipment can be returned to the distributor at the end of its working life when buying new

equipment

3. The equipment may contain hazardous substances: the improper use or incorrect disposal of such

may have negative effects on human health and on the environment

4. The symbol (crossed-out wheeled bin) shown on the product or on the packaging and on the

instruction sheet indicates that the equipment must be disposed of separately

5. In the event of illegal disposal of electrical and electronic waste, the penalties are specified by local

waste disposal legislation.

Reading instructions

The following symbols are used to draw the reader’s attention to different warning levels.

Important information

Danger!! General danger

Danger!! High voltage. Danger of electrical current or voltage

SG-150-1 5

1.1 Reference guide

Before installation, the user should be thoroughly familiarized with this reference guide,

especially with purposes, installation and operation.

Special care should be taken when installing and connecting external equipment (PTC sensor,

high voltage etc.) and handling the modules correctly according to protection against ESD (Electro

Static Discharge).

Installation of the CM-SW-01 must be performed by authorized personnel only. All warranties

are excluded in case installation is performed by unauthorized personnel or in case the CM-

SW-01 has not been correctly installed.

1.2 Safety

The CM-SW-01 is a protection device and not a safety component according to the Machinery

Directive and cannot be used in “medical” or “life support” equipment

Before commissioning, the service technician shall ensure that personal safety requirements are

met in conformity with the Machinery Directive and local legislation based on safety estimations.

Electrical plant failures are to be immediately solved, even though no immediate danger exists;

the CM-SW-01 and motor must be without power.

Before soldering or welding on the compressor, all connections on the CM-SW-01 must be

secured against overvoltage!

6 SG-150-1

2. Definitions

BEST

BEST Software

Capacity Regulation

DOL

Direct On Line (motor start)

ESD

Electro Static Discharge

Frequency inverter

High Pressure

Hardware/electronics.

I/O

Input / Output (electrical signals in and out of a unit)

Low Pressure

Modbus

Application-layer messaging protocol - http://www.modbus.org/specs.php

Normally Closed (relay)

Normally Open (relay)

NTC

Negative Temperature Coefficient (sensor element)

PTC

Positive Temperature Coefficient (sensor element)

Part winding (motor start)

Y/∆

Star/delta (motor start)

SG-150-1 7

3. Functions

The CM-SW-01 compressor module has a number of built-in functions to protect, diagnose, control and

communicate the status of the OS.KA95 screw compressor.

3.1 Control functions

Via the BEST Software, the CM-SW-01 can be configured to take care of control functions.

The CM-SW-01 thereby secures the safe operation of the OS.KA95 screw compressor.

3.2 Monitoring and diagnosis

3.2.1 Motor temperature

One of the functions of the CM-SW-01 is to protect the compressor motor against overload.

By monitoring the resistance in a PTC sensor mounted in the motor windings, the CM-SW-01 will lockout

and stop the motor if the resistance increases above the limit as shown below.

When the lockout has been activated, the two start relays K1 and K2 are released immediately to stop the

compressor.

There is a restart blocking function to prevent the motor from being started too soon after having been

overheated.

If the CM-SW-01 is locked, an external reset must be performed by either powering off the device for

minimum 5 seconds or sending a reset command on the serial bus.

When power is turned on to the CM-SW-01 module, the PTC resistance is measured:

If PTC resistance is below the reset limit 2,9 kΩ:

No alarm: The relays are energized immediately (if no other faults are present)

If PTC resistance is between 2,9 kΩ and 11,4 kΩ:

Alarm: The relays are first energized when below 2,9 kΩ

(compressor motor has cooled down)

If PTC resistance is above 11,4 kΩ:

Alarm lock: The relays are not energized and the module is locked

Alarm

Fault

Clear

2,9 kΩ ±20%11,4 kΩ±20%

Fault

Relay open

RPTC

Relay closed

8 SG-150-1

3.2.2 Discharge temperature

A temperature sensor is mounted on the discharge side of the compressor; the CM-SW-01 will open the

relays and break the safety chain if the discharge temperature threshold is exceeded.

3.2.3 Oil supply

The oil supply monitor is configured for oil level (OLC-D1) monitoring. Actual status is always accessible via

Modbus.

If an oil level fault is detected, the status is immediately updated via Modbus. However, the first 90 seconds

after compressor start, the fault signal is not activated. If the oil level is still too low, the CM-SW-01 releases

the fault relay and locks out immediately.

The OLC-D1 module (24 V version) must be used for the oil level detection.

A warning signal is set immediately if the compressor is running and the OLC input is open.

The oil fault alarm must be externally reset by either powering off the device for minimum 5 seconds or

sending a reset command on the serial bus.

3.2.4 Short-cycling warning

To protect the motor windings, the module will give a warning if the compressor is started too many times

within 1 hour, but the compressor will not be locked.

SG-150-1 9

3.2.5 Application limits

The application limits function monitors if the operating conditions of the compressor is within the safe

operation area limits –as shown in the BITZER Software when doing compressor calculations.

The BITZER Software can be downloaded from BITZER’s homepage, www.bitzer.de.

The operating point is determined by the saturated suction and discharge gas temperatures, which are

calculated from the suction and discharge gas pressure based on the selected refrigerant.

The figure below shows the multi-level monitoring of the application limits and behaviour when a limit is

reached.

Active warning, critical and faults are set inactive when the operating point again is within the reset-limit.

HP cut-out and LP cut-out are configured

in the BEST Software.

Application limit

Warning reset

Warning limit

Critical limit (shut off after 30s)

Fault limit (Immediately shut-off)

High- and Low pressure cut-out

}Active 120 s after

compressor start

Evaporating temperature to(SST) [°C]

Condensing temperature tc(SDT) [°C]

HP cut-out

LP cut-out

Fault limit, direct shut-off:

The compressor will stop immediately if this

limit is reached!

Envelope status = 6 Fault

Critical limit, shut-off after 30 s:

30s delay time to bring compressor back

inside application envelope else the

compressor is stopped with a Fault alarm

Critical (30s period starts)

Envelope status = 5 Critical

Warning limit:

Warning to system controller

No further actions

Envelope status = 4 Warning

Warning reset

10 SG-150-1

There are nine zones in the application limit as shown on the figure below.

Zone zero (the green-shaded area) is the normal, safe operation area within the application limits.

A warning and a fault will be given if the warning level or fault level is reached.

Please also see envelope faults ‘30-*’ in section 9 Alarm system.

After a stop due to fault limit, the fault can be reset when the compressor is stopped. If timed resets are

enabled, the CM-SW-01 will perform a timed reset otherwise an external reset is required. The CM-SW-01

will start the compressor again if the start command is active or when it is applied again.

Please observe:

There is no Application limits monitoring the first period after start of the compressor.

The period varies for the compressor type, can be up to 120 s.

Envelope status = 2–Start up

Section 10.4.2 Status –compressor lists two parameters that relate to the application envelope:

Envelope Status lists the status of the compressor and if there should be warnings related to the

envelope:

Envelope status 4–warning means the operating point of the compressor is between the warning

limit and the critical limit.

Envelope status 5–critical means the operating point of the compressor is between the critical limit

and the fault limit and is only allowed to be there for 30 seconds from this warning became active.

Envelope status 6–fault means the compressor is stopped since the operating point of the

compressor has been outside the critical limit for more than 30 seconds or has exceeded the fault

limit

Envelope Zone shows in which zone the compressors operating point is right now or if a fault is

active, in which zone the operating point was when the fault was set.

The zones are listed above.

The zone is zero if the operating point is within the warning limit and no envelope faults are active.

6.SH2.SL

1.SLDL

3.SLDH 4.DH

5.SHDH

7.SHDL

8.DL

Evaporating temperature t0(SST) [°C]

Condensing temperature tc(SDT)[°C]

0: Ok

Zone number, description and alarm number:

Zone 1:SST Low, SDT Low 3001

Zone 2:SST Low 3002

Zone 3:SST Low, SDT High 3003

Zone 4:SDT High 3004

Zone 5:SST High & SDT High3005

Zone 6:SST High 3006

Zone 7:SST High & SDT Low 3007

Zone 8:SDT Low 3008

Zone 0: Normal operation within application

limit and no alarms

t0(SST) = Evaporating temperature

tc(SDT) = Condensing temperature

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