GEA Bock BCM2000 User Manual

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BCM2000

Bock Compressor Management

Operating instructions BCM2000

engineering for a better world GEA Refrigeration Technologies

09794-05.2012-DGbFEI

Foreword

Dear Customer, The BCM 2000 (Bock Compressor Management) has been developed by Bock. It constitutes a compact compressor monitoring unit with logical, simple functions. The unit can be used for early detection of faults, to reduce damage and failures, and thus to increase the operating reliability and service life of your refrigerating compressor or refrigerating machine. The unit has been designed and certiﬁ ed only for Bock hermetic compressors. It is located in the terminal box (instead of the motor protection trigger device). All possible monitoring functions are connected and have been activated and tested in the factory. Only the control voltage has to be connected and the unit integrated in the machine control safety chain for it to be ready to operate.

Bock Kältemaschinen GmbH Postfach 11 61

D-72632 Frickenhausen Benzstr. 7

D-72636 Frickenhausen Fon: +49 7022 9454-0

Fax: +49 7022 9454-137 mail@bock.de www.bock.de

All we ask of you:

Please read the information summarised for you in this manual before starting work.

It contains important instructions for safety, control, initial commissioning and troubleshooting. In addition you will ﬁ nd information on spare parts and accessories.

Some instructions are identiﬁ ed by special symbols:

WARNING! This symbol is used to indicate that inaccurate compliance or total failure to comply with the instructions could cause injury to persons or damage to the compressor or refrigerating machine.

This symbol indicates important additional instructions which you should observe during your work.

The high quality standard of Bock compressors is guaranteed also by on-going further development of the design, features and accessories. This could possibly result in nonconformities between this present manual and your unit. Please understand that it is not possible for any claims to be derived from the details, illustrations and descriptions.

Your team at Bock Kältemaschinen GmbH

GEA Bock GmbH GEA Bock GmbH Benzstraße 7

72636 Frickenhausen

Germany

Telephone +49 7022 9454 0

Fax +49 7022 9454 137

bock@gea.com

www.bock.de

GEA Bock GmbH

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Contents

Contents Page

Foreword 2

Safety instructions 4

Technical data 4

Structure / functions 4

Standart settings 6

Adjustable setting 6

Sensor details 6

Electrical connection 7

- General 7

- Connecting the unit 7

- Integration of additional switching and control components 9

Checking functions 9

Activating or bridging certain monitoring functions 10

Reset button 11

Error messages - information messages - emergency operation 11

- Temperature displays

- Oil pressure displays

- Compressor displays 1 3

- Surge guard displays 1 3

- Service displays 1 3

Spare parts and accessories 14

Troubleshooting 15

Legend:

LED on or ashes

LED off

Structure / functions

The BCM 2000 is used solely for monitoring the operation of BOCK refrigerating compressors. All monitoring parameters have been coordinated exactly to the compressor connected up in the factory. Incoming signals are detected as status, information or error messages and processed to release, shutdown and reporting functions. The unit does not exercise any regulating function.

Product description

Safety

Work on the BCM 2000 may only be carried out by persons whose technical training, skills and experience together with their knowledge of pertinent regulations means that they are capable of assessing the work to be carried out and detecting any possible dangers.

Safety instructions CAUTION HIGH-VOLTAGE CURRENT!

Only qualied electricians are allowed to handle the unit.

The monitoring unit BCM 2000 is mounted in the compressor connection box. Although the motor connection is covered, the machine must be disconnected from the mains before and during all work and when testing the machine, otherwise there is a risk of injuries.

National safety regulations, accident prevention regulations, technical rules and other

specications must be observed.

Compare the voltage and frequency details with the data for the local electricity mains.

The unit may only be connected to the mains when the data coincide.

The terminals of the control unit must not come into contact with the mains voltage,

otherwise the unit and the monitoring sensors will be destroyed.

Technical data

Connection voltage: AC 230 V + 10% 50/60 Hz tol. ambient temperature: -30°C … +60°C Relay: AC 250 V, 3A, 750 VA ind.

Connection terminals:

- on power supply section up to 1,5 mm²

- on control section up to 0,25 mm²

B C

Structure / functions

L = 100

B = 60

H = 52

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Product description

Structure / functions

The unit has three main components:

- Electronic section B - Power supply section C - Control section

Altogether the unit has 8 monitoring functions: motor winding temperature, compressed gas temperature, oil temperature, oil pressure, liquid detection during start-up, compressor rotation detection, surge guard, recommended oil change.

910

Item No. Designation Function 1 Mains voltage LED green for mains voltage

2 Compressor operation LED green for compressor operation 3 Automatic compressor start LED yellow for automatic compressor release. Com pressor starts after a delay via the machine control or lube oil pre-heating 4 Motor winding temperature LED red when temperature too high 5 Compressed gas temperature LED red when temperature too high 6 Oil temperature LED red when temperature too low Compressor is enabled for starting only when the lube oil is pre-heated to +25°C, but at the latest after 30 min. 7 Temperature display + LED red comb. with item 4 / 5 / 6 8 Temperature display - temperature too high (+) or too low (-) 9 Oil pressure LED red when oil pressure too low Delay: approx. 90 s 10 Liquid detection LED red for liquid hammers during start-up 10 Compressor rotation detection LED red when compressor does not start although motor supplied with power 11 Surge guard LED yellow for more than 12 starts per hour Compressor continues to operate, no stop 12 Recommended oil change LED yellow after a certain interval has been exceeded Compressor continues to operate, no stop 13 Reset button Reset to operating function 14 Bridging switch Activates or bridges individual functions 15 PC interface For reading

}

Standard settings

Monitoring Procedure Value

Motor temperature Compressor switched off at motor overtemperature 130° C

Reset release when cooled down after motor overtemperature 120° C

Oil temperature Automatic release after the oil has pre-heated 25° C

or automatic release after maximum pre-heating time 30 min Automatic shut-down of the compressor at oil overtemperature 120° C Automatic release when cooled down after oil overtemperature 95° C Automatic shut-down of the compressor at oil undertemperature 17° C

Discharge gas Shut-down of the compressor at hot gas overtemperature 140° C temperature Reset release when cooled down after hot gas overtemperature 130° C

Oil differential Minimum value for oil differential pressure 0,65 bar pressure Shut-down of the compressor when differential pressure too low 0,6 bar

Shut-down delay time when differential pressure too low 90s

Sensor details

Discharge gas tem-

PTC sensor switching at 140 °C. perature sensor: Resistance range 20 - 100 Ω at 15 - 50°C (value for each sensor). Functioning principle: only slight change in resistance when heated up below the switching point temperature, but in the switching point range the resistance value suddenly changes by several kOhm.

Oil temperature sensor: Sensor KTY84-130 (see diagram: resistance temperature curve) Functioning principle: resistance value changes according to the change in oil temperature

Differential pressure switch:

∆P Reed contact, IP 65

Switching current: 30 mA, switching power: max.

30 VA; Ambient temperature: -30 … +70°C

brown

red

orange

L+

∆P good

red

orange

L+

∆P bad

brown

Adjustable settings

All the errors saved in BCM 2000 (up to 170) incl. the operating hours counter total can be read out with a PC, the reading program on CD-ROM and the cable. In addition, the following trigger settings can be changed on the spot depending on the prevailing conditions: Out-of-step: Compressor blocked after every standart shut-down: 180 s

Variable time range: 0 - 255 s For rack operation, set this position to “0” or hide with bypass switch 7, see pos. 7 in the chapter “error messages – information messages – emergency operation. Oil pressure error time: Shut-down delay (standart setting): 90 s Variable time range: 15 - 90 s Rotation detection: Vibration factor (standart setting): 2 Variable time range: 0 - 40

KTY84-130

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orange

brown

red

Connecting the unit

PTC

compressed gas

temperature sensor

PTC

motor winding

temperature sensor

oil temperature

sensor

oil pressure

sensor

oil sump

heating E1

brown

red

orange

Electrical connection

General

The unit has two different connection blocks:

1) Power supply section

2) Control section

The power supply section is for connection to the machine mains voltage. It is to be integrated in the machine control by the refrigerating engineer (qualiﬁ ed engineer). The unit is to be integrated in ﬁ rst position of the safety chain. The power supply at L1-N should be identical with the switching voltage at relay contacts 11, 12 and 14. The control section is used for connection of the individual monitoring functions. These are normally ready wired in the factory and prefabricated ready for operation so that no additional work is necessary here.

The whole control section (terminals 15 - 25) and all monitoring sensors, probes and corresponding connections must not have any contact with mains voltage. Otherwise the BCM 2000 and sensor components will be destroyed.

Electrical connection

Connecting the unit

E1 Oil sump heater F1 Control fuse K1.1 Auxiliary contactor K2T Delay relay 10-60 min., Connection facility for external collective error message

F Safety chain with regulating unit (thermostat) Kx Compressor load contactor or protection combination with motor protection switches S1 Switch for control voltage Off / On

Electrical connection of the unit is to be carried out by a qualied electrician accor-

ding to the circuit diagramm. Comply with the local safety regulations. Always disconnect the machine from the power supply before and during working

on the machine. Compare the voltage and frequency details on the nameplate with the details for

the electricity mains. Unit may only be connected up when these coincide.

Electrical connection

ca. 10 - 40 min.

orange

brown

red

10-60 min

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Checking functions

Integration of additional switching and control components

• Auxiliary contactor K1.1

An auxiliary contactor K1.1 is provided to protect the contacts in the unit (max. tol. load AC

250 V / 3 A / 750 VA ind.)

• Delay relay K2T

A delay relay K2T 10 - 60 min is to be superposed so that various operating interruptions are

not indicated as fault (adjustment range approx. 10 to 60 minutes, settling time 40 min.)

• Oil sump heating E1

The compressor oil sump heater E1 is to be connected up in combination with the oil tempera-

ture function. The oil sump heater should already be running during the evacuation phase.

If the oil temperature is under +25°C, the compressor is blocked and the oil sump heater is running.

For oil temperatures exceeding +25°C, but at the latest after 30 min. pre-heating

heater

time the compressor is released for operation and the oil sump

switches off.

Checking the functions

General

The unit is mounted in the compressor terminal box. All monitoring sensors are connected and their functions have been checked. A separate function check is not necessary. The following function checks can be carried out when spare parts have been supplied or as part of troubleshooting:

Function check for compressed gas/winding/oil temperature Function check for oil pressure

Procedure for checking the compressed gas / winding / oil temperature functions

1 Disconnect from the mains

Disconnect the temperature sensor (terminal 15, 17 or 19) Important! Every sensor must be checked individually!

2 Insert wire bridge L1 - 5

3 Apply mains voltage

The 2 corresponding LEDs must light up after 30 s delay

4 Disconnect from the mains, remove the wire bridge (see no. 2), connect sensor (see no. 1)

5 Apply mains voltage

Unit ready

Activation / bridging the monitoring functions

Procedure for checking the oil pressure function

1 Disconnect from the mains

Disconnect the sensor (terminal 22)

2 Insert wire bridge L1 - 5

3 Apply mains voltage

The corresponding LED must light up after approx. 90 s delay

4 Disconnect from the mains, remove the wire bridge (see no. 2), connect sensor (see no. 1)

5 Apply mains voltage

Unit ready

Activating or bridging individual monitoring functions

General

Each of the 8 possible functions can be individually activated or bridged. The works setting is always „activated“. Every function is numbered and allocated to the function switch with the same number. The adjustment of the function switch is only activated after quitting with the reset button for safety reasons. The adjustment can be made when the compressor is running or at a standstill.

No safety functions work in bridged state. Therefore use only for

emergency operation. LED ashes until function is activated again.

Bridge function

(e.g. service display) Switch setting to the left (off)

Activate function

(e.g. service display) Switch setting to the right (on)

Reset

LED ashes

Reset

LED off

Reset button

Function switches

Compressor starts up or continues through the machine control

Compressor starts up or continues through the machine control; exception: longer power failure. operation only released after lube oil has pre-heated

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Reset, messages, emergency operation

Reset

General

Every message can be quit with reset. The procedure can be repeated as often as necessary.

Caution! First rectify the fault, then release the compressor. After quitting the fault with the reset button, the compressor starts up again without any delay

Quit fault (e.g. oil fault)

Compressor starts up immediately. Exception: longer

Reset

LED on LED off

power failure. operation only released after lube oil has preheated

Reset button

Fault messages - information messages - emergency operation

General

The unit has 8 monitoring functions. These are divided into:

- 5 fault messages (compressor shutdown when triggered)

- 2 information messages (compressor not shutdown when triggered)

- 1 status message (compressor automatically released when triggered)

There are two possibilities for reactivating the messages:

a) reset to initial function (using reset button) b) bridging the functions (emergency operation using function switch)

The unit can save several approx. 170 fault messages. The device can save up to 170 error messages. The saved error messages can be read via the PC interface with the special interface cable (accessory, article no.

06988) and the Bock reading program (accessory, article no. 06992).

CAUTION! Remedy fault rst, then release compressor!

No protection functions available in bridged status. Therefore only use

for emergency operation! LED ashes until function activated again.

Function switches

Reset button

Messages and emergency operation

Display a) Reset to initial function b) operation - no safety function)

Fault message

Compressed gas temperature

too high. LED ON / Compressor

OFF

Fault message

Winding temperature too high.

LED ON / Compressor OFF

Status message

Oil temperature too low.

LED ON / Compressor OFF

Possible after cooling down

to operating temperature

Reset

Compressor starts up immedi-

ately.

LED OFF

Possible after cooling down

to operating temperature

Reset

Compressor starts up immedi-

ately.

LED OFF

Reset not possible

Compressor starts automa-

tically after preheating the

lube oil to +25°C, but at

the latest after 30 min.

pre-heating time

LED - OFF / Compressor - ON

Function bridged (emergency

Possible without cooling down

to operating temperature

Reset

Switch 1 Off

Compressor starts up through

machine control. LED ashes

Possible without cooling down

to operating temperature

Reset

Switch 2 Off

Compressor starts up through

machine control. LED ashes

Reset

Switch 3 Off

Compressor starts up through

machine control. LED ashes

Status message

Oil temperature too high.

LED ON / Compressor OFF

Reset not possible

Compressor starts automa-

tically after cooling down.

LED - OFF / Compressor - ON

Reset

Switch 3 Off

Compressor starts up through

machine control. LED ashes

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Messages and emergency operation

Display a) Reset to initial function b) operation - no safety function)

Fault message

Reset

Oil pressure too low

LED ON / Compressor OFF

Fault message

Combined function 1: Liquid at start

LED ON / Compressor OFF

Fault message

Combined function 2: Compressor not turning.

LED ON / Compressor OFF

Information message

Compressor starts up immedi-

ately.

LED OFF

Reset

Compressor starts up

immediately.

LED OFF

Reset

Compressor starts up after fault eliminated.

LED OFF

12 starts per hour

exceeded

Function bridged (emergency

Reset

Switch 4 Off

Compressor starts up through

machine control. LED ashes

Reset

Switch 5 Off

5 + 6 are bridged. Compressor

starts up through machine control.

LED ashes

Reset

Switch 6 Off

Only 6 is bridged. Compressor

LED OFF

Engine monitoring by winding temperature feeler

Surge op. too high

LED ON / Compressor ON

Information message

Recommended oil change

LED ON / Compressor ON

Reset

LED OFF

Reset to „0“

Counting starts again

Reset

LED OFF

Reset to „0“

Evaluation starts again

Reset

Switch 7 Off

Compressor starts up through

machine control. LED ashes

Reset

Switch 8 Off

Compressor starts up through

machine control. LED ashes

Spare parts and accessories

General

The basic BCM 2000 unit is designed and programmed in the factory to work with the corresponding compressor. This guarantees the best possible functional reliability. When spare parts are required, we must know the compressor type and machine number before delivering an individual unit to ensure that it will function properly.

Overview of spare parts / accessories

Item. Designation Art. No.

1 Electronic compressor protection

Bock - BCM 2000, 230 V~ 06950 consisting of: basic unit with microprocessor for all possible functions, display with individual function displays, adjusting switches for the various functions, reset button, interface for PC connection, power supply section, control section for the individual functions

2 Oil pressure monitoring ∆P

2 a: Delta-P screw-on part ¾“ 16 UNF 06990 (to version ID 17) 2 b: INT 250 - circuit part with lead 06989 2 c: Delta-P screw-on part M20x1,5 50225 (starting from version ID 18)

2a, 2c

3 Oil temperature monitoring

NTC screw-on temperature sensor 06947 Thread NPTF 1/8“ with lead Lead colour: black

4 Compressed gas temperature monitoring

PTC screw-on temperature sensor 06033 Thread NPTF 1/8“ with lead Lead colour: red-brown

5 Interface lead

for PC connection 06988

6 CD with read-out program 06992

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Troubleshooting

What to do, when ….

Display Possible fault causes or information message > Check control fuse and voltage at terminals

L and N on the BCM 2000 Control voltage is ON

but no LED lights up > Interruption (open contact) in the safety chain.

Check all integrated switches and units for continuity LED „power on“ and „compressor on“

light up but the compressor does not turn Fault message

> discharge end temperature too high > Suction gas overheating too high > Condensing temperature too high > Bypass from pressure to suction side 1 = compressed gas temp. too high LED ON / Compressor OFF

Fault message > Motor overload > Undervoltage > Control error > Winding short, short circuit, accidental ground > Two-phase mode 2 = winding temperature too high > Motor cooling insufﬁ cient LED ON / Compressor OFF > Extremely unequal phase load

Status message > Oil sump heating not working

> Pre-heating phase too short Operation released at +25°C, but at the latest 3 = Oil temperature too low after 30 min. pre-heating time LED ON / Compressor OFF

> Oil sensor is not screwed as far as it will go into the Fault message screw-in sleeve > Not enough oil > Liquid coolant in compressor / in oil > Dirt in machine / in oil > Oil pump defect 4 = Oil pressure too low > Inadequate oil return LED ON / Compressor OFF > Unsuitable oil grade > Damage to bearings or power plant, wear

What to do, when ... ?

Troubleshooting

Display Possible fault causes or information message

Fault message > Refrigerant or oil displaced in the machine > Check electric valve, solenoid in liquid pipe for function and leaks

5 = liquid at start

Fault message > One or all power supply phases not connected. > For parallel operation: Sensor possibly affected by the operation of an adjacent compressor (–> bypass function).

Fault message 6 is displayed although the compressor is running: 6 = compressor not turning > Operating vibrations too low. Vibration sensor cannot LED ON / Compressor OFF detect the compressor running due to the exception-

ally quiet operation. > Adjust the sensor’s sensitivity (Bock service software

required for this). This position can also be temporarily shut down without the service software by tripping DIP switch 6. Multiple monitoring of this position ensures that the compressor is fully monitored.

Information message > More than 12 start-ups per hour > Faulty control or setting > Insufcient refrigerant > Condenser pressure control fault > Evaporator icing 7 = Surge op. too high > E-valve problem LED ON / Compressor ON > SL lter or dryer contaminated

Information message > Oil change is recommended > Filter or dryer change can be associated with this message

8 = Recommended oil change LED ON / Compressor ON

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Standard Paragraph Designation Value EN 60730 2.2.15 Purpose of control unit: Motor protection device

6.2.6 Type of controlled load: pilot load

6.4 Reset characteristic: not automatic: type 3BH automatic: type 3C Software class A

Device protection class

Relevant standards

Fault memory:

The Bock BCM 2000 (v1.4) software provides the possibility of exporting the complete fault memory of the BCM 2000 to a text le thus making a backup of it.

Procedure for backing up the fault memory:

1. A voltage of 230 V must be applied between L1 and N of the BCM 2000.

2. The BCM 2000 must be connected to a PC using the special cable.

3. Start the BCM 2000 software and wait until the fault report is read out.

4. On the “Diagnostics” screen, there is the “Export” button next to the “Retrieve” button which makes a new readout of the BCM 2000 possible when clicked.

5. The BCM 2000 software creates a text le (“Export File”) when the “Export” button is clicked.

6. Select the destination where the text le should be saved. Input lename and conrm with “Save”. The name of the backup le should contain the machine number, type and date.

Example: AN022334A014-HGX8-2830-4S-01012006.txt

Excellence Passion Integrity Responsibility GEA-versity

GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology. GEA Group is listed in the STOXX Europe 600 Index.

GEA Refrigeration Technologies

GEA Bock GmbH

Benzstraße 7, 72636 Frickenhausen, Germany Telephone: +49 7022 9454-0, Fax: +49 7022 9454-137 bock@gea.com, www.bock.de

09794-05.2012-DGbFEI

GEA Bock BCM2000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual