GEA Bock BCM2000 User Manual

BCM2000

Bock Compressor Management

Operating instructions BCM2000

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engineering for a better world GEA Refrigeration Technologies

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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: [phone]

Fax: [phone]
[e-mail]
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

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GEA Bock GmbH
GEA Bock GmbH
Benzstraße 7

72636 Frickenhausen

Germany

Telephone [phone]

Fax [phone]

[e-mail]

www.bock.de

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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

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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.

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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.

B

Connection terminals:

- on power supply section up to 1,5 mm²

- on control section up to 0,25 mm²

B
C

Structure / functions

4

L = 100

B = 60

H = 52

C

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Product description

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.

The unit has three main components:

A

- 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.

A

B

C

12

11

4

910

65

15

14

13

8

7

2

3

1

A

B

C

12

11

4

910

65

15

14

13

8

7

2

3

1

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

1)

1)

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

2)

2)

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

A

A

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

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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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