BCM2000
Bock Compressor Management
Operating instructions BCM2000
09794-05.2012-DGbFEI
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 certified 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.
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GEA Bock GmbH
GEABockBockKältemaschinenGmbH GmbH
Benzstraße 7
Postfach 11 61
72636 Frickenhausen
D-72632 Frickenhausen
Germany
Benzstr. 7
D-72636 Frickenhausen
Telephone +49 7022 9454 0
Fon: |
+49 |
7022 9454-0 |
Fax |
+49 |
+49 7022 9454 137 |
Fax: |
7022 9454-137 |
bock@gea.com
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 identified 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
GEABockBockKältemaschinenGmbH GmbH
09794-05.2012-DGbFEI
09794-05.2012-DGbFEI
Contents
Contents |
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Foreword |
2 |
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Safety instructions |
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Technical data |
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Structure / functions |
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Standart settings |
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Adjustable setting |
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Sensor details |
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Electrical connection |
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General |
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Connecting the unit |
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- Integration of additional switching and control components |
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Checking functions |
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Activating or bridging certain monitoring functions |
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Reset button |
11 |
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Error messages - information messages - emergency operation |
11 |
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Temperature displays |
12 |
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Oil pressure displays |
12 |
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Compressor displays |
13 |
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Surge guard displays |
13 |
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Service displays |
13 |
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Spare parts and accessories |
14 |
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Troubleshooting |
15 |
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Legend:
LED on or flashes
LED off
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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 qualified 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 specifications 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 …
Relay:AC 250 V, 3A, 750 VA ind.
B
H = 52
C
Connection terminals: |
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60 |
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- on power supply section |
B up to 1,5 mm² |
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B |
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- on control section |
C up to 0,25 mm² |
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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.
09794-05.2012-DGbFEI
09794-05.2012-DGbFEI
Product description
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. |
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B |
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C |
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Item No. Designation |
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Function |
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1 |
Mains voltage |
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LED green |
for mains voltage |
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2 |
Compressor operation |
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LED green |
for compressor operation |
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3 |
Automatic compressor start |
LED yellow |
for automatic compressor release. Com |
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pressor starts after a delay via the machine |
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control or lube oil pre-heating |
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Motor winding temperature |
LED red |
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when temperature too high |
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Compressed gas temperature |
LED red |
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when temperature too high |
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Oil temperature |
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LED red |
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when temperature too low |
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Compressor is enabled for starting only |
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when the lube oil is pre-heated to +25°C, |
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but at the latest after 30 min. |
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Temperature display + |
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LED red |
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comb. with item 4 / 5 / 6 |
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Temperature display - |
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temperature too high (+) or too low (-) |
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Oil pressure |
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LED red |
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when oil pressure too low |
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Delay: approx. 90 s |
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Liquid detection |
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LED red |
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for liquid hammers during start-up |
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Compressor rotation detection |
LED red |
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when compressor does not start although |
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motor supplied with power |
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Surge guard |
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LED yellow |
for more than 12 starts per hour |
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Compressor continues to operate, no stop |
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Recommended oil change |
LED yellow |
after a certain interval has been exceeded |
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Compressor continues to operate, no stop |
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Reset button |
Reset to operating function |
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Bridging switch |
Activates or bridges individual functions |
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PC interface |
For reading |
5 |
Standard settings
Monitoring |
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Procedure |
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Value |
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Motor temperature |
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Compressor switched off at motor overtemperature |
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130° C |
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Reset release when cooled down after motor overtemperature |
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120° C |
Oil temperature |
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Automatic release after the oil has pre-heated |
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25° C1) |
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1) or automatic release after maximum pre-heating time |
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30 min |
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Automatic shut-down of the compressor at oil overtemperature |
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120° C |
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Automatic release when cooled down after oil overtemperature |
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95° C |
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Automatic shut-down of the compressor at oil undertemperature |
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17° C |
Discharge gas |
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Shut-down of the compressor at hot gas overtemperature |
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140° C |
temperature |
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Reset release when cooled down after hot gas overtemperature |
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130° C |
Oil differential |
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Minimum value for oil differential pressure |
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0,65 bar |
pressure |
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Shut-down of the compressor when differential pressure too low |
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0,6 bar 2) |
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2) Shut-down delay time when differential pressure too low |
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90s |
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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
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can be changed on the spot depending on the prevailing conditions: |
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Out-of-step: |
Compressor blocked after every standart shut-down: |
180 s |
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Variable time range: |
0 - 255 s |
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For rack operation, set this position to “0” or hide with bypass switch 7, |
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GB |
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see pos. 7 in the chapter “error messages – information messages – |
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emergency operation. |
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Oil pressure error time: |
Shut-down delay (standart setting): |
90 s |
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Rotation detection: |
Variable time range: |
15 - 90 s |
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Vibration factor (standart setting): |
2 |
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Variable time range: |
0 - 40 |
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Sensor details |
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Discharge gas tem- |
PTC sensor switching at 140 °C. |
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perature sensor: |
Resistance range 20 - 100 Ω at 15 - 50°C (value for each sensor). |
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Functioning principle: only slight change in resistance when heated up |
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below the switching point temperature, but in the switching point range |
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the resistance value suddenly changes by several kOhm. |
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Oil temperature sensor: |
Sensor KTY84-130 (see diagram: resistance temperature curve) |
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Functioning principle: resistance value changes according to the |
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change in oil temperature |
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Differential pressure switch: |
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ΔP Reed contact, IP 65 |
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ΔP good |
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ΔP bad |
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L+ |
brown |
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L+ |
brown |
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KTY84-130 |
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orange |
red |
orange |
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red |
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Switching current: 30 mA, switching power: max. |
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630 VA; Ambient temperature: -30 … +70°C
09794-05.2012-DGbFEI
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