Intelligent Compressor Solutions - Bock

Intelligent compressor solutions

MP10 Motor ProtectionBCM2000 Bock Compressor Management EFC, EFCe Electronic Frequency ControlERC Electronic Rack ControlESS Electronic Soft StartESP Electronic Single PhaseTrend-setting compressor variants

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Progressive technology in and around the compressor Bock has been the pioneer under this motto in developing technical solutions which set the benchmarks for energy and effi ciency, operating safety, and reliability, not only for compressors but for the whole refrigeration plant.

Type MP10 BCM2000 EFC/ERC EFCe ESS ESP

HG(HA)12P

HG(HA)22P

HG(HA)34P

HG(HA)4 1)

HG(HA)5 1)

HG(HA)6 1)

HG7

HG8

standard option 1) not for HA version available

MP10 Motor Protection Activate motor protection Information see page 15

BCM2000 Bock Compressor Management The multifunctional management systemInformation see page 16

EFC Electronic Frequency Control Continuously variable speed control directly mounted on the compressorInformation see page 18

ERC Electronic Rack Control Rack control for Pluscom compres-sors with frequency converterInformation see page 25

ESS Electronic Soft Start Start electronic for Pluscom compressorsInformation see page 26

ESP Electronic Single PhasePhase converter from single to three phase ACInformation see page 28

EFCe Electronic Frequency Control externContinuously variable speed control for individual set-upInformation see page 18

Availability


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MP10 Motor Protection

Temperature safety drive for the drive motor

Standard on all compressors (except HG8)

The exceptional feature is that the monitoring function and mains availability are shown by coloured LEDs. There are no complicated or time-consuming defect locating processes.

The MP10 also provides the usual functions as standard, e.g. a reconnection preventing device, a reset, free terminals for PTC temperature sensors (e.g. heat protection thermostat) and other useful items.

Supply sectioncable connections withscrewless terminals

Red LED Temperature fault in motor

Red LED Temperature fault (random e.g. heat protection thermostat)

Drive section cable connections byscrewless terminals

Green LEDMains supply availablecable connections with

Red LED

Unit designation MP10

Connection voltage AC 230 V - 1 - 50/60 Hz

Relay AC 250 V, 3 A, 750 VA ind.

Dimensions L/B/H 100 x 60 x 52 mm

Technical data

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Multifunctional management system

Included as standard in HG8Available as an option for HG(HA)4, 5, 6 and HG7

With the BCM2000, Bock ist the first compressor manufacturer who offers a complete management system providing all the main functions for safe compressor operation in a practical compact as-sembly, user friendly and economical.

Two central functions Protection against liquid slugging during start-up through the -

start-up identification systemOil service recommendations -

(calculation is based on operating data)

Other important functions Monitoring of discharge gas temperature, motor winding tempera-ture, oil temperature as well as oil pressure and cycle protection

Simple and logical operationSelf-explanatory symbols -

Status is indicated by LEDs -

Clearly designed control unit -

Unit designation BCM2000

Connection voltage AC 230 V - 1 - 50/60 Hz

Relay AC 250 V, 3 A, 750 VA ind.

Dimensions L/B/H 100 x 60 x 52 mm

BCM2000 Bock Compressor Management

Technical data

Simple electrical connectionAll monitoring functions are wired ready for operation -

Simple integration of the BCM2000 into the control circuit -

All cable connections have screwless terminals -

Practical and easily accessible positioning in the compressorconnection box

Installed in place of the usual motor protection unit MP10 (same -

dimensions)Optimal visibility by inspection window in the cover of the con- -

nection box (HG8 only)

Reliable and economical Eight monitoring functions in one central unit -

Intelligent monitoring of the various functions including operating -

hour meteringSimple recognition of the current status using an optical display -

Each function can be short cut for emergency operation -

Read facility for stored messages for fast and safe error analysis -

in the event of a fault or breakdownLoss-proof error memory even after power failure -

Self-monitoring sensor technology -

Connection facility for remote data monitoring (error messages) -


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Oil pressure management

Temperature gauge

Supply section

Double function1. Protection against slugging2. Start-up identifi cation after start release

Cycle protection

Bridge switch for emer-gency operation

Oil service recom-mendation

PC interface

Control section

Motor winding temperature

Oil temperatureDischarge gas temperature

BCM2000 Bock Compressor Management

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EFC, EFCe Systems – Electronic Frequency Control

Continuously variable speed control using frequencyconverter technology

With the EFC and EFCe system Bock offers the most effi cient means of adapting the capacity of the compressor to current refrigeration plant requirements: “Progressively adjustable speed control using frequency converter technology“.

Up to 25 % less power consumption!

The EFC system is optionally available for all Pluscom compressors HG(HA)12P, 22P, 34P.

EFC-systems are compactly mounted on the compressor, wired and connected ready for use. It is activated by a pressure transdu-cer mounted on the suction side. The adjustment range can be set individually.

In December 2009, the Bock EFC system received the BMU (German Environment Ministry) Climate Protection Innovation Award in Refrigeration Technology from the German Minister for Environment.

NEW: The EFCe systems are optionally available for the com-pressors of the series HG4 to HG8.

EFCe systems are also optimally adjusted to the compressor at the factory and programmed with the necessary control settings.Due to their size, however, they are not directly build on the com-pressor but are instead intended to be set up individually. The device iscontrolled via a pressure sensor arranged on the intake side, or via an external control signal.The trigger for the system (start/stop) is via a pump down presso-stat. The control range can be adjusted on an individual basis. The device is designed for mounting on the wall or switch cabinet.

Thanks to the oil pump lubrication all Bock compressors are ideal for speed control, in particular for low frequencies.Not available for HA designs.

EFC EFCe

received the BMU (German Environment Ministry) Climate Protection Innovation


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EFC, EFCe Systems – Electronic Frequency Control Versions

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At a glance

The advantages of frequency-converter operation:

Set for immediate connection and optimally programmed with -

data for the relevant compressorFully variable adjustment of the refrigerating capacity on demand -

No high energy, high-wear start/stop operation -

Up to 25% less power consumption -

Reduced mechanical compressor load for longer service life -

Always optimum machine pressures and operating conditions -

Lower pressure losses in the heat exchangers -

Lower cooling down and heating up losses throughout the -

systemReduced start-up current at full torque -

Part windings and star-delta circuits no longer required -

Including motor monitoring -

Further advantages of the EFC system:

Wired for immediate connection and compactly mounted on the -

compressorNo additional wiring required -

Takes up no space in the switchboard -

Needs no screened supply lines to the compressor -

Control module also included for simple adjustment of the -

EFC-SystemWith the auxiliary module ERC4 also suitable for racks -

Further advantages of the EFCe system:

No power contactor and/or soft start necessary to trigger -

controlled compressors Easy adjustment of the EFCe system by means of full graphic -

display (operating unit)EFCe system fulfils the requirements of safety category 3 in -

EN 954-1 (safe stop function)


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Software version 2)

Electronic Frequency Control

Installation variant e= from 11 kW for individual external installation (not mounted on the compressor)Capacity 1)

Type key Systems| EFC/EFCe

E FC e 15 , 0 A1/

1) Capacity - Product selection

Type EFC EFCe

2,2 kW 4,0 kw 7,5 kW 11,0 kW 15,0 kW 18,5 kW 30,0 kW 37,0 kW 45,0 kW 55,0 kW 75,0 kW 90,0 kWHG12P, HA12P

HG22P, HA22P

HG34P, HA34P

HG4/465-4 HG4/465-4 S

HG4/555-4HG4/555-4 S

HG4/650-4HG4/650-4 S

HG5/725-4HG5/725-4 S

HG5/830-4HG5/830-4 S

HG5/945-4 HG5/945-4 S

HG6/1080-4HG6/1080-4 S

HG6/1240-4 HG6/1240-4 S

HG6/1410-4 HG6/1410-4 S

HG7/1620-4HG7/1620-4 S

HG7/1860-4HG7/1860-4 S

HG7/2110-4 HG7/2110-4 S

HG8/2470-4 HG8/2470-4 S

HG8/2830-4 HG8/2830-4 S

HG8/3220-4 HG8/3220-4 S

2) Software versionA1 Control signal 4-20 mA with pressure transducer

A2 Control signal 4-20 mA external (without pressure transducer)

A3 Control signal 0-10 V external (without pressure transducer)

A4 for duplex compressors, control signal 4-20 mA with pressure transducer

A5 for duplex compressors, control signal 4-20 mA external (without pressure transducer)

A6 for duplex compressors, control signal 1-10 V external (without pressure transducer)

A7 for compressor racks (2 to 4 compressors), control signal 1-10 V with pressure transducer including Electronic Rack Control (ERC) only EFC

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Calculations

As a rule, the maximum permissible power consumption of the compressor Pmax must not be exceeded. The maximum permissible frequency is always restricted in case of high evaporation temperatures associated with high condensing pressures with refrigerants R404A, R507, R407C, R22, ... At the compressors HG12P/110-4 S, HG22P/190-4 S and HG34P/380-4 S you have to reduce the performance by about 5 Hz.

Technical data

EFC

Unit designation EFC 2,2 EFC 4,0 EFC 7,5

Protection IP 65 IP 54 IP 54

Max. output current under continuous load 6 A 9,5 A 19 A

Max. output power 2,2 kW 4 k W 7,5 kW

Input AC 400/500 V -3- PE 50/60 Hz

5,5/4,5 A 12,3/9,8 A 21,5/17,3 A

Output AC 0-400/500 V -3- PE 0-650 Hz

Permissible control range 30 - 70 Hz 30 - 70 Hz 25 - 70 Hz

EFCe

Unit designation EFCe 11 EFCe 15 EFCe 18,5 EFCe 30 EFCe 37 EFCe 45 EFCe 55 EFCe 75 EFCe 90

Protection IP 54

Max. output current under continuous load

24 A 32 A 37,5 A 61 A 73 A 90 A 106 A 147 A 177 A

Max. output power 11 kW 15 kW 18,5 kW 30 kW 37 kW 45 kW 55 kW 75 kW 90 kW

Input AC 380/500V (+/- 10%) -3- PE 50/60 Hz

Output AC 0- 380/500V -3- PE 0-300 Hz

Permissible control range 1) 25 - 70 Hz

Weight 23 kg 27 kg 45 kg 65 kg 104 kg

1) The specified control ranges may vary depending on the operating condition and system structure

Pmax x 50 HzPe

foperation x Q0 50Hz

50 Hz

Calculating the corresponding refrigerating capacity:

Refrigeration capacity can be determined as a function offrequency from the following calculation:

Qo operation =

Qo operation = refrigerating capacity at the chosen operating point [W]

f operation = frequency at the chosen operating point [Hz]

Qo 50 Hz = refrigerating capacity at the operating point at 50 Hz [W] (see performance data, compressors)

Calculating the maximum possible frequency of thecompressor under specific operating conditions:

The following calculation is used to obtain the maximumpossible frequency at the selected operating point:

fmax =

fmax = maximum permissible frequency [Hz]

Pmax = maximum power consumption [kW] (see technical data, compressors)

Pe = power consumption at the operating point at 50 Hz [kW] (see performance data, compressors)

i

•

•

•

•


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Dimensions EFCe systems

Dimensions EFCe systems

Dimensions in mm

EFCe 11, EFCe 15, EFCe 18,5

245

480

(650

)

260

680

31031

0

EFCe 30, EFCe 37, EFCe 45

335

770

370

EFCe 55, EFCe 75420

380

1210

EFCe 90

Dimensions in ( ) = EFCe 18,5

Dimensional variations with the EFC system

Dimensions in ( ) = HA version

ca.4

80 (5

10)

ca.4

80 (5

10)

Maße in ( ) = HA-Ausführung

ca.4

55 (4

85)

HG(HA)12P HG(HA)22P HG(HA)34P

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Scope of supply EFCe

Basic device for individual set-up, full graphic display, pre-pro- -

grammed with basic settings for the corresponding compressorPressure sensor for suction-pressure-dependent speed control - 1)

enclosedAccessories for individual set-up -

Upstream relay to separate input power and control power, inclu- -

ding terminal strip component

Scope of supply EFC

Basic equipment with intermediate adapter mounted on com- -

pressor terminal box, programmed and assembled ready for operationPressure transducer for suction pressure based speed control - 1)

mounted on the compressor

Programming and readout hand-held terminal with connecting -

cable

1) Configuration based on design required see table on page 21 for software variant A1 and A4


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ERC SystemElectronic Rack Control

Principal regulating and control device for eachcompressor of the rack

In racks with progressively adjustable speed control, the equipment is part of the EFC system (see page 19).

It takes on the function of rack control.

The basic load of each individual compressor, and fine-tuning of the EFC frequency converter (control signal 0-10 V) is controlled by a pressure transducer on the suction side.The ERC is also equipped with operating time register and com-pensation, switch-on and switch-off delays, surge protection and default memory. There are max. four compressors controllable. It is intended for installation in the switch cabinet.

Dimensions

120

140

60

Type ERC4

Protection IP20

Voltage DC 24 V 4,2 A

3 digital inputs DC 24 V à 8 mA

4 digital outputs DC 24 V à 1 A busy}

Technical data

ERC Electronic Rack Control

Dimensions in mm

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ESS SystemElectronic Soft Start

Electronic compressor starter unit

Available as option for: HG(HA)22P, 34P HG(HA)4, 5, 6HG7

The start process uses an electronic soft start unit, instead of the conventional start unloader through the bypass solenoid valve, non-return valve and star-delta protector combination. This means that the compressor gets up to its nominal speed in a set time and therefore produces much lower power peaks than the classical star-delta start.The unit is designed to fit into a switch cabinet.

The advantages:

Soft compressor start from zero to nominal speed, time con- -

trolled and monitored.Up to 40 % lower start-up power consumption than when -

using star-delta start.No star-delta protection combination needed, no bypass bet- -

ween pressure and suction side needed. No solenoid valve or non-return valve needed.No compressor damage resulting from malfunction of the start -

unloader.

Product selection

Type ESS 25 ESS 38 ESS 63 ESS 75 ESS 100

HG22P, HA22P

HG34P, HA34P

HG4/465-4, HA4/465-4HG4/465-4 S

HG4/555-4, HA4/555-4HG4/555-4 S

HG4/650-4, HA4/650-4HG4/650-4 S

HG5/725-4, HA5/725-4HG5/725-4 S

HG5/830-4, HA5/830-4HG5/830-4 S

HG5/945-4, HA5/945-4HG5/945-4 S

HG6/1080-4, HA6/1080-4HG6/1080-4 S

HG6/1240-4, HG6/1240-4HG6/1240-4 S

HG6/1410-4, HG6/1410-4HG6/1410-4 S

HG7/1620-4HG7/1620-4 S

HG7/1860-4HG7/1860-4 S 1)

HG7/2110-4 1)

1) up to +40 °C ambient temperature


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Dimensions

a

c

b

Unit designation ProtectionMax.

output current 1) Input Lost heatDimensions

a / b / c

ESS 25

IP 20Connectors

IP00

25 A

AC 400 V -3- 50/60 Hz

13 W 125 x 45 x 125

ESS 38 38 A 13 W 162 x 55 x 150

ESS 63 63 A 22 W 170 x 71 x 185

ESS 75 75 A 29 W 170 x 71 x 185

ESS 100 100 A 48 W 170 x 71 x 185

Scope of supply: Unit programmed ready to operate -

compressor allotment can be set by the potentiometer -

Unit suitable for fitting into a switch cabinet -

Voltage AC 400 V - 3 - 50/60 Hz -

Technical data

1) at +50 °C ambient temperature

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ESP SystemElectronic Single Phase

Phase converter from single to three phase AC

Available as an option for HG(HA)12P

The ESP System consists of a phase converter and a power choke to limit the power. This unit converts single phase input power to three phase output power and therefore enables the compressor model HG(HA)12P to operate with a standard three phase AC motor using a single phase mains supply. The unit is designed to be fi tted into a switch cabinet.

Single-phase current

Inputsingle-phase

alternating current

Outputthree-phase

alternating current

Power choke

Phase converter

i For the compressors HGX12P/90-4 S and HGX12P/110-4 with R404A please note:tO = -5 °C / tC = +50 °C may not be exceeded.

Another option is to have the possibility of stepless speed capacity control. The parts for this are a suction pressure transducer and a programming and readout hand-held terminal.


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At a glance

The Advantages: Standard three phase AC compressor can be used on a single -

phase supply.Soft compressor start from zero to nominal speed, time controlled -

and monitored.U - p to 40 % lower start-up power consumption than using star delta-start.

Dimensions

No start-up or operating condensers or relays required. -

Contact free switching of main phases, no switch protection -

needed.Option available for stepless speed capacity control. -

Technical Data

Unit designation ESP 1/3 - 2,2 consisting of: phase converter and power choke

Phase converter:Protection IP 20

Max. output current undercontinuous load

9,5 A

Max. output power 2,2 kW

Input AC 230/240 V - 1 - 50/60 Hz

Output AC 230/240 V - 3 - 50/60 Hz

Permissable control range(compressor)*

30 - 60 Hz

* only for extension to stepless speed capacity control

Power choke:

Protection IP 20

Power consumption AC 230/240 V - 1 - 50/60 Hz 18 A

Scope of supply: ESP 1/3 - 2,2, comprising phase converter, programmed and tu- -

ned to the compressor and also a power choke to control the po-wer. Both units are intended for use in switching cabinets.Input: Single phase AC 230/240 V -

Output: Three phase AC 230/240 V -

Phase converter Power choke

Accessories: (only possible ex-works, not retrofit)

Extension of function to stepless speed capacity control 30-60 Hz comprising:

Suction pressure transducer 4-20 mA -

Programming and readout hand-held terminal -

dimensions in mm

60

240

150

90

80 100

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Trend-setting compressor variants

For current market trends e.g. alternative refrigerants, deep-freezing applications or Ex protection, Bock offers a selection of interesting compressor variants from the established semi-hermetic range.

HA (Hermetic Air-cooled) Semi-hermetic air-cooled compressor for the deep-freezetemperature (R22/R404A), see page 31

CO2 compressors (subcritical)Semi-hermetic compressors for subcritical cascade systems,see chapter 4

CO2 compressors (transcritical)Semi hermetic compressors for transcritical CO2 applications, see chapter 5 and 6

R410A compressorsSemi-hermetic compressors for R410A, see chapter 7

ATEX (ATmospheres EXplosibles)Semi-hermetic compressors in explosion-risk environments, see chapter 8

Aluminium compressorsSemi-hermetic compressors in lightweight aluminium design, see catalogue for mobile applications

Type HA CO2(subcritical)

R410A ATEX

HG12P

HG22P

HG34P

HG4

HG5

HG6

HG7

HG8

Availability


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HA System Hermetic Air-cooled

Semi-hermetic air-cooled compressor for the deep-freezingtemperature (R22/R404A)

Can be obtained for all 2 and 4 cylinder versions

Increasingly high specifi cations are being set for all suction gas-cooled semi-hermetic compressors for deep-freezing applications.

Compressors rapidly reach their temperature limits due to the rise in temperature of the suction gas caused by the drive motor. The refrigeration capacity also diminishes. But not in Bock HA com-pressors.

The unique “Bock HA principle“ prevents this. The drive motor is air-cooled and compressor suction is direct. The suction gas is not heated by the motor, but is fed directly to the compressor without being diverted through the motor. The motor is cooled by a compact integrated ventilation unit. Its precise airfl ow cools not only the mo-tor but also the compressor and especially the cylinder heads.

A semi-hermetic compressor with the advantages of an open type.

Suction gas is fed directly into the compressor

The motor is cooled by an integrated ventilation unit

Cool air is directed over the motor through an air duct hood

This results in a reduced discharge gas temperature and thereforean extended range of applications combined with improved capaci-ty (deep-freezing - e.g. R22, R404A).In addition, the compressor is separate from the motor, which is a particular advantage in the event of a motor burn-out.

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Intelligent Compressor Solutions - Bock

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