GEA Bock Plusbox SHG 34e/215-4 S P&P Series User manual

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GEA Bock Plusbox
Assembly instructions
96284-09-2016-Gb
Translation of the original instructions
SHG(X)34e/215-4 (S)PB SHG(X)34e/215-4 (S)P&P
SHG(X)34e/255-4 (S)PB SHG(X)34e/255-4 (S)P&P
SHG(X)34e/315-4 (S)PB SHG(X)34e/315-4 (S)P&P
SHG(X)34e/380-4 (S)PB SHG(X)34e/380-4 (S)P&P

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About these instructions
Read these instructions before assembly and before using the Plusbox. This will avoid misunderstand-
ings and prevent damage. Improper assembly and use can result in serious or fatal injury.
Observe the safety instructions contained in these instructions and in the compressor instructions.
These instructions must be passed onto the end customer along with the unit in which the Plusbox
is installed.
Observe also the other documentation included with the Plusbox.
GEA Bock GmbH
72636 Frickenhausen
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone [phone]
Fax [phone]
[email protected]
www.gea.com
Manufacturer
Contact

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Contents Page
1 Safety 4
 1.1 Identicationofsafetyinstructions
 1.2 Qualicationsrequiredofpersonnel
1.3 Safety instructions
1.4 Intended use
2 Product description 6
2.1 Short description
2.2 Name plate
2.3 Type key
3 Assembly 8
3.1 Setting up
4 Electrical connection 9
4.1 Circuit diagram for Plusbox with accessories
 4.2 CircuitdiagramforPlusboxwithfrequencyconverter
5 Commissioning 16
5.1 Commissioning Plusbox without EFCe
5.2 Commissioning Plusbox with EFCe
6 Running 24
6.1 Status Messages
6.2 Application Example
7 Maintenance 26
7.1 Preparation
7.2 Work to be carried out
8 Technical data 27
9 Dimensions and connections 28
10 Service 29
Note:
According to Commission Regulation (EU) 2015/1095 of 5 May 2015 implementing Directive
2009/125/ECoftheEuropeanParliamentandoftheCouncilwithregardtoecodesignrequirements
for professional condensing units, starting 2016 July 1st in the EU only products may be sold which
fulllminimumefciencyrequirements.Theseminimumefciencyrequirementsmustbedocumen-
tedbyacerticate.
ThematchingcerticateforyourcondensingunitcanbecreatedontheInternetonoursoftware
(VAP) under http://vap.gea.com/stationaryapplication/

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1.1 Identicationofsafetyinstructions:
1|Safety
1.2 Qualicationsrequiredofpersonnel
WARNING Inadequatelyqualied personnelposes therisk ofaccidents,the
consequencebeingseriousor fatalinjury.Workoncompressors
isthereforereservedforpersonnelwhichisqualiedtoworkon
pressurized refrigerant systems:
• For example, a refrigeration technician, refrigeration mechatronic
engineer. As well as professions with comparable training, which
enables personnel to assemble,install,maintain and repair refrigeration
and air-conditioning systems. Personnel must be capable of assessing
the work to be carried out and recognising any potential dangers.
DANGER Indicatesadangeroussituationwhich,ifnotavoided,
willcauseimmediatefatalorseriousinjury.
WARNING Indicatesadangeroussituationwhich,ifnotavoided,
maycausefatalorseriousinjury.
CAUTION Indicatesadangeroussituationwhich,ifnotavoided,
maycausefairlysevereorminorinjury.
ATTENTION Indicatesasituationwhich,ifnotavoided,
may cause property damage.
INFO Importantinformationortipsonsimplifyingwork.

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1|Safety
1.4 Intended use
1.3 Safety instructions
WARNING Riskofaccidents.
Refrigerating compressors are pressurised machines and as such
call for heightened caution and care in handling.
The maximum permissible overpressure must not be exceeded,
even for testing purposes.
Riskofburns!
- Dependingontheoperatingconditions,surfacetemperaturesof
over 60°C on the discharge side or below 0°C on the suction side
can be reached.
- Avoid contact with refrigerant necessarily.
Contactwithrefrigerantcancausesevereburnsandskin
damage.
WARNING The Plusbox may not be used in potentially explosive
environments!
These assembly instructions describe the standard version of the Plusbox named in the title manufac-
tured by GEA. The Plusbox is intended for installation in a machine (within the EU according to the EU
Directives2006/42/ECMachineryDirective,2014/68/EUPressureEquipmentDirective).
Commissioning is permissible only if the Plusbox has been installed in accordance with these assem-
bly instructions and the entire system into which it is integrated has been inspected and approved in
accordance with legal regulations.
Only refrigerants may be used which are released on
http://vap.gea.com/stationaryapplication/
AnyotheruseofthePlusboxisprohibited!

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2|Product description
Dimension and connection values can be found in Chapter 9.
2.1 Short description
Possibility to transport
Fan speed
controller
High/low pressure
controller
Compressor
Switch panel
Filter drier
Fan Refrigerant receiverCondenser
Plusbox Basic
Plusbox Plug&Play
Oil sump heater
Sight glass
Fig. 1
Fig. 2
4x 8
649
Y2
X
Y1
+2
968
679 +2
-
-
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E
D
C
A
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E
D
C
41
A
B
5
6
7
8
1
2
34
5
6
78
Zeichn.-Nr. / Drawing no. :
B
32
168195
Part-No. Maßstab /
±0.1
über / above
Freigabe / Approved
zy
Der Lieferant muss sicherstellen, dass die Ware
in einwandfreiem Zustand angeliefert wird
(Korrosionsschutz, Verpackung für sicheren
Layh
Allgemeintoleranzen / General tolerances
Drawing-No.
bis / up to
Dok-ID:
xw uts
-
Kunde / Customer:
packaging for safe transportation).
model or design.
-
in proper conditions (corrosion prevention,
DIN ISO 2768-mK
Ra Rz
18.05.16
Ersatz für / replacement for:
The supplier has to ensure the delivery of parts
Transport).
prohibited. Offenders will be held liable for the Dimension Passung / Clearance
Baumustergeprüft / Type examination:
--
K.-Auftrag / C.-Task:
Projektleiter / Project leader:
120
400
±0.5
0.5
6
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
-
Unbemaßte Radien / Undimensioned radii:
-
Bearb. / EditedDatum / Date
payment of damages. All rights reserved in the event Änd.-Nr. / Mod-No.
Werkstoff (Zeile 2+3 alternativ) /
Base part, Raw part:
-
-
Geprüft / Appr.
NameDatum / Date
18.05.16
Material (Line 2+3 alternative):
Ausgangsteil, Rohteil /
Workpiece edges
DIN ISO 13715
Erstellt / Drawn
Geprüft / Verified Zuder
Büttner
1/3
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
18.05.16
Werkstückkanten /
Page:
400 Benennung / Description:
±0.8
1000
306
206,0
±0.3
12030
-
Blatt /
±0.2
of the grant of a patent, utility /
DIN EN ISO 1302
Zust. / Rev.
Gußtoleranzen / General casting tolerances:
Gewicht / Weight: (kg)
Zeichnungs-Nr. /
Indication of surface texture
Scale:
%
U - SHG34e/380-4 SPB
Rz 25
Rz 160
25 0,05 Rz 1,6 0,3
0,7
1,6
2Rz 16
6,3 Rz 63 Rz 6,3
Rz 12,5 Status:
-
-
in Bearbeitung (CAD)
Nein / No 16145 .2
A - SHG34e/380-4 SPB
-
10231.
Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
boten, soweit nicht ausdrücklich gestattet. Zuwider-
handlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster-
oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this
document as well as the communication of its
contents to others without express authorization is
Maß
Oberflächenangaben /
Teile-Nr. /
Layh
Weitere Anschlüsse siehe Maßzeichnung Verdichter
For further connections see dimensional drawing of the compressor
Maße in mm
Dimensions in mm Änderungen vorbehalten Subject to change without notice
Luftgekühlter Verflüssigungssatz / Air-cooled condensing unit
Aggregat
Bezeichnung /
unit description
Bestehend aus / composed of:
Verdichter
Teile Nr. /
compressor
part-no.
X-Verdichter
Teile Nr. /
X-compressor
part-no.
Sammler
Teile Nr. /
receiver
part-no.
Inhalt
(Ltr.) /
volume
(Ltr.)
SHG(X)34e/215-4 PB 16050 16058
60028 8
SHG(X)34e/215-4 SPB 16054 16062
SHG(X)34e/255-4 PB 16051 16059
SHG(X)34e/255-4 SPB 16055 16063
SHG(X)34e/315-4 PB 16052 16060
SHG(X)34e/315-4 SPB 16056 16064 60029 10SHG(X)34e/380-4 PB 16053 16061
SHG(X)34e/380-4 SPB 16057 16065
Anschlüsse /
Connections
SHG34/215 (S)PB
SHG34/255 (S)PB
SHG34/315 PB
SHG34/315 SPB
SHG34/380 (S)PB
SV Saugabsperrventil, Rohr (L)* mm / Zoll 28 - 1 1/8" 35 - 1 3/8"
Suction line valve, tube (L)* mm / inch
FLA Flüssigkeitsaustritt, Rohr (L)* mm / Zoll 12 - 1/2" 16 - 5/8"
Liquid outlet, tube (L)* mm / inch
SI Anschluss Sicherheitsventil Zoll 1/2" NPTF
Connection safety valve inch
Y1 Anschluss Flüssigkeitsseite, absperrbar Zoll 7/16" UNF
Connection liquid side, lockable inch
Y2 Anschluss Flüssigkeitsseite, nicht absperrbar Zoll 7/16" UNF
Connection liquid side, not lockable inch
Y3 Anschluss Drehzahlregler Zoll 7/16" UNF
Connection Speed Controller inch
(L)* = Lötanschluß
(L)* = Brazing connection
1.1023-16145.2
Typ /
type Teile-Nr./ part-no. Typ / type Teile-Nr./ part-no. Typ / type Teile-Nr./ part-no. Typ / type Teile-Nr./ part-no.
SHG34e/215-4 PB 16138 SHGX34e/215-4 PB 16146 SHG34e/215-4 SPB 16142 SHGX34e/215-4 SPB 16150
SHG34e/255-4 PB 16139 SHGX34e/255-4 PB 16147 SHG34e/255-4 SPB 16143 SHGX34e/255-4 SPB 16151
SHG34e/315-4 PB 16140 SHGX34e/315-4 PB 16148 SHG34e/315-4 SPB 16144 SHGX34e/315-4 SPB 16152
SHG34e/380-4 PB 16141 SHGX34e/380-4 PB 16149 SHG34e/380-4 SPB 16145 SHGX34e/380-4 SPB 16153
4x 8
649
Y2
Y1
X
Weitere Anschlüsse siehe Maßzeichnung Verdichter
For further connections see dimensional drawing of the compressor
Maße in mm
Dimensions in mm Änderungen vorbehalten Subject to change without notice
Luftgekühlter Verflüssigungssatz / Air-cooled condensing unit
Aggregat
Bezeichnung /
unit description
Bestehend aus / composed of:
Verdichter
Teile-Nr. /
compressor
part-no.
X-Verdichter
Teile-Nr. /
X-compressor
part-no.
Sammler
Teile-Nr. /
receiver
part-no.
Inhalt (Ltr.) /
volume (ltr.)
SHG(X)34e/215-4 P&P 16050 16058
60028 8
SHG(X)34e/215-4 SP&P 16054 16062
SHG(X)34e/255-4 P&P 16051 16059
SHG(X)34e/255-4 SP&P 16055 16063
SHG(X)34e/315-4 P&P 16052 16060
SHG(X)34e/315-4 SP&P 16056 16064 60029 10SHG(X)34e/380-4 P&P 16053 16061
SHG(X)34e/380-4 SP&P 16057 16065
1.1023-16129.2
Typ /
type Teile-Nr./ part-no. Typ / type Teile-Nr./ part-no. Typ / type Teile-Nr./ part-no. Typ / type Teile-Nr./ part-no.
SHG34e/215-4 P&P 16122 SHGX34e/215-4 P&P 16130 SHG34e/215-4 SP&P 16126 SHGX34e/215-4 SP&P 16134
SHG34e/255-4 P&P 16123 SHGX34e/255-4 P&P 16131 SHG34e/255-4 SP&P 16127 SHGX34e/255-4 SP&P 16135
SHG34e/315-4 P&P 16124 SHGX34e/315-4 P&P 16132 SHG34e/315-4 SP&P 16128 SHGX34e/315-4 SP&P 16136
SHG34e/380-4 P&P 16125 SHGX34e/380-4 P&P 16133 SHG34e/380-4 SP&P 16129 SHGX34e/380-4 SP&P 16137
Anschlüsse /
Connections
SHG34/215 (S)P&P
SHG34/255 (S)P&P
SHG34/315 P&P
SHG34/315 SP&P
SHG34/380 (S)P&P
SV Saugabsperrventil, Rohr (L)* mm / Zoll
mm / inch 28 - 1 1/8" 35 - 1 3/8"
Suction line valve, tube (L)*
DV Druckabsperrventil, Rohr (L)* mm / Zoll
mm / inch 16 – 5/8" 16 – 5/8"
Discharge line valve, tube (L)*
FLA Flüssigkeitsaustritt, Rohr (L)* mm / Zoll
mm / inch 12 - 1/2" 16 - 5/8"
Liquid outlet, tube (L)*
FLE Flüssigkeitseintritt, Rohr (L)* mm / Zoll
mm / inch 12 - 1/2" 16 – 5/8"
Liquid inlet, tube (L)*
SI Anschluss Sicherheitsventil Zoll / inch 1/2" NPTF
Connection safety valve
Y1 Anschluss Flüssigkeitsseite, absperrbar Zoll / inch 7/16" UNF
Connection liquid side, lockable
Y2 Anschluss Flüssigkeitsseite, nicht absperrbar Zoll / inch 7/16" UNF
Connection liquid side, not lockable
Y3 Anschluss Drehzahlregler Zoll / inch 7/16" UNF
Connection Speed Controller
(L)* = Lötanschluss
(L)* = Brazing connection
-
-
F
E
D
C
A
F
E
D
C
41
A
B
5
6
7
8
1
2
34
5
6
78
Zeichn.-Nr. / Drawing no. :
B
32
166951
Part-No. Maßstab /
±0.1
über / above
Freigabe / Approved
zy
Der Lieferant muss sicherstellen, dass die Ware
in einwandfreiem Zustand angeliefert wird
(Korrosionsschutz, Verpackung für sicheren
Layh
Allgemeintoleranzen / General tolerances
Drawing-No.
bis / up to
Dok-ID:
xw uts
-
Kunde / Customer:
packaging for safe transportation).
model or design.
-
in proper conditions (corrosion prevention,
DIN ISO 2768-mK
Ra Rz
18.05.16
Ersatz für / replacement for:
The supplier has to ensure the delivery of parts
Transport).
prohibited. Offenders will be held liable for the Dimension Passung / Clearance
Baumustergeprüft / Type examination:
--
K.-Auftrag / C.-Task:
Projektleiter / Project leader:
120
400
±0.5
0.5
6
GEA Bock GmbH - Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
-
Unbemaßte Radien / Undimensioned radii:
-
Bearb. / EditedDatum / Date
payment of damages. All rights reserved in the event Änd.-Nr. / Mod-No.
Werkstoff (Zeile 2+3 alternativ) /
Base part, Raw part:
-
-
Geprüft / Appr.
NameDatum / Date
18.05.16
Material (Line 2+3 alternative):
Ausgangsteil, Rohteil /
Workpiece edges
DIN ISO 13715
Erstellt / Drawn
Geprüft / Verified Zuder
Büttner
1/3
Oberflächenbehandlung, Härte / Treatment of surface, Hardness:
18.05.16
Werkstückkanten /
Page:
400 Benennung / Description:
±0.8
1000
306
-
±0.3
12030
-
Blatt /
±0.2
of the grant of a patent, utility /
DIN EN ISO 1302
Zust. / Rev.
Gußtoleranzen / General casting tolerances:
Gewicht / Weight: (kg)
Zeichnungs-Nr. /
Indication of surface texture
Scale:
%
U - SHG34e/380-4 SP&P
Rz 25
Rz 160
25 0,05 Rz 1,6 0,3
0,7
1,6
2Rz 16
6,3 Rz 63 Rz 6,3
Rz 12,5 Status:
-
-
in Bearbeitung (CAD)
Nein / No 16129 .2
A - SHG34e/380-4 SP&P
-
10231.
Weitergabe sowie Vervielfältigung dieses Dokuments,
Verwertung und Mitteilung seines Inhalts sind ver-
boten, soweit nicht ausdrücklich gestattet. Zuwider-
handlungen verpflichten zu Schadenersatz. Alle
Rechte für den Fall der Patent-, Gebrauchsmuster-
oder Geschmacksmustereintragung vorbehalten.
The reproduction, distribution and utilization of this
document as well as the communication of its
contents to others without express authorization is
Maß
Oberflächenangaben /
Teile-Nr. /
Layh
+2
968
+2
679
60-80

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1
2
3
1 Type designation
2 Machine number
3 ND (LP): Max. admissible operating pressure suction side
HD (HP): Max. admissible operating pressure high-pressure side
SHGX34e/315-4 P&P
AV38125A001
/
SHG 43 e 380- PB 4 SX
2.3 Typekey (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X - Ester oil charge
3) S - Stronger motor
4) PB = Plusbox,
P&P = Plug and Play
Plusbox 4)
Motor variant 3)
Number of poles
Swept volume
e-Series
Number of cylinders
Size
Oil charge ²)
Series ¹)
GEA Bock GmbH
72636 Frickenhausen, Germany
19/28
2|Product description
2.2 Name plate (example)
Fig. 3

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?
3 |Assembly
3.1 Setting up
Setuponanevensurfaceorframewithsufcientload-bearing
capacity. Only set up on a slant after following consulting.
Preferably on vibration damper or mounting rubbers.
Do not lift manually
Use lifting gear
Transport preferably via forklift truck,
alternatively bolted to a pallet
Provideadequateclearanceformaintenancework.
Distance from wall to condenser minimum 300 mm.
Do not use in a dusty, damp atmosphere or a combustible
environment.
F
E
D
C
B
A
1 2
3
4
F
E
D
C
4
3
2
1
A
B
Tol.-Ang. DIN ISO 2768-mK
Ra Rz
Maß Passung
Freigabe
Alternativbezug:
Baumustergeprüft
Teil inaktiv
Lieferantenzeichnung
-
-
K.-Auftrag:
PL:
Zeichnung ungültig
Entwicklungsstand
Teil keine Serie
120
400
±0.5
über 0.5
bis 6
Benzstraße 7 - 72636 Frickenhausen - Germany - www.bock.de
-
-
Unbemaßte Radien:
-
Diese Zeichnung ist unser Eigentum!
Sie darf ohne unsere Genehmigung weder nach-
gebildet, vervielfältigt, oder Dritten Personen zu-
gänglich gemacht werden. Der Nachbau nach
dieser Zeichnung, oder an Hand der nach dieser
Zeichnung hergestellten Gegenstände durch den
Abnehmer oder Dritte ist nicht gestattet.
Wir behalten uns alle Rechte, gemäß DIN ISO 16016
an dieser Zeichnung vor.
Bearb.
Datum
Änderungs-Nr.
Werkstoff:
Ausgangsteil, bzw. Rohteil:
--
Gepr.
Name Datum
19.04.
Werkstückkanten
DIN ISO 13715
Ersatz für:
Ersetzt durch:
Erstellt
2010
Geprüft
-
Kurz
Zone
1/x
Oberflächenbehandlung / Härte:
-
Blatt:
Änderungsbeschreibung
400
Benennung:
±0.8
1000
30 6
-
±0.3
120
30
±0.2
Zeichn.-Nr. Teile-Nr.
Oberflächenangaben ISO 1302
x.xxxx-xxxxx.x
Zust.
Gußtoleranzen:
Gewicht: (kg)
±0.1
Maßstab:
1:1
Wasserwaage
für Indesign
Der Lieferant muß sicherstellen, dass die Ware in
einwandfreiem Zustand angeliefert wird (Korrosions-
schutz, Verpackung für sicheren Transport).
Rz 25
Rz 160
s
25
z y x w u t
0,05
Rz 1,6
0,3
0,7
1,6
2
Rz 16
6,3
Rz 63
Rz 6,3
Rz 12,5
F:\user\kurz\3D Sachen\3D Teile\Zeichnungen\Wasserwaage
INFO Newcompressorsarefactory-lledwithinertgas(3barnitrogen).
Leave this service charge in the compressor for as long as possible
and prevent the ingress of air.
OnthePlusboxbacksidethereisasheetmetalintheareaofthe
connection lines. The sheet metal can be moved after releasing
thefourscrews,sothelinescanbeeasierconnected.
Immediately after connecting the Plusbox to the refrigeration
system,closetheshut-offvalvesinthesuction,dischargelines
etc. and evacuate the compressor.
CheckthePlusboxfortransportdamagebeforestartinganywork.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
-
-
-
-

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4 |Electrical connection
FC1 Safety switch main circuit
FC2 Fuse safety chain
QA1 Main switch
QA2 Compressor contactor
QA3 Capacity regulator
QA4 Fan speed controller
MA1 Condenser fan
EC1 compressor motor
EB1 Oil sump heater
INT69 G Electronic trigger unit INT69 G
BT1 PTC Motor
BT2 Heat protection thermostat (PTC sensor)
BT3 Enabling switch (thermostat/pressostat)
BP1 Safety chain (high/low pressure controller)
BP2 Oil pressure safety switch
X1 Terminal strip switch cabinet
X3 Terminal strip terminal box
Legend circuit diagram for Plusbox with accessories
DANGER Riskofelectricshock!High voltage!
Onlycarryoutworkwhentheelectricalsystemisdiscon-
nectedfromthepowersupply!
4 Electrical connection
to4.2CircuitdiagramforPlusboxwithfrequencyconverter(seeFig.10)
ATTENTION Forfrequency-converteroperation:
- Max. permissible ambient temperature -10°C to 40°C.
- Permissible storage temperature -25°C to 65°C.
-Forfurthertechnicaldata,seeDanfosstechnical
documentation supplied.
QA2 Compressor relais
QA3 Signal compressor operation
BP3 Pressure transmitter 4-20 mA
KF1 Frequencyconverter
Difference,legendcircuitdiagramforPlusboxwithfrequencyconverter

10
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4.1 Circuit diagram for Plusbox with accessories
Fig. 8
0123456789
Urspr.
Ers.f.
Ers.d.
Anlagenbezeichnung
Οnderung
Vorblatt:
Datum Name
Bearb.
Gepr.
Norm
Plusbox ohne FU
Kommission:
Gesamtblatt:
Datum
20.10.2016
20.10.2016
4
Bauknecht
Name
Zeichnungsnummer:
Kundennummer:
Kunde:
Anlage
Bl. Gruppe:
=
Ohne P-ÖL Seite 1
Ort
Bl.
Fbl.
+
BA Version mit allem Seite 1
BA Version mit allem Seite 2
20.10.2016ESSG_A1_35_01D
Klemmenkasten Verdichter
INT69 G
KF1
P-Oil
BP2BP1
BT1
T1
L1
T2
L2
T3
L3
-QA1
-EB1
PE
-EC1 3~
M
Θ
-BT2
Θ
13
14
BT3
21
22
FC1 13
14
1/L1
2/T1
3/L2
4/T2
5/L3
6/T3
FC1
I> I> I>
A1
A2
QA2
21
22
QA2
X1 1 2 4 5 6 7 10 11 12 13
14 15 1817 19 20
8
2116
3
X3 1 2
22 23 24
PE
PE
9
1
2
FC2
L N B1 B2 12 14 11
OG OG
X3
11
1
2
QA2
3
4
5
6
PEPE
Duopress
P
T2 N L M S
1 2 3 4
PE PE
13
14
QA2
400V
4x4mm²
W1
123PE230
3x1,0mm²
W8
1 2PE 230V
5x1,0mm²
W2
1 2 3 4PE
230V
5x1,0mm"
W3
1 2 43PE 230V
5x1,0mm²
W4
1 2 3 4PE
-BT2
Θ
X3
10
X3
9
L1 L2 L3
StSP1 /
StSP1 /
N PE
PE /
N/
Compressor terminal box

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HP
LP
ex factory not
connected
0123456789
Urspr.
Ers.f.
Ers.d.
Anlagenbezeichnung
Οnderung
Vorblatt:
Datum Name
Bearb.
Gepr.
Norm
Plusbox ohne FU
Kommission:
Gesamtblatt:
Datum
20.10.2016
20.10.2016
4
Bauknecht
Name
Zeichnungsnummer:
Kundennummer:
Kunde:
Anlage
Bl. Gruppe:
=
Ohne P-ÖL Seite 1
Ort
Bl.
Fbl.
+
BA Version mit allem Seite 1
BA Version mit allem Seite 2
20.10.2016ESSG_A1_35_01D
Klemmenkasten Verdichter
INT69 G
KF1
P-Oil
BP2BP1
BT1
T1
L1
T2
L2
T3
L3
-QA1
-EB1
PE
-EC1 3~
M
Θ
-BT2
Θ
13
14
BT3
21
22
FC1 13
14
1/L1
2/T1
3/L2
4/T2
5/L3
6/T3
FC1
I> I> I>
A1
A2
QA2
21
22
QA2
X1 1 2 4 5 6 7 10 11 12 13
14 15 1817 19 20
8
2116
3
X3 1 2
22 23 24
PE
PE
9
1
2
FC2
L N B1 B2 12 14 11
OG OG
X3
11
1
2
QA2
3
4
5
6
PE
PE
Duopress
P
T2 N L M S
1 2 3 4
PE PE
13
14
QA2
400V
4x4mm²
W1
123PE230
3x1,0mm²
W8
1 2PE 230V
5x1,0mm²
W2
1 2 3 4PE
230V
5x1,0mm"
W3
1 2 43PE 230V
5x1,0mm²
W4
1 2 3 4PE
-BT2
Θ
X3
10
X3
9
L1 L2 L3
StSP1 /
StSP1 /
N PE
PE /
N/

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P
N
PE
1 2
PE
-MA1
Kondensator-
lüfter
1~
M
x1
x2
-QA4
Drehzahl-
steuerung
Lüfter
-QA3
Leistungs
Regler
0-230V
3x1,0mm²
W5
PE1 2
0-230V
3x1,0mm²
W6
230V
3x1,0mm²
W7
13
14
Freigabe
Leistungsregler
X1 PE 25 26 27 28 PE 29 30
31 32 PE
1
1
PE1
Gehäuseboden
1
PE2
Gehäusedeckel
PE PE
X4 12 3 X5 1 2 3
1 2 PE
PE
2 PE
StSP1
/
N
/
PE
/
StSP2
/
4.1 Circuit diagram for Plusbox with accessories -continuation-
Release
Capacity regulator
Capacity
regulator
rotation
speed
control
fan
ex factory not
connected
Fig. 9

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P
N
PE
1 2
PE
-MA1
Kondensator-
lüfter
1~
M
x1
x2
-QA4
Drehzahl-
steuerung
Lüfter
-QA3
Leistungs
Regler
0-230V
3x1,0mm²
W5
PE1 2
0-230V
3x1,0mm²
W6
230V
3x1,0mm²
W7
13
14
Freigabe
Leistungsregler
X1 PE 25 26 27 28 PE 29 30
31 32 PE
1
1
PE1
Gehäuseboden
1
PE2
Gehäusedeckel
PE PE
X4 12 3 X5 1 2 3
1 2 PE
PE
2 PE
StSP1
/
N
/
PE
/
StSP2
/
housing coverhousing base
fan

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4.2 CircuitdiagramforPlusboxwithfrequencyconverter
Fig. 10
HP
LP
Klemmenkasten Verdichter
P
L1
U
L2
V
Netz-Versorgung
Motor
L3
W
PE
PE
+24V
OUT
D
IN
D
IN
Analog
IN
-KF1
P-Oil
BP2
BP1
-KF2
+24V
OUT
Grün
Braun
BT1
T1
L1
T2
L2
T3
L3
-QA1
-EB1
PE
1 2
PE
-MA1 1~
M
x1
x2
-QA4
-EC1 3~
M
Θ
13
14
BT3
91
96
92
97
93
98
95
99
12 1819 54
01
Relais1
03 02
BP3
1 2
Duopress
P
T2 N L M S
11
14
QA2
21
22
FC1 13
14
L1
T1
L2
T2
L3
T3
FC1
I> I> I>
A1
A2
QA2
X1 1 2 4 5 6 7 10 11 12 13 14 15
1817 19 20
8
2116
3
400V
4x4,0mm²
W9
PE1 2 3
0-400V
4x4,0mm²
W10
123PE 230V
3x1,0mm²
W11
1 2
230V
5x1,0mm²
W12
4321
230V
PE1,0mm²
W13
1234 230V
3x1,0mm²
W14
21 230V
3x1,0mm²
W16
PE1 2
X3 12 11
13
22 23 24 25 26 PEPE
PEPE
27 28 29PE
24V DC
3x1,0mm²
W17
230V
5x1,0mm²
W18
PE
1
9
04
Relais2
06 05
A1
A2
QA3
PE
123
PE
PE
10
PE
PE
24V DC
5x1,0mm²
W16
123
1
2
FC2
X4 1 2 3
12
11
14
QA3
2
1234
L1
2.0
L2
2.0
L3
2.0
N
/
PE
/
N
2.1
PE
2.1
Drehzahl-
steuerung
Lüfter
Konden-
sator-
lüfter
Compressor terminal box
Power supply
Motor
green
brown

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ex factory not
connected
Klemmenkasten Verdichter
P
L1
U
L2
V
Netz-Versorgung
Motor
L3
W
PE
PE
+24V
OUT
D
IN
D
IN
Analog
IN
-KF1
P-Oil
BP2
BP1
-KF2
+24V
OUT
Grün
Braun
BT1
T1
L1
T2
L2
T3
L3
-QA1
-EB1
PE
1 2
PE
-MA1 1~
M
x1
x2
-QA4
-EC1 3~
M
Θ
13
14
BT3
91
96
92
97
93
98
95
99
12 1819 54
01
Relais1
03 02
BP3
1 2
Duopress
P
T2 N L M S
11
14
QA2
21
22
FC1 13
14
L1
T1
L2
T2
L3
T3
FC1
I> I> I>
A1
A2
QA2
X1 1 2 4 5 6 7 10 11 12 13 14 15
1817 19 20
8
2116
3
400V
4x4,0mm²
W9
PE1 2 3
0-400V
4x4,0mm²
W10
123PE 230V
3x1,0mm²
W11
1 2
230V
5x1,0mm²
W12
4321
230V
PE1,0mm²
W13
1234 230V
3x1,0mm²
W14
21 230V
3x1,0mm²
W16
PE1 2
X3 12 11
13
22 23 24 25 26 PEPE
PEPE
27 28 29PE
24V DC
3x1,0mm²
W17
230V
5x1,0mm²
W18
PE
1
9
04
Relais2
06 05
A1
A2
QA3
PE
123
PE
PE
10
PE
PE
24V DC
5x1,0mm²
W16
123
1
2
FC2
X4 123
12
11
14
QA3
2
1234
L1
2.0
L2
2.0
L3
2.0
N
/
PE
/
N
2.1
PE
2.1
Drehzahl-
steuerung
Lüfter
Konden-
sator-
lüfter

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5 |Commissioning
Commissioning according to the assembly instructions of the compressor.
Check the funtion of the safety chain and set the High-/Low pressure monitoring. Set the fan speed
controller according to the operating conditions of the plant.
Commissioning according to the assembly instructions of the compressor.
Check the funtion of the safety chain and set the High-/Low pressure monitoring. Set the fan speed
controller according to the operating conditions of the plant.
Commissioning EFCe:
5.1 Commissioning Plusbox without EFCe
5.2 Commissioning Plusbox with EFCe
Note the enclosed Danfoss product manual. The
function and operation of the user interface are
described there.
Here take a look what you need to set values and
parametersspecicallyfortheGEAPlusbox.
Due to software updates of the company Danfoss,
differences may appear to the instructions shown
here.
Follow the instructions of the startup wizard. This
shouldappearwhenyoustartrst.Also,thesetup
wizard can be launched from the Quick Menu.

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5 |Commissioning
1. Set the desired language.
2. Set the desired application.
3. Set the type of motor.
4.Setthemotorvoltageandthefrequency.
 Youcanndthevaluesonthenameplateofthe
compressor..
5. Set the maximum continuous current and the
 nominalspeed.Youcanndthevaluesonthe
nameplate of the compressor.
Please select language:
English
AKD Wizard
Select Application:
Compressor
AKD-Assistent
Which motor type is
connected to the drive?
Asynchron
VLT-Assistent
Select Motor Voltage:
400 V
Compressor
SelectMotorFrequency:
50 Hz
Max. Cont. Current (MCC):
9.000 A
Compressor
Enter Nominal Speed:
1420 RPM

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5 |Commissioning
6. Doestheapplicationincludeasinewavelter?
7. Would you like to run Automatic Motor Adaptation?
8. Set the desired minimum and maximum
 frequency.Theyarebetween25and70Hz.
10. This setting depends on the application.
9. Set the desired recycle time.
We recommend 3 minutes.
Does the application include
asinewavelter?
No
Compressor
Would you like to run AMA
(Recommended, AS takes a
few min. / PM takes a few sec.)?
Yes
Compressor
Min.Frequency:
30.0 Hz
Compressor
Max.Frequency:
60.0 Hz
Recycle Time (Start to Start):
3 1/min
Compressor
Does the application include
a bypass valve?
No
Compressor

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5 |Commissioning
11. This setting depends on the application.
Setting ex factory: Internal control
12. Setting at Internal control:
Pressure Transmitter [bar]
13. The sensor range is to be adjusted later.
13.1 Sensor signal 4-20 mA.
14. This connection is already pre-wired
by GEA.
15. Check switch position below the user interface.
Compressor
Attention!
Connect your
4-20-mA-Signal
as shown:
+ 13
- 54
Compressor
Attention!
Please switch
A54 to
position I
(under LCP)
U I
Select Sensor Range:
-1 / +12 bar
Compressor
Select Sensor Signal
4-20 mA
Sensor Type:
Pressure Transmitter [bar]
Compressor
Select internal or external
control
Internai control
Compressor

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5 |Commissioning
20. Those settings depend on the application
(Pump-Downfrequency-converter)
19. This setting depends on the application.
19.1 Set Maximum Setpoint limit.
19.2 Set Minimum Setpoint limit.
16. Set setpoint unit, depends on the application.
16.1 Select type of refrigerant..
17. Set setpoint type.
Recommended setting: Constant.
18. Enter setpoint, depends on the application.
Select Setpoint Unit:
°C
Compressor
Select Refrigerant Type:
R404a
Select Setpoint Type:
Constant
Compressor
Setpoint:
-10.000 °C
Compressor
Max. Setpoint Limit:
40.000 °C
Compressor
Min. Setpoint Limit:
-60.000 °C
Cut-out Value:
-25.000 °C
Compressor
Cut-in Value:
-5.000 °C