Operating instructions - QED · 2018-01-24 · 1. Ensure that no commissioning and maintenance work...

Operatinginstructions

Belt-drivenscrew compressorsseries S 6-...S 29-

S 6-...D...S15-...DSD 6...SD 29SD 6-...SD 29-

Index1

BOGE Operating instructions for S 6 - SD 29 series screw compressorsInhalt.pm6.5 - 05/2002 - GB

Page I

Operating instructionsfor the belt-drivenscrew compressors

– S 6/S 6- /S 6-...D/SD 6/SD 6- ( 4 kW)

– S 8/S 8- /S 8-...D/SD 8/SD 8- ( 5,5 kW)

– S 10/S 10- /S 10-...D/SD 10/SD 10- ( 7,5 kW)

– S 15/S 15- /S 15-...D/SD 15/SD 15- (11 kW)

– S 20/S 20- /SD 20/SD 20- (15 kW)

– S 24/S 24- /SD 24/SD 24- (18,5 kW)

– S 29/S 29- /SD 29/SD 29- (22 kW)

No. 596.0683.01

Cover charge: € 5,00

BOGE KOMPRESSORENPostfach 10 07 13D-33507 Bielefeld

Lechtermannshof 26D-33739 Bielefeld

Fon: ++49 / 52 06 / 6 01-0Fax: ++49 / 52 06 / 6 01-200Mail: [email protected]: www.boge.com

Index1


Page III

Index

1.1 General safety instructions ......................................................... 1.1Safety instructions for compressor operation ................................. 1.1Safety instructions for maintenance and repair of the compressor . 1.2Accident prevention regulations ..................................................... 1.2

1.2 Introduction .................................................................................. 1.3Symbols used................................................................................. 1.3Symbols on the compressor ........................................................... 1.4Intended use .................................................................................. 1.5Inadmissible use ............................................................................ 1.5Transport damage .......................................................................... 1.6Data on the type plate .................................................................... 1.6Service ........................................................................................... 1.6

2.1 Technical data .............................................................................. 2.1Technical data S 6 to SD 29, part 1 ................................................ 2.1Technical data S 6 to SD 29, part 2 ................................................ 2.6

2.2 Function description .................................................................. 2.11Function principle of the air end ................................................... 2.11Air circuit ...................................................................................... 2.11Oil circuit ...................................................................................... 2.12

2.3 Compressor control ................................................................... 2.13Network pressure ......................................................................... 2.13Operating states ........................................................................... 2.13Operating modes .......................................................................... 2.13Short operating times ................................................................... 2.13

2.4 Control devices .......................................................................... 2.14Proportional controller (Option) .................................................... 2.14

2.5 Safety and monitoring devices ................................................. 2.15General ........................................................................................ 2.15Safety temperature limiting device ............................................... 2.15Safety valve .................................................................................. 2.15Monitoring the drive motor ........................................................... 2.15

Part 1:General

Part 2:Product description

Page IV BOGE Operating instructions for S 6 - SD 29 series screw compressorsInhalt.pm6.5 - 05/2002 - GB

Index1

3.1 Transport ....................................................................................... 3.1General .......................................................................................... 3.1Transport possibilities ..................................................................... 3.1

3.2 Compressor room ........................................................................ 3.2Installation, maintenance conditions and application forcompressed air receivers arranged below or separately ................ 3.2Installation surface ......................................................................... 3.2Fire protection ................................................................................ 3.2Sound protection ............................................................................ 3.2Admissible ambient influences ....................................................... 3.3Ventilation ....................................................................................... 3.3Cooling air requirement .................................................................. 3.4Ventilation possibilities ................................................................... 3.5Condensate disposal ...................................................................... 3.5

3.3 Installation .................................................................................... 3.6General .......................................................................................... 3.6Checking the delivery scope .......................................................... 3.6Installing the compressor ............................................................... 3.6Connecting the compressor to the compressed air network .......... 3.7Remove warm air hood .................................................................. 3.7Activating the belt tensioning device .............................................. 3.8Checking the oil level ...................................................................... 3.8

3.4 Electrical connection ................................................................... 3.9

3.5 Commissioning .......................................................................... 3.10Checking the rotational direction .................................................. 3.10Opening the stop valve ................................................................. 3.10Checking for leaks ........................................................................ 3.10Conduct trial run ........................................................................... 3.10Commissioning following extended stoppages ............................. 3.10Refrigeration compressed air dryer .............................................. 3.11

4.1 The BOGE ARS control concept (Autotronic) ............................ 4.1General .......................................................................................... 4.1Microcontroller ................................................................................ 4.1Modular design ............................................................................... 4.1

4.2 Operating and control panel ....................................................... 4.2

4.3 Operating elements ...................................................................... 4.3

4.4 Operation ...................................................................................... 4.6

4.5 Control Parameterization ........................................................... 4.11Error key table .............................................................................. 4.11General ........................................................................................ 4.12Parameterization .......................................................................... 4.12Set the compressor servicing interval and zero the counter ......... 4.12Set motor servicing interval and zero the counter ........................ 4.12

Part 3:Installation

Part 4:Auto-/Ratiotronic

Index1


Page V

Set receiver load cycles and restart ............................................. 4.13Change target pressure values (Pmax and Pmin) ............................. 4.13External output enable ................................................................. 4.13Change after-running time ........................................................... 4.14Set continuous mode ................................................................... 4.14Enable network-independent ON-OFF memory (AWAL) .............. 4.14Anti-freeze idling (only in mode: Ready for operation) .................. 4.15Motor switching limitation ............................................................. 4.15Star phase time control ................................................................ 4.15Idling control with extremely short operation time (option) ........... 4.15Service request ............................................................................ 4.15

4.6 Service ........................................................................................ 4.16Configure binary input pre-processing messages ........................ 4.16Fuses ........................................................................................... 4.16

4.7 The BOGE ARS control concept (Ratiotronic) ......................... 4.17Operating and control panel ......................................................... 4.17

4.8 Operating elements .................................................................... 4.18

4.9 Operation .................................................................................... 4.21

4.10 Control Parameterization ........................................................... 4.26Error key table .............................................................................. 4.26General ........................................................................................ 4.26Parameterization .......................................................................... 4.26Enter Parameterization Code ....................................................... 4.27Set the compressor servicing interval and zero the counter ......... 4.27Set the motor servicing interval and zero the counter .................. 4.27Set load cycles receiver servicing/change of wearing partsand restart .................................................................................... 4.28Change target pressure values (Pmax and Pmin) ............................. 4.28External output enable ................................................................. 4.28Remote On/Off control ................................................................. 4.29Change min. after-running time .................................................... 4.29Set continuous mode ................................................................... 4.30Enable network independent ON-OFF memory (AWAL) .............. 4.30Anti freeze operation (only in mode: Ready for operation) ........... 4.31Idling control with extremely short operation time ........................ 4.31RS 485-Bus-address .................................................................... 4.31Parameter overview...................................................................... 4.32

5.1 General .......................................................................................... 5.1Automatic monitoring of the control systems .................................. 5.1

5.2 General faults ............................................................................... 5.2

5.3 Fault messages of the control system ....................................... 5.3Options of the Ratiotronic ............................................................... 5.4

Part 5:Faults

Page VI BOGE Operating instructions for S 6 - SD 29 series screw compressorsInhalt.pm6.5 - 05/2002 - GB

Index1

6.1 Safety instructions .......................................................................6.1

6.2 General .......................................................................................... 6.2Maintenance through BOGE service .............................................. 6.2Review of regular maintenance work ............................................. 6.2Maintenance intervals .................................................................... 6.3General information concerning the lubricants used ...................... 6.4Disposal of used operating material ............................................... 6.4Spare and wearing parts ................................................................ 6.4

6.3 Regular maintenance work .......................................................... 6.5Draining off the condensate from the compressed air receiver ...... 6.5Draining off the condensate from the compressed air receiverwith automatic condensate separator ............................................. 6.5Clean or change suction filter ......................................................... 6.6Cleaning the filter cartridge ............................................................ 6.6Changing the supply air filter mats ................................................. 6.7Lubricating the drive motor bearings .............................................. 6.7Drive motors with permanent lubrication ....................................... 6.7Changing the V-belt ........................................................................ 6.8Settings of the GM- drive systems S 6 – SD 15 ............................. 6.9Settings of the GM- drive systems S 20 – SD 29 ........................... 6.9Checking the oil level, topping up oil ............................................ 6.10Changing the oil filter ................................................................... 6.11Changing the oil separator ........................................................... 6.12Oil change .................................................................................... 6.13Flushing the oil circuit ................................................................... 6.15Cleaning the compressed air/oil cooling unit ................................ 6.16Checking the safety valve ............................................................. 6.17

6.4 Spare parts and optional equipment ........................................ 6.18List of spare and wearing parts (for maintenance) ....................... 6.18List of available optional equipment ............................................. 6.18

7.1 Flow chart ..................................................................................... 7.1Air cooled version, standard ........................................................... 7.1Air cooled version, with proportional controller ............................... 7.1

7.2 List of maintenance and service work ........................................ 7.2

Part 7:Appendix

Part 6:Maintenance

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Page1.1

General

BOGE Operating instructions for S 6 - SD 29 series screw compressors

Nonobservance of the following safety instructions may lead to injuriesand damage to the compressor.Also observe the generally valid safety and accident prevention regu-lations in addition to the information in these operating instructions!

1. Ensure that no commissioning and maintenance work on the compressoris undertaken until these operating instructions are understood.

02. Only use the compressor for its intended use, as described in theseoperating instructions.

03. The owner must ensure– that only appropriately trained and authorized personnel work on this

compressor.– that the operating, maintenance and repair personnel has been

made fully familiar with all safety instructions, and that they are beingobserved.

– that the compressor is only operated in a safe operating condition.

04. Avoid any operating method which may impair the safety of the com-pressor.

05. Do not exceed the limit value for the final compression pressure specifiedon the type plate.

06. Do not operate the compressor without the attendant protection andsafety devices.Do not dismantle any built-in safety devices or put them out of operation.Ensure that all safety claddings and doors are closed prior to commis-sioning/starting up the compressor and is not opened during operation.

07. Place the compressor out of operation as described in these operatinginstructions, when dismantling the safety claddings or safety devices forrepair or maintenance work. Reattach and close all cladding and safetydevices immediately upon completion of the repair or maintenancework.

08 Only operate the compressor using the additional equipment (options)recommended or authorized by the manufacturer.

09. Undertake conversions and modifications of the compressor only inagreement with BOGE, taking all relevant safety regulations into consid-eration.The manufacturer is not liable for damages resulting from independentmodifications on the compressor.

10. Never start the compressor when one or serveral parts (e.g. cable, plug)are damaged, when not in perfect working order, when damage is de-tected or suspected.

11. Observe all safety and danger signs directly attached on the compressor!

12. The compressed air/oil receiver is subject to the pressure receiver regu-lations "Druckgeräterichtlinie" (Recommendation for compressors) andhas to be checked in prescribed intervals.

Safety instructions forcompressor operation

1.1 General safety instructions


Page 1.2

General


1. Ensure that maintenance work is only carried out by appropriately trainedpersons.

2. Ensure that setting work, malfunction rectification and repair is only car-ried out by specialists or appropriately trained persons.

3. Prior to maintenance or repair work:– Switch off the main switch.– Secure main switch against unintentional switch-on.– Check to ensure that all parts currentless.– Disconnect the compressor from the compressed air network (relieve

or block pressurized lines).4. Exercise extreme caution during repair or maintenance work requiring

the compressor to be operational.Ensure that no persons are located in the hazardous area.

5. Ensure that work on the electrical equipment is only undertaken byqualified electricians.

6. Work on parts and devices under current is prohibited. Exceptions aregoverned by the appropriate regulations, e.g. DIN VDE 0105.

7. Only use original spare parts, compressor oils and operatingmaterials released by BOGE during repair or maintenance.

8. The operator is responsible to check the compressor daily for externallyvisible damage and defects, and to immediately report any changes(including operational behaviour).

9. When the automatic restart (AWAL) is activated the compressor restartsautomatically following a voltage loss.Prerequisite: The line pressure is lower than the switch-on pressure set.

The owner of a compressor plant is responsible to ensure that it is properlyinstalled, operated and maintained.Owners in the Federal Republic of Germany urgently have to read the follow-ing regulations of the Main Association of the Industrial Employers' LiabilityInsurance:– Accident prevention regulation 13.4 "Compressor" (VBG 16)– Pressure receiver regulation– Safety requirements EN 1012 "Compressors"The regulations are available at the following locations:BerufsgenossenschaftCarl-Heymanns-Verlag KG, Luxemburger Str. 449, 50939 KölnBeuth Verlag GmbH, 10772 Berlin

For operation of the compressor plant outside the Federal Republic of Ger-many, the accident prevention regulations of the owner country must beobserved in addition to the data contained in these operating instructions.In the event that measures are required above and beyond the legal regula-tions specified in the Federal Republic of Germany or the data contained inthese operating instructions, then it is of utmost importance that these becarried out prior to commissioning the compressor plant.

Accident preventionregulations

Safety instructions formaintenance and repairof the compressor

1.1 General safety instructions


Page1.3

General


1.2

The purpose of these operating instructions is to familiarize the user with thefunction and all application possibilities of the compressor.

These operating instructions contain important information on how to operatethe compressor safely, economically and according to its intened use. Ob-serving these operating instructions will assist in avoiding danger, to reducerepair costs and down times and to increase the reliability and service life ofthe compressor. It contains important information concerning the requiredmaintenance and repair measures, assists in case of malfunctions and con-tains data concerning spare and wearing parts.

The operating instructions must be available to the compressor operatingpersonnel at the place of operation, at all times.The operating instructions must be carefully read and applied by all personsengaged to undertake the following work on the compressor:– Operation, including fault rectification and daily care– Maintenance (service, inspection, repair)– Commissioning– Transport

The compressor and its additional equipment must not be installed andcommissioned until the operating instructions are understood.

These operating instructions can be supplemented with instructions on thebasis of existing national regulations concerning accident prevention andenvironmental protection.

In the illustrations, the compressor is shown in part without safety claddingor safety devices for better visualization. However, operation without thesecomponents is prohibited!

In these operating instructions, important safety instructions and tips areidentified by the following symbols:

CAUTION: Risk of injury!This symbol indicates information warning of possible danger to life and limbof the operator or other persons.

ATTENTION!This symbol indicates information warning of dangers to life and limb of theoperator or other persons or dangers, which might destroy or damage thecompressor.

WARNING: Voltage!This symbol indicates information warning of life threatening electrical volt-age levels.It indicates work which must be exclusively performed by skilled electricians.

This symbol indicates information and tips concerning the economical andcareful operation of the compressor.

Symbols used

Introduction


Page 1.4

General


The following symbols and warning signs are fitted on the compressor:

Warning:Hot surfaces: Do not touch!

Warning:The unit is operated by remote control, and might start without warning.

Note:Instructions for the operating personnel must be read.

Prohibited:Never open the valve before the air hose (connection to the compressed airnetwork) is connected.

Symbols on thecompressor

1.2 Introduction


Page1.5

General


Intended use

Inadmissible use

BOGE S series screw compressor, including its additional equipment, isexclusively intended for the compression of air.The air taken in must not contain any explosive or chemically instable gasesor vapours.Do not exceed the specified final compression temperature.

BOGE screw compressors are designed for stationary operation. Ensurethat they are only installed and operated in dry and clean rooms.

Operation and control are designed to be executed by trained and authorizedoperators.

Never direct the produced compressed air towards persons.Danger to life!

Oil is injected into the pressure rooms of the compressor.Only use the produced compressed air for breathing or let it come in contactwith foods, if it was treated beforehand.

This BOGE screw compressor is not explosion protected. Do not operate inexplosive areas!

Do not operate the compressor in rooms in which extreme dust, toxic orflammable vapours and gases may occur.

The following is not permitted:

– Exceeding the final compression pressure indicated on the type plate.

– Altering the safety devices and safety cladding or placing them out ofoperation.

– Removing or painting over signs and symbols on the compressor.

– Operation of the compressor by unauthorized or untrained persons.

1.2 Introduction


Page 1.6

General


Dataon the type plate

Fig. 1.1: Data on the type plate

1.2 Introduction

BOGE does not accept any liability for breakage or transport damage.Please inspect the compressor immediately after delivery and direct dam-age claims to the last haulier – even when the packing is not damaged! To safeguard claims against the haulier we recommend leaving the machine,devices and packing material in the same condition as they were in whenthe damage was detected.

In the event of any other complaints, please inform us within six days afterarrival of the delivery.

Enter the data of your compressor from the type plate or enclosed datasheet in the illustration below. This will ensure that in the event of enquiries,you will always have the most important data to hand.

Transport damage

Please do not hesitate to contact BOGE service if you have any questions.Please call:

� ++49 / 52 06 / 6 01-0

In the event of inquiries, always specify the following data of your compres-sor to prevent any delays.:

– Type

– Year of manufacture

– Machine number

ATTENTION!Only BOGE service technicians or persons authorized by BOGE in writingmay repair or alter the compressor during the warranty period. Otherwise allwarranty claims will expire!

Service

TypeYear of constructionSerial numberF.a.d. CFMMaximum service pressure PSIGMotor speed RPMMotor power HP

Lechtermannshof 26 · D-33739 Bielefeld · Telefon (05206) 601-0Postfach 100713 · D-33507 Bielefeld · Fax (05206) 601-200

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Page 2.1

Product description


Technical data for S 6 to S 29, part 1

Type S 6 S 8 S 10 S 15 S 20 S 24 S 29

Dimensions– Height (silenced) [mm] 720 720 770 770 930 930 930– Height (super silenced) [mm] 1650 1650 1750 1750 2120 2120 2120– Width (silenced / super silenced) [mm] 850 850 890/940 890/940 1200 1200 1200– Depth (silenced / super silenced) [mm] 690 690 810 810 980 980 980

Weight– silenced [kg] 140 150 170 180 300 315 315– silenced / super silenced [kg] 170 180 210 220 350 365 365

Max. sound pressure level [±3 dB(A)]accord. to DIN 45635, part 13 76/68 78/70 80/70 82/72 80/72 85/78 86/79– silenced / super silenced [dB(A)]

Measuring surface dimension14/14 14/14 14/14 14/14 15/15 15/15 15/15– silenced / super silenced [dB(A)]

Sound capacity level90/82 92/84 94/84 96/86 95/87 100/93 101/94– silenced / super silenced [dB(A)]

Compressormax. final compression temperature [°C] 110 110 110 110 110 110 110Volume flow according toPN 2 CPTC 2 at:– p

max = 8 bar [m3/min] 0,55 0,83 1,18 1,65 2,40 2,80 3,35– pmax = 10 bar [m3/min] 0,48 0,72 1,06 1,45 2,06 2,45 2,85– pmax = 13 bar [m3/min] 0,36 0,58 0,91 1,25 1,70 2,05 2,45

Drive motorRated power [kW] 4 5,5 7,5 11 15 18,5 22Rated speed– 50 Hz [min-1] 3000 3000 3000 3000 3000 3000 3000– 60 Hz [min-1] 3600 3600 3600 3600 3600 3600 3600

Protection type IP 55 55 55 55 55 55 55Design IMB 3 3 3 3 3 3 3ISO class F F F F F F F

Electrical connectionMains voltage 1) [V] 400 400 400 400 400 400 400Frequency 1) [Hz] 50 50 50 50 50 50 50Min. fuse protection 2) [A] 16 20 35 35 50 50 50Recommended fuse protection 2) [A] 20 25 35 35 50 63 63

2.1 Technical data

1) Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.2) Only for 400 V / 50 Hz. The fuse values change in the case of other mains voltages and frequencies.

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Page 2.2

Product description


Technical data for S 6- to S 29-, part 1

Type S 6- S 8- S 10- S 15- S 20- S 24- S 29-

Dimensions– Height (silenced) [mm] 1170 1270 1320 1350 1750 1750 1750– Height (super silenced) [mm] 2100 2200 2300 2330 2930 2930 2930– Width (silenced / super silenced) [mm] 1550 1700 1700 1850 2000 2000 2000– Depth (silenced / super silenced) [mm] 690 690 790 790 980 980 980

Receiver volume l 150 270/250 270/250 350 750 750 750

Weight– silenced [kg] 215 265 295 330 570 585 585– silenced / super silenced [kg] 245 295 325 360 600 615 615

Max. sound pressure level [±3 dB(A)]accord. to DIN 45635, part 13 per compr. 76/68 78/70 80/70 82/72 80/72 85/78 86/79– silenced / super silenced [dB(A)]





Drive motorRated power [kW] 4 5,5 7,5 11 15 18,5 22Rated speed– 50 Hz [min-1] 3000 3000 3000 3000 3000 3000 3000– 60 Hz [min-1] 3600 3600 3600 3600 3600 3600 3600


Electrical connectionMains voltage 1) [V] 400 400 400 400 400 400 400Frequency 1) [Hz] 50 50 50 50 50 50 50Min. fuse protection 2) [A] 16 20 35 35 50 50 50Recommended fuse protection 2) [A] 20 25 35 35 50 63 63

2.1 Technical data


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Page 2.3

Product description


Technical data for S 6-...D to S 15...D, part 1

Type S 6-...D S 8-...D S 10-...D S 15-...D

Dimensions– Height (silenced) [mm] 1350 1350 1550 1550– Height (super silenced) [mm] 2240 2240 2540 2540– Width (silenced / super silenced) [mm] 2150/2180 2150/2180 2220/2270 2220/2270– Depth (silenced / super silenced) [mm] 570 670 730 730

Behälterinhalt l 500 500 750 750

Weight bar 8/10 13 8/10 13 8/10 13 8/10 13

– silenced [kg] 485 535 495 545 615 675 635 715– silenced / super silenced [kg] 545 595 555 605 695 755 695 775

Max. sound pressure level [±3 dB(A)]accord. to DIN 45635, part 13 per compr. 76/68 78/70 80/70 82/72– silenced / super silenced [dB(A)]

Measuring surface dimension per compr.14/14 14/14 14/14 14/14– silenced / super silenced [dB(A)]

Sound capacity level per compessor90/82 92/84 94/84 96/86– silenced / super silenced [dB(A)]

Compressormax. final compression temperature [°C] 110 110 110 110Volume flow according toPN 2 CPTC 2 at:– p

max = 8 bar [m3/min] 0,55 0,83 1,18 1,65– pmax = 10 bar [m3/min] 0,48 0,72 1,06 1,45– pmax = 13 bar [m3/min] 0,36 0,58 0,91 1,25

Drive motorRated power [kW] 2 x 4 2 x 5,5 2 x 7,5 2 x 11Rated speed– 50 Hz [min-1] 3000 3000 3000 3000– 60 Hz [min-1] 3600 3600 3600 3600

Protection type IP 55 55 55 55Design IMB 3 3 3 3ISO class F F F F

Electrical connectionMains voltage 1) [V] 2 x 400 2 x 400 2 x 400 2 x 400Frequency 1) [Hz] 50 50 50 50Min. fuse protection 2) [A] 2 x 16 2 x 20 2 x 35 2 x 35Recommended fuse protection 2) [A] 2 x 20 2 x 25 2 x 35 2 x 35

2.1 Technical data


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Page 2.4

Product description


Technical data for SD 6 to SD 29, part 1

Type SD 6 SD 8 SD 10 SD 15 SD 20 SD 24 SD 29

Dimensions– Height (super silenced) [mm] 1960 1960 2060 2060 2480 2480 2480– Width (silenced / super silenced) [mm] 910 910 975 975 1230 1230 1230– Depth (silenced / super silenced) [mm] 690 690 810 810 980 980 980

Weight– silenced / super silenced [kg] 210 220 250 260 400 425 425






Drive motorRated power [kW] 4 5,5 7,5 11 15 18,5 22Electr. power intake dryer [kW] 0,24 0,24 0,25 0,35 0,40 0,46 0,65Rated speed– 50 Hz [min-1] 3000 3000 3000 3000 3000 3000 3000– 60 Hz [min-1] 3600 3600 3600 3600 3600 3600 3600


Electrical connectionMains voltage compressor / dryer 1) [V] 400/230 400/230 400/230 400/230 400/230 400/230 400/230Frequency 1) [Hz] 50 50 50 50 50 50 50Min. fuse protection 2) [A] 16 20 35 35 50 50 50Recommended fuse protection 2) [A] 20 25 35 35 50 63 63

2.1 Technical data


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Page 2.5

Product description


Technical data for SD 6- to SD 29-, part 1

Type SD 6- SD 8- SD 10- SD 15- SD 20- SD 24- SD 29-

Dimensions– Height (silenced) [mm] 1490 1490 1520 1520 1750 1750 1750– Height (super silenced) [mm] 2200 2200 2330 2330 2930 2930 2930– Width (silenced / super silenced) [mm] 1700 1700 1850 1850 2195/2510 2195/2510 2195/2510– Depth (silenced / super silenced) [mm] 690 690 690 690 955 955 955

Receiver volume l 270/250 270/250 350 350 750 750 750

Weight bar 8/10 13 8/10 13 8/10 13 8/10 13 8/10 13 8/10 13 8/10 13

– silenced [kg] 305 325 320 340 380 420 390 425 425 485 645 705 645 705– silenced / super silenced [kg] 335 355 350 360 420 450 430 485 475 535 695 755 695 755






Drive motorRated power [kW] 4 5,5 7,5 11 15 18,5 22Electr. power intake dryer [kW] 0,21 0,28 0,32 0,40 0,46 0,55 0,60Rated speed– 50 Hz [min-1] 3000 3000 3000 3000 3000 3000 3000– 60 Hz [min-1] 3600 3600 3600 3600 3600 3600 3600


Electrical connectionMains voltage compressor / dryer 1) [V] 400/230 400/230 400/230 400/230 400/230 400/230 400/230Frequency 1) [Hz] 50 50 50 50 50 50 50Min. fuse protection 2) [A] 16 20 35 35 50 50 50Recommended fuse protection 2) [A] 20 25 35 35 50 63 63

2.1 Technical data


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Page 2.6

Product description


Type S 6 S 8 S 10 S 15 S 20 S 24 S 29

Oil filling quantityOil receiver volume [l] 6,6 6,6 6,6 6,6 17 18 18Total oil filling quantity [l] 4 4 4 4 9 9 9Oil topping up quantitybetween min. + max. [l] 1 1 1 1 1,5 1,5 1,5

Intake air temperature– min. [°C] + 5 + 5 + 5 + 5 + 5 + 5 + 5– max. [°C] + 40 + 40 + 40 + 40 + 40 + 40 + 40

Cooling air requirement– free-standing installation [m3/h] 1800 2270 3025 3700 5000 7600 7600– with supply and exhaust air duct [m3/h] 800 1000 1300 1700 2500 3800 3800– free ventilator pressure [Pa] 50 50 50 50 50 50 50– free ventilator pressure [mm WC] 5 5 5 5 5 5 5

Operating pressure sensor 2)(factory settings)

– pmax = 18 bar: Switch-off press. pmax [bar] 8 8 8 8 8 8 8Switch-on press. pmin [bar] 7 7 7 7 7 7 7



Safety valveActivation pressure at:– pmax = 8 bar [bar] 11 11 11 11 11 11 11– pmax = 10 bar [bar] 11 11 11 11 11 11 11– pmax = 13 bar [bar] 14 14 14 14 14 14 14

2.1 Technical data

2) Compressors for other operating pressures Pmin = Pmax –1 bar

Technical data for S 6 to S 29, part 2

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Page 2.7

Product description


Type S 6- S 8- S 10- S 15- S 20- S 24- S 29-





– pmax = 18 bar: Switch-off press.pmax [bar] 8 8 8 8 8 8 8Switch-on press.pmin [bar] 7 7 7 7 7 7 7




2.1 Technical data


Technical data for S 6- to S 29-, part 2

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Page 2.8

Product description


Type S 6-...D S 8-...D S 10-...D S 15-...D

Oil filling quantityOil receiver volume [l] 2 x 6,6 2 x 6,6 2 x 6,6 2 x 6,6Total oil filling quantity [l] 2 x 4 2 x 4 2 x 4 2 x 4Oil topping up quantitybetween min. + max. [l] 2 x 1 2 x 1 2 x 1 2 x 1

Intake air temperature– min. [°C] + 5 + 5 + 5 + 5– max. [°C] + 40 + 40 + 40 + 40

Cooling air requirement– free-standing installation [m3/h] 2 x 1800 2 x 2270 2 x 3025 2 x 3700– with supply and exhaust air duct [m3/h] 2 x 800 2 x 1000 2 x 1300 2 x 1700– free ventilator pressure [Pa] 2 x 50 2 x 50 2 x 50 2 x 50– free ventilator pressure [mm WC] 2 x 5 2 x 5 2 x 5 2 x 5


– pmax = 18 bar: Switch-off press.pmax [bar] 8 8 8 8Switch-on press.pmin [bar] 7 7 7 7



Safety valveActivation pressure at:– pmax = 8 bar [bar] 11 11 11 11– pmax = 10 bar [bar] 11 11 11 11– pmax = 13 bar [bar] 14 14 14 14

2.1 Technical data


Technical data for S 6-...D to S 15...D, part 2

Produkt.pm6.5 - 05/2002 - GB

Page 2.9

Product description


Type SD 6 SD 8 SD 10 SD 15 SD 20 SD 24 SD 29









2.1 Technical data


Technical data for SD 6 to SD 29, part 2

Produkt.pm6.5 - 05/2002 - GB

Page 2.10

Product description


Type SD 6- SD 8- SD 10- SD 15- SD 20- SD 24- SD 29-









2.1 Technical data


Technical data for SD 6- to SD 29-, part 2

Produkt.pm6.5 - 05/2002 - GB

Page 2.11

Product description


Function principleof the air end

Air circuit

The air end operates according to the displacement principle. In the housing,the main and secondary screws are driven by means of an electric motorand V-belt.Both screws have screw-shaped profiles, intermeshing without contact.Together with the housing wall, these screws form chambers which graduallyreduce in size, seen in air flow direction.Rotation of the rotors causes the air taken in to be compressed to the finalpressure in the chambers.During compression oil is continuously injected into the air end. This havinga cooling, sealing and lubricating function.

1 = Intake filterThe intake filter cleans the air suctioned by the air end.

2 = Intake regulatorThe intake regulator opens (load operation) or closes (idling operation orstandstill) the suction line depending on the operating condition of the com-pressor.

3 = Air endThe air end compresses the suctioned air.

4 = Compressed air/oil receiverThe compressed air separates from the oil under the force of gravity in thecompressed air/oil receiver.

5 = Oil separatorThe oil separator separates the residual oil contained in the compressed air.

6 = Minimum pressure check valveThe minimum pressure check valve does not open until the system pressurehas increased to 3.5 bar. This causes a rapid build-up of the system pressureand ensures lubrication in the starting phase. Once the compressor has beenswitched off, the check valve prevents the compressed air from flowing backout of the mains line.

7 = Compressed air after-cooler (air and water cooled)The compressed air is cooled in the compressed air after-cooler, causing thewater contained in the air to condensate.

8 = Stop valveThe screw compressor may be isolated from the mains by means of the stopvalve.

2.2 Function description

Fig. 2.1:Components ofthe air circuit

78 6

543

2

1

Produkt.pm6.5 - 05/2002 - GB

Page 2.12

Product description


Oil circuit The oil injected into the air end has the following function:

– It dissipates the compression heat (cooling)

– It seals the gaps between the screws and between the screws and housing

– It lubricates the bearings

2.2 Function description

1 = Compressed air/oil receiverThe oil separated from the compressed air through the force of gravity collectsin the compressed air/oil receiver.The system pressure forces it out of the receiver into the air end.

2 = Thermostatic oil control valveDepending on the oil temperature, the thermostatic oil control valve eitherallows the oil to pass through the oil cooler or through a bypass (e.g. in thestarting phase).Thus the oil constantly maintains its optimum operating temperature.

3 = Oil cooler (air or water cooled)The oil cooler cools down the hot oil to operating temperature.

4 = Oil filterThe oil filter traps impurities in the oil.

5 = Air endThe injected oil returns to the compressed air/oil receiver together with thecompressed air. There, it is separated through the force of gravity.

6 = Drainage lineThe air end suctions the residual oil which collects in the oil separator backinto the oil circuit via a drainage line.

Fig. 2.2:Components of the oil circuit

4

5 6

2

1

3

Produkt.pm6.5 - 05/2002 - GB

Page 2.13

Product description


Network pressure

Operating states

Operating modes

Short operatingtimes

For the compressor, the pressure downstream of the check valve is termednetwork pressure. The control system switches the compressor on and offduring operation depending on the network pressure.

All screw compressor controls are based on three basic operating states:

1. Load operation– The compressor delivers its maximum amount of compressed air.

– It consumes its maximum energy.

2. Idling operation– The compressor runs but does not deliver any compressed air.

– It consumes approx. 75% less energy than in load operation.

– When compressed air is required, it switches to load operation without delay.

– Idling operation reduces switching frequencies which can damage thedrive motor, and reduces wear of the system.

3. Standstill ready for operation– The compressor is standing still but ready for operation.

– When compressed air is required, it switches automatically to loadoperation.

The two most important operating modes are achieved by combining thethree operating states:

1. Intermittent operationIn intermittent operation the energy balance is perfect.

– The compressor operates in load operation.

– Upon reaching the switch-off pressure pmax the compressor switchesto standstill. It does not consume any energy.

– Once the pressure has dropped to the switch-on pressure pmin thecompressor switches back to load operation.

2. Continuous operationContinuous operation limits the drive motor switching cycles and reduceswear to the system.

– The compressor operates in load operation.

– Upon reaching the switch-off pressure pmax the compressor switchesto idling operation.

– Once the pressure has dropped to the switch-on pressure pmin thecompressor switches from idling operation back to load operation.

ATTENTION!During short operating times, the compressor does not reach its operatingtemperature. It operates below the dew point. The generated condensatemixes with the oil. The lubricating ability of the oil is reduced. This leads todamage on the air end.It is of utmost importance to consult BOGE, if you operate your system withshort operating times.

2.3 Compressor control

Produkt.pm6.5 - 05/2002 - GB

Page 2.14

Product description


Proportional controller(Option)

The proportional controller is an additional control device intervening in thesequences of the intake regulator.

The intake regulator only opens as far as necessary to supply the currentcompressed air requirement. Thus the compressor saves compressionenergy.

A compressor with proportional controller is able to supply its ’deliveredquantity variable between 0% and 100%. However, the energy consumptiondoes not reduce accordingly. Therefore, a control is only practical between50% and 100% of the delivered quantity.

The proportional controller is factory set to a delivered quantity between50% and 100% of the compressor capacity.

The proportional controller closes when the desired delivered quantity hasdropped below 50% of the compressor capacity. The compressor then oper-ates in idling operation (continuous operation) or switches off (intermittentoperation).

2.4 Control devices

Produkt.pm6.5 - 05/2002 - GB

Page 2.15

Product description


General

Safety temperaturelimiting device

Safety valve

Monitoringthe drive motor

The safety devices guarantee a high degree of operational safety, in connec-tion with the BOGE ARS monitoring system.

When one of the safety devices responds, the control system reacts asfollows:

– The compressor is immediately switched off.

– A flashing fault number in the left field of the display indicates the causeof the fault.

ATTENTION!Do not operate the compressor without built-in safety devices.Do not dismantle the safety devices or put them out of operation.

The safety temperature limiting device switches off the compressor oncethe maximum admissible final compression temperature has been reached.The compressor does not switch on when dropping below the minimumtemperature.

– Switch off the compressor (OFF button). Fault is acknowledged.

– Rectify the fault.

– Switch on the compressor (ON button).

The safety valve � on the compressed air/oil receiver prevents the maxi-mum admissible pressure being exceeded. When the maximum pressure isexceeded (e.g. incorrect setting of the operating pressure value), the entiredelivery volume of the compressor is ejected.

The following monitoring devices are standard for BOGE ARS control sys-tems:The drive motor is monitored by PTC resistors.

2.5 Safety and monitoring devices

1

Aufstellung.pm6.5 - 05/2002 - GB

Page 3.1

Installation


General Please observe the generally accepted safety and accident prevention regu-lations when transporting the compressor. BOGE accepts no liability fordamage caused by improper transport!

ATTENTION!The compressor is delivered filled with oil.Do not tilt during transport!

Transport possibilities Forklift truck or liftingcarriage transport

Ensure that the forks gripunderneath the base frameof the compressor.

Crane transport

Only use suitable transport slings having aminimum length of approx. 8 metres.Position the slings at the ends underneaththe base frame of the compressor.

ATTENTION!Do not subject the safety cladding to force during transport.Protect the compressor using wooden spacers (see arrows).Remove the transport timbers.

3.1 Transport


Page 3.2

Installation


Installation surface

Sound protection

Fire protection

3.2 Compressor room

Installation, mainte-nance conditions andapplication for pressurereceivers arrangedbelow or separately

– Protect compressed air receivers against damage through mechanicaleffects (e.g. falling objects).

– Operate the compressed air receiver and its equipment from a safelocation.

– Adhere to safety areas and safety clearances.

– Ensure that the compressed air receiver stands securely. It must not shiftor tilt due to external forces. This also includes the additional weight dur-ing a pressure test!

– Ensure that the compressed air receiver is easily accessible from all sides(for recurring tests).

– Ensure that the factory label is clearly visible.

– Ensure that compressed air receivers are adequatly protected againstcorrosion.

– Only use the compressed air receiver for compressors operating with cut-in and cut-out mode if the pressure fluctuation range amounts to ∆ p ≤ 20%of the maximum operating pressure.

A level industrial floor without foundation is adequate for the installation ofthe compressor. No special fastening elements are required.

The following applies to rooms in which compressors with oil injection cool-ing are to be installed:

– For compressors with motor ratings exceeding 40 kW, ensure that thecompressor room is equipped with special fire protection.

– Install compressors with motor ratings exceeding 100 kW in a separatefire protected room.

Requirements of fire protected compressor rooms:– Walls, ceilings, floor and doors must be designed in fire protection class

F30 or higher.

– Flammable liquids must never be stored in the compressor room.

– The floor around the compressor must be made of non-flammablematerial.

– Leaking oil must not spread out over the floor.

– No inflammable materials must be located within a radius of at least3 metres around the compressor.

– No inflammable machine parts, such as cable ducts, may run overheadof the compressor.

Only install compressors in workrooms if the sound pressure level oftheir measuring surfaces does not exceed 85 dB(A).


Page 3.3

Installation


Ventilation

3.2 Compressor room

Admissibleenvironmentalinfluences

The compressor room must be clean, dry, cool and free of dust.

Admissible ambient temperaturesMaximum ambient temperature (for air cooling): + 40°CMinimum ambient temperature: + 5°C

ATTENTION!Nonobservance of the admissible ambient temperature may lead to thefollowing problems:– The compressor will switch off when the admissible final compres-

sion temperature is exceeded or gone below.– Pipe lines and valves will freeze up at low temperatures.– Damage due to reduced lubricating ability of the compressor oil.

Measures to be taken to ensure that admissible ambient temperaturesare observed:– Avoid any pipe lines or units radiating heat in the vicinity of the compres-

sor, or insulate them well.

– Never install the compressor in the cooling air flow of other machines.

– Provide the supply air openings with adjustable louvres to ensure that theminimum temperature is not gone below in winter.

– Use of BOGE anti-frost facility.

If the following instructions are not observed, the admissible final com-pression temperature may be exceeded.In this case, the compressor will switch off automatically.

Attention!Arrange the compressor intake openings or ducts such, that dangerousadmixtures (e.g. explosive or chemically unstable materials) cannot bedrawn in.

Ventilation openings (free-standing installation)– Arrange supply air openings close to the floor.

– Arrange exhaust air openings in the ceiling or at the top of the wall.

– The required cross sections for the supply openings (as well as for theflaps and weather protection grids) are indicated in the table.


Page 3.4

Installation


3.2 Compressor room

Supply and exhaust air ducts– Ensure that the flow rates in the ducts do not exceed 4 m/s.

– Never position cooling air ducts directly on the compressor.Always use a compensator to avoid distortion and the transfer of vibrations.

VentilatorsEnsure that the heated exhaust air is not aken in again.If necessary, the heated air must be extracted by ventilators.

To ensure perfect cooling even at higher temperatures in the summer, theventilators must be designed as follows:

– The ventilator capacity must be rated approx. 10 - 15% higher than thesum of the cooling air quantity required for all machines operated in theroom (VDMA Code of Practice sheet 4363 "Ventilation of compressorrooms").

– For free-standing installation, the cooling air requirement specified in thetable corresponds to the required ventilator capacity.

Supply air filter– Equip the compressor with supply air filter mats if the compressor room

is contaminated with dust (option).

Please refer to the following table for the cooling air requirement and size ofthe supply air openings for your compressor. Ensure that flaps and weatherprotection grids have the necessary free cross section. We generally recom-mend contacting a specialist company for performing the duct constructionwork and planning.

Cooling airrequirement

Type Drive * Cooling air Required * Cooling air Requiredrating requirement for supply air requirement for free duct

free-standing opening for installation crossinstallation free-standing with duct section

[kW] [m3/h] [m2] [m3/h] [m2]

S 6-SD 6 4 1.800 0,25 800 0,06

S 8-SD 8 5,5 2.270 0,30 1.000 0,08

S10-SD10 7,5 3.025 0,40 1.300 0,10

S15-SD15 11 3.700 0,50 1.700 0,13

S20-SD20 15 5.000 0,62 2.500 0,19

S24-SD24 18,5 7.600 0,94 3.800 0,29

S29-SD29 22 7.600 0,94 3.800 0,29

Table 1: Cooling air requirement, required opening and duct cross sections.

* The cooling air requirement was based on a 4°C temperature difference between the ambienttemperature and the outside temperature.


Page 3.5

Installation


BA

DC

E

A: Supply and exhaust air openings in the outside walls (free-standinginstallation)

B: Supported by exhaust air ventilatorC: Exhaust air duct into the openD: Exhaust air duct with recirculation flap

Hot exhaust air is mixed with the cold ambient air, as required. Thuspreventing the plant from freezing up at temperatures below freezing.

E: Using the hot exhaust air for heatingIn the winter, the hot exhaust air is used for room heating. In summer it isdirected into the open.

The air taken in contains water in form of vapour, which turns into conden-sation during compression.

ATTENTION!The condensate contains oil. Never lead it into the public sewage systemwithout prior treatment.Strictly observe the effluent disposal laws of your local authorities.

Oil-water separatorThe BOGE-oil-water-separator separates the oil from the condensate.The cleaned water may be fed directly into the public sewage system.The oil is collected in a separate container. Dispose of the oil according toenvironmental regulations.

If, due to special operating conditions, the oil should emulsify, use an emul-sion cracking plant.

Condensatedisposal

3.2 Compressor room

Ventilationpossibilities


Page 3.6

Installation


General BOGE screw compressor units are supplied ready for connection. Only thework described in the following paragraphs needs to be carried out duringthe installation.

ATTENTION!Only have the installation work carried out by appropriately trained personsor specialists.

Prior to delivery, each compressor is subjected to a trail run at the factory.It is carefully tested and set. However, possible transport damage cannot beexcluded.

– Please inspect the compressor immediately after delivery and directdamage claims to the last haulier - even when the packing is not dam-aged! To safeguard claims against the haulier we recommend leaving themachine, devices and packing material in the same condition as theywere in when the damage was detected.

– Prior to commissioning, check the compressor for external damage.

– Observe the compressor very closely during commissioning and the fol-lowing trial run.

– If malfunctions occur, switch off the compressor immediately and informthe BOGE-Service.

The delivery scope depends on your order.Prior to commissioning, please check whether all required parts have beenprovided. Please check the order confirmation for any possible accessoryequipment.

The delivery scope includes the following component parts:

– Operating instructions

– Electric circuit diagram (in the compartment of the switch cabinet)

– List of electrical equipment (in the compartment of the switch cabinet)

– Oil drainage hose (in air intake box)

– Cap nut (in compartment behind switch cabinet)

– Spare parts list

– Remove the packing material on and in the compressor.

– Install compressor and align horizontally.The compressor must stand firmly on the ground on all feet.

Checking thedelivery scope

Installingthe compressor

3.3 Installation


Page 3.7

Installation


3.3 Installation

– Connect the compressor to the compressed air network or a compressedair receiver.For this, use a BOGE high pressure hose.

Do not install a check valve in the pressure line.The compressor is already equipped with a check valve.

– Unscrew the access safety device.

– Lift the hood upwards out of the fixing device and remove.

Connecting the compressor to thecompressed airnetwork

Removewarm air hood

� Electrical connection� Compressed air connection

Fig. 3.2:Connecting the compressor

ATTENTION!To avoid damage to the cooler, support the screw connection at the cooleroutlet using a spanner.

Fig. 3.1:Remove warm air hood

1

2

Access protection device


Page 3.8

Installation


Checking the oil level BOGE compressors are supplied with a complete oil filling.

Prior to commissioning/start up, check the oil level as described in chapter6.3.

Activating the belttensioning device

The V-belts are slackened for transport.Activate the GM belt tensioning device prior to commissioning by loweringthe motor plate.

– Using spanner NW 17 turn the adjusting nut � down as far as possible.

The belt tensioning device is activated. It automatically sets the correct V-belttension in every operating mode.

ATTENTION!Do not loosen or change the sealed nuts for setting the spring tension.

Fig. 3.3: Activating the belt tensioning device

3.3 Installation

1

1


Page 3.9

Installation


Electrical connection WARNING: Voltage!Ensure that work on the electrical equipment of the compressor is only carriedout by authorized electricians.

When connecting to the power supply, observe the valid VDE, DIN and EVUregulations or the local safety regulations.

Also observe the regulations of your local power supply company regardingthe load rating of your power supply.

Main switchAccording to accident prevention regulation VBG 5, §12, the customer isresponsible to provide the following safety measures:

Compressor plants having a drive motor larger than 3 kW and current inten-sities larger than 16 amperes must be equipped with a lockable main switch(DIN VDE 0660, ...0105) and series fuses.

Please refer to the technical data (chapter 2.1) for the design and fuse rating.

Rated voltageThe data of your mains (operating voltage, control voltage, type of current,frequency, ...) must coincide with the data on the type plate on the switchcabinet.

In the event of deviations, please contact the BOGE service or your supplier.

Connecting the leads– Check to ensure that the terminals in the switch cabinet are firmly tightened.

If necessary, retighten the screw connections.

– Guide the lead cable through the PG screw connection.

– Connect the leads L1, L2, L3, N, Pe (PEN) to the terminal strip.A clockwise rotational field must be created.

CAUTION: Risk of injury!Prior to any work on the compressor:

– switch off the main switch and secure against unintentional switch-on.

– Check that all electrical components are not under power.

– Depressurize all areas under pressure.

Never omit a single safety step! Otherwise, you will risk injuries due torestarting, electric shock or self-releasing parts.

WARNING!When the automatic restart (AWAL) is activated, the compressor will auto-matically restart following a power failure.Prerequisite: the mains pressure is lower than the switch-on pressure set onthe operating pressure sensor.

3.4 Electrical connection


Page 3.10

Installation


ATTENTION!Always check the rotational direction of the drive motor prior to commission-ing/initial start up.Even brief operation in the wrong direction of rotation (more than approx.5 seconds) may cause total destruction of the air end!

Ensure that the rotational direction coincides with the rotational directionarrow on the air end.

– Switch on the main switch.

– Switch the compressor on and immediately off again to check the rota-tional direction.

Changing the rotational direction:

CAUTION: Risk of injury!Switch off the main switch and secure against unintentional switching-on.

– Interchange two phases (L1, L2 or L3) in the motor power cable.

– Check rotational direction again.

Open ball valve 1 on the compressor delivery.

Undertake the following to prevent leaks:

– Check screw connection of the lines and retighten, if necessary.

– Check to ensure that the oil filter and oil separator are hand tight seated.

Switch on the main switch.

– Switch on the compressor using the ON key. The compressor starts.

– The compressor switches off automatically once the switch-off pressure,factory set on the operating pressure switch, has been reached.

– Check network pressure on control display.If necessary, reset operating pressure (pressure target value).(see page 4.13 Autotronic or 4.28 Ratiotronic).

– The compressor is ready for operation.

Checking therotational direction

Opening the stop valve

3.5 Commissioning

Checking for leaks

Conduct trail run


Page 3.11

Installation


Commissioningfollowing extendedstoppages

Following an extended stoppage of more than 2 months, fill a small amountof oil in the suction controller prior to starting the compressor.

ATTENTION!Only fill the suction controller with the grade of oil used to operate the com-pressor.Never mix different oil grades and brands.

CAUTION: Risk of injury!Switch off main switch and secure against unintentional switching-on.

– Unscrew the plug on the suction controller �.

– Fill approx. 1/4 l compressor oil into the suction controller.

– Reclose the controller using the plug.

– Turn the air end by hand 5 to 10 times to distribute the oil evenly.

3.5 Commissioning

Fig. 3.4: Suction controller

1

Refrigerationcompressed air dryer

Before commissioning the refrigeration compressed air dryer see separateoperating instructions series D-, DP- or DU-.

Auto-Ratio.pm6.5 - 05/2002 - GB

Page 4.1BOGE Operating instructions for S 6 - SD 29 series screw compressors

These operating instructions contain a description of the Autotronicand Ratiotronic control system.

BOGE screw compressors are equipped with the modern ARS control systemconcept (Autotronic, Ratiotronic, Supertronic).One of these control systems will be built into your compressor, dependingon the desired equipment and the monitoring functions.

ARS is an integrated control and monitoring concept, having two objectives:

– Energy savings and thus reduction of ongoing costs

– Prolonging the service life of the compressor due to wear which is as lowas possible

All programmed data is stored in a memory module (EEPROM). Thus thestored information is even available following a power failure.

The BOGE ARS control system concept dynamically adapts to the respectiveoperating conditions. A micro-controller assumes the following three tasks:

1. Automatic selection of the most economical operating modeThe micro-controller calculates the optimum operating mode from thecurrent operating state and a programmed ideal value, also taking intoaccount the constant compressor system data (e.g. delivery quantity,receiver volume, motor switching cycles) as well as the current variables(e.g. compressed air consumption, supply and non-supply times, pressureincrease and decrease speed).In order to save operating costs, it always strives for the most economicalintermittent operation.

2. Automatic optimization of the motor switching cyclesThe micro-controller calculates the optimum number of motor switchingcycles. This protects the drive motor and prolongs the service life of theplant.

3. Automatic reminder of the maintenance intervalsThe microcontroller monitors the maintenance intervals.

All ARS control systems comprise of standard components which can bepurchased separately. They are also easy to retrofit. In this manner, thecontrol systems can be optimally adapted to individual customer wishes.Rapid replaceability of the controls in the event of failures increases theavailability of the compressor. This eliminates time consuming and costlytrouble shooting by specialists.

Microcontroller

General

Modular design

The BOGE ARS control concept4.1ARS


Page 4.2 BOGE Operating instructions for S 6 - SD 29 series screw compressors

The BOGE ARS control concept4.2Autotronic

Operating and control panel

EMERGENCY OFFLC-Display Error:

redReady:green

Information Enter ON OFF

Indicator lamps

Fig. 4.1: Autotronic operating panel



Operating elements4.3Autotronic

Operating elements Autotronic

Operating/control element Function

– Press the EMERGENCY OFF switch.The switch engages and interrupts the controlvoltage.All displays are cut off from the power.

After rectifying the fault, unlock the EMERGENCYOFF switch:– Turn the EMERGENCY OFF key a quarter turn

clockwise.– Quit the display test by pressing OFF key .– The compressor is ready to use.

Important!Always switch the compressor offwith the OFF key. Only use EMER-GENCY OFF in an emergency!

ON switch – Press the ON switch:The operating status depends on the networkpressure:1. Network pressure greater than lower cut-in

pressure. Compressor remains ready.2. Network pressure lower than lower cut-in

pressure. Compressor starts and changes toload after a few seconds.

To switch thecompressor on

OFF switch Compressor may continue to run for 30 secondsidling mode

To switch thecompressor off

INFO key – Press the INFO button.The display shows the next set of information.

Select desiredinformation

EMERGENCY OFF switch To switch off thecompressorin an emergency

Operation/Explanation

ENTER key – See parameterization sectionFor confirmation inparameterization




The green lamp indicates that the machine isready.

Lamp = red The red lamp indicates a fault.Fault

Pressure gauge or target value (network)Network pressuredisplay

If parameterization has been started, this symbolappears in the top left of the display

Parameterization

Ready


3-digit 7-segment displayP:

Shown in bar with a decimal point between thesecond and third digit

Displays:Pressure

Lamp = green

3-digit 7-segment displayT:

In °CDisplays:Temperature

Thermometer


bar

°C

Compressed air parameterization start undergoingparameterization





The circle stands for three functions:1. The compressor is switched off2. For motor servicing period3. Servicing symbol (receiver inspection)

(replace wearing parts)

Automatic standbyStand by

(Automatic) idling phaseIdle

OFF ormotor orreceiver



Output phase or output cycleLoad or load speed

Automatic mode with standby phases enabledAutomatic operatingmode selection

Automatic mode without standby phases enabledContinuousoperation

Total motor operatinghours

Total operation time

Idle operating hoursIdle operation time

Information on current or impending servicingServicing due

Energy-independent ON-OFF save function setAWAL(automatic restartenabled afternetwork failure)

Remote output enable (eg, from MCS)External outputenable

Remote ON-OFF (eg, from control panel) – notused here

Online – not used here





– After unlocking the EMERGENCY OFF switchand turning on the supply voltage, all enablabledisplay elements of the control appear at thesame time – including the two indicator lamps.

– If standby was not saved (no AWAL), this statusmust first be ended by pressing the OFF switchO, before the compressor can be switched on.

– Otherwise it disappears automatically after a settime and the compressor is on standby againwithout touching the controls.

Function control ofdisplay elements


Operation Autotronic

– This display appears automatically after com-pletion of the network failure phase (as de-scribed under display element function control):

– The network pressure is shown at the top left(pressure gauge 21),and at the top right the (final compression)Temperature,In the centre are the two operating mode curves:the left arrow shaded (as shown here) = auto-matic mode selection,right = contnuous operation,The circle left of this means: off here.The symbol at the bottom left is for setting ex-ternal output enable and the symbol for cut-insave (AWAL) is shown at the bottom right.These two symbols only appear when the re-spective setting has been made.

Main display

If no fault is reported, pressing will switch on thegreen indicator lamp (compressor on standby)which means:the pressure control function is activated

Switch on thecompressor

green red

green

Operation4.4Autotronic




The presssure control starts the motor if required� the idling symbol appears during the time-controlled star phase (the star contactor is switchedon first followed by the network contactor 20mslater). The idling symbol also appears for 30 sec-onds after reaching the set maximum pressure.



The star phase is automatically ended and achange to delta switching started (the star con-tactor drops and 60ms later the delta contactorcuts in), the valve status Load is switched on andthe symbol is shown in the display.

Press O � Compressor Off � and the pressurecontrol function is deactivated and the displayshows the idling symbol for up to 30 seconds.During this time the green indicator blinks. Thesymbol O then appears and the green indicatorturns off.

Switch off thecompressor

Power-up phase

Delta switch

Stand by After the set maximum pressure is reached, theidling appears, in most cases for 30 seconds.If during this time the pressure drops to below theset minimum pressure, the compressor switchesback to load and the respective symbol is displayedagain.Otherwise the control unit switches the motor offand the Stand by symbol is shown in the dis-play.





If the control unit detects a fault, the compressor isswitched off immediately and automatically – with-out an idling phase –, the fault relay drops and anumber on the right of the current pressure blinkstogether with the red indicator lamp:

The blinking number indicates the detected fault(see also message key table Page 4.11).



Press i � and the segment display shows thetotal operating time in hours, together with the totalup-time.

Press i a third time � and the display shows theoperating time until the compressor servicing andthe Running time and Servicing symbols (spanner).

Compressorservicing interval

Fault

red

Total hours

Press i a second time � and the display showsthe Idling time counter and the Idling symbol.

Idling hours

Operation,servicing periods,display testand software-No.

Means: 124hrs Total up-time

Means: 2hrs Idling time

Means: 500hrs until the nextcompressor servicing





Press i a fifth time � and the display shows the1000-output cycle servicing counter with thesingle exponent 103 (x 1000), the load speed sym-bol, the circle (here for the receiver) and the ser-vicing symbol (spanner), meaning the number ofpossible output cycles until the next receiver in-spection.



Press i a sixth time � and the segment displayshows the Upper target pressure and an under-score at the top right next to it.

Receiver servicinginterval

Upper targetpressure value

Press i a seventh time � and the segment displayshows the Lower target pressure and an under-score at the bottom right next to it.

Lower targetpressure value

Press i a fourth time � and the display shows theoperating time ntil the next Motor servicing andthe symbols O (here for motor), running tme andservicing (spanner).

Motor servicinginterval

Means: 1000hrs until the nextmotor servicing

Means: 20 x 103 = 20000 Loadcycles until the next receiverservicing.

Means: PMax. = 10,0 bar

Means: PMin. = 9,0 bar





Press i a ninth time � and the segment displayarea shows the Software-No.



Press i one more time � to return to the maindisplay.If no key is pressed for five minutes, the maindisplay automatically reappears.

Software-No.

Press i an eighth time � and the display showsall symbols and segments together with the twoindicator lamps.

Display elementtest

red green

Means Software-No. 1105




Error key table Error Meaning CompressorNo. cut-out

0 Dryer reports fault adjustable

1 Final compression temperature > 110°C, 230°F X

2 Motor temperature too high X

3 Not assigned here

4 Not assigned here

5 Not assigned here

6 Not assigned here

7 Not assigned here

8 Not assigned here

9 Not assigned here

10 Motor servicing due

11 Compressor servicing due

12 Not assigned here


14 Temperature too low X


16 Network pressure transmitter faulty X





21 Receiver inspection:Wearing parts due to be replaced




25 Control unit EEPROM / reconciliation error X


27 Control unit ON-key I does not open X


29 Control unit ENTER key ↵ does not open X




Control Parameterization4.5Autotronic



General The control unit calculates from the current operating data the respectivebest operating mode and automatically selects it.The parameters are adjustable.In order to prevent unintentional changes to pre-set parameters, these pa-rameters are codeword-protected.

ATTENTION!Never change the value of a parameter if you do not know what it means!This may cause incorrect behaviour of the control unit!Do not experiment with parameter settings!Always call BOGE-Service if you are unsure or have any doubts.

From the main display the first step in parameterization is performed by re-peated pressing of the INFO key i until the display the software-no., andthen proceeding as follows:

1. Press ENTER ↵ → and the parameterization symbol is shown on theleft, followed by three zeros, the left of which blinks.

2. Press i to change the first digit.

3. Press ↵ → and now the middle zero blinks.

4. Press i to change the second digit.

5. Press ↵ → and now the right zero blinks.

6. Press i to change the third digit.

7. Press ↵ → the display will now branch off depending on the set number– if the value is invalid the main display will reappear.

To make changes easier, the respective setting is changed in large steps.

1. Enter Code 111 as described under coded parameterization → and thedisplay shows, as already described, the compressor servicing intervalin blinking digits

2. Press the INFO key i to change the value.

3. Press ENTER ↵ to overwrite the non-volatile EEPROM with the blinkingvalue, and the main display reappears.


1. Enter Code 222 as described under coded parameterization → and thedisplay shows, as already described, the motor servicing interval in blink-ing digits



Parameterization

Set the compressorservicing interval andzero the counter

Set the motorservicing interval andzero the counter




Set receiver inspectionload cycles and restart


1. Enter Code 333 as described under coded parameterization → and thedisplay shows, as already described, the receiver inspection interval inblinking digits.



If changes are made to these target values, the value of Pmin is automaticallyheld or brought outside any applicable minimum hysteresis range.

1. Enter Code 360 as described under coded parameterization → and thedisplay shows, as already described, the upper target pressure value,but blinking.


3. Press ENTER ↵ to overwrite the non-volatile EEPROM with the blinkingvalue, and the lower target pressure value apears (blinking).

4. This value can now be changed by pressing the INFO key i.


If the output of a compressor is to be enabled by a higher level control unit,its parameterization must be changed as follows:

1. Enter Code 210 as described under parameterization → and the displayshows Fig. � left.The ‚square’ at the top right blinks. This display means: no additionalenabling device is programmed.

2. Press the INFO key i to change to Fig. � (or press again to toggleback...).The 7-segmente range blinks. This display means: an enabling device(e.g., MCS) is programmed.

3. Press ENTER ↵ to overwrite the non-volatile EEPROM as per the blink-ing symbol, and the main display reappears.If the compressor is set for an output enabling device, the bottom of themain display shows the appropriate Symbol .The following applies even with external enabling: if the upper targetpressure value in the compressor is exceeded, the output will be shutoff. Only when the the pressure drops to the lower target pressure valuedoes external control resume.

Change targetpressure values(Pmax and Pmin)

External output enable

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Change after-runningtime

For compressors that are seldom in operation there is an option to changethe after-running time:1. Code 019 as described under parameterization → and the display shows

the Fig. on the leftThe number 30 blinks. The quotation mark symbol here stands for sec-onds. A run-out curve is indicated on the two right positions.



If pressure drops in relatively small receiver/pneumatic network volumesmust be avoided at any price, continuous operation can be set as follows:

1. Enter Code 733 as described under parameterization → and the displayshows Fig. � on the left.The shading of the left arrow blinks. this means: automatic power economyoperating mode selection.

2. Press the INFO key i to change to Fig. � links (press again to toggleback...).The shading of the right arrow blinks. this means: continuous operation.

3. Press ENTER ↵ to overwrite the non-volatile EEPROM with the blinkingsymbol, and the main display from the selected symbol appears.

IMPORTANT!With automatic restart (AWAL) the compressor restarts automatically after apower failure.Condition: the network pressure is lower than the set cut-in pressure and itwas switched on beforehand.

Using energy independent memory for remembering ON-OFF:Normally a compressor always assumes an OFF status directly after anelectrical power failure.However, there is an option to automatically restart the compressor with aset delay after a power failure. This is done as follows:

1. Enter Code 134 as described under parameterization → and the displayshows Fig. � on the left: the 'line' at the top right blinks.This display means: no remembering of On-Off status (standby) after apower failure.

2. Press the INFO key i to change to Fig. � links (press again to toggleback...).The ‚curve’ at the top right blinks.This display means: remember the On-Off status (AWAL).

3. Press ENTER ↵ to overwrite the non-volatile EEPROM acc. to the blink-ing symbol. If the top symbol was selected, the main display is shown.Otherwise Fig. � on the left is shown.The number 120 blinks. The quotation mark symbol here stands for sec-onds.

4. Press the INFO key i to change the value.Press ENTER ↵ to overwrite the EEPROM with the blinking value andthe main display appears with the at the bottom right.

Set continuous mode

Enable networkindependent ON-OFF memory(AWAL)

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Anti-freeze idling(only in mode: Ready foroperation)

The compressor is set to automatically start an idling phase from standbywhen the temperature drops to below +4°C, and to remain idling until reach-ing +20°C final compression temperature.

Motor switching limitation is only activated when the air requirement makesit necessary, ie, after the "Motor start count per quarter hour" is reached be-fore time.Only now does it switch from intermittent to a limited continuous operation –synchronous DB control. The control unit calcuates the through time sothat on the one hand the maximum allowed switch count per 12 minutes cannot be exceeded, and that unnecessary idling times can be saved on theother.

The star time is fixed in the control unit according to the type of compressor.

If the compressor automatically (eg, on reaching the upper target pressurelevel) from load to idling, it will continue to run until the after-running time(max. 655 sec.) has expired.To change the after-running time see page 4.14.

The main display shows a blinking spanner.– all other Functions are unchanged.

If the INFO key i is pressed, the display only shows the service requestNumber and the spanner.Press the ENTER key ↵ to acknowledge the request. If necessary (seealso message key table) one of the three servicing interval back-counters must be reset to its start value as under the respective serviceinterval setting or receiver inspection load cycle setting, and changed orconfirmed by pressing ↵ .

Pre-acknowledgementIf a service message is acknowledged, the cause of which has not (yet)been attended to, the spanner symbol continues to appear (but no longerblinking).

Service request

Idling control withextremely shortoperating time (option)

Star phase time control

Motor switchinglimitation




Fuses

Configure binaryinput pre-processingmessages

Opener contacts (closed in good condition) should normally be connectedwith this input. Also, in many cases a warning message from the compressorcontrol unit is sufficient. Both can be parameterized as follows:

1. Enter Code 245 as described under parameterization → and the displayshows the following figure (Fig. � left).The "dash" lines blink. They represent an opener contact. The thermom-eter stands here for compressed air pre-processing.

2. Press INFO i to switch to Fig. � left (press again to toggle back...).The "dash" lines blink. They represent an closer contact.

3. Press ENTER ↵ to overwrite the non-volatile EEPROM as per the blink-ing symbol and Fig. � on the left is shownon the display.The spanner blinks. It stands here for warning message assignment.Here too, The thermometer stands here for compressed input air pre-processing.

4. Press INFO i to switch to Fig. � left (press again to toggle back...).The circle blinks. It stands here for error message assignment (compres-sor cut-out).

5. Press ENTER ↵ to overwrite the non-volatile EEPROM as per the blink-ing symbol and the main display from which the symbol was selected isshown.

CPU supply (5 V): automatic reset by power cutout after cooling.I/O supply (20 V/5 V): automatic reset by power cutout after cooling.

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Service4.6Autotronic



Operating and control panel

The BOGE ARS control concept4.7Ratiotronic

EMERGENCY OFF

Fig. 4.1: Ratiotronic operating panel

LC-Display Error: red Ready: green

nextinformation

Enter

ON

OFF

Indicator lamps

previousinformation Main display



Operating elements Ratiotronic


– Press the EMERGENCY OFF switch.The switch engages and interrupts the controlvoltage.All displays are cut off from the power.

After rectifying the fault, unlock the EMERGENCYOFF switch:– Turn the EMERGENCY OFF key a quarter turn

clockwise.– Quit the display test by pressing OFF key .– The compressor is ready to use.

Important!Always switch the compressor offwith the OFF key. Only use EMER-GENCY OFF in an emergency!

ON switch – Press the ON switch:The operating status depends on the networkpressure:1. Network pressure greater than lower cut-in

pressure. Compressor remains ready.2. Network pressure lower than lower cut-in

pressure. Compressor starts.

To switch thecompressor on

OFF switch Compressor may continue to run for 30 secondsidling mode

To switch thecompressor off

EMERGENCY OFF switch To switch off thecompressorin an emergency


Operating elements4.8Ratiotronic

[Up] key The key has two functions:1. It shows trhe next information one step back-

wards.2. It changes the parameter values one value

backwards.

Display selectionin LC-Display

[Down] key The key has two functions:1. It shows trhe next information one step for-

wards.2. It changes the parameter values one value for-

wards.

Display selectionin LC-Display

INFO key – Press the INFO button.The display shows the main information or fault/warning message.

Select desired maininformation

ENTER key – See parameterization sectionFor confirmation inparameterizationand acknowledge-ment of messages




The green lamp indicates that the machine isready.

Lamp = red The red lamp indicates a fault.Fault

Pressure gauge or target value (network)Network pressuredisplay

If parameterization has been started, this symbolappears in the top left of the display

Parameterization

Ready


3-digit 7-segment displayP:

Shown in bar with a decimal point between thesecond and third digit

Displays:Pressure

Lamp = green

3-digit 7-segment displayT:

In °CDisplays:Temperature

Thermometer


Operating elements4.8

bar

°C

Compressed air parameterization start undergoingparameterization

Ratiotronic

Pressure gauge system presssure (compressor)System pressuredisplay




The circle stands for three functions:1. The compressor is switched off2. For motor servicing period3. Servicing symbol (receiver inspection)

(replace wearing parts)

Automatic standbyStand by

(Automatic) idling phaseIdle

OFF ormotor orreceiver



Output phase or output cycleLoad or load speed

Automatic mode with standby phases enabledAutomatic operatingmode selection

Automatic mode without standby phases enabledContinuous opera-tion

Total motor operating hoursTotal operation time

Idle operating hoursIdle operation

Information on current or impending servicingServicing due

Energy-independent ON-OFF save function setAWAL(automatic restartenabled afternetwork failure)

Remote output enable (eg, from MCS)External outputenable

Remote ON-OFF (eg, from control panel)

Serial interface enabled

Remote On-OffMode

Online-Mode

Operating elements4.8Ratiotronic




– After unlocking the EMERGENCY OFF switchand turning on the supply voltage, all enablabledisplay elements of the control appear at thesame time – including the two indicator lamps.

– If standby was not saved (no AWAL), this statusmust first be ended by pressing the OFF switchO, before the compressor can be switched on.

– Otherwise it disappears automatically after a settime and the compressor is on standby againwithout touching the controls.

Function control ofdisplay elements


Operation Ratiotronic

– This display appears automatically after com-pletion of the network failure phase (as de-scribed under display element function control):

– The network pressure is shown at the top left(pressure gauge 21),and at the top right the (final compression)Temperature,In the centre are the two operating mode curves:the left arrow shaded (as shown here) = auto-matic mode selection,right = contnuous operation,The circle left of this means: off here.The symbol at the bottom left is for setting ex-ternal output enable and the symbol for cut-insave (AWAL) is shown at the bottom right.These two symbols only appear when the re-spective setting has been made.

Main displayRatiotronic

green red

green

If no fault is reported, pressing will switch on thegreen indicator lamp (compressor on standby)which means:the pressure control function is activated.

Switch on thecompressor

Operation4.9Ratiotronic




The presssure control starts the motor if required� the idling symbol appears during the time-controlled star phase (the star contactor is switchedon first followed by the network contactor 20mslater). The idling symbol also appears for 30 sec-onds after reaching the set maximum pressure.



The star phase is automatically ended and achange to delta switching started (the star con-tactor drops and 60ms later the delta contactorcuts in), the valve status Load is switched on andthe symbol is shown in the display.

Press O � Compressor Off � and the pressurecontrol function is deactivated and the displayshows the idling symbol for up to 30 seconds.During this time the green indicator blinks. Thesymbol O then appears and the green indicatorturns off.

Switch off thecompressor

Power-up phase

Delta switch

Stand by After the set maximum pressure is reached, theidling appears, in most cases for 30 seconds.If during this time the pressure drops to below theset minimum pressure, the compressor switchesback to load and the respective symbol is displayedagain.Otherwise the control unit switches the motor offand the Stand by symbol is shown in the dis-play.

If the control unit detects a fault, the compressor isswitched off immediately and automatically – with-out an idling phase –, the fault relay drops and anumber on the right of the current pressure blinkstogether with the red indicator lamp:

The blinking number indicates the detected fault(see also message key table page 4.11 or page4.26 Ratiotronic).

Fault

red




Operating/control element Function Operation/Explanation


Press � � and the segment display shows thecompressor system pressure (pressure gauge 22).

Press � a third time � and the display shows theIdling time counter and the Idling symbol:

Idling hours

Compressorsystem pressure

Press � a second time � and the segment displayshows the total operating time in hours, togetherwith the total up-time:

Total hours

Operation time,output cyclesservicing periods,display testand software-No.

Means: 124h Total up-time

Means: 2hrs Idling time

Press ↓ a fourth time → and the display shows the1000-output-cycles counter with the exponent 103

(x 1000), the load cycle symbol and the circle (here:receiver):

Output-cycle-counter

Means: 12 x 103 = 12000 outputcycles





Press ↓ (a fifth time) → and the display shows theoperating time (in hours) until the compressorservicing and the Running time and Servicingsymbols (spanner).



Press ↓ (a sixth time) → and the display shows theoperating time until the next Motor servicing andthe symbols O (here for motor), running time andservicing (spanner).

Compressorservicing interval

Motor servicinginterval

Press ↓ (a seventh time) → and the display showsthe 1000-output cycle servicing counter with theexponent 103 (x 1000), the Load-cycle symbol, thecircle (here for receiver) and the servicing symbol(spanner), meaning the number of possible outputcycles until the next receiver inspection or changeof wearing parts

Output cycles untilthe next receiverservicing/change ofwearing parts

Means: 500hrs until the nextcompressor servicing

Means: 1000hrs until the nextmotor servicing

Means: 20 x 103 = 2000020 x 103 = 20000 Load cyclesuntil the next receiver servicingor change of wearing parts

Press ↓ (an eighth time) → and the segment dis-play shows the Upper target pressure and anunderscore at the top right next to it.

Upper targetpressure(Network pressure)

Means: PMax. = 10,0 bar(Switch off pressure)

Press ↓ (a ninth time) → and the segment displayshows the Lower target pressure and an under-score at the bottom right next to it.

Lower targetpressure(Network pressure)

bedeutet: PMax. = 9,0 bar(Switch on pressure)





Press ↓ (an eleventh time) → and the segmentdisplay area shows the Software-No.



Software-No.

Display element testPress ↓ (a tenth time) → and the display showsall symbols and segments together with the twoindicator lamps.

Display elementtest

red green

Means Software-No. 1105

Press ↓ (a twelfth time) → to return to the statusdisplay.Press key ↑ to watch the displays in the reverseddirection.If no key is pressed for five minutes, the statusdisplay automatically reappears.




Control Parameterization

Error key tableEach message is automaticallyregistered by the control, to-gether with the associated time,thus putting an overview at thedisposal of BOGE-Service.

Error Meaning Compressor-No. cut-out

0 Dryer reports fault adjustable

1 Final compression temperature > 110°C, 230°F X

2 Excessive motor temperature X

3 Not assigned here X

4 Incorrect direction of rotation X

5 Excessive compressor system pressure X

6 Excessive diff. pressure of intake filter

7 Excessive diff. pressure of oil filter

8 Excessive diff. pressure of oil separator

9 No output X

10 Motor servicing due

11 Compressor servicing due

12 System pressure decrease too slow


14 Temperature too low X


16 Line pressure transmitter faulty X





21 Receiver servicing due




25 Control unit Reconciliation error X

26 Control unit O-key does not open X

27 Control unit I-key does not open X

28 Control unit i-key does not open X

29 Control unit ↵-key does not open X

30 Control unit "arrow up" does not open X

31 Control unit "arrow down" does not open X

32 Network pressure transmitter-wire breakage X

33 Compr.system-pressure-transmitter-wirebreakage X

34 Compr.system-pressure-transmitter faulty X

4.10Ratiotronic



Control Parameterization4.10

General The control unit calculates from the current operating data the respectivebest operating mode and automatically selects it.The parameters are adjustable.In order to prevent unintentional changes to pre-set parameters, these pa-rameters are codeword-protected.

ATTENTION!Never change the value of a parameter if you do not know what it means!This may cause incorrect behaviour of the control unit!Do not experiment with parameter settings!Always call BOGE-Service if you are unsure or have any doubts.

In general the following is applicable: If a parameterization, as describedbelow, is started at the top right in the display the symbol appears andthe set value or status blinks.

1. Display Software-No. (see Software No.).

2. Press ENTER ↵ → and the parameterization symbol is shown on theleft, followed by three zeros, the left of which blinks.

3. Press ↑ or ↓ to change the first digit.

4. Press ↵ → and now the middle zero blinks.

5. Press ↑ or ↓ to change the second digit.

6. Press ↵ → and now the right zero blinks.

7. Press ↑ or ↓ to change the third digit.

8. Press ↵ → the display will now branch off depending on the set number– if the value is invalid the main display will reappear.

Each parameterization is automatically registered by the control, togetherwith the associated time, thus putting an overview at the disposal of BOGE-Service.

1. Enter Code 111 as described under coded parameterization → and thedisplay shows the compressor servicing interval in blinking digits (Com-pressor servicing).

2. Press the ↑ or ↓-key to change the value in big steps.

3. Press ↵-key to overwrite the non-volatile EEPROM with the blinkingvalue, and the main display reappears.

1. Enter Code 222 as described under coded parameterization → and thedisplay shows the motor servicing interval in blinking digits (Motor servic-ing).

2. Press the ↑ or ↓-key to change the value in big steps.


Parameterization

Set the compressorservicing interval andzero the counter

Ratiotronic

Set the motorservicing interval andzero the counter

Enter ParameterizationCode



Control Parameterization4.10Ratiotronic

1. Enter Code 333 as described under coded parameterization → and thedisplay shows the receiver inspection interval in blinking digits (receiverinspection/change of wearing parts).

2. Press the ↑ or ↓ keys to change the value in big steps.


If changes are made to these target values, the value of Pmin is automaticallyheld or brought outside any applicable minimum hysteresis range.

1. Enter Code 360 as described under coded parameterization → and thedisplay shows the upper target pressure value, but blinking.

2. Press ↑ or ↓-key to change the value.

3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,and the lower target pressure value apears (blinking).

4. This value can now be changed by pressing the ↑ or ↓-key.

5. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,and the main display reappears.

If the output of a compressor is to be enabled by a higher level control unit,its parameterization must be changed as follows:

1. Enter Code 210 as described under parameterization → and the displayshows Fig. � left.The 'square' at the top right blinks. This display means: no additionalenabling device is programmed.

2. Press ↑ or ↓-key to change to Fig. � (or press again to toggle back...).The 7-segmente range blinks. This display means: an enabling device(eg, MCS) is programmed.

3. Press ↵-key to overwrite the non-volatile EEPROM as per the blinkingsymbol, and the main display reappears.If the compressor is set for an output enabling device, the bottom of themain display shows the appropriate Symbol .The following applies even with external enabling: if the upper target pres-sure value in the compressor is exceeded, the output will be shut off.Only when the the pressure drops to the lower target pressure value doesexternal control resume.

Set load cycles receiverservicing/ changeof wearing parts andrestart

Change target pressurevalues(Pmax and Pmin)

External output enable

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If the compressor has to be switched On/Off from a control room – withoutkey switch – the parameterization has to be changed as follows:

1. Enter Code 451 as described under parameterization → iand the displayshows Fig. � left.The 'square' at the top right blinks. This display means: no remote On/Offcontrol enabled.

2. Press the ↑ or ↓-key to change to Fig. � (or press again to toggle back...).The 7-segmente range blinks. This display means: an enabling device forremote On/Off control (continuous mode) is programmed.

3. Press ↵-key to overwrite the non-volatile EEPROM as per the blinkingsymbol, and the main display reappears.If the control unit registers Remote On/Off, it is not possible to switch overvia keyboard.If the compressor is set for Remote On/Off control, the bottom of themain display shows at the bottom of the display the appropriate Symbol

.Now the compressor can only be switched on/off via remote control. Thisdoes not concern the Emergency Off function. It remains unchanged.

After an output phase the compressor switches to an idling phase beforedecreasing the system pressure and finally switching into stand-by.For compressors that are seldom in operation there is an option to changethe min. after-running time:

1. Code 019 as described under parameterization → and the display showsthe Fig. � on the left: The number (here 1) blinks. The quotation marksymbol here stands for seconds. A run-out curve is indicated on the tworight positions.

2. Press the ↑ or ↓-key to change the value. Above 119 minutes appearand the apostrophe Symbol instead of the quotation mark symbol.


Remote On/Off control

Change min. after-running time

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If pressure drops in relatively small receiver/pneumatic network volumesmust be avoided at any price, continuous operation can be set as follows:

1. Enter Code 733 as described under parameterization → and the displayshows Fig. � on the left.The shading of the left arrow blinks. This means: automatic power economyoperating mode selection.

2. Press the ↑ or ↓-key to change to Fig. � on the left (press again to toggleback...).The shading of the right arrow blinks. This means: continuous operation.

3. Press ↵-key to overwrite the non-volatile EEPROM with the blinkingsymbol, and the main display from the selected symbol appears.

Using energy independent memory for remembering ON-OFF:Normally a compressor always assumes an OFF status directly after anelectrical power failure.However, there is an option to automatically restart the compressor with aset delay after a power failure. This is done as follows:

1. Enter Code 134 as described under parameterization → and the displayshows Fig. � on the left: the ‚line’ at the top right blinks.This display means: no remembering of On-Off status (standby) after apower failure.

2. Press the ↑ or ↓-key to change to Fig. � on the left (press again to toggleback...).The 'curve' at the top right blinks.This display means: Remembering of the On-Off status even after a powerfailure (AWAL).

3. Press ↵-key to overwrite the non-volatile EEPROM acc. to the blinkingsymbol. If the top symbol was selected, the main display is shown. Oth-erwise Fig. � on the left is shown.The number 120 blinks. The quotation mark symbol here stands for sec-onds.

4. Press the ↑ or ↓-key to change the value.Press ↵-key to overwrite the EEPROM with the blinking value and themain display appears with the at the bottom right.

Set continuous mode

Enable networkindependent ON-OFFmemory (AWAL)

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Ratiotronic

The compressor is set to automatically start an idling phase – in star modei.e. without switching on a probably existing ventilator motor – from standbywhen the temperature drops to below +4°C. During this phase in the maindisplay a thermometer blinks left of the temperature display. The idling phaseis finished as soon as the min. after-running time or +20°C final compressiontemperature are reached.This anti-freeze function can be switched off as follows:

1. Enter Code 056 as described under parameterization → and the displayshows Fig. � on the left: the 'curve' left of the thermometer blinks.This display means: automatic idling phase in frost.

2. Press ↑ or ↓-key to change to Fig. � left (press again to toggle back...)The 3x dotted line left of the thermometer blinks.This display means: no automatic running phase in frost, shown by meansof the right dash as to the thermometer.

3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking sym-bol, and the main display from the selected symbol appears.

If the compressor changes automatically (e.g., on reaching the upper targetpressure level) from load to idling, it will continue to run in cold conditionuntil +20°C final compression temperature is reached and the min. after-running time has expired.

If the serial interface – optionally – is used, an individual address – abovezero – has to be set:

1. Enter Code 830 as described under parameterization → and the displayshows the figure on the left.: The digit (here 0) blinks.

2. Press ↑ or ↓-key to change the value.Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,and the main display reappears.

Control Parameterization4.10

Anti freeze operation(only in mode: Ready foroperation)

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Idling controlwith extremely shortoperating time

RS 485-Bus-address



Parameter overview Code Function Page

019 Change min. after-running time 4.29

056 Anti freeze operation 4.31

111 Set compressor servicing intervals and restart 4.27

134 Enable network-independent on-off storage (AWAL) 4.30

210 External output release 4.28

222 Set motor servicing intervals and restart 4.27

333 Set load cycles receiver servicing/change of wearing 4.28parts and restart

360 Change pressure target values (Pmax and Pmin) 4.28

451 Remote On/Off control 4.29

733 Set permanent operation 4.30

830 Set RS 485-Bus-address 4.31


Stoerung.pm6.5 - 05/2002 - GB

Page 5.1

Faults


5.1 General

General The tables on the following pages give information on the possible causes ofoperating faults and measures for their rectification.

ATTENTION!Ensure that any work required to rectify faults is only carried out by trainedpersonnel or specialists.Ensure that components which have a safety function are only set, repairedor exchanged by BOGE Service!

Please contact BOGE-Service at the following telephone number, if you haveany questions.

� ++49 / 52 06 / 6 01-0

All data is stored in a memory module (EEPROM).If a fault occurs while the data stored in the EEPROM is being read, thecontrol system will react as follows:

– The compressor is switched off.

– The following fault message appears in the display.

Automatic monitoringof the control systems

Error message

ErE(Error EEPROM)

ErA(Error compensation)

F(Error Fuse)

Remedy

– First, reinsert previous software and note downall parameter values.

– Subseuqently, insert desired software, performthe basic setting function of the control systemand acknowledge the message. The messagewill disappear.

– Then check the parameters and correct accord-ing to the noted down values.

– Printed circuit board must be removed andinspected by BOGE-Service.

– Establish voltage supply

– Replace fuse

Cause

– Data from the plugged-in EEPROM is notaccepted by the controlsystem.

– Incorrect compensationdata for the temperaturesensor is read from thesoldered-in EEPROM.

– No supply voltage forthe inputs

– Fuse may be defective


Page 5.2

Faults


5.2 General faults

Fault RectificationPossible cause

Compressor does notstart up

Check electrical connection

Check the mains and control fuses, replace ifnecessary

Check venting valve and replace, if necessary

Ensure constant voltage in accordance with IEC 38

Heat up the compressor(additional heater available as as option)

No electric power to com-pressor

Fuses are defective

Machine has not ventedperfectly

Voltage fluctuations in theelectrical mains power

Compressor oil is veryviscous due to low ambienttemperature

Oil in suction filter Check the minimum pressure check valve andreplace, if necessary

Check the suction controller and replace,if necessary

Minimum pressure non-return valve is leaking

Suction controller is leaking

Excessive oilconsumption

Dismantle and clean drain line

Check oil separator and replace, if necessary

Drain off oil

Drain line is blocked

Defective oil separatorelement

Excessive oil filling

Safety valve blows Set operating pressure to the maximum permissiblepressure of the screw compressor

Replace safety valve

Operating pressure switchhas been misadjusted

Defective safety valve

System pressuredoes not decreasewhen switching off

Check venting valve and replace, if necessary

Check the check valve and replace, if necessary

Venting valve does not open

Check valve is leaking

No quantity delivered,no pressure build-up,max. pressure 0.5 bar

System components in thecompressor are leaking

Minimum pressure valve isdefective

Electromagnetic ventingvalve does not close

Suction controller does notopen

V-belts are torn

Check oil and compressed air lines inside the com-pressor; tighten and/or reseal screw connections,if necessary

Close ball valve and check whether pressure buildsup; if so, open ball valve again immediately; replaceminimum pressure valve

Check solenoid valve and replace, if necessary

Suction controller or solenoid valve is defective;check and replace, if necessary

Fit new V-belts


Page 5.3

Faults


Malfunction of the con-nected compressed airtreatment unit

5.3 Fault messages of the control system

If a fault occurs in the monitored assembly groups during operation, thecontrol system will react as follows:

– The compressor is switched off.

– The corresponding error number flashes in the left field of the display.

– The compressor cannot be restarted as long as a fault message exists.To acknowledge the error message on the display, press the red OFFbutton (0) until the blinking red light goes out or switches to permanentlight. (The fault is not rectified if it switches to permanent light.)


Final1 compressiontemperature

Ambient temperature toohigh

Cooling unit soiled

Insufficient cooling airquantity

Insufficient oil quantity

Safety temperature sensordefective or wire break

Employ suitable measures to improve the air inletand ventilation in the installation room

Clean cooling unit externally

Keep air inlet opening to the compressor clean;check to ensure that any existing cooling air ductsystems are adequatly dimensioned

Top up oil

Exchange safety temperature sensor or repair wirebreak

Drive motor2 Motor overload!Excessive winding temp.due to under-voltage

Insufficient motor cooling

Excessive switchingfrequency of the motor

Motor soiled

Excessive system pressure

Excessive line pressure

PTC resistor defective oraged

Ensure correct voltage conditions:Constant voltage in accordance with IEC 38

Improve motor cooling:improve ventilation of the installation room;clean the cooling unit

Fit a larger compressed air receiver volume;increase the switching difference of the operatingpressure switch;Set parameter 13 (percentage of non-supply share):< 100 %;increase idle running times

Clean motor cooling air supply

Exchange oil separator cartridge

Reduce line pressure to prevent compr. building upa compr. load above approved max. pressure

Overhaul motor

Compressed air0 treatment(option)

Service or repair compressed air treatment unitNote:This message does not lead to a switch-off of thecompressor in the standard configuration


Page 5.4

Faults


5.3 Fault messages of the control system

Options of the Ratiotronic


Rotational4 direction/belt tear /system relief(option)

2 phases of power cableincorrectly poled (incorrectrotary field connected)

Torn V-belts

Minimum pressure checkvalve does not close

Air relief valves does notopen

Change the 2 phases of the power cable

Fit new V-belts

Check the minimum pressure check valve andreplace, if necessary

Replace solenoid valve

Excessive pressure due tosoiled oil separator

Safety pressure switchincorrectly set

Operating pressure switchincorrectly set

Ball valve at compressoroutlet closed

Replace oil separator cartridges

Check safety pressure switch and replace,if necessary

Set back operating pressure switch to compressormaximum pressure

Open ball valve

Pressure limitation5 (safety pressureswitch)(option)

Air relief valve does notclose

Suction controller does notopen

Leakage in system

System pressure9 build-up(option)

Check air relief valve and replace, if necessary

Check suction controller and replace, if necessary

Check system, overcome leaks

Soiled filter cartridge

Defective low pressureswitch

Clean or replace cartridge

Replace pressure switch

Suction filter6


Defective differentialpressure switch

Replace cartridge

Replace pressure switch

Oil filter7


Differential pressure switchis misadjusted or defective

Replace cartridge

Readjust or replace pressure switch

Oil separator8

Wartung.pm6.5 - 05/2002 - GB

Page 6.1

Maintenance


ATTENTION!Ensure that maintenance work is ony carried out by specialists or appro-priately trained person.

– In case of removing any cladding or safety devices prior to starting anymaintenance work, always stop the compressor as described in theseoperating instructions. Refit the cladding or safety devices immediatelyupon completion of the maintenance work.

– Only use original spare parts, compressor oils and operating materialsreleased by BOGE for the maintenance work.

– When the automatic restart (AWAL) is activated, the compressor willstart automatically following a voltage loss.Prerequisite: The line pressure is lower than the switch-on pressure seton the operating pressure sensor.

CAUTION: Risk of injury!Always adhere to the prescribed operating method described below forall maintenance work. Never omit a single safety step!Otherwise you will risk injury from restarting, electric shock or partswhich may fly off.

Prior to all maintenance work:1. Switch off the compressor using the OFF button.2. Switch off the main switch and secure against unintentional switching

on.3. Check to ensure that all machine elements are definitely currentless.4. Separate the compressor from the compressed air network by closing

the ball valve at the compressed air outlet.5. Vent the compressor.

To this effect open the safety valve on the combined compressed air-oil receiver as follows:– Turn the knurled nut counterclockwise until you can feel a resilient

resistance.– Tun the knurled nut a little further.

Any possibly existing air will escape.– Once the residual air has completely escaped from the system,

firmly retighten the knurled nut.6. Remove all safety cladding necessary to perform the maintenance

work.

Once the maintenance work has been concluded:7. Reattach all removed safety cladding.8. Open the ball valve at the compressed air outlet.9. Prior to switching on again, check whether anyone else is working on

the compressor!

6.1 Safety instructions

Wartung.pm6.5 - 05/2002 - GB

Page 6.2

Maintenance


6.2 General

Maintenance throughBOGE service

Have BOGE-Service check your compressor every 3000 operating hours orannually.

Maintenance agreementEnter into a maintenance agreement with BOGE.BOGE service will carry out the proper maintenance on your compres-sor at regular intervals. This guarantees maximum safety and realiabilityof your compressed air supply.

Fig. 6.1: Review of regular maintenance work

Review of regular maintenance work

Clean com-pressed air/oilcooler externally

Changeoil filter

Check V-belts

Change supply air filter

Check suction filter– Clean filter and cartridge– Change filter cartridge

Top up oil in the suction controllerafter an extended down time

Change oil separator

– Check oil level– Top up oil

Oil change

Fig. 6.2: Review of regular maintenance work

Draining off the condensate fromthe compressed air receiver

or check automatic condensatedraining

Check automaticcondensate draining (seeoperating instructionsrefrigeration compressedair dryer)

Wartung.pm6.5 - 05/2002 - GB

Page 6.3

Maintenance


Maintenance intervals The maintenance intervals specified in the table are based on average oper-ating and ambient conditions.Extreme conditions may require shorter maintenance intervals.

Note down any maintenance work in the table on the last page.This will facilitate trouble shooting for Boge service.

1. Oil changeChange the oil and the oil filter after the first 500 operating hours!

Retighten the electrical connections.Retighten the electrical connection in the switch cabinet after the first 50operating hours.

Maintenance work Maintenance intervals in operating hours 1) Page

weekly / 1000 1500 3000 9000monthly annually annually annually every

2 years

General maintenance work

Check final compression temperature(set point value: 70 – 100°C)

w 4.6/.21

Check compressor for leaks X –

Check function of EMERGENCY STOP button m 4.3/.18

Check and if necessary change supply air filter w 6.7

Clean oil cooler X 6.16

Draining off condensate from compr. air receiver w 6.5

Check automatic condensate draining w 6.5

Air circuit

Check and if necessary change suction filter m 6.6

Change suction filter cartridge X 6.6

Check and reset operating pressure sensor X 4.13/.28

Check safety valve X 6.17

Oil circuit

Check oil level and top up as required 2) X 6.10

Change oil separator 2) X 6.12

Change oil filter 2) X 6.11

Change oil 2) X 6.13

Drive

Check/change V-belt X 6.8

Lubricate drive motor bearings See data on type plate of drive motor

Replace grease in motor bearings Depending on mains frequency: 50 Hz 10,000 operat. hrs. 60 Hz 08,000 operat. hrs.

6.2 General

1) If the compressor is not often used, undertake the maintenance according to the specified intervals (weekly/monatlich/annually) dependingon the number of operating hours.

2) The specified intervals only apply when BOGE compressor oil Longlife S 46 is used! The service life may differ depending on theambient temperature. In this case have the oil analyzed by your BOGE service!

Wartung.pm6.5 - 05/2002 - GB

Page 6.4

Maintenance


Generalinformationconcerningthe lubricantsused

CAUTION: Risk of injury!Oil presents a potential danger to health and environment due to theiradditives.

– Avoid contact with skin and eyes.Wear protective gloves made of resistant synthetic material.Wash yourself thoroughly after contact with oils.

– Do not inhale the fumes or mist.

– Protect your environment.Ensure that no oil is spilt.

– Fire, naked flames and smoking is strictly prohibited when handlingoil.

– Only use BOGE compressor oil Longlife S 46. The specified maintenanceintervals are based exclusively on this special oil!Longlife S 46 can only be purchased from BOGE retailers.

– Never mix different oil types and brands. The additives may be incompatible.It may lead to foam formation, premature ageing or loss of lubricating ability.

ATTENTION!The handling and disposal of mineral oils is subject to legal regulations.It is an offense not to ensure correct and safe disposal of old oil!

Please instruct one of the known service companies to dispose of usedoperating materials or deliver them to an authorized disposal point.

Observe the following points when disposing of old oil:

– Never mix the oil with other material or liquids.

– Used oil filters and oil separator cartridges require special waste treatmentand must be kept separate from normal waste!

Spare and wearing parts

Disposal ofused operatingmaterial

6.2 General

ATTENTION!Only use original spare parts, compressor oils and operating materialsreleased by BOGE for repair and maintenance work.

BOGE is not liable for any damage resulting from the use of other spareparts or operating materials.

Wartung.pm6.5 - 05/2002 - GB

Page 6.5

Maintenance


6.3 Regular maintenance work

Draining off thecondensate from thecompressed airreceiver

Draining: If no automatic condensate darining is fitted, then drain off thecondensate at least once a week.

The compressor is lubricated with oil. The condensate contains oil and maynot be drained off into the public sewage system!Pay attention to the pertaining rules and regulations of your local authorities!

– Switch off the compressor using the OFF button.


– Depressurize receiver.

– Place a suitable basin underneath the condensate drain of the receiver.

– Open the ball valve and drain off the condensate.

– Close the ball valve again.

– Dispose the condensate properly.

Fig. 6.3:Draining off the condensate manually

Condensateshut-off valveon receiver

Electr. power supply

The fully automatic, electronically controlled condensate separator is equippedwith a wear free sensor which monitors the condensate level in the integratedcollecting basin. As soon as the collecting basin is full, a solenoid valve opensand the condensate is drained off.

Unlike the Konsatronik the fuilly automatic condensate separator operateswithout causing any pressure losses. In the event of a malfunction a redLED lights up and a potential-free contact is switched.Regularly check the function using the additional test switch on the device.

Draining off thecondensate from thecompressed air receiverwith automaticcondensateseparator

Condensateoutlet (to oil-water separator)

Fig. 6.4: Fully automatic, electronically controlled condensate separator

Wartung.pm6.5 - 05/2002 - GB

Page 6.6

Maintenance


Clean or changesuction filter

Cleaning: – 1x weekly,however, at least every 500 operating hours

– Correspondingly earlier if the air taken in is heavily soiled

Change: – In the event of damage

– After the second cleaning



Removing the filter cartridge– Open safety sound insulating hood (only super-silenced types).

– Remove lid � of the filter housing.

– Remove filter cartridge �.

ATTENTION! Do not clean filter cartridges in liquids.Do not use any hard objects when cleaning to avoid damaging the filter paper.

Refit a new filter cartridge in the event of damage or once it has beencleaned twice.

– Hit on the filter cartridge using the palm of your hand to knock out coarsedust.

– Blow out fine dust from the inside to the outside using dry compressedair (maximum pressure 5 bar).

– Clean the sealing surface of the filter cartridge.

Fitting a filter cartridge– Insert filter cartridge into the filter housing.

– Attach lid of the filter housing.

– Reattach safety sound insulating hood.


Cleaning the filtercartridge

Fig. 6.5: Changing the suction filter

1

2

Wartung.pm6.5 - 05/2002 - GB

Page 6.7

Maintenance


Lubricating thedrive motorbearings

Drive motors withpermanent lubrication

Changing the supplyair filter mats

Check: – 1x weekly,however, at least every 500 operating hours.

– Correspondingly earlier if the air taken in is heavily soiled.

Change: – When a crust of dirt has accumulated on the filter mat.

– When the final compression temperature has exceeded itsset point value by 4 to 5°C.The crust of dirt on the filter mat prevents an adequatecooling air supply.

– Switch off compressor using the OFF button.

CAUTION: Risk of injury!Switch off the main switch and secure it against unintentional switch-on.

– Pull filter mat � out of its holder from above.

– Insert new filter mat � into the holder.

As a rule, the bearings of the drive motors are provided with a maintenancefree permanent lubrication.The drive motor of some series are equipped with a post-lubricating unit.These motors can be easily recognised by the two grease nipples on theupper side of the housing. In addition, plates on the compressor indicate thetype of motor lubrication.

Under normal operating conditions (coolant temperature max. 40°C,continous operation) the bearings are maintenance free for the servicelife.

Bearing service life:

Mains frequency Operating hours

50 10,000

60 18,000

The service life decreases or increases as thermal stress increases ordecreases (due to increased or reduced coolant temperature).

ATTENTION!Have BOGE service dismantle and regrease the bearings once the specifiedservice life has expired!


1

Wartung.pm6.5 - 05/2002 - GB

Page 6.8

Maintenance


Changing the V-belt Check: – 1x per year for damage

Change: – If damage is visible

The BOGE GM drive system automatically adjusts the V-belt to the correctV-belt tension in any operating mode.Thus maintenance of the V-belt drive is limited to the above mentioned work.


CAUTION: Risk of injury!Switch off the main switch and secure against unintentional switch-on.

Let the compressor cool down. There is a danger of burning as the coolerhas a temperature of approx. 80–90°C.

Change the V-belts:– Open safety sound insulation hood and take off safety warm air hood

(see page 3.7).

– Turn lock nut � upwards.The two sleeves in the spring must have contact.

– Remove the slackened belts from the belt pulley.

– Fit new V-belts.

– Turn lock nut � downwards again as far as possible. The V-belts areautomatically correctly tensioned by the BOGE GM drive system.

– Close safety sound insulation hood and reattach safety warm air hood.


Fig. 6.6: Lifting the motor plate

1

Wartung.pm6.5 - 05/2002 - GB

Page 6.9

Maintenance



Settings of theGM- drive systemsS 6 – SD 15

Model Pressure Standard Settings motor

+0 / –1

bar kg mm

S 6 – SD 6 8 40 90S 6 – SD 6 10 40 90S 6 – SD 6 13 40 90

S 8 – SD 8 8 46 98S 8 – SD 8 10 46 98S 8 – SD 8 13 46 98

S 10 – SD 10 8 66 105S 10 – SD 10 10 66 105S 10 – SD 10 13 66 105

S 15 – SD 15 8 77 105S 15 – SD 15 10 77 105S 15 – SD 15 13 77 105

The settings shown in the table are fixed by the manufacturer and may notbe changed. Slight deviations are allowed and compensated by the GMdrive system.The current settings are also shown on a sticker on the GM drive system.With special versions the settings on the sticker may deviate from the stand-ard values.

blue

sealed

1

Set

tings

+0

/–1

mm

Settings of theGM- drive systemsS 20 – SD 29

Model Pressure Standard Settings motor

+0 / –1

bar kg mm

S 20 – SD 20 8 78 90S 20 – SD 20 10 78 90S 20 – SD 20 13 78 90

S 24 – SD 24 8 89 108S 24 – SD 24 10 89 108S 24 – SD 24 13 89 108

S 29 – SD 29 8 98 99S 29 – SD 29 10 98 99S 29 – SD 29 13 98 99

blue

sealed

1

Set

tings

+0

/–1

mm

Wartung.pm6.5 - 05/2002 - GB

Page 6.10

Maintenance


Fig. 6.7: Checking the oil level, topping up oil

Check: – Prior to commissioning/start-up of the compressor– Then every 1000 operating hours,

however at least once a year

Topping up: – When the oil level has dropped below the "min" mark(see sketch)

ATTENTION!Always use the same oil type when topping up.Never mix different oil types and brands.



– Close ball valve at the compressed air outlet.

– Open safety sound insulation hood.

– Vent the compressor (as described in chapter 6.1).

– Wait approx. 3 minutes to permit the oil to settle.

CAUTION: Risk of injury!Danger of burning due to hot oil!


– Remove plug � of oil filling socket �.– Check oil level.

The oil level must not drop below the "min" mark (see sketch).– If necessary, top up with oil to the lower edge of the thread ("max." mark)

on the oil filling socket.– Screw plug � back in.

– Close safety sound insulation hood.

– Open ball valve at the compressed air outlet.

Checking the oil level,topping up oil


1

2

Wartung.pm6.5 - 05/2002 - GB

Page 6.11

Maintenance


Changing the oil filter Change: – After 3000 operating hours,however, no later than after one year.

– With each oil change!







– Open safety sound insulatioon hood and take off safety warm air hood(see page 3.7).

– Unscrew soiled oil filter � by hand or use a strap wrench, turning counter-clockwise.Catch the draining oil and dispose of properly according to environmentalregulations.

– Lightly oil the sealing ring of the new oil filter.

– Screw in new oil filter � by hand, turning clockwise.

– Close safety sound insulation hood..

ATTENTION!Do not use tools to screw in the new oil filter!You might damage the oil filter or its sealing ring.A hand tight seating of the oil filter is sufficient.

– Reattach safety warm air hood.



– Switch on the compressor and heat up to operating temperature.

– Subsequently, check the oil filter for leaks once again and tighten byhand, if necessary (Procedure as described above).


– Check the oil filter for leaks and tighten by hand, if necessary.

– Check oil level.Top up oil losses, if any.


Wartung.pm6.5 - 05/2002 - GB

Page 6.12

Maintenance


Fig. 6.8: Change oil filter

Changing the oilseparator

Change: – When warning message "8" appears on the controlsystem display (Ratiotronic only).

– After 3000 operating hours,however, no later than after one year.

If the prescribed maintenance intervals are not observed, the oil sepa-rators might become blocked. In this case, the differential pressure willincrease until the safety valve blows.








– Unscrew soiled oil separators � by hand or use a strap wrench, turningcounterclockwise.Catch the draining oil and dispose of properly according to environmentalregulations.

– Lightly oil the sealing ring of the new oil filter.

– Screw in new oil separators � (Fig. 6.6) by hand, turning clockwise.


3

Wartung.pm6.5 - 05/2002 - GB

Page 6.13

Maintenance


ATTENTION!Do not use tools to screw in the new oil separators!You might damage the oil separators or their sealing rings.A hand tight seating of the oil filter is sufficient.



– Switch on the compressor and heat up to operating temperature.

– Subsequently, check the oil filter for leaks once again and tighten by hand,if necessary (Procedure as described above).


– Check the oil separators for leaks and tighten by hand, if necessary.

Fig. 6.9:Changing the oil separator


Change: – After 9000 operating hours,however, at the latest after two years.

– With other types of oil e.g., ÖKOKLUB or USDA-H1 orBOGE oil 3000 PLUS the appropriate oil change intervalsmust be complied with.

The service life of the oil, the oil filter and oil separators is reduced under thefollowing conditions:

– When the compressor is operated at extreme ambient temperatures.

– When the intake air is extremely soiled.

Oil change

4

Wartung.pm6.5 - 05/2002 - GB

Page 6.14

Maintenance


Building up a pressure cushionThe combined compressed air / oil receiver is located at the lowest point ofthe system. Therefore, a light pressure cushion (approx. 1.5 bar systempressure) must be applied to drain the oil. This pressure cushion forces theoil through the drain hose into a suitable collecting basin.



Draining old oil– Close ball valve at the compressed air outlet.


– After approx. 2 sec. screw cap nut � on the bleed aperture of the mag-netic valve. (The nut is located in the storage compartment of the switchcabinet.)


– Remove the blind plug � at the oil drain with the tap closed �.

– Fit oil drainage hose �. (With silenced compressors the hose is locatedbelow the motor-driven rocker dolly switch, with super-silenced compres-sors in the supply air box.)

– Place the oil drain hose into a suitable container.

– Slowly open the stop valve.The pressure cushion forces the oil into the container.

– Once the compressed air/oil receiver has been completely drained, closethe stop valve.

– Remove oil drainage hose and replace blind plug together with a newcopper sealing ring.

– Remove the cap nut from the solenoid valve.– Change oil filter (see page 6.11).

– Change oil separator (see page 6.12).


Fig. 6.12:Drain off oil with fitted oil draininghose

Fig. 6.11:Drain off oil from oil/compressedair receiver

Fig. 6.10:Solenoid valve on the suction con-troller with the cap nut screwed on

3

1

2

5

Wartung.pm6.5 - 05/2002 - GB

Page 6.15

Maintenance


Filling with new oil:– Fill up to the edge of the thread of the filling socket (max.) (see page 6.10).

ATTENTION!Always fill with the same oil type as previously used. Never mix different oiltypes and brands.

The oil circuit must be flushed prior to changing the oil type (see page 6.15).



– Conduct trial run.


– Check the oil filters and oil separators for leaks and tighten by hand,if necessary (see page 6.11 and 6.12).

– Check oil level (see page 6.10).Top up oil losses, if any.

Flushing the oil circuit with clean oil becomes necessary:– when the oil is excessively soiled.

– prior to changing the oil type.

ATTENTION!To flush out the oil circuit, only use oil of the same type to that which is to beused later.

– Drain off old oil completely (see page 6.14).

– Leave old oil filter and oil separator in the compressor.

– Fill oil/compressed air receiver with clean oil up to approx. one third of thetotal capacity.

– Close oil filling socket.

– Let compressor run for approx. 10 minutes.

– Drain off flushing oil and dispose of it properly.

– Change oil filter and oil separator cartridges (see page 6.11 and 6.12).

– Fill up with oil to the specified level (see page 6.10).

Flushing the oil circuit


Fig. 6.13:Flushing the oil circuit

Wartung.pm6.5 - 05/2002 - GB

Page 6.16

Maintenance


Fig. 6.14: Cleaning the compressed air/oil cooling unit

Cleaning thecompressed air/oilcooling unit

Cleaning: – After 1500 operating hours,however, at the latest after one year.

The service life of the compressed air/oil cooling unit depends on thedegree of soiling (dust, oil vapour) of the suctioned cooling air. Extremeexternal soiling of the cooling unit leads to an increased temperaturein the oil circuit.


CAUTION: Risk of injury!Switch off the main switch and secure it against unintentional switch-on.

– Remove safety warm air hood.

– Pull housing at the front side of the compressor out of the holding deviceand put aside.

– Remove accumulated soiling with a fibre brush.

ATTENTION!Do not use any sharp objects for cleaning!These could damage the cooling unit!

– Blow down the dirt with compressed air � in the opposite direction to thenormal cooling air flow. Vacuum out the dirt using an industrial vacuumcleaner (see Fig. 6.14).

– Reattach safety warm air hood.

If the cooling unit is excessively soiled (cleaning is no longer possible withcompressed air), have it disassembled and cleaned by BOGE-Service.

1

Regular maintenance work6.3

Wartung.pm6.5 - 05/2002 - GB

Page 6.17

Maintenance


Check: – After approx. 3000 operating hours,however, at least once a year.

Check safety valve by opening the screw plug �.


Take extreme care when checking the safety valve with the compressorrunning taking all safety measures into consideration.

A hot air-oil mixture escapes when opening!

– Open the threaded plug � counterclockwise.The air-oil mixture escapes.

– Tighten the threaded plug by turning clockwise.

Checkingthe safety valve


Fig. 6.15: Check safety valve

1

Wartung.pm6.5 - 05/2002 - GB

Page 6.18

Maintenance


Designation

Filter mat for supply air filter

Compressor oil Longlife S 46

Set of V-belts

Lubrication for drive motor bearings

Maintenance kit comprising of:oil filter, oil separator, suction filter cartridge, gaskets

Wearing part kit comprising of:Oil regulator, suction regulator

Solenoid valve

Intake regulator

Star delta contactor

List of spare andwearing parts(for maintenance)

Designation

Optional equipment for compressed air treatment

Oil/water separator

Infinitely variable capacity control

Automatic condensate draining unit Bekomat

List of availableoptional equipment

6.4 Spare parts and optional equipment

When ordering, please specify the data on the type plate:– Type

– Year of manufacture

– Machine number

Fließ.pm6.5 - 05/2002 - GB

Page 7.1

Appendix


7.1

Air cooled version,standard

Air cooled version,with proportional controller

Flow chart

1 = Suction filter3 = Suction filter monitoring (Ratiotronic only)*4 = Suction controller5 = Air relief and regulation control valve6 = Monitoring for rotational direction with double

pressure check valve (Ratiotronic only)*7 = Drive motor8 = Air end9 = Sensor for final compression temperature

10 = Combined compressed air/oil receiver11 = Oil separator12 = Safety valve16 = Thermostatic oil control valve17 = Oil cooler18 = Oil filter19 = Oil filter monitoring (Ratiotronic only)*

21 = Minimum pressure check valve22 = Compressed air after-cooler23 = System pressure transmitter

(Ratiotronic only)*24 = Network pressure transmitter25 = Stop valve, compressed air outlet27 = Oil drainage28 = Check valve drainage line29 = Proportional controller *30 = Pressure switch for prop.controller *31 = 3/2-way solenoid valve for prop.controller

(with standard control passage here) *

* = Option

Compressedair OUT

AirIN

Compressedair OUT

AirIN

Fließ.pm6.5 - 05/2002 - GB

Page 7.2

Appendix


7.2 List of maintenance and service workP

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lean

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W =

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