Operating instructions
Belt-driven
screw compressors
C 15
C 15 F
Separate manuals:
Compressor control
Frequency converter (C F)
www.boge.com
Operating instructions
for belt-driven
screw compressors
–C 15 (15 Hp)
–C 15 F(15 Hp)
BOGE KOMPRESSOREN
Postfach 10 07 13
D-33507 Bielefeld
Otto-Boge-Straße 1-7
D-33739 Bielefeld
Fon: +49 5206 601-0
Fax: +49 5206 601-200
Mail: info@boge.com
Net: www.boge.com
Issue: 03 / 2012
No. 596.1192.18
BOGE Operating instructions for C 15 series screw compressors Page I
Index
Index
Part 1:
General
1.1 General safety instructions ........................................................... 1
Safety instructions for operation ....................................................... 1
Special hazard warnings................................................................... 2
Electrical energy hazards ................................................................. 3
Obligations of the owner ................................................................... 3
Personnel requirements.................................................................... 4
Personal protective equipment ......................................................... 4
Safety instructions for maintenance and repair ................................ 4
Accident prevention regulations........................................................ 5
First Aid............................................................................................. 6
Disposal ............................................................................................ 6
1.2 Introduction..................................................................................... 6
Symbols used ................................................................................... 7
Symbols on the compressor ............................................................. 8
Intended use ................................................................................... 13
Foreseeable Misuse ....................................................................... 13
Transport damage .......................................................................... 14
Data on the type plate..................................................................... 14
Service............................................................................................ 14
Part 2:
2.1 Technical data – compressor ...................................................... 15
Product description
2.2 Function description compressor............................................... 16
Function principle of the air end...................................................... 16
Air circuit ......................................................................................... 17
Oil circuit ......................................................................................... 18
2.3 Compressor control ..................................................................... 19
Network pressure............................................................................ 19
Operating states ............................................................................. 19
Operating modes ............................................................................ 19
Control of compressors with frequency control (C 15 F) ................ 20
Short operating times...................................................................... 20
2.4 Safety and monitoring devices.................................................... 20
General ........................................................................................... 20
Safety temperature limiting device.................................................. 20
Safety valve .................................................................................... 21
Monitoring the drive motor .............................................................. 21
BOGE Operating instructions for C 15 series screw compressors Page III
Index
Part 3:
Installation
3.1 Transport and storage.................................................................. 23
General ........................................................................................... 23
Transport possibilities ..................................................................... 23
Intermediate storage....................................................................... 24
3.2 Compressor room......................................................................... 25
Installation conditions for separately arranged compressed air
receivers ......................................................................................... 25
Installation surface.......................................................................... 25
Fire protection................................................................................. 25
Sound protection............................................................................. 26
Admissible environmental influences.............................................. 26
Ventilation ....................................................................................... 26
Cooling air requirement .................................................................. 27
Ventilation possibilities.................................................................... 28
Condensate disposal ...................................................................... 28
3.3 Installation..................................................................................... 29
General ........................................................................................... 29
Checking the delivery scope........................................................... 29
Installing the compressor................................................................ 29
Connecting the compressor to the compressed air network........... 30
Remove cladding ............................................................................ 30
Activating the belt tensioning device............................................... 31
Checking the oil level...................................................................... 32
Part 4:
Optional equipment
Part 5:
Faults
3.4 Electrical connection.................................................................... 32
3.5 Commissioning............................................................................. 34
Checking installation requirements ................................................. 34
Checking the rotational direction .................................................... 34
Checking compressed air outlet for tightness ................................. 35
Opening the stop valves ................................................................. 35
Checking for leaks .......................................................................... 36
Conducting trial run......................................................................... 36
Commissioning following extended stoppages............................... 36
3.6 Dismantling ................................................................................... 37
4.1 BOGE-Duotherm BPT................................................................... 39
Function .......................................................................................... 39
Assembly ........................................................................................ 39
Commissioning ............................................................................... 39
Maintenance ................................................................................... 40
5.1 General .......................................................................................... 41
5.2 Faults – Compressor .................................................................... 41
Page IV BOGE Operating instructions for C 15 series screw compressors
Index
Part 6:
Maintenance
6.1 Safety instructions ....................................................................... 43
6.2 General .......................................................................................... 45
Maintenance through BOGE customer service .............................. 45
Review of regular maintenance work.............................................. 45
Maintenance intervals..................................................................... 46
General information concerning the lubricants used ...................... 48
Disposal of used operating material ............................................... 49
Pressure hoses............................................................................... 49
Spare and wearing parts................................................................. 49
6.3 Maintenance work compressor ................................................... 50
Cleaning or changing suction filter.................................................. 50
Cleaning the filter cartridge............................................................. 50
Changing the supply air filter mats ................................................. 51
Drive motors with permanent lubrication ........................................ 52
Changing the V-belt ........................................................................ 52
Setting of the GM-drive system C 15 / C 15 F ................................ 53
Checking the oil level, topping up oil .............................................. 54
Changing the oil filter (Fig. 6.6)....................................................... 55
Changing oil separators (Fig. 6.6) .................................................. 56
Oil change....................................................................................... 57
Flushing the oil circuit ..................................................................... 59
Cleaning the compressed air/oil cooling unit .................................. 60
Checking the safety valve............................................................... 60
Nozzle with dirt catch...................................................................... 61
Part 7:
Appendix
6.4 Spare parts and optional equipment .......................................... 62
List of spare and wearing parts of the compressor
(for maintenance)............................................................................ 62
List of available optional equipment................................................ 62
7.1 Flow chart...................................................................................... 63
Air cooled version, standard, C 15 / C 15 F.................................... 64
BOGE-Duotherm BPT plate heat exchanger.................................. 66
7.2 List of maintenance and service work ....................................... 67
BOGE Operating instructions for C 15 series screw compressors Page V
General 1.1 General safety instructions
Part 1: General 1.1 General safety instructions
WARNING!
Nonobservance of the following safety instructions may lead to injuries and
damage to the compressor.
Also observe the generally valid safety and accident prevention regulations
in addition to the information in these operating instructions!
Safety instructions for operation
Compressor
1. Ensure that no commissioning and maintenance work on the compressor
is undertaken until these operating instructions are understood.
2. Only use the compressor for its intended use, as described in these operating instructions.
3. The owner must ensure,
– that only appropriately trained and authorized personnel work on this
compressor,
– that no persons work on this compressor, whose ability to react is re-
stricted due to misuse of e.g. drugs, alcohol, medication etc.,
– that the operating, maintenance and repair personnel has been made
fully familiar with all safety instructions, and that they are being observed,
– that the compressor is only operated in a safe operating condition.
4. Avoid any operating method which may impair the safety of the compressor.
5. Always wear your compulsory personal protective quipment as a protection against injuries from sharp corners or edges when working on the
compressor.
6. To avoid dangers from debris or parts lying around, the service area of the
compressor has always to be kept tiedied up and clean.
7. Always squat when working on components mounted at low height, never
stoop. When working on components mounted higher up always stand upright and erect.
8. Do not exceed the limit value for the final compression pressure specified
on the type plate.
9. Do not operate the compressor without the attendant protection and safety
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 commissioning/starting up the compressor and that they are not opened during operation.
10. Place the compressor out of operation as described in these operating instructions, when dismantling the safety claddings or safety devices for repair or maintenance work. Reattach and close all cladding and safety devices immediately upon completion of the repair or maintenance work.
11. Only operate the compressor using the additional equipment (options) recommended or authorized by the manufacturer.
BOGE Operating instructions for C 15 series screw compressors Page 1
General 1.1 General safety instructions
12. Undertake conversions and modifications of the compressor only in agreement with BOGE, taking all relevant safety regulations into consideration.
The manufacturer is not liable for damages resulting from independent
modifications on the compressor.
13. Never start the compressor when one or serveral parts (e.g. cable, plug)
are damaged, when not in perfect working order and when damage is detected or suspected.
14. Observe all safety and danger signs directly attached on the compressor!
15. To avoid damages, special precautions have to be taken during (re-) operation of compressors with frequency control, if the frequency converter
was cut off from the power supply for a longer period of time (> 12 months).
In this case please contact the BOGE-Service.
Special hazard warnings
– Any performance of work on pressurized system components may be car-
ried out by duly qualified and specialized personnel only.
– Always wear your compulsory personal protective equipment when work-
ing on pressure pipes and connections!
– A protective grid serves to prevent you from accidentally reaching into the
impeller of the cooling fan.
WARNING: Risk of injury!
A protective grid serves to prevent you from accidentally reaching into the impeller of the cooling fan!
Please note that the cooling fan may run on for a certain time even after the
compressor has been switched off!
– During operation, the compressor generates a high sound pressure level
which may cause permanent hearing damage due to continuous noise
stress. As a rule, the compressor may only be operated with its housing
cover closed. Make sure to additionally wear a hearing protection in case
of a noise pressure level above 80 dB(A)!
– Any pipelines and/or auxiliary equipment on the compressor are designed
such as to resist to any adverse operating conditions and any predictable
external influences. Make sure to operate your compressor within the parameters specified in the Technical Data Sheet!
– Exceeding the max. pressure or simultaneous failure of several safety de-
vices will cause the safety valve to be activated. There will be risk of escaping hot air!
Page 2 BOGE Operating instructions for C 15 series screw compressors
General 1.1 General safety instructions
Electrical energy hazards
DANGER: Voltage!
There is danger of life when working on the electrical equipment of the
compressor!
– Only duly authorized professional electricians (e.g. plant electricians) are
allowed to carry out works in the electrical area of the machine.
– Disconnect mains connection prior to starting work on the compressor
and use padlock to secure against switching on again.
– Check to ensure that all parts are currentless.
– Make sure to check the electrical equipment of the compressor at regular
intervals for defects such as loose connections or scorched cables and
have any defects repaired immediately.
– Make sure to have all electrical equipment and fixed electrical installa-
tions checked by a professional electrician at least every 4 years.
– Make sure to check all safety installations on the machine for proper func-
tioning at regular intervals.
– Only use original fuses.
Obligations of the owner
The owner is obliged to,
– operate the compressor only in technically perfect condition,
– check the Emergency Stop device of the compressor regularly for com-
pleteness and functionality,
– assess the hazards of the machine working places in his area of respon-
sibility and to issue the ensuing operating instructions,
– to name a person responsible beeing in charge of the safe operation of the
machine as well as the coordination of all service work performed on it,
– avoid stress situations while operating the compressor by means of tech-
nological and organizational operation scheduling,
– ensure a proper workplace lighting at the compressor control section ac-
cording to the local health and safety regulations,
– observe the safety data sheet of the used lubricants and to customize the
personnel all information as to said data sheet,
– provide the compulsory personal protective equipment and to stipulate and
check the wearing of said protective equipment on a regular basis,
– assign the personnel responsible for various tasks and work on the ma-
chine,
– instruct the personnel on a regular basis with respect to all obligations as
to compressor related preservation of safety and tidiness.
BOGE Operating instructions for C 15 series screw compressors Page 3
General 1.1 General safety instructions
Personnel requirements
Personal protective equipment
Work on and with the compressor may only be carried out by personnel duly
authorized by the owner of the compressor.
The personnel working on the compressor has to observe all industrial safety
regulations and operating instructions, properly recognize responsibilities and
read and understand the operating instructions. It is essential to wear the compulsory personal protective equipment when working on the compressor!
In general for all work on the compressor
– protective clothing,
– chemicals resistant gloves,
– slip-resistant safety shoes and
– hearing protection, if applicable
are compulsory.
For special duties
– protective helmets (for transport work with lifting gear) and
– safety goggles (when working on the compressed air system and/or on the
control pneumatics)
must be worn.
Before starting work using oils or greases a skin protection cream must be applied. Having finished the work a skin care product must be applied.
Safety instructions for maintenance and repair
Compressor
WARNING!
Only use original spare parts, compressor oils and operating materials released by BOGE during repair or maintenance!
DANGER: Voltage!
When working on the electrical system there is a constant danger of getting
into contact with live parts!
To avoid such dangers the mains connection must be equipped with a disconnecting device!
1. Ensure that maintenance work is only carried out by appropriately trained
persons.
2. Ensure that setting work, malfunction rectification and repair is only carried
out by specialists or appropriately trained persons.
Page 4 BOGE Operating instructions for C 15 series screw compressors
General 1.1 General safety instructions
3. Prior to maintenance or repair work:
– Switch off the compressor using the OFF button.
– Actuate emergency-stop switch/button.
– Open mains disconnecting device.
– Secure mains disconnecting device by means of lock out tag out.
– Fix a warning label to the control and fill in the name of the person re-
sponsible who is authorized to switch on the maschine again.
– Check to ensure that all parts are currentless.
– Cover or block off adjacent energised parts.
– Prior to starting work let cool down all hot components of the compres-
sor to 122°F.
– 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 persons keep out of reach of
the hazardous area.
5. Ensure that work on the electrical equipment is only executed by qualified
electricians.
6. Work on parts and devices under current is prohibited. Exceptions are governed by the appropriate regulations.
7. Prior to starting work on the electrical system the power supply has to be
switched off and secured against unintentional switching on again. Immediately after having finished the work all dismantled claddings and safety
devices must be refitted.
8. The operator is responsible to check the compressor daily for externally
visible damage and defects, and to immediately report any changes (including operational behaviour).
9. When the automatic restart (Auto-Restart) is activated, the compressor will
start automatically following a voltage loss. Prerequisite: The net pressure
is lower than the set switch-on pressure.
Accident prevention regulations
BOGE Operating instructions for C 15 series screw compressors Page 5
The owner of a compressor plant is responsible to ensure that it is properly
installed, operated and maintained.
For operation of the compressor plant outside the Federal Republic of Germany, the accident prevention regulations of the country, where the compressor is operated, must be observed in addition to the data contained in these
operating instructions. In the event that measures are required above and
beyond the legal regulations specified in the Federal Republic of Germany or
the data contained in these operating instructions, then it is of utmost importance that these be carried out prior to commissioning the compressor plant.
General 1.2 Introduction
First Aid
Disposal
1. Any victims are to be immediately removed into fresh air or a well ventilated room.
2. Any refrigerant splashes in the eyes are to be blown off by mouth. Rinse
eyes with plenty of water. Do not use cloths to wipe eyes!
3. If the victim does not breathe, rescue breathing is to be started by means
of artificial breathing or the use of an oxygen breathing apparatus until the
arrival of the emergency doctor.
4. CALL A DOCTOR and inform him that refrigerants as specified on the
nameplate are being used!
5. Never leave the victim unattended!
WARNING!
Waste oil must in no way be disposed of in the environment, mixed with domestic refuse, or burnt in plants unapproved for that purpose.
1.2 Introduction
The purpose of these operating instructions is to familiarize the user with the
function and all application possibilities of the compressor.
These operating instructions contain important information on how to operate
the compressor safely, economically and according to its intented use. Observing these operating instructions will assist in avoiding danger, to reduce
repair costs and down times and to increase the reliability and service life of
the compressor. It contains important information concerning the required
maintenance and repair measures, assists in case of malfunctions and contains data concerning spare and wearing parts.
The operating instructions must be available to the compressor operating personnel at the place of operation, at all times.
The operating instructions must be carefully read and applied by all persons
engaged to undertake the following work on the compressor:
– Operation, including fault rectification and daily care
– Maintenance (service, inspection, repair)
– Commissioning
– Transport
Page 6 BOGE Operating instructions for C 15 series screw compressors
General 1.2 Introduction
The compressor and its additional equipment must not be installed and commissioned until the operating instructions are understood.
These operating instructions can be supplemented with instructions on the
basis of existing national regulations concerning accident prevention and environmental protection.
In the illustrations, the compressor is shown in part without safety cladding or
safety devices for better visualization. However, operation without these components is prohibited!
Symbols used
In these operating instructions, important safety instructions and tips are identified by the following symbols:
WARNING!
This symbol indicates information warning of dangers to life and limb of the
operator or other persons or dangers, which might destroy or damage the
compressor.
WARNING: Risk of injury!
This symbol indicates information warning of possible danger to life and limb
of the operator or other persons.
DANGER: Voltage!
This symbol indicates information warning of life threatening electrical voltage levels.
It indicates work which must be exclusively performed by skilled electricians.
NOTICE!
This symbol indicates information and tips concerning the economical and
careful operation of the compressor.
BOGE Operating instructions for C 15 series screw compressors Page 7
General 1.2 Introduction
Symbols on the compressor
NOTICE!
All warning signs on the compressor and in its surrounding must always be
kept in a legible condition. Missing or damaged signs must be replaced at
once!
The following symbols and warning signs are fitted on the compressor:
Symbols on the switch cabinet:
NOTICE
Refer to the
Instruction/ Operators Manual
before performing any
maintenance.
Page 8 BOGE Operating instructions for C 15 series screw compressors
General 1.2 Introduction
Symbols on the outside cladding, part 1
Before working at the compressor:
– disconnect all current-carr ying parts!
– check if all par ts are actually voltage-free!
– secure the compressor against switching-on!
– reduce the pressure in all areas!
If you neglect these rules, your health will be endangered!
Before putting into service:
– read the instructions
– check electric connections
– check oil-level (not for oil-free)
– if applicable, remove the transportation safety
device
– check the direction of rotation of compressor
– operate only with a belt protective grating
or a sound protection bonnet.
– do not close the cooling air inlets and outlets
during operation!
Regular maintenance:
Observe the operating instructions!
– check suction filter monthly, if necessary clean
or replace it
– check cooler for dirt, if necessary clean it
– check oil-level weekly (not for oil-free)
– drain condensation water from pressure tank
at least once a week
– check operativeness of automatic steam trap
BOGE Operating instructions for C 15 series screw compressors Page 9
General 1.2 Introduction
Symbols on the outside cladding, part 2
NOTICE
Electrical power inlet.
Page 10 BOGE Operating instructions for C 15 series screw compressors
General 1.2 Introduction
Symbols on the inside of the compressor, part 1
NOTICE
Rotation.
WARNING
High pressure air.
Can cause severe injury or death.
Relieve pressure before removing
filter plugs / caps, fittings or covers.
BOGE Operating instructions for C 15 series screw compressors Page 11
General 1.2 Introduction
Symbols on the inside of the compressor, part 2
WARNING
Exposed fan blade.
Can cause severe injury.
Do not operate with covers
removed. Disconnect power.
Lock and tag.
Page 12 BOGE Operating instructions for C 15 series screw compressors
General 1.2 Introduction
Intended use
WARNING!
BOGE compressors, including their additional equipment, are exclusively intended for the compression of air.The air taken in must not contain any explosive or chemically instable gases or vapours.
Do not exceed the specified final compression temperature.
BOGE compressors are designed for stationary operation.
Ensure that they are only installed and operated in dry and clean rooms.
The emergency stop device of the compressor (emergency stop switch/button) is exclusively intended to switch off the compressor in case of emergency.
Operation and control are designed to be executed by trained and authorized
operators.
Foreseeable Misuse
WARNING!
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 contact
with foods, if it was treated beforehand.
This BOGE compressor is not explosion protected.
Do not operate in explosive areas or in a possibly explosive atmosphere!
Do not operate the compressor in rooms in which extreme dust, toxic or flammable vapours and gases may occur.
The emergency stop device of the compressor (emergency stop switch/button) may not be used for operational tripping of the compressor. Make sure
to actuate the OFF button for operational tripping of the compressor.
The following is not permitted:
– Compression of other media than those mentioned under intended use
or compression of air loaded with contaminants.
– Exceeding the final compression pressure indicated on the type plate.
– Altering the safety devices and safety cladding or placing them out of
operation.
– Removing or painting over signs and symbols on the compressor.
– Operation of the compressor by unauthorized or untrained persons.
BOGE Operating instructions for C 15 series screw compressors Page 13
General 1.2 Introduction
Transport damage
Data on the type plate
BOGE does not accept any liability for breakage or transport damage. Please
inspect the compressor immediately after delivery and direct damage 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 when the damage was
detected.
In the event of any other complaints, please inform us within six days after arrival of the delivery.
Enter the data of your compressor from the type plate or enclosed data sheet
in the folllowing illustration 1.1.
This will ensure that in the event of enquiries, you will always have the most
important data to hand.
Service
Fig. 1.1: Data on the type plate
Please do not hesitate to contact BOGE service if you have any questions.
Please call:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
In the event of inquiries, always specify the following data of your compressor
to prevent any delays:
–Type
– Year of manufacture
– Machine number
WARNING!
Only BOGE service technicians or persons authorized by BOGE in writing
may repair or alter the compressor during the warranty period. Otherwise all
warranty claims will expire!
Page 14 BOGE Operating instructions for C 15 series screw compressors
Product description 2.1 Technical data – compressor
Part 2: Product description
2.1 Technical data – compressor
Technical data C 15 / C 15 F, part 1
Type C 15 C 15 F
Dimensions
– Width [inch] 28.4 28.4
– Depth [inch] 39 39
– Height (super silenced) [inch] 68.3 68.3
Weight
– super silenced [lbs.] 904 961
Max. sound pressure level [±3 dB(A)]
– super silenced [dB(A)] 67 67
Reference surface measure
– super silenced [dB(A)] 16 16
Sound power level
– super silenced [dB(A)] 83 83
Compressor
max. final compression temperature [°F] + 230 + 230
Volume flow
– p
= 100 psig [cfm] 61.4 61.4
max
– p
= 115 psig [cfm] 61.4 61.4
max
– p
= 150 psig [cfm] 54.0 54.0
max
– p
= 190 psig [cfm] 47.0 47.0
max
Drive motor
Rated power [Hp] 15 15
Nominal speed
– 60 Hz [rpm] 3600 3600
Protection type TEFC TEFC
ISO class F F
Electrical connection
2) 3)
2) 3)
2) 3)
2) 3)
1)
[V] 208-230 / 460 / 575 208-230 / 460 / 575
[Hz] 60 60
[A] 60 60
[A] 60 60
[A] 30 30
[A] 30 30
Mains voltages compressor
Frequency
1)
Fuse protection for 208 V
Fuse protection for 230 V
Fuse protection for 460 V
Fuse protection for 575 V
1)
Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.
2)
The fuse values change in the case of other mains voltages and frequencies.
3)
Use fuse Class RK 5 only.
BOGE Operating instructions for C 15 series screw compressors Page 15
Product description 2.2 Function description compressor
Technical data C 15 / C 15 F, part 2
Type C 15 C 15 F
Oil filling quantity
Total oil filling quantity [gallon] 1.6 1.6
Oil topping up quantity
between min. + max. [gallon] 0.3 0.3
Intake air temperature
– min. [°F] + 41 + 41
– max. [°F] + 113 + 113
Cooling air requirement
– free-standing installation [cfm] 2180 2180
– with supply and exhaust air duct [cfm] 1002 1002
– free ventilator pressure [Pa] 60 60
Air cooling
– free ventilator pressure [inch Hg] 0.203 0.203
Operating pressure values
(factory settings)
– p
= 100 psig:switch-off pressure p
max
switch-on pressure p
– p
= 115 psig:switch-off pressure p
max
switch-on pressure p
– p
= 150 psig:switch-off pressure p
max
switch-on pressure p
– p
= 190 psig:switch-off pressure p
max
switch-on pressure p
Safety valve
Activation pressure at:
– p
= 100 psig [psig] 160 160
max
– p
= 115 psig [psig] 160 160
max
– p
= 150 psig [psig] 160 160
max
– p
= 190 psig [psig] 203 203
max
1)
For fixed compressors with other operating pressures p
1)
[psig] 100 100
max
[psig] 85 94
min
[psig] 115 115
max
[psig] 100 109
min
[psig] 150 150
max
[psig] 135 144
min
[psig] 190 190
max
[psig] 175 184
min
= p
– 15 psig, for frequency controlled compressors with other operating pressures p
min
max
= p
– 6 psig.
min
max
2.2 Function description compressor
Function principle of the air end
Page 16 BOGE Operating instructions for C 15 series screw compressors
The air end operates according to the displacement principle. In the housing,
the main and secondary screws are driven by means of an electric motor and
V-belts.
Both screws have screw-shaped profiles, intermeshing without contact. Together with the housing wall, these screws form chambers which gradually
reduce in size, seen in air flow direction.
Product description 2.2 Function description compressor
Rotation of the rotors causes the air taken in to be compressed to the final
pressure in the chambers.
During compression oil is continuously injected into the air end. This having a
cooling, sealing and lubricating function.
Air circuit
Fig. 2.1: Components of the air circuit
1 Suction filter
The suction filter cleans the air suctioned by the air end.
2 Suction controller
The suction controller opens (load operation) or closes (idling operation
or standstill) the suction line depending on the operating condition of the
compressor.
3 Air end
The air end compresses the sucked in air.
4 Compressed air/oil vessel
The compressed air separates from the oil under the force of gravity in the
compressed air/oil receiver.
5 Oil separator
The oil separator separates the residual oil contained in the compressed air.
6 Minimum pressure check valve
The minimum pressure check valve does not open until the system pressure has increased to 51 psig. This causes a rapid build-up of the system
pressure and ensures lubrication in the starting phase. Once the compressor has been switched off, the check valve prevents the compressed
air from flowing back out of the mains line.
7 Compressed air after-cooler (air cooled)
The compressed air is cooled in the compressed air after-cooler, causing
the water contained in the air to condensate.
8 Stop valve
The screw compressor may be isolated from the mains by means of the
stop valve.
BOGE Operating instructions for C 15 series screw compressors Page 17
Product description 2.2 Function description compressor
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 hous-
ing.
– It lubricates the bearings.
Fig. 2.2: Components of the oil circuit
1 Compressed air/oil vessel
The oil separated from the compressed air through the force of gravity collects in the compressed air/oil vessel.
The system pressure forces it out of the receiver into the air end.
2 Thermostatic oil control valve
Depending on the oil temperature, the thermostatic oil control valve either
allows the oil to pass through the oil cooler or through a bypass (e.g. in
the starting 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 filter
The oil filter traps impurities in the oil.
5 Air end
The injected oil returns to the compressed air/oil chamber together with
the compressed air. There, it is separated through the force of gravity.
6 Drainage line
The air end suctions the residual oil which collects in the oil separator
back into the oil circuit via a drainage line.
Page 18 BOGE Operating instructions for C 15 series screw compressors
Product description 2.3 Compressor control
2.3 Compressor control
Network pressure
Operating states
Operating modes
For the compressor, the pressure downstream of the check valve is termed
network pressure. The control system switches the compressor on and off during 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 with out
delay.
– Idling operation reduces switching frequencies which can damage the
drive 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 load
operation.
The two most important operating modes are achieved by combining the three
operating states:
1. Intermittent operation
In intermittent operation the energy balance is perfect.
– The compressor operates in load operation.
– Upon reaching the switch-off pressure p
the compressor switches
max
to standstill. It does not consume any energy.
– Once the pressure has dropped to the switch-on pressure p
the com-
min
pressor switches back to load operation.
2. Continuous operation
Continuous operation limits the drive motor switching cycles and reduces
wear to the system.
– The compressor operates in load operation.
– Upon reaching the switch-off pressure p
the compressor switches to
max
idling operation.
– Once the pressure has dropped to the switch-on pressure p
the com-
min
pressor switches from idling operation back to load operation.
BOGE Operating instructions for C 15 series screw compressors Page 19
Product description 2.4 Safety and monitoring devices
Control of compressors with frequency control (C 15 F)
Short operating times
When the operating pressure psoll (target value) is exceeded the control becomes active and reduces the speed.
When the operating pressure p
(target value) is dropped below the control
soll
becomes active and increases the speed..
The settings for p
min
, p
max
and p
(target value) are made by parameterization of
soll
the FOCUS control..
The standard settings are:
p
– 4 psig = p
max
p
– 6 psig = p
max
soll
min
WARNING!
During short operating times, the compressor does not reach its operating
temperature. It operates below the dew point. The generated condensate
mixes with the oil. The lubricating ability of the oil is reduced. This leads to
damage on the air end. It is of utmost importance to consult BOGE, if you
operate your system with short operating times.
General
Safety temperature limiting device
2.4 Safety and monitoring devices
The safety devices guarantee a high degree of operational safety, in connection with the BOGE monitoring system.
When one of the safety devices responds, the control system reacts as follows:
– The compressor is immediately switched off.
– A flashing fault number in the left field of the display indicates the cause of
the fault.
WARNING: Risk of injury!
Do not operate the compressor without built-in safety devices!
Do not dismantle the safety devices or put them out of operation!
The following monitoring devices are standard for BOGE control systems:
The safety temperature limiting device switches off the compressor once the
maximum admissible final compression temperature has been reached. In
case the necessary minimum temperature to run the compressor is not guaranteed, the compressor does not start.
– Rectify the fault.
– Acknowledge fault by pressing ENTER key .
– Switch on the compressor (ON key).
Page 20 BOGE Operating instructions for C 15 series screw compressors
Product description 2.4 Safety and monitoring devices
Safety valve
Monitoring the drive motor
The safety valve (1) on the
compressed air/oil chamber
prevents the maximum admissible pressure being exceeded.
Fig. 2.3: Safety valve
WARNING: Risk of injury!
When the maximum pressure is exceeded (e.g. incorrect setting of the operating pressure value), the entire delivery volume of the compressor is ejected!
The drive motor is monitored by PTC resistors.
BOGE Operating instructions for C 15 series screw compressors Page 21
Installation 3.1 Transport and storage
Part 3: Installation 3.1 Transport and storage
General
Transport possibilities
Please observe the generally accepted safety and accident prevention regulations when transporting the compressor.
BOGE accepts no liability for damage caused by improper transport!
WARNING!
The transport of the compressor may only be carried out by adequately instructed and authorized personnel!
The capacity of the lifting gear (lifting cart or forklift truck) must correspond at
least to that of the compressor (see Technical Data)!
Mind the position of the mass centre prior to lifting the compressor! The position of the mass centre is specified both in the attached dimensioned drawing
and on the packing of the compressor.
Lifting lugs on certain component parts (e.g. electric motor) are exclusively
intended for lifting the individual parts, however not for lifting the entire compressor!
The compressor is delivered filled with oil. Do not tilt during transport!
Transport the compressor to its location as described in the chapters below.
Forklift truck or lifting cart transport
WARNING!
Inappropriate transport may lead to compressor damages. Do not subject the
safety cladding to force during transport.
Ensure that the forks are underneath the base frame of
the compressor (see illustration).
See below if there is no base
frame (crane transport).
Fig. 3.1: Transport with forklift truck
BOGE Operating instructions for C 15 series screw compressors Page 23
Installation 3.1 Transport and storage
Crane transport
WARNING!
Inappropriate transport may lead to compressor damages. Do not subject the
safety cladding to force during transport.
– Protect the compressor using wooden spacers (see arrows in the follow-
ing illustration).
– Remove transport timbers.
– Only use suitable transport slings having a minimum length of approx.
120 inches!
Position the slings at the ends underneath
the base frame of the compressor.
Neither fasten the transport slings to the
suction filter nor to the eyelet on the motor.
Intermediate storage
Fig. 3.2: Crane transport
In case the compressor is not installed immediately after delivery, it has to be
stored at a sheltered location. It must be ensured that during the intermediate
storage neither dust nor humidity can penetrate.
NOTICE!
In case of an intermediate storage please observe the specifications and directions as to permissible environmental impacts (see chapter „3.2 Compressor room: Installation conditions for separately arranged compressed air
receivers“).
In case of a careless storage we assume no liability for consequent damages!
In the event of an extended intermediate storage or after an extended standstill (six months) you should consult BOGE-Service.
Please observe the directions for commissioning after an extended standstill
(see chapter „3.5 Commissioning“) if the intermediate storage takes longer
than two months.
Page 24 BOGE Operating instructions for C 15 series screw compressors
Installation 3.2 Compressor room
3.2 Compressor room
Installation conditions for separately arranged compressed air receivers
WARNING!
– Protect compressed air receivers against damage through mechanical
effects (e.g. falling objects).
– Operate the compressed air receiver and its equipment from a safe loca-
tion.
– Adhere to safety areas and safety clearances.
– Ensure that the compressed air receiver stands securely. It must not shift
or tilt due to external forces. This also includes the additional weight during a pressure test!
– The compressed air receiver must not be bolted to the base.
– Ensure that the compressed air receiver is easily accessible from all
sides (for recurring tests). For the necessary operating and maintenance
areas have a look at the attached dimensioned drawings.
– Ensure that the factory label is clearly visible.
– Ensure that compressed air receivers are adequatly protected against
corrosion.
– Only use the compressed air receiver for compressors operating with cut-
in and cut-out mode if the pressure fluctuation range amounts to Δ p ≤
20% of the maximum operating pressure.
Installation surface
Fire protection
A level industrial floor without foundation is adequate for the installation of the
compressor. No special fastening elements are required.
The following applies to rooms in which compressors with oil injection cooling
are to be installed:
WARNING!
– For compressors with motor ratings exceeding 54 Hp, ensure that the
compressor room is equipped with special fire protection.
– Install compressors with motor ratings exceeding 134 Hp in a separate
fire 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-flammable mate-
rial.
BOGE Operating instructions for C 15 series screw compressors Page 25
Installation 3.2 Compressor room
– Leaking oil must not spread out over the floor.
– No inflammable materials must be located within a radius of at least
118 inches around the compressor.
– No inflammable machine parts, such as cable ducts, may run overhead of
the compressor.
Sound protection
Admissible environmental influences
Only install compressors in workrooms if the sound pressure level of
their measuring surfaces does not exceed 85 dB (A).
The compressor room must be clean, dry, cool and free of dust.
Admissible environmental influences
Maximum ambient temperature (for air cooling): + 113°F
Minimum ambient temperature: + 41°F
WARNING!
Non-observance of the admissible ambient temperature may lead to the following problems:
– The compressor will switch off when the admissible final compression
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 temperatures
are 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 the
minimum temperature is not gone below in winter.
– Use the BOGE frost protection device (series).
Ventilation
Page 26 BOGE Operating instructions for C 15 series screw compressors
If the following instructions are not observed, the admissible final compression temperature may be exceeded.
In this case, the compressor will switch off automatically.
WARNING!
Arrange the compressor intake openings or ducts in such a way, that dangerous admixtures (e.g. explosive or chemically unstable materials) cannot
be drawn 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 the
flaps and weather protection grids) are indicated in the table.
Installation 3.2 Compressor room
Supply and exhaust air ducts
– Ensure that the flow rates in the ducts do not exceed 157 inches/s.
– Never position cooling air ducts directly on the compressor. Always use a
compensator to avoid distortion and the transfer of vibrations.
Ventilators
Ensure that the heated exhaust air is not taken in again.
If necessary, the heated air must be extracted by ventilators.
To ensure perfect cooling even at higher temperatures in the summer, the
ventilators must be designed as follows:
– The ventilator capacity must be rated approx. 10...15% higher than the sum
of the cooling air quantity required for all machines operated in the room.
– For free-standing installation, the cooling air requirement specified in the
table corresponds to the required ventilator capacity.
Supply air filter
– The compressor is fitted with supply air filter mats.
Cooling air requirement
Please refer to the following table for the cooling air requirement and size of
the supply air openings for your compressor. Ensure that flaps and weather
protection grids have the necessary free cross section. We generally recommend contacting a specialist company for performing the duct construction
work and planning.
Type Drive
rating
[Hp] [cfm] [sq. ft.] [cfm] [sq. ft.]
C 15 / C 15 F 15.0 2180 5.4 1002 1.2
* For the cooling air requirements the basis is a 39°F temperature difference between room and outside temperature.
Tab. 3.1: cooling air requirement, necessary cross sections for openings and
ducts
* Cooling air
requirement
for free
standing unit
Necessary
inlet
opening
for free
standing unit
* Cooling air
requirement
for instal-
lation with
ducting
Necessary
free duct
cross section
BOGE Operating instructions for C 15 series screw compressors Page 27
Installation 3.2 Compressor room
Ventilation possibilities
Condensate disposal
Fig. 3.3: Ventilation possibilities
A Supply and exhaust air openings in the outside walls
(free-standing installation)
B Supported by exhaust air ventilator
C Exhaust air duct into the open
D Exhaust air duct with recirculation flap
Hot exhaust air is mixed with the cold ambient air, as required. Thus pre-
venting the plant from freezing up at temperatures below freezing.
E Using the hot exhaust air for heating
In the winter, the hot exhaust air is used for room heating. In summer it is
directed into the open.
The air taken in contains water in form of vapour, which turns into condensation during compression.
WARNING!
The condensate contains oil. Never lead it into the public sewage system
without prior treatment.
Strictly observe the effluent disposal laws of your local authorities.
Oil-water separator
The 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 to
environmental regulations.
If, due to special operating conditions, the oil should emulsify, use an emulsion cracking plant.
Page 28 BOGE Operating instructions for C 15 series screw compressors
Installation 3.3 Installation
3.3 Installation
General
BOGE compressor units are supplied ready for connection. Only the work described in the following paragraphs needs to be carried out during the installation.
WARNING!
Only have the installation work carried out by appropriately trained persons
or specialists.
Lay out all energy supply lines in a trip-proof and barrier-free manner so that
potential accidents can be avoided!
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 be
excluded.
– 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 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 inform
the BOGE-Service.
Checking the delivery scope
Installing the compressor
The delivery scope depends on your order.
Prior to commissioning, please check whether all required parts have been
provided. Please check the order confirmation for any possible accessory
equipment.
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
– Head nut (in the compartment of the 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.
BOGE Operating instructions for C 15 series screw compressors Page 29
Installation 3.3 Installation
Connecting the compressor to the compressed air network
Remove cladding
– Connect the compressor to the compressed air network or a compressed
air receiver.
For this, use a BOGE high pressure hose.
NOTICE!
Do not install a check valve in the pressure line.
The compressor is already equipped with a check valve.
WARNING: Risk of injury!
Make sure to always wear protective gloves to protect yourself against any
sharp edges and corners on covering components!
– Lift off top cover (1) (for super silenced version only).
– Loosen cabinet bolts (2) above lateral sheets and backwall and remove
cladding.
Fig. 3.4: Remove cladding (illustration shows super silenced version)
WARNING!
To avoid damages to the cooler you must counter the screw connections at
the compressed air outlet with a spanner.
Page 30 BOGE Operating instructions for C 15 series screw compressors
Installation 3.3 Installation
Fig. 3.5: Connect compressor
Activating the belt tensioning device
1 Electrical connection
2 Compressed air outlet
The V-belts are slackened for the transport.
The GM belt tensioning device must be activated prior to first commissioning
by lowering the motor plate.
– Turn the adjusting nut (1) down as far as possible using a spanner (M`NW
17) and counter.
The belt tensioning device is activated. It adjusts automatically the correct belt
tensioning in every operating status.
sealed
Fig. 3.6: Activate belt tensioning
WARNING!
The sealed nuts for adjustment of the spring tension must not be loosened
or modified.
BOGE Operating instructions for C 15 series screw compressors Page 31
Installation 3.4 Electrical connection
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 chapter
"Maintenance".
3.4 Electrical connection
DANGER: Voltage!
Ensure that work on the electrical equipment of the compressor is only carried out by authorized electricians.
When connecting to the power supply, observe the valid safety regulations.
Also observe the regulations of your local power supply company regarding
the load rating of your power supply.
Power disconnecting device
Each compressor plant has to be equipped with a mains disconnecting device.
Rated voltage
The data of your mains (operating voltage, control voltage, type of current, frequency, ...) must coincide with the data on the type plate on the switch cabinet.
In the event of deviations, please contact the BOGE service or your supplier.
Please see "Technical Data" for layout of mains fuse.
Connecting the leads
– Check to ensure that all terminals in the switch cabinet are firmly tight-
ened. If necessary, retighten the screw connections.
– Guide the lead cable through the PG screw connection.
– Connect the leads L1, L2, L3, N, Pe (PEN) firmly to the power supply ter-
minal. A clockwise rotational field must be created.
– Retighten the electrical connections after the first 50 operating hours.
Page 32 BOGE Operating instructions for C 15 series screw compressors
Installation 3.4 Electrical connection
Drive with frequency converter
Caution: Voltage!
According to operational conditions electrical drive systems with frequency
converter may have an earth leakage current above 10 mA.
Therefore the required precautions have to be applied as soon as the compressor is electrically connected.
A permanently installed connection is required.
One or several of the following qualifications for the protective-conductor
system have to be fulfilled:
1. The protective conductor must have a minimum cross section of 10 mm
Cu along its total length.
2. If the protective conductor has a minimum cross section of less than
10 mm
to be provided up to the point from where the protective conductor has a
minimum cross section of more than 10 mm
3. Automatic interruption of the supply if the continuity of the protective conductor is lost.
2
Cu a second conductor with at least the same cross section has
2
.
2
Please observe any additional national and local rules and regulations!
WARNING: Risk of injury!
Prior to any work on the compressor:
– Press Emergency Stop button, open mains disconnecting device and
secure with lock out tag out.
– Check to ensure that all conducting machine parts are voltage free.
– Depressurize all areas under pressure.
Never omit a single safety step! Otherwise, you will risk injuries due to restarting, electric shock or self-releasing parts.
WARNING!
When the automatic restart (Auto-Restart) is activated, the compressor will
start automatically following a power loss.
Prerequisite: The net pressure is lower than the set switch-on pressure.
BOGE Operating instructions for C 15 series screw compressors Page 33
Installation 3.5 Commissioning
3.5 Commissioning
NOTICE!
We recommend the drawing up of a commissioning certificate in which the
test results during the commissioning process can be listed up.
WARNING: Risk of injury!
The commissioning may only be carried out by experienced and authorized
qualified personnel!
Always wear protective gloves when working on the compressor to avoid
bruising of fingers or hands while opening or closing components!
Checking installation requirements
Checking the rotational direction
WARNING!
Make sure that the compressor is installed according to the installation requirements!
Prior to starting the compressor for the first time, check if the transport securing device was duly removed and the GM belt tensioning device activated
(see chapter „3.3 Installation“)!
List up the test results in the commissioning certificate.
WARNING!
Always check the rotational direction of the drive motor prior to commissioning/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!
List up the test results in the commissioning certificate.
WARNING!
Ensure that the rotational direction coincides with the rotational direction arrow on the air end.
– Close mains disconnecting device.
– Switch the compressor on and immediately off again to check the rota-
tional direction.
Page 34 BOGE Operating instructions for C 15 series screw compressors
Installation 3.5 Commissioning
Changing the rotational direction
WARNING: Risk of injury!
– Switch off the compressor using the OFF button.
– Actuate emergency-stop switch/button.
– Open mains disconnecting device.
– Secure mains disconnecting device against unintentional switch-on.
– Check to ensure that all machine elements are definitely currentless.
– Cover or block off adjacent energized parts.
– Interchange two phases (L1, L2 or L3) in the power cable.
Checking compressed air outlet for tightness
WARNING: Risk of injury!
Work on the compressed air system may only be carried out by experienced
and authorized qualified personnel!
Always wear protective clothing and goggles!
Immediately after having switched on the machine the connection of the compressed air outlet must be checked for tightness!
Make sure to observe an appropriate safety distance during the inspection!
Opening the stop valves
– Close mains disconnecting device.
– To conduct the inspection switch on the compressor and check the com-
pressed air outlet for tightness.
– Switch off compressor.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions as described on page 5.
– If necessary, have leakages repaired by skilled qualified pesonnel.
– List up the test results in the commissioning certificate.
Open ball valve on the compressor delivery.
BOGE Operating instructions for C 15 series screw compressors Page 35
Installation 3.5 Commissioning
Checking for leaks
WARNING: Risk of injury!
In case of leakages in the oil circuit there is a certain danger to slip and fall
because of oil spills!
Have all connections of the oil circuit checked for leakages by authorized
qualified personnel!
During the inspection slip-resistant safety shoes and protective clothing are
obligatory!
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.
Conducting trial run
Commissioning following extended stoppages
Close mains disconnecting device.
– Switch on the compressor using the ON key. The compressor starts.
– When the factory-set switch-off pressure is reached, the compressor cuts
off automatically.
– Check network pressure on control display.
If necessary, reset operating pressure (pressure target value).
– The compressor is ready for operation.
Switch off the compressor after a trial run of several hours under maximum
load.
List up the test results in the commissioning certificate.
If an extended stoppage is scheduled, you should contact BOGE-Service beforehand.
Following an extended stoppage of more than two months, fill a small amount
of oil in the suction controller prior to starting the compressor.
WARNING!
Only fill the suction controller with the grade of oil used to operate the compressor.
Never mix different oil grades and brands.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions as described on page 5.
Page 36 BOGE Operating instructions for C 15 series screw compressors
Installation 3.6 Dismantling
– Unscrew the plug on the suction
controller (1).
– Fill approx. 0.03 gallons com-
pressor oil into the suction controller.
– Reclose the controller using the
plug.
– Prior to switching on the com-
pressor wait for approx.10 min.
until the oil has spread evenly.
Then switch the compressor on
and immediately off again.
– After approx.10 sec. the com-
pressor can be started.
Fig. 3.7: Suction controller
3.6 Dismantling
NOTICE!
To avoid dangers when dismantling the compressor please consult your
BOGE Service:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
WARNING!
Dismantling of the compressor may only be carried out by experienced and
authorized qualified personnel!
DANGER: Voltage!
All work on the electrical installation may only be carried out by authorized
and skilled electricians!
Prior to starting the work the power cable to the switch cabinet must be disconnected from the mains and secured against unintentional switching on!
BOGE Operating instructions for C 15 series screw compressors Page 37
Optional equipment 4.1 BOGE-Duotherm BPT
Part 4: Optional equipment
Function
Assembly
4.1 BOGE-Duotherm BPT
The heat recovery system BOGE-Duotherm BPT utilizes the heat energy released during compression to produce warm water free of charge (e.g. for production systems or to supply a heater).
The plate heat exchanger is connected in the main stream of the hot oil. It comprises of stainless steel plates which are soldered together. These form two
separate duct systems. Compressor oil and water run through these ducts with
opposing flow directions. The hot oil transfers its heat to the colder water via
the plates.
As a rule, the plate heat exchanger is installed into the compressor at the factory and comes equipped with all necessary pipework. Only the following work
is required during installation:
– Connect the supply and discharge water lines to the pipeline mains.
Route the pipelines to prevent transmission of stresses/tension and vibrations to the heat exchanger.
– Provide venting and draining facilities.
The customer must provide the following components for installation:
– Stop valves
Stop valves in the water supply and discharge lines enable simple removal
of the heat exchanger.
– Expansion vessel and safety valve.
Commissioning
WARNING!
If the stop valves in the water supply and discharge lines are closed simultaneously, an enclosed space is created. If the water in this space is heated, it
expands and the pressure increases.
Therefore, an expansion vessel and safety valve must be installed to avoid
damage to the plate heat exchanger.
– Dirt trap (pore size: max. 0.02 inches)
The dirt trap at the water inlet protects the plate heat exchanger against
dirt deposits in the event of a high degree of water contamination.
– Flushing connections
The flushing connections serve to clean the plate heat exchanger.
Separate installation
The plate heat exchanger may also be separately installed or retrofitted by the
customer.
Normally, the plate heat exchanger is held in place by the pipelines. However,
when installing larger types, the customer may have to provide a bracket.
Proceed as follows during commissioning:
– Check oil level in the oil circuit. If necessary, top up oil.
– Slowly open the stop valves in the water supply and discharge line.
Avoid pressure hammers!
– Vent the pipelines.
BOGE Operating instructions for C 15 series screw compressors Page 39
Optional equipment 4.1 BOGE-Duotherm BPT
Maintenance
Lime, oxides as well as grease or oil will deposit in the ducts of the plate heat
exchanger during operation.
Regular cleaning will prevent thick deposits clogging individual ducts of the
plate heat exchanger.
Cleaning intervals
Excessively soiled and limy water: six months
Moderately soiled water, surface water: one year
Lightly soiled water: three years
Recommended cleaning agents
Grease or oil deposits: Paraffin
Oxide or lime deposits: formic acid, acetic acid or citric acid
WARNING!
Always observe the instructions of the cleaning agent manufacturer!
Cleaning methods
Flushing:
– First close all stop valves in the supply lines.
– Close all stop valves in the discharge lines.
– Wait until the plate heat exchanger has cooled down.
– Open the flushing connections and drain the plate heat exchanger.
– Flush the plate heat exchangers.
For this purpose, pump one of the above mentioned cleaning agents
through the plate heat exchangers for an extended period of time.
– After flushing, rinse the plate heat exchanger thoroughly with water
(e.g. using a high pressure hose).
Enhance the cleaning action by the following measures:
– Use a larger mass flow rate than for standard operation.
– Flush the cleaning agent through the plate heat exchanger in opposite
direction to standard operation.
Allow to react (tenacious soiling):
– Dismantle plate heat exchanger.
– Fill plate heat exchanger with one of the above mentioned cleaning
agents.
– Allow the cleaning agent to act for at least six hours.
Point the connection upward to allow gases to escape.
– After cleaning, rinse the plate heat exchanger thoroughly with water
(e.g. using a high pressure hose).
NOTICE!
If the cleaning measures specified above are not sufficient, you should have
the exchanger cleaned by a service company. Boge service will recommend
contracting firms on request.
Page 40 BOGE Operating instructions for C 15 series screw compressors
Faults 5.1 General
Part 5: Faults 5.1 General
The tables on the following pages give information on the possible causes of
operating faults and measures for their rectification (please also refer to operating instructions of the compressor control).
WARNING!
Ensure that any work required to rectify faults is only carried out by trained
personnel or specialists.
Any performance of work on pressurized system components may be carried
out by duly qualified and specialized personnel only.
Ensure that components which have a safety function are only set, repaired
or exchanged by BOGE Service!
Please contact BOGE-Service at the following telephone numbers, if you
have any questions.
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
DANGER: Voltage!
Prior to any work required to rectify faults it is essential to take all necessary
safety precautions as described on page 5!
5.2 Faults – Compressor
Fault Possible cause Rectification
No quantity delivered,
no pressure build-up,
max. pressure 7 psig
System components in the
compressor are leaking
Minimum pressure valve is
defective
Electromagnetic venting valve
does not close
Suction controller does
not open
Check oil and compressed air lines inside the compressor; tighten
and/or reseal screw connections, if necessary
Close ball valve and check whether pressure builds up; if so, open
ball valve again immediately; replace minimum pressure valve
Check solenoid valve and replace, if necessary
Suction controller or solenoid valve is defective; check and replace,
if necessary
V-belts are torn Fit new V-belts
BOGE Operating instructions for C 15 series screw compressors Page 41
Faults 5.2 Faults – Compressor
Fault Possible cause Rectification
Compressor system
does not start up
Oil in suction filter Minimum pressure non-return
Excessive oil
consumption
No electric power to compressor Check electrical connection
Fuses are defective Check the mains and control fuses, replace if necessary
Machine has not vented perfectly Check venting valve and replace, if necessary
Voltage fluctuations in the electrical mains power
Compressor oil is very viscous due
to low ambient temperature
valve is leaking
Suction controller is leaking Check the suction controller and replace, if necessary
Switch-off performed by emergency-off switch/button
Drain line is blocked Dismantle and clean drain line
Defective oil separator element Check oil separator and replace, if necessary
Excessive oil filling Drain off oil
Ensure constant voltage
Heat compressor room
Check the minimum pressure check valve and replace, if necessary
Cut-out normally via O-key
Safety valve blows Operating pressure target value
maladjusted
Defective safety valve Replace safety valve
System pressure does
not decrease when
switching off
Venting valve does not open Check the venting valve and replace, if necessary
Check valve is leaking Examine check valve and replace, if necessary
Set operating pressure to maximum permissible pressure of the
screw compressor
Page 42 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.1 Safety instructions
Part 6: Maintenance 6.1 Safety instructions
WARNING!
Ensure that maintenance work is ony carried out by specialists or appropriately trained persons.
Any performance of work on pressurized system components may be carried
out by duly qualified and specialized personnel only.
– Prior to starting any maintenance work, always stop the compressor as
described in these operating instructions prior to removing any cladding
or safety devices. Refit the cladding or safety devices immediately upon
completion of the maintenance work.
– Heavy components may only be lifted up by various persons in due con-
sideration of the local industrial safety regulations.
– Only use original spare parts, compressor oils and operating materials
released by BOGE for the maintenance work.
– With an activated automatic restart (Auto-Restart) the compressor may
restart automatically after a voltage failure.
Prerequisite: The net pressure is lower than the set switch-on pressure.
BOGE Operating instructions for C 15 series screw compressors Page 43
Maintenance 6.1 Safety instructions
WARNING: Risk of injury!
Always adhere to the prescribed operating method described below for all
maintenance work. Never omit a single safety step!
Otherwise you will risk injury from restarting, electric shock or parts which
may fly off.
Prior to all maintenance work:
1. Switch off the compressor using the OFF button.
2. Actuate emergency-stop switch/button.
3. Open mains disconnecting device and secure by means of lock out tag
out.
4. Fix a warning label to the control and fill in the name of the person responsible who is authorized to switch on the maschine again.
5. Check to ensure that all machine elements are definitely currentless.
6. Cover or block off adjacent energised parts.
7. Prior to starting work let cool down all hot components of the compressor
to 122°F.
8. Separate the compressor from the compressed air network by closing
the ball valve at the compressed air outlet.
9. 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.
– Turn the knurled nut a little further.
Any possibly existing air will escape.
The system pressure gauge will indicate a pressure of 0 psig.
– Once the residual air has completely escaped from the system, firmly
retighten the knurled nut.
10. Remove all safety cladding necessary to perform the maintenance work.
Once the maintenance work has been concluded:
11. Reattach all removed safety cladding.
12. Open the ball valve at the compressed air outlet.
13. Prior to switching on again, check whether anyone else is working on the
compressor.
14. Remove all covers previously installed at adjacent parts for maintenance
and servicing work.
15. Remove warning sign not until then and release mains disconnecting
device.
16. Unlock emergency-stop switch/button.
Page 44 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.2 General
6.2 General
Maintenance through BOGE customer service
Review of regular maintenance work
Have BOGE service check your compressor every 3000 operating hours or
annually.
NOTICE!
Maintenance agreement!
Enter into a maintenance agreement with BOGE.
BOGE service will carry out the proper maintenance on your compressor at
regular intervals. This guarantees maximum safety and realiability of your
compressed air supply.
Fig. 6.1: Review of regular maintenance work C 15 / C 15 F
1 Check suction filter
– Clean / replace filter insert
2 Check oil level / top up oil
3 Change supply air filter
4 Check V-belt
5 Change oil filter and oil separator
6 Clean compressed air / oil cooler externally
7 Following extended stoppages: Fill oil into the suction controller
8 Check / adjust pressure (Control)
BOGE Operating instructions for C 15 series screw compressors Page 45
Maintenance 6.2 General
Maintenance intervals
The maintenance intervals specified in the table below are based on average
operating and ambient conditions.
Extreme conditions may require shorter maintenance intervals.
NOTICE!
Note down any maintenance work in the table on the last page.
This will facilitate trouble shooting for BOGE service.
WARNING!
Check monthly if all screw connections on the compressor are fully tightened.
Oil change:
Prior to using mineral or food compatible oil make sure to change oil filter after the first 500 operating hours.
Page 46 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.2 General
Maintenance work Maintenance intervals in operating hours
weekly,
monthly
1000
annually
1500
annually
3000
annually
1)
Page
9000
every
2 years
General maintenance work
Check final compr. temp. (set point value: 158...212°F) w Control
Check compressor for leaks X –
Check system relief on system pressure gauge (22)
(set point value: 0 – 22 psig)
w Control
Check function of emergency-stop switch/button m Control
Cleaning the oil cooling unit X 60
Check or change supply filter w 51
Check if electrical connections are tightened X –
Air circuit
Check and if necessary clean suction filter m 50
Change suction filter cartridge X 50
Check safety valve X 60
Replace minimum pressure valve (wearing parts set) X –
Replace suction controller X–
Oil circuit
Check oil level and top up as required
Change oil separator
Change oil filter
Change oil
2)
2)
2)
2)
Replace oil regulator (wearing parts set)
2)
m54
X56
X55
X57
X–
Replace nozzle with dirt catch X 61
Drive
Check/replace V-belt X 52
Lubricate drive motor bearings Drive motors with permanent lubrication:
Change when replacing the motor bearings
52
Replace motor bearing 20000 operating hours
1)
If the compressor is not often used, undertake the maintenance according to the specified intervals (weekly/monthly/annually) depending on the number of operating
hours.
2)
The specified intervals only apply when BOGE compressor oil Syprem 8000 S is used! The service life may differ depending on the ambient temperature. In this case
have the oil analyzed by your BOGE service!
Tab. 6.1: Maintenance intervals
BOGE Operating instructions for C 15 series screw compressors Page 47
Maintenance 6.2 General
General information concerning the lubricants used
WARNING: Risk of injury!
Oil presents a potential danger to health and environment due to their additives.
– 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 handling oil.
Please take notice of the directions in the corresponding safety data sheet!
We recommend using only oil according to following specification:
– Viscosity range of 55 cSt at 104°F.
– Minimum viscosity at 212°F of 8 cSt.
– Maximum viscosity at 32°F of 1000 cSt.
– (FZG A/8.3/90 min 10).
– Excellent oxidation stability: Meets requirements of Pneurop oxidation test.
– Antifoam – additives.
– Additives to prevent residue formation.
– Compatibility with all used sealing materials like Neoprene, FPM, PTFE,
FKM (Viton) and acrylic and epoxy resin paints.
– Flash point > 446°F.
– Additives for excellent demulsifying properties.
– Additives for corrosion protection of metallic surfaces.
– Excellent oxidation stability: Rotating bomb oxidation Test (ASTM D 2272)
higher than 2400 minutes.
– Meets VDL requirements DIN 51 506 for lube oils (including Pneurop test).
– Or you use BOGE compressor oil Syprem 8000 S. The stated mainte-
nance intervals refer to the use of Syprem 8000 S only.
– Syprem 8000 S can be purchased from BOGE retailers.
– Never mix different oil types and brands.
The additives may be incompatible. It may lead to foam formation, premature aging or loss of lubricating ability.
Page 48 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.2 General
Disposal of used operating material
WARNING!
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 used operating 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 treat-
ment and must be kept separate from normal waste!
Pressure hoses
WARNING!
Risk of injury and damage to compressor due to obsolete pressure hoses!
Never use pressure hoses beyond the prescribed service life!
Check hoses and connections regularly for leakages! Check the service life
of the hoses and replace them in due time!
As replacement only use original spare parts released by BOGE!
Used pressure hoses are not permitted as a replacement!
Spare and wearing parts
WARNING!
Only use original spare parts, compressor oils and operating materials released by BOGE for repair and maintenance work.
BOGE is not liable for any damage resulting from the use of other spare parts
or operating materials.
WARNING!
If the nozzle with dirt catch is soiled the oil consumption may increase significantly!
BOGE Operating instructions for C 15 series screw compressors Page 49
Maintenance 6.3 Maintenance work compressor
6.3 Maintenance work compressor
Cleaning or changing suction filter
Cleaning:
– 1x monthly,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.
Switch off the compressor with the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
Removing the filter cartridge
– Open safety sound insu-
lation hood.
– Unscrew lid (1) of filter
housing in the direction
of the arrow.
– Take out filter insert.
Fig. 6.2: Changing the intake filter
Cleaning the filter cartridge
WARNING!
Do not clean filter cartridges in liquids.
Do not use hard objects for cleaning in order that the filter paper is not damaged.
Replace the filter cartridge if it is damaged or has been cleaned twice.
– Tap the filter cartridge with your hand to knock out coarse dust.
– Blow out fine dust (max. pressure 73 psig) from the inside to the out-
side.
– Clean the sealing surfaces of the filter cartridge.
Page 50 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.3 Maintenance work compressor
Fitting a filter cartridge
– Insert the filter cartridge into the filter case.
– Attach lid of the filter housing.
– Remount safety sound insulation hood.
Changing the supply air 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 its set point value
by 39 to 41°F.
The crust of dirt on the filter mat prevents an adequate cooling air supply.
Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
Wear safety gloves to avoid cuts due to sharp edges!
Fig. 6.3: Changing the supply air filter mats
– Pull insert (1) out of the holder.
– Fit new insert (1) into the holder.
BOGE Operating instructions for C 15 series screw compressors Page 51
Maintenance 6.3 Maintenance work compressor
Drive motors with permanent lubrication
Changing the V-belt
As a rule, the bearings of the drive motors are provided with a maintenance
free permanent lubrication.
Under normal operating conditions (refrigerant temperature max. 104°F, continous operation) the bearings are maintenance free for the service life.
The service life decreases or increases as thermal stress increases or decreases (due to increased or reduced refrigerant temperature).
WARNING!
Have BOGE service dismantle the bearings and install new bearings once
the specified service life has expired (see „Maintenance intervals”, page 47).
Check:
– 1x per year for damages.
Change:
– In case of visible damages.
NOTICE!
The BOGE GM drive system automatically adjusts the belt drive in every
operating status to the correct tensioning.
Thus maintenance of the belt drive is reduced to the tasks mentioned above.
Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
Let the compressor cool down. Otherwise you can burn yourself when touching the approx. 170 – 195°F hot cooler.
Changing the V-belt:
– Open safety sound insulation hood.
– Turn adusting nut (1) upwards. The two bushings inside the spring must
touch.
– Pull slackened belts from the pulley.
– Fit new V-belts.
– Turn adjusting screw (1) downwards as far as possible. The V-belts are
tensioned automatically by means of the BOGE GM drive system.
– Remount safety sound insulation hood.
Page 52 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.3 Maintenance work compressor
Fig. 6.4: Lift motor plate
Setting of the GM-drive system C 15 / C 15 F
sealed
Setting
+ 0 / – 0.04 inch
blue
Model Pressure
[psig]
The setting value given in the following table is setted by the manufacturer and must not be changed. Slight
modifications are permissible and
compensated by the GM drive system.
The current setting value is also marked on a lable on the GM drive system. In case of special constructions
the setting values on the label may
deviate from the standard value.
1 adjusting nut
Standard
motor
[lbs.]
Setting
+ 0 / – 0.04
[inch]
C 15 / C 15 F 100/ 115 / 150/ 190 270
Tab. 6.1: Setting for standard motors
BOGE Operating instructions for C 15 series screw compressors Page 53
Motor tensioning spring w/o pretension
(Tensioning device must not rattle)
Maintenance 6.3 Maintenance work compressor
Checking the oil level, topping up oil
Check:
– Prior to commissioning/start-up of the compressor.
– After that every month.
Topping up:
– If the oil level has dropped to a level 0.39 – 0.79 inch below the bottom
edge of the thread.
WARNING!
Always use the same oil type when topping up. Never mix different oil types
and brands.
– Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
– Close ball valve at the compressed air outlet.
– Vent the compressor (as described in the beginning of the chapter).
– Wait approx. 3 minutes to permit the oil to settle.
WARNING: Risk of injury!
Danger of burning due to hot oil!
Always wear safety gloves!
– Remove plug (2) from oil fill-
ing socket (1).
– Check oil level.
The oil level must not drop
to a level more than
0.79 inch below the bottom
edge of the thread.
– If necessary, top up with oil
to the lower edge of the
thread ("max." mark) on the
oil filling socket.
– Screw plug (2) back in.
– Open the ball valve at the
compressed air outlet.
Fig. 6.5: Checking the oil level, topping up with oil
Page 54 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.3 Maintenance work compressor
Changing the oil filter (Fig. 6.6)
Change:
– After 3000 operating hours, however, no later than after one year.
– With each oil change!
WARNING!
When using mineral oil or oil suitable for the foodstuff industry: Change oil
filter after the first 500 operating hours!
Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
– Close ball valve at the compressed air outlet.
– Vent the compressor (as described in the beginning of the chapter).
– Open safety sound insulation hood.
– Wait approx. 3 minutes to permit the oil to settle.
WARNING: Risk of injury!
Hot surfaces: Do not touch!
– Slacken screws on service cover and remove cover (see arrows in figure
6.6).
– Take out oil filter cartridge (4) and remove from support body (5) (see fig-
ure 6.6).
– Slide support body into the new oil filter cartridge.
WARNING!
Over-current / Non-return valve (6) must be fitted facing up.
– Fit oil filter cartridge (4) with support body (5).
– Check o-rings on service cover for damage and replace if necessary.
– Fit service cover (3) and tighten screws (see arrows in figure 6.6).
– Open the ball valve at the compressed air outlet.
– Switch on the compressor and heat up to operating temperature.
– Check tightness of service cover and re-tighten screws.
– Close sound insulation hood
BOGE Operating instructions for C 15 series screw compressors Page 55
Maintenance 6.3 Maintenance work compressor
Fig. 6.6: Changing the oil filter / Changing the oil separators
Changing oil separators (Fig. 6.6)
Change:
– When warning message "8" appears on the control system display.
– After 3000 operating hours, but no less than once a year.
WARNING: Risk of injury!
If the prescribed maintenance intervals are not observed, the oil separators
might become blocked. In this case, the differential pressure will increase
until the safety valve blows.
– Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
– Close ball valve at the compressed air outlet.
– Open safety sound insulation hood.
– Vent the compressor (as described in the beginning of the chapter).
– Wait approx. 3 minutes to permit the oil to settle.
WARNING: Risk of injury!
Danger of burning due to hot oil!
Always wear safety gloves!
WARNING: Risk of injury!
The servicing cover heats up during compressor operation.
– Hot surfaces: Do not touch!
– Let service cover cool down!
Page 56 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.3 Maintenance work compressor
– Slacken screws on service cover and remove cover (see arrows in figure
6.6).
– Pull oil disperser cartridge (1) out of the o-ring seal (see Fig. 6.6).
– Check seat of o-ring.
– Lightly oil bottom of new cartridge in and press into o-ring seal.
– Check o-rings on service cover for damage and replace if necessary.
– Fit service cover and tighten screws (see arrows in figure 6.6).
Caution: Risk of injury!
Take extreme care when checking the servicing cover for leaks and always
observe all safety measures!
– Open the ball valve at the compressed air outlet.
– Switch on the compressor and heat up to operating temperature.
– Switch off the compressor using the OFF button.
– Actuate emergency-stop switch/button.
– Open power disconnecting device.
– Secure power disconnecting device against unintentional switch-on.
– Prior to starting work let cool down all hot components of the compressor
to 122°F.
– Check tightness of service cover and re-tighten screws.
– Close sound insulation hood.
Oil change
Change:
– After 9000 operating hours, however, at the latest after two years.
– For other types of oil the appropriate oil change intervals must be complied
with.
NOTICE!
The service life of the oil, the oil filter and oil separators is reduced under the
following conditions:
– When the compressor is operated at extreme ambient temperatures.
– When the intake air is extremely soiled.
Building up a pressure cushion
To enable a quick draining of the oil from the compressed air/oil tank and to
overcome a difference in height a small pressure cushion can be built up (approx. 22 psig system pressure). This pressure cushion forces the oil through
the drain hose into a suitable collecting basin.
BOGE Operating instructions for C 15 series screw compressors Page 57
Maintenance 6.3 Maintenance work compressor
– Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
Do not vent compressor completely so that a pressure cushion is still available.
Draining old oil
– Switch off compressor. After ap-
prox 2 sec screw cap nut (see arrow) on the bleed aperture of the
solenoid valve (the nut is located
in the storage compartment of the
switch cabinet).
Fig. 6.7: Solenoid valve on the suction controller with the cap nut screwed on
WARNING: Risk of injury!
Danger of burning due to hot oil!
Always wear safety gloves!
– Remove blind plu (1) at oil drain
(3) with the tap closed.
– Fit oil drainage hose (2). (The
hose is located on the machine)
– 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, close the stop valve.
Fig. 6.8: Oil drain from oil compressed air receiver
Page 58 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.3 Maintenance work compressor
– Remove oil drainage hose and replace blind plug with new copper seal.
– Remove the cap nut from the solenoid valve.
– Change oil filter (procedure as described above).
– Change oil separators (procedure as described above).
Filling with new oil:
– Fill up to the edge of the thread of the filling socket (max.) (procedure as
described above).
WARNING!
Always fill with the same oil type as previously used. Never mix different oil
types and brands.
The oil circuit must be flushed prior to changing the oil type.
– Conduct trial run.
WARNING: Risk of injury!
Prior to checking tightness and oil level again take all necessary safety precautions described on page 44!
Flushing the oil circuit
– Check the oil filters and oil separators for leaks and tighten by hand, if nec-
essary.
– Check oil level (procedure as described above).
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.
WARNING!
Detailed information as to the flushing with BOGE oils you can obtain from
the following service numbers:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
BOGE Operating instructions for C 15 series screw compressors Page 59
Maintenance 6.3 Maintenance work compressor
Cleaning the compressed air/oil cooling
unit
Cleaning:
– After 1500 operating hours, however, at the latest after one year.
NOTICE!
The service life of the compressed air/oil cooling unit depends on the degree
of soiling (dust, oil vapour) of the suctioned cooling air. Extreme external soiling of the cooling unit leads to an increased temperature in the oil circuit.
– Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
WARNING!
Do not use any sharp objects for cleaning!
These could damage the cooling unit.
Checking the safety valve
– Blow down the dirt with
compressed air in the
opposite direction to the
normal cooling air flow.
Vacuum out the dirt using
an industrial vacuum
cleaner.
If the cooling unit is excessively soiled (cleaning is no
longer possible with compressed air), have it disassembled and cleaned by
BOGE service.
Fig. 6.9: Cleaning the compressed air/oil cooling unit
Check:
– After approx. 3000 operating hours, however, at least once a year.
Check safety valve by opening the screw plug.
WARNING: Risk of injury!
Danger of burning due to hot oil!
Take extreme care when checking the safety valve with the compressor running taking all safety measures into consideration.
Always wear safety gloves!
A hot air-oil mixture escapes when opening!
Page 60 BOGE Operating instructions for C 15 series screw compressors
Maintenance 6.3 Maintenance work compressor
– Open the threaded plug
(see arrow) anticlockwise. The air/oil mixture
escapes.
– Tighten the threaded plug
by turning clockwise.
Fig. 6.10: Lock nut on safety valve
Nozzle with dirt catch
Change:
– After 3000 operating hours, however, no later than after one year.
WARNING!
If the prescribed maintenance interval is not observed, the residual oil content in the compressed air increases considerably.
– Switch off the compressor using the OFF button.
WARNING: Risk of injury!
Prior to any maintenance and servicing work take all necessary safety precautions described on page 44!
– Close ball valve at the compressed air outlet.
– Open safety sound insulation hood.
– Vent the compressor (as described in the beginning of the chapter).
– Wait approx. 3 minutes to permit the oil to settle.
– Unscrew nozzle with dirt catch (see arrow) (1).
– Screw in new nozzle with dirt catch.
Fig. 6.11: Nozzle with dirt catch
BOGE Operating instructions for C 15 series screw compressors Page 61
Maintenance 6.4 Spare parts and optional equipment
6.4 Spare parts and optional equipment
List of spare and wearing parts of the compressor (for maintenance)
List of available optional equipment
Designation
Compressor oil Syprem 8000 S
Set of V-belts
Maintenance kit consisting of:
oil filter, oil separator, suction filter cartridge, gaskets, nozzle with dirt catch
Wearing part kits for:
oil regulator, minimum pressure valve, solenoid valve
Intake regulator incl. solenoid valve
Designation
Optional equipment for compressed air treatment
Oil/water separator
Automatic condensate draining unit Bekomat
WARNING!
When ordering, please specify the data on the type plate:
– Type
– Year of manufacture
– Machine number
Page 62 BOGE Operating instructions for C 15 series screw compressors
Appendix 7.1 Flow chart
Part 7: Appendix 7.1 Flow chart
On the following pages you will find the individual flow charts for your compressor and components.
BOGE Operating instructions for C 15 series screw compressors Page 63
Appendix 7.1 Flow chart
Air cooled version, standard, C 15 / C 15 F
5
28
10
10
16
11
12
27
21
20
I
24
P
23
I
P
4
7
M
9
6
1
1
8
3
19
18
17 22
29
102
Page 64 BOGE Operating instructions for C 15 series screw compressors
Appendix 7.1 Flow chart
101 Intake air INLET
102 Compressed air OUTLET
1 Suction filter
3 Suction filter monitoring (FOCUS only) *
4 Suction controller
5 Ventilation and regulation control valve
6 Direction of rotation monitoring with double check valve (FOCUS only) *
7 Drive motor
8 Air end
9 Final compression temperature display and switch
10 Combined compressed air/oil receiver
11 Oil separator
12 Safety valve
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
19 Oil filter monitoring (FOCUS only) *
20 Pressure gauge reading in display
21 Minimum pressure check valve
22 Compressed air after-cooler
23 Pressure transmitter system pressure (FOCUS only)
24 Pressure transmitter net pressure
25 Stop valve, compressed air outlet
27 Oil drainage
28 Throttle with filter
*Option
BOGE Operating instructions for C 15 series screw compressors Page 65
Appendix 7.1 Flow chart
BOGE-Duotherm BPT plate heat exchanger
101 Compressed air OUTLET
102 Return
103 Flow
1 Suction filter
4 Suction controller
8 Compressor air end
10 Combined compressed air/oil receiver
11 Oil separator
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
21 Minimum pressure non-return valve
22 Compressed air after-cooler
50 Heat exchanger
Page 66 BOGE Operating instructions for C 15 series screw compressors
Appendix 7.2 List of maintenance and service work
7.2 List of maintenance and service work
RemarksMotor
servicing
unit
Cooling
cleaning
Oil
separator
**
Oil
level
Oil
filter
Supply
air filter
*
filter
Suction
rature
Tempe-
Please note the completed maintenance work in the respective columns
System
pressure
Supply
pressure
ating
hours
Oper-
Date
BOGE Operating instructions for C 15 series screw compressors Page 67
** Co = Control
* Cl = Cleaning
** Ch = Change
* Ch = Change
Appendix 7.2 List of maintenance and service work
RemarksMotor
servicing
unit
Cooling
cleaning
Oil
separator
Oil
level
Oil
filter
Supply
air filter
filter
Suction
rature
Te m p e -
Please note the completed maintenance work in the respective columns
System
pressure
Supply
pressure
**
*
** Co = Control
** Ch = Change
ating
hours
Oper-
Date
Page 68 BOGE Operating instructions for C 15 series screw compressors
* Cl = Cleaning
* Ch = Change
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