Boge C 10 L, C 15 L, C 20 L Operating Instructions Manual

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Operating instructions

Directly coupled

screw compressors

Series

C 10 L...C 20 L

Separate manual:

Compressor control

www.boge.com

Operating instructions for directly coupled screw compressors

– C 10 L (10.0 Hp) – C 15 L (15.0 Hp) – C 20 L (20.0 Hp)

BOGE KOMPRESSOREN Postfach 10 07 13 33507 Bielefeld Germany

Otto-Boge-Straße 1-7 33739 Bielefeld

Phone: +49 5206 601-0 Fax: +49 5206 601-200 Mail: info@boge.com Net: www.boge.com

Issue: 12 / 2011

No. 596.1191.18

Nominal price: € 5,00

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page I

Index

Part 1: General

Part 2: Product description

1.1 General safety instructions ........................................................... 1

Safety instructions for compressor operation ................................... 1

Safety instructions for maintenance and repair of the compressor... 2

Accident prevention regulations........................................................ 2

1.2 Introduction..................................................................................... 3

Symbols used ................................................................................... 4

Intended use ..................................................................................... 7

Foreseeable misuse ......................................................................... 7

Transport damage ............................................................................ 8

Data on the type plate....................................................................... 8

Service.............................................................................................. 8

2.1 Technical data................................................................................. 9

2.2 Function description .................................................................... 10

Function principle of the air end...................................................... 10

Air circuit ......................................................................................... 11

Oil circuit ......................................................................................... 12

2.3 Compressor control ..................................................................... 13

Network pressure............................................................................ 13

Operating states ............................................................................. 13

Operating modes ............................................................................ 13

Short operating times...................................................................... 14

2.4 Control devices............................................................................. 14

Operating pressure sensor ............................................................. 14

2.5 Safety and monitoring devices.................................................... 14

General ........................................................................................... 14

Safety valve .................................................................................... 15

Safety temperature limiting device.................................................. 15

Monitoring the drive motor .............................................................. 15

Part 3: Installation

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page III

3.1 Transport and storage.................................................................. 17

General ........................................................................................... 17

Transport possibilities ..................................................................... 17

Intermediate storage....................................................................... 18

Index

3.2 Compressor room......................................................................... 19

Installation, maintenance conditions and application for com-

pressed air receivers arranged below or separately ....................... 19

Installation surface.......................................................................... 19

Fire protection................................................................................. 19

Sound protection............................................................................. 20

Admissible environmental influences.............................................. 20

Ventilation ....................................................................................... 20

Cooling air requirement .................................................................. 21

Condensate disposal ...................................................................... 21

3.3 Installation..................................................................................... 22

General ........................................................................................... 22

Checking the delivery scope........................................................... 22

Installing the compressor................................................................ 22

Connecting the compressor to the compressed air network........... 23

Checking the oil level...................................................................... 23

Part 4: Faults

Part 5: Maintenance

3.4 Electrical connection.................................................................... 23

3.5 Commissioning............................................................................. 24

Check installation requirements...................................................... 24

Checking the rotational direction .................................................... 25

Check compressed air outlet for tightness...................................... 25

Opening the stop valves ................................................................. 26

Checking for leaks .......................................................................... 26

Conduct trial run ............................................................................. 26

Commissioning following extended stoppages............................... 26

Refrigeration compressed air dryer ................................................ 27

3.6 Dismantling ................................................................................... 28

4.1 General .......................................................................................... 29

4.2 General faults................................................................................ 29

5.1 Safety instructions ....................................................................... 31

5.2 General .......................................................................................... 32

Maintenance through BOGE service .............................................. 32

Review of regular maintenance work.............................................. 32

Maintenance intervals..................................................................... 33

General information concerning the lubricants used ...................... 35

Disposal of used operating material ............................................... 36

Pressure hoses............................................................................... 36

Spare and wearing parts................................................................. 36

Page IV BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Index

5.3 Regular maintenance work .......................................................... 37

Clean or change suction filter ......................................................... 37

Cleaning the filter cartridge............................................................. 37

Drive motors with permanent lubrication ........................................ 38

Checking the oil level, topping up oil .............................................. 38

Changing the oil filter ...................................................................... 39

Changing the oil separator.............................................................. 40

Oil change....................................................................................... 42

Flushing the oil circuit ..................................................................... 44

Cleaning the compressed air/oil cooling unit .................................. 44

Checking the safety valve............................................................... 45

Nozzle with dirt catch...................................................................... 45

5.4 Spare parts and optional equipment .......................................... 47

List of spare and wearing parts (for maintenance) ......................... 47

List of available optional equipment................................................ 47

Part 6: Appendix

6.1 Flow chart...................................................................................... 49

Air cooled version, standard ........................................................... 50

6.2 List of maintenance and service work........................................ 52

BOGE Operating instructions for C 10 L...C 20 L 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 compressor operation

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 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. Do not exceed the limit value for the final compression pressure specified on the type plate.

6. 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.

7. 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.

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

9. 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.

10. 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.

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

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 1

General 1.1 General safety instructions

Safety instructions for maintenance and repair of the compressor

Caution!

Only use original spare parts, compressor oils and operating materials released by BOGE during repair or maintenance!

Attention: High 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.

3. Prior to maintenance or repair work:

– Switch off the main switch.

– Secure main switch against unintentional switch-on.

– Check to ensure that all parts are currentless.

– Disconnect the compressor from the compressed air network (relieve

or block pressurized lines).

4. Exercise extreme caution during repair or maintenance work requiring the compressor to be operational. Ensure that 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. The operator is responsible to check the compressor daily for externally visible damage and defects, and to immediately report any changes (including operational behaviour).

8. 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

Page 2 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

The owner of a compressor plant is required to ensure that it is properly installed, operated and maintained.

For operation of the compressor plant, the accident prevention regulations of the owner country must be observed in addition to the data contained in these operating instructions.

General 1.2 Introduction

In the event that measures are required above and beyond the legal regulations 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.

WARNING!

Failure to adhere to these recommendations can result in mechanical failure, property damange and serious injury or death.

All air and water inlet as well as air and water discharge pipework to and from the inlet and discharge port connections must be designed in such a way as to take into account vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In addition, it should be noted that lubricated compressors will discharge some oil into the air stream; there fore, compatibility between discharge piping, system accessories and software must be assured.

For those reasons, the use of plastic piping and soldered copper fittings as discharge piping is not recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the operating parameters of the system.

It is the responsibility of the installer and owner to provide the appropriate service pipework to and from the machine.

WARNING!

Statement concerning inadvertent breathing of compressed air exhaust.

The purchaser/user must ensure that adequate ventilation and make-up air are provided if a non-BAP designated compressor is likely to discharge air into a confined area harboring air consuming devices such as air motors, air tools, solenoids, air cylinders, air guns, nozzles, etc. The compressed air dis charge stream may contain residual coolants/lubricants/carbon monoxide and condensable hydrocarbons or other materials which may be hazardous to health with prolonged inhalation.

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. Ob serving 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 con tains data concerning spare and wearing parts.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 3

General 1.2 Introduction

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

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 envi ronmental protection.

In the illustrations, the compressor is shown in part without safety cladding or safety devices for better visualization. However, operation without these com ponents is prohibited!

Symbols used

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

DANGER: Risk of injury!

This symbol indicates information warning of possible danger to life and limb of the operator or other persons.

CAUTION!

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.

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.

Page 4 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

General 1.2 Introduction

DANGER

Discharge air. Can contain carbon monoxide or other contaminants. Will cause severe injury or death.

Do not breathe this air.

NOTICE

Refer to the Instruction/ Operators Manual before performing any maintenance.

Warning:

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

WARNING

Hazardous voltage. Can cause severe injury or death.

Disconnect power before servicing. Lockout/Tagout machine.

Before working at the compressor:

– disconnect all current-carrying parts! – check if all parts 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 weekly, 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 10 L...C 20 L series screw compressors Page 5

General 1.2 Introduction

WARNING

Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

WARNING

High pressure air. Can cause severe injury or death.

Relieve pressure before removing filter plugs / caps, fittings or covers.

WARNING

Exposed fan blade. Can cause severe injury.

Do not operate with covers removed. Disconnect power. Lock and tag.

NOTICE

Rotation.

High pressure air. Can cause severe injury or death.

Relieve pressure before removing filter plugs / caps, fittings or covers.

WARNING

Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

NOTICE

Lift here.

WARNING

Hot surface. Can cause severe injury.

Do not touch. Allow to cool before servicing.

NOTICE

Rotation.

Page 6 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

General 1.2 Introduction

Intended use

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.

Operation and control are designed to be executed by trained and authorized operators.

The emergency stop device of the compressor (emergency stop switch/button) is exclusively intended to switch off the compressor in case of emergency.

Foreseeable misuse

Never direct the produced compressed air towards persons.

Danger to life!

WARNING!

Statement concerning the use of this equipment for breathing air and/ or aqua lung service. If the model number on this air compressor contains

the letters "BAP", the compressor is suitable for use in breathing air services. In the absence of such a designation, the compressor is NOT considered as capable of producing air of brathing quality. For a compressor to be capable of use in breathing air services it must be fitted with additional specialized equipment to properly filter and/or purify the air to meet all applicable federal, state and local laws, rules, regulations and codes, such as, but not limited to, OSHA 29 CFR 1910.134, Compressed Gas Association Commodity Speci fication G-7, 1-1966, Grade D Breathing Air and/or Canadian Standards Association. Should the Purchaser and/or User fail to add such specialized equipment and proceeds to use the compressor for brathing air service, the Purchaser/User assumes all liability resulting therefrom without any respon sibility or liability being assumed by BOGE COMPRESSORS.

The Purchaser is urged to include the above provision in any agreement for any resale of this compressor.

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:

– 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.

– Operation of the compressor with removed cladding or safety devices.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 7

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,

ces and packing material in the same condition as they were in when the

devi damage was detected.

In the event of any other complaints, please infor rival of the delivery.

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

m us within six days after ar-

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 to prevent any delays:

–Type

– Year of manufacture

– Machine number

Attention!

Only BOGE service technicians or persons authorized by BOGE in writing may repa warranty claims will expire!

ir or alter the compressor during the warranty period. Otherwise all

following data of your compressor

Page 8 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Product description 2.1 Technical data

Part 2: Product description

2.1 Technical data

Technical data for C 10 L...C 20 L compressor assembly, part 1

Type C 10 L C 15 L C 20 L Dimensions

– Width [inch] 46.1 52.5 52.5 – Depth [inch] 23.6 24.2 24.2 – Height [inch] 23.4 25.3 25.3

Weight

– silenced [lbs.] 313.2 361.4 361.4 Max. sound pressure level [± 3 dB(A)]

accord. to DIN 45635, part 13 – silenced / super silenced [dB(A)] 68 75 75

Reference surface measure – silenced / super silenced [dB(A)] 13 13 13

Sound power level – silenced / super silenced [dB(A)] 81 88 88

Compressor

max. final compression temperature [°F] 230 230 230 Volume flow according to

ISO 1217 appendix C at: – p

= 115 psig [cfm] – 69 –

max

– p

= 150 psig [cfm] 36 – 77

max

Drive motor

Rated power [Hp] 10 15 20

Nominal speed

– 60 Hz [min Protection type TEFC TEFC TEFC ISO class F F F

Electrical connection

Mains voltage Frequency Recommended fuse protection

Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.

The fuse values change in the case of other mains voltages and frequencies.

Use fuse Class RK 5 only.

2) 3)

-1

] 1800 3600 3600

[V]

[Hz]

[A] [V]

[Hz]

[A] [V]

[Hz]

[A] [V]

[Hz]

[A]

200

60 40

208 – 230

60 40

460

60 25

575

60 15

200

60 70

208 – 230

60 60

460

60 30

575

60 30

200

208 – 230

460

575

60 70

60 60

60 30

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 9

Product description 2.2 Function description

Technical data for C 10 L...C 20 L compressor assembly, part 2

Type C 10 L C 15 L C 20 L

Oil filling quantity

Total oil filling quantity [gallon] 2.12 2.12 2.12

Oil topping up quantity between min. + max. [gallon] 0.264 0.264 0.264

Intake air temperature

– min. [°F] + 41 + 41 + 41

– max. [°F] + 104 + 104 + 104

Cooling air requirement

– free-standing installation [cfm] 1765 2825 2825

Operating pressure values

(factory settings) – p

= 115 psig: Switch-off press. p

max

Switch-on press. p

– p

= 150 psig: Switch-off press. p

max

Switch-on press. p

Safety valve

Activation pressure at: – p

= 115 psig [psig] – 160 –

max

– p

= 150 psig [psig] 160 – 160

max

Compressors for other operating pressures p

[psig] – 115 –

max

[psig] – 100 –

min

[psig] 150 – 150

max

[psig] 135 – 135

min

= p

– 15 psig.

min

max

Function principle of the air end

2.2 Function description

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.

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.

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.

Page 10 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Product description 2.2 Function description

Air circuit

Fig. 2.1: Components of the air circuit

1 Intake filter

The intake filter cleans the air suctioned by the air end.

2 Intake regulator

The intake regulator 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 receiver

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 com pressor 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.

* Optionally for receiver systems without refrigeration compressed air dry-

ers

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 11

Product description 2.2 Function description

Oil circuit

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

– It dissipates the compression heat (cooling).

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

– It lubricates the bearings.

Fig. 2.2: Components of the oil circuit

1 Compressed air/oil separation chamber

The oil separated from the compressed air through the force of gravity col-

lects in the compressed air/oil receiver.

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 receiver together with the

compressed air. There, it is separated through the force of gravity.

6 Drainage line with dirt trap

The air end suctions the residual oil which collects in the oil separator

back into the oil circuit via a drainage line.

Page 12 BOGE Operating instructions for C 10 L...C 20 L 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 dur ing 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 pmax the compressor switches

to standstill. It does not consume any energy.

– Once the pressure has dropped to the switch-on pressure pmin the

compressor 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 pmax the compressor switches

to idling operation.

– Once the pressure has dropped to the switch-on pressure pmin the

compressor switches from idling operation back to load operation.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 13

Product description 2.4 Control devices

Short operating times

Attention!

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.

2.4 Control devices

Operating pressure sensor

General

The operating pressure sensor allows controlled operation of the compressors within the set switching limits.

Switch-on pressure p

If the supply pressure drops to the set switch-on pressure p switches on.

Switch-off pressure p

If the supply pressure increases to the switch-off pressure p sor either switches off (intermittent operation) or switches to idling operation (continuous operation).

min

max

, the compressor

min

, the compres-

max

2.5 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.

Caution: 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:

Page 14 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Product description 2.5 Safety and monitoring devices

Safety valve

Safety temperature limiting device

The safety valve (1) on the compressed air/oil receiver prevents the maximum admissible pressure being exceeded.

When the maximum pressure is exceeded (e.g. incorrect setting of the operating pres sure value), the entire delivery volume of the compressor is ejected.

Fig. 2.3: Safety valve

Caution: 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 safety temperature limiting device switches off the compressor once the maximum admissible final compression temperature has been reached. The compressor does not switch on when dropping below the minimum tempera ture.

– Rectify the fault.

– Acknowledge fault by pressing ENTER key .

– Switch on the compressor (ON-button).

Monitoring the drive motor

The drive motor is monitored by PTC resistors.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 15

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!

Attention!

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 com pressor!

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

Forklift truck or lifting cart transport

Attention!

Inappropriate transport may lead to compressor damages. Do not subject the safety cladding to force during transport.

Fig. 3.1: Transport with forklift truck

Ensure that the forks are underneath the base frame of the compressor (see illustra tion).

See below if there is no base frame (crane transport).

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 17

Installation 3.1 Transport and storage

Crane transport

Attention!

Inappropriate transport may lead to compressor damages. Do not subject the safety cladding to force during transport.

– Only lift compressor by using the supplied transport pallet.

– Protect the compressor using wooden spacers (see arrows in the illus-

tration below).

– Remove transport timber.

– Only use suitable transport slings having a minimum length of approx.

315 inches!

Place loops of the transport slings at the head sides underneath the supplied transport pallet 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.

Note!

In case of an intermediate storage please observe the specifications and directions as to permissible environmental impacts (see chapter „ pressor room: Installation, maintenance conditions and application for compressed air receivers arranged below or separately“).

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 „ than two months.

3.5 Commissioning“) if the intermediate storage takes longer

3.2 Com-

Page 18 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Installation 3.2 Compressor room

3.2 Compressor room

Installation, maintenance conditions and application for compressed air receivers arranged below or separately

–Caution!

– 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 dur ing 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).

– 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 ∆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:

–Caution!

– For compressors with motor ratings exceeding 55 Hp, ensure that the

compressor room is equipped with special fire protection.

– Install compressors with motor ratings exceeding 136 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 10 L...C 20 L series screw compressors Page 19

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 10 ft

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 ambient temperatures

Maximum ambient temperature (for colling): + 104°F

Minimum ambient temperature: + 41°F

Attention!

Nonobservance 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.

– BOGE anti-frost facility (series).

Ventilation

Page 20 BOGE Operating instructions for C 10 L...C 20 L 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.

Caution!

Arrange the compressor intake openings or ducts such, 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

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 a free-standing installation, the cooling air requirement specified in the

table corresponds to the required ventilator capacity.

Cooling air requirement

Condensate disposal

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 recom mend contacting a specialist company for performing the duct construction work and planning.

Type Drive rating * Cooling air

requirement

for free

standing unit

[Hp] [cfm] [sq. ft.]

C 10 L C 15 L C 20 L

* For the cooling air requirements the basis is a 39°F temperature difference between room and outside tempera-

ture.

Table 3.1: Cooling air requirement, necessary aperture dimensions.

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

10 15 20

1766 2825 2825

Necessary

inlet opening

for free

standing unit

4.3

7.0

Attention!

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.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 21

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.

Caution!

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.

– For compressor assemblies of the series C 10 L to C 20 L the operating

height of he control has to be 16 inches. For this reason the compressor assembly has to be installed on a console or pedestal (on site).

– The compressors have to be installed in such a manner that an ergonom-

ically convenient operation from the operator's stand is guaranteed.

Page 22 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Installation 3.4 Electrical connection

Connecting the compressor to the compressed air network

Checking the oil level

– Connect the compressor to the compressed air network or a compressed

air receiver. For this, use a BOGE high pressure hose. Pneumatic connection see scale drawing.

Note!

Do not install a check valve in the pressure line.

The compressor is already equipped with a check valve.

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

Caution: High 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 local safety regulations.

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

Mains disconnecting device

According to accident prevention regulations, the customer is responsible to provide the following safety measures:

All Compressor plants have to be equipped with a power disconnecting device.

Please refer to the "Technical data" for the design and fuse rating.

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.

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.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 23

Installation 3.5 Commissioning

Caution: Risk of injury!

Prior to any work on the compressor:

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

– 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.

Caution!

With an activated automatic restart (Auto-Restart) the compressor may restart automatically after a voltage failure. Prerequisite: The network pressure is lower than the set cut-in pressure of the operating switch and it was al ready switched on before the mains failure – green indicator lamp = ON.

Check installation requirements

3.5 Commissioning

Note!

We recommend the drawing up of a commissioning certificate in which the test results during the commissioning process can be listed up.

Caution: 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!

Attention!

Make sure that the compressor is installed according to the installation requirements!

List up the test results in the commissioning certificate.

Page 24 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Installation 3.5 Commissioning

Checking the rotational direction

Attention!

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.

seconds) may cause total destruction of the air end!

List up the test results in the commissioning certificate.

Caution!

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

– Switch on the main switch.

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

tional direction.

Check compressed air outlet for tightness

Changing the rotational direction

Caution: Risk of injury!

Switch off the main switch and secure against unintentional switching-on.

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

Caution: 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!

– Close mains disconnecting device.

– To conduct the inspection switch on the compressor and check the com-

pressed air outlet for tightness.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 25

Installation 3.5 Commissioning

– Switch off compressor.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

– If necessary, have leakages repaired by skilled qualified pesonnel.

List up the test results in the commissioning certificate.

Opening the stop valves

Checking for leaks

Conduct trial run

Open ball valve on the compressor delivery.

Caution: 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.

– Switch on the main switch.

– 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.

– The compressor is ready for operation.

Commissioning following extended stoppages

Page 26 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

If an extended stoppage is scheduled, you should contact BOGE-Service beforehand.

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

Attention!

Only fill the suction controller with the grade of oil used to operate the compressor.

Never mix different oil grades and brands.

Installation 3.5 Commissioning

Caution: Risk of injury!

Switch off the main switch and secure against unintentional switching-on.

– Unscrew the plug on the

– Fill approx. 0.026 gallon

– Reclose the controller

– Prior to switching on the

– After approx.10 sec. the

suction controller (1).

compressor oil into the suction controller.

using the plug.

compressor wait for ap prox.10 min until the oil has spread evenly. Then switch the compressor

and immediately off

on again.

compressor can be start ed.

Refrigeration compressed air dryer

Fig. 3.3: Suction controller

Before commissioning the refrigeration compressed air dryer read attached operating instructions.

Caution: Risk of injury!

Observe all safety notes specified in the attached operating instructions when working with coolants!

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 27

Installation 3.6 Dismantling

3.6 Dismantling

Note!

To avoid dangers when dismantling the compressor please consult your BOGE Service:

Telephone: +1-770-874-1570

Telephone: +49 5206 601-140

Caution!

Dismantling of the compressor may only be carried out by experienced and authorized qualified personnel!

Make also sure to observe all information in the attached operation instructions as to a safe dismantling of the refrigeration compressed air dryer and a secure disposal of the coolant!

Caution: High 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!

Page 28 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Faults 4.1 General

Part 4: Faults 4.1 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 oper ating instructions of the compressor control).

Caution!

Ensure that any work required to rectify faults is only carried out by trained personnel or specialists.

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 number, if you have any questions.

Telephone: +1-770-874-1570

Telephone: +49 5206 601-140

Caution: High voltage!

Prior to any work required to rectify faults:

Open mains disconnection device and secure against unintentional switch on by means of a padlock.

4.2 General faults

Fault Possible cause Rectification

No quantity delivered, no pressure build-up, max. pressure 0,5 bar

System components in the compressor are leaking

Minimum pressure valve is defective

Electromagnetic venting valve does not close

Suction controller does not open Suction controller or solenoid valve is defective; check and replace,

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

if necessary

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 29

Faults 4.2 General faults

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

Voltage fluctuations in the electrical mains power

Compressor oil is very viscous due to low ambient temperature

valve is leaking

Suction controller is leaking

Cut-out performed by emergency-stop button

Drain line is blocked Dismantle and clean nozzle with dirt catch

Defective oil separator element Check oil separator and replace, if necessary

Check venting valve and replace, if necessary

Ensure constant voltage in accordance with IEC 38

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

Check the minimum pressure check valve and replace, if necessary

Check the suction controller and replace, if necessary

Cut-out normally via O-key

Excessive oil filling Drain off oil

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 venting valve and replace, if necessary

Check valve is leaking Check the check valve and replace, if necessary

Set operating pressure to maximum permissible pressure of the screw compressor

Page 30 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.1 Safety instructions

Part 5: Maintenance 5.1 Safety instructions

Caution!

Ensure that maintenance work is ony carried out by specialists or appropriately trained person.

– Prior to starting any maintenance work, always stop the compressor as

described in these operating instructions prior to removing any safety cladding or safety devices. Refit the safety 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.

Caution: 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. Switch off the main switch and secure against unintentional switching-on.

3. Check to ensure that all machine elements are definitely currentless.

4. Separate the compressor from the compressed air network by closing

the ball valve at the compressed air outlet.

5. Vent the compressor.

To this effect open the safety valve on the combined compressed air-oil receiver as follows:

– Turn the knurled nut counterclockwise until you can feel a resilient

resistance.

– Turn the knurled nut a little further.

Any possibly existing air will escape.

– Once the residual air has completely escaped from the system, firmly

retighten the knurled nut.

Once the maintenance work has been concluded:

6. Open the ball valve at the compressed air outlet.

7. Prior to switching on again, check whether anyone else is working on the

compressor.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 31

Maintenance 5.2 General

5.2 General

Maintenance through BOGE service

Review of regular maintenance work

Have BOGE service check your compressor every 3,000 operating hours or annually.

Note!

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. 5.1: Review of regular maintenance work

1 Check / adjust pressure

2 Clean oil cooler

3 Top up oil in the suction controller after an extended down time

4 Check suction filter

– Clean / Change filter cartridge

5 Change oil separator

6 Change oil filter

7 Replace nozzle with dirt catch

8 – Check oil level

– Top up oil

9 Change oil

Page 32 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.2 General

Maintenance intervals

The maintenance intervals specified in the table are based on average operating and ambient conditions.

Extreme conditions may require shorter maintenance intervals.

Note!

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

Attention!

Check monthly if all screw connections on the compressor are fully tightened.

Please change oil and replace oil filter and nozzle with dirt catch after the first 500 operating hours!

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 33

Maintenance 5.2 General

Maintenance work Maintenance intervals in operating hours

weeky,

monthly

1,000

annually

1,500

annually

3,000

annually

Page

9,000 every

2 years

General maintenance work

Check final compression temperature (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 button m -

Clean oil cooler X 44

Draining off condensate from compr. air receiver w –

Check automatic condensate drainage w –

Check if electrical connections are tightened X –

Air circuit

Check and if necessary clean suction filter m 37

Change suction filter cartridge X 37

Check safety valve X 45

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

X 38

X 40

X 39

X 42

Replace oil regulator (wearing parts set) X –

Replace nozzle with dirt catch X 45

Drive

Lubricate drive motor bearings Drive motors with permanent lubrication 38

Replace motor bearing Depending on mains frequency: 50 Hz 10,000 operating hours

60 Hz 8,000 operating hours

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.

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!

Table 5.1: Maintenance intervals

Page 34 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.2 General

General information concerning the lubricants used

Caution: 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.

– Do not eat or drink when working with oil!

– Fire, naked flames and smoking is stricltly prohibited when handling oil.

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 1,000 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 2,400 minutes.

– Or you use BOGE compressor oil Syprem 8000 S. The stated maintenance

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.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 35

Maintenance 5.2 General

Disposal of used operating material

Attention!

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

Please instruct one of the known service companies to dispose of 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

Caution!

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

Caution!

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.

Attention!

If the nozzle with dirt catch is soiled the oil consumption may increase significantly (see fig. 5.10)!

Page 36 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.3 Regular maintenance work

5.3 Regular maintenance work

Clean or change suction filter

Cleaning:

– 1 x 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.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

Removing the filter cartridge

Remove lid (1) of the filter housing.

Remove filter cartridge (2).

Fig. 5.2: Changing the suction filter

Cleaning the filter cartridge

Attention!

Do not clean filter cartridges in liquids. Do not use any hard objects when cleaning to avoid damaging the filter pa-

per. Refit a new filter cartridge in the event of damage or once it has been cleaned

twice.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 37

Maintenance 5.3 Regular maintenance work

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

dust.

– Blow out fine dust from the inside to the outside using dry compressed

air (maximum pressure 72.5 psig).

– Clean the sealing surface of the filter cartridge.

Fitting a filter cartridge

– Insert filter cartridge into the filter housing.

– Attach lid of the filter housing.

Drive motors with permanent lubrication

Checking the oil level, topping up oil

As a rule, the bearings of the drive motors are provided with a maintenance free permanent lubrication.

Under normal operating conditions (coolant temperature max. 104°F, continous operation) the bearings are maintenance free for the service life.

For motor maintenance see operating instructions of the compressor comtrol.

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

Attention!

Have BOGE service dismantle the bearings and install new bearings once the specified service life has expired.

Check:

– Prior to commissioning/start-up of the compressor.

– Then every 1,000 operating hours, however at least once a year.

Topping up:

– If the oil has dropped to a level 0.4 – 0.8 inch below the bottom edge of the

thread.

Attention!

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

– Switch off the compressor using the OFF button.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

Page 38 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.3 Regular maintenance work

– 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.

Caution: Risk of injury!

Danger of burning due to hot oil!

Always wear safety gloves!

– Remove plug (2) of oil fill-

ing socket(1).

– Check oil level.

The oil level must not drop to a level more than

0.8 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 ball valve at the

compressed air outlet.

Changing the oil filter

Fig. 5.3: Checking the oil level, topping up with oil

Change:

– If mineral or food-suited oils are to be used,

please be advised that the oil filter must be replaced after the first 500 operating hours.

– After 3,000 operating hours, however, no later than after one year.

– With each oil change!

– Switch off the compressor using the OFF button.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 39

Maintenance 5.3 Regular maintenance work

– Close ball valve at the compressed air outlet.

– Vent the compressor (procedure as described above).

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

Caution: Risk of injury!

Do not touch hot surfaces!

– Losen screws at service cover (3) and pull out cover with oil filter cartridge.

– Unscrew oil filter cartridge (4) from cover (3), place new oil filter cartridge

into the maintenace cover and reattach both. Make sure that the bore hole (5) and the bore hole in the cover fit on top of each other.

– Check o-rings on service cover for damage and replace if necessary.

– Screw on service cover (3) and tighten screws.

– Open ball valve at the compressed air outlet.

– Switch on compressor and run till it reaches operating temperature.

– Check tightness of service cover and re-tighten screws.

Fig. 5.4: Changing the oil filter / Changing the oil separators

Changing the oil separator

Change:

– When warning message "8" appears on the control system display

(FOCUS only).

– After 3,000 operating hours, however, no later than after one year.

Caution: 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.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

Page 40 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.3 Regular maintenance work

– 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.

Caution: Risk of injury!

Danger of burning due to hot oil!

Always wear safety gloves!

– Remove cladding from

the service side.

– Unscrew soiled oil sepa-

rators (4) by hand or use a strap wrench, turning counterclockwise.

– Catch the draining oil and

dispose of properly ac cording to environmental regulations.

– Lightly oil the sealing

rings of the new oil sepa rator.

– Screw in new oil separa-

tors (4) by hand, turning clockwise.

Fig. 5.5: Changing the oil separators

Attention!

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

– Open ball valve at the compressed air outlet.

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

– Check the oil separators for leaks once again (procedure as described

above).

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

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

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 41

Maintenance 5.3 Regular maintenance work

Oil change

Change:

– After 9,000 operating hours, however, at the latest after two years.

– For other types of oil the appropriate oil change intervals must be complied

with.

Note!

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 discharge of the oil from the compressed air/oil chamber or to overcome a height difference, a small pressure cushion (approx. 22 psig system pressure) can be built up. This pressure cushion forces the oil through the drain hose into a suitable collecting basin.

– Switch off the compressor using the OFF button.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

Draining old oil

– Switch off compressor. After ap-

prox 2 sec. screw cap nut (5) on the bleed aperture of the mag netic valve (the nut is located in the storage compartment of the switch cabinet).

Fig. 5.6: Solenoid valve on the suction controller with the cap nut screwed on

Caution: Risk of injury!

Danger of burning due to hot oil!

Always wear safety gloves!

Page 42 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.3 Regular maintenance work

– Remove blind plug (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. 5.7: Oil drain from oil compressed air receiver

– 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).

Attention!

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.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

– 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.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 43

Maintenance 5.3 Regular maintenance work

Flushing the oil circuit

Cleaning the compressed air/oil cooling unit

Flushing the oil circuit with clean oil becomes necessary:

– When the oil is excessively soiled.

– Prior to changing the oil type.

Attention!

Detailed information as to the flushing with BOGE oils you can obtain from the following service number:

Telephone: +1-770-874-1570

Telephone: +49 5206 601-140

Cleaning:

– After 1,500 operating hours, however, at the latest after one year.

Note!

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 soil ing of the cooling unit leads to an increased temperature in the oil circuit.

– Switch off the compressor using the OFF button.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

Attention!

Do not use any sharp objects for cleaning!

These could damage the cooling unit.

– Blow down the dirt with

compressed air in the opposite direction to 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 com pressed air), have it disassembled and cleaned by BOGE service.

Fig. 5.8: Cleaning the compressed air/oil cooling unit

Page 44 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.3 Regular maintenance work

Checking the safety valve

Check:

– After approx. 3,000 operating hours, however, at least once a year.

Check safety valve by opening the screw plug (1).

Caution: 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!

– Open the threaded plug

(1) counterclockwise. The air-oil mixture escapes.

– Tighten the threaded plug

by turning clockwise.

Nozzle with dirt catch

Fig. 5.9: Check safety valve

Change:

– After 3,000 operating hours, however, no later than after one year.

Attention!

If the prescribed maintenance intervals are not complied with, the residual oil content in the compressed air rises considerably.

– Switch off the compressor using the OFF button.

Caution: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on by means of a padlock.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 45

Maintenance 5.3 Regular maintenance work

– 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.

– Screw out plug (1) and nozzle (2).

– Pull out dirt catcher (3): to do so take a screw e.g. M5 x 25, screw it into

the dirt catcher and pull it out

– The reassembly has to be performed in the reverse order. First the dirt

catcher plug

(3) and the nozzle (2) and then finally close the bore (4) with the

(1).

Fig. 5.10: Nozzle with dirt catch

Page 46 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Maintenance 5.4 Spare parts and optional equipment

5.4 Spare parts and optional equipment

List of spare and wearing parts (for maintenance)

List of available optional equipment

Designation

Compressor oil Syprem 8000 S

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

Attention!

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

– Type

– Year of manufacture

– Machine number

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 47

Appendix 6.1 Flow chart

Part 6: Appendix 6.1 Flow chart

On the following page you will find the individual flow chart for your machine type and components.

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 49

Appendix 6.1 Flow chart

Air cooled version, standard

Page 50 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

Appendix 6.1 Flow chart

101 Intake air INLET

102 Compressed air OUTLET

1 Suction filter

4 Suction controller

5 Ventilation and regulation control valve

7 Drive motor

8 Compressor air end

9 Final compression temperature display and switch

10 Combined compressed air/oil receiver

11 Oil separator

12 Safety valve

15 Compressed air after-cooler

Optionally for receiver systems without refrigeration compressed air dryer

16 Thermostatic oil control valve

17 Oil cooler

18 Oil filter

21 Minimum pressure check valve

23 Network pressure transmitter

24 Pressure gauge reading in display

25 Stop valve, compressed air outlet

27 Stop valve, oil drainage

28 Throttle with filter

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 51

Appendix 6.2 List of maintenance and service work

6.2 List of maintenance and service work

Remarks

columns

Com-

pressed

air dryer

Motor

nance

mainte-

unit

Cooling

cleaning

Oil

separator

Oil-

level

Oil

filter

Intake

rature

Tempe-

Please note the completed maintenance work in the respective

System

pressure

Control

Network

pressure

hours

Operating

Date

Page 52 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

** Co =

Cleaning

* Cl =

Change

Ch =

Change

Ch =

Appendix 6.2 List of maintenance and service work

Remarks

Com-

pressed

air dryer

Motor

nance

mainte-

unit

Cooling

cleaning

Oil

separator

Oil-

level

Oil

filter

Intake

rature

Tempe-

Please note the completed maintenance work in the respective columns

System

pressure

Control

Network

pressure

hours

Operating

Date

BOGE Operating instructions for C 10 L...C 20 L series screw compressors Page 53

** Co =

Cleaning

* Cl =

Change

Ch =

Change

Ch =

Appendix 6.2 List of maintenance and service work

Remarks

Com-

pressed

air dryer

Motor

nance

mainte-

unit

Cooling

cleaning

Oil

separator

Oil-

level

Oil

filter

Intake

rature

Tempe-

Please note the completed maintenance work in the respective columns

System

pressure

Control

Network

pressure

hours

Operating

Date

Page 54 BOGE Operating instructions for C 10 L...C 20 L series screw compressors

** Co =

Cleaning

* Cl =

Change

Ch =

Change

Ch =

Boge C 10 L, C 15 L, C 20 L Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General 1.1 General safety instructions

Part 1: General 1.1 General safety instructions

Safety instructions for compressor operation

Safety instructions for maintenance and repair of the compressor

Accident prevention regulations

1.2 Introduction

Symbols used

Intended use

Foreseeable misuse

Transport damage

Data on the type plate

Service

Product description 2.1 Technical data

2.1 Technical data

Function principle of the air end

2.2 Function description

Air circuit

Oil circuit

2.3 Compressor control

Network pressure

Operating states

Operating modes

Short operating times

2.4 Control devices

Operating pressure sensor

General

2.5 Safety and monitoring devices

Safety valve

Safety temperature limiting device

Monitoring the drive motor

Installation 3.1 Transport and storage

Part 3: Installation 3.1 Transport and storage

General

Transport possibilities

Intermediate storage

3.2 Compressor room

Installation, maintenance conditions and application for compressed air receivers arranged below or separately

Installation surface

Fire protection

Sound protection

Admissible environmental influences

Ventilation

Cooling air requirement

Condensate disposal

3.3 Installation

General

Checking the delivery scope

Installing the compressor

Connecting the compressor to the compressed air network

Checking the oil level

3.4 Electrical connection

Check installation requirements

3.5 Commissioning

Checking the rotational direction

Check compressed air outlet for tightness

Opening the stop valves

Checking for leaks

Conduct trial run

Commissioning following extended stoppages

Refrigeration compressed air dryer

3.6 Dismantling

Faults 4.1 General

Part 4: Faults 4.1 General

4.2 General faults

Maintenance 5.1 Safety instructions

Part 5: Maintenance 5.1 Safety instructions

5.2 General

Maintenance through BOGE service

Review of regular maintenance work

Maintenance intervals

General information concerning the lubricants used

Disposal of used operating material

Pressure hoses

Spare and wearing parts

5.3 Regular maintenance work

Clean or change suction filter