Boge C 16 N, C 20 N, C 30 N, C 16 F N, C 20 F N Operating Instructions Manual

www.boge.com

Operating instructions

Belt-driven

screw compressors

Series

C 16 N...C 30 N

C 16 F N...C 30 F N

Separate manual:

compressor control

frequency converter (C F N)

Operating instructions
for belt-driven
screw compressors

–C16 N (15.0 Hp)

–C20 N (20.0 Hp)

–C25 N (25.0 Hp)

–C30 N (30.0 Hp)

– C 16 F N (15.0 Hp)

–C20F N (20.0 Hp)

–C25F N (25.0 Hp)

–C30F N (30.0 Hp)

IMPORTANT!

READ CAREFULLY BEFORE USE

RETAIN FOR FUTURE REFERENCE

BOGE KOMPRESSOREN
Otto Boge GmbH & Co. KG
Postfach 10 07 13
D-33507 Bielefeld

Otto-Boge-Straße 1-7
D-33739 Bielefeld

Fon: [phone]
Fax: [phone]
Mail: [e-mail]
Net: www.boge.com

Issue: 07 / 2016

No. 596.1188.18

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page I

Index

Index

Part 1:
General

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

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

Special hazard warnings................................................................... 2

Electrical energy hazards ................................................................. 3

Obligations of the owner ................................................................... 3

Personnel requirements.................................................................... 3

Personal protective equipment ......................................................... 4

Safety instructions for maintenance and repair ................................ 4

Accident prevention regulations........................................................ 5

Disposal ............................................................................................ 5

1.2 Introduction..................................................................................... 5

Symbols used ................................................................................... 6

Symbols on the compressor ............................................................. 6

Intended use ................................................................................... 10

Foreseeable Misuse ....................................................................... 10

Transport damage .......................................................................... 10

Data on the type plate..................................................................... 11

Service............................................................................................ 11

Part 2:
Product description

2.1 Technical data – compressor ...................................................... 13

2.2 Function description compressor............................................... 17

Function principle of the air end...................................................... 17

Air circuit ......................................................................................... 17

Oil circuit ......................................................................................... 18

2.3 Water cooling ................................................................................ 19

Water cooling.................................................................................. 19

Series connection ........................................................................... 19

2.4 Cooling water ................................................................................ 19

Water connection (for water cooling) .............................................. 19

Cooling water quality ...................................................................... 20

2.5 Compressor control ..................................................................... 20

Network pressure............................................................................ 20

Operating states ............................................................................. 20

Operating modes ............................................................................ 21

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page III

Index

Control of compressors with frequency control (C F N) .................. 21

Short operating times...................................................................... 21

2.6 Safety and monitoring devices.................................................... 22

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

Safety temperature limiting device.................................................. 22

Safety valve .................................................................................... 22

Monitoring the drive motor .............................................................. 22

Part 3:
Installation

3.1 Transport and storage.................................................................. 23

General ........................................................................................... 23

Transport possibilities ..................................................................... 23

Intermediate storage....................................................................... 24

3.2 Compressor room......................................................................... 25

Installation, maintenance conditions and application for com-

pressed air receivers: receiver mounted or seperately installed..... 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

Connection condensate drain ......................................................... 30

Connecting the compressor to the compressed air network........... 30

Remove cladding ............................................................................ 30

Activating the belt tensioning device............................................... 32

Checking the oil level...................................................................... 32

3.4 Electrical connection.................................................................... 32

3.5 Commissioning............................................................................. 33

Checking installation requirements ................................................. 34

Checking the rotational direction .................................................... 34

Checking compressed air outlet for tightness ................................. 35

Opening the stop valves ................................................................. 35

Checking for leaks .......................................................................... 35

Conducting trial run......................................................................... 36

Commissioning following extended stoppages............................... 36

3.6 Dismantling ................................................................................... 37

Page IV BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Index

Part 4:
Optional equipment

Part 5:
Faults

Part 6:
Maintenance

4.1 BOGE-Duotherm BPT................................................................... 39

Function .......................................................................................... 39

Assembly ........................................................................................ 39

Commissioning ............................................................................... 39

Maintenance ................................................................................... 40

5.1 General .......................................................................................... 41

5.2 Faults – Compressor .................................................................... 41

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 ............................................... 48

Pressure hoses............................................................................... 48

Spare and wearing parts................................................................. 49

6.3 Maintenance work compressor ................................................... 49

Cleaning or changing suction filter.................................................. 49

Cleaning the filter cartridge............................................................. 50

Changing the supply air filter mats ................................................. 50

Drive motors with permanent lubrication ........................................ 51

Changing the V-belt ........................................................................ 51

Settings of the GM-drive system C 16 N...C 30 N,

C 16 F N...C 30 F N ........................................................................ 53

Checking the oil level, topping up oil .............................................. 54

Changing the oil filter ...................................................................... 55

Changing oil separators.................................................................. 56

Oil change....................................................................................... 57

Flushing the oil circuit ..................................................................... 59

Cleaning the compressed air/oil cooling unit .................................. 59

Function check of the safety valve.................................................. 60

Inline filter ....................................................................................... 61

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

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page V

Index

Part 7:
Appendix

7.1 Flow chart...................................................................................... 63

Air cooled version, standard, series C 16 N...C 30 N,

C 16 F N...C 30 F N ........................................................................ 64

Water cooled version, serial connection, series C 16 N...C 30 N,

C 20 F N...C 30 F N ........................................................................ 66

BOGE-Duotherm BPT plate heat exchanger.................................. 68

7.2 List of maintenance and service work ........................................ 69

Page VI BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

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

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

restricted 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 16 N...C 30 N, C 16 F N...C 30 F N 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

devices will cause the safety valve to be activated. There will be risk of
escaping hot air!

Page 2 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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!

– Disconnect mains connection prior to starting to carry out works on the

compressor and use padlock to secure against switching on again.

– Only duly authorized professional electricians (e.g. plant electricians) are

allowed to carry out works in the electrical area of the machine.

– 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

functioning at regular intervals.

– Only use original fuses.

Obligations of the owner

Personnel requirements

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 familiarize per-

sonnel with all information pertaining 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.

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!

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 3

General 1.1 General safety instructions

Personal protective equipment

Safety instructions for maintenance and repair

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 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.

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!

The mains disconnecting device has to meet local requirements!

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:

– Actuate emergency-stop switch/button.

– Open mains disconnecting device.

– Secure mains disconnecting device against unintentional switching on

by means of a padlock.

– 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.

– Check to ensure that all parts are deenergized.

– Disconnect the compressor from the compressed air network (relieve

or isolate 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.

Page 4 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

General 1.2 Introduction

5. Ensure that work on the electrical equipment is only executed by qualified
electricians.

6. Work on parts and devices with power applied 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

Disposal

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.

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 time 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:

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 5

General 1.2 Introduction

– Operation, including fault rectification and daily care

– Maintenance (service, inspection, repair)

– Commissioning

– Transport

The compressor and its ancillary 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: Risk of injury!

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

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.

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.

Symbols on the compressor

NOTICE!

All warning signs on the compressor and in its surroundings must be kept in
a legible condition at all times. Missing or damaged signs must be replaced
at once!

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

Page 6 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

General 1.2 Introduction

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

NOTICE

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

This machine is remote start and
stop equipped.
May start or stop at any time.
Can cause severe injury or death.
Disconnect power before servicing.
Lock and tag out.
See operator's instruction manual.

WARNING

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

Do not breathe this air.

DANGER

Hazardous voltage. Can cause
severe injury or death.

Disconnect power before
servicing.
Lockout/Tagout machine.

WARNING

Improper coolant filter replace­ment will cause compressor
damage.

Replace filter element after first
500 hours of operation and every
3000 hours thereafter or when
coolant is changed.

CAUTION

Moving parts.
Can cause severe injury.

Do not operate with covers removed.
Service only with machine blocked to
prevent turn over.

WARNING

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 7

General 1.2 Introduction

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

Hazardous voltage. Can cause
severe injury or death.

Disconnect power before
servicing.
Lockout/Tagout machine.

WARNING

Exposed fan blade.
Can cause severe injury.

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

WARNING

NOTICE

Rotation.

Page 8 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

General 1.2 Introduction

Moving parts.
Can cause severe injury.

Do not operate with covers removed.
Service only with machine blocked to
prevent turn over.

WARNING

Hot surface.
Can cause severe injury.

Do not touch. Allow to cool before
servicing.

WARNING

NOTICE

Air discharge.

NOTICE

Electrical power inlet.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 9

General 1.2 Introduction

Intended use

WARNING!

BOGE compressors, including their ancillary equipment, are exclusively
intended for the compression of air in industrial applications.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.

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 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.

Transport damage

Page 10 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

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.

General 1.2 Introduction

Otto-Boge-Straße 1–7 · D-33739 Bielefeld · Telefon [phone]
Postfach 1007 13 · D-33507 Bielefeld · Fax [phone]

www.boge.com · [e-mail]

Type
Year of construction
Serial number
F. a.d.

Motor speed
Motor power

Patent No. 5,785,620

cfm

psig

rpm

Maximum service pressure

Hp

Data on the type plate

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.

Fig. 1.1: Data on the type plate

Service

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 11

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

Telephone: [phone]

Telephone: [phone]

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!

Product description 2.1 Technical data – compressor

Part 2: Product description

2.1 Technical data – compressor

Technical data C 16 N...C 30 N, part 1

Type

C 16 N C 20 N C 25 N C 30 N

Dimensions

– Width [inch]
– Depth [inch]
– Height [inch]

28.4 28.4 28.4 28.4

41.6 41.6 41.6 41.6

68.3 68.3 68.3 68.3

Weight

– silenced [lbs.]
– super silenced [lbs.]

––––

1060 1082 1111 1193
Max. sound pressure level [±3 dB(A)]
accord. to DIN 45635, part 13
– silenced / super silenced [dB(A)]

63 65 68 69
Reference surface measure
– silenced / super silenced [dB(A)]

16 16 16 16
Sound power level
– silenced / super silenced [dB(A)]

79 81 84 85

Compressor

max. final compression temperature [°F]

+ 230 + 230 + 230 + 230
Volume flow according to
ISO 1217 appendix C at:
– p

= 100 psig [cfm]

max

– p

= 115 psig [cfm]

max

– p

= 150 psig [cfm]

max

– p

= 190 psig [cfm]

max

70.76 95.47 116.06 135.51*

66.75 90.07 109.49 127.84*

57.57 79.47 95.72 113.36*

47.68 66.75 81.94 95.70*

Drive motor

Rated power [Hp]
Electrical power intake dryer [Hp]

15 20 25 30

––––
Nominal speed
– 60 Hz [rpm]
Protection type
ISO class

3600 3600 3600 3600

TEFC TEFC TEFC TEFC

FFFF

Electrical connection

Mains voltages compressor

Frequency
Fuse protection
Fuse protection
Fuse protection
Fuse protection
Fuse protection

1)

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

2)

Use fuse RK 5 only.

* By using 208 V mains voltage: Volume flow decreases by 10 %.

1)

2)

for 200 V [A]

2)

for 208 V [A]

2)

for 230 V [A]

2)

for 460 V [A]

2)

for 575 V [A]

1)

[V]

[Hz]

208-230 / 208-230 / 208-230 / 208-230 /
460 / 575 460 / 575 460 / 575 460 / 575

60 60 60 60
50 70 90 100
50 70 90 100
50 60 70 100
30 30 40 50
20 30 30 40

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 13

Product description 2.1 Technical data – compressor

Technical data C 16 N...C 30 N, part 2

Type
Oil filling quantity

Total oil filling quantity [gallon]
Oil topping up quantity
between min. + max. [gallon]

Intake air temperature

– min. [°F]
– max. [°F]

Cooling air requirement

– free-standing installation [cfm]
– with supply and exhaust air duct [cfm]

Air cooling

– free fan pressing [psig]
Cooling air requirement
– free-standing installation [cfm]
– with supply and exhaust [cfm]
Required cooling water quantity
– delta t = 15 K [cfm]
– delta t = 30 K [cfm]
Max. cooling water quantity [cfm]
Cooling water inlet temperature
– min. [°F]

Water cooling

– max. [°F]
Cooling water outlet temperature
– max. [°F]
Cooling water pressure
– min. [psig]
– max. [psig]

Operating pressure values

1)

(factory settings)

= 100 psig: switch-off pressure p

– 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

max

min

max

min

max

min

max

max

[psig]
[psig]
[psig]
[psig]

[psig]

[psig]
[psig]
[psig]

Safety valve

Activation pressure at:
– p

= 100 psig [psig]

max

– p

= 115 psig [psig]

max

– p

= 150 psig [psig]

max

– p

= 190 psig [psig]

max

1)

Compressors for other operating pressures p

= p

min

max

C 16 N C 20 N C 25 N C 30 N

2.6 2.6 2.6 2.6

0.3 0.3 0.3 0.3

+ 41 + 41 + 41 + 41

+ 113 + 113 + 113 + 113

2179 2886 3534 4123
1001 1473 1826 2032

0.0087 0.0087 0.0087 0.0087

1178 1178 1178 1178

589 589 589 589

0.35 0.48 0.59 0.71

0.18 0.24 0.3 0.35

0.74 0.74 0.74 0.74

+ 41 + 41 + 41 + 41
+ 86 + 86 + 86 + 86

+ 113 + 113 + 113 + 113

29 29 29 29

145 145 145 145

100 100 100 100

85 85 85 85
115 115 115 115
100 100 100 100
150 150 150 150
135 135 135 135
190 190 190 190
175 175 175 175

160 160 160 160
160 160 160 160
160 160 160 160
203 203 203 203

– 15 psig.

Page 14 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Product description 2.1 Technical data – compressor

Technical data C 16 F N...C 30 F N, part 1

Type

C16F N C20F N C25F N C30F N

Dimensions

– Width [inch]
– Depth [inch]
– Height [inch]

28.4 28.4 28.4 28.4

39.8 39.8 39.8 39.8

68.5 68.5 68.5 68.5

Weight

– silenced [lbs.]
– super silenced [lbs.]

––––

1116 1133 1221 1221
Max. sound pressure level [±3 dB(A)]
accord. to DIN 45635, part 13
– silenced / super silenced [dB(A)]

56 65 68 69
Reference surface measure
– silenced / super silenced [dB(A)]

16 16 16 16
Sound power level
– silenced / super silenced [dB(A)]

72 81 84 85

Compressor

max. final compression temperature [°F]

+ 230 + 230 + 230 + 230
Volume flow according to
ISO 1217 appendix C at:
– p

= 100 psig [cfm]

max

– p

= 115 psig [cfm]

max

– p

= 150 psig [cfm]

max

– p

= 190 psig [cfm]

max

– 95.47 116.06 135.51

69.22 90.07 109.49 127.84

60.39 79.47 95.72 113.36

47.67 66.75 81.94 95.70

Drive motor

Rated power [Hp]

15 20 25 30
Electrical power intake dryer [Hp] – – – –
Nominal speed
– 60 Hz [rpm]
Protection type
ISO class

3600 3600 3600 3600

TEFC TEFC TEFC TEFC

FFFF

Electrical connection

Mains voltages compressor
Frequency
Fuse protection
Fuse protection

1)

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

2)

Use fuse RK 5 only.

1)

2)

for 460 V [A]

2)

for 575 V [A]

1)

[V]

[Hz]

460 / 575 460 / 575 460 / 575 460

60 60 60 60

30 30 40 50

20 30 30 –

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 15

Product description 2.1 Technical data – compressor

Technical data C 16 F N...C 30 F N, part 2

Type
Oil filling quantity

Total oil filling quantity [gallon]
Oil topping up quantity
between min. + max. [gallon]

Intake air temperature

– min. [°F]
– max. [°F]

Cooling air requirement

– free-standing installation [cfm]
– with supply and exhaust air duct [cfm]

Air cooling

– free fan pressing [psig]
Cooling air requirement
– free-standing installation [cfm]
– with supply and exhaust [cfm]
Required cooling water quantity
– delta t = 15 K [cfm]
– delta t = 30 K [cfm]
Max. cooling water quantity [cfm]
Cooling water inlet temperature
– min. [°F]

Water cooling

– max. [°F]
Cooling water outlet temperature
– max. [°F]
Cooling water pressure
– min. [psig]
– max. [psig]

Operating pressure values

1)

(factory settings)

= 100 psig: switch-off pressure p

– 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

max

min

max

min

max

min

max

min

[psig]
[psig]
[psig]
[psig]
[psig]
[psig]
[psig]
[psig]

Safety valve

Activation pressure at:
– p

= 100 psig [psig]

max

– p

= 115 psig [psig]

max

– p

= 150 psig [psig]

max

– p

= 190 psig [psig]

max

1)

Compressors for other operating pressures p

= p

min

max

C16F N C20F N C25F N C30F N

2.6 2.6 2.6 2.6

0.3 0.3 0.3 0.3

+ 41 + 41 + 41 + 41

+ 113 + 113 + 113 + 113

2178 2886 3534 4123
1001 1473 1826 2032

0.0087 0.0087 0.0087 0.0087

– 1178 1178 1178
– 589 589 589

– 0.48 0.59 0.71
– 0.24 0.3 0.35
– 0.74 0.74 0.74

– + 41 + 41 + 41
– + 86 + 86 + 86

– + 113 + 113 + 113

– 29 29 29
– 145 145 145

100 100 100 100

85 85 85 85
115 115 115 115
100 100 100 100
150 150 150 150
135 135 135 135
190 190 190 190
175 175 175 175

160 160 160 160
160 160 160 160
160 160 160 160
203 203 203 203

– 15 psig.

Page 16 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Product description 2.2 Function description compressor

2.2 Function description compressor

Function principle of the air end

Air circuit

The air end operates according to the displacement principle. In the housing,
the main and secondary screws are driven by means of an electric 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.

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.

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 oil separator separates the residual oil contained in the compressed
air.

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.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 17

Product description 2.2 Function description compressor

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.

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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Product description 2.3 Water cooling

2.3 Water cooling

Water cooling

Series connection

BOGE screw compressors are available in water or air-cooled design.

In the standard version, the oil and compressed air after-coolers are connect­ed in series on the water side.

Fig. 2.3: Serial connection

1 Cooling water solenoid valve

The cooling water solenoid valve closed the cooling water supply when
the compressor switches off.

2 Cooling water stop valve (provided by customer)

The compressor may be separated from the cooling water supply by
means of the stop valve (e.g. for maintenance or repair work).

3 Dirt trap (provided by customer)

The dirt trap protects the cooling unit against sedimenting.
Pore size: max. 0.02 inch.

4 Oil cooling unit

5 Compressed air after-cooler

The water cooling units are designed for specific standard cooling water
quantities, temperatures and pressures (see "Technical data"). For indi­vidually fluctuating values, they are designed according to the specified
order data.

2.4 Cooling water

Water connection (for water cooling)

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 19

The cooling water must have the following properties:

Electrical conductivity – > 50 µS/cm at pH value 7 – 9
Carbonate hardness (CaCO
Cooling water pressure – max. 145,0 psig

Cooling water inlet temperature – min. + 41 °F

Max. cooling water quantity see "Technical data".

)– < 284,8 °aH

3

– min. 29,0 psig

– max. + 86 °F

Product description 2.5 Compressor control

Cooling water quality

The cooling units are fitted with nonferrous heat exchangers, as standard. To
avoid damage to these components and to guarantee a long term function, en­sure that the substances contained in the cooling water used do not exceed
the following values.

Substances Symbol max. admissible concentration [ppm]

Ammonia NH

3

< 2

Chloride < 70°F Cl 100

Free chlorine Cl < 5

Iron Fe < 2

Free carbon dioxide CO

2

< 20

Manganese Mn < 1

Nitrate NO

Oxygen O

Silicon oxide SiO

Sulphate SO

3

2

4

< 100

< 2

< 8

2

< 60

Total dissolved solids TDS < 600

Tab. 2.1: Maximum admissible concentration of the substances

Network pressure

NOTICE!

If the specified limit values are exceeded, use cooling units made of other
materials.

Please consult BOGE service.

WARNING!

If the cooling water data changes, the cooling units may have to be rede­signed. Incorrectly designed cooling units may cause malfunctions and the
compressor to switch off!

Please consult BOGE.

2.5 Compressor control

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.

Operating states

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.

Page 20 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Product description 2.5 Compressor control

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.

Operating modes

Control of compressors with frequency control (C F N)

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

min

the

compressor switches from idling operation back to load operation.

When the operating pressure p

(target value) is exceeded the control

soll

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

max

and p

(target value) are made by parameterization

soll

, p

of the FOCUS control.

The standard settings are: p

– 4 psig = p

max

p

– 6 psig = p

max

soll

min

Short operating times

WARNING!

During short operating times, the compressor does not reach its operating
temperature. It operates below the dew point. The condensate generated
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.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 21

Product description 2.6 Safety and monitoring devices

2.6 Safety and monitoring devices

General

Safety temperature limiting device

The safety devices guarantee a high degree of operational safety, in conjunc­tion 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. The
compressor does not switch on when dropping below the minimum tempera­ture.

– Rectify the fault.

– Acknowledge fault by pressing ENTER key .

– Switch on the compressor (ON key).

Safety valve

Monitoring the drive motor

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

Fig. 2.4: 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.

Page 22 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

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
trained 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.

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

Forklift truck or lifting cart 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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 23

Installation 3.1 Transport and storage

Crane transport

WARNING!

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

Only use suitable transport slings. Position
the slings at the ends underneath the base
frame of the compressor.

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, maintenance conditions and application for com­pressed air receivers: receiver mounted or seperately installed“).

In case of a careless storage we assume no liability for consequent dam­ages!

In the event of an extended intermediate storage you should consult BOGE­Service.

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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Installation 3.2 Compressor room

3.2 Compressor room

Installation, mainte­nance conditions and
application for com­pressed air receivers:
receiver mounted or
seperately installed

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 floor.

– 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

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 25

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.

Installation 3.2 Compressor 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.

– 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 permissible 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 permissible 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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

If the following instructions are not observed, the permissible 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.

Installation 3.2 Compressor room

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.

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.

Cooling air requirement

Supply air filter

– The compressor is fitted with supply air filter mats.

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 * Cooling air

requirement

for free

standing unit

Necessary

inlet opening

for free

standing unit

* Cooling air
requirement

for instal-

lation with

Necessary

free duct

cross

section

ducting

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

C 16 N
C 20 N
C 25 N
C 30 N
C 16 F N
C 20 F N
C 25 F N
C 30 F N

15.0

20.0

25.0

30.0

15.0

20.0

25.0

30.0

2178
2886
3534
4123
2178
2886
3534
4123

5.4

7.2

8.3

9.9

5.4

7.2

8.3

9.9

1001
1473
1826
2032
1001
1473
1826
2032

1.2

1.8

2.3

2.6

1.2

1.8

2.3

2.6

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

ture.

Tab. 3.1: cooling air requirement, necessary cross sections for openings and
ducts

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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
preventing 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 16 N...C 30 N, C 16 F N...C 30 F N 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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 29

Installation 3.3 Installation

Connection condensate drain

WARNING!

The water/oil mixture must not be discharged into the waste water system.
Oil and water must be separated by appropriate separating devices (addi­tional equipment).

A minimum 29 psig pressure is required for operational safety.

WARNING!

The condensate discharge is to be designed such as to prevent persons or
objects from being hit by the condensate (condensate discharge with oper­ating pressure)!

1 from condensate drain

2 to treatment (oil/water separator)

The condensate discharge pipe (3)
must be installed not extend more than
190 inches upward on the wall.
The min. operating pressure will in­crease by 1.5 psig per meter. Manifold
(4) is to be designed as to have at least
the condensate discharge diameter.

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).

– Loosen cabinet bolts (2) above lateral sheets and backwall and remove

cladding.

Page 30 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Installation 3.3 Installation

Fig. 3.4: Remove cladding

WARNING!

To avoid damages to the cooler you must counter the screw connections at
the compressed air outlet with a spanner.

Fig. 3.5: Connect compressor

1 Electrical connection

2 Compressed air outlet

3 Condensate line dryer

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 31

Installation 3.4 Electrical connection

Activating the belt tensioning device

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

Checking the oil level

WARNING!

The sealed nuts for adjustment of the spring tension must not be loosened
or modified.

BOGE compressors are supplied filled with lubricant.

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 power disconnecting device.

Page 32 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Installation 3.5 Commissioning

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

terminal. A clockwise rotational field must be created.

– Retighten the electrical connections after the first 50 operating hours.

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 current carrying 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.

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!

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 33

Installation 3.5 Commissioning

Checking installation requirements

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“)!

Record the test results in the commissioning certificate.

Checking the rotational direction

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 significant damage to the air end!

Record 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.

Changing the rotational direction

WARNING: Risk of injury!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

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

Page 34 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Installation 3.5 Commissioning

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!

– Close mains disconnecting device.

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

pressed air outlet for tightness.

– Switch off compressor.

Opening the stop valves

Checking for leaks

WARNING: Risk of injury!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

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

Record the test results in the commissioning certificate.

Open ball valve on the compressor delivery.

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.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 35

Installation 3.5 Commissioning

1

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 2 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!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

– 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.

– rior to switching on the compres-

sor 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

Page 36 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Installation 3.6 Dismantling

3.6 Dismantling

NOTICE!

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

Telephone: [phone]

Telephone: [phone]

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 16 N...C 30 N, C 16 F N...C 30 F N 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 16 N...C 30 N, C 16 F N...C 30 F N 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: 6 months

Moderately soiled water, surface water: 1 year

Lightly soiled water: 3 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 16 N...C 30 N, C 16 F N...C 30 F N 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 number, if you have
any questions.

Telephone: [phone]

Telephone: [phone]

DANGER: Voltage!

Prior to any work required to rectify faults:

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

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 16 N...C 30 N, C 16 F N...C 30 F N 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 in accordance with IEC 38

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 16 N...C 30 N, C 16 F N...C 30 F N 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 16 N...C 30 N, C 16 F N...C 30 F N 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 disconnection device and secure against unintentional
switch on by means of a padlock.

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. Prior to starting work let cool down all hot components of the compressor
to 122°F.

7. Separate the compressor from the compressed air network by closing
the ball valve at the compressed air outlet.

8. 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.

9. Remove all safety cladding necessary to perform the maintenance work.

Once the maintenance work has been concluded:

10. Reattach all removed safety cladding.

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

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

13. Remove warning sign not until then and release mains disconnecting
device.

14. Unlock emergency-stop switch/button.

Page 44 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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 16 N – C 30 N

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

8 Check/adjust pressure (Control)

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 45

Maintenance 6.2 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.

WARNING!

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

NOTICE!

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

Page 46 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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 59

Check or change supply filter w 50

Check if electrical connections are tightened X –

Air circuit

Check and if necessary clean suction filter m 49

Change suction filter cartridge X 50

Function check of the safety valve X60

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

X53

X56

X55

2)

3)

X

57

Change oil every 6000 operating hours 57

Replace oil regulator (wearing parts set)

2)

X–

Replace inline filter X 61

Drive

Check/replace V-belt X 51

Lubricate drive motor bearings Drive motors with permanent lubrication 51

Replace motor bearing Depending on mains frequency: 50 Hz 10000 operating hours

60 Hz 8000 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 3000plus and FoodLub-H1 S is used! The service life may differ depending on the ambient tempera-
ture. In this case have the oil analyzed by your BOGE service!

3)

The specified intervals only apply when BOGE compressor oil Syprem 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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 47

Maintenance 6.2 General

General information concerning the lubricants used

You find detailed information as to the lubricants used in the safety data sheet,
you may receive on request!

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!

WARNING!

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.

Disposal of used operating material

Pressure hoses

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!

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!

Page 48 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

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 scavenge line filter is soiled the oil consumption may increase signifi­cantly!

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!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

Removing the filter car­tridge

– Open safety sound insu-

lation hood.

– Remove lid (1) of the filter

housing.

– Take out filter insert (2).

Fig. 6.2: Changing the intake filter

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 49

Maintenance 6.3 Maintenance work compressor

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

outside.

– Clean the sealing surfaces of the filter cartridge.

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!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

Page 50 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

Fig. 6.3: Changing the supply air filter mats

– Pull insert (1) out of the holder.

– Fit new insert (1) into the holder.

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.

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.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 51

Maintenance 6.3 Maintenance work compressor

Switch off the compressor using the OFF button.

WARNING: Risk of injury!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure against unintentional switch on by means of a padlock.

Let the compressor cool down. Otherwise you can burn yourself when touch­ing the approx. 176 – 194°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.

Fig. 6.4: Lift motor plate

Page 52 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

Settings of the GM-drive system C 16 N...C 30 N, C 16 F N...C 30 F N

sealed

Setting

+ 0 / - 0.04 inch

blue

Model Pressure

[psig]

Standard

motor

[lbs.]

The settings specified in the following
table are factory-set by the manufac­turer and must not be changed. Slight
modifications are permissible and
compensated by the GM drive sys­tem.

The current settings are marked on a
label attached to the GM drive sys­tem. For special types the settings on
the label might deviate from the stand­ard values.

1 adjusting nut

Setting

+ 0 / – 0.04

[inch]

C 16 N 100 / 115 / 150 / 190 254

C 20 N 100 / 115 / 150 / 190 262

C 25 N 100 / 115 / 150 / 190 300

C 30 N

C 16 F N

C 20 F N

C 25 F N
C 30 F N

Tab. 6.2: Settings for standard motors

100 / 115 / 150 / 190

115 / 150 / 190 262

100 / 115 / 150 / 190 300

100 / 115 / 150 / 190

388

388

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

Motor tensioning spring w/o pretension
(Tensioning device must not rattle)

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 53

Maintenance 6.3 Maintenance work compressor

Checking the oil level, topping up oil

Check:

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

– Then 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!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

– 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 filling socket (1) (see
figure below).

– 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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

Changing the oil filter

Change:

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

– With each oil change!

WARNING: Risk of injury!

Do not touch hot surfaces!

– Slacken screws on service cover (3) and remove cover.

– Take out oil filter cartridge (4) and remove from support body (5).

– Slide support body into the new oil filter cartridge.

WARNING: Risk of injury!

Hot surfaces: Do not touch!

– Slacken screws on service cover (3) and remove cover.

– Pull oil disperser cartridge (1) out of the o-ring seal.

– 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 (3) and tighten screws.

– 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.

Fig. 6.6: Changing the oil filter / Changing the oil separators

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 55

Maintenance 6.3 Maintenance work compressor

Changing oil separators

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!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

– 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!

Fig. 6.7: Changing the oil separator

– 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 ac­cording to environmental
regulations.

– Lightly oil the sealing

rings of the new oil sepa­rator.

– Screw in new oil separa-

tors (4) by hand, turning
clockwise.

Page 56 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

– Open the ball valve at the compressed air outlet.

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

– Check the oil filter for leaks once again (procedure as described above).

WARNING!

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 separators is sufficient.

WARNING: Risk of injury!

Open mains disconnection device and secure by means of lock out tag out.

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

Oil change

Change:

– With compressor oils 3000plus and FoodLub-H1 S:

After 3000 operating hours, however, at the latest after one year.

– With compressor oil HighLub 6000: After 6000 operating hours.

– With compressor oil Syprem S: 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.

– Switch off the compressor using the OFF button.

WARNING: Risk of injury!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 57

Maintenance 6.3 Maintenance work compressor

5

Draining old oil

– Switch off compressor.

After approx 2 sec screw cap nut (5) on the bleed aperture of the solenoid
valve (the nut is located in the storage compartment of the switch cabinet).

Fig. 6.8: 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 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. 6.9: 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).

Page 58 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

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!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

– Check the oil filters and oil separators for leaks and tighten by hand,

if necessary.

– Check oil level (procedure as described above).

Top up oil losses, if any.

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.

WARNING!

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

Telephone: [phone]

Telephone: [phone]

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.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 59

Maintenance 6.3 Maintenance work compressor

– Switch off the compressor using the OFF button.

WARNING: Risk of injury!

Actuate emergency-stop switch/button, open mains disconnecting device
and secure by means of lock out tag out.

WARNING!

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.

Function check of the safety valve

If the cooling unit is exces­sively soiled (cleaning is no
longer possible with com­pressed air), have it disas­sembled and cleaned by
BOGE service.

Fig. 6.10: Cleaning the compressed air/oil cooling unit

WARNING: Risk of injury!

Risk of injury from flying parts caused by overpressure, e.g. pressu­rised components bursting or detonating!

Risk of injury due to sudden discharge of hot compressed air!

It is forbidden to operate the compressor without the installed safety devices.

A safety valve prevents inadmissible overpressure.

The specified final compression pressure must not be exceeded.

Observe the statutory regulations applicable in the installation location for
operating safety devices against overpressure.

Have the function of the safety valve checked exclusively by BOGE Service
personnel.

Interval: after approximately 3,000 operating hours but at least once a year.

Page 60 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Maintenance 6.3 Maintenance work compressor

Inline filter

Change:

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

WARNING!

If the prescribed maintenance intervals are not observed,the residual oil
content in the compressed air increases considerably.

– Switch off the compressor using the OFF button.

WARNING: Risk of injury!

Press Emergency Stop button, open mains disconnection device and secure
by means of lock out tag out.

– 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 plug (1) and nozzle (2).

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

the filter and pull the filter out.

– Mount sintered filter (3) and nozzle (2) in reverse order and close the bore

hole (4) with the plug (1).

Fig. 6.11: Nozzle with sintered filter

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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 oils 3000plus / FoodLub-H1 S / HighLub 6000 / Syprem S

Set of V-belts

Maintenance kit consisting of:
oil filter, oil separator, suction filter cartridge, gaskets, nozzle with filter

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 16 N...C 30 N, C 16 F N...C 30 F N 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 the different
machine types and components.

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 63

Appendix 7.1 Flow chart

Air cooled version, standard, series C16 N...C 30 N, C16F N...C 30 F N

Page 64 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 65

Appendix 7.1 Flow chart

Water cooled version, serial connection, series C16 N...C 30 N, C20F N...C 30 F N

Serial connection

Page 66 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

Appendix 7.1 Flow chart

101 Intake air INLET

102 Compressed air OUTLET

103 Water OUT

104 Water IN

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 Compressor 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

32 2/2-way solenoid valve

To be supplied by customer:

35 Dirt trap

36 Non-return valve

*Option

BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 67

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 68 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N 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 filterSupply

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 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 69

** 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 filterSupply

air filter

*

filter

Suction

rature

Te m p e -

Please note the completed maintenance work in the respective columns

System

pressure

Supply

pressure

ating

hours

Oper-

Date

Page 70 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors

** Co= Control

* Cl = Cleaning

Ch = Change

Ch = Change