Operating
instructions
RATIO compressor
control for
screw compressors
Before installing or starting the
compressor for the first time, this
manual should be studied carefully to
obtain a clear knowledge of the unit
and of the duties to be performed while
operating and maintaining the unit.
RETAIN THIS MANUAL WITH UNIT.
This technical manual contains
IMPORTANT SAFETY DATA and should
be kept with the air compressor at all
times.
Index
BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Page I
Operating instructions
RATIO compressor control
for screw compressors
Issue: 09/2009
No. 596.0840.18
Nominal price: US $ 5.00
BOGE KOMPRESSOREN
Postfach 10 07 13
D-33507 Bielefeld
Germany
Otto-Boge-Straße 1–7
D-33739 Bielefeld
Phone: ++49 / 52 06 / 6 01-0
Fax: ++49 / 52 06 / 6 01-200
Mail: info@boge.com
Net: www.boge.com
Page II BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Index
Index
BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Page III
Index
1.1 The BOGE control ........................................................................1.1
General .......................................................................................... 1.1
Microcontroller................................................................................ 1.1
1.2 The BOGE control concept .........................................................1.2
Operating and control panel ...........................................................1.2
1.3 Operating elements......................................................................1.3
1.4 Operation ......................................................................................1.6
Parameterization of frequency converter without running motor .. 1.11
1.5 Control Parameterization ........................................................... 1.12
Error key table .............................................................................. 1.12
General ........................................................................................ 1.13
Parameterization ..........................................................................1.13
Enter Parameterization Code .......................................................1.13
Set the compressor servicing interval and restart ........................ 1.13
Set the motor servicing interval and restart .................................. 1.14
Set load cycles dependent servicing / inspection and restart .......1.14
Change target pressure values (P
max
and P
min
) ............................. 1.14
External output enable ................................................................. 1.15
Proportional control ......................................................................1.16
Timer ............................................................................................ 1.16
Switching
Local-Remote
via key switch ........................................ 1.16
Remote On-Off control .................................................................1.17
Enable network independent ON-OFF memory (Auto-Restart) .... 1.18
Idling control for extremely short operating times
(Change after-running time) .........................................................1.18
Set continuous mode ................................................................... 1.19
Anti freeze operation (only in mode
ready for operation
) .............. 1.19
RS 485-Bus-Address ................................................................... 1.20
Parameter overview...................................................................... 1.20
1.6 Faults – General ......................................................................... 1.21
Automatic monitoring of the control systems ................................ 1.21
1.7 Fault messages of the control system ..................................... 1.22
Fault .............................................................................................1.22
Acknowledge messages............................................................... 1.22
1.8 Warning messages of the control ............................................. 1.25
Part 1:
RATIO
Page IV BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Index
RATIO.pm6.5 - USA
Page 1.1
RATIO
BOGE – RATIO compressor control for screw compressors
These operating instructions contain a description of the RATIO control system.
BOGE compressors are equipped with a modern control.
RATIO, an integrated control and monitoring concept, with two objectives:
– Energy savings and thus reduction of ongoing costs.
– Prolonging the service life of the compressor due to minimum wear.
All programmed data is stored in a memory module (EEPROM).
Thus the stored information is even available following a power failure.
The BOGE-RATIO control adapts dynamically to the respective operating
conditions. A micro-controller assumes the following three tasks:
1. Automatic selection of the most economical operating mode
The micro-controller calculates the optimum operating mode from the
current operating state and a programmed ideal value, also taking into
account the constant compressor system data (e.g. delivery quantity,
receiver volume, motor switching cycles) as well as the current variables
(e.g. compressed air consumption, supply and non-supply times, pressure increase and decrease speed).
In order to save operating costs, it always strives for the most economical
intermittent operation.
2. Automatic optimization of the motor switching cycles
The micro-controller calculates the optimum number of motor switching
cycles. This protects the drive motor and prolongs the service life of the
plant.
3. Automatic reminder of the maintenance intervals
The microcontroller monitors the maintenance intervals.
The BOGE control1.1
Microcontroller
General
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RATIO
BOGE – RATIO compressor control for screw compressors
Operating and control panel
The BOGE control concept1.2
Fig. 1.1: RATIO operating panel
LC-
Display
Error:
red
Ready:
green
next
information
Enter
ON
OFF
Indicator lamps
previous
information
Main display
EMERGENCY OFF
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Page 1.3
RATIO
BOGE – RATIO compressor control for screw compressors
Operating elements1.3
Operating elements RATIO
Operating/control element Function
– Press the EMERGENCY OFF switch.
The switch engages and interrupts the control
voltage.
All displays are cut off from the power.
After rectifying the fault, unlock the EMERGENCY
OFF switch:
– Turn the EMERGENCY OFF switch a quarter
turn clockwise.
– Quit the display test by pressing OFF key .
– The compressor is ready to use.
Important!
Always switch the compressor off
with the OFF key. Only use EMERGENCY OFF in an emergency!
ON key – Press the ON key:
The operating status depends on the network
pressure:
1. Network pressure greater than lower cut-in
pressure. Compressor remains ready.
2. Network pressure lower than lower cut-in
pressure. Compressor starts.
To switch the
compressor on
OFF key If necessary, continues to run in idle until decrease
in system pressure.
To switch the
compressor off
EMERGENCY OFF switch To switch off the
compressor
in an emergency
Operation/Explanation
[Up] key
The key has two functions:
1. It shows the previous information, one step
backward.
2. It normally increases the parameter value.
Display selection
in LC-Display
[Down] key
The key has two functions:
1. It shows the next information one step for-
wards.
2. It normally reduces the parameter value.
Display selection
in LC-Display
INFO key – Press the INFO key.
The display shows the main information or fault/
warning message.
Select desired main
information
ENTER key – See parameterization section.For confirmation in
parameterization
and acknowledgement of messages
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RATIO
BOGE – RATIO compressor control for screw compressors
Operating/control element Function
The green indicator lamp indicates that the
machine is ready.
Lamp = red The red indicator lamp indicates a fault.Fault
Pressure gauge or target value (network).Network pressure
display
If parameterization has been started, this symbol
appears in the top left of the display.
Parameterization
Ready
Operation/Explanation
3-digit 7-segment display
P:
Shown in bar with a decimal point between the
second and third digit.
Displays:
Pressure
Lamp = green
3-digit 7-segment display
T:
In °C.Displays:
Temperature
Thermometer
Operating elements RATIO
Operating elements1.3
bar
°C
Compressed air parameterization start undergoing
parameterization or frost run = blinks.
Pressure gauge system pressure (compressor).System pressure
display
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RATIO
BOGE – RATIO compressor control for screw compressors
Operating elements1.3
Operating/control element Function
The circle stands for three functions:
1. The compressor is switched off.
2. For motor servicing period.
3. Servicing symbol (receiver inspection)
(replace wearing parts).
Automatic standby.Stand by
(Automatic) idling phase.Idle
OFF or
motor or
receiver
Operation/Explanation
Operating elements RATIO
Output phase or output cycle.Load or load speed
Automatic mode with standby phases enabled.Automatic operating
mode selection
Automatic mode without standby phases enabled.Continuous
operation
Total motor operating hours.Total running time
Idle operating hours.Idle operation
Information on current or impending servicing.Servicing due
Energy-independent ON-OFF save function set.
Auto-Restart
(automatic restart
enabled after
network failure)
Remote output enable (e.g., from master control).External output
enable
Remote ON-OFF (e.g., from control panel).
Serial interface activated.
Remote On-Off
Mode
Online-Mode
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RATIO
BOGE – RATIO compressor control for screw compressors
Operating/control element Function
– After unlocking the EMERGENCY OFF switch
and turning on the supply voltage, all enablable
display elements of the control appear at the
same time – including the two indicator lamps.
– If standby was not saved (no Auto-Restart),
this status must first be ended by pressing the
OFF switch O, before the compressor can be
switched on.
– Otherwise it disappears automatically after a
set time and the compressor is on standby
again without touching the controls – see also
Power failure cycle protection.
Function control of
display elements
Operation/Explanation
Operation RATIO
Main display
RATIO
green red
green
If no fault is reported, pressing will switch on the
green indicator lamp (compressor on standby)
which means: the pressure control function is activated – see also Remote On-Off.
Switch on the
compressor
Operation1.4
– This display either appears after completion of
the network failure phase (as described under
display element function control) or by pressing
the i key or by scrolling via È or Ç-keys:
– The network pressure is shown at the top left
(pressure gauge 21), and at the top right the
(final compression) temperature, in the centre
are the two operating mode curves: the left
arrow shaded (as shown here) = automatic
mode selection, right = continuous operation,
the circle left of this means: off here.
The symbol at the bottom left is for
setting
Remote-On-Off and next to it the symbol for
external output enable,
next to the right the
symbol
online
and at the extreme right at the
bottom the symbol for
cut-in-save
(Auto-Restart). These four symbols only appear when
the respective setting has been made.
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RATIO
BOGE – RATIO compressor control for screw compressors
Operation RATIO
Operation1.4
Run-up phase
Load operation
Stand by
(Ready for operation)
The run-up phase – or star phase – is automatically
finished by switching the electropneumatical control
into load operation and the symbol appears
in the display – probably first a change to delta
connection takes place 60ms after the star phase.
Once the set maximum pressure is reached, the
idling symbol appears. The system pressure
is reduced automatically.
bar °C
!
bar °C
If required the pressure control starts the motor –
if the motor spinning time is finished, the system
pressure has decreased and no motor switching
limitation is necessary (otherwise the idling symbol
- blinks → the idling symbol appears during the
time-controlled run-up or star phase. For a star/
delta contactor combination the following applies:
the star contactor is switched on first followed by
the network contactor 20ms later. The idling symbol
signals the state of the electropneumatic control.
Thus it also appears after reaching the set maximum pressure – during the decrease phase of the
system pressure.
If the network pressure (in idling mode) drops below
the max. start-up back pressure and the automatic
operating cycles monitoring allows it, the control
unit switches the motor off and the Stand by symbol
is shown in the display. If the network pressure
drops to the set minimum pressure within the idling
phase, the compressor switches back to load operation and the respective symbol is displayed again.
If this happens shortly after having switched to
stand still, it has to be waited in case of contactor
connection – cf. also motor spinning time – until the
compressors is switched off for 20s, to be sure that
the motor stands completely still, before you may
start it again. If the pressure is below the switch-on
pressure this is signalled by the blinking of the
Stand-by symbol until the compressor starts again.
bar °C
Operating/control element Function Operation/Explanation
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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key → and the segment display shows the
compressor system pressure (pressure gauge 22).
Compressor
system pressure
Press ↓-key a second time → and the segment
display shows the total operating time in hours
together with the total running time symbol: .
Total operating time
Operating times,
output cycles,
maintenance deadlines, display test
and Software-No.
means: 124h total running time
Press O → Compressor Off → and the pressure
control function is deactivated and the display
shows the
idling symbol.
During this time the green
indicator blinks. The symbol O then appears and
the green indicator lamp is extinguished.
Switch off the
compressor
If the control unit detects a fault, the compressor is
switched off immediately and automatically – without an idling phase –, the
fault
relay drops and
a digit on the right of the current pressure blinks
together with the red indicator lamp.
The blinking digit indicates the detected fault
(see also message key table page 1.12).
Fault messages
red
!
bar °C
Operating/control element Function Operation/Explanation
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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key a fifth time → and the display shows
the operating time (in hours) until the compressor
servicing and the Running time and Servicing symbols (spanner).
Press ↓-key a sixth time → and the display shows
the operating time until the next Motor servicing and
the symbols O (here for motor), running time and
servicing (spanner).
Compressor
servicing
Motor servicing
Press ↓-key a seventh time → and the display
shows the 1000-output cycle servicing counter with
the exponent 103 (x 1000), the Load-cycle symbol,
the circle (here for receiver) and the servicing
symbol (spanner), meaning the number of possible
output cycles until the next receiver inspection or
change of wearing parts.
Next receiver
servicing/change
of wearing parts
depending on
output cycles
means: 500hrs until the next
compressor servicing
means: 1000hrs until the next
motor servicing
Press ↓-key a third time → and the display shows
the Idling time counter in h (hours) and the Idling
symbol: .
Idling time
means: 2hrs idling time
Press ↓-key a fourth time → and the display shows
the 1000-output-cycles counter with the exponent
103 (x 1000), the load cycle symbol and the circle
(here: receiver).
Output-cyclecounter
means: 12 x 103 = 12000 output
cycles
means: 20 x 103 = 20000 Load
cycles until the next receiver
servicing or change of wearing
parts
Operating/control element Function Operation/Explanation
RATIO.pm6.5 - USA
Page 1.10
RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key an eleventh time → and the segment
display area shows the Software-No.
Software-No.
Press ↓-key a tenth time → and the display shows
all symbols and segments together with the two
indicator lamps.
Display
element test
red green
means Software-No. 1105
Upper target
pressure
(network pressure)
means: P
Max.
= 10,0 bar
(cut out pressure)
Press ↓-key a ninth time → and the segment
display shows the Lower target pressure and a
dash at the bottom right next to it.
Lower target
pressure
(network pressure)
means: P
Min.
= 9,0 bar
(cut in pressure)
Software-Version
No.
0xx xxx
1xx xxx
2xx xxx
3xx xxx
Meaning
Screw compressor, all sizes
Screw compressor up to 22 kW
with frequency converter
Screw compressor bigger than 22 kW
with frequency converter
Piston compressor
Operating/control element Function Operation/Explanation
Press ↓-key an eighth time → and the segment
display shows the Upper target pressure and a
dash at the top right next to it.
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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key a twelfth time → to return to the main
display. Press ↑-key - to watch the displays in the
reversed direction.
If no key is pressed for five minutes, the main
display automatically reappears.
Parameterization
of frequency converter
without running motor
Normally the converter is under tension as soon as the I-key (On) is pressed
and the compressor motor starts. In case the frequency converter has to be
parameterized during motor stand-still – you only have to press the ↵-key
– when the main display is shown – and the compressor is switched off.
Then the converter supply contactor starts up and the motor remains in standstill – the green LED is not illuminated.
By pressing the O-key (Off) the converter supply contactor drops out.
Operating/control element Function Operation/Explanation
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
Error key table
Each message is automatically
registered by the control, together with the associated time,
thus putting an overview at the
disposal of BOGE-Service.
1
) adjustable
Error Meaning Compr.No. cut-out
0 Compr. air treatment (dryer or condensate drain gives error message)
1
)
1 Final compression temperature > 110°C, 230°F X
2 Motor temperature too high X
3 Excessive current of vent. motor X
4 Incorrect direction of rotation X
5 Excessive compressor system pressure X
6 Excessive diff. pressure of intake filter
7 Excessive diff. pressure of oil filter
8 Excessive diff. pressure of oil separator
9 No output X
10 Motor servicing due
11 Compressor servicing due
12 System pressure decrease too slow
13 Frequency converter gives error message X
14 Temperature too low X
15
Suction control faulty (suction control or solenoid valve, if necessary clean
proportional controller)
16 Network pressure transmitter faulty X
System pressure increases too quickly (lack of oil, oil too old or even with
17 monitoring of the rotational direction a false rotational direction cannot be X
excluded)
18 Master control tries to go below P
min
– cf parameterization "External output enable"
Previous net switch-on phase was too short (possible reasons: coil short-circuit
19 'solenoid valve', 'delta contactor' or 'ventilator contactor') → automatically
increased delay time in corr. with permissible number of motor switch cycles
20 Master control tires to exceed P
max
– cf parameterization "External output enable"
21 Receiver or wearing parts inspection due
22 Not assigned here
23 Not assigned here
24 Not assigned here
25 Control unit Reconciliation error X
26 Control unit O-key does not open X
27 Control unit I-key does not open X
28 Control unit i-key does not open
29 Control unit ↵-key does not open
30 Control unit "arrow up" does not open
31 Control unit "arrow down" does not open
32 Network pressure-transmitter wire breakage X
33 Compr.system pressure-transmitter wire breakage X
34 Compr.system pressure-transmitter faulty X
35 Excessive diff. pressure return valve
36 Bus Life-Bit did not toggle
38 Current of compressor motor is too high X
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
General
The control unit calculates from the current operating data the respective
best operating mode and automatically selects it.
The parameters are adjustable.
In order to prevent unintentional changes to pre-set parameters, these
parameters are codeword-protected.
ATTENTION!
Never change the value of a parameter if you do not know what it means!
This may cause incorrect behaviour of the control unit!
Do not experiment with parameter settings!
Always call BOGE-Service if you are unsure or have any doubts.
In general the following is applicable: If a parameterization, as described
below, is started at the top right in the display the symbol appears and
the set value or status blinks.
1. Display Software-No. (see Software No.).
2. Press ENTER ↵ → and the parameterization symbol is shown on the
left, followed by three zeros, the left of which blinks.
3. Press ↑ or ↓ to change the first digit.
4. Press ↵ → and now the middle zero blinks.
5. Press ↑ or ↓ to change the second digit.
6. Press ↵ → and now the right zero blinks.
7. Press ↑ or ↓ to change the third digit.
8. Press ↵ → the display will now branch off depending on the set number
– if the value is invalid the main display will reappear.
Each parameterization is automatically registered by the control, together
with the associated time, thus putting an overview at the disposal of BOGEService.
The servicing interval memory can be set to a value between 300 and
9900 hours in one hundred hours increments as long as the interval time
limit is monitored by the control – if it is not used it has to be set to 10000h,
as it stops the down counter.
1. Enter Code 111 as described under coded parameterization → and the
display shows the compressor servicing interval in blinking digits (Compressor servicing).
2. Press the ↑ or ↓-key to change the value in big steps.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking
value, and the main display reappears.
Parameterization
Enter Parameterization
Code
Set the compressor
servicing interval
and restart
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
The motor servicing interval memory can be set to a value between 500 and
29900 hours in one hundred hours increments as long as the motor interval
time limit is monitored by the control – if it is not used it has to be set to 30000 h,
as it stops the down counter.
1. Enter Code 222 as described under coded parameterization → and the
display shows the compressor servicing interval in blinking digits (Motor
servicing).
2. Press the ↑ or ↓-key to change the value in big steps.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
The output cycles servicing interval memory can be set to a value between
100,000 and 1,900,000 cycles in increments of onehundredthousand, as long
as the output cycles servicing interval is monitored by the control – if it is not
used it has to be set to 2,000,000 cycles as it stops the down counter.
1. Enter Code 333 as described under coded parameterization → and the
display shows the receiver inspection interval in blinking digits (receiver
inspection/change of wearing parts).
2. Press the ↑ or ↓ keys to change the value in big steps.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
If changes are made to these target values, the value of P
min
is automatically
held or brought outside any applicable minimum hysteresis range.
1. Enter Code 360 as described under coded parameterization → and the
display shows the upper target pressure value, but blinking.
2. Press ↑ or ↓-key to change the value.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the lower target pressure value apears (blinking).
4. This value can now be changed by pressing the ↑ or ↓-key.
5. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
6. It is not permissible to set the bottom pressure target value below the
stipulated p
min
value. In case this should be necessary please contact
BOGE-Service beforehand.
Set the motor
servicing interval
and restart
Set load cycles
dependent servicing /
inspection and restart
Change target
pressure values
(P
max
and P
min
)
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
If the output of a compressor is to be enabled by a higher level control unit,
its parameterization must be changed as follows:
1. Enter Code 210 as described under parameterization → and the display
shows from Fig. c on the left. The 'zero' at the top right blinks. This dis-
play means: no additional enabling device is programmed.
2. Press ↓-key to switch to Fig. d – ↑-key to switch back. Digit One and
the bottom symbol 'external output release' are blinking.
This display means: enabling device (e.g., MCS) is enabled via input
'Pressure control' (for potential-free contact) – see also 'Switching
Local/
Remote
via key switch' and 'RS485-Bus-address setting'. If the ↵-key is
pressed during this, one of the following pictures appears e + f –:
Fig. 3: The three top dashes and the 1 are blinking. The P and the three
top dashes mean, that falling below the network pressure (Manometer 21)
P
min
starts a load operation, even with an open input 'Pressure control'
– number '18' is displayed and the "warning" relay is activated – thus actuating the operating mode. Press ↓-key to switch to Fig. f – press ↑
to toggle back –:
Fig. 4: The falling and rising (dotted) pressure curve and digit 0 are blinking. This figures means that due to the open input 'Pressure control' a
falling below the network pressure P
min
is possible (as e.g. at night and
over the weekend).
Press ↵-key to overwrite the non-volatile EEPROM as per the blinking
symbol, and the main display reappears.
In the bottom display the symbol appears. The following applies
even with external enabling: If the upper target pressure value in the
compressor is exceeded, the output will be shut off. Only when the the
pressure drops to the lower target pressure value the external control
resumes.
If the ↵-key under point 2 was not pressed, press ↓-key to change to Fig. g
– press ↑ to toggle back –:
Digit Two and the two bottom symbols 'external output release' and 'online' are blinking. This display means: enabling device (e.g., master control) is enabled via a serial interface, if the input 'external output release'
is closed – see also 'Switching
Local/Remote
via key switch' and 'RS485-
Bus-address setting'.
3. Press ↓-key, if convenient (not with key switch function) to switch to Fig. h
– press ↑ to toggle back.
Manometer '22' and digit 3 are blinking. This setting means that a limiting
suction pressure switch (continuous output control) is connected to the
input 'Pressure control'.
4. Press ↵-key to overwrite the non-volatile EEPROM as per the blinking
symbol, and the main display reappears. If the compressor is set for an
output enabling device (e.g. mode 2), the bottom of the main display shows
the appropriate Symbol . The following applies even with external enabling: If the upper target pressure value in the compressor is ex-
ceeded, the output will be shut off. Only when the the pressure drops
to the lower target pressure value the external control resumes.
External
output enable
c
d
e
!
!
!
!
f
g
h
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
Proportional control
(not in the case of frequency
regulated compressors)
Timer
The limiting suction pressure switch (min. output) of a proportional control is
– in case of a single compressor (without higher-level pressure control ) –
connected to the input
external output enable
– cf point 3 (external output
enable).
If the proportional control is used in connection with a suitable higher-
level control, the limiting suction pressure switch is connected directly to the
higher-level control and this control subsequently to the input
external output
enable,
which then has to be parameterized correspondingly – cf point 2 and
3 (external output enable).
A timer can either be connected individually or in combination with a proportional control or a higher-level control. The parameterization has to be done
according to the following table:
Timer at input 'external output enable' External output enable
alias 'Pressure control' – ...
Parameteriz. Sub-
no. parameteriz. no.
single 1 0
series connection with higher-level control 1 0
and pressure control via RS485 (as e.g. Profibus DP) 2 not available
series connection with limiting suction
3 not available
pressure switch for proportional control
If a key switch is switched to 'Remote' for the first time or if Code 770 was
entered after the control unit was able to register a key switch, one of the
figures on the left appears.
1. Number One and the symbol 'Remote On-Off' are blinking. Fig. c means,
that the key switch exclusively refers to the selection of switching sources
for the readiness for operation of the compressor (green LED). If this setting is selected, the parameterization 'Remote On-Off Switching' automatically appears – otherwise to be reached via Code 451.
2. Press ↓-key to switch to Fig. d – ↑-key to switch back. Number Two and
the symbol 'external output release' are blinking. This figure means, that
the key switch exclusively refers to the selection of control sources for
the network air pressure (master control or individual pressure sensor).
If this setting is selected, the parameterization 'external output release'
appears automatically – otherwise to be reached via Code 210.
3. Press ↓-key to switch to Fig. e – ↑-key to switch back. Number Three
and the symbole 'Remote On-Off' and 'external output release' are blinking. This figure means, hat the key switch refers either to the selection
of switching sources for the readiness for operation of the compressor
(green LED) or to the selection of control sources for the network air
pressure (master control or individual pressure sensor). If this setting is
selected, the parameterization 'external output release' appears automatically – otherwise to be reached via Code 210 – and 'Remote On-Off
Switching' automatically appears – otherwise to be reached via Code 451.
Switching
Local-Remote
via key switch
0I
!
c
!
d
0I
!
e
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
4. Press ↵-key to overwrite the non-volatile EEPROM as per the blinking
symbol and the corresponding additional parameterization figures, as
described under the respective headlines, appear. Mode '0' does not make
any sense here and is therefore not displayed.
Each time the control is activated by parameterization, afterwards a blinking
time value appears, which is described under
Network independent On-Off-
memory (Auto-Restart)
. Likewise it can be changed after having selected the
On-Off-memory function.
This value is used as a start delay time, if the control was set to 'Remote' –
via key switch or parameterization – with closed control room contact directly
after a power failure.
If the compressor has to be switched on and off from a control room, the
parameterization has to be set to the 2nd, 3rd or 4th of the following figures:
1. Enter Code 451 as described under parameterization and the display
shows Fig. c on the left: The Zero on the top right blinks. This display
means: On/off switching is only possible using the keys of the control
unit.
2. Press ↓-key to switch to Fig. d –↑-key to switch back. Digit One and the
symbol 'Remote On-Off' are blinking. This display means: Neither the keyboard of the control unit nor the serial interface but exclusively the Input
for Remote On-Off switch (continuous contact) are used for cut-in and
cut-out (green LED) – see also Switching
Local-Remote
via key switch.
3. Press ↓-key to switch to Fig e –↑-key to switch back. Digit Two and the
symbol ‚online‘ are blinking. This display means: the compressor is exclusively switched on or off via the optional serial Interface 'RS485', plugable into the control unit – the keyboard and the input for Remote On-Off
switch (continuous contact) are not considered – see also 'Switching
Local-
Remote
via key switch' and 'RS485-Bus-Address setting'.
4. Press ↓-key to switch to Fig f –↑-key to switch back. Digit Three and the
symbole 'Remote On-Off' and 'online' are blinking. This display means:
The compressor is either switched on or off via the Input for Remote
On-Off switch (continuous contact) or via the optional serial Interface
'RS485', plugable into the control unit, but not by the keys of the control
unit. If the continuous contact is opened, the compressor cut out – see
also Switching Local-Remote via key switch. If the continuous contact is
closed, switching on/off is possible via the serial interface – see also
'Switching
Local-Remote
via key switch' and 'RS485-Bus-Address setting'.
5. Press ↵-key to overwrite the non-volatile EEPROM as per the blinking
symbol and if the above figure is selected the main display reappears.
Otherwise, the figure shown under
Network independent On-Off-Storage
(Auto-Restart)
point 3 appears.
If the compressor is set to a Remote-On-Off switch, at the bottom of the main
display the corresponding symbol is shown. Then the compressor
can only be switched on/ff from Remote. The Emergency Off function is not
concerned. It remains unchanged.
Remote On-Off
control
c
d
e
f
!
0I
!
!
0I
!
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
Normally a compressor always assumes an OFF status directly after an
electrical power failure.
However, after a power failure there is an option to automatically restart the
compressor with a set delay time, also acknowledged in combination with a
parameterization Remote On/Off – after mains return, automatically delayed
– see also power failure protection – repair. This is done as follows:
1. Enter Code 134 as described under parameterization → and the display
shows Fig. c on the left: The 'line' at the top right blinks.
This display means: no remembering of On-Off status (no automatic
standby) after a power failure.
2. Press ↑ or ↓-keys to switch to figure d on the left (press again to toggle
back...): The 'curve' at the top right blinks. This display means: Remembering of the On-Off status even after a power failure (Auto-Restart).
3. Press ↵-key to overwrite the non-volatile EEPROM acc. to the blinking
symbol. If the top symbol was selected, the main display is shown. Otherwise figure e on the left appears: The number 120 blinks. The quotation
mark symbol here stands for seconds. Press the ↑ or ↓-key to change the
value.
4. Press ↵-key to overwrite the EEPROM with the blinking value and the
main display appears with the at the bottom right.
After an output phase the compressor switches to an idling phase before
decreasing the system pressure and finally switching into stand-by. For compressors with special ventilation an additonal after-running time is necessary
to avoid the formation of condensate in the compressor. The after-running
time can be adjusted as follows:
1. Enter Code 019 as described under parameterization → and the display
shows Fig. c on the left: The digit (here 1) blinks. The quotation mark
symbol here stands for seconds. A run-out curve is indicated on the two
right positions.
2. Press the ↑ or ↓-key to change the value. Above 119 minutes appear and
the apostrophe symbol instead of the quotation mark symbol.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
Enable network
independent ON-OFF
memory (Auto-Restart)
c
d
e
Idling control for
extremely short
operation times
(Change after-running
time)
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
If pressure drops in relatively small receiver/pneumatic network volumes must
be avoided at any price, continuous operation can be set as follows – if no
continuous control was parameterized in connection with a single compressor:
1. Enter Code 733 as described under parameterization → and the display
shows Fig. c on the left.
The shading of the left arrow blinks. This means: automatic power economy
operating mode selection.
2. Press the ↑ or ↓-key to change to Fig. d on the left. (press again to toggle
back...).
The shading of the right arrow blinks. This means: continuous operation.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking sym-
bol, and the main display from the selected symbol appears.
The compressor is set to automatically start an idling phase – in star mode
i.e. without switching on a probably existing ventilator motor – from standby
when the temperature drops to below +4°C. During this phase in the main
display a thermometer blinks left of the temperature display. The idling phase
is finished as soon as the min. after-running time or +20°C final compression
temperature are reached.
This anti-freeze function can be switched off as follows:
1. Enter Code 056 as described under parameterization → and the display
shows Fig. c on the left: the 'curve' left of the thermometer blinks.
This display means: automatic idling phase in frost.
2. Press ↑ or ↓-key to change to Fig. d on the left (press again to toggle
back...) The 3x dotted line left of the thermometer blinks.
This display means: no automatic running phase in frost, shown by means
of the right dash as to the thermometer.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking sym-
bol, and the main display from the selected symbol appears.
Set continuous mode
c
d
Anti freeze operation
(only in mode
ready for operation
)
c
d
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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
Parameter overview
The control is already set for a bus coupler (BOGE-Bus-Address 32) for each
compressor according to customer specifications – as e.g. for Profibus. If
used another communication of RS485 then the following action is necesarry:
1. Enter Code 830 as described under parameterization → the display shows
one of the following fig. c or d.
2. Press ↑ or ↓-key to select the picture (bobus = BOGE-Bus, rtu = Modbus
type RTU) and quit by ↵-key. Depending upon selection one of the two
following fig. appears e or f:
With the BOGE-Bus only the desired address (flashing here 32) is to be
selected and quit by ↵-key, while with the Modbus-RTU after confirmation
of the address (flashing here on 0 = offline) by the key ↵, if address >0,
still additionally the Baud rate and the data format are adjustable as follows fig. g:
first the number 96 (= 9600 Baud) flashes – after confirmation by the ↵-
key 8E1 flashes (8E1 = 8 data bits, parity check of Even and 1 stop bit).
By means of key ↑ or ↓ then the necessary combination can be selected
(n = not parity check, o = odd).
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
A blinking Online symbol refers to a fault in the RS485 connection.
Code Function Page
019 Idling control for extremely short operation times 1.18
056 Anti freeze operation (only in mode
ready for operation
) 1.19
111 Set the compressor servicing interval and restart 1.13
134 Network independent ON-OFF memory (Auto-Restart) 1.18
210 External output enable 1.15
222 Set the motor servicing interval and restart 1.14
333
Set load cycles dependent servicing / inspection
1.14
and restart
360 Change target pressure values (P
max
and P
min
) 1.14
451 Remote On-Off control 1.17
733 Set continuous mode 1.19
770 Switching
Local-Remote
via key switch 1.16
830 Set RS 485-Bus-Address 1.20
RS 485-Bus-Address
!
!
c
d
!
!
!
e
f
g
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RATIO
BOGE – RATIO compressor control for screw compressors
1.6 Faults – General
General
The tables on the following pages give information on the possible causes of
operating faults and measures for their rectification.
ATTENTION!
Ensure that any work required to rectify faults is only carried out by trained
personnel or specialists.
Ensure that components which have a safety function are only set, repaired
or exchanged by BOGE Service!
Please contact BOGE-Service at the following telephone number, if you have
any questions.
770-874 -1570
All data is stored in a memory module (EEPROM).
If a fault occurs while the data stored in the EEPROM is being read, the
control system will react as follows:
– The compressor is switched off.
– The following fault message appears in the display.
Automatic monitoring
of the control systems
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RATIO
BOGE – RATIO compressor control for screw compressors
Fault messages of the control system
The control unit registers an Error, the compressor is immediately and without an idling phase – automatically shutdown, the error Relay drops and on
the right next to the actual pressure value there blinks a number next to the
red indicator lamp:
– the blinking number indicates the registered cause (see also message
key table under error messages).
Display the message – e.g. by pressing the i-key. Press ↵-key to cancel
the display and acknowledge the message. The main display appears, if the
cause for the fault was rectified.
FAULT RectificationPossible cause
Excessive final
1compression
temperature
Ambient temperature too
high
Cooling unit soiled
Insufficient cooling air
quantity
Insufficient oil quantity
Temperature sensor defec-
tive or wire break
Employ suitable measures to improve the air inlet
and ventilation in the installation room
Clean cooling unit externally
Keep air inlet opening to the compressor clean;
check to ensure that any existing cooling air duct
systems are adequatly dimensioned
Top up oil
Replace temperature sensor or repair the wire
break
Frequency
13 converter /
motor
Motor overload!
Power input too high
caused by undervoltage
Insufficient cooling
of motor /
frequency converter
Motor soiled
Excessive system pressure
Network pressure P
soll
/ P
max
too high
PTC resistor defective or
aged
Ensure correct voltage conditions:
Constant voltage in accordance with IEC 38
Ensure better cooling of motor / frequency converter: improve ventilation of the installation room;
Clean cooling unit and supply air filter
Clean motor cooling air supply
Exchange oil separator cartridge
Reduce line pressure to prevent compr. building up
a compr. load above approved max. pressure
Overhaul motor
Compressed air
0pre-processing
(option)
External unit of the
compressed air treatment
signals malfunction
Service or repair compressed air treatment unit
Note:
This message does not lead to switch-off the compressor and the standard configuration
Fault
red
Acknowledge
messages
RATIO
1.7
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RATIO
BOGE – RATIO compressor control for screw compressors
Fault messages of the control system
RATIO
FAULT RectificationPossible cause
Rotational
4 direction
(option)
2 phases of power cable
incorrectly poled (incorrect
rotary field connected)
Change the 2 phases of the power cable
Excessive pressure due
to soiled oil separator
Ball valve at compressor
outlet closed
Replace oil separator cartridges
Open ball valve
Pressure limitation
5
Air relief valve does not
close
Suction controller does not
open
Leakage in system
Check air relief valve and replace, if necessary
Check suction controller and replace, if necessary
Check system, overcome leaks
System pressure
9 build-up
Soiled filter cartridge
Defective low pressure
switch
Clean or replace cartridge
Replace pressure switch
Suction filter
6 (option)
Soiled filter cartridge
Defective differential
pressure switch
Replace cartridge
Replace pressure switch
Oil filter
7 (option)
Soiled filter cartridge
Replace cartridge
Oil separator
8
1.7
Suction con-
15 trol defective
Vent valve / quick acting
starting valve does not
close
Clean valves or replace wearing parts
Ambient temperature too
low
Apply anti-freeze measures
Temperature
14 too low
Network
16 pressure trans-
mitter faulty
Network pressure transmitter defective or wire
breakage
Replace network pressure transmitter or
re-establish electrical connection
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RATIO
BOGE – RATIO compressor control for screw compressors
Fault messages of the control system1.7
Control unit
29 Key Enter ↵
does not open
Control unit defective
Replace control unit
Control unit
25 EPROM /recon-
ciliation error
Error loading software.
Control unit defective
Reload software or replace control unit
Control unit
26 Key (Off) O
does not open
Control unit defective Replace control unit
Control unit
27 Key i
does not open
Control unit defective
Replace control unit
Control unit
28 Key (ON) I
does not open
Control unit defective
Replace control unit
Control unit
30
Key
does not open
Control unit defective
Replace control unit
Control unit
31
Key
does not open
Control unit defective
Replace control unit
Network pressure transmitter defective or wire
breakage
Replace network pressure transmitter or
re-establish electrical connection
Network press.
32 transmitter
faulty
Master
18 control
defective
Master control defective
Check supply voltage of master control.
Parameterization of external output enable
RATIO
FAULT RectificationPossible cause
System press.
33 transmitter
faulty
System pressure transmitter defective or wire
breakage
Replace system pressure transmitter or
re-establish electrical connection
System press.
34 transmitter
faulty
System pressure transmitter faulty
Replace system pressure transmitter
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RATIO
BOGE – RATIO compressor control for screw compressors
Warning messages of the control1.8
WARNING RectificationPossible cause
Compressed air
0 pre-processing
(option)
Warning
Motor
10 servicing
due
Servicing intervals
See operating instructions for servicing
Compressor
11 servicing
due
Servicing intervals
See operating instructions for servicing
Receiver
21 inspection
due or replace
wearing parts
Servicing intervals
Inspect receiver acc. to local rules and/or replace
wearing parts
See operating instructions for compr. air preprocessing
Suction control
15 and / or
ventilation
Warning
Check suction controller
Check solenoid valve
Check continuous output control (option)
RATIO
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RATIO
BOGE – RATIO compressor control for screw compressors
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