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Operating instructions

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1. seneee 29 Check compressed air outlet for tightness ssssssssss 29 Opening the stop valves ssssssssesemme 30 Checking for leaks eeeeeeeeeeeeeeeiesee esee te enne nnne 30 Conduct trial TUM se rete eR UH e mud 30 Commissioning following extended stoppages sss 31 Refrigeration compressed air dryer ssssseee 31 3 6 Dis manting ease cece teret ere teret prre uan DnE 32 Part 4 4 1 G eral inicie dicem era a i A raa e n E EVER RYE NM TREE 33 Faults 4 2 General faults Ideni d eurn nER 33 Part 5 5 1 Safety instructions ccceeceeeeeecee eee ee eee eeeeeeeeeeeeeaeeeseeeeeeeeneeeeeees 35 Maintenance 5 2 General csse tecto sata ied c e aaa ansa dua a aE S 37 Maintenance through BOGE customer service 37 Review of regular maintenance work ssssseeesee 37 Maintenance intervals sss 38 Page IV BOGE Operating instructions for C 3 L C 7 L series screw compressors Index 5 3 5 4 Part 6 6 1 A ndi PERSA 6 2 6 3 General information concerning the lubricants used 40 Disposal of used operating material sssssssss 41 Pressure NOSES acn a adadan aa aoa ionia heana Aa ae AARETE 41 Spare and wearing parts ssssssssssssseeeeeenee 41 Regular maintenance work
2. eene 42 Draining off the condensate from the compressed air receiver 42 Draining off the condensate from the compressed air receiver with automatic condensate separator sssssssssssssss 43 Clean or change suction filter sse 43 Cleaning the filter cartridge 44 Drive motors with permanent lubrication sssssssssssss 44 Checking the oil level topping up oil sssessesssse 45 Changing the oil filter m 46 Changing the oil separator sessssm 47 Oil CHANGE tech eere E emanate perte edad ade 48 Flushing the oil circuit ssee m 50 Cleaning the compressed air oil cooling unit sssse 51 Checking the safety valve sssssssssssssee 52 Spare parts and optional equipment 53 List of spare and wearing parts for maintenance 53 List of available optional equipment ssssssssssessss 53 Guidelines and standards complied with 55 Flow Kerr me 55 Air cooled version standard cccecccccesessceeeeaeeeeeeeeeeaaeeeeeees 56 List of maintenance and service work 58 BOGE Operating instructions for C 3 L C 7 L series screw compressors Page V General EN General safety instructions 1 1 Gener
3. Changing the rotational direction Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Interchange two phases L1 L2 or L3 in the power cable Check compressed air outlet for tightness Caution Risk of injury Work on the compressed air system may only be carried out by experienced and authorized qualified personnel Always wear protective clothing and goggles Immediately after having switched on the machine the connection of the compressed air outlet must be checked for tightness Make sure to observe an appropriate safety distance during the inspection BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 29 Installation Commissioning Close mains disconnecting device To conduct the inspection switch on the compressor and check the com pressed air outlet for tightness Switch off compressor Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock f necessary have leakages repaired by skilled qualified pesonnel Opening the stop valves Checking for leaks List up the test results in the commissioning certificate Open ball valve on the compressor delivery Caution Risk of injury In c
4. Unlike the Konsatronik the fully automatic condensate separator operates without causing any pressure losses In the event of a malfunction a red LED lights up and a potential free contact is switched Regularly check the func tion using the additional test switch on the device Clean or change suction filter Fig 5 3 Fully automatic electronically controlled condensate separator 1 Condensate shut off valve on receiver 2 Condensate outlet to oil water separator 3 Electr power supply Cleaning 1x monthly however at least every 500 operating hours Correspondingly earlier if the air taken in is heavily soiled Change Inthe event of damage After the second cleaning Switch off the compressor with the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 43 Maintenance Regular maintenance work Cleaning the filter cartridge Removing the filter car tridge Remove lid 1 of the filter housing Remove filter cartridge 2 Fig 5 4 Changing the suction filter Attention Do not clean filter cartridges in liquids Do not use any hard objects when cleaning to avoid damaging the filter paper Refit a new filter cartridge in the event of damage or when
5. Always use the same oil type when topping up Never mix different oil types and brands Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock 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 AN Caution Risk of injury Danger of burning due to hot oil Always wear safety gloves Remove plug 1 of oil filling socket 2 see figure below Check oil level The oil level must not drop below the min mark see sketch Ifnecessary top up with oil to the lower edge of the thread max mark on the oil filling socket Screw plug back in Open ball valve at the compressed air outlet BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 45 Maintenance Changing the oil filter Regular maintenance work SSS Fig 5 5 Checking the oil level topping up with oil Change After the first 500 operating hours After 3 000 operating hours however no later than after one year With each oil change Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains discon
6. Installation Transport and storage General 3 1 Transport and storage Please observe the generally accepted safety and accident prevention regu lations when transporting the compressor BOGE accepts no liability for dam age caused by improper transport Attention The transport of the compressor may only be carried out by adequately in structed 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 posi tion 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 Transport possibilities Forklift truck or lifting cart transport Ensure that the forks are underneath the base frame of the compressor see illustra tion See below if there is no base frame crane transport 1 Fig 3 1 Transport with forklift truck BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 21 Installation Transport and storage Crane transport Attention Do not subject the safety cladding to force during transport Protect the com pressor using wooden spacers see arrows in the following illustrations Remove the transport timbers Intermedia
7. 5 ccencuvsnneceosecbenceescenacdersumndteaseedcerisiestavestanscenctnetects 6 Syt bolS Used Hats di eir ieri 7 Symbols on the compressor 8 Intended Useni ii a eei eter are Ee e e eria 9 Foreseeable Misuse ssssssssssseeeeeme 9 Transport damage sarin ra a a araa ennemis 9 Data on the type plate sssssssssssemm 10 Ig TEM 10 Part 2 2 1 Technical data eet n eerte 11 Product description 2 2 Function description eeeseeseeeeeeee eene nennen nnn nnn 14 Function principle of the air end sssssssssse 14 P gelroU P a a a a 15 Oilcircuit eaaa a aa a rage meaner creer 16 2 3 Compressor CONIO lania ae ienee aa eene teret rye incen 17 Network PreSSUure c ccccccceceeceeeeeeeeeeeeeeaceeceeeeeeeeeeeeseeeeceseneeaeeees 17 Operating states aanere etienne tetra nnne 17 Operatingimodes eben 17 Short operating times eiecti 18 24 Control devices uteri anre ara e aAa e NEE 18 Operating pressure transmitter 18 2 5 Safety and monitoring devices eene 18 General t nA E ee t i e de reb t at 18 Safety valve cad e edd e Pues dde dde a 19 Safety temperature limiting device sseeee 19 Monitoring the drive motor emm 19 BOGE Operating instructions for C 3 L C 7 L series screw compressors Page III Index E Part 3 3 1 Transpor
8. Year of construction Serial number F a d max m Mmin Final compression pressure bar Motor speed min Motor power TEE kW Postfach 100713 D 33507 Bielefeld Fax 05206 601 200 www boge com info boge com C C Otto Boge StraBe 1 7 D 33739 Bielefeld Telefon 052 06 601 0 Fig 1 1 Data on the type plate Service Please do not hesitate to contact BOGE service if you have any questions Please call Telephone 49 5206 601 140 In the event of inquiries always specify the following data of your compressor to prevent any delays Type Year of manufacture Machine number Attention Only BOGE service technicians or persons authorized by BOGE in writing may repair or alter the compressor during the warranty period Otherwise all warranty claims will expire Page 10 BOGE Operating instructions for C 3 L C 7 L series screw compressors Product description EN Technical data 2 1 Technical data Technical data for C 3 L C 7 L Compressor assembly part 1 Type C3L C4L C5L C7L Dimensions Width mm 755 755 755 755 Depth mm 485 485 485 485 Height mm 492 492 492 492 Weight silenced kg 105 110 125 130 super silenced kg Max sound pressure level 3 dB A accord to DIN 45635 part 13 silenced super silenced dB A 61 62 67 68 Reference surface measure sile
9. capacity must be rated approx 10 1596 higher than the sum of the cooling air quantity required for all machines operated in the room VDMA Code of Practice sheet 4363 Ventilation of compressor rooms Fora free standing installation the cooling air requirement specified in the table corresponds to the required ventilator capacity Cooling air requirement Please refer to the following table for the cooling air requirement and size of the supply air openings for your compressor Ensure that flaps and weather protection grids have the necessary free cross section We generally recom mend contacting a specialist company for performing the duct construction work and planning Type Drive rating Cooling air Necessary inlet requirement opening for free for free standing unit standing unit kW m R m7 C3L C3LR C3LDR 2 2 800 0 10 C4L C4LR C4LDR 3 0 1200 0 20 C5L CS5LR C5LDR 4 0 1600 0 20 C7L C7LR C7LDR 5 5 2000 0 25 For the cooling air requirements the basis is a 4 C temperature difference between room and outside temperature Tab 3 1 Cooling air requirement necessary aperture dimensions Condensate disposal The air taken in contains water in form of vapour which turns into condensa tion during compression Attention The condensate contains oil Never lead it into the public sewage system without prior treatment Strictly observe the effluent disposal laws of your local authorities
10. 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 The delivery scope depends on your order Prior to commissioning please check whether all required parts have been provided Please check the order confirmation for any possible accessory equipment The delivery scope includes the following component parts Operating instructions Electric circuit diagram in the compartment of the switch cabinet List of electrical equipment in the compartment of the switch cabinet Oil drainage hose Head nut in the compartment of the switch cabinet Spare parts list Remove the packing material on and in the compressor Install compressor and align horizontally The compressor must stand firmly on the ground on all feet For compressor assemblies of the series C 3 L to C 7 L the operating height of he control has to be 400 mm according to EN 60204 400 For this reason the compressor assembly has to be installed on a console or pedestal on site Page 26 BOGE Operating instructions for C 3 L C 7 L series screw compressors Installation Electrical connection The compressors have to be installed in such a manner that an ergonom ically convenient operation from the
11. dryer V 230 230 230 230 Frequency Hz 50 50 50 50 50 50 50 50 Recommended fuse protection A 16 20 25 25 16 20 25 25 Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fuse gL gG or circuit breaker with C characteristic only Page 12 BOGE Operating instructions for C 3 L C 7 L series screw compressors Product description EN Technical data for C 4 LR C 7 LR Compressed air system 160 litre receiver 13 bar part 1 C 4 LDR C 7 LDR Compressed air centre 350 litre receiver 13 bar part 1 Technical data Type C 4LR C 7 LR C 4LDR C 7 LDR Dimensions Width mm 1445 1445 1755 1755 Depth mm 550 550 720 720 Height mm 1080 1080 1215 1215 Receiver volume I 160 160 350 350 Weight silenced kg 230 250 300 320 super silenced kg Max sound pressure level 3 dB A accord to DIN 45635 part 13 silenced super silenced dB A 62 68 62 68 Reference surface measure silenced super silenced dB A 13 13 13 13 Sound power level silenced super silenced dB A 75 81 75 81 Compressor max final compression temperature C 110 110 110 110 Volume flow according to ISO 1217 appendix C at Pmax 8 bar m min Pmax 10 bar m min
12. filter The intake filter cleans the air suctioned by the air end Intake regulator The intake regulator opens load operation or closes idling operation or standstill the suction line depending on the operating condition of the compressor Air end The air end compresses the sucked in air Compressed air oil receiver The compressed air separates from the oil under the force of gravity in the compressed air oil receiver Oil separator The oil separator separates the residual oil contained in the compressed air Minimum pressure check valve The minimum pressure check valve does not open until the system pres sure has increased to 3 5 bar This causes a rapid build up of the system pressure and ensures lubrication in the starting phase Once the com pressor has been switched off the check valve prevents the compressed air from flowing back out of the mains line 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 Stop valve The screw compressor may be isolated from the mains by means of the stop valve ptionally for receiver systems without refrigeration compressed air dryers BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 15 Product description EN Function description Cil circuit The oil injected into the air end has the following functions It dissipates the compressi
13. it has been cleaned twice Hitonthe filter cartridge using the palm of your hand to knock out coarse dust Blow out fine dust from the inside to the outside using dry compressed air maximum pressure 5 bar Clean the sealing surface of the filter cartridge Drive motors with permanent lubrication Fitting a filter cartridge Insert filter cartridge into the filter housing Attach lid of the filter housing As a rule the bearings of the drive motors are provided with a maintenance free permanent lubrication Under normal operating conditions coolant temperature max 40 C continous operation the bearings are maintenance free for the service life For motor maintenance see operating instructions of the compressor comtrol Page 44 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance Regular maintenance work The service life decreases or increases as thermal stress increases or decreases due to increased or reduced coolant temperature A Attention Have BOGE service dismantle the bearings and install new bearings once the specified service life has expired Checking the oil level topping up oil Check Prior to commissioning start up of the compressor Then every 1 000 operating hours however at least once a year Topping up When the oil level has dropped below the min mark see sketch Attention
14. mineral oils is subject to legal regulations It is an offense not to ensure correct and safe disposal of old oil Please instruct one of the known service companies to dispose of used operating materials or deliver them to an authorized disposal point Observe the following points when disposing of old oil Never mix the oil with other material or liquids Used oil filters and oil separator cartridges require special waste treat ment and must be kept separate from normal waste Pressure hoses AA Caution Risk of injury and damage to compressor due to obsolete pressure hoses Never use pressure hoses beyond the prescribed service life Check hoses and connections regularly for leakages Check the service life of the hoses and replace them in due time As replacement only use original spare parts released by BOGE Used pressure hoses are not permitted as a replacement Spare and wearing parts AA Caution Only use original spare parts compressor oils and operating materials released by BOGE for repair and maintenance work BOGE is not liable for any damage resulting from the use of other spare parts or operating materials Attention If the nozzle with dirt catch is soiled the oil consumption may increase sig nificantly BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 41 Maintenance Regular maintenance work Drainin
15. off dur ing operation depending on the network pressure All screw compressor controls are based on three basic operating states 1 Load operation The compressor delivers its maximum amount of compressed air It consumes its maximum energy 2 Idling operation The compressor runs but does not deliver any compressed air It consumes approx 75 less energy than in load operation When compressed air is required it switches to load operation without delay Idling operation reduces switching frequencies which can damage the drive motor and reduces wear of the system 3 Standstill ready for operation The compressor is standing still but ready for operation When compressed air is required it switches automatically to load operation The two most important operating modes are achieved by combining the three operating states 1 Intermittent operation In intermittent operation the energy balance is perfect The compressor operates in load operation Upon reaching the switch off pressure Pmax the compressor switches to standstill It does not consume any energy Once the pressure has dropped to the switch on pressure p compressor switches back to load operation 2 Continuous operation Continuous operation limits the drive motor switching cycles and reduces wear to the system The compressor operates in load operation Upon reaching the switch off pressure p the comp
16. operator s stand is guaranteed The local specifications of the EN 60204 regulations always have to be complied with Connecting the Connect the compressor to the compressed air network or a compressed compressor to the air receiver compressed air network For this use a BOGE high pressure hose For pneumatic connection see dimensioned drawing Note 3 Do not install a check valve in the pressure line The compressor is already equipped with a check valve Checking the oil level BOGE compressors are supplied with a complete oil filling Prior to commissioning start up check the oil level as described in chapter Maintenance 3 4 Electrical connection Warning Voltage Ensure that work on the electrical equipment of the compressor is only car ried out by authorized electricians When connecting to the power supply observe the valid VDE DIN and EVU regulations or the local safety regulations Also observe the regulations of your local power supply company regarding the load rating of your power supply Mains disconnecting device According to accident prevention regulation VBG 5 12 the customer is re sponsible to provide the following safety measures Each compressor plant has to be equipped with a power disconnecting device according to DIN EN 60204 1 2007 Please refer to the Technical data for the design and fuse rating Rated voltage The data of your mains op
17. pressure cushion The combined compressed air oil receiver is located atthe lowest point of the system Therefore a light pressure cushion approx 1 5 bar system pressure must be applied to drain the oil This pressure cushion forces the oil through the drain hose into a suitable collecting basin Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Draining old oil Switch off compressor Open ball valve at the compressed air outlet Switch off compressor After approx 2 sec screw cap nut 5 on the bleed aperture of the magnetic valve the nut is located in the storage compart ment of the switch cabinet Caution Risk of injury Danger of burning due to hot oil Always wear safety gloves Page 48 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance Regular maintenance work Remove blind plu 1 at oil drain 3 with the tap closed Fitoil 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 Remove oil drainage hose and replace blind
18. soiled Prior to changing the oil type Attention Detailed information as to the flushing with BOGE oils you can obtain from the following service number Telephone 49 5206 601 140 Page 50 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance Regular maintenance work Cleaning the compressed air oil Cleaning After 1 500 operating hours however at the latest after one year cooling unit Note The service life of the compressed air oil cooling unit depends on the degree of soiling dust oil vapour of the suctioned cooling air Extreme external soil ing of the cooling unit leads to an increased temperature in the oil circuit Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Attention Do not use any sharp objects for cleaning These could damage the cooling unit Blow down the dirt with compressed air in the opposite direction to the normal cooling air flow Vacuum out the dirt using an industrial vacuum cleaner If the cooling unit is excessively soiled cleaning is no longer possible with compressed air have it disassembled and cleaned by BOGE service Compressed air oil cooling unit Fig 5 10 Cleaning the compressed air oil cooling unit BOGE Operat
19. the compressed air receiver and its equipment from a safe loca tion Adhere to safety areas and safety clearances Ensure that the compressed air receiver stands securely It must not shift or tilt due to external forces This also includes the additional weight dur ing a pressure test The compressed air receiver must not be bolted to the base Ensure that the compressed air receiver is easily accessible from all sides for recurring tests 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 p lt 20 of the maximum operating pressure Installation surface Fire protection A level industrial floor without foundation is adequate for the installation of the compressor No special fastening elements are required The following applies to rooms in which compressors with oil injection cooling are to be installed Caution For compressors with motor ratings exceeding 40 kW ensure that the compressor room is equipped with special fire protection Install compressors with motor ratings exceeding 100 kW in a separate fire protected room Requirements of fire prot
20. the hazards of the machine working places in his area of respon sibility and to issue the ensuing operating instructions to name a person responsible beeing in charge of the safe operation of the machine as well as the coordination of all service work performed on it avoid stress situations while operating the compressor by means of tech nological and organizational operation scheduling ensure a proper workplace lighting at the compressor control section ac cording to the local health and safety regulations Observe the safety data sheet of the used lubricants and to customize the personnel all information as to said data sheet provide the compulsory personal protective equipment and to stipulate and check the wearing of said protective equipment on a regular basis assign the personnel responsible for various tasks and work on the ma chine instruct the personnel on a regular basis with respect to all obligations as to compressor related preservation of safety and tidiness BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 3 General E General safety instructions Personnel requirements Personal protective equipment Safety instructions for maintenance and repair of the compressor 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 regulati
21. Attention When ordering please specify the data on the type plate Type Year of manufacture Machine number BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 53 Appendix EN Guidelines and standards complied with 6 1 Guidelines and standards complied with The compressor conforms to the following guidelines and standards Guidelines and directives EC Machine Directive 2006 42 EC Pressure Equipment Directive 97 23 EC EMC Guideline 2004 108 EC Low Voltage Directive 2006 95 EC Applied harmonized standards DIN EN 1012 1 1996 DIN EN ISO 13857 2008 DIN EN ISO 12100 1 2004 DIN EN ISO 12100 2 2004 DIN EN 60204 1 VDE 0113 1 2007 DIN EN 61000 6 2 VDE 0839 6 2 2006 DIN EN 61000 6 4 VDE 0839 6 4 2007 6 2 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 3 L C 7 L series screw compressors Page 55 Appendix LE Flow chart Air cooled version standard 21 N24 e Page 56 BOGE Operating instructions for C 3 L C 7 L series screw compressors Appendix e Flow chart 10 102 Intake air INLET Compressed air OUTLET Suction filter Suction controller Ventilation and regulation control valve Drive motor Compressor air end Final compression temperature display and switch Combined compressed air o
22. BOGE AIR THE AIR TO WORK BOG COMPRESSED AIR SYSTEMS Operating instructions Directly coupled screw compressors Series 63b Cy ll C 3LR C 7 LR C 3 LDR 6C 7 LDR Separate manuals Compressor control Refrigeration compressed air dryer C LDR www boge com Operating instructions for directly coupled Screw compressors C3L C3LR C3LDR 2 2 kW CAL CALR CALDR 3 0 kW C5L C5LR C5LDR 4 0 kW C7L C7LR C7LDR 5 5 kW BOGE KOMPRESSOREN Postfach 10 07 13 33507 Bielefeld Otto Boge StraRe 1 7 33739 Bielefeld Phone 49 5206 601 0 Fax 49 5206 601 200 Mail info boge com Net www boge com Issue 05 2011 No 596 1144 01 Nominal price 5 00 BOGE Operating instructions for C 3 L C 7 L series screw compressors Pagel Index Part 1 1 1 General safety instructions cccceseeeeeeeeeee eee eeeeeeeeeeeneaeeeeeeeees 1 General Safety instructions for compressor operation suus 1 Special hazard warnings ssesssee e 2 Electrical energy hazards sesssseeee e 3 Obligations of the owner ssssem 3 Personnel requirements ssssssssssseeeeeemee 4 Personal protective equipment ssssssssssee 4 Safety instructions for maintenance and repair of the compressor 4 Accident prevention regulations seee 5 1 2 Introdu ctiOn
23. 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 emul sion cracking plant BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 25 Installation Installation General 3 3 Installation BOGE compressor units are supplied ready for connection Only the work de scribed in the following paragraphs needs to be carried out during the installa tion Caution Only have the installation work carried out by appropriately trained persons or specialists Lay out all energy supply lines in a trip proof and barrier free manner so that potential accidents can be avoided Prior to delivery each compressor is subjected to a trail run at the factory It is carefully tested and set However possible transport damage cannot be excluded Checking the delivery scope Installing the compressor 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
24. Pmax 13 bar m min 0 234 0 525 0 234 0 525 Drive motor Rated power kW 3 0 5 5 3 0 5 5 Electrical power intake dryer kW 0 21 0 28 Nominal speed 50 Hz min 1500 3000 1500 3000 Protection type IP 55 55 55 55 Design IMB 35 35 35 35 ISO class F F F F Electrical connection Mains voltage 3 Ph V 400 400 400 400 Mains voltage dryer M 230 230 Frequency Hz 50 50 50 50 Recommended fuse protection A 20 25 20 25 Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fuse gL gG or circuit breaker with C characterist ic only BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 13 Product description Function description Technical data for C 3 L C 7 L Compressor assembly Compressed air system part 2 C 3 LDR C 7 LDR Compressed air centre part 2 C3L C4L C5L C7L Type C3LR C4LR C5LR C7LR C 3 LDR C4LDR C5LDR C7LDR Oil filling quantity Total oil filling quantity I 4 4 4 4 Oil topping up quantity between min max I 1 1 1 1 Intake air temperature min C 5 5 5 5 max C 40 40 40 40 Cooling air requirement free standing installation m n 800 1200 1600 2000 with supply and exhaust m h free ventilator pressure Pa free ve
25. al safety instructions Caution Nonobservance of the following safety instructions may lead to injuries and damage to the compressor Also observe the generally valid safety and accident prevention regulations in addition to the information in these operating instructions Safety instructions for compressor operation 1 10 11 Ensure that no commissioning and maintenance work on the compressor is undertaken until these operating instructions are understood Only use the compressor for its intended use as described in these operating instructions 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 thatthe 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 Avoid any operating method which may impair the safety of the compres sor Always wear your compulsory personal protective quipment as a protec tion against injuries from sharp corners or edges when working on the compressor To avoid dangers from debris or parts lying around the service area of the compressor has always to be kept tiedied up and clean Always squat when worki
26. andling oil We recommend using only oil according to the following specification Viscosity range of 55 mm s at 40 C Minimum viscosity at 100 C of 8 mm s Maximum viscosity at 0 C of 1 000 mm s Failure load stage 10 FZG Test DIN 51 354 02 ISO DIS 14 635 1 Test Method A 8 3 90 10 Excellent oxidation stability Meets requirements of Pneurop oxidation test Antifoam additives Additives to prevent residue formation Compatibility with all materials which are resistant to mineral hydrocar bons e g Neoprene NBR FPM PTFE acrylic and epoxy resin pains nylon polyamide and PVC Flash point DIN ISO 2592 gt 230 C Excellent demulsifying properties Additives for corrosion protection of metallic surfaces Excellent oxidation stability Rotating bomb oxidation Test ASTM D 2272 higher than 2 400 minutes Meets VDL requirements DIN 51 506 including Pneurop test Or you use BOGE compressor oil Syprem 8000 S The stated maintenance intervals refer to the use of Syprem 8000 S only Syprem 8000 S can be purchased from BOGE retailers Never mix different oil types and brands The additives may be incompat ible It may lead to foam formation premature aging or loss of lubricating ability Page 40 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance EN General Disposal of used operating material Attention The handling and disposal of
27. ase 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 Conduct trial run Undertake the following to prevent leaks Check screw connection of the lines and retighten if necessary 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 Page 30 BOGE Operating instructions for C 3 L C 7 L series screw compressors Installation Commissioning Commissioning If an extended stoppage is scheduled you should contact BOGE Service be following extended forehand stoppages Following an extended stoppage of more than 2 months fill a small amount of oil in the suction controller prior to starting the compressor Attention Only fill the suction controller with the grade of oil used to operate the com pressor Never mix
28. cident prevention and envi ronmental protection In the illustrations the compressor is shown in part without safety cladding or safety devices for better visualization However operation without these com ponents is prohibited Page 6 BOGE Operating instructions for C 3 L C 7 L series screw compressors General E Introduction Symbols used In these operating instructions the most important safety notes and tips are especially characterized by the following symbols Caution Risk of injury This symbol indicates information warning of possible danger to life and limb of the operator or other persons Attention This symbol indicates information warning of dangers to life and limb of the operator or other persons or dangers which might destroy or damage the compressor Warning Voltage This symbol indicates information warning of life threatening electrical volt age levels It indicates work which must be exclusively performed by skilled electricians Note This symbol indicates information and tips concerning the economical and careful operation of the compressor a gt gt BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 7 General EH Introduction Symbols on the compressor Note 3 All warning signs on the compressor and in its surrounding must always be kept in a legible condition Missin
29. different oil grades and brands Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Unscrew the plug on the suction controller 1 Fill approx 1 4 compres Sor oil into the suction controller Reclose the controller using the plug Turn compressor stage at the shaft by hand 5 to 10 times to spread the oil evenly Fig 3 3 Suction controller Refrigeration Before commissioning the refrigeration compressed air dryer read attached compressed air dryer operating instructions Caution Risk of injury Observe all safety notes specified in the attached operating instructions when working with coolants BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 31 Installation Dismantling 3 6 Dismantling Ry Note To avoid dangers when dismantling the compressor please consult your BOGE Service Telephone 49 5206 601 140 AA Caution Dismantling of the compressor may only be carried out by experienced and authorized qualified personnel Make also sure to observe all information in the attached operation instruc tions as to a safe dismantling of the refrigeration compressed air dryer and a secure disposal of the coolant Warning Voltage All work on the electrical installation may only be carried out by authorized and skilled
30. e operating switch and it was already switched on before the mains failure green indicator lamp ON 3 5 Commissioning Note We recommend the drawing up of a commissioning certificate in which the test results during the commissioning process can be listed up Caution Risk of injury The commissioning may only be carried out by experienced and authorized qualified personnel Always wear protective gloves when working on the compressor to avoid bruising of fingers or hands while opening or closing components Page 28 BOGE Operating instructions for C 3 L C 7 L series screw compressors Installation Commissioning Check installation requirements Attention Make sure that the compressor is installed according to the installation re quirements List up the test results in the commissioning certificate Checking the rotational direction Attention Always check the rotational direction of the drive motor prior to commission ing initial start up Even brief operation in the wrong direction of rotation more than approx 5 seconds may cause total destruction of the air end List up the test results in the commissioning certificate Caution Ensure that the rotational direction coincides with the rotational direction ar row on the air end Close mains disconnecting device Switch the compressor on and immediately off again to check the rota tional direction
31. ected compressor rooms Walls ceilings floor and doors must be designed in fire protection class F30 or higher Flammable liquids must never be stored in the compressor room The floor around the compressor must be made of non flammable mate rial BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 23 Installation Compressor room Sound protection Admissible environmental influences Leaking oil must not spread out over the floor Noinflammable materials must be located within a radius of at least 3 me tres around the compressor Noinflammable machine parts such as cable ducts may run overhead of the compressor Only install compressors in workrooms if the sound pressure level of their measuring surfaces does not exceed 85 dB A The compressor room must be clean dry cool and free of dust Admissible ambient temperatures Maximum ambient temperature 40 C Minimum ambient temperature 5C Attention Nonobservance of the admissible ambient temperature may lead to the following problems The compressor will switch off when the admissible final compression temperature is exceeded or gone below Pipe lines and valves will freeze up at low temperatures Damage due to reduced lubricating ability of the compressor oil Measures to be taken to ensure that admissible ambient temperatures are observed Avoid any pipe line
32. ed 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 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 Caution 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 A rigidly screwed down protective cover prevents you from accidentally reaching into the drive coupling during operation of the compressor Caution Risk of injury Never operate the compressor with dismantled coupling protection There is a risk that you reach into the fast rotating coupling Any servicing on the coupling may only be carried out during standstill of the compressor The pressure relief valves as well as the intake and exhaust opening on the suction
33. electricians Prior to starting the work the power cable to the switch cabinet must be dis connected from the mains and secured against unintentional switching on Page 32 BOGE Operating instructions for C 3 L C 7 L series screw compressors Faults DH General 4 1 General The tables on the following pages give information on the possible causes of operating faults and measures for their rectification please also refer to operating instructions of the compressor control Caution Ensure that any work required to rectify faults is only carried out by qualified personnel or specialists Ensure that components which have a safety function are only set repaired or exchanged by BOGE Service Please contact BOGE Service at the following telephone number if you have any questions Telephone 49 5206 601 140 4 2 General faults Fault Possible cause Rectification No quantity delivered no pressure build up max pressure 0 5 bar System components in the compressor are leaking Check oil and compressed air lines inside the compressor tighten and or reseal screw connections if necessary Minimum pressure valve is defective Close ball valve and check whether pressure builds up if so open ball valve again immediately replace minimum pressure valve Electromagnetic venting valve does not close Check solenoid valve and replace if necessary Suction controller does not open Suc
34. erating voltage control voltage type of current fre quency 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 BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 27 Installation Commissioning Connecting the leads Check to ensure that all terminals in the switch cabinet are firmly tight ened If necessary retighten the screw connections Guide the lead cable through the PG screw connection Connect the leads L1 L2 L3 N Pe PEN firmly to the power supply ter minal A clockwise rotational field must be created Retighten the electrical connections after the first 50 operating hours Caution Risk of injury Prior to any work on the compressor Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Check to ensure that all conducting machine parts are voltage free Depressurize all areas under pressure Never omit a single safety step Otherwise you will risk injuries due to restart ing electric shock or self releasing parts Caution With an activated automatic restart Auto Restart the compressor may re start automatically after a voltage failure Prerequisite The network pressure is lower than the set cut in pressure of th
35. fety 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 button Page 36 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance E General 5 2 General Maintenance through Have BOGE service check your compressor every 3 000 operating hours or BOGE customer service annually Note Maintenance agreement Enter into a maintenance agreement with BOGE BOGE service will carry out the proper maintenance on your compressor at regular intervals This guarantees maximum safety and realiability of your compressed air supply Review of regular maintenance work Fig RWwWRN D Lt Q RO Sos EN 5 1 Review of regular maintenance work Check adjust pressure Clean oil cooler Top up oil in the suction controller after an extended down time Check suction filter Clean Change filter cartridge Change oil filter Change oil separator Check oil level Top up oil Change oil BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 37 Maintenance EN General Maintenance intervals The maintenance intervals specified in the table are based on average oper ating and ambient conditions E
36. filter are mounted at the back in order to prevent the com pressed air exhaust jet from pointing toward the operator Page 2 BOGE Operating instructions for C 3 L C 7 L series screw compressors General EN General safety instructions Electrical energy hazards Warning 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 Any modifications that may have been carried out after examination must conform to DIN EN 60204 1 2007 Make sure to check all safety installations on the machine for proper func tioning at regular intervals Only use original fuses Obligations of the owner The owner is obliged to operate the compressor only in technically perfect condition check the Emergency Stop device of the compressor regularly for com pleteness and functionality assess
37. g off the condensate from the compressed air receiver 5 3 Regular maintenance work Draining If no automatic condensate darining is fitted then drain off the condensate at least once a week Attention The compressor is lubricated with oil The condensate contains oil and may not be drained off into the public sewage system Pay attention to the pertaining rules and regulations of your local authorities Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Depressurize receiver Place a suitable basin underneath the condensate drain of the receiver Open the ball valve and drain off the condensate Close the ball valve again Dispose the condensate properly Fig 5 2 Draining off the condensate manually Page 42 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance Regular maintenance work Draining off the condensate from the compressed air receiver with automatic condensate separator The fully automatic electronically controlled condensate separator is equipped with a wear free sensor which monitors the condensate level in the integrated collecting basin As soon as the collecting basin is full a solenoid valve opens and the condensate is drained off Ry Note
38. g or damaged signs must be replaced at once The following symbols and warning signs are fitted on the compressor Warning Hot surfaces Do not touch Warning The unit is operated by remote control and might start without warning ag Note ILL Instructions for the operating personnel must be read Prohibited Never open the valve before the air hose connection to the compressed air network is connected Page 8 BOGE Operating instructions for C 3 L C 7 L series screw compressors General E Introduction Intended use AA Caution BOGE compressors including their additional equipment are exclusively intended for the compression of air The air taken in must not contain any explosive or chemically instable gases or vapours Do not exceed the specified final compression temperature BOGE compressors are designed for stationary operation Ensure that they are only installed and operated in dry and clean rooms Operation and control are designed to be executed by trained and authorized operators Foreseeable Misuse AA Caution 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 ex
39. il receiver Oil separator Safety valve Compressed air after cooler Optionally for receiver systems without refrigeration compressed airdryer Thermostatic oil control valve Oil cooler Oil filter Minimum pressure check valve Network pressure transmitter Pressure gauge reading in display Stop valve compressed air outlet Stop valve oil drainage Throttle with filter BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 57 List of maintenance and service work 6 3 Appendix 6 3 List of maintenance and service work obueu u2 oDueu u2 J04ju02 09 xx Bujuee o JeKup JIe 92Ueu Buiuea o passaid jujew yun Jojesedas ana Joy 13y an ainssaid eunssejd sunoy SXJEUIOM W09 10o Buijo0 IIO 10 IIO oyeju amp Joduo ulejs S ylomjay Bugejedo ajeq suuinjoo aAnoedsai eu ui 4104 e2ueuo ureui pajojduuoo au ojou esea d BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 58 List of maintenance and service work 6 3 Appendix oDueu Yd JOUOD 09 ax abueyd y Duiueej z 2 x syieway JeKup 1e passaid W09 e2ueu ejuieul 100W Bulueajo jun BuiJoo Jojejedas I0 Janay 10 Jayy JO sel exejul aun eadwa ainssald ainssald wa
40. ing instructions for C 3 L C 7 L series screw compressors Page 51 Maintenance Regular maintenance work Checking the safety Check valve After approx 3 000 operating hours however at least once a year Check safety valve by opening the screw plug 1 Caution Risk of injury Danger of burning due to hot oil Take extreme care when checking the safety valve with the compressor running taking all safety measures into consideration Always wear safety gloves A hot air oil mixture escapes when opening Open the threaded plug 1 anticlockwise The compressed air escapes Tighten the threaded plug by turning clockwise Fig 5 11 Check safety valve Page 52 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance List of spare and wearing parts for maintenance List of available optional equipment EN Spare parts and optional equipment 5 4 Spare parts and optional equipment Designation Compressor oil Syprem 8000 S Maintenance kit consisting of oil filter oil separator suction filter cartridge gaskets nozzle with dirt catch Wearing part kits for oil regulator minimum pressure valve solenoid valve Intake regulator incl solenoid valve Designation Optional equipment for compressed air treatment Oil water separator Automatic condensate draining unit Bekomat
41. jsfs YIOMJON sunoy bugeiedo aeq suuinjoo 9Anoedseai eui ui YOM e2ueuojureui pajojduuoo aui 40u esea d Page 59 BOGE Operating instructions for C 3 L C 7 L series screw compressors List of maintenance and service work 6 3 Appendix obueu y9 10 U09 02 xx abuey uy Bujues o x syeway JeKAp se p ss sd w09 eoueu ejuleul JOJO Bulueajo jun BuiJoo Jojejedes I0 Janay 10 JOY TO Joy exejul aun EJedio enssoJd wajsfs ainssald XJ0MJON sunoy Bugeiedo ejeg suuinjoo 9Anoedseai eui ui YOM e2ueuojureui pdw aui ojou esea d BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 60
42. level and top up as required 45 Change oil separator 47 Change oil filter 46 Change oil 48 Replace oil regulator wearing parts set Replace nozzle with dirt catch Drive Lubricate drive motor bearings Drive motors with permanent lubrication 44 Replace motor bearing Depending on mains frequency 50 Hz 10 000 operating hours 60 Hz 8 000 operating hours If the compressor is not often used undertake the maintenance according to the specified intervals weekly monthly annually depending on the number of operating hours The specified intervals only apply when BOGE compressor oil Syprem 8000 S is used The service life may differ depending on the ambient temperature In this case have the oil analyzed by your BOGE service Tab 5 1 Maintenance intervals BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 39 Maintenance EN General General information concerning the lubricants used Caution Risk of injury Oil presents a potential danger to health and environment due to their additives Avoid contact with skin and eyes Wear protective gloves made of resistant synthetic material Wash yourself thoroughly after contact with oils Do not inhale the fumes or mist Protect your environment Ensure that no oil is spilt Fire naked flames and smoking is strictly prohibited when h
43. mensions Width nm 1185 1185 1185 1185 1725 1725 1725 1725 Depth mm 550 550 550 550 675 675 675 675 Height mm 965 965 965 965 1165 1165 1165 1165 Receiver volume I 90 90 90 90 270 270 270 270 Weight silenced kg 175 180 195 200 245 250 265 270 super silenced kg Max sound pressure level 3 dB A accord to DIN 45635 part 13 silenced super silenced dB A 61 62 67 68 61 62 67 68 Reference surface measure silenced super silenced dB A 13 13 13 13 13 13 13 13 Sound power level silenced super silenced dB A 74 75 80 81 74 75 80 81 Compressor max final compression temperature C 110 110 110 110 110 110 110 110 Volume flow according to ISO 1217 appendix C at Pmax 8 bar m min Pmax 10 bar m min 0 240 0 340 0 545 0 728 0 240 0 340 0 545 0 728 Pmax 13 bar m min Drive motor Rated power kW 2 2 3 0 4 0 5 5 2 2 3 0 4 0 5 5 Electrical power intake dryer kW 0 19 0 21 0 21 0 28 Nominal speed 50 Hz min 1500 1500 3000 3000 1500 1500 3000 3000 Protection type IP 55 55 55 55 55 55 55 55 Design IMB 35 35 35 35 35 35 35 35 ISO class F F F F F F F F Electrical connection Mains voltage 1 Ph V 230 230 Mains voltage dryer V 230 Frequency Hz 50 50 Recommended fuse protection A 16 16 Mains voltage 3 Ph V 400 400 400 400 400 400 400 400 Mains voltage
44. nced super silenced dB A 13 13 13 13 Sound power level silenced super silenced dB A 74 75 80 81 Compressor max final compression temperature C 110 110 110 110 Volume flow according to ISO 1217 appendix C at Pmax 8 bar m min Pmax 10 bar m min 0 240 0 340 0 545 0 728 Pmax 13 bar m min 0 234 0 525 Drive motor Rated power kW 2 2 3 0 4 0 5 5 Nominal speed 50 Hz min 1500 1500 3000 3000 Protection type IP 55 55 55 55 Design IMB 35 35 35 35 ISO class F F F F Electrical connection Mains voltage 1 Ph V 230 Frequency Hz 50 Recommended fuse protection A 16 Mains voltage 3 Ph M 400 400 400 400 Frequency Hz 50 50 50 50 Recommended fuse protection A 16 20 25 25 Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fuse gL gG or circuit breaker with C characteristic only BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 11 Product description Technical data Technical data for C 3 LR C 7 LR Compressed air system 90 litre receiver 10 bar part 1 C 3 LDR C 7 LDR Compressed air centre 270 litre receiver 10 bar part 1 Type C3LR C4LR C5LR C7LR C3LDR CALDR C5LDR C7 LDR Di
45. nection device and secure against unintentional switch on by means of a padlock Close ball valve at the compressed air outlet Vent the compressor procedure as described above Wait approx 3 minutes to permit the oil to settle Caution Risk of injury Do not touch hot surfaces 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 Page 46 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance Regular maintenance work Attention Over current Non return valve 6 must be fitted facing up Fit oil filter cartridge 4 with support body 5 Check o rings on service cover for damage and replace if necessary Fit service cover 3 and tighten screws Open ball valve at the compressed air outlet Switch on compressor and run till it reaches operating temperature Check tightness of service cover and re tighten screws Changing the oil separator Fig 5 6 Changing the oil filter Changing the oil separators Change When warning message 8 appears on the control system display RATIO only After 3 000 operating hours however no later than after one year Caution Risk of injury If the prescribed maintenance intervals are not observed the oil separat
46. ng on components mounted at low height never stoop When working on components mounted higher up always stand upright and erect Do not exceed the limit value for the final compression pressure specified on the type plate 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 commission ing starting up the compressor and that they are not opened during oper ation 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 Only operate the compressor using the additional equipment options rec ommended or authorized by the manufacturer BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 1 General E General safety instructions Special hazard warnings 12 Undertake conversions and modifications of the compressor only with BOGE prior approval taking all relevant safety regulations into considera tion The manufacturer is not liable for damages resulting from independ ent modifications on the compressor 13 Never start the compressor when one or several parts e g cable plug are damag
47. ntilator pressure mm WC Operating pressure values factory settings Pmax 8 bar Switch off press p bar Switch on press Pmin bar Pmmax 10 bar Switch off press p bar 10 10 10 10 Switch on press Pmin bar 9 9 9 9 Pmax 13 bar Switch off press p bar 13 E 13 Switch on press Pmin bar 12 12 Safety valve Activation pressure at Pmax 8 bar bar 11 11 11 11 Pmax 10 bar bar 11 11 11 11 Pmax 13 bar bar 14 14 14 14 Compressors for other operating pressures Pin Prax 1 bar Function principle of the air end 2 2 Function description The air end operates according to the displacement principle In the housing the main and secondary screws are driven by means of an electric motor Both screws have screw shaped profiles intermeshing without contact To gether with the housing wall these screws form chambers which gradually re duce in size seen in air flow direction Rotation of the rotors causes the air taken in to be compressed to the final pressure in the chambers During compression oil is continuously injected into the air end This having a cooling sealing and lubricating function Page 14 BOGE Operating instructions for C 3 L C 7 L series screw compressors Product description EN Function description Air circuit Fig 7 O 2 1 Components of the air circuit Intake
48. ompressor Defective safety valve Replace safety valve System pressure does not decrease when switching off Venting valve does not open Check venting valve and replace if necessary Check valve is leaking Check the valve and replace if necessary Page 34 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance EN Safety instructions 5 1 Safety instructions Caution Ensure that maintenance work is ony carried out by specialists or appro priately trained persons Prior to starting any maintenance work always stop the compressor as described in these operating instructions before removing any safety cladding or safety devices Refit the safety cladding or safety devices immediately upon completion of the maintenance work Heavy components may only be lifted up by various persons in due con sideration of the local industrial safety regulations Only use original spare parts compressor oils and operating materials released by BOGE for the maintenance work With an activated automatic restart Auto Restart the compressor may restart automatically after a voltage failure Prerequisite The net pressure is lower than the set switch on pressure BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 35 Maintenance EN Safety instructions Caution Risk of injury Always adhere to the
49. on heat cooling It seals the gaps between the screws and between screws and housing It lubricates the bearings Fig 2 2 Components of the oil circuit Compressed air oil receiver The oil separated from the compressed air through the force of gravity col lects in the compressed air oil receiver The system pressure forces it out of the receiver into the air end 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 Cil cooler air or water cooled The oil cooler cools down the hot oil to operating temperature Oil filter The oil filter traps impurities in the oil Air end The injected oil returns to the compressed air oil receiver together with the compressed air There it is separated through the force of gravity 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 16 BOGE Operating instructions for C 3 L C 7 L series screw compressors Product description Compressor control Network pressure Operating states Operating modes 2 3 Compressor control For the compressor the pressure downstream of the check valve is termed network pressure The control system switches the compressor on and
50. ons and operating instructions properly recognize responsibilities and read and understand the operating instructions It is essential to wear the com pulsory personal protective equipment when working on the compressor In general for all work on the compressor protective clothing chemicals resistant gloves Slip resistant safety shoes and hearing protection if applicable are compulsory For special duties protective helmets for transport work with lifting gear and safety goggles when working on the compressed air system on the con trol pneumatics and or on the cooling system of the built in dryer 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 Caution Only use original spare parts compressor oils and operating materials re leased by BOGE during repair or maintenance Warning 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 dis connecting device The mains disconnecting device has to meet the requirements of DIN EN 60204 1 2007 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 appro
51. ors might become blocked In this case the differential pressure will increase until the safety valve blows Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Do not touch hot surfaces BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 47 Maintenance Regular maintenance work Oil change Slacken screws on service cover 3 and remove cover Pull oil disperser cartridg 1 up 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 ball tap at compressed air exit Switch on compressor and run till it reaches operating temperature Check tightness of service cover and re tighten screws Change After 9 000 operating hours however at the latest after two years For other types of oil the appropriate oil change intervals must be complied with Note The service life of the oil the oil filter and oil separators is reduced under the following conditions When the compressor is operated at extreme ambient temperatures When the intake air is extremely soiled Building up a
52. plosive atmosphere Do not operate the compressor in rooms in which extreme dust toxic or flam mable 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 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 BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 9 General kA Introduction Data on the type plate Enter the data of your compressor from the type plate or enclosed data sheet in the illustration below This will ensure that in the event of enquiries you will always have the most important data to hand gt BOGE Type
53. plug with new copper seal Remove the cap nut from the solenoid valve Change oil filter procedure as described above Change oil separators procedure as described above Filling with new oil Fill up to the edge of the thread of the filling socket max procedure as described above Attention After each oil change you have to fill a small quantity of oil into the suction controller before starting the compressor For oil quantity and procedure see chapter Installation chapter Commis sioning following extended stoppages Attention Always fill with the same oil type as previously used Never mix different oil types and brands The oil circuit must be flushed prior to changing the oil type Conduct trial run Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Check the oil filters and oil separators for leaks and tighten by hand if necessary procedure as described above Check oil level procedure as described above Top up oil losses if any BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 49 Maintenance Regular maintenance work Fig 5 9 Oil drain with fitted oil drainage hose Flushing the oil circuit Flushing the oil circuit with clean oil becomes necessary When the oil is excessively
54. 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 Press Emergency Stop button 3 Press Emergency Stop button 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 re sponsible 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 50 C 7 Separate the compressor from the compressed air network by closing the ball valve at the compressed air outlet 8 Vent the compressor To do so open the safety valve on the combined compressed air oil re ceiver as follows Turn the knurled nut anticlockwise until you can feel a resilient resist ance Tun the knurled nut a little further Any possibly existing air will escape The system pressure gauge will indicate a pressure of 0 bar 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 sa
55. priately trained persons Page 4 BOGE Operating instructions for C 3 L C 7 L series screw compressors General EN General safety instructions Accident prevention regulations 3 Prior to maintenance or repair work Press Emergency Stop 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 re sponsible who is authorized to switch on the maschine again Check to ensure that all parts are currentless Disconnect the compressor from the compressed air network relieve or block pressurized lines 4 Exercise extreme caution during repair or maintenance work requiring the compressor to be operational Ensure that persons keep out of reach of the hazardous area 5 Ensure that work on the electrical equipment is only executed by qualified electricians 6 Work on parts and devices under current is prohibited Exceptions are governed by the appropriate regulations e g DIN VDE 0105 7 Prior to starting work on the electrical system the power supply has to be switched off and secured against unintentional switching on again Imme diately 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
56. r plant BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 5 General kA Introduction 1 2 Introduction The purpose of these operating instructions is to familiarize the user with the function and all application possibilities of the compressor These operating instructions contain important information on how to operate the compressor safely economically and according to its intented use Ob serving these operating instructions will assist in avoiding danger to reduce repair costs and down times and to increase the reliability and service life of the compressor It contains important information concerning the required maintenance and repair measures assists in case of malfunctions and con tains data concerning spare and wearing parts The operating instructions must be available to the compressor operating per sonnel at the place of operation at all times The operating instructions must be carefully read and applied by all persons engaged to undertake the following work on the compressor Operation including fault rectification and daily care Maintenance service inspection repair Commissioning Transport The compressor and its additional equipment must not be installed and com missioned until the operating instructions are understood These operating instructions can be supplemented with instructions on the basis of existing national regulations concerning ac
57. ressor switches to idling operation Once the pressure has dropped to the switch on pressure pnn the compressor switches from idling operation back to load operation he min t max BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 17 Product description ER Control devices Short operating times Attention During short operating times the compressor does not reach its operating temperature It operates below the dew point The generated condensate mixes with the oil The lubricating ability of the oil is reduced This leads to damage on the air end It is of utmost importance to consult BOGE if you operate your system with short operating times Operating pressure transmitter General 2 4 Control devices The operating pressure transmitter enables an operation of the compressor within the set switching limits Switch on pressure p If the supply pressure drops to the set switch on pressure p Switches on Switch off pressure Pmax If the supply pressure increases to the switch off pressure p the compres sor either switches off intermittent operation or switches to idling operation continuous operation the compressor min 2 5 Safety and monitoring devices The safety devices guarantee a high degree of operational safety in connec tion with the BOGE monitoring system When one of the safety devices responds the control system react
58. s as fol lows The compressor is immediately switched off A flashing fault number in the left field of the display indicates the cause of the fault Caution Risk of injury Do not operate the compressor without built in safety devices Do not dismantle the safety devices or put them out of operation The following monitoring devices are standard for BOGE control systems Page 18 BOGE Operating instructions for C 3 L C 7 L series screw compressors Product description Safety valve Safety and monitoring devices The safety valve 1 on the compressed air oil receiver prevents the maximum admissible pressure being exceeded Fig 2 3 Safety valve Caution Risk of injury When the maximum pressure is exceeded e g incorrect setting of the oper ating pressure value the entire delivery volume of the compressor is eject ed Safety temperature limiting device Monitoring the drive motor 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 tem perature Rectify the fault Acknowledge fault by pressing ENTER key Switch on the compressor ON button The drive motor is monitored by PTC resistors BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 19
59. s 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 of anti freeze function only in mode Ready for operation Ventilation If the following instructions are not observed the admissible final com pression temperature may be exceeded In this case the compressor will switch off automatically Caution Arrange the compressor intake openings or ducts in such a way that dan gerous admixtures e g explosive or chemically unstable materials cannot be drawn in Ventilation openings free standing installation Arrange supply air openings close to the floor Arrange exhaust air openings in the ceiling or at the top of the wall The required cross sections for the supply openings as well as for the flaps and weather protection grids are indicated in the table Page 24 BOGE Operating instructions for C 3 L C 7 L series screw compressors Installation Compressor room Ventilators Ensure that the heated exhaust air is not taken in again If necessary the heated air must be extracted by ventilators To ensure perfect cooling even at higher temperatures in the summer the ven tilators must be designed as follows The ventilator
60. t and storage eese 21 Installation Generalis ode tet me m ha de tiet La i vila e AEE 21 Transport possibilities ssssemmRRII 21 Intermediate storage ssssssssssssssseeeeneemes 22 3 2 Compressor rOOm eieuiieicce eco ch tenente Donee entre Dena Rana rau 23 Installation maintenance conditions and application for compressed air receivers arranged below or separately 23 Installation surface sssssssssssseeeeeen ees 23 Fire protection nunica rr PR sant deans S RARE aa aaaea ea raTa 23 Sound protectlOn s ux eie dade incederet ineunt dna Eee geek t 24 Admissible environmental influences sssssssssssss 24 Ventilatio ET 24 Cooling air requirement sssseeenn ee 25 Condensate disposal sss 25 3 3 Installationi crore riti octo eer inert nece tc rcc nen Tes eie 26 Generale daten 26 Checking the delivery scope ss m 26 Installing the compressor sseenm mH 26 Connecting the compressor to the compressed air network 27 Checking the oil level nne 27 3 4 Electrical connection ueeeeeeeseeseesseeeeer ener 27 3 5 Commissioning seekar nani Nanananananana a Ea ANAA rada dence 28 Check installation requireMents ccccccceceeeeeeeeeeeeecaeeeeeeeeeeeeees 29 Checking the rotational direction
61. te storage Only use suitable transport slings having a minimum length of approx 8 metres Position the slings at the ends underneath the base frame of the compressor 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 Ry Note In case of an intermediate storage please observe the specifications and directions as to permissible environmental impacts see chapter 3 2 Com pressor room Installation maintenance conditions and application for com pressed air receivers arranged below or separately In case of a careless storage we assume no liability for consequent dam ages In the event of an extended intermediate storage you should consult BOGE Service Please observe the directions for commissioning after an extended standstill see chapter 3 5 Commissioning if the intermediate storage takes longer than two months Page 22 BOGE Operating instructions for C 3 L C 7 L series screw compressors Installation Compressor room Installation maintenance conditions and application for compressed air receivers arranged below or separately 3 2 Compressor room Caution Protect compressed air receivers against damage through mechanical effects e g falling objects Operate
62. tion controller or solenoid valve is defective check and replace if necessary Compressor system does not start up 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 elec trical mains power Ensure constant voltage in accordance with IEC 38 Compressor oil is very viscous due to low ambient temperature Heat up the compressor system additional heater available as an option BOGE Operating instructions for C 3 L C 7 L series screw compressors Page 33 Faults General faults Fault Possible cause Rectification Cil in suction filter Minimum pressure non return valve is leaking Check the minimum pressure check valve and replace if necessary Suction controller is leaking Check the suction controller and replace if necessary Cut out performed by emergency off switch Cut out normally via O key Excessive oil consumption 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 Operating pressure target value maladjusted Set operating pressure to maximum permissible pressure of the screw c
63. 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 The owner of a compressor plant is responsible to ensure that it is properly installed operated and maintained Prior to commissioning owners in the Federal Republic of Germany urgently have to read the currently valid regulations of the Main Association of the Industrial Employers Liability Insurance Apart from other regulations particu larly the Ordinance on Industrial Safety and Health BetrSichV is applicable The regulations are available at the following locations Berufsgenossenschaft Industrial Employers Liability Insurance Carl Heymanns Verlag KG Luxemburger Straf e 449 D 50939 K ln Beuth Verlag GmbH Burggrafenstraf e 6 D 10787 Berlin For operation of the compressor plant outside the Federal Republic of Ger many the accident prevention regulations of the country where the compres sor 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 regula tions specified in the Federal Republic of Germany or the data contained in these operating instructions then it is of utmost importance that these be car ried out prior to commissioning the compresso
64. xtreme conditions may require shorter maintenance intervals Ry Note Note down any maintenance work in the table on the last page This will facil itate trouble shooting for Boge service Attention Check monthly if all screw connections on the compressor are fully tight ened Oil change Please change oil and replace oil filter and nozzle with dirt catch after the first 500 operating hours Page 38 BOGE Operating instructions for C 3 L C 7 L series screw compressors Maintenance General Maintenance work Maintenance intervals in operating hours weekly monthly 1 000 annually 1 500 annually 3 000 annually 9 000 every 2 years Page General maintenance work Check final compression temperature set point value 70 100 C Control Check compressor for leaks Check system relief on system pressure gauge 22 set point value 0 1 5 bar Control Check function of EMERGENCY STOP button Clean oil cooler 51 Draining off condensate from compr air receiver Check automatic condensate drainage Check if electrical connections are tightened Air circuit Check and if necessary clean suction filter 43 Change suction filter cartridge 44 Check safety valve 52 Replace minimum pressure valve wearing parts set Replace suction controller Oil circuit Check oil

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