Boge C 15 User manual

www.boge.com
Operating instructions
Belt-driven
screw compressors
C 15
C 15 F
Separate manuals:
Compressor control
Frequency converter (C F)

BOGE Operating instructions for C 15 series screw compressors Page I
Operating instructions
for belt-driven
screw compressors
–C15 (15 Hp)
–C15 F(15Hp)
BOGE KOMPRESSOREN
Postfach 10 07 13
D-33507 Bielefeld
Otto-Boge-Straße 1-7
D-33739 Bielefeld
Fon: [phone]
Fax: [phone]
Mail: [email protected]
Net: www.boge.com
Issue: 03 / 2012
No. 596.1192.18

BOGE Operating instructions for C 15 series screw compressors Page III
Index
Index
Part 1:
General
1.1 General safety instructions ........................................................... 1
Safety instructions for operation ....................................................... 1
Special hazard warnings................................................................... 2
Electrical energy hazards ................................................................. 3
Obligations of the owner ................................................................... 3
Personnel requirements.................................................................... 4
Personal protective equipment ......................................................... 4
Safety instructions for maintenance and repair ................................ 4
Accident prevention regulations........................................................ 5
First Aid............................................................................................. 6
Disposal ............................................................................................ 6
1.2 Introduction..................................................................................... 6
Symbols used ................................................................................... 7
Symbols on the compressor ............................................................. 8
Intended use ................................................................................... 13
Foreseeable Misuse ....................................................................... 13
Transport damage .......................................................................... 14
Data on the type plate..................................................................... 14
Service............................................................................................ 14
Part 2:
Product description
2.1 Technical data – compressor ...................................................... 15
2.2 Function description compressor............................................... 16
Function principle of the air end...................................................... 16
Air circuit ......................................................................................... 17
Oil circuit ......................................................................................... 18
2.3 Compressor control ..................................................................... 19
Network pressure............................................................................ 19
Operating states ............................................................................. 19
Operating modes ............................................................................ 19
Control of compressors with frequency control (C 15 F) ................ 20
Short operating times...................................................................... 20
2.4 Safety and monitoring devices.................................................... 20
General ........................................................................................... 20
Safety temperature limiting device.................................................. 20
Safety valve .................................................................................... 21
Monitoring the drive motor .............................................................. 21

Index
Page IV BOGE Operating instructions for C 15 series screw compressors
Part 3:
Installation
3.1 Transport and storage.................................................................. 23
General ........................................................................................... 23
Transport possibilities ..................................................................... 23
Intermediate storage....................................................................... 24
3.2 Compressor room......................................................................... 25
Installation conditions for separately arranged compressed air
receivers ......................................................................................... 25
Installation surface.......................................................................... 25
Fire protection................................................................................. 25
Sound protection............................................................................. 26
Admissible environmental influences.............................................. 26
Ventilation ....................................................................................... 26
Cooling air requirement .................................................................. 27
Ventilation possibilities.................................................................... 28
Condensate disposal ...................................................................... 28
3.3 Installation..................................................................................... 29
General ........................................................................................... 29
Checking the delivery scope........................................................... 29
Installing the compressor................................................................ 29
Connecting the compressor to the compressed air network........... 30
Remove cladding ............................................................................ 30
Activating the belt tensioning device............................................... 31
Checking the oil level...................................................................... 32
3.4 Electrical connection.................................................................... 32
3.5 Commissioning............................................................................. 34
Checking installation requirements ................................................. 34
Checking the rotational direction .................................................... 34
Checking compressed air outlet for tightness ................................. 35
Opening the stop valves ................................................................. 35
Checking for leaks .......................................................................... 36
Conducting trial run......................................................................... 36
Commissioning following extended stoppages............................... 36
3.6 Dismantling ................................................................................... 37
Part 4:
Optional equipment
4.1 BOGE-Duotherm BPT................................................................... 39
Function .......................................................................................... 39
Assembly ........................................................................................ 39
Commissioning ............................................................................... 39
Maintenance ................................................................................... 40
Part 5:
Faults
5.1 General .......................................................................................... 41
5.2 Faults – Compressor .................................................................... 41

BOGE Operating instructions for C 15 series screw compressors Page V
Index
Part 6:
Maintenance
6.1 Safety instructions ....................................................................... 43
6.2 General .......................................................................................... 45
Maintenance through BOGE customer service .............................. 45
Review of regular maintenance work.............................................. 45
Maintenance intervals..................................................................... 46
General information concerning the lubricants used ...................... 48
Disposal of used operating material ............................................... 49
Pressure hoses............................................................................... 49
Spare and wearing parts................................................................. 49
6.3 Maintenance work compressor ................................................... 50
Cleaning or changing suction filter.................................................. 50
Cleaning the filter cartridge............................................................. 50
Changing the supply air filter mats ................................................. 51
Drive motors with permanent lubrication ........................................ 52
Changing the V-belt ........................................................................ 52
Setting of the GM-drive system C 15 / C 15 F ................................ 53
Checking the oil level, topping up oil .............................................. 54
Changing the oil filter (Fig. 6.6)....................................................... 55
Changing oil separators (Fig. 6.6) .................................................. 56
Oil change....................................................................................... 57
Flushing the oil circuit ..................................................................... 59
Cleaning the compressed air/oil cooling unit .................................. 60
Checking the safety valve............................................................... 60
Nozzle with dirt catch...................................................................... 61
6.4 Spare parts and optional equipment .......................................... 62
List of spare and wearing parts of the compressor
(for maintenance)............................................................................ 62
List of available optional equipment................................................ 62
Part 7:
Appendix
7.1 Flow chart...................................................................................... 63
Air cooled version, standard, C 15 / C 15 F.................................... 64
BOGE-Duotherm BPT plate heat exchanger.................................. 66
7.2 List of maintenance and service work ....................................... 67

BOGE Operating instructions for C 15 series screw compressors Page 1
General 1.1 General safety instructions
Part 1: General 1.1 General safety instructions
Safety instructions for
operation
Compressor
1. Ensure that no commissioning and maintenance work on the compressor
is undertaken until these operating instructions are understood.
2. Only use the compressor for its intended use, as described in these oper-
ating instructions.
3. The owner must ensure,
– that only appropriately trained and authorized personnel work on this
compressor,
– that no persons work on this compressor, whose ability to react is re-
stricted due to misuse of e.g. drugs, alcohol, medication etc.,
– that the operating, maintenance and repair personnel has been made
fully familiar with all safety instructions, and that they are being ob-
served,
– that the compressor is only operated in a safe operating condition.
4. Avoid any operating method which may impair the safety of the compres-
sor.
5. Always wear your compulsory personal protective quipment as a protec-
tion against injuries from sharp corners or edges when working on the
compressor.
6. To avoid dangers from debris or parts lying around, the service area of the
compressor has always to be kept tiedied up and clean.
7. Always squat when working on components mounted at low height, never
stoop. When working on components mounted higher up always stand up-
right and erect.
8. Do not exceed the limit value for the final compression pressure specified
on the type plate.
9. Do not operate the compressor without the attendant protection and safety
devices.
Do not dismantle any built-in safety devices or put them out of operation.
Ensure that all safety claddings and doors are closed prior to commission-
ing/starting up the compressor and that they are not opened during oper-
ation.
10. Place the compressor out of operation as described in these operating in-
structions, when dismantling the safety claddings or safety devices for re-
pair or maintenance work. Reattach and close all cladding and safety de-
vices immediately upon completion of the repair or maintenance work.
11. Only operate the compressor using the additional equipment (options) rec-
ommended or authorized by the manufacturer.
WARNING!
Nonobservance of the following safety instructions may lead to injuries and
damage to the compressor.
Also observe the generally valid safety and accident prevention regulations
in addition to the information in these operating instructions!

General 1.1 General safety instructions
Page 2 BOGE Operating instructions for C 15 series screw compressors
12. Undertake conversions and modifications of the compressor only in agree-
ment with BOGE, taking all relevant safety regulations into consideration.
The manufacturer is not liable for damages resulting from independent
modifications on the compressor.
13. Never start the compressor when one or serveral parts (e.g. cable, plug)
are damaged, when not in perfect working order and when damage is de-
tected or suspected.
14. Observe all safety and danger signs directly attached on the compressor!
15. To avoid damages, special precautions have to be taken during (re-) oper-
ation of compressors with frequency control, if the frequency converter
was cut off from the power supply for a longer period of time (> 12 months).
In this case please contact the BOGE-Service.
Special hazard warnings – Any performance of work on pressurized system components may be car-
ried out by duly qualified and specialized personnel only.
– Always wear your compulsory personal protective equipment when work-
ing on pressure pipes and connections!
– A protective grid serves to prevent you from accidentally reaching into the
impeller of the cooling fan.
– During operation, the compressor generates a high sound pressure level
which may cause permanent hearing damage due to continuous noise
stress. As a rule, the compressor may only be operated with its housing
cover closed. Make sure to additionally wear a hearing protection in case
of a noise pressure level above 80 dB(A)!
– Any pipelines and/or auxiliary equipment on the compressor are designed
such as to resist to any adverse operating conditions and any predictable
external influences. Make sure to operate your compressor within the pa-
rameters specified in the Technical Data Sheet!
– Exceeding the max. pressure or simultaneous failure of several safety de-
vices will cause the safety valve to be activated. There will be risk of es-
caping hot air!
WARNING: Risk of injury!
A protective grid serves to prevent you from accidentally reaching into the im-
peller 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!

BOGE Operating instructions for C 15 series screw compressors Page 3
General 1.1 General safety instructions
Electrical energy
hazards
Obligations of the owner The owner is obliged to,
– operate the compressor only in technically perfect condition,
– check the Emergency Stop device of the compressor regularly for com-
pleteness and functionality,
– assess the hazards of the machine working places in his area of respon-
sibility and to issue the ensuing operating instructions,
– to name a person responsible beeing in charge of the safe operation of the
machine as well as the coordination of all service work performed on it,
– avoid stress situations while operating the compressor by means of tech-
nological and organizational operation scheduling,
– ensure a proper workplace lighting at the compressor control section ac-
cording to the local health and safety regulations,
– observe the safety data sheet of the used lubricants and to customize the
personnel all information as to said data sheet,
– provide the compulsory personal protective equipment and to stipulate and
check the wearing of said protective equipment on a regular basis,
– assign the personnel responsible for various tasks and work on the ma-
chine,
– instruct the personnel on a regular basis with respect to all obligations as
to compressor related preservation of safety and tidiness.
DANGER: Voltage!
There is danger of life when working on the electrical equipment of the
compressor!
– Only duly authorized professional electricians (e.g. plant electricians) are
allowed to carry out works in the electrical area of the machine.
– Disconnect mains connection prior to starting work on the compressor
and use padlock to secure against switching on again.
– Check to ensure that all parts are currentless.
– Make sure to check the electrical equipment of the compressor at regular
intervals for defects such as loose connections or scorched cables and
have any defects repaired immediately.
– Make sure to have all electrical equipment and fixed electrical installa-
tions checked by a professional electrician at least every 4 years.
– Make sure to check all safety installations on the machine for proper func-
tioning at regular intervals.
– Only use original fuses.

General 1.1 General safety instructions
Page 4 BOGE Operating instructions for C 15 series screw compressors
Personnel requirements Work on and with the compressor may only be carried out by personnel duly
authorized by the owner of the compressor.
The personnel working on the compressor has to observe all industrial safety
regulations and operating instructions, properly recognize responsibilities and
read and understand the operating instructions. It is essential to wear the com-
pulsory personal protective equipment when working on the compressor!
Personal protective
equipment
In general for all work on the compressor
– protective clothing,
– chemicals resistant gloves,
– slip-resistant safety shoes and
– hearing protection, if applicable
are compulsory.
For special duties
– protective helmets (for transport work with lifting gear) and
– safety goggles (when working on the compressed air system and/or on the
control pneumatics)
must be worn.
Before starting work using oils or greases a skin protection cream must be ap-
plied. Having finished the work a skin care product must be applied.
Safety instructions for
maintenance and repair
Compressor
1. Ensure that maintenance work is only carried out by appropriately trained
persons.
2. Ensure that setting work, malfunction rectification and repair is only carried
out by specialists or appropriately trained persons.
WARNING!
Only use original spare parts, compressor oils and operating materials re-
leased by BOGE during repair or maintenance!
DANGER: Voltage!
When working on the electrical system there is a constant danger of getting
into contact with live parts!
To avoid such dangers the mains connection must be equipped with a dis-
connecting device!

BOGE Operating instructions for C 15 series screw compressors Page 5
General 1.1 General safety instructions
3. Prior to maintenance or repair work:
– Switch off the compressor using the OFF button.
– Actuate emergency-stop switch/button.
– Open mains disconnecting device.
– Secure mains disconnecting device by means of lock out tag out.
– Fix a warning label to the control and fill in the name of the person re-
sponsible who is authorized to switch on the maschine again.
– Check to ensure that all parts are currentless.
– Cover or block off adjacent energised parts.
– Prior to starting work let cool down all hot components of the compres-
sor to 122°F.
– Disconnect the compressor from the compressed air network (relieve
or block pressurized lines).
4. Exercise extreme caution during repair or maintenance work requiring the
compressor to be operational. Ensure that persons keep out of reach of
the hazardous area.
5. Ensure that work on the electrical equipment is only executed by qualified
electricians.
6. Work on parts and devices under current is prohibited. Exceptions are gov-
erned by the appropriate regulations.
7. Prior to starting work on the electrical system the power supply has to be
switched off and secured against unintentional switching on again. 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 to immediately report any changes (in-
cluding operational behaviour).
9. When the automatic restart (Auto-Restart) is activated, the compressor will
start automatically following a voltage loss. Prerequisite:The net pressure
is lower than the set switch-on pressure.
Accident prevention
regulations
The owner of a compressor plant is responsible to ensure that it is properly
installed, operated and maintained.
For operation of the compressor plant outside the Federal Republic of 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 regulations specified in the Federal Republic of Germany or
the data contained in these operating instructions, then it is of utmost impor-
tance that these be carried out prior to commissioning the compressor plant.

General 1.2 Introduction
Page 6 BOGE Operating instructions for C 15 series screw compressors
First Aid 1. Any victims are to be immediately removed into fresh air or a well venti-
lated room.
2. Any refrigerant splashes in the eyes are to be blown off by mouth. Rinse
eyes with plenty of water. Do not use cloths to wipe eyes!
3. If the victim does not breathe, rescue breathing is to be started by means
of artificial breathing or the use of an oxygen breathing apparatus until the
arrival of the emergency doctor.
4. CALL A DOCTOR and inform him that refrigerants as specified on the
nameplate are being used!
5. Never leave the victim unattended!
Disposal
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
WARNING!
Waste oil must in no way be disposed of in the environment, mixed with do-
mestic refuse, or burnt in plants unapproved for that purpose.

BOGE Operating instructions for C 15 series screw compressors Page 7
General 1.2 Introduction
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 accident prevention and envi-
ronmental protection.
In the illustrations, the compressor is shown in part without safety cladding or
safety devices for better visualization. However, operation without these com-
ponents is prohibited!
Symbols used In these operating instructions, important safety instructions and tips are iden-
tified by the following symbols:
WARNING!
This symbol indicates information warning of dangers to life and limb of the
operator or other persons or dangers, which might destroy or damage the
compressor.
WARNING: Risk of injury!
This symbol indicates information warning of possible danger to life and limb
of the operator or other persons.
DANGER: Voltage!
This symbol indicates information warning of life threatening electrical volt-
age levels.
It indicates work which must be exclusively performed by skilled electricians.
NOTICE!
This symbol indicates information and tips concerning the economical and
careful operation of the compressor.

General 1.2 Introduction
Page 8 BOGE Operating instructions for C 15 series screw compressors
Symbols on the
compressor
The following symbols and warning signs are fitted on the compressor:
Symbols on the switch cabinet:
NOTICE!
All warning signs on the compressor and in its surrounding must always be
kept in a legible condition. Missing or damaged signs must be replaced at
once!
NOTICE
Refer to the
Instruction/Operators Manual
before performing any
maintenance.

BOGE Operating instructions for C 15 series screw compressors Page 9
General 1.2 Introduction
Symbols on the outside cladding, part 1
Before working at the compressor:
– disconnect all current-carrying parts!
– check if all parts are actually voltage-free!
– secure the compressor against switching-on!
– reduce the pressure in all areas!
If you neglect these rules, your health will be endangered!
Before putting into service:
– read the instructions
– check electric connections
– check oil-level (not for oil-free)
– if applicable, remove the transportation safety
device
– check the direction of rotation of compressor
– operate only with a belt protective grating
or a sound protection bonnet.
– do not close the cooling air inlets and outlets
during operation!
Regular maintenance:
Observe the operating instructions!
– check suction filter monthly, if necessary clean
or replace it
– check cooler for dirt, if necessary clean it
– check oil-level weekly (not for oil-free)
– drain condensation water from pressure tank
at least once a week
– check operativeness of automatic steam trap

General 1.2 Introduction
Page 10 BOGE Operating instructions for C 15 series screw compressors
Symbols on the outside cladding, part 2
NOTICE
Electrical power inlet.

BOGE Operating instructions for C 15 series screw compressors Page 11
General 1.2 Introduction
Symbols on the inside of the compressor, part 1
High pressure air.
Can cause severe injury or death.
Relieve pressure before removing
filter plugs /caps, fittings or covers.
WARNING
NOTICE
Rotation.

General 1.2 Introduction
Page 12 BOGE Operating instructions for C 15 series screw compressors
Symbols on the inside of the compressor, part 2
Exposed fan blade.
Can cause severe injury.
Do not operate with covers
removed.Disconnect power.
Lock and tag.
WARNING