Boge C 16 N User manual
www.boge.com
Operating instructions
Belt-driven
screw compressors
Series
C 16 N...C 30 N
C16 F N...C 30 F N
Separate manual:
compressor control
frequency converter (C F N)
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page I
Operating instructions
for belt-driven
screw compressors
–C16N(15.0 Hp)
–C20N(20.0 Hp)
–C25N(25.0 Hp)
–C30N(30.0 Hp)
– C 16 F N (15.0 Hp)
–C20FN(20.0 Hp)
–C25FN(25.0 Hp)
–C30FN(30.0 Hp)
BOGE KOMPRESSOREN
Otto Boge GmbH & Co. KG
Postfach 10 07 13
D-33507 Bielefeld
Otto-Boge-Straße 1-7
D-33739 Bielefeld
Fon: +1-770-874-1570
Fax: +1-770-874-1571
Mail: [email protected]
Net: www.boge.com
Issue: 07 / 2016
No. 596.1188.18
IMPORTANT!
READ CAREFULLY BEFORE USE
RETAIN FOR FUTURE REFERENCE
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page III
Index
Index
Part 1:
General
1.1 General safety instructions ........................................................... 1
Safety instructions for compressor operation ................................... 1
Special hazard warnings................................................................... 2
Electrical energy hazards ................................................................. 3
Obligations of the owner ................................................................... 3
Personnel requirements.................................................................... 3
Personal protective equipment ......................................................... 4
Safety instructions for maintenance and repair ................................ 4
Accident prevention regulations........................................................ 5
Disposal ............................................................................................ 5
1.2 Introduction..................................................................................... 5
Symbols used ................................................................................... 6
Symbols on the compressor ............................................................. 6
Intended use ................................................................................... 10
Foreseeable Misuse ....................................................................... 10
Transport damage .......................................................................... 10
Data on the type plate..................................................................... 11
Service............................................................................................ 11
Part 2:
Product description
2.1 Technical data – compressor ...................................................... 13
2.2 Function description compressor............................................... 17
Function principle of the air end...................................................... 17
Air circuit ......................................................................................... 17
Oil circuit ......................................................................................... 18
2.3 Water cooling ................................................................................ 19
Water cooling.................................................................................. 19
Series connection ........................................................................... 19
2.4 Cooling water ................................................................................ 19
Water connection (for water cooling) .............................................. 19
Cooling water quality ...................................................................... 20
2.5 Compressor control ..................................................................... 20
Network pressure............................................................................ 20
Operating states ............................................................................. 20
Operating modes ............................................................................ 21
Index
Page IV BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors
Control of compressors with frequency control (C F N) .................. 21
Short operating times...................................................................... 21
2.6 Safety and monitoring devices.................................................... 22
General ........................................................................................... 22
Safety temperature limiting device.................................................. 22
Safety valve .................................................................................... 22
Monitoring the drive motor .............................................................. 22
Part 3:
Installation
3.1 Transport and storage.................................................................. 23
General ........................................................................................... 23
Transport possibilities ..................................................................... 23
Intermediate storage....................................................................... 24
3.2 Compressor room......................................................................... 25
Installation, maintenance conditions and application for com-
pressed air receivers: receiver mounted or seperately installed..... 25
Installation surface.......................................................................... 25
Fire protection................................................................................. 25
Sound protection............................................................................. 26
Admissible environmental influences.............................................. 26
Ventilation ....................................................................................... 26
Cooling air requirement .................................................................. 27
Ventilation possibilities.................................................................... 28
Condensate disposal ...................................................................... 28
3.3 Installation..................................................................................... 29
General ........................................................................................... 29
Checking the delivery scope........................................................... 29
Installing the compressor................................................................ 29
Connection condensate drain ......................................................... 30
Connecting the compressor to the compressed air network........... 30
Remove cladding ............................................................................ 30
Activating the belt tensioning device............................................... 32
Checking the oil level...................................................................... 32
3.4 Electrical connection.................................................................... 32
3.5 Commissioning............................................................................. 33
Checking installation requirements ................................................. 34
Checking the rotational direction .................................................... 34
Checking compressed air outlet for tightness................................. 35
Opening the stop valves ................................................................. 35
Checking for leaks .......................................................................... 35
Conducting trial run......................................................................... 36
Commissioning following extended stoppages............................... 36
3.6 Dismantling ................................................................................... 37
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page V
Index
Part 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
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 ............................................... 48
Pressure hoses............................................................................... 48
Spare and wearing parts................................................................. 49
6.3 Maintenance work compressor ................................................... 49
Cleaning or changing suction filter.................................................. 49
Cleaning the filter cartridge............................................................. 50
Changing the supply air filter mats ................................................. 50
Drive motors with permanent lubrication ........................................ 51
Changing the V-belt ........................................................................ 51
Settings of the GM-drive system C 16 N...C 30 N,
C 16 F N...C 30 F N ........................................................................ 53
Checking the oil level, topping up oil .............................................. 54
Changing the oil filter ...................................................................... 55
Changing oil separators.................................................................. 56
Oil change....................................................................................... 57
Flushing the oil circuit ..................................................................... 59
Cleaning the compressed air/oil cooling unit .................................. 59
Function check of the safety valve.................................................. 60
Inline filter ....................................................................................... 61
6.4 Spare parts and optional equipment .......................................... 62
List of spare and wearing parts of the compressor
(for maintenance)............................................................................ 62
List of available optional equipment................................................ 62
Index
Page VI BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors
Part 7:
Appendix
7.1 Flow chart...................................................................................... 63
Air cooled version, standard, series C 16 N...C 30 N,
C 16 F N...C 30 F N ........................................................................ 64
Water cooled version, serial connection, series C 16 N...C 30 N,
C 20 F N...C 30 F N ........................................................................ 66
BOGE-Duotherm BPT plate heat exchanger .................................. 68
7.2 List of maintenance and service work ........................................ 69
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 1
General 1.1 General safety instructions
Part 1: General 1.1 General safety instructions
Safety instructions for
compressor operation
Compressor
1. Ensure that no commissioning and maintenance work on the compressor
is undertaken until these operating instructions are understood.
2. Only use the compressor for its intended use, as described in these 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
restricted due to misuse of e.g. drugs, alcohol, medication etc.,
– that the operating, maintenance and repair personnel has been made
fully familiar with all safety instructions, and that they are being 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
upright and erect.
8. Do not exceed the limit value for the final compression pressure specified
on the type plate.
9. Do not operate the compressor without the attendant protection and safety
devices.
Do not dismantle any built-in safety devices or put them out of operation.
Ensure that all safety claddings and doors are closed prior to 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
instructions, when dismantling the safety claddings or safety devices for
repair or maintenance work. Reattach and close all cladding and safety
devices immediately upon completion of the repair or maintenance work.
11. Only operate the compressor using the additional equipment (options) 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 16 N...C 30 N, C 16 F N...C 30 F N 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
parameters specified in the Technical Data Sheet!
– Exceeding the max. pressure or simultaneous failure of several safety
devices will cause the safety valve to be activated. There will be risk of
escaping hot air!
WARNING: Risk of injury!
A protective grid serves to prevent you from accidentally reaching into the
impeller of the cooling fan!
Please note that the cooling fan may run on for a certain time even after the
compressor has been switched off!
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 3
General 1.1 General safety instructions
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 familiarize per-
sonnel with all information pertaining to said data sheet,
– provide the compulsory personal protective equipment and to stipulate and
check the wearing of said protective equipment on a regular basis,
– assign the personnel responsible for various tasks and work on the ma-
chine,
– instruct the personnel on a regular basis with respect to all obligations as
to compressor related preservation of safety and tidiness.
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!
DANGER: Voltage!
There is danger of life when working on the electrical equipment of the
compressor!
– Disconnect mains connection prior to starting to carry out works on the
compressor and use padlock to secure against switching on again.
– Only duly authorized professional electricians (e.g. plant electricians) are
allowed to carry out works in the electrical area of the machine.
– Make sure to check the electrical equipment of the compressor at regular
intervals for defects such as loose connections or scorched cables and
have any defects repaired immediately.
– Make sure to have all electrical equipment and fixed electrical installa-
tions checked by a professional electrician at least every 4 years.
– Make sure to check all safety installations on the machine for proper
functioning at regular intervals.
– Only use original fuses.
General 1.1 General safety instructions
Page 4 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors
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 or on the
control pneumatics)
must be worn.
Before starting work using oils or greases a skin protection cream must be
applied. Having finished the work a skin care product must be applied.
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.
3. Prior to maintenance or repair work:
– Actuate emergency-stop switch/button.
– Open mains disconnecting device.
– Secure mains disconnecting device against unintentional switching on
by means of a padlock.
– Fix a warning label to the control and fill in the name of the person
responsible who is authorized to switch on the maschine again.
– Check to ensure that all parts are deenergized.
– Disconnect the compressor from the compressed air network (relieve
or isolate pressurized lines).
4. Exercise extreme caution during repair or maintenance work requiring the
compressor to be operational. Ensure that persons keep out of reach of
the hazardous area.
WARNING!
Only use original spare parts, compressor oils and operating materials
released by BOGE during repair or maintenance!
DANGER: Voltage!
When working on the electrical system there is a constant danger of getting
into contact with live parts!
To avoid such dangers the mains connection must be equipped with a dis-
connecting device!
The mains disconnecting device has to meet local requirements!
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 5
General 1.2 Introduction
5. Ensure that work on the electrical equipment is only executed by qualified
electricians.
6. Work on parts and devices with power applied is prohibited. Exceptions
are governed by the appropriate regulations.
7. Prior to starting work on the electrical system the power supply has to be
switched off and secured against unintentional switching on again. 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 in-
stalled, 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.
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 time and to increase the reliability and service life of the
compressor. It contains important information concerning the required mainte-
nance and repair measures, assists in case of malfunctions and contains data
concerning spare and wearing parts.
The operating instructions must be available to the compressor operating 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:
WARNING!
Waste oil must in no way be disposed of in the environment, mixed with
domestic refuse, or burnt in plants unapproved for that purpose.
General 1.2 Introduction
Page 6 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors
– Operation, including fault rectification and daily care
– Maintenance (service, inspection, repair)
– Commissioning
– Transport
The compressor and its ancillary equipment must not be installed and commis-
sioned 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:
Symbols on the
compressor
The following symbols and warning signs are fitted on the compressor:
WARNING: Risk of injury!
This symbol indicates information warning of possible danger to life and limb
of the operator or other persons.
WARNING!
This symbol indicates information warning of dangers to life and limb of the
operator or other persons or dangers, which might destroy or damage the
compressor.
DANGER: Voltage!
This symbol indicates information warning of life threatening electrical 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.
NOTICE!
All warning signs on the compressor and in its surroundings must be kept in
a legible condition at all times. Missing or damaged signs must be replaced
at once!
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 7
General 1.2 Introduction
Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before
servicing.
WARNING
High pressure air.
Can cause severe injury or death.
Relieve pressure before removing
filter plugs / caps, fittings or covers.
WARNING
NOTICE
Refer to the
Instruction/ Operators Manual
before performing any
maintenance.
This machine is remote start and
stop equipped.
May start or stop at any time.
Can cause severe injury or death.
Disconnect power before servicing.
Lock and tag out.
See operator's instruction manual.
WARNING
Discharge air.
Can contain carbon monoxide
or other contaminants.Will
cause severe injury or death.
Do not breathe this air.
DANGER
Hazardous voltage. Can cause
severe injury or death.
Disconnect power before
servicing.
Lockout/Tagout machine.
WARNING
Improper coolant filter replace-
ment will cause compressor
damage.
Replace filter element after first
500 hours of operation and every
3000 hours thereafter or when
coolant is changed.
CAUTION
Moving parts.
Can cause severe injury.
Do not operate with covers removed.
Service only with machine blocked to
prevent turn over.
WARNING
General 1.2 Introduction
Page 8 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors
Before working at the compressor:
–disconnect all current-carrying parts!
– check if all parts are actually voltage-free!
– secure the compressor against switching-on!
– reduce the pressure in all areas!
If you neglect these rules, your health will be endangered!
Before putting into service:
– read the instructions
– check electric connections
– check oil-level (not for oil-free)
–if applicable, remove the transportation safety
device
– check the direction of rotation of compressor
– operate only with a belt protective grating
or a sound protection bonnet.
– do not close the cooling air inlets and outlets
during operation!
Regular maintenance:
Observe the operating instructions!
– check suction filter weekly, if necessary clean
or replace it
– check cooler for dirt, if necessary clean it
– check oil-level weekly (not for oil-free)
–drain condensation water from pressure tank
at least once a week
– check operativeness of automatic steam trap
Hazardous voltage. Can cause
severe injury or death.
Disconnect power before
servicing.
Lockout/Tagout machine.
WARNING
Exposed fan blade.
Can cause severe injury.
Do not operate with covers
removed. Disconnect power.
Lock and tag.
WARNING
NOTICE
Rotation.
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 9
General 1.2 Introduction
Moving parts.
Can cause severe injury.
Do not operate with covers removed.
Service only with machine blocked to
prevent turn over.
WARNING
Hot surface.
Can cause severe injury.
Do not touch. Allow to cool before
servicing.
WARNING
NOTICE
Air discharge.
NOTICE
Electrical power inlet.
General 1.2 Introduction
Page 10 BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors
Intended use
Foreseeable Misuse
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.
WARNING!
BOGE compressors, including their ancillary equipment, are exclusively
intended for the compression of air in industrial applications.The air taken
in must not contain any explosive or chemically instable gases or vapours.
Do not exceed the specified final compression temperature.
BOGE compressors are designed for stationary operation.
Ensure that they are only installed and operated in dry and clean rooms.
Operation and control are designed to be executed by trained and authorized
operators.
WARNING!
Never direct the produced compressed air towards persons. Danger to life!
Oil is injected into the pressure rooms of the compressor.
Only use the produced compressed air for breathing or let it come in contact
with foods, if it was treated beforehand.
This BOGE compressor is not explosion protected.
Do not operate in explosive areas or in a possibly explosive atmosphere!
Do not operate the compressor in rooms in which extreme dust, toxic or 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.
BOGE Operating instructions for C 16 N...C 30 N, C 16 F N...C 30 F N series screw compressors Page 11
General 1.2 Introduction
Data on the type plate Enter the data of your compressor from the type plate or enclosed data sheet
in the folllowing illustration 1.1.
This will ensure that in the event of enquiries, you will always have the most
important data to hand.
Fig. 1.1: Data on the type plate
Service Please do not hesitate to contact BOGE service if you have any questions.
Please call:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
In the event of inquiries, always specify the following data of your compressor
to prevent any delays:
–Type
– Year of manufacture
– Machine number
Otto-Boge-Straße 1–7 · D-33739 Bielefeld · Telefon (052 06) 601-0
Postfach 10 0713 · D-33507 Bielefeld · Fax (052 06) 601-200
www.boge.com · info@boge.com
Type
Year of construction
Serial number
F.a.d.
Motor speed
Motor power
Patent No.5,785,620
cfm
psig
rpm
Maximum service pressure
Hp
WARNING!
Only BOGE service technicians or persons authorized by BOGE in writing
may repair or alter the compressor during the warranty period. Otherwise all
warranty claims will expire!
This manual suits for next models
7
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