Boge base control User manual

Operating instructions
base control
for screw compressors

BOGE base control for screw compressors Page I
Operating instructions
base control
for screw compressors
BOGE KOMPRESSOREN
Otto Boge GmbH & Co. KG
Postfach 10 07 13
33507 Bielefeld
Otto-Boge-Straße 1-7
33739 Bielefeld
Fon: [phone]
Fax: [phone]
Mail: [email protected]
Net: www.boge.com
Issue: 08 / 2017
No. 596.1495.18
Nominal price: € 5,00

BOGE base control for screw compressors Page III
Index
Index
Part 1:
base control
1.1 The BOGE control concept............................................................ 1
General ............................................................................................. 1
Control .............................................................................................. 1
Ease of servicing .............................................................................. 1
Operating and control panel ............................................................. 2
Position of the Emergency Stop button ............................................ 2
1.2 Operating and control elements.................................................... 3
1.3 Operation......................................................................................... 6
1.4 Parameterization of the control................................................... 11
Message key table.......................................................................... 11
General ........................................................................................... 12
Parameterization............................................................................. 12
Set the compressor servicing interval and zero the counter........... 13
Set the motor servicing interval and zero the counter .................... 13
Set receiver inspection load cycles and restart .............................. 13
Start leakage measurement............................................................ 13
Change pressure target values (pmax and pmin) ............................. 15
Set external output release............................................................. 16
Change after-running time .............................................................. 17
Set continuous operation ................................................................ 18
Enable network independent ON-OFF memory (Auto-Restart)...... 18
Anti-freeze idling (only in mode: Ready for operation).................... 19
Motor switching limitation................................................................ 19
Star phase time control................................................................... 19
Service request............................................................................... 20
1.5 Faults ............................................................................................. 20
General ........................................................................................... 20
Automatic monitoring of the control systems .................................. 20
Fault messages of the control......................................................... 21
Warning messages of the control ................................................... 23

BOGE base control for screw compressors Page 1
base control 1.1 The BOGE control concept
Part 1: base control 1.1 The BOGE control concept
General base control is an integrated control and monitoring concept, having two ob-
jectives:
– Energy savings and thus reduction of ongoing costs.
– Prolonging the service life of the compressor due to wear which is as low
as possible.
All programmed data is stored in a memory module (EEPROM). Thus the
stored information is even available following a power failure.
Control The BOGE control concept dynamically adapts to the respective operating
conditions. The control assumes the following three tasks:
1. Automatic selection of the most economical operating mode
In order to save operating costs, it always strives for the most economical
intermittent operation.
2. Automatic optimization of the motor switching cycles
3. Automatic display of the maintenance intervals
The control monitors the maintenance intervals.
Ease of servicing Rapid replacement of the controls in the event of failures increases the avail-
ability of the compressor. This eliminates time consuming and costly trouble
shooting by specialists.

base control 1.1 The BOGE control concept
Page 2 BOGE base control for screw compressors
Operating and control
panel
Fig. 1.1: base control operating panel
1LCdisplay
2 Indicator lamp – Fault (red)
3 Indicator lamp – Ready (green)
4Info key
5Enter key
6On key
7Off key
Position of the
Emergency Stop button
Depending on the compressor type the Emergency Stop button is either
mounted on the side (1) or front (2) of the switch cabinet.
Fig. 1.2: Possible positions of the Emergency Stop button: side (1) / front (2)

BOGE base control for screw compressors Page 3
base control 1.2 Operating and control elements
1.2 Operating and control elements
Operating and control element Function Operation / Explanation
Emergency Stop button on the side (1):
Emergency Stop button on the front (2):
Shutting down the
compressor in an emer-
gency
– Press the Emergency Stop button.
The Emergency Stop button engages and interrupts
the control voltage. All displays are cut off from the
power.
After rectifying the fault, unlock the Emergency Stop but-
ton:
– Turn the Emergency Stop button a quarter turn clock-
wise.
– Quit the display element test by pressing the Off key
.
– The compressor is ready for operation again.
Attention!
Always switch the compressor off with the
Off key .
Only use the Emergency Stop button in
case of an emergency!
Power disconnecting device
(with Emergency Off function) (3)
Only for C LF N series
with power disconnecting device
Disconnect compressor
from the power supply /
switch off in case of an
emergency
– Turn switch of the power disconnecting device to the
left to the position ‚0‘. The supply voltage is discon-
nected. All displays are cut off from the power.
Once the fault has been rectified, turn switch of the power
disconnecting device into position ‚1‘:
– Quit display element test by pressing the Off key .
– The compressor is ready for operation again.
Attention!
Always switch the compressor off with the
Off key .
Only use power disconnecting device
with Emergency Off function in case of
an emergency!
On key To switch the
compressor on
– Press the ON key :
The operating status depends on the net pressure:
1. Net pressure greater than lower switch-on pressure.
Compressor remains ready.
2. Network pressure lower than lower switch-on pres-
sure. Compressor starts and changes to load run
after a few seconds.
Off key To switch the
compressor off
Compressor may continue to run in idling mode
(factory setting 30 seconds).
Info key Select desired
information
– Press the Info key .
The display changes to the next set of information.

base control 1.2 Operating and control elements
Page 4 BOGE base control for screw compressors
Enter key For confirmation during
parameterisation / for
acknowledging warning
and fault messages
– see section „Parameterization of the control“ on
page 11.
Indicator lamp – Ready (green) Ready indicator The green lamp indicates that the machine is ready.
Indicator lamp – Fault (red) Fault indicator The red lamp indicates the existence of a fault.
Net pressure display Pressure gauge or target value (net pressure).
Parameterisation If parameterisation has been started, this symbol appears
in the top left of the display.
3-digit 7-segment display
P:
psi
Display:
Pressure
Shown in psi with a decimal point between the second
and third digit.
3-digit 7-segment display
T:
°F
Display:
Temperature
Measured in °F.
Thermometer
Anti-freeze idling
OFF
or motor
or receiver
The circle stands for three functions:
1. The compressor is switched off
2. For motor servicing interval
3. Servicing symbol (receiver inspection)
(replace wearing parts).
Standby Automatic standby phase
Operating and control element Function Operation / Explanation

BOGE base control for screw compressors Page 5
base control 1.2 Operating and control elements
Idling (Automatic) idling phase.
Load run or load speed Output phase or number of output cycles
Automatic operating
mode selection
Automatic mode with standby phases enabled.
(Restart from "Ready" state only).
Continuous operation Automatic mode without standby phases enabled.
Total operation time Total motor operating hours.
Idling time Load-free run time.
Servicing due Information on current or pending servicing.
Auto-Restart
(automatic restart
enabled after power
failure)
Energy-independent ON-OFF save function set.
External
output enable
Remote output enable (e.g. by MCS).
– Remote ON-OFF (e.g. from control panel) – not used
here.
Online – not used here.
Operating and control element Function Operation / Explanation

base control 1.3 Operation
Page 6 BOGE base control for screw compressors
1.3 Operation
CAUTION: Risk of injury!
If the compressor is not closed there is a risk of injury due to rotating or pro-
jecting parts respectively a crushing hazard due to flaps or doors standing
open!
The compressor may only be operated with all flaps and doors closed!
Operating and control element Function Operation / Explanation
1 Indicator lamp – Fault (red)
2 Indicator lamp – Ready (green)
Function control of display
elements
– After unlocking the Emergency Stop but-
ton and turning on the supply voltage, all
available display elements of the control
appear at the same time – including the two
indicator lamps.
– If stand-by was not saved (no Auto-
Restart), this status must first be ended
by pressing the Off switch , before
the compressor can be switched on.
– Otherwise the symbol at the bottom
right flashes, it disappears automatically
after a set time and the compressor is
ready for operation again without having
to touch any keys.
Main display – This display appears automatically after
completion of the network failure phase
(as described under display element func-
tion control):
– The net pressure is shown at the top left
(pressure gauge 21),
and at the top right the (final compression)
temperature.
In the centre the two operating mode
curves appear: the left arrow shaded (as
shown here)
= automatic mode selection,
right = continuous operation.
The circle left of this means: Off here.
The symbol at the bottom left is for setting
external output enable and the symbol for
switch-on save (Auto-Restart) is shown at
the bottom right.
These two symbols only appear when the
respective setting has been made.

BOGE base control for screw compressors Page 7
base control 1.3 Operation
1 Indicator lamp – Ready (green)
Switching on the
compressor
If no fault is reported, pressing On key will
switch on the green indicator lamp (compressor
ready for operation) which means: the pressure
control function is activated.
Power-up phase The pressure control starts the motor if required
→the idling symbol appears during the
time-controlled star phase (the star contactor
is switched on first followed by the network con-
tactor 20 ms later). The idling symbol also
appears after reaching the set maximum pres-
sure (factory setting 30 seconds).
Delta switching The star phase is automatically ended and a
change to delta switching started (the star con-
tactor drops and 60 ms later the delta contactor
cuts in), the valve status Load is switched on
and the symbol is shown in the display.
Stand by After the set maximum pressure is reached,
the idling symbol appears, (factory setting
30 seconds).
If during this time the pressure drops to below
the set minimum pressure, the compressor
switches back to load and the respective sym-
bol is displayed again.
Otherwise the control unit switches the motor
off and the Stand by symbol is shown in the
display.
Switching off the com-
pressor
Press Off key
→Compressor Off →the
pressure control function is deactivated and the
display shows the idling symbol .for up to
30 seconds. During this time the green indicator
blinks. The symbol Othen appears and the
green indicator lamp goes out.
Operating and control element Function Operation / Explanation

base control 1.3 Operation
Page 8 BOGE base control for screw compressors
1 Indicator lamp – Fault (red)
Fault If the control unit detects a fault, the compressor
is switched off immediately and automatically
– without any idling phase –, the fault relay
drops and on the RH side of the actual pressure
value a number flashes together with the red
indicator lamp:
The blinking number indicates the detected
fault (see also section „Message key table“ on
page 11).
Operation, servicing periods, display test and software-no.
means: 124 h total running-time
Total hours Press Info key →and the segment display
shows the total operating time counter in hours,
together with the total up-time
bmeans: 2 h idling time
Idling hours Press Info key a second time → and the
display shows the Idling time counter and the
Idling time symbol.
means: 500 h until next compressor servicing
Compressor servicing
interval
Press Info key a third time →and the
display shows the operating time until the
Compressor servicing and the Running time
and Servicing symbols (spanner).
means: 1000 h until next motor servicing
Motor servicing interval Press Info key a fourth time →and the
display shows the operating time until the next
Motor servicing and the symbols O(stands for
motor) running time and servicing (spanner).
Operating and control element Function Operation / Explanation

BOGE base control for screw compressors Page 9
base control 1.3 Operation
means: 20 x 103= 20000 load cycles until next
receiver servicing.
Check wearing parts Press Info key a fifth time → and the
display shows the 1000-output cycle servicing
counter with the single exponent 103(x 1000),
the load speed symbol, the circle (here for the
receiver) and the servicing symbol (spanner),
meaning the number of possible output cycles
until the next wearing parts inspection (suction
regulator).
Single leakage
measurement
Press Info key a sixth time → now the
display shows the value for the single leakage
measurement (LE).
The abbreviation LE stands for "single leakage
measurement". The displayed value shows the
anticipated annual operating load times due to
leakage.
Continuous leakage
measurement
Press INFO key a seventh time →now the
display shows the value for the continuous leak-
age measurement (Lc / LC).
The abbreviation Lc stands for "continuous
leakage measurement". The displayed value
shows the anticipated annual operating load
times due to leakage. When the abbreviation
LC is displayed, continuous measurement has
been carried out for more than a week.
means: pmax. = 145 psi
Upper target pressure
value
Press INFO key an eighth time → and
the segment display shows the Upper target
pressure and an underscore at the top right
next to it.
means: pmin. = 130 psi
Lower target pressure
value
Press INFO key a ninth time →and the
segment display shows the Lower target pres-
sure and an underscore at the bottom right next
to it.
Operating and control element Function Operation / Explanation

base control 1.3 Operation
Page 10 BOGE base control for screw compressors
1 Indicator lamp – Fault (red)
2 Indicator lamp – Ready (green)
Display element test Press INFO key a tenth time →and the
display shows all symbols and segments
together with the two indicator lamps.
means software no. 1105
Software version number Press INFO key an eleventh time →and
the segment display area shows the Software
no.
Press INFO key one more time →to return
to the main display.
If no key is pressed for five minutes, the main
display automatically reappears.
Operating and control element Function Operation / Explanation

BOGE base control for screw compressors Page 11
base control 1.4 Parameterization of the control
1.4 Parameterization of the control
Message key table Error
no.
Meaning Compressor
cut-out
0 not assigned here
1 Final compression temperature > 230 °F X
2 Motor temperature too high X
3 not assigned here
4 not assigned here
5 System pressure too high X
6 not assigned here
7 not assigned here
8 not assigned here
9 not assigned here
10 Motor servicing due
11 Compressor servicing due
12 not assigned here
13 Frequency converter and / or fan motor gives error
message X
14 Temperature too low X
15 Suction control 1)
16
a) Net pressure transmitter faulty
or:
b) Fan motor overcurrent
X
17 not assigned here
18 Fault of an external control
19
Previous net switch-on phases were too short (possible
reasons: coil short-circuit "solenoid valve" or "delta con-
tactor") →automatically increased delay time accord-
ing to permissible number of motor switch cycles
20 Continuous contact of an external control
21 Receiver or wearing parts inspection due
22 not assigned here
23 not assigned here

base control 1.4 Parameterization of the control
Page 12 BOGE base control for screw compressors
General The control unit calculates from the current operating data the respective best
operating mode and automatically selects it.The parameters are adjustable.
In order to prevent unintentional changes to pre-set parameters, these param-
eters are code-protected.
Parameterization From the main display the first step in parameterization is performed by re-
peated pressing of the Info key , until the display the software-no., and then
proceeding as follows:
1. Press Enter key
→and the parameterization symbol is shown on
the left, followed by three zeros, the left of which blinks.
2. Press Info key to change the first digit.
3. Press Enter key
→and now the middle zero blinks.
4. Press Info key to change the second digit.
5. Press Enter key
→and now the right zero blinks.
6. Press Info key to change the third digit.
7. Press Enter key
→the display will now branch off depending on the
set number – if the value is invalid the main display will reappear.
24 not assigned here
25 Control unit EEPROM / reconciliation error X
26 not assigned here
27 Control unit On key does not open X
28 not assigned here
29 Control unit Enter key does not open
30 not assigned here
31 not assigned here
32 not assigned here
1) Parameterization of external output enable necessary if no infinite output control is available
Error
no.
Meaning Compressor
cut-out
Caution!
Never change the value of a parameter if you do not know what it means!
This may cause incorrect behaviour of the control unit!
Do not experiment with parameter settings!
Always call BOGE-Service if you are unsure or have any doubts.

BOGE base control for screw compressors Page 13
base control 1.4 Parameterization of the control
Set the compressor
servicing interval and
zero the counter
To make changes easier, the respective setting is changed in large steps.
1. Enter Code 111, as described under parameterization (see page 12) →
and the display shows, as already described, the compressor servicing
interval in blinking digits.
2. Press Info key to change the value.
3. Press Enter key to overwrite the non-volatile EEPROM with the blink-
ing value, and the main display reappears.
Set the motor servicing
interval and zero the
counter
To make changes easier, the respective setting is changed in large steps.
1. Enter Code 222, as described under parameterization (see page 12) →
and the display shows, as already described, the motor servicing interval
in blinking digits.
2. Press Info key to change the value.
3. Press Enter key to overwrite the non-volatile EEPROM with the blink-
ing value, and the main display reappears.
Set receiver inspection
load cycles and restart
To make changes easier, the respective setting is changed in large steps.
1. Enter Code 333, as described under parameterization (see page 12) →
and the display shows, as already described, the receiver inspection inter-
val in blinking digits.
2. Press the Info key to change the value.
3. Press Enter key to overwrite the non-volatile EEPROM with the blink-
ing value, and the main display reappears.
Start leakage measure-
ment
This function serves to determine the energy loss resulting from any potential
leaks in your compressed air network.
To this purpose, the control unit measures the duration of the operating loads
in time periods during which, under normal circumstances, no production of
compressed air takes place, as for example over night or during operation
downtimes.
This, however, is conditioned on the fact that operational compressed air pro-
duction be discontinued for a protracted period of time and that the compres-
sor be set into the "ready" mode by means of the control system. In case of a
potential pressure reduction below the preset minimum pressure value result-
ing from leaks in the compressed air network, this compressor automatically
switches into the operating mode in order to recover the set pressure range.
The leakage measurement serves to record the duration of the operating load
times and to extrapolate them for the whole year. This allows you to quantify
any leakages and to easily determine their portion of additional costs due to
any energy losses.
A potential leakage is either measured by a single (LE) or continuous (Lc /
LC) value measurement:
In case of single leakage measurement a single measurement operation
over six hours serves to determine the hourly operating load times per year
due to leakage.

base control 1.4 Parameterization of the control
Page 14 BOGE base control for screw compressors
In order to obtain a precise value it is imperative that no operational com-
pressed air consumption take place during measurement, viz. production is to
be shut off for at least six hours. If measurement is actuated by means of the
control system, measurement will be deferred by six hours. This allows you to
activate the leakage function already in the afternoon causing the measuring
operation to start in the evening (six hours later) to continue over night.
Unlike continuous value measurement, single value measurement is also pos-
sible if several compressors are being operated in the basic load mode at the
same time. Starting separate single value measurement of each compressor
enables you, after a six-hour measurement period, to read and to add up all
of the single values of the compressor control units. Their total value corre-
sponds to the anticipated annual number of hours of operating load times as
a result of leakage in your compressed air network.
Continuous leakage measurement is designed to continuously calculate
operating load values for one week at six-hour intervals.
Unlike single leakage measurement, continuous leakage measurement can
also be started during current daily production with measurement starting at
once. The first value obtained after a six-hour period will probably be distorted
since any operational compressed air production will be added to any potential
leakage related operating load. Most probably, however, no operational pro-
duction will be in effect during any subsequent value measurement. The then
obtained value, which is exclusively due to leakage, will be smaller than the
first obtained value. The control system is designed to always display the
smallest value of all measurements, in this case, however, the last obtained
value. This means that any distorted calculation of production operating loads
will be excluded.
In order to determine exact leakage measurement values make sure that,
within a time frame of 12 hours, there will in all probability be no operational
compressed air production.
Start single leakage measurement
Single leakage measurement will not start but six hours after actuation of this
process. Therefore, make sure
– that, after the deferred start of the measurement process no operational
compressed air production will take place over a period of six hours.
– that the compressor is set into the "ready" mode by means of the control
unit and that the green LED of the control is lit.
– when using the "external output release": The external flow release may
neither be shut off manually nor by the switch clock.
In order to start single measurement:
1. Call up „Single Leakage Measurement“ in the display (see “Single leakage
measurement” on page 9.).
2. Press Enter key .
The number 9999 appears and single value measurement will start in six
hours. After a period of twelve hours, the single measurement value will be
displayed. This value will be saved until a new measurement process is
carried out.
If, after having started measurement, a power failure takes place the number
9980 will be displayed. In such case it is recommended to repeat the meas-
urement process at a later stage.