Boge RATIO User manual

Operating
instructions
RATIO compressor
control for
screw compressors
Before installing or starting the
compressor for the first time, this
manual should be studied carefully to
obtain a clear knowledge of the unit
and of the duties to be performed while
operating and maintaining the unit.
RETAIN THIS MANUAL WITH UNIT.
This technical manual contains
IMPORTANT SAFETY DATA and should
be kept with the air compressor at all
times.

Index
BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Page I
Operating instructions
RATIO compressor control
for screw compressors
Issue: 09/2009
No. 596.0840.18
Nominal price: US $ 5.00
BOGE KOMPRESSOREN
Postfach 10 0713
D-33507 Bielefeld
Germany
Otto-Boge-Straße 1–7
D-33739 Bielefeld
Phone: ++49 / 52 06 / 6 01-0
Fax: ++49 / 52 06 / 6 01-200
Mail: [e-mail]
Net: www.boge.com

Page II BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Index

Index
BOGE – RATIO compressor control for screw compressors
Inhalt.pm6.5 - USA
Page III
Index
1.1 The BOGE control ........................................................................ 1.1
General .......................................................................................... 1.1
Microcontroller................................................................................ 1.1
1.2 The BOGE control concept ......................................................... 1.2
Operating and control panel ........................................................... 1.2
1.3 Operating elements ......................................................................1.3
1.4 Operation ...................................................................................... 1.6
Parameterization of frequency converter without running motor .. 1.11
1.5 Control Parameterization ........................................................... 1.12
Error key table .............................................................................. 1.12
General ........................................................................................ 1.13
Parameterization .......................................................................... 1.13
Enter Parameterization Code ....................................................... 1.13
Set the compressor servicing interval and restart ........................1.13
Set the motor servicing interval and restart .................................. 1.14
Set load cycles dependent servicing / inspection and restart ....... 1.14
Change target pressure values (Pmax and Pmin) ............................. 1.14
External output enable ................................................................. 1.15
Proportional control ...................................................................... 1.16
Timer ............................................................................................ 1.16
Switching Local-Remote via key switch ........................................ 1.16
Remote On-Off control ................................................................. 1.17
Enable network independent ON-OFF memory (Auto-Restart).... 1.18
Idling control for extremely short operating times
(Change after-running time) ......................................................... 1.18
Set continuous mode ................................................................... 1.19
Anti freeze operation (only in mode ready for operation ) .............. 1.19
RS 485-Bus-Address ................................................................... 1.20
Parameter overview...................................................................... 1.20
1.6 Faults – General ......................................................................... 1.21
Automatic monitoring of the control systems ................................ 1.21
1.7 Fault messages of the control system ..................................... 1.22
Fault ............................................................................................. 1.22
Acknowledge messages ............................................................... 1.22
1.8 Warning messages of the control ............................................. 1.25
Part 1:
RATIO

Page IV BOGE – RATIO compressor control for screw compressors
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Index

RATIO.pm6.5 - USA
Page 1.1
RATIO
BOGE – RATIO compressor control for screw compressors
These operating instructions contain a description of the RATIO con-
trol system.
BOGE compressors are equipped with a modern control.
RATIO, an integrated control and monitoring concept, with two objectives:
– Energy savings and thus reduction of ongoing costs.
– Prolonging the service life of the compressor due to minimum wear.
All programmed data is stored in a memory module (EEPROM).
Thus the stored information is even available following a power failure.
The BOGE-RATIO control adapts dynamically to the respective operating
conditions. A micro-controller assumes the following three tasks:
1. Automatic selection of the most economical operating mode
The micro-controller calculates the optimum operating mode from the
current operating state and a programmed ideal value, also taking into
account the constant compressor system data (e.g. delivery quantity,
receiver volume, motor switching cycles) as well as the current variables
(e.g. compressed air consumption, supply and non-supply times, pres-
sure increase and decrease speed).
In order to save operating costs, it always strives for the most economical
intermittent operation.
2. Automatic optimization of the motor switching cycles
The micro-controller calculates the optimum number of motor switching
cycles. This protects the drive motor and prolongs the service life of the
plant.
3. Automatic reminder of the maintenance intervals
The microcontroller monitors the maintenance intervals.
The BOGE control1.1
Microcontroller
General

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RATIO
BOGE – RATIO compressor control for screw compressors
Operating and control panel
The BOGE control concept1.2
Fig. 1.1: RATIO operating panel
LC-
Display
Error:
red
Ready:
green
next
information Enter
ON
OFF
Indicator lamps
previous
information Main display
EMERGENCY OFF

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RATIO
BOGE – RATIO compressor control for screw compressors
Operating elements1.3
Operating elements RATIO
Operating/control element Function
– Press the EMERGENCY OFF switch.
The switch engages and interrupts the control
voltage.
All displays are cut off from the power.
After rectifying the fault, unlock the EMERGENCY
OFF switch:
– Turn the EMERGENCY OFF switch a quarter
turn clockwise.
– Quit the display test by pressing OFF key .
– The compressor is ready to use.
Important!
Always switch the compressor off
with the OFF key. Only use EMER-
GENCY OFF in an emergency!
ON key – Press the ON key:
The operating status depends on the network
pressure:
1. Network pressure greater than lower cut-in
pressure. Compressor remains ready.
2. Network pressure lower than lower cut-in
pressure. Compressor starts.
To switch the
compressor on
OFF key If necessary, continues to run in idle until decrease
in system pressure.
To switch the
compressor off
EMERGENCY OFF switch To switch off the
compressor
in an emergency
Operation/Explanation
[Up] key The key has two functions:
1. It shows the previous information, one step
backward.
2. It normally increases the parameter value.
Display selection
in LC-Display
[Down] key The key has two functions:
1. It shows the next information one step for-
wards.
2. It normally reduces the parameter value.
Display selection
in LC-Display
INFO key – Press the INFO key.
The display shows the main information or fault/
warning message.
Select desired main
information
ENTER key – See parameterization section.For confirmation in
parameterization
and acknowledge-
ment of messages

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RATIO
BOGE – RATIO compressor control for screw compressors
Operating/control element Function
The green indicator lamp indicates that the
machine is ready.
Lamp = red The red indicator lamp indicates a fault.Fault
Pressure gauge or target value (network).Network pressure
display
If parameterization has been started, this symbol
appears in the top left of the display.
Parameterization
Ready
Operation/Explanation
3-digit 7-segment display
P:
Shown in bar with a decimal point between the
second and third digit.
Displays:
Pressure
Lamp = green
3-digit 7-segment display
T:
In °C.Displays:
Temperature
Thermometer
Operating elements RATIO
Operating elements1.3
bar
°C
Compressed air parameterization start undergoing
parameterization or frost run = blinks.
Pressure gauge system pressure (compressor).System pressure
display

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RATIO
BOGE – RATIO compressor control for screw compressors
Operating elements1.3
Operating/control element Function
The circle stands for three functions:
1. The compressor is switched off.
2. For motor servicing period.
3. Servicing symbol (receiver inspection)
(replace wearing parts).
Automatic standby.Stand by
(Automatic) idling phase.Idle
OFF or
motor or
receiver
Operation/Explanation
Operating elements RATIO
Output phase or output cycle.Load or load speed
Automatic mode with standby phases enabled.Automatic operating
mode selection
Automatic mode without standby phases enabled.Continuous
operation
Total motor operating hours.Total running time
Idle operating hours.Idle operation
Information on current or impending servicing.Servicing due
Energy-independent ON-OFF save function set.
Auto-Restart
(automatic restart
enabled after
network failure)
Remote output enable (e.g., from master control).External output
enable
Remote ON-OFF (e.g., from control panel).
Serial interface activated.
Remote On-Off
Mode
Online-Mode

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RATIO
BOGE – RATIO compressor control for screw compressors
Operating/control element Function
– After unlocking the EMERGENCY OFF switch
and turning on the supply voltage, all enablable
display elements of the control appear at the
same time – including the two indicator lamps.
– If standby was not saved (no Auto-Restart),
this status must first be ended by pressing the
OFF switch O, before the compressor can be
switched on.
– Otherwise it disappears automatically after a
set time and the compressor is on standby
again without touching the controls – see also
Power failure cycle protection.
Function control of
display elements
Operation/Explanation
Operation RATIO
Main display
RATIO
green red
green
If no fault is reported, pressing will switch on the
green indicator lamp (compressor on standby)
which means: the pressure control function is acti-
vated – see also Remote On-Off.
Switch on the
compressor
Operation1.4
– This display either appears after completion of
the network failure phase (as described under
display element function control) or by pressing
the ikey or by scrolling via Èor Ç-keys:
– The network pressure is shown at the top left
(pressure gauge 21), and at the top right the
(final compression) temperature, in the centre
are the two operating mode curves: the left
arrow shaded (as shown here) = automatic
mode selection, right = continuous operation,
the circle left of this means: off here.
The symbol at the bottom left is for setting
Remote-On-Off and next to it the symbol for
external output enable, next to the right the
symbol online and at the extreme right at the
bottom the symbol for cut-in-save (Auto-Re-
start). These four symbols only appear when
the respective setting has been made.

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RATIO
BOGE – RATIO compressor control for screw compressors
Operation RATIO
Operation1.4
Run-up phase
Load operation
Stand by
(Ready for operation)
The run-up phase – or star phase – is automatically
finished by switching the electropneumatical control
into load operation and the symbol appears
in the display – probably first a change to delta
connection takes place 60ms after the star phase.
Once the set maximum pressure is reached, the
idling symbol appears. The system pressure
is reduced automatically.
bar °C
!
bar °C
If required the pressure control starts the motor –
if the motor spinning time is finished, the system
pressure has decreased and no motor switching
limitation is necessary (otherwise the idling symbol
- blinks →the idling symbol appears during the
time-controlled run-up or star phase. For a star/
delta contactor combination the following applies:
the star contactor is switched on first followed by
the network contactor 20ms later. The idling symbol
signals the state of the electropneumatic control.
Thus it also appears after reaching the set maxi-
mum pressure – during the decrease phase of the
system pressure.
If the network pressure (in idling mode) drops below
the max. start-up back pressure and the automatic
operating cycles monitoring allows it, the control
unit switches the motor off and the Stand by symbol
is shown in the display. If the network pressure
drops to the set minimum pressure within the idling
phase, the compressor switches back to load opera-
tion and the respective symbol is displayed again.
If this happens shortly after having switched to
stand still, it has to be waited in case of contactor
connection – cf. also motor spinning time – until the
compressors is switched off for 20s, to be sure that
the motor stands completely still, before you may
start it again. If the pressure is below the switch-on
pressure this is signalled by the blinking of the
Stand-by symbol until the compressor starts again.
bar °C
Operating/control element Function Operation/Explanation

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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key →and the segment display shows the
compressor system pressure (pressure gauge 22).
Compressor
system pressure
Press ↓-key a second time →and the segment
display shows the total operating time in hours
together with the total running time symbol: .
Total operating time
Operating times,
output cycles,
maintenance dead-
lines, display test
and Software-No.
means: 124h total running time
Press O →Compressor Off →and the pressure
control function is deactivated and the display
shows the idling symbol. During this time the green
indicator blinks. The symbol O then appears and
the green indicator lamp is extinguished.
Switch off the
compressor
If the control unit detects a fault, the compressor is
switched off immediately and automatically – with-
out an idling phase –, the fault relay drops and
a digit on the right of the current pressure blinks
together with the red indicator lamp.
The blinking digit indicates the detected fault
(see also message key table page 1.12).
Fault messages
red
!
bar °C
Operating/control element Function Operation/Explanation

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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key a fifth time →and the display shows
the operating time (in hours) until the compressor
servicing and the Running time and Servicing sym-
bols (spanner).
Press ↓-key a sixth time →and the display shows
the operating time until the next Motor servicing and
the symbols O(here for motor), running time and
servicing (spanner).
Compressor
servicing
Motor servicing
Press ↓-key a seventh time →and the display
shows the 1000-output cycle servicing counter with
the exponent 103(x 1000), the Load-cycle symbol,
the circle (here for receiver) and the servicing
symbol (spanner), meaning the number of possible
output cycles until the next receiver inspection or
change of wearing parts.
Next receiver
servicing/change
of wearing parts
depending on
output cycles
means: 500hrs until the next
compressor servicing
means: 1000hrs until the next
motor servicing
Press ↓-key a third time →and the display shows
the Idling time counter in h (hours) and the Idling
symbol: .
Idling time
means: 2hrs idling time
Press ↓-key a fourth time →and the display shows
the 1000-output-cycles counter with the exponent
103(x 1000), the load cycle symbol and the circle
(here: receiver).
Output-cycle-
counter
means: 12 x 103= 12000 output
cycles
means: 20 x 103= 20000 Load
cycles until the next receiver
servicing or change of wearing
parts
Operating/control element Function Operation/Explanation

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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key an eleventh time →and the segment
display area shows the Software-No.
Software-No.
Press ↓-key a tenth time →and the display shows
all symbols and segments together with the two
indicator lamps.
Display
element test
red green
means Software-No. 1105
Upper target
pressure
(network pressure)
means: PMax. = 10,0 bar
(cut out pressure)
Press ↓-key a ninth time →and the segment
display shows the Lower target pressure and a
dash at the bottom right next to it.
Lower target
pressure
(network pressure)
means: PMin. = 9,0 bar
(cut in pressure)
Software-Version
No.
0xx xxx
1xx xxx
2xx xxx
3xx xxx
Meaning
Screw compressor, all sizes
Screw compressor up to 22 kW
with frequency converter
Screw compressor bigger than 22 kW
with frequency converter
Piston compressor
Operating/control element Function Operation/Explanation
Press ↓-key an eighth time →and the segment
display shows the Upper target pressure and a
dash at the top right next to it.

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RATIO
BOGE – RATIO compressor control for screw compressors
Operation1.4
Operation RATIO
Press ↓-key a twelfth time →to return to the main
display. Press ↑-key - to watch the displays in the
reversed direction.
If no key is pressed for five minutes, the main
display automatically reappears.
Parameterization
of frequency converter
without running motor
Normally the converter is under tension as soon as the I-key (On) is pressed
and the compressor motor starts. In case the frequency converter has to be
parameterized during motor stand-still – you only have to press the ↵-key
– when the main display is shown – and the compressor is switched off.
Then the converter supply contactor starts up and the motor remains in stand-
still – the green LED is not illuminated.
By pressing the O-key (Off) the converter supply contactor drops out.
Operating/control element Function Operation/Explanation

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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
Error key table
Each message is automatically
registered by the control, to-
gether with the associated time,
thus putting an overview at the
disposal of BOGE-Service.
1) adjustable
Error Meaning Compr.-
No. cut-out
0 Compr. air treatment (dryer or condensate drain gives error message) 1)
1 Final compression temperature > 110°C, 230°F X
2 Motor temperature too high X
3 Excessive current of vent. motor X
4 Incorrect direction of rotation X
5 Excessive compressor system pressure X
6 Excessive diff. pressure of intake filter
7 Excessive diff. pressure of oil filter
8 Excessive diff. pressure of oil separator
9 No output X
10 Motor servicing due
11 Compressor servicing due
12 System pressure decrease too slow
13 Frequency converter gives error message X
14 Temperature too low X
15 Suction control faulty (suction control or solenoid valve, if necessary clean
proportional controller)
16 Network pressure transmitter faulty X
System pressure increases too quickly (lack of oil, oil too old or even with
17 monitoring of the rotational direction a false rotational direction cannot be X
excluded)
18 Master control tries to go below Pmin – cf parameterization "External output enable"
Previous net switch-on phase was too short (possible reasons: coil short-circuit
19 'solenoid valve', 'delta contactor' or 'ventilator contactor') →automatically
increased delay time in corr. with permissible number of motor switch cycles
20 Master control tires to exceed Pmax – cf parameterization "External output enable"
21 Receiver or wearing parts inspection due
22 Not assigned here
23 Not assigned here
24 Not assigned here
25 Control unit Reconciliation error X
26 Control unit O-key does not open X
27 Control unit I-key does not open X
28 Control unit i-key does not open
29 Control unit ↵ -key does not open
30 Control unit "arrow up" does not open
31 Control unit "arrow down" does not open
32 Network pressure-transmitter wire breakage X
33 Compr.system pressure-transmitter wire breakage X
34 Compr.system pressure-transmitter faulty X
35 Excessive diff. pressure return valve
36 Bus Life-Bit did not toggle
38 Current of compressor motor is too high X

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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
General The control unit calculates from the current operating data the respective
best operating mode and automatically selects it.
The parameters are adjustable.
In order to prevent unintentional changes to pre-set parameters, these
parameters are codeword-protected.
ATTENTION!
Never change the value of a parameter if you do not know what it means!
This may cause incorrect behaviour of the control unit!
Do not experiment with parameter settings!
Always call BOGE-Service if you are unsure or have any doubts.
In general the following is applicable: If a parameterization, as described
below, is started at the top right in the display the symbol appears and
the set value or status blinks.
1. Display Software-No. (see Software No.).
2. Press ENTER ↵→and the parameterization symbol is shown on the
left, followed by three zeros, the left of which blinks.
3. Press ↑or ↓to change the first digit.
4. Press ↵→and now the middle zero blinks.
5. Press ↑or ↓to change the second digit.
6. Press ↵→and now the right zero blinks.
7. Press ↑or ↓to change the third digit.
8. Press ↵→the display will now branch off depending on the set number
– if the value is invalid the main display will reappear.
Each parameterization is automatically registered by the control, together
with the associated time, thus putting an overview at the disposal of BOGE-
Service.
The servicing interval memory can be set to a value between 300 and
9900 hours in one hundred hours increments as long as the interval time
limit is monitored by the control – if it is not used it has to be set to 10000h,
as it stops the down counter.
1. Enter Code 111 as described under coded parameterization →and the
display shows the compressor servicing interval in blinking digits (Com-
pressor servicing).
2. Press the ↑or ↓-key to change the value in big steps.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking
value, and the main display reappears.
Parameterization
Enter Parameterization
Code
Set the compressor
servicing interval
and restart

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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
The motor servicing interval memory can be set to a value between 500 and
29900 hours in one hundred hours increments as long as the motor interval
time limit is monitored by the control – if it is not used it has to be set to 30000 h,
as it stops the down counter.
1. Enter Code 222 as described under coded parameterization →and the
display shows the compressor servicing interval in blinking digits (Motor
servicing).
2. Press the ↑or ↓-key to change the value in big steps.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
The output cycles servicing interval memory can be set to a value between
100,000 and 1,900,000 cycles in increments of onehundredthousand, as long
as the output cycles servicing interval is monitored by the control – if it is not
used it has to be set to 2,000,000 cycles as it stops the down counter.
1. Enter Code 333 as described under coded parameterization →and the
display shows the receiver inspection interval in blinking digits (receiver
inspection/change of wearing parts).
2. Press the ↑or ↓keys to change the value in big steps.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
If changes are made to these target values, the value of Pmin is automatically
held or brought outside any applicable minimum hysteresis range.
1. Enter Code 360 as described under coded parameterization →and the
display shows the upper target pressure value, but blinking.
2. Press ↑or ↓-key to change the value.
3. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the lower target pressure value apears (blinking).
4. This value can now be changed by pressing the ↑or ↓-key.
5. Press ↵-key to overwrite the non-volatile EEPROM with the blinking value,
and the main display reappears.
6. It is not permissible to set the bottom pressure target value below the
stipulated pmin value. In case this should be necessary please contact
BOGE-Service beforehand.
Set the motor
servicing interval
and restart
Set load cycles
dependent servicing /
inspection and restart
Change target
pressure values
(Pmax and Pmin)

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RATIO
BOGE – RATIO compressor control for screw compressors
Control Parameterization1.5
If the output of a compressor is to be enabled by a higher level control unit,
its parameterization must be changed as follows:
1. Enter Code 210 as described under parameterization →and the display
shows from Fig. con the left. The 'zero' at the top right blinks. This dis-
play means: no additional enabling device is programmed.
2. Press ↓-key to switch to Fig. d– ↑-key to switch back. Digit One and
the bottom symbol 'external output release' are blinking.
This display means: enabling device (e.g., MCS) is enabled via input
'Pressure control' (for potential-free contact) – see also 'Switching Local/
Remote via key switch' and 'RS485-Bus-address setting'. If the ↵-key is
pressed during this, one of the following pictures appears e+ f–:
Fig. 3: The three top dashes and the 1 are blinking. The P and the three
top dashes mean, that falling below the network pressure (Manometer 21)
Pmin starts a load operation, even with an open input 'Pressure control'
– number '18' is displayed and the "warning" relay is activated – thus ac-
tuating the operating mode. Press ↓-key to switch to Fig. f– press ↑
to toggle back –:
Fig. 4: The falling and rising (dotted) pressure curve and digit 0 are blink-
ing. This figures means that due to the open input 'Pressure control' a
falling below the network pressure Pmin is possible (as e.g. at night and
over the weekend).
Press ↵-key to overwrite the non-volatile EEPROM as per the blinking
symbol, and the main display reappears.
In the bottom display the symbol appears. The following applies
even with external enabling: If the upper target pressure value in the
compressor is exceeded, the output will be shut off. Only when the the
pressure drops to the lower target pressure value the external control
resumes.
If the ↵-key under point 2 was not pressed, press ↓-key to change to Fig. g
– press ↑to toggle back –:
Digit Two and the two bottom symbols 'external output release' and 'on-
line' are blinking. This display means: enabling device (e.g., master con-
trol) is enabled via a serial interface, if the input 'external output release'
is closed – see also 'Switching Local/Remote via key switch' and 'RS485-
Bus-address setting'.
3. Press ↓-key, if convenient (not with key switch function) to switch to Fig. h
– press ↑to toggle back.
Manometer '22' and digit 3 are blinking. This setting means that a limiting
suction pressure switch (continuous output control) is connected to the
input 'Pressure control'.
4. Press ↵-key to overwrite the non-volatile EEPROM as per the blinking
symbol, and the main display reappears. If the compressor is set for an
output enabling device (e.g. mode 2), the bottom of the main display shows
the appropriate Symbol . The following applies even with exter-
nal enabling: If the upper target pressure value in the compressor is ex-
ceeded, the output will be shut off. Only when the the pressure drops
to the lower target pressure value the external control resumes.
External
output enable
c
d
e
!
!
!
!
f
g
h