Operating instructions

base control
for screw compressors
 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: +49 5206 601-0

Fax: +49 5206 601-200
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 I

Index

Index

Part 1: 1.1 The BOGE control concept............................................................ 1

base control 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 III

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.

BOGE base control for screw compressors Page 1

base control 1.1 The BOGE control concept

Operating and control

panel

Fig. 1.1: base control operating panel

1 LC display
2 Indicator lamp – Fault (red)
3 Indicator lamp – Ready (green)
4 Info key
5 Enter key
6 On key
7 Off key

Position of the Depending on the compressor type the Emergency Stop button is either
Emergency Stop button 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)

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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): Shutting down the – Press the Emergency Stop button.
compressor in an emer- The Emergency Stop button engages and interrupts
gency 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.
Emergency Stop button on the front (2): – 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 Disconnect compressor – Turn switch of the power disconnecting device to the
(with Emergency Off function) (3) from the power supply / left to the position ‚0‘. The supply voltage is discon-
switch off in case of an nected. All displays are cut off from the power.
emergency 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 for C LF N series Only use power disconnecting device
with power disconnecting device with Emergency Off function in case of
an emergency!

On key To switch the – Press the ON key :

compressor on 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 may continue to run in idling mode
compressor off (factory setting 30 seconds).

Info key Select desired – Press the Info key .

information The display changes to the next set of information.

BOGE base control for screw compressors Page 3

base control 1.2 Operating and control elements

Operating and control element Function Operation / Explanation

Enter key For confirmation during – see section „Parameterization of the control“ on
parameterisation / for page 11.
acknowledging warning
and fault messages

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 Display: Shown in psi with a decimal point between the second
P: Pressure and third digit.

psi

3-digit 7-segment display Display: Measured in °F.

T: Temperature

°F

Anti-freeze idling
Thermometer

OFF The circle stands for three functions:

or motor 1. The compressor is switched off
or receiver
2. For motor servicing interval
3. Servicing symbol (receiver inspection)
(replace wearing parts).

Standby Automatic standby phase

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base control 1.2 Operating and control elements

Operating and control element Function Operation / Explanation

Idling (Automatic) idling phase.

Load run or load speed Output phase or number of output cycles

Automatic operating Automatic mode with standby phases enabled.

mode selection (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 Energy-independent ON-OFF save function set.

(automatic restart
enabled after power
failure)

External Remote output enable (e.g. by MCS).

output enable

– Remote ON-OFF (e.g. from control panel) – not used

here.

Online – not used here.

BOGE base control for screw compressors Page 5

base control 1.3 Operation

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

Function control of display – After unlocking the Emergency Stop but-

elements 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.

1 Indicator lamp – Fault (red)

2 Indicator lamp – Ready (green)

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.

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base control 1.3 Operation

Operating and control element Function Operation / Explanation

Switching on the If no fault is reported, pressing On key will

compressor switch on the green indicator lamp (compressor
ready for operation) which means: the pressure
control function is activated.

1 Indicator lamp – Ready (green)

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- Press Off key → Compressor Off → the
pressor 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 O then appears and the
green indicator lamp goes out.

BOGE base control for screw compressors Page 7

base control 1.3 Operation

Operating and control element Function Operation / Explanation

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).

1 Indicator lamp – Fault (red)

Operation, servicing periods, display test and software-no.

Total hours Press Info key → and the segment display

shows the total operating time counter in hours,
together with the total up-time

means: 124 h total running-time

Idling hours Press Info key a second time → and the

display shows the Idling time counter and the
Idling time symbol.

bmeans: 2 h idling time

Compressor servicing Press Info key a third time → and the

interval display shows the operating time until the
Compressor servicing and the Running time
and Servicing symbols (spanner).

means: 500 h until next compressor 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).

means: 1000 h until next motor servicing

Page 8 BOGE base control for screw compressors

base control 1.3 Operation

Operating and control element Function Operation / Explanation

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
means: 20 x 103 = 20000 load cycles until next regulator).
receiver servicing.

Single leakage Press Info key a sixth time → now the

measurement 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 Press INFO key a seventh time → now the

measurement 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.

Upper target pressure Press INFO key an eighth time → and

value the segment display shows the Upper target
pressure and an underscore at the top right
next to it.

means: pmax. = 145 psi

Lower target pressure Press INFO key a ninth time → and the
value segment display shows the Lower target pres-
sure and an underscore at the bottom right next
to it.

means: pmin. = 130 psi

BOGE base control for screw compressors Page 9

base control 1.3 Operation

Operating and control element Function Operation / Explanation

Display element test Press INFO key a tenth time → and the
display shows all symbols and segments
together with the two indicator lamps.

1 Indicator lamp – Fault (red)

2 Indicator lamp – Ready (green)

Software version number Press INFO key an eleventh time → and

the segment display area shows the Software
no.

means software no. 1105

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.

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base control 1.4 Parameterization of the control

1.4 Parameterization of the control

Message key table

Error Meaning Compressor
no. 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

Frequency converter and / or fan motor gives error

13 X
message

14 Temperature too low X

15 Suction control 1)

a) Net pressure transmitter faulty

16 or: X
b) Fan motor overcurrent

17 not assigned here

18 Fault of an external control

Previous net switch-on phases were too short (possible

reasons: coil short-circuit "solenoid valve" or "delta con-
19
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

BOGE base control for screw compressors Page 11

base control 1.4 Parameterization of the control

Error Meaning Compressor

no. cut-out

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

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.

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.

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.

Page 12 BOGE base control for screw compressors

base control 1.4 Parameterization of the control

Set the compressor To make changes easier, the respective setting is changed in large steps.
servicing interval and 1. Enter Code 111, as described under parameterization (see page 12) →
zero the counter 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 To make changes easier, the respective setting is changed in large steps.
interval and zero the 1. Enter Code 222, as described under parameterization (see page 12) →
counter 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 To make changes easier, the respective setting is changed in large steps.
load cycles and restart 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- This function serves to determine the energy loss resulting from any potential
ment 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.

BOGE base control for screw compressors Page 13

base control 1.4 Parameterization of the control

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.

Page 14 BOGE base control for screw compressors

base control 1.4 Parameterization of the control

If, during measurement, the compressor is put out of operation the number
9990 will be displayed, i.e. the compressor is switched off and the energy loss
due to leakage could not be properly determined during said measurement. In
this case, too, the measurement process should be repeated at a later stage
while making sure that the compressor be switched off during measurement.

Start continuous measurement

Continuous leakage measurement will start immediately. Make sure
– that during the following days, at least for once during a time frame of
12 hours, no operational compressed air production takes place;
– that the compressor be set into the "ready" mode by means of the control
unit and that the green LED of the control be lit

In order to start continuous measurement:

1. Call up „Continuous Leakage Measurement“ in the display“
(see “Continuous leakage measurement” on page 9.).
2. Press ENTER key .
The number 9999 appears next to Lc. Continuous measurement will start
immediately and keep being carried out. After the twelve-hour time frame,
during which no operational production has taken place, has been exceed-
ed a sound measurement value is obtained.
The control system will always save the lowest value. A search for the lowest
value – as a background process – will be restarted once a week. This allows,
after expiry of another week, a higher value compared to the one of the pre-
vious week to be displayed if the measured minimum value has increased
during that period. Any potential increase of leakages in the compressed air
network will therefore also be possible to be determined.
Any power failures during measurement will not be indicated by a sequence
of digits because new values will be calculated every six hours and because
any such power failure during measurement will not prevent the values of the
subsequent measurement to be displayed

Change pressure target If changes are made to these target values, the value of Pmin is automatically
values (pmax and pmin) held or brought outside any applicable minimum hysteresis range.
1. Enter Code 360, as described under parameterization (see page 12) →
and the display shows, as already described, the upper target pressure
value, but blinking.
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 lower target pressure value appears (blinking).
4. This value can now be changed by pressing the Info key .
5. Press Enter key to overwrite the non-volatile EEPROM with the blink-
ing 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.

BOGE base control for screw compressors Page 15

base control 1.4 Parameterization of the control

Set external output

release
If the output of a compressor is to be enabled by an output release device
(higher-level control unit), the base control must be set as follows:
1. Enter Code 210, as described under parameterization (see page 12).
The display shows illustration . The ‚square’ at the top right blinks.
This display means: no additional output release device is considered.
The base control independently follows its given settings. These are the de-
fault settings.
No output release device must be considered:
2. a) Press Enter key in display
The setting, that no output release device must be considered, is
saved. The main display reappears.

Additional output release device to be considered

2. b) Press Info key in display with the ‚Square‘ blinking.
The display shows illustration . The 7-segment-range blinks.
This display means: output release device is considered.
The (lower level) base control follows the settings of the output release device
(higher-level control unit).
To save this setting:
3. Press Enter key .
The setting, enabling an output release device to be considered,
is saved. In this case the display subsequently appears (see figure
below):
Now the output release mode must be selected:
Display visualises the first output release mode.
In this case the following applies, despite external output release: if the actual
pressure drops below the lower pressure target value (pmin) as set in the con-
trol, output release is independently granted to the compressor by the control
to prevent a complete pressure loss. At the same time warning message 18
is generated. If the upper pressure target value (pmax) is exceeded, the control
unit automatically switches the compressor off and generates warning mes-
sage 20. This mode is recommended as an additional safety feature prevent-
ing a comple te pressure loss (e.g. in hospitals).
Press Info key to change from display to display (or press again to
toggle back...).

Page 16 BOGE base control for screw compressors

base control 1.4 Parameterization of the control

Display visualises the second output release mode.

If the actual pressure in this mode drops below the minimum pressure (pmin)
as set in the control, the control unit does not react. The control will not start
the compressor until it is enabled by the external output release device. There-
fore even a net pressure reduction below pmin is possible. In this mode the
control also switches the compressor automatically off, if the maximum pres-
sure (pmax) is exceeded but no warning message is generated. Only when the
pressure drops to the lower target pressure value, the external control is prior-
itised again. This mode is recommended if pressure reductions or a standstill
of compressed air production is required within certain periods of time (e.g.
reductions at night or during the weekend).
To set the required output release mode:
4. By means of the Info key select display or .
5. Press Enter key .
The required output release mode is set. The main display reap-
pears.

Note!
If the compressor is set for an output release device, the bottom of the main
display shows the appropriate symbol . The following always applies,
even with external output release: if the upper target pressure value in the
compressor is exceeded, the output will be shut off.

Change after-running
time
The after-running time determines the time interval for which the compressor
remains in idling after having reached the parameterised switch-off pressure.
1. Enter Code 019, as described under parameterization (see page 12) →
and the display shows the figure on the left.
The number 30 blinks. The quotation mark symbol here stands for sec-
onds. A run-out curve is indicated on the two right positions.
2. Press Info key to change the value.
(Setting range between 8 and 655 seconds).
3. Press Enter key to overwrite the non-volatile EEPROM with the blink-
ing value, and the main display reappears.

BOGE base control for screw compressors Page 17

base control 1.4 Parameterization of the control

Set continuous
operation
If pressure drops in relatively small receiver / pressure network volumes must
be avoided at any price, continuous operation can be set as follows:
1. Enter Code 733, as described under parameterization (see page 12) →
and the display shows illustration left.
The shading of the left arrow blinks. This means: automatic power econ-
omy operating mode selection.
2. Press Info key to change to illustration (press again to toggle
back...).
The shading of the right arrow blinks. This means: continuous operation.
3. Press Enter key to overwrite the non-volatile EEPROM with the blink-
ing symbol, and the main display with the selected symbol appears.

Enable network
independent ON-OFF
memory (Auto-Restart)

Caution!
With activated automatic restart (Auto-Restart) the compressor restarts
automatically after a power failure.
Condition: the network pressure is lower than the set switch-on pressure and
it was switched on beforehand.
Using energy independent memory for remembering ON-OFF:
Normally a compressor always assumes an OFF status directly after an elec-
trical power failure.

Page 18 BOGE base control for screw compressors

base control 1.4 Parameterization of the control

However, there is an option to automatically restart the compressor with a set

delay after a power failure. This is done as follows:
1. Enter Code 134, as described under parameterization (see page 12) →
and the display shows illustration . The 'line' at the top right blinks. This
display means: no remembering of switch-on memory (standby) after a
power failure.
2. Press Info key to change to illustration , (press again to toggle
back...): The ‚curve’ at the top right blinks. This display means: remem-
bering the On-Off status (Auto-Restart) even in case of a power failure.
3. Press Enter key to overwrite the non-volatile EEPROM according to
the blinking symbol. If the top symbol was acknowledged, the main display
reappears. Otherwise illustration on the left is shown. The number 120
blinks. The quotation mark symbol here stands for seconds.
4. Press Info key to change the value. (Setting range between 30 and
650 seconds).
Press Enter key to overwrite the EEPROM with the blinking value and
the main display appears with the symbol at the bottom right.

Anti-freeze idling The compressor is set to automatically start an idling phase from standby
(only in mode: when the temperature drops to below +40 °F, and to remain idling until reach-
ing +68 °F final compression temperature.
Ready for operation)

Motor switching Motor switching limitation is only activated when the air requirement makes
limitation it necessary.
Then a switching from intermittent to limited continuous operation – syn-
chronous DB control, is effected. The control unit calculates the cycle time
so that on the one hand the maximum allowed number of cycles per 12 min-
utes can not be exceeded, and on the other hand unnecessary idling times
can be avoided.

Star phase time control The star time is fixed in the control unit according to the type of compressor.

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base control 1.5 Faults

Service request The main display shows a blinking spanner.

– all other functions remain unchanged.
If the Info key is pressed, the display only shows the blinking service
request number and the spanner.
Press Enter key to acknowledge the request. If necessary (see also
message key table) one of the three servicing interval back-counters must
be reset to its start value as under the respective service interval setting or
receiver inspection load cycle setting, and changed or confirmed by press-
ing Enter key .

Pre-acknowledgement
If a service message is acknowledged, the cause of which has not (yet) been
attended to, the spanner symbol continues to appear (but no longer blinking).

1.5 Faults

General The tables on the following pages give information on the possible causes of
operating faults and measures for their rectification.

Caution!
Ensure that any work required to rectify faults is only carried out by trained
personnel or specialists. Ensure that components which have a safety func-
tion are only set, repaired or exchanged by BOGE Service!
Please contact the Technical Support at the following telephone numbers, if
you have any questions.
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140

Automatic monitoring of All data is stored in a memory module (EEPROM).

the control systems If a fault occurs while the data stored in the EEPROM is being read, the control
system will react as follows:
– The compressor is switched off.
– The following fault message appears in the display.

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base control 1.5 Faults

Fault messages of the

control

If the control unit registers a fault, the compressor is immediately and

– without any idling phase – automatically shut down. The error relay drops
and on the right, next to the actual pressure value, a number blinks next
to the red indicator lamp:
– the blinking number indicates the registered cause (see also section „Mes-
sage key table“ on page 11).

1 Indicator lamp – Fault (red)

Acknowledgement of messages
Display the message – e.g. by pressing the Info key . Press Enter key
to cancel the display and acknowledge the message. The main display ap-
pears, if the cause for the fault was rectified.

Overview fault messages

FAULT Possible cause Rectification

1 Final compression
temperature too high
Ambient temperature too
high
Employ suitable measures to improve the air inlet and venti-
lation in the installation room

Cooling unit soiled Clean cooling unit externally

Insufficient cooling air Keep air inlet opening to the compressor clean;
quantity check to ensure that any existing cooling air duct systems are
adequatly dimensioned

Insufficient oil quantity Top up oil

Temperature sensor defec- Replace temperature sensor or repair the wire break
tive or wire breakage

2 Motor temperature too

high
Motor overload!
Excessive winding temp.
Ensure correct voltage conditions:
Constant voltage in accordance with IEC 38
due to under-voltage

Insufficient motor cooling Improve motor cooling:

improve ventilation of the installation room;
clean the cooling unit

Motor soiled Clean motor cooling air supply

Excessive system pressure Exchange oil separator cartridge

Excessive network pressure Reduce net pressure to prevent compressor from building up
a pressure exceeding the permissible max. pressure
PTC resistor defective or Overhaul motor
aged

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base control 1.5 Faults

FAULT Possible cause Rectification

5 System pressure too

high
Suction regulator does not
close
Clean suction regulator or suction regulator insert, replace if
necessary

Ball valve on the compres- Open ball valve

sor delivery closed

Pressure value Pmax set Check or set pressure value Pmax

too high

Venting of solenoid valve Clean solenoid valve, replace if necessary.

does not work

13 Frequency converter /
motor
Motor overload!
Power input too high caused
Ensure correct voltage conditions:
Constant voltage in accordance with IEC 38
by undervoltage

Insufficient cooling of Ensure better cooling of motor / frequency converter:

motor / frequency converter improve ventilation of the installation room;
clean cooling unit and supply air filter

Motor soiled Clean motor cooling air supply

Excessive system pressure Exchange oil separator cartridge

Network pressure ptarget / Reduce net pressure to prevent compressor building up a

pmax too high compression load above approved max. pressure

PTC resistor defective or Overhaul motor

aged

14 Temperature too low Ambient temperature too

low
Apply anti-freeze measures

16* a) Network pressure

transmitter faulty
Network pressure trans-
mitter defective or wire
Replace network pressure transmitter or re-establish electrical
connection
breakage

b) Fan motor overloaded Have fan motor checked by BOGE service personnel
Overcurrent fan motor

25 Reconciliation error
Control unit EEPROM
Error loading software.
Control unit defective
Reload software or have control replaced by BOGE-Service
personnel

27 Control unit On key

does not open
Control unit defective Have control replaced by BOGE-Service personnel

* Type of message depends on machine configuration

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base control 1.5 Faults

Warning messages
of the control

WARNING Possible cause Rectification

10 Motor servicing due Servicing intervals see operating instructions for servicing

11 Compressor servicing
due
Servicing intervals see operating instructions for servicing

15 Suction control and /

or ventilation
Warning Check suction controller
Check solenoid valve
Check continuous output control (option)

18 Fault of an external
control
Higher level (Master) control
faulty
Check supply voltage of master control. Parameterization
of external output release.
Otherwise have control repaired or replaced by BOGE-
Service personnel.

19 Power-up phases too

short
Coil short circuit ‚Solenoid
valve‘ or ‚Delta contactor‘
Have coil replaced by BOGE-Service personnel, check
lines and have them repaired, if necessary.
→ according to the per-
missible amount of motor
cycle switches automatically
increased delay time

20 Continuous contact of
an external control
Higher level (Master) control
faulty
Check supply voltage of master control. Parameterization
of external output release.
Otherwise have control repaired or replaced by BOGE-
Service personnel.

21 Receiver inspection due

or replace wearing parts
Servicing intervals Inspect receiver according to local rules and / or replace
wearing parts

29 Control unit ENTER

key does not open
Control unit defective Have control replaced by BOGE-Service personnel

BOGE base control for screw compressors Page 23