Certified in accordance with ISO 9001

Germanischer Lloyd Certification

Certificate No.: QS410 HH

The Highest Quality Compressed air treatment Compressed air storage Condensate management

Solutions to improve air quality Guidance on the treatment of compressed air

1 m3 of

untreated air
contains up to 180 million particles of dirt, 50 80% water vapour and oil in the form of unburnt hydrocarbons at between 0.01 mg/m3 and 0.03 mg/m3.

Compressed air is used today in diverse industrial sectors. The multitude of applications range from untreated blow-down air to absolutely dry, oil-free and sterile compressed air for the pharmaceutical and food industry. This rich spectrum of applications demands individual levels of compressed air treatment, designed precisely for each application. 1 m3 of compressor intake air can contain up to 180 million particles of dirt. Besides these particles of dirt, the intake air can also contain 50 80% water vapour and oil in the form of unburnt hydrocarbons from machinery and waste gases. In addition, tiny amounts of lubricating oil and dust from the compressor can get into the compressed air network. When compressed to 10 bar for example, the concentration of these harmful substances increases eleven-fold, i. e. 1 m3 of compressed air can contains up to 2 billion particles of dirt. Depending on the application, these particles of dirt will have to be removed until the compressed air becomes absolutely dry, oil-free and sterile. The table on page 3 gives a summary of levels of achievable air quality. However, it can only show an overview of the possibilities. When choosing a treatment system, the starting point must be to accurately determine the use of the air the application. This establishes the required quality for the compressed air.

Compressed air treatment requires: additional investment cost maintenance work on treatment systems

But correct compressed air treatment: increases the service life of compressed air operated equipment improves the quality of your products increases your competitiveness increases your companys profitability reduces the risk of operating problems reduces repair costs for compressed air operated equipment reduces purchasing costs for piping systems At the planning stage, the experienced BOGE team can advise you about the type of compressed air treatment most suited for your application. This support protects you from installing a higher or lower level of air treatment equipment than necessary. BOGE can provide you with the optimum solution for your application, both from the point of view of cost and quality.

Contents:

Page 4 57 89 10 11 12 Activated carbon adsorbers Cyclone separators Filters 13 14 15 16 17 18 19 23

Purified
compressed air: Absolutely dry, oil-free and sterile

Compressed air dryers Refrigerant dryers Membrane dryers Adsorption dryers, heatless regenerated Adsorption dryers, heat regenerated

Compressed air treatment equipment Compressed air storage Condensate management

Air treatment to match your requirements

Not all compressed air is the same Untreated compressed air contains water vapour (humidity) as well as particles of dust and oil. These impurities can cause problems in compressed air equipment, resulting in expensive downtime, high maintenance costs and reduced product quality.

The advantages of using BOGE air treatment technology

Greater availability of pneumatic tools and equipment trouble-free operation minimum maintenance low operating costs Consistent product quality reliability and long service life for compressed air equipment

economic work processes increased competitiveness increased profitability Low-cost installation of the compressed air pipe network pipes free of condensation and rust horizontal pipe runs branch lines direct to the work place pipelines without the need for condensate collectors

Compressed Air Treatment Plan:

Activated carbon filter Dust Water Oil Sterile filter Refrigerant dryer Adsorption dryer Membrane dryer Cycloneseparator* Pre-filter** Microfilter Activated carbon adsorber Pre-filter Application for compressed air DIN ISO 8573-1 Class Air compressor

General industrial air Blow-down air Sandblasting Simple painting work Conveying air General factory air High-quality sandblasting Simple paint spraying Pneumatic tools Control air Paint spraying Air Conditioning Fluidics Measuring and control systems Dental laboratory Photographic laboratory Control air Instrument air Pneumatics High-quality paint spraying Surface finishing Breathing air

BOGE- SCREW OR PISTON COMPRESSOR

1-3

or

Mediacal systems Breathing Air High quality conveying air Food industry

3-4

or

Breweries Dairies Pharmaceutical industry

1-3

or

* Only for compressors without compressed air receiver

** Coarser impurities separated out to extend service life of microfilter

A complete range of quality drying solutions BOGE Compressed Air Dryers

Pressure C dewpoint
+ 10

BOGE refrigerant dryer for standard pressure dewpoint +3C

+7

+3

BOGE DB and D refrigerant dryer

83 110 182 250 0,08 0,11 0,18 0,25 5,0 7,0 10,8 15 1000 1 60 2,6 154 6,7 400 14 850 30,40 45,8 18,24 2750 93 124 146 5600 7440 8750 l/min 241,7 m3/min 14500 m3/h

Freezing 0 point
20 25 40

BOGE DM membrane dryer

BOGE membrane dryer / BOGE adsorption dryer for standard pressure dewpoint 20 C, 25 C, 40 C, 70 C

Flow capacity

70

BOGE DAZ / DA adsorption dryer BOGE DACZ / DAC air treatment unit BOGE DAV adsorption dryer

D, DB DM DAZ / DA DAV DACZ / DAC

Impurities and quality classes according to DIN ISO 8573-1

Class Solid impurities Max. particle size per m3 Max. particle size in m < = 0,1 0,1 < d 0,5 < d < = 0,5 < = 1,0 As specified by user A/R 100 1 A/R 100.000 1.000 A/R A/R 10.000 A/R A/R A/R A/R A/R A/R Classes 6 and 7 are defined according to the maximum particle size and maximum density. 3 Class 6: d < = 5 m and density < = 5 mg/m Class 7: d < = 40 m and density < = 10 mg/m3 Humidity Max. pressure dewpoint 1,0 < d < = 5,0 0 10 500 1.000 20.000 < = 70C < = 40C < = 20C < = + 3C < = + 7C < = +10C Classes 7 to 9 are defined according to their liquid water content. Class 7: C w < = 5 mg/m3 Class 8: 0.5 g/m3 < C w < = 5 mg/m3 Class 9: 5 g/m3 < C w < = 10 mg/m3 < = 0,01 mg/m3 < = 0,1 mg/m3 < = 1 mg/m3 < = 5 mg/m3 Max. oil content mg/m3

0 1 2 3 4 5 6

L
= = = = =

Refrigerant dryer Membrane dryer Adsorption dryer, heatless Adsorption dryer, heat-regeneration with vacuum cooling Air treatment unit comprising DA adsorption dryer, heatless with activated carbon adsorber

BOGE DB and D range of Refrigerant Dryers

Capacity: 0.167 208 m3/min., 6 7350 cfm Max. operating pressure: 16 bar, 230 psig The advantages of using a BOGE refrigerant dryer
Pressure dewpoint + 3 C consistent high-quality compressed air lower pressure differential saving on running costs by avoiding high compression Large heat-exchanger surface, pressure dewpoint up to +15 C possible at maximum ambient temperature of + 50 C and maximum compressed air inlet temperature of + 60 C Higher flow capacity protect against production problems during brief extreme conditions Dryer control dependent on capacity Series from DB 15 Avoidance of unnecessary energy costs Refrigerant R 134 a through the whole range ozone-friendly environmentally friendly operation minimum amount of refrigerant required

Refrigerant Dryers
One of the most economic methods of treating compressed air is with a refrigerant dryer. By cooling the compressed air down to near freezing point, the water and oil vapour are condensed and particles of dirt are bound together, the resulting condensate is then separated from the air flow. In many cases, the pressure dewpoint need only be a few degrees lower than the ambient temperature to prevent condensate from forming in the pipes.

Recycling and Waste Disposal

Recycling and waste disposal are growing problems around the world. Therefore, a recycling list is attached inside the machine housing, defining exactly which materials have been used.

Reduced quantity of refrigerant

R 134 a is the standard refrigerant used throughout the whole DB and D range. Unlike more traditional refrigerant dryers, the quantity required has been reduced considerably by up to 70%.

Environmentally friendly BOGE refrigeration technology

Anyone involved in refrigeration technology, has a special responsibility. That is why when designing the DB and D series, right from the outset, a great deal of importance was attached to the environmentally friendly manufacture, operation and final wastedisposal of our refrigerant dryers.

Technical data for the BOGE DB series of Refrigerant Dryers Flow capacity 0.167 27.5 m3/min., 6 972 cfm
Type Flow capacity DB 1 2 3 6 7 10 12 15 18 23 27 30 50 60 70 85 110 115 130 150 180 190 225 235 275 l/min 167 250 300 585 670 1000 1135 1500 1750 2250 2585 3000 4585 6000 6670 8170 10500 11000 12500 14670 17750 18500 22500 23500 27500 m3/h 10 15 18 35 40 60 68 90 105 135 155 180 275 360 400 490 630 660 750 880 1065 1110 1350 1410 1650 cfm 6 9 11 21 24 35 40 53 62 80 91 106 162 212 236 289 371 389 442 518 627 654 795 830 972 Pressure differential at full load bar psig 0.11 1.6 0.23 3.3 0.26 3.7 0.35 5.0 0.29 4.1 0.29 4.1 0.32 4.6 0.16 2.3 0.13 1.9 0.18 2.6 0.23 3.3 0.26 3.7 0.27 3.9 0.31 4.4 0.31 4.4 0.23 3.3 0.32 4.6 0.31 4.4 0.22 3.1 0.31 4.4 0.30 4.3 0.28 4.0 0.16 2.3 0.19 2.7 0.31 4.4 Electr. power consumption kW PS 0.13 0.18 0.14 0.19 0.15 0.20 0.16 0.20 0.25 0.34 0.27 0.37 0.33 0.45 0.35 0.48 0.46 0.63 0.70 0.95 0.74 1.00 0.76 1.03 0.88 1.20 0.95 1.29 1.08 1.47 1.25 1.70 1.28 1.74 1.45 1.97 1.80 2.45 2.40 3.26 2.56 3.48 2.80 3.80 2.95 4.01 3.10 4.22 3.25 4.42 Electr. power supply V/50 Hz 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 230 400 400 400 400 400 400 Compressed air connection G 3 /8 3 /8 3 /8 1 /2 1 /2 3 /4 3 /4 3 /4 1 1 1 1 11/2 11/2 11/2 11/2 2 2 2 2 2 1/2 2 1/2 2 1/2 2 1/2 2 1/2 Cooling air required m3/h cfm 260 153 260 153 260 153 240 141 240 141 450 265 450 265 450 265 740 435 740 435 1000 590 1000 590 1300 766 920 540 920 540 920 540 2900 1705 2900 1705 2900 1705 2600 1530 3100 1825 2600 1530 2600 1530 2600 1530 2600 1530 Dimensions WxDxH mm 350 x 300 x 375 350 x 300 x 375 350 x 300 x 375 350 x 350 x 400 350 x 350 x 400 450 x 450 x 500 450 x 450 x 500 450 x 450 x 500 600 x 450 x 550 600 x 450 x 550 600 x 450 x 550 600 x 450 x 550 600 x 600 x 650 600 x 600 x 650 600 x 600 x 650 600 x 600 x 650 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 900 x 800 x 1230 Weight kg 21 22 23 25 26 38 40 44 48 50 52 53 74 85 95 99 150 155 168 175 176 181 186 191 197

Installation Requirements
For standard dryer designs, the room temperature and ambient temperature must not exceed + 50 C or fall below + 2 C. Sufficient clearance must be provided on all sides of the dryer to ensure good circulation of the cooling air. A suitably dimensioned drainage pipe must be installed to remove condensate.

Pressure dewpoint + 3 C (different pressure dewpoints are possible) measured at dryer outlet Technical data according to DIN ISO 7183. For higher pressures and temperatures, different pressure dewpoints, and dryer capacities for values differing from DIN ISO 7183, available upon request. Refrigeration system: Complete refrigeration system with fully hermetic, refrigerant compressor. Condensate drainage: Cyclone/Float DB 1 DB 12 Solenoid valve controlled dependent on capacity (Option: Bekomat from DB 10) DB 15 DB 275 Pressure dewpoint display: Pressure dewpoint trend display on models DB 1 DB 275

Explanations / Installation data

Flow capacity is based on the compressors air intake + 20 C and 1 bar Compressed air temperature +35 C (max. +55 C or +60 C is possible) Operating pressure 7 bar (max. 16 bar is possible) Ambient temperature + 25 C (max. +45 C or +50 C is possible)

Multifunction display (from DB 15): Monitoring of pressure dew point Relative humidity at dryer outlet Malfunction display Dew point sensor defect Ambient temperature sensor defect EEPROM error Undervoltage Dew point too high Dew point too low (Anti-freeze protection) Malfunction history Maintenance interval expired Operating state condensate Operating hours Refrigerant: R 134 a Options: On models DB 1 to DB 275: Bypass assembly potential-free fault indication special voltages water-cooling (from model D 110 onwards) wall mounting on models DB 1 to DB 15 Series DB 18 DB 30 as option internal frost protection (down to 10 C) from model DB 18 onwards

Conversion factors

According to DIN ISO 7183, refrigerant dryers are designed for 7 bar operating pressure, an ambient temperature of 25 C and an inlet temperature of 35 C. For different operating pressures and temperatures, the following conversion factors should be used.
Ambient/cooling water temperature Factor DB range Inlet temperature Factor Operating pressure Factor (C) 25 1 30 0.97 35 0.94 40 0.87 45 0.75 50 0.50

(C)

30 1.28 2 0.6 3 0.7 4 0.8

35 1

40 0.90 7 1

45 0.82

50 0.58 11 1.1

55 0.48

60 0.38

(bar)

5 6 0.88 0.94

8 9 10 1.04 1.06 1.09

12 13 14 15 16 1.12 1.14 1.15 1.16 1.17

Technical data for the BOGE D series of Refrigerant Dryers Flow capacity 33 208 m3/min., 1148 7350 cfm
Type Flow capacity D 325 375 460 585 670 835 m3/min 33 38 46 58 67 83 m3/h 1950 2250 2750 3500 4000 5000 cfm 1148 1325 1619 2061 2356 2945 Pressure differential Electr. power at full load consumption bar psig kW PS 0.19 2.8 3.15 4.28 0.19 2.8 3.70 5.03 0.25 3.6 3.90 5.30 0.17 2.5 5.70 7.75 0.22 3.2 6.30 8.57 0.25 3.6 8.20 11.15 Pressure differential at full load bar psig 0.21 3.1 0.22 3.2 0.21 3.1 0.21 3.1 Electr. power consumption kW PS 12.20 16.59 14.50 19.72 13.90 18.90 18.20 24.75 Electr. power supply V/50 Hz 400 400 400 400 400 400 Electr. power supply V/50 Hz 400 400 400 400 Compressed air connection (DIN 2633) DN 100 DN 100 DN 100 DN 150 DN 150 DN 150 Compressed air connection (DIN 2633) DN 200 DN 200 DN 250 DN 250 Cooling air required m3/h cfm 10000 5890 10000 5890 10000 5890 9500 5595 9500 5595 9500 5595 Cooling water required m3/h cfm 3.90 2.29 4.50 2.65 5.50 3.23 6.40 3.76 Dimensions Weight WxDxH mm kg 1200 x 1255 x 1900 430 1200 x 1255 x 1900 450 1200 x 1255 x 1900 460 1200 x 1255 x 1900 600 1200 x 1255 x 1900 610 1200 x 1255 x 1900 645 Dimensions WxDxH mm 2225 x 1255 x 1900 2225 x 1255 x 1900 3340 x 1200 x 2040 3340 x 1200 x 2040 Weight kg 1010 1180 1760 1990

Type Flow capacity D 1165 1450 1750 2030 m3/min m3/h 117 7000 146 8750 175 10500 208 12500 cfm 4122 5153 6174 7350

Installation Requirements
For standard dryer designs, the room temperature and ambient temperature must not exceed + 50 C or fall below + 2 C. Sufficient clearance must be provided on all sides of the dryer to ensure good circulation of the cooling air. A suitably dimensioned drainage pipe must be installed to remove condensate.

Pressure dewpoint + 3 C (different pressure dewpoints are possible) measured at dryer outlet Technical data according to DIN ISO 7183. For higher pressures and temperatures, different pressure dewpoints, and dryer capacities for values differing from DIN ISO 7183, available upon request. Refrigeration system: Complete refrigeration system with fully hermetic, refrigerant compressor. Condensate drainage: Electronic, level-controlled condensate drain for model D 325 2030. Pressure dewpoint display: On dryers D 325 D 1450, the pressure dewpoint is shown in the display.

Display: On models D 325 D 1450, the following are displayed: Pressure dewpoint temperature Refrigerant intake temperature Compressed air inlet temperature Ambient temperature Operating time Potential-free contacts: On models D 325 D 1450 for: Collective fault warning Dewpoint error warning Refrigerant: R 134 a Options: On models D 325 D 1450: Bypass assembly 60 Hz operation water-cooling energy saving regulation internal frost protection (down to 10 C)

Explanations / Installation data

Flow capacity is based on the compressors air intake + 20 C and 1 bar Compressed air temperature +35 C (max. +55 C or +60 C is possible) Operating pressure 7 bar (max. 16 bar is possible) Ambient temperature + 25 C (max. +45 C or +50 C is possible)

Conversion factors According to DIN ISO 7183, refrigerant dryers are designed for 7 bar operating pressure, an ambient temperature of 25 C and an inlet temperature of 35 C. For different operating pressures and temperatures, the following conversion factors should be used.
Ambient/cooling water temperature Factor D range Inlet temperature Factor Operating pressure Factor (C) 25 1 30 0.97 35 0.94 40 0.87 45 0.75 50 0.50

(C)

30 1.2 2 0.6 3 0.7 4 0.8

35 1

40 0.83 7 1

45 0.75

50 0.55 11 1.1

55 0.45

60 0.35

(bar)

5 6 0.88 0.94

8 9 10 1.04 1.06 1.09

12 13 14 15 16 1.12 1.14 1.15 1.16 1.17

BOGE DM Series Membrane Dryer

Flow capacity: 102 2855 l/min., 3.60 100.78 cfm Max. operating pressure: 12 bar, 175 psig

Dry compressed air can save you money !

Compressed air always contains humidity, traces of compressor oil and particles of dust. These impurities can lead to serious problems. Pockets of corrosion or deposits can form on tooling and pneumatics, reducing efficiency and spoiling product quality. Maintenance work is required resulting in costly downtime.

Membrane Dryers can be installed in the pipelines of a system or installed as part of a screw or piston compressor assembly.
Pressure dewpoint reduced (t) between 20 and 55 K a multitude of applications are suitable for the Membrane Dryer No condensate precipitation during drying no condensate removal necessary Compact unit easy to install, small space required minimum installation costs

Compressed air filter fitted upstream as standard technically oil-free compressed air

No moving parts,no motors electrical energy savings

CFC free significant contribution to protecting the ozone layer and the environment

Drying process through dynamic concentration

Nitrogen Oxygen Water vapour The membrane diffuses the water molecules into the purge air.

Type DM 3 3 3 3 3 3 3 3 3 35 35 35 35 35 35 35 35 35 4 4 4 4 4 4 4 4 4 6 6 6 6 6 6 6 6 6 9 9 9 9 9 9 9 9 9 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 15 15 15 15 15 15 15 15 15

Max. operating pressure bar psig 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175 7 100 9 130 12 175

Flow volume Dryer Inlet l/min cfm 237 8.37 324 11.44 484 17.09 162 5.72 224 7.91 334 11.79 102 3.60 139 4.91 209 7.38 222 7.84 312 11.01 460 16.24 157 5.54 222 7.84 330 11.65 510 18.00 710 25.06 1050 37.07 360 12.71 505 17.83 750 26.48 235 8.30 330 11.65 485 17.12 700 24.71 980 34.59 1450 51.19 515 18.18 720 25.42 1065 37.60 340 12.00 475 16.77 700 24.71 550 19.42 770 27.18 1140 40.24 370 13.06 515 18.18 765 27.01 805 28.42 1125 39.71 1665 58.78 560 19.77 785 27.71 1160 40.95 1380 48.71 1930 68.13 2855 100.78 980 34.59 1370 48.36 2025 71.48 660 23.30 925 32.65 1365 48.19 1180 41.65 1650 58.25 2440 86.13 860 30.36 1205 42.54 1780 62.83

Purge air t 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K 20 K 20 K 20 K 35 K 35 K 35 K 55 K 55 K 55 K l/min 27 34 44 27 34 44 27 34 44 37 47 60 37 47 60 60 75 100 60 75 100 60 75 100 90 115 150 90 115 150 90 115 150 90 115 145 90 115 145 150 190 245 150 190 245 180 230 295 180 230 295 180 230 295 230 295 375 230 295 375

Flow volume Dryer Outlet l/min (air used) 210 290 440 135 190 290 75 105 165 185 265 400 120 175 270 450 635 950 300 430 650 175 255 385 610 865 1300 425 605 915 250 360 550 460 655 995 280 400 620 655 935 1420 410 595 915 1200 1700 2560 800 1140 1730 480 695 1070 950 1355 2065 630 910 1405

cfm 7.41 10.24 15.53 4.77 6.71 10.24 2.65 3.71 5.83 6.53 9.36 14.12 4.24 6.18 9.53 15.89 22.42 33.54 10.59 15.18 22.95 6.18 9.00 13.59 21.53 30.54 45.89 15.00 21.36 32.30 8.83 12.71 19.42 16.24 23.12 35.12 9.88 14.12 21.89 23.12 33.01 50.13 14.47 21.00 32.30 42.36 60.01 90.37 28.24 40.24 61.07 16.94 24.53 37.77 33.54 47.83 72.90 22.24 32.12 49.60

Compressed air connection IN / OUT G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/4 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 1/2 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4 G 3/4

Dimensions LxWxH mm 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 860 x 55 x 55 1117 x 55 x 55 1117 x 55 x 55 1117 x 55 x 55 1117 x 55 x 55 1117 x 55 x 55 1117 x 55 x 55 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 890 x 61 x 72 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 901 x 74 x 84 1109 x 61 x 72 1109 x 61 x 72 1109 x 61 x 72 1109 x 61 x 72 1109 x 61 x 72 1109 x 61 x 72 1120 x 74 x 84 1120 x 74 x 84 1120 x 74 x 84 1120 x 74 x 84 1120 x 74 x 84 1120 x 74 x 84 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 912 x 105 x 115 1131 x 105 x 115 1131 x 105 x 115 1131 x 105 x 115 1131 x 105 x 115 1131 x 105 x 115 1131 x 105 x 115

Weight kg 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.5 1.7 1.7 1.7 1.7 1.7 1.7 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 3.0 2.5 2.5 2.5 2.5 2.5 2.5 3.4 3.4 3.4 3.4 3.4 3.4 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 5.5 6.4 6.4 6.4 6.4 6.4 6.4

BOGE DAZ series Adsorption Dryers

heatless with pre- and after filters Flow capacity: 8 6100 m3/h, 4 3587 cfm Max. operating pressure: 10 and 16 bar, 150 and 230 psig
Heatless adsorption dryers with pressure dewpoints down to 70 C are suitable when D series refrigerant dryers with pressure dewpoints of + 3 to + 7 C will not meet the requirement. Before drying, the standard BOGE FPseries micro-filter removes any solid and liquid impurities up to 0.01 mm from the compressed air supply. In the adsorption dryer, the desiccant material adsorbs moisture from the air, resulting in clean, dry compressed air. Pressure dewpoints down to 40 C can be achieved with the standard model. In parallel with moisture adsorption, regeneration takes place in a second vessel. With type DAZ heatless adsorption dryers, compressed air which has already been dried is used to regenerate the desiccant.

The advantages of using the BOGE DAC treatment system

Complete and ready for use saving on installation and piping costs for pre-filters and after-filters (up to DAZ 160)

Generously dimensioned inlet and outlet valves low differential pressure, saving on energy costs

Robust, flexible adsorption principle maximum availability

Microprocessor-based control Adjustment of pressure dew point at option

Display of function on front panel of switch cabinet Permanently displayed status

BOGE DACZ series Treatment System

DAZ Adsorption Dryer and DCZ Activated Carbon Adsorber with Pre-filter and After-filter Flow capacity: 8 950 m3/h, 4 559 cfm Max. operating pressure: 10 and 16 bar, 150 and 230 psig
Heatless adsorption dryers with builtin activated carbon adsorbers are installed where the compressed air is required to have a residual oil content down to 0.003 mg/m3 and a pressure dewpoint down to 70 C. See also page 13.

Regeneration without an external energy supply economic, trouble-free operation

10-minutes-cyclus approx. 6% energy saving

Optional dewpoint control operating costs reduced by decreasing the volume of purge air, depending on pressure, volume and temperature

Condensate removed via the purge air no costs for condensate removal / drainage

Standard pressure dewpoint 40 C no condensate formed in pipework installed outside

CFC-free significant contribution to protecting the ozone layer and environment

10

Type
B

Capacity* m3/h 8 15 25 35 56 72 86 145 200 255 360 400 620 750 950 1200 1550 2000 2500 3000 3800 4850 6100 cfm 4 8 13 21 30 40 50 85 118 150 212 235 365 441 559 706 912 1176 1470 1764 2235 2852 3587

T DAZ 4-14

DAZ 4 5 6 8 9 11 14 25 35 45 60 70 100 125 160 200 260 340 420 500 645 810 1020

Dimensions W/ D/ H mm 312/ 210/ 390 312/ 210/ 565 359/ 210/ 815 359/ 210/1085 436/ 300/1160 436/ 300/1410 436/ 300/1610 566/ 480/1730 592/ 480/1740 634/ 490/1845 660/ 490/1859 823/ 585/1930 874/ 585/1925 930/ 585/2030 981/ 620/2030 1060/ 840/2070 1270/ 900/2110 1350/ 990/2150 1530/1040/2210 1600/1100/2255 1875/1200/2385 1925/1250/2660 2160/1150/3585

Connection G 1/4 G 1/4 G 1/4 G 1/4 G 3/8 G 3/8 G 1/2 G1 G1 G1 G1 G 11/2 G 11/2 G 11/2 G2 DN 50 DN 65 DN 65 DN 80 DN 80 DN 100 DN 100 DN 125

Wt. kg 9 13 17 25 52 65 77 121 142 176 220 280 365 465 560 640 830 955 1075 1500 1990 2410 2850

Typ

Capacity*

DACZ m3/h cfm 4 8 4 5 15 8 6 25 13 8 35 21 9 56 30 11 72 40 14 86 50 25 145 85 35 200 118 45 255 150 60 360 212 70 400 235 100 620 365 125 750 441 160 950 559 200 270 310 390 Upon 500 640 770 940

Dimensions W/ D/ H mm 445/ 210/ 390 445/ 210/ 565 492/ 210/ 815 492/ 210/1085 629/ 300/1160 629/ 300/1410 629/ 300/1610 770/ 480/1650 820/ 480/1680 890/ 490/1730 910/ 490/1790 1150/ 585/1820 1250/ 585/1815 1340/ 585/1980 1450/ 620/1980

Wt. kg 12 17 24 34 72 90 107 155 186 262 324 369 485 629 720

request

B DAZ 25-160

* Capacity in m3/h at 1 bar to DIN ISO 7183 Max. operating pressure DAZ 4 DAZ 160 16 bar DAZ 200 DA 1020 10 bar Electrical connection 230 V; 50 Hz; 0.021 kW (Dimensions and weights for models DA / DAC 200 onwards do not include pre-filters and after filters) Receiver as per PED individual acceptance / CE standard

Conversion factors to determine dryer size for PDP down to 40 C

B DAZ 200-1020 T

Effective bar C 35 40 45 50 5 0.75 0.64 0.61 0.59 6 0.89 0.78 0.73 0.67 7 1.00 0.91 0.82 0.79 8 1.08 1.00 0.94 0.86 9 1.26 1.08 1.03 0.99 10 1.31 1.16 1.07 1.03 11 1.36 1.24 1.10 1.07 12 1.49 1.35 1.22 1.18 13 1.62 1.47 1.35 1.29 14 1.70 1.57 1.46 1.37 15 1.79 1.67 1.57 1.46 16 1.90 1.77 1.66 1.55

Higher inlet temperatures available upon request Subject to modification

H

T DACZ 4-14

Examples: 380 m3/h of air is to be dried at 8 bar operating pressure and + 35 C. Pressure dewpoint required: 40 C.
H

a) To calculate the specific dryer capacity:

b) To calculate the max dryer capacity in m3/h Nominal capacity m3/h x factor (DAZ 60) = 365 m3/h x 1.08 = 394 m3/h

effective capacity m3/h factor

B DACZ 25-160 T

380 m3/h = 352 m3/h 1.08

Type DAZ 60 is selected.

11

BOGE DAV Adsorption Dryer

externally heated regeneration and vacuum purging, complete with pre-filter and after-filter Flow capacity: 420 14500 m3/h, 247 8526 cfm Max. operating pressure: 10 bar, 150 psig
Heat regenerated adsorption dryers are more economic than heatless adsorption dryers. Available with higher outputs and pressure dewpoints down to 70C. Before drying, the standard BOGE F-series micro-filter removes any solid and liquid impurities up to 0.01 mm from the compressed air supply. In the adsorption dryer, the desiccant material adsorbs moisture from the air, resulting in clean, dry compressed air. Pressure dewpoints down to 40 C can be achieved with the standard model. In parallel with moisture adsorption, regeneration is carried out in a second vessel. With DAV series vacuum regeneration adsorption dryers, ambient air is drawn into the package, heated and then used to regenerate the desiccant.
Active heat in vacuum area due to physically restricted humidity at 98 C. Low regeneration temperature the drying tower is under vacuum conditions thereby efficient removal of moisture takes place at a lower temperature. Intensive cooling the vacuum lowers the point where moisture flashes off to atmosphere. Pressure equalisation on wet side Purge air is only used to equalize pressure. Consistent pressure dewpoint as the purge air is fed through the dryers inlet. Vessel changeover with no pressure dewpoint peaks as the humidity of the purge air does not reach the dry areas of the desiccant. Pressure dewpoints down to 70 C can also be achieved, as well as the standard 25 C or 40 C. Function messages for pressure, temperature, heater operation, vacuum pump and changeover. Alternative energy for regeneration using steam or hot water (+ others) is available as an option. Modular System Options Purge air bypass, thyrister control-heaters, frequency control vacuum pump.

The advantages of using the BOGE DAV Adsorption Dryer

Low-energy system savings of up to 25 % compared with conventional systems 2-stage drying filled with waterproof and fast-acting desiccant Volume of flow*

Examples: a) Compressed air to be dried: Volume of flow Min. operating pressure Max. outlet temperature Pressure dewpoint Factor from table 3000 m3/h 5 bar () + 30 C 25 C 0.80

effective capacity = factor from table

3000 m3/h = 3750 m3/h 0.80
Selected: type DAV 685 b) To calculate the max. dryer capacity: Nominal capacity x factor from table 4100 x 0.80 = 3280 m3/h c) Reserve dryer capacity: Max. dryer capacity volume of flow 3280 m3/h 3000 m3/h = 280 m3/h

ConWidth Height Depth Weight Power nection (mm) (mm) (mm) kg required DAV m3/min. m3/h cfm DN kWh/h 75 7.0 420 241 40 1215 1955 985 460 3.1 85 8.5 510 293 40 1215 2205 985 560 3.8 105 10.7 640 370 50 1305 2250 1085 640 5.2 145 14.2 850 487 50 1360 2275 1095 770 6.7 200 19.7 1180 681 80 1560 2665 1280 940 10.9 250 25.0 1500 863 80 1610 2680 1285 1200 12.8 330 33.0 1980 1141 80 1700 2730 1390 1580 16.3 390 39.2 2350 1353 100 2020 2845 1415 1880 18.1 455 48.8 2930 1688 100 2085 2870 1515 2350 22.5 555 59.2 3530 2047 100 2170 2950 1630 2850 27.8 685 68.3 4100 2365 150 2450 3190 1655 3300 32.2 790 79.0 4740 2735 150 2515 3210 1835 3800 38.9 875 87.5 5250 3029 150 2550 3230 1870 4200 44.9 1035 103.5 6210 3582 150 2600 3500 1910 4950 52.3 1185 118.3 7100 4094 150 2650 3520 1940 5700 56.4 1335 133.3 8000 4611 200 3210 3585 2180 6400 67.1 1535 153.3 9200 5306 200 3150 3655 2300 7400 75.6 1800 180.0 10800 6224 200 3250 3690 2355 8700 85.3 2050 205.0 12300 7088 250 3500 3785 2520 11500 98.9 2415 241.7 14500 8359 250 3600 4000 2530 13500 111.4 * m3/h at 1 bar to DIN 7183. Higher capacities and lower pressure dewpoints down to 70 C are available upon request. Receiver as per PED individual acceptance / CE standard

Conversion factors, depending on pressure and temperature bar () / t C 4 5 6 7 30 0.69 0.80 0.90 1.02 35 0.44 0.62 0.80 1.00 40 0.28 0.42 0.59 0.70
Subject to modification

8 1.06 1.05 0.79

9 1.17 1.16 0.88

10 1.29 1.28 0.96

12

BOGE DCZ Activated Carbon Adsorbers

Flow capacity: 8 950 m3/h, 4 559 cfm Max. operating pressure: 16 bar, 230 psig
Activated carbon adsorbers are recommended for installation downstream of compressed air dryers with filters, in order to reduce the residual oil content of the compressed air to 0.003 mg/m3. Even after filtering out solid and liquid contaminants up to 0.01 m, and installing a compressed air dryer, compressed air can still contain oil vapour. Oil vapour can be passed by the compressor or be drawn in from the atmosphere. Oil contamination can depend on the type of oil and the temperature of operation. The BOGE DC activated carbon adsorber is used wherever there is the requirement for the highest quality compressed air. The compressed air flows from top to bottom of the adsorber vessel, through a bed of special activated carbon. Optimal contact time, air flow-rate, bed depth and the quality of the activated carbon ensure high-quality compressed air.

The advantages of using the BOGE DC activated carbon adsorber

Large volume of activated carbon high quality compressed air due to a residual oil content of only 0.003 mg/m3 Optimum technical design high-quality compressed air Oil indicator supplied as standard controllable compressed air quality ensures reliable operation Long-life activated carbon when the type FP filter is fitted upstream (option) low down-times

For safety reasons, it is recommended that a type V filter should also be installed downstream (option), as very fine solid particles from the activated carbon bed may contaminate the compressed air.

Type
H

Capacity* m3/h 8 15 25 35 56 72 86 145 200 255 360 400 620 750 950 cfm 4 8 13 21 30 40 50 85 118 150 212 235 365 441 559

DCZ 4 -14

DCZ 4 5 6 8 9 11 14 25 35 45 60 70 100 125 160

Dimensions W/D/H mm 107/ 170/ 390 107/ 170/ 565 107/ 170/ 815 107/ 170/1085 240/ 340/1160 240/ 340/1410 240/ 340/1610 255/ 280/1670 290/ 280/1690 330/ 340/1650 360/ 340/1670 385/ 420/1780 445/ 420/1800 475/ 500/1910 525/ 500/1930

Connection

G G G G G G G G G G G G G G G

/4 1 /4 1 /4 1 /4 3 /8 3 /8 1 /2 1 1 1 1 11/2 11/2 11/2 2

1

Max. Pressure bar 16 16 16 16 16 16 15 16 16 16 16 16 16 16 16

Weight kg 2.9 4.4 6.0 9.0 23.0 28.0 33.0 45 54 75 92 103 134 177 209

DCZ 25 -150

Higher capacities are available upon request * m3/h at 1 bar to DIN ISO 7183 Receiver as per PED individual acceptance / CE standard

Examples: Compressed air to be treated: Volume of flow Min. operating over-pressure Factor P from table Factor T from table Max. inlet temperature 150 m3/h 8 bar () 1.08 0.85 + 40 C Conversion factor: Pressure bar Factor P 4 0.62 5 0.75 6 0.89 7 1.00 8 1.08 9 1.26 10 1.36 12 1.62 14 1.79 16 2.14

eff. capacity 150 m3/h = = 163.4 m3/h factor P + T 1.08 0.85

Selected Type: DCZ 35

Temp. C Factor T

20 1.01

25 1.01

30 1.01

35 1.0

40 0.85

45 0.75

50 0.5

Subject to modification

13

BOGE Cyclone Separators/ Compressed Air Filters

BOGE-High-capacity Cyclone Separators
Cyclone separators remove liquids, fine mists and solids from the compressed air

Cost-efficient use of BOGE cyclone separators Directly downstream of the compressor if no compressed air receiver is fitted if no compressed air receiver is a long distance away if the compressed air pipeline rises vertically

Type

Flow capacity* m3/min. at 8 bar 10 bar 2.91 5.25 8.75 12.84 17.50 23.24 38.50 52.92 13 bar 3.64 6.56 10.93 16.03 21.88 29.05 48.13 65.63

Compressed air connection G 2

1

Max. operating pressure bar 16 16 16 16 16 16 16 16

Dimensions mm A 80 95 110 110 150 150 180 180 B 260 280 355 355 470 470 580 580

Z 20 Z 40 Z 65 Z 90 Z 125 Z 170 Z 275 Z 375

2.28 4.13 6.88 10.08 13.75 18.26 30.25 41.25

G 34 G1 G 1 4
1

G 112 G2 G 212 G3

* relates to the compressors intake condition (+ 20 C, 1 bar)

Cyclone separator with BEKOMAT electronic level-controlled condensate drain (option).

14

BOGE preliminary filter, series V

Preliminary filters separate out coarse impurities from the compressed air BOGE preliminary filters remove solids from compressed air with an efficiency of 99.99 % relative to 3 m.

Cost-efficient use of BOGE preliminary filters Upstream of compressed air dryer and micro-filter for applications where the intake air has a very high dust content for compressors with a high oil carry-over characteristic.
Type 1) Capacity [m3/h] 2) Connection Dimensions Wt. Filter element Number/ type

[mm] A V5 V 10 V 12 V 20 V 30 V 50 V 80 V 120 V 160 V 250 VF 250 VF 400 VF 490 30 50 70 100 180 300 470 700 940 1450 1450 2400 2900 G 14 G 14 G 38 G 2
1

B 167 209 209 279 315 415 515 715 823 1073 1260 1310 1440

C 14 21 21 21 43 43 43 43 48 48 170 200 230

D 60 75 90 160 135 235 335 525 520 770 530 530 550

[kg] 0.8 1.5 1.5 1.7 4.3 5 5.5 6.9 9.6 17.9 54 80 108 1/5 V 1/10 V 1/12 V 1/20 V 1/30 V 1/50 V 1/80 V 1/120 V 1/160 V 1/250 V 1/250 V 1/400 V 2/250 V

Aluminium housing with threaded connector as per DIN 2999 60 87 87 87 130 130 130 130 164 164 380 440 500

G 34 G1 G 112 G 112 G2 G2 DN 80 DN 80 DN 100

Steel housing with flanged connector as per DIN 2633

Max. operating pressure 16 bar 1) incl. automatic condensate drain, differential pressure gauge from V 10 onwards 2) relative to 20 C and 1 bar absolute at 7 bar over pressure

Conversion factor f at other operating pressures Over-pressure in bar f= 1 0.25 2 0.38 3 0.5 4 0.63 5 0.75 6 0.88 7 1 8 1.13 9 1.25 10 1.38

V5

Differential pressure and efficiency Differential pressure in clean condition Efficiency p 0.03 bar 99.99 % at 3 m

Higher pressures and capacities are available upon request

V 10 to V 250 with differential pressure gauge

VF 250 to VF 490 with differential pressure gauge

15

BOGE microfilters, series FP

Microfilters separate out extremely fine impurities in the compressed air. BOGE microfilters remove solids from compressed air with an efficiency of 99.99999% relative to 0.01 m and a residual oil content up to 0.01 mg/m3. Cost-efficient use of BOGE microfilters As the main filter in the compressed air line or as an end-of-line filter upstream of pneumatic equipment

BOGE activated carbon filter, series A

Activated carbon filters remove flavours and odours from compressed air. In combination with BOGE microfilters, BOGE activated carbon filters remove solids from compressed air with an efficiency of 99.99999% relative to 0.01 m and a residual oil content of up to 0.003 mg/m3. Cost-efficient use of BOGE activated carbon filters Downstream from compressed air dryers, in combination with microfilters if technically oil-free and clean compressed air is required

Type 1)

Capacity 2)

Connection

Dimensions

Combi- Wt. nation F/A D 60 75 90 A 120 174 174 174 260 260 260 260 340 340 760 880 [kg] 0.8 1.5 1.5 1.7 4.3 5 5.5 6.9 9.6 17.9 54 80 108

[m3/h] FP5/A5 FP10/A10 FP12/A12 FP20/A20 FP30/A30 FP 10 to FP 250 with differential pressure gauge FP50/A50 FP80/A80 FP120/A120 FP160/A160 FP250/A250 FFP250/AF200 FFP400/AF400 FFP 250 to FFP 490 with differential pressure gauge FFP490/AF490 30 50 70 100 180 300 470 700 940 1450 1450 2400 2900 G 14 G 14 G 8
3

[mm] A B 60 165 87 215 87 215 87 285 130 325 130 425 130 525 130 725 164 825 164 1075

C 14 21 21

Wt. combination F/A [kg] 1.6 3 3 3.4 8.9 10.7 11.6 14.2 19.7 25.8 108 160 215

Filter element Number/ type F or A 1/5 FP/A 1/10 FP/A 1/12 FP/A 1/20 FP/A 1/30 FP/A 1/50 FP/A 1/80 FP/A 1/120 FP/A 1/160 FP/A 1/250 FP/A 1/250 FP/A 1/400 FP/A 2/250 FP/A

Aluminium housing with threaded connector as per DIN 2999

G 12 G 34 G1 G 112 G 112 G2 G2

21 160 43 135 43 235 43 335 43 525 48 520 48 770

Steel housing with flanged connector as per DIN 2633 DN 80 380 1280 170 530 DN 80 440 1320 200 530

DN 100 500 1440 230 550 1000

Max. operating pressure 16 bar 1) incl. automatic condensate drain on model FP 5 onwards, differential pressure gauge on model FP 10 onwards 2) relative to 20 C and 1 bar absolute at 7 bar over pressure, technical data for series FP and A are identical

Conversion factor f at other operating pressures Over-pressure in bar f= Combination of FP filter and A 10 to 250 with differential pressure gauge Differential pressure and efficiency Differential pressure in clean condition Efficiency Series FP p 0.06 bar 99.99999 % relative to 0.01 m Residual oil content max. 0.01 mg/m3 Series A Differential pressure in clean condition Efficiency Combination of FFP filter and AF 250 to 490 with differential pressure gauge p 0.03 bar Residual oil content = 0.003 mg/m3 Series FP/A p 0.2 bar 99.99999 % relative to 0.01 m 1 0.25 2 0.38 3 0.5 4 0.63 5 0.75 6 0.88 7 1 8 1.13 9 1.25 10 1.38

Higher pressures and capacities are available upon request

16

BOGE compressed air treatment systems

Filter / water separators in compact block design. Other equipment can be connected on both sides. Condensate drainage manually or using an automatic drain.
Size of connection Dimensions: Length installed (width) mm Height mm G 14 40 120 G 38 47 155 G 12 69 200 G 34 69 200

Pressure reducers, complete with pressure gauge in compact block design. Other equipment can be connected on both sides. Easy to adjust by turning the large handwheel.
Size of connection Dimensions: Length installed (width) mm Height mm G 14 40 105 G 38 47 115 G 12 69 144 G 34 69 144

Lubricators Automatic operation, in compact block design. Other equipment can be connected on both sides.
Size of connection Dimensions: Length installed (width) mm Height mm G 14 40 140 G 38 47 185 G 12 69 230 G 34 69 230

Combi-system (filter/pressure reducer), complete with pressure gauge Filter and pressure reducer combined in one space-saving, block-design unit. Condensate drainage manually or using an automatic drain. Pressure reducer with secondary ventilation. Can be adjusted by turning the large handwheel.
Size of connection Dimensions: Length installed (width) mm Height mm G 14 40 175 G 38 47 210 G 12 69 265 G 34 69 265

Accessories:

Fixing bracket (wall mounting) Set of couplings Set of 30 micron filters Set of 5 micron filters Set of 30 micron filters / regulators Set of 5 micron filters / regulators

17

BOGE compressed air storage

Compressed air receivers, operating pressure 11 bar
Capacity Dim. mm litres A B Receiver horizontal 50 780 300 90 995 350 150 1360 400 270 1540 500 350 1610 550 500 1730 600 1000 2070 800 2000 2170 1150 3000 2675 1250 5000 3500 1400 A B Receiver vertical 270 1765 500 350 1835 550 500 1980 600 1000 2340 800 2000 2390 1150 3000 2790 1250 5000 3730 1400 5000 3730 1400 C D E F G 14 14 14 19 19 24 24 23 23 23 Weight Airkg Inlet 30 37 66 100 125 150 285 555 765 1170 G G G G G G G G G G 2 4 1 2 1 2 3 4 114 114 112 112 112
1 3

Air outlet Ball Inspection stopcock apertures G G G G G G G G G G 8 8 1 2 1 2 3 4 1 114 2 2 2

3 3

380 380 400 320 390 500 550 330 410 480 800 350 570 625 800 500 620 660 900 550 670 705 1100 600 790 885 1200 720 1200 1325 1300 1100 1350 1450 1500 1250 1500 1600 2200 1400 C 500 550 655 800 1000 1250 1400 1400 F 460 510 525 670 1000 1150 1300 1300 G 13 13 22 22 23 23 23 23

2 x 1 sleeve on the back

1 hand hole* 2 hand holes or 1 manhole (option) 1 manhole

height when installed 1780 1845 2070 2400 2510 2865 3800 3800 100 125 150 285 555 765 1170 1180 G1 G1 G 112 G 112 G 212 G 212 G 212 DN 100 G 12 G 34 G 112 G2 G 212 G 212 G 212 DN 100

1 hand hole* 2 hand holes or 1 manhole (option) 1 manhole 1 manhole

Compressed air receivers, operating pressure 16 bar

Capacity Dim. mm litres A B Receiver horizontal 50 780 300 150 1310 400 250 1380 500 350 1600 550 500 1780 600 1000 2100 800 2000 2170 1150 3000 2675 1250 5000 3500 1400 A B Receiver vertical 250 1605 500 350 1835 550 500 1995 600 1000 2340 800 2000 2410 1150 3000 2790 1250 5000 3730 1400 5000 3730 1400 C D E F G 14 14 19 19 24 24 23 23 23 Weight Airkg Inlet 37 74 113 145 180 355 720 935 1340 G G G G G G G G G 2 2 3 4 3 4 114 114 112 112 112
1 1

Air outlet Ball Inspection stopcock apertures G G G G G G G G G 8 2 1 2 3 4 1 114 2 2 2

3 1

380 380 400 320 410 480 800 350 570 625 800 500 620 660 900 550 670 705 1100 600 790 885 1200 720 1200 1325 1300 1100 1350 1450 1500 1250 1500 1600 2200 1400 C 500 550 600 800 1150 1250 1400 1400 F 380 510 525 670 1000 1150 1300 1300 G 13 13 22 22 23 23 23 23

2 x 1 sleeve on the back 1 hand hole 2 hand holes or 1 manhole (option) 1 manhole

height when installed 1615 1845 2100 2400 2510 2865 3800 3800 113 145 180 355 720 935 1340 1350 G1 G1 G 112 G 112 G 212 G 212 G 212 DN 100 G 12 G 34 G 112 G2 G 212 G 212 G 212 DN 100

1 hand hole 2 hand holes or 1 manhole (option) 1 manhole 1 manhole

Compressed air receivers with higher operating pressures are available upon request * External thread

18

BOGE condensate management

1 m3 of

untreated air
contains up to 180 million particles of dirt, 50 80% water vapour and oil in the form of unburnt hydrocarbons at between 0.01 mg/m3 and 0.03 mg/m3.

Condition of the ambient air

Besides nitrogen and oxygen, the ambient air also contains impurities and moisture in the form of water (aerosols) or water vapour (relative humidity).
Vapour, fumes, smoke Perceptible under microscope

Particle diameter

Dust Mist Perceptible under microscope

Spray Droplets, Grains Visually perceptible

Impurities in the ambient air

Depending on the location, ambient air contains various impurities which cannot be seen by the naked eye. They can impair the reliability of compressed air equipment and furthermore, they can reduce the quality of products produced using the compressed air.

Oil/vapour Tobacco smoke Soot Sulphur clouds Pigments Dried milk

Fertiliser/crushed limestone Coal dust Cement dust Human hair Water clouds Spores Pollen Flour Bacteria Drifting sand

Behaviour of impurities during compression

When air is compressed, the concentration of impurities increases. The impurities and moisture drawn in from the atmosphere is precipitated as condensate in the compressed air installation; depending on the concentration of its constituents, it can be oily, greasy and / or aggressive.

Grains of sea salt Gas molecules Viruses

The most important impurities in ambient air and their sizes

The most important impurities in ambient air and their sizes

Location

Limits Atmospheric at 10 bar

Avarage value Atmospheric at 10 bar

In the country

In towns

In industrial areas

In large factories

Concentrations of particles in ambient air

19

Clean and Dry Compressed Air Condensate precipitated in the compressed air system
Impurities from the compressed air system are washed out in the form of condensate.

Water content and Condensate precipitation in the air

Temperature/ Pressure dewpoint Atmosphere Compressor Aftercooler Compressed air receiver Refrigerant dryer Adsorption dryer Compressed Water content air pipe of air

Water content of air

22.9 l/h condensate precipit

Condensate precipitated from the compressed air

The amount of condensate in compressed air depends on the humidity of the intake air, the temperature and the volume of air. Condensate precipitates in different amounts at different places in a compressed air installation and in the compressed air pipe network. Condensate forms when the temperature of the compressed air falls below the pressure dewpoint. The pressure dewpoint is the temperature at which the compressed air can be cooled without condensate precipitating. In our example of a compressed air installation, condensate precipitates in the compressor after-cooler, in the compressed air receiver, in the refrigerant dryer and adsorption dryer. Condensate can also precipitate in the downstream air-line if the compressed air cools much below the pressure dewpoint, 40 C in our example. The condensate from oil-lubricated compressors consists of impurities and moisture drawn in from the atmosphere, as well as oil particles in the form of aerosols and vapours from the oil lubrication system of the compressor. Only proper condensate separation, drainage, removal and treatment will ensure, environmentally friendly operation.

Pressure dewpoint Temperature

Beispiel: Volumenstrom 1000 m3/h Ansaugdruck 1 bar abs. Ansaugtemperatur + 33 C relative Feuchte 80 % Betriebsberdruck 10 bar

Water content of air Condensate precipitation Graph: Temperature/pressure dewpoint

Different amounts of condensate in a compressed air installation

Relative humidity

Temperature C

Water content in g/m3

Diagram to determine the water content of air in g/m3 at various temperatures and degrees of saturation (relative humidity).

20

Condensate drainage Mechanical condensate float drains

Float drains have to be sized specifically to match the calculated volume of condensate. The advantage of a float drain is that it only opens when condensate actually accumulates. In this way, there is no loss of compressed air. Float drains are maintenance-intensive. Problems can occur due to dirty, greasy or solid condensate.

Float-controlled Float drain 85 mm , H = 185 mm Connection: In G 1/2, Out G 3/8

Electrical solenoid condensate drains

Electrical solenoid drains are less maintenance-intensive than float drains. The large internal cross-section ensures that the condensate is drained away without restriction, even with viscous condensates. They can be used for all applications, thanks to step-by-step adjustment of the discharge time and interval.

The advantage of time-controlled solenoids is their great adaptability for summer and winter running and for different sizes of machine. Condensate precipitation is variable. Whilst float drains only discharge when condensate is present, the solenoid always opens at pre-set times. This means that when there is little condensate, expensively produced compressed air is constantly being blown away. The noise of this can be detrimental to the environment.

Solenoid-controlled Konsatronic 3 Discharge intervals: 0.5 45 mins., Duration: 0.5 10 secs. Connection: G 3/8

Electronic level-controlled condensate drains; the ultimate solution

Capacity controlled drainage without compressed air loss, working automatically with the actual condensate precipitated. The large cross-section drain ports ensure safe drainage of even the dirtiest of condensates.

Special intelligent control-electronics control drainage. They also monitorthe status of the equipment. Faults on the drain unit are notified by LED and can be forwarded to a central monitoring point via a potential-free contact.

Electronic, level-controlled Type Bekomat 10 Bekomat 20 Bekomat 21 Bekomat 12 Bekomat 13 Bekomat 14 Bekomat 16 CO Max. compressor output m3/min 1.5 4 4.2 6.3 28 126 1400 Max. dryer output m3/min 100 % saturated 3 8 8.4 12.6 56 252 2800 use for a, b a, b a, b a, b a a a a, b Dimensions, mm W/ D/ H 134 / 50 / 110 140 / 72 / 140 171 / 69 / 105 65 / 150 / 141 93 / 212 / 162 120 / 252 / 180 280 / 280 / 280 Connection In/ Out G 12 /G 14 G 12 /G 14 G 12 /G 14 G 12 /G 38 G 12 /G 12 G 34 /G 12 G 34 /G 12

Output figures based on central European climate conditions a = condensate with oil b = oilfree, aggressiv condensate

21

Condensate treatment and removal

Why does condensate from oil-lubricated compressors need to be treated?

Unless condensate is treated of removed completely, then serious environmental damage can occur. Only 1 Litre of condensate is required to contaminate 1.000.000 Litres of water ! All industrial nations now forbid the drainage of condensate from oil-lubricated compressors into main drains. Laws now cover the separation of condensate into oil and water and only allow water to be drained away. In oil-free compressors, the compressed air does not come into contact with oil. Therefore, it follows that the condensate has no contact with oil. Clearly, any traces of oil drawn in are also found in the condensate; the amount depends on the compressors location.

Condensate test
There is a simple test to determine whether the condensate is an emulsion or a dispersed mixture. Fill a clean glass with condensate. Stir the liquid and after a short time, the oil separates from the water. The oil floats to the surface. The remaining water is clear. The dispersed mixture can be separated out, using an oil/water separator. If, after stirring, the condensate forms as cloudy water under the layer of oil, then you can assume that it is an emulsion which can only be separated out using an emulsion separating unit.

Condensate treatment options

Depending on national regulations and the operators environmental policy, the condensate from oil-lubricated compressors must be treated before it is disposed of into the main drain system. There are two possibilities: 1. Collect the condensate and have it removed by a specialist company; this is generally very expensive. 2. Treat it directly on site. As the condensate consists of 99% water and only 1% oil, on-site treatment using the BOGE oil/water separator is the most economic solution.

Method of operation at a glance The dirt collection tank retains solid impurities Oil/water separation by gravity Preliminary filter Adsorption filter

Types of condensate
Condensate from oil-lubricated compressors can occur in the form of: emulsions dispersed mixtures An analysis of the condensate will determine the scope of separation required. Can a simple oil/water separator be used or should an expensive separation or filtration system be used, or does the condensate collected require the services of a specialist company ?

Emulsions
Emulsions (milky mixtures) form a bond of oil and water which cannot be separated by gravity. Emulsions can only be purified using expensive and costly emulsion separating equipment.

Dispersed mixtures
Unlike emulsions, dispersed mixtures can be purified by gravity, using relatively inexpensive oil/water separators.

22

BOGE oil/water separator

Larger overflow for lumpy oils No oil residue in the filter Dual filter monitoring: integral level warning and optical reference (test procedure to compare samples) Economic Unit to suit all installations, no additional power costs Low maintenance Optimum use of filters

Optimum separation
In order to maintain uniform quality for condensate treatment, it is necessary to change the pre-filter and adsorption filter periodically. The sample test will show if the filter needs to be changed.

Condensate drainage
Type Piston compressors Max. compressor output in m3/h WAMAT 1 18- 36 WAMAT 2 36- 78 WAMAT 4 78- 186 WAMAT 5R 186- 378 WAMAT 6 378-1002 WAMAT 8 1002-3000 Output details for central European climate. Screw compressors Max. compressor output in m3/h 66 132 330 660 1320 3960 Dimensions, mm W/D/H 200 / 200 / 525 445 / 360 / 755 565 / 540 / 1000 570 / 590 / 1150 920 / 670 / 1245 1200 / 1000 / 1615

23

BOGE KOMPRESSOREN Bielefeld plant State-of-the-art production facilities guarantee the highest manufacturing quality.

We at BOGE
We at BOGE Compressors plan, develop, manufacture, market and service compressed air supply systems for customers in all aspects of service and industry. Our range of services include: Planning and engineering Oil-free piston, screw and turbocompressors Screw compressors with oil-injection cooling and oil-lubricated piston compressors Compressed air treatment Compressed air distribution and storage Compressed air accessories Compressed air service and support Plant control and display
Changes reserved. Errors and omissions excluded.

From our German base we are represented world-wide in over 70 countries by our own branch offices, subsidiaries, distributors and service partners.

Quality: Made in Germany

P.O. Box 10 0713 D-33507 Bielefeld Lechtermannshof 26 D-33739 Bielefeld Fon (+49) (52 06) 6 01-0 Fax (+49) (52 06) 6 01-2 00 info@boge.com www.boge.com

MMW 184-GB-4-09.2003/T