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Operating instructions for S 40-3...S 150-3 series screw compressors

Page 29

Installation

3.1

Transport and storage

Part 3: Installation

3.1 Transport and storage

General information

Please observe the generally accepted safety and accident prevention regu-
lations when transporting the compressor. BOGE accepts no liability for dam-
age caused by improper transport!

Transport the compressor to the installation site as described in the sections
which follow.

How to transport the
compressor

Using forklift truck or lifting cart

Fig. 3.1: Transport with forklift truck

WARNING!

The transport of the compressor must only be carried out by adequately
instructed and authorised personnel!
The capacity of the lifting gear (lifting cart or forklift truck) must correspond
atleast to that of the compressor / the system (see section entitled 2.1 Tech-
nical data)!
Note the position of the centre of gravity prior to lifting the compressor!
The position of the centre of gravity is specified both in the attached dimen-
sioned drawing and on the compressor packaging.
Any loose or pivoting parts must be removed before lifting the unit.
Lifting rings on individual components (such as electric motors) are only
intended for lifting individual components, not for lifting the entire compres-
sor!
The compressor is delivered filled with oil. Do not tilt during transport!

WARNING!

Improper transportation can damage the compressor. During transport, the
safety covers must not be subjected to any forces or loads.

Ensure that the forks are underneath
the base frame of the compressor
(see illustration).

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Summary of Contents for S 100-3

Page 1: ...Operating instructions Belt driven screw compressors Series S 40 3 S 150 3 SF 60 3 SF 150 3 Separate manuals Compressor control Frequency converter SF ...

Page 2: ......

Page 3: ... 50 3 50 Hp S 60 3 60 Hp S 61 3 60 Hp S 75 3 74 Hp S 100 3 101 Hp S 101 3 101 Hp S 125 3 121 Hp S 150 3 147 Hp SF 60 3 60 Hp SF 100 3 101 Hp SF 150 3 147 Hp BOGE KOMPRESSOREN Postfach 10 07 33507 Bielefeld Otto Boge Straße 1 7 33739 Bielefeld Phone 49 5206 601 0 Fax 49 5206 601 200 Mail info boge com Net www boge com Issue 07 2013 No 596 1252 18 ...

Page 4: ......

Page 5: ...ols used 7 Warning signs on the compressor 7 Intended use 13 Foreseeable misuse 13 Transport damage 13 Data on the rating plate 14 Service 14 Part 2 Product description 2 1 Technical data 15 2 2 Operating principle of compressor 20 Functional principle of the air end 20 Air circuit 21 Oil circuit 22 2 3 Compressor control 23 Network pressure 23 Operating states 23 Operating modes 23 Controlled ope...

Page 6: ... horizontal or free standing compressed air receivers 31 Installation surface 31 Fire protection 32 Sound protection 32 Admissible ambient temperatures 32 Frost protection 33 Ventilation 33 Cooling air requirement 34 Ventilation possibilities 35 Condensate disposal 35 3 3 Installation 36 General information 36 Checking the scope of delivery 36 Installing the compressor 36 Connecting the compressor...

Page 7: ...ugh BOGE customer service 53 List of maintenance and service work 54 Maintenance intervals 55 General information concerning the lubricants used 57 Disposal of used operating material 58 Pressure hoses 58 Spare and wearing parts 58 6 3 Maintenance work between scheduled services 58 Weekly Inspect replace supply air filter optional accessory 59 Monthly Clean the suction filter 60 Monthly Check oil ...

Page 8: ...on 73 Drive motors with lubrication device 73 Drive motors with automatic lubricating equipment 74 Have proportional regulation checked Optional accessory for S series 75 6 6 Spare parts and accessory equipment 76 List of spare and wear parts for maintenance 76 List of available accessory equipment 76 Part 7 Appendix 7 1 Flow chart 77 Air cooled version standard 78 Water cooled version serial conn...

Page 9: ...on the com pressor 6 To avoid dangers from debris or parts lying around the working area of the compressor must always be kept tidy and clean 7 Always squat when working on components mounted at low height never stoop When working on components mounted higher up always stand up right and erect 8 Do not exceed the limit value for the end of compression pressure specified on the type plate 9 Do not ...

Page 10: ... re commis sioning of compressors with a frequency control if the frequency converter has been disconnected from the power supply for a lengthy period of time 12 months In this case please contact the BOGE s service department Special hazard warnings Always wear your compulsory personal protective equipment when work ing on pressure pipes and connections A protective grid serves to prevent you fro...

Page 11: ...tective equipment and stipulate and regularly check the wearing of this protective equipment designate personnel responsible for the various types of work on the ma chine instruct personnel on a regular basis about the extent of obligations to keep the area around the compressor safe tidy and in good order in the event that the compressor requires to be dismantled develop a safe technical means of...

Page 12: ...ng lifting gear to transport equipment and safety goggles when working on the compressed air system and or on the pneumatic control system must be worn Before working with oils or greases barrier cream must be applied to the skin After the work is finished a skin care product must be applied Safety instructions for maintenance and repair of the compressor Ensure that maintenance work is carried ou...

Page 13: ...starting work on the electrical system the power supply must be switched off and a safeguard must be provided to prevent it from being un intentionally switched on again Immediately after finishing the work all dis mantled covers and safety devices must be refitted The machine operator is responsible for inspecting the compressor daily for externally visible damage and defects and for immediately ...

Page 14: ...mation on spare and wear parts These operating instructions must be available at all times to the compressor operating personnel at the place of use The operating instructions must be carefully read and applied by all persons authorised to undertake the following work on the compressor Operation including fault rectification and daily care Servicing maintenance inspection repairs Commissioning Tra...

Page 15: ...s symbol warns of danger to life and limb of the machine operator or other persons or dangers which might destroy or damage the compressor DANGER High voltage This symbol warns of danger due to electricity This symbol indicates a warning of life threatening electrical voltage levels It indicates work which must be performed by skilled electricians only NOTICE This symbol indicates information and ...

Page 16: ...General information 1 2 Introduction Page 8 Operating instructions for S 40 3 S 150 3 series screw compressors S 40 3 S 150 3 part 1 front outside ...

Page 17: ...Operating instructions for S 40 3 S 150 3 series screw compressors Page 9 General information 1 2 Introduction S 40 3 S 150 3 part 2 front outside inside ...

Page 18: ...General information 1 2 Introduction Page 10 Operating instructions for S 40 3 S 150 3 series screw compressors S 40 3 S 150 3 part 3 front inside S 40 3 S 150 3 part 4 rear panel outside inside ...

Page 19: ...Operating instructions for S 40 3 S 150 3 series screw compressors Page 11 General information 1 2 Introduction S 40 3 S 150 3 part 5 and 6 inside top ...

Page 20: ...General information 1 2 Introduction Page 12 Operating instructions for S 40 3 S 150 3 series screw compressors S 40 3 S 150 3 part 7 and 8 sides outside inside hidden ...

Page 21: ...tch button is exclusively intended to switch off the compressor in case of emer gency Operation and control are designed to be carried out by trained and author ised operators WARNING Never direct the compressed air generated towards persons This can be life threatening Oil is injected into the pressure chambers of the compressor Only use the compressed air generated for breathing purposes or allo...

Page 22: ...ortant data to hand Fig 1 1 Data on the rating plate Service Please do not hesitate to contact BOGE service if you have any questions Please call Telephone 1 770 874 1570 Telephone 49 5206 601 140 If you have any queries please always specify the following data for your com pressor to prevent any delays Type Year of manufacture Machine number WARNING Only BOGE service technicians or persons author...

Page 23: ...16 16 17 16 17 16 17 Sound power level silenced super silenced dB A 78 87 86 88 87 92 87 94 89 95 89 Compressor Max final compression temperature F 230 230 230 230 230 230 Volume flow according to ISO 1217 appendix C at pmax 100 psig cfm 192 24 244 83 269 10 286 76 352 02 474 70 pmax 115 psig cfm 183 97 228 81 257 76 272 95 336 86 451 97 pmax 125 psig cfm 183 97 228 81 257 76 272 95 336 86 451 97 ...

Page 24: ...er silenced dB A 17 18 17 18 17 18 Sound power level silenced super silenced dB A 92 89 95 91 95 91 Compressor Max final compression temperature F 230 230 230 Volume flow according to ISO 1217 appendix C at pmax 100 psig cfm 504 78 565 29 682 58 pmax 115 psig cfm 483 04 540 95 649 70 pmax 125 psig cfm 483 04 540 95 649 70 pmax 150 psig cfm 421 25 519 41 575 55 pmax 190 psig cfm 349 57 432 55 501 4...

Page 25: ...ing water quantity cfm 2 1 2 1 2 1 2 5 2 5 2 5 Cooling water inlet temperature min F 41 41 41 41 41 41 max F 86 86 86 86 86 86 Cooling water outlet temperature max F 113 113 113 113 113 113 Cooling water pressure min psig 30 30 30 30 30 30 max psig 145 145 145 145 145 145 Operating pressure sensor 1 1 Compressors for other operating pressures pmin pmax 15 psig factory settings pmax 100 psig Switch...

Page 26: ...0 K cfm 1 20 1 44 1 77 Max cooling water quantity cfm 5 3 5 3 5 3 Cooling water inlet temperature min F 41 41 41 max F 86 86 86 Cooling water outlet temperature max F 113 113 113 Cooling water pressure min psig 30 30 30 max psig 145 145 145 Operating pressure sensor 1 1 Compressors for other operating pressures pmin pmax 15 psig factory settings pmax 100 psig Switch off press pmax psig 100 100 100...

Page 27: ...ilenced dB A 15 16 16 17 17 18 Sound power level silenced super silenced dB A 88 87 95 89 95 91 Compressor Max final compression temperature F 230 230 230 Volume flow according to ISO 1217 appendix C at pmax 100 psig cfm 58 24 269 10 119 79 474 70 172 13 682 58 pmax 115 psig cfm 55 79 257 76 114 05 451 97 163 84 649 70 pmax 125 psig cfm 55 79 257 76 114 05 451 97 163 84 649 70 pmax 150 psig cfm 50...

Page 28: ... with supply and exhaust duct cfm 600 600 1000 Required cooling water quantity delta t 15 K cfm 1 44 2 41 3 53 delta t 30 K cfm 0 72 1 20 1 77 Max cooling water quantity cfm 2 1 2 5 5 3 Cooling water inlet temperature min F 41 41 41 max F 86 86 86 Cooling water outlet temperature max F 113 113 113 Cooling water pressure min psig 30 30 30 max psig 145 145 145 Operating pressure transmitter 1 1 Comp...

Page 29: ...on line depending on the operating condition of the compressor 3 Air end The air end compresses the air which is sucked in 4 Compressed air oil separator vessel The compressed air separates from the oil under the force of gravity in the compressed air oil vessel 5 Oil separator The oil separator separates the residual oil contained in the compressed air 6 Minimum pressure non return valve The mini...

Page 30: ... pressure forces it out of the vessel into the air end 2 Thermostatic oil control valve Depending on the oil temperature the thermostatic oil control valve either allows the oil to pass through the oil cooler or through a bypass e g in the starting phase Thus the oil constantly maintains its optimum operating temperature 3 Oil cooler air or water cooled The oil cooler cools down the hot oil to ope...

Page 31: ...amage the drive motor and reduces wear of the system 3 Standstill ready for operation The compressor is standing still but ready for operation When compressed air is required it switches automatically to load operation Operating modes The two most important operating modes are achieved by combining the three operating states 1 Intermittent operation In intermittent operation the energy balance is ...

Page 32: ...trol the setting for ptarget is effected via parameterisation of the control Short operating times 2 4 Control devices Operating pressure transmitter The operating pressure transmitter 1 controls the operation of the compres sor within the set switching limits Fig 2 3 Operating pressure transmitter WARNING During short operating times the compressor does not reach its operating temperature It oper...

Page 33: ...r ates in idling operation continuous operation or switches off intermittent op eration 2 5 Safety and monitoring devices General information The safety devices guarantee a high degree of operational safety in connec tion with the BOGE monitoring system When one of the safety devices responds the control system reacts as fol lows The compressor is immediately switched off A flashing fault number i...

Page 34: ...tional accessory The pressure switch checks the rotational direction of the drive motor each time the system starts up System pressure build up optional accessory The system pressure build up unit monitors the system pressure build up when the compressor starts up Safety valve 1 on the com pressed air oil vessel pre vents the maximum admissi ble pressure being exceeded WARNING Risk of injury When ...

Page 35: ...ling water solenoid valve The cooling water solenoid valve closed the cooling water supply when the compressor switches off 2 Cooling water stop valve The compressor may be separated from the cooling water supply by means of the stop valve e g for maintenance or repair work 3 Dirt trap provided by customer The dirt trap protects the cooling unit against sedimenting Pore size max 0 024 inch 4 Oil c...

Page 36: ...ate hardness CaCO3 15 dH Total hardness 21 dH Cooling water pressure max 145 psig min 30 psig Cooling water inlet temperature max 86 F min 41 F Max cooling water quantity see Technical data Substances Symbol max admissible concentration mg l Ammonia NH3 2 0 Chloride 158 F Cl 100 Free chlorine Cl 0 5 Iron Fe 0 2 Free agressive carbon dioxide CO2 20 Manganese Mn 0 1 Nitrate NO3 100 Oxygen O2 2 Silic...

Page 37: ...capacity of the lifting gear lifting cart or forklift truck must correspond atleast to that of the compressor the system see section entitled 2 1 Tech nical data Note the position of the centre of gravity prior to lifting the compressor The position of the centre of gravity is specified both in the attached dimen sioned drawing and on the compressor packaging Any loose or pivoting parts must be re...

Page 38: ...sport blocks Use only suitable lifting straps with a minimum length of approx 315 inch es Place the loops of the lifting strap under neath the compressor transport pallet pro vided from one head end to the other The loops of the lifting straps must not be attached to the suction filter Furthermore they must not be attached to the lug on the motor NOTICE In the case of intermediate storage please o...

Page 39: ...sed air receiver stands securely It must also not shift or tilt due to external forces This also includes the additional weight exerted during pressure testing The compressed air receiver must not be bolted to the floor Ensure that the compressed air receiver is easily accessible from all sides for periodic testing Refer to the attached dimensioned drawing for details of the operating and maintena...

Page 40: ...e of dust Admissible ambient temperatures see also Technical data Maximum ambient temperature for air cooling 104 F Minimum ambient temperature 41 F WARNING For compressors with motor ratings exceeding 54 Hp ensure that the compressor room is equipped with special fire protection Install compressors with motor ratings exceeding 134 Hp in a separate fire protected room WARNING Failure to observe th...

Page 41: ...xhaust air ducts Ensure that the flow rate in the ducts does not exceed 157 inches s Never position cooling air ducts directly on the compressor Always use a compensator to avoid distortion and the transfer of vibrations Fans Ensure that the heated exhaust air is not taken in again If necessary the heated air must be extracted by fans To ensure perfect cooling even at higher temperatures in the su...

Page 42: ...ucting Necessary free duct cross section Cooling air requirement for free standing unit Necessary inlet opening for free standing unit Hp cfm sq ft cfm sq ft cfm sq ft S 40 3 40 6467 15 0 3237 4 5 1200 2 7 S 50 3 50 7651 17 5 3825 5 2 1200 2 7 S 60 3 60 7651 17 5 3825 5 2 1200 2 7 S 61 3 60 7651 17 5 3825 5 2 1200 2 7 S 75 3 74 9418 22 0 4709 6 4 1200 2 7 S 100 3 101 10830 25 0 5415 7 4 1200 2 7 S...

Page 43: ...is used for heating rooms In summer it is directed into the open Condensate disposal The air taken in contains water in form of vapour which turns into condensa tion during compression WARNING The condensate contains oil Never dispose of it in the public sewage system without prior treatment Strictly observe the effluent disposal laws of your local authorities Comply with the Water Act BOGE recomm...

Page 44: ...e parts required have been delivered Please check the order confirmation for any possible accessory equipment The scope of delivery includes the following component parts Operating instructions Switch cabinet key Electric circuit diagram in the compartment of the switch cabinet List of electrical equipment in the compartment of the switch cabinet Spare parts list Installing the compres sor 1 Remov...

Page 45: ...oned drawing The following additional components must be provided by the customer when installing the water cooling unit Dirt trap The dirt trap at the cooling water inlet protects the cooling units against sed iment collecting Pore width max 0 02 inch Expansion vessel and safety valve NOTICE Do not install a non return valve in the pressure line The compressor is already equipped with a non retur...

Page 46: ...mmissioning by lowering the motor plate Fig 3 5 Activating the belt tension Checking the oil level BOGE compressors are supplied with a full oil filling Prior to commissioning check the oil level as described in the section entitled Maintenance 1 Remove the four bolts 1 and 2 marked in red two on each long side together with their spacer sleeves 1 Hold the bolt head 1 with a spanner to prevent it ...

Page 47: ... created After the first 50 operating hours retighten the electrical connections DANGER High voltage Ensure that work on the electrical equipment of the compressor is only car ried out by authorised electricians Observe current national and international regulations such as the German VDE regulations DIN EN directives and local safety regulations Also observe the regulations of your local power su...

Page 48: ...f less than 10 mm2 Cu a second conductor with at least the same cross section must be provided up to the point at which the protective conductor has a minimum cross section of more than 10 mm2 3 Automatic interruption of the power supply if the conductivity of the pro tective earth conductor is lost Please observe any additional national rules and regulations WARNING Risk of injury Prior to any wo...

Page 49: ...nsure whether the transport securing device was removed correctly and the GM belt ten sioning device was activated see chapter 3 3 Installation Record the test results in the commissioning certificate WARNING Always check the rotational direction of the drive and fan motor prior to com missioning Even brief operation in the wrong direction of rotation more than approx 5 seconds may cause the total...

Page 50: ...system may only be carried out by authorised and qualified personnel with the necessary experience Always wear protective clothing and goggles Immediately after switching on the machine the connection for the com pressed air outlet must be checked for leak tightness Keep an appropriate safe distance from the compressor during the inspec tion WARNING Risk of injury Press the emergency stop switch b...

Page 51: ...rial operation under maximum working load Record the test results in the commissioning certificate Commissioning follow ing extended stoppages If an extended stoppage is scheduled you should contact BOGE s service department beforehand Following an extended stoppage of more than 2 months fill a small amount of oil into the suction controller prior to starting the compressor Fig 3 6 Suction control...

Page 52: ...3 SF 100 3 approx 0 66 S 101 3 S 150 3 SF 150 3 approx 1 32 NOTICE To avoid danger when dismantling the compressor please consult BOGE s service department Telephone 1 770 874 1570 Telephone 49 5206 601 140 WARNING Dismantling the compressor must only be carried out by authorised and qual ified personnel with the necessary experience DANGER High voltage All work on the electrical installation must...

Page 53: ...874 1570 Telephone 49 5206 601 140 DANGER High voltage Before starting any work to remedy faults Press the emergency stop button use the mains disconnection device to iso late the compressor from the power supply and fix a padlock to prevent the power from being switched on again unintentionally Fault Possible cause Rectification Not delivered no pressure build up max pressure 7 psig System compon...

Page 54: ...ng Check the minimum pressure non return valve and replace if necessary Suction regulator is leaking Check the suction controller and replace if necessary Cutout triggered by emergency off switch Normally switched off with O key Excessive oil consump tion Drain line is blocked Dismantle and clean drain line Defective oil separator element Check oil separator and replace if necessary Oil filling le...

Page 55: ...nes to prevent stresses and vibrations from being transmit ted to the heat exchanger Provide venting and draining facilities The customer must provide the following components for installation Stop valves Stop valves in the water supply and discharge lines enable the heat ex changer to be removed easily Expansion vessel and safety valve Free standing installation The plate heat exchanger may also ...

Page 56: ...methods Flushing First close all stop valves in the supply lines Close all stop valves in the discharge lines Wait until the plate heat exchanger has cooled down Open the flushing connections and drain the plate heat exchanger Flush out the plate heat exchangers For this purpose pump one of the above mentioned cleaning agents through the plate heat exchangers for an extended period of time After f...

Page 57: ...il and water from mixing It is impossible therefore for the drinking water to become contaminated Pressure control device A pressure control device responds immediately to a burst or fractured pipe within the system emitting a pulse which can be individually processed e g alarm switching off the system Operating conditions NOTICE If the cleaning measures specified above are not sufficient you shou...

Page 58: ...es Any residual air contained in the heat exchanger will be carried along by the media conveyed and will escape through the system Maintenance The safety circuit including the pressure control device and the expansion vessel forms a closed maintenance free system WARNING Do not open the system under any circumstances Opening the system will put the operation and safety of the heat exchanger at ris...

Page 59: ... in these operating instructions before removing any safety covers or safety devices Refit the safety covers or safety de vices immediately after completion of the maintenance work Heavy components may only be lifted up by various persons in due con sideration of the local industrial safety regulations Only use original spare parts compressor oils and operating materials released by BOGE for the m...

Page 60: ...let cool down all hot components of the compressor to 122 F 7 Separate the compressor from the compressed air network by closing the ball valve at the compressed air outlet 8 Vent the compressor To this effect open the safety valve on the combined compressed air oil receiver as follows Turn the knurled nut counterclockwise until you can feel a resilient resistance Turn the knurled nut a little fur...

Page 61: ...g depending upon the envi ronmental conditions This enables the most important maintenance work to be carried out regularly and so achieve a sustainable effect in order to reduce compressor wear to a minimum and guarantee a long life Maintenance through BOGE customer service Have your compressor inspected and maintained in a full service by BOGE customer service every 3 000 operating hours or once...

Page 62: ... final compressor temperature system relief emergency stop button 2 Check change if necessary supply air filter 3 Check suction filter Clean filter and cartridge Change filter cartridge 4 Check oil level Top up oil 5 Clean compressed air oil cooler externally 6 Change oil filter 7 Change oil separator 8 Check change V belt 9 After extended stoppages Fill the suction controller with oil 10 Oil chan...

Page 63: ...intenance work between annual service The following maintenance and repair work can be carried out yourself and will ensure that your compressor operates trouble free in the periods between the fixed service dates Table 6 1 Maintenance work between service intervals NOTICE Note down any maintenance work completed in the table on the last page This will facilitate troubleshooting by BOGE s service ...

Page 64: ...e with dirt trap only up to S F 60 3 Change oil filter 2 64 Change oil separator 2 66 Check V belt 67 Every 9 000 operating hours1 or every 2 years Change V belt 68 Check the suction controller and if necessary replace or repair with the repair kit Check solenoid valve and replace if necessary Change oil 2 70 Special maintenance intervals see also page 73 onwards Flush out oil circuit Maintenance ...

Page 65: ...s Excellent oxidation stability Rotating bomb oxidation Test ASTM D 2272 higher than 2 400 minutes Or you use BOGE compressor oil Syprem S The stated maintenance inter vals refer to the use of Syprem S only Syprem S can be purchased from BOGE retailers Never mix different oil types and brands The additives may be incompatible It may lead to foam formation prema ture ageing or loss of lubricating a...

Page 66: ...the following points when disposing of old oil Never mix the oil with other material or liquids Used oil filters and oil separator cartridges require special waste treat ment and must be kept separate from normal waste WARNING Risk of injury and damage to compressor due to obsolete pressure hoses Never use pressure hoses beyond the prescribed service life Check hoses and connections regularly for ...

Page 67: ...value the dirt crust on the filter mat prevents the provision of an adequate cooling air supply Changing the supply air filter mats 1 Switch off the compressor with the OFF button Fig 6 2 Changing the supply air filter mats NOTICE Keep a packet of spare filter mats in reserve at all times WARNING Risk of injury Press the emergency stop button use the mains disconnection device to iso late the comp...

Page 68: ...the sealing surface of the filter cartridge Fitting the filter cartridge 1 Insert filter cartridge 3 into the filter housing 2 Replace the lid 2 on the filter housing 3 Fasten the clips 1 on the filter housing 4 Put the cover back on on the maintenance side WARNING Risk of injury Press the emergency stop button use the mains disconnection device to iso late the compressor from the power supply and...

Page 69: ...l to settle 6 Remove plug 2 of oil filling socket 1 see figure below 7 Check oil level Æ The oil level must not drop below the min mark see figure below 8 If necessary top up with oil to the lower edge of the thread max mark on the oil filling socket see figure below 9 Screw plug 2 back in see figure below 10 Put the cover back on on the maintenance side 11 Open ball valve at the compressed air ou...

Page 70: ...ve accumulated dirt with a fibre brush 5 Blow out the dirt with compressed air 1 in the opposite direction to the nor mal cooling air flow see figure below NOTICE The service life of the compressed air oil cooling unit depends on the degree of soiling dust oil vapour of the suctioned cooling air Extreme external soil ing of the cooling unit leads to an increased temperature in the oil circuit WARN...

Page 71: ...sive lime deposits and dirt Carry out the cleaning as described for plate heat exchangers 6 4 Maintenance work at fixed service intervals The following sections contain a description of the maintenance work to be carried out at fixed service intervals This work is listed in table 6 2 on page 56 To retain your warranty entitlement BOGE recommends that you have this work carried out by certified BOG...

Page 72: ... Have safety valve checked Interval After approx 3 000 operating hours but at least once a year Every 3 000 operating hours once a year Change the oil filter Change the oil filter After 3 000 operating hours but not less than once a year Every time an oil change is carried out Change the oil filter 1 Switch the compressor off with the OFF button WARNING Risk of injury Press the emergency stop butt...

Page 73: ...w Æ Catch the draining oil and dispose of it properly in line with environmen tal regulations Fig 6 6 Changing the oil filter 7 Fill the new oil filter 3 with compressor oil 8 Lightly oil the seal on the new oil filter 9 Screw in new oil filter by hand 10 Put the cover back on on the maintenance side 11 Open ball valve at the compressed air outlet 12 Switch the compressor on and let it heat up unt...

Page 74: ...cribed at the start of this section 5 Wait approx 3 minutes to allow the oil to settle 6 Unscrew soiled oil separators 4 by hand or use a strap wrench turning counterclockwise see figure below Æ Catch the draining oil and dispose of it properly in line with environmen tal regulations WARNING Risk of injury Press the emergency stop button use the mains disconnection device to iso late the compresso...

Page 75: ...with the OFF button 13 Check the oil separator for leaks once again and tighten by hand if neces sary procedure as described above Every 3 000 operating hours once a year Check V belt Check the V belt After 3 000 operating hours but at least once a year to look for signs of damage WARNING Do not use tools to screw in the new oil separators You might damage the oil separators or their sealing rings...

Page 76: ...r this purpose secure screw head 3 against turning 10 Then turn locknut 4 counterclockwise and lock by means of the screw head Æ The V belts are automatically correctly tensioned by the BOGE GM drive system 11 Fit belt protection 12 Put the cover back on on the maintenance side WARNING Risk of injury Press the emergency stop button use the mains disconnection device to iso late the compressor from...

Page 77: ... 190 4 7 4 7 4 7 4 6 4 6 S 75 3 100 115 125 150 190 4 4 4 4 4 4 4 4 4 3 S 100 3 100 115 125 150 190 3 5 3 5 3 5 3 5 3 6 S 101 3 100 115 125 150 190 4 7 4 3 4 3 4 3 4 0 S 125 3 100 115 125 150 190 5 2 4 8 4 8 4 8 4 3 S 150 3 100 115 125 150 190 6 1 6 1 6 1 5 7 5 2 SF 60 3 100 115 125 150 190 4 3 4 4 4 4 4 4 4 4 SF 100 3 100 115 125 150 190 3 5 3 5 3 5 3 5 3 6 SF 150 3 100 115 125 150 190 6 1 6 1 6 ...

Page 78: ...itch cabinet 5 Close off the vent hole of the solenoid valve with the cap nut 6 During the output phase press the OFF button on the compressor and after approx 3 seconds or after a residual pressure of 29 psig shut down the compressor with the emergency stop button WARNING If you use a different oil instead of Syprem S it is essential that you contact the BOGE service department to determine the r...

Page 79: ...h the cover on the maintenance side 18 Conduct trial run 19 Switch the compressor off with the OFF button 20 Check the oil filter and oil separator for leaks 21 If necessary tighten the oil filter and oil separator by hand procedure as described above 22 Check oil level procedure as described above 23 If necessary top up with oil to offset any losses WARNING After each oil change you have to fill ...

Page 80: ...2 Operating instructions for S 40 3 S 150 3 series screw compressors Fig 6 9 Solenoid valve on the suction controller with the cap nut screwed on Fig 6 10 Drain off old oil from oil compressed air receiver Fig 6 11 Drain off residual oil from compressed air oil cooler ...

Page 81: ...maintenance free for the entire service life The service life decreases or increases as thermal stress increases or de creases due to increased or reduced refrigerant temperature Drive motors with lubri cation device Motors with lubricating devices are easily recognised by the two grease nip ples on the top of the cover Additionally stickers on the compressor refer to the lubricating device see il...

Page 82: ...tors with automatic lubricating equipment Read the attached operating instructions carefully before putting the automatic lubrication device into operation WARNING Risk of injury Always exercise great caution when lubricating the bearings with the com pressor running and observe all safety precautions Never put your hand in the area of the V belt and the fan wheel Fitted safety devices and claddin...

Page 83: ...etting the proportional controller 3 Pressure switch for infinitely variable capacity control The low pressure switch for the infinitely variable capacity control limits the re duction of the quantity delivered and switches the compressor to idling mode or off completely if the quantity delivered falls below 50 2 Setting the proportional controller Displace the control range of the propor tional c...

Page 84: ... for oil air service Oil filter oil separator suction filter cartridge gaskets nozzle with dirt trap cairpac 3000 Full maintenance kit for 3 000 operating hour service Oil filter oil separator suction filter cartridge gaskets repair kit oil regulator repair kit nozzle with dirt trap only up to S F 60 3 Solenoid valve Designation Accessory equipment for compressed air treatment Oil water separator ...

Page 85: ...ons for S 40 3 S 150 3 series screw compressors Page 77 Appendix 7 1 Flow chart Part 7 Appendix 7 1 Flow chart On the following pages you will find the individual flow charts for the different machine types and components ...

Page 86: ...Appendix 7 1 Flow chart Page 78 Operating instructions for S 40 3 S 150 3 series screw compressors Air cooled version standard ...

Page 87: ...ure switch for oil filter monitoring 20 Oil throttle 21 Minimum pressure non return valve 22 Compressed air aftercooler 23 Pressure sensor for system pressure 24 Pressure sensor for network pressure 25 Stop valve compressed air outlet 27 Stop valve oil drainage 28 Non return valve drainage line up to 102 Hp 29 Proportional controller 30 Differential pressure switch for proportional controller 31 3...

Page 88: ...Appendix 7 1 Flow chart Page 80 Operating instructions for S 40 3 S 150 3 series screw compressors Water cooled version serial connection parallel connection Parallel connection Series connected circuit ...

Page 89: ...um pressure non return valve 22 Compressed air aftercooler 23 Pressure sensor system pressure 24 Pressure sensor network pressure 25 Stop valve compressed air outlet 27 Stop valve oil drainage 28 Non return valve drainage line up to 102 Hp 29 Proportional controller 30 Differential pressure switch for proportional controller 31 3 2 way solenoid valve for suction control regulation for standard con...

Page 90: ...Appendix 7 1 Flow chart Page 82 Operating instructions for S 40 3 S 150 3 series screw compressors Air cooled version frequency controlled 101 102 ...

Page 91: ...al pressure switch for oil separator monitoring 13 System pressure switch for system pressure build up and monitoring 15 Safety pressure switch for pressure limitation 16 Thermostatic oil control valve 17 Oil cooler 18 Oil filter 19 Differential pressure switch for oil filter monitoring 20 Oil throttle 21 Minimum pressure non return valve 22 Compressed air aftercooler 23 Operating pressure switch ...

Page 92: ...Appendix 7 1 Flow chart Page 84 Operating instructions for S 40 3 S 150 3 series screw compressors Water cooled version serial connection frequency controlled 101 102 104 103 ...

Page 93: ...afety valve 13 Differential pressure switch for oil separator monitoring 14 System pressure switch for system pressure build up and monitoring 15 Safety pressure switch for pressure limitation 16 Thermostatic oil control valve 17 Oil cooler 18 Oil filter 19 Differential pressure switch for oil filter monitoring 20 Oil throttle 21 Minimum pressure non return valve 22 Compressed air aftercooler 23 O...

Page 94: ... exchanger 101 Compressed air OUTLET 102 Feed line 103 Return line 1 Suction filter 4 Suction controller 8 Compressor air end 10 Combined compressed air oil receiver 11 Oil separator 16 Thermostatic oil control valve 17 Oil cooler 18 Oil filter 21 Minimum pressure non return valve 22 Compressed air aftercooler 50 Heat exchanger ...

Page 95: ...ir OFF 102 Feed line 103 Return line 1 Suction filter 4 Suction controller 8 Compressor air end 10 Combined compressed air oil receiver 11 Oil separator 16 Thermostatic oil control valve 17 Oil cooler 18 Oil filter 21 Minimum pressure non return valve 22 Compressed air aftercooler 51 Safety heat exchanger 52 Pressure monitor for leakage 53 Compensation vessel ...

Page 96: ...tenance and service work Please record any maintenance work you have completed in the appropriate column Remarks Oil water separator Filter Drain Motor mainte nance Cooling unit cleaning Oil separator Oil level Oil filter Intake filter Tempe rature System pressure C Check Ch Change Network pressure Operating hours Cl Cleaning Ch Change Date ...

Page 97: ...work Please record any maintenance work you have completed in the appropriate column Remarks Oil water separator Filter Drain Motor mainte nance Cooling unit cleaning Oil separator Oil level Oil filter Intake filter Tempe rature System pressure C Check Ch Change Network pressure Operating hours Cl Cleaning Ch Change Date ...

Page 98: ...sors Please record any maintenance work you have completed in the appropriate column Remarks Oil water separator Filter Drain Motor mainte nance Cooling unit cleaning Oil separator Oil level Oil filter Intake filter Tempe rature System pressure C Check Ch Change Network pressure Operating hours Cl Cleaning Ch Change Date ...

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