Boge S 100-3, S 61-3, S 101-3, S 125-3, S 150-3 Operating Instructions Manual

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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)

Operating instructions for belt-driven screw compressors

– S 40-3 (40 Hp) – S 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

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

Contents

Part 1: General information

Part 2: Product description

1.1 General safety instructions ........................................................... 1

Safety instructions for compressor operation ................................... 1

Special hazard warnings................................................................... 2

Dangers of electricity ........................................................................ 3

Obligations of the operator ............................................................... 3

Personnel requirements.................................................................... 4

Personal protective equipment ......................................................... 4

Safety instructions for maintenance and repair of the compressor... 4

Accident prevention regulations........................................................ 5

1.2 Introduction..................................................................................... 6

Symbols 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

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 operation (frequency control) ........................................ 24

Short operating times...................................................................... 24

2.4 Control devices............................................................................. 24

Operating pressure transmitter ....................................................... 24

Proportional controller (optional accessory for S series) ................ 25

2.5 Safety and monitoring devices.................................................... 25

General information ........................................................................ 25

Safety temperature limiting device.................................................. 25

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

Contents

Safety valve .................................................................................... 26

Monitoring the drive and fan motor ................................................. 26

Rotational direction monitoring (optional accessory) ...................... 26

System pressure build-up (optional accessory).............................. 26

2.6 Water cooling ................................................................................ 27

Water cooling.................................................................................. 27

Serial connection ............................................................................ 27

Parallel connection ......................................................................... 27

2.7 Cooling water ................................................................................ 28

Water connection (for water cooling) .............................................. 28

Cooling water quality ...................................................................... 28

Part 3: Installation

3.1 Transport and storage.................................................................. 29

General information ........................................................................ 29

How to transport the compressor.................................................... 29

Intermediate storage....................................................................... 30

3.2 Compressor room......................................................................... 31

Installation conditions for 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 to the compressed air network........... 37

Connecting the cooling water (optional accessory) ........................ 37

Removing the transport securing bolts ........................................... 38

Activating the belt tensioning device............................................... 38

Checking the oil level...................................................................... 38

3.4 Electrical connection.................................................................... 39

3.5 Commissioning............................................................................. 40

Check installation requirements...................................................... 41

Checking the rotational direction of drive and fan motor ................ 41

Check compressed air outlet for leak tightness .............................. 42

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

Contents

Opening the stop valves ................................................................. 42

Checking for leaks .......................................................................... 42

Conduct trial run ............................................................................. 43

Commissioning following extended stoppages............................... 43

3.6 Dismantling ................................................................................... 44

Part 4: Faults

Part 5: Accessory equipment

Part 6: Maintenance

4.1 General information...................................................................... 45

4.2 General faults................................................................................ 45

5.1 BOGE Duotherm BPT ................................................................... 47

Function.......................................................................................... 47

Installation....................................................................................... 47

Commissioning ............................................................................... 48

Maintenance ................................................................................... 48

5.2 BOGE Duotherm BSW.................................................................. 49

Function.......................................................................................... 49

Commissioning ............................................................................... 50

Maintenance ................................................................................... 50

6.1 Safety instructions for maintenance........................................... 51

6.2 The BOGE maintenance concept................................................ 53

Maintenance through 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 level / top up with oil if necessary..................... 61

Every 1,500 operating hours: Clean the oil cooler (air cooling)...... 62

Every 1,500 operating hours: Clean the oil cooler / air cooler

(water cooling) ................................................................................ 63

6.4 Maintenance work at fixed service intervals.............................. 63

Every 3,000 operating hours / once a year:

Change the suction filter cartridge.................................................. 64

Every 3,000 operating hours / once a year:

Have safety valve checked............................................................. 64

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

Contents

Every 3,000 operating hours / once a year:

Change the oil filter......................................................................... 64

Every 3,000 operating hours / once a year:

Change the oil separator ................................................................ 66

Every 3,000 operating hours / once a year: Check V-belt .............. 67

Every 9,000 operating hours: Change V-belt.................................. 68

Every 9,000 operating hours / every 2 years: Oil change............... 70

6.5 Special maintenance work........................................................... 73

Flush out oil circuit .......................................................................... 73

Drive motors with permanent lubrication ........................................ 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 connection – parallel connection....... 80

Air cooled version, frequency controlled......................................... 82

Water cooled version, serial connection – frequency controlled..... 84

BOGE Duotherm BPT plate heat exchanger .................................. 86

BOGE Duotherm-Plus BSW safety heat exchanger....................... 87

7.2 List of maintenance and service work........................................ 88

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

General information 1.1 General safety instructions

Part 1: General information

Safety instructions for compressor operation

1.1 General safety instructions

WARNING!

Failure to observe the following safety instructions can lead to injuries and damage to the compressor.

Observe the general safety and accident prevention regulations in addition to the information in these operating instructions!

1. Ensure that no commissioning and maintenance work on the compressor is undertaken until these operating instructions have been read and understood.

2. Only use the compressor for its intended use, as described in these operating instructions.

3. The owner must ensure,

– that only appropriately trained and authorised personnel work on this

compressor,

– that persons whose ability to react is restricted due to the misuse of

e.g. drugs, alcohol, medication etc., are prevented from working on this compressor,

– that operating, maintenance and repair personnel is fully conversant

with all safety instructions, and that these safety instructions are observed,

– that the compressor is only operated if it is in safe working order.

4. Avoid any way of working which may impair the safety of the compressor.

5. Always wear your compulsory personal protective equipment as protection against injuries from sharp corners or edges when working on the compressor.

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 upright and erect.

8. Do not exceed the limit value for the end of compression pressure specified on the type plate.

9. Do not operate the compressor without the attendant protective equipment and safety devices.

Do not dismantle any built-in safety devices or put them out of operation.

10.Ensure that all safety covers and doors are closed prior to commissioning/ starting up the compressor and that they are not opened during operation.

11.Place the compressor out of operation as described in these operating instructions, when dismantling the safety covers or safety devices for repair or maintenance work. Reattach and close all covers and safety devices immediately upon completion of the repair or maintenance work.

12.Operate the compressor only if any optional accessory equipment used is recommended or authorised by the manufacturer.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 1

General information 1.1 General safety instructions

13.Undertake conversions and modifications to the compressor only with the prior approval of BOGE, and in compliance with all relevant safety regulations. The manufacturer is not liable for damages resulting from unauthorised modifications to the compressor.

14.Never start the compressor if one or more parts (e.g. cable, plug) are damaged, or if the compressor is not in perfect working order, or if damage is visible or suspected.

15.Observe all safety and danger signs attached to the compressor itself!

16.The compressed air/oil receiver is pressure equipment and requires testing in accordance with national standards.

17.To avoid damage, special precautions must be taken during (re-)commissioning 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 from accidentally reaching into the

impeller in the cooling fan.

WARNING: Risk of injury!

Never operate the compressor with the protective grid removed! There is constant danger of accidentally reaching into the impeller in the cooling fan!

Please note that the cooling fan may run on for a certain time even after the compressor has been switched off!

– During operation, the compressor generates a high noise level which may

cause permanent hearing damage due to prolonged exposure. The compressor must ALWAYS be operated with its housing closed! Wear additional hearing protection at noise levels of over 80 dB(A)!

Page 2 Operating instructions for S 40-3...S 150-3 series screw compressors

General information 1.1 General safety instructions

Dangers of electricity

DANGER: High voltage! Persons working on the electrical equipment of the compressor are ex-

posed to mortal danger!

– Disconnect from the mains power supply before starting any work on the

compressor and use a padlock to prevent the power from being switched on again.

– Only duly authorised professional electricians (e.g. plant electricians) are

permitted to carry out work on the electrical system of the machine.

– Inspect the electrical equipment of the compressor at regular intervals for

defects such as loose connections or scorched cables and have any defects repaired immediately.

– Have all electrical equipment and fixed electrical installations checked by

a professional electrician at least every 4 years.

– Check all safety devices on the machine at regular intervals to ensure

they work properly.

– Only use original fuses.

Obligations of the operator

The operator is obliged to, – operate the compressor only if it is in perfect technical working order, – provide an automatic cutout device for disconnecting the electrical power

supply in the event of a fault to prevent hazards due to electricity.

– check the emergency stop device for the compressor regularly to ensure

that nothing is missing and that it works properly,

– assess the hazards of the machine workstations in his area of responsibility

and to issue specific user instructions on the basis of this,

– appoint a person who is responsible for the safe operation of the machine

as well as the coordination of all service work performed on it,

– avoid stress situations while operating the compressor by implementing

appropriate technological and organisational work preparation measures,

– ensure proper lighting at the compressor control panel in line with local

health and safety regulations,

– observe the safety data sheets for the lubricants used and make all infor-

mation specified by the data sheet accessible to personnel,

– provide the compulsory personal protective 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 dismantling the structure, designate persons responsible (for safety at work, supervision, completing the work), supervise the dismantling work and monitor compliance with the safety precautions and instructions drawn up,

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

General information 1.1 General safety instructions

Personnel requirements

Personal protective equipment

Work on and with the compressor must only be carried out by personnel duly authorised by the operator of the compressor.

The personnel working on the compressor must observe all industrial safety regulations and user instructions, properly recognize responsibilities and have read and understood the operating instructions. It is essential to wear the compulsory personal protective equipment at all times when working on the compressor!

During all work on the compressor, – protective clothing, – chemical resistant gloves, – slip-resistant safety shoes and – hearing protection, if applicable, must be worn.

For special tasks, – safety helmets (when operating 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

WARNING!

During repair and maintenance, use only original spare parts, compressor oils and operating materials approved by BOGE.

DANGER: High voltage!

When working on the electrical system be aware of the constant danger of contact with live parts!

To prevent danger, the mains connection must be equipped with an automatic circuit breaker!

The automatic circuit breaker must comply with the requirements of national regulations!

– Ensure that maintenance work is carried out by suitably trained persons

only.

– Settings, fault rectification and repair work must be carried out by special-

ists or suitably trained persons only.

– Before carrying out any maintenance or repair work:

Page 4 Operating instructions for S 40-3...S 150-3 series screw compressors

General information 1.1 General safety instructions

1. Switch off the compressor using the OFF button.

2. Press the emergency stop button.

3. Disconnect the compressor from all electric power sources using the circuit

breaker.

4. Take preventive action to prevent the current from being inadvertently

switched back on.

5. Check to ensure that all current-carrying parts are zero-potential.

6. Earth and short-circuit.

7. Cover or shield adjacent current-carrying parts.

8. Fix a warning label to the control and fill in the name of the person respon-

sible who is authorised to switch on the machine again.

9. Disconnect the compressor from the compressed air network (relieve or

block pressure lines).

– Exercise extreme caution during repair or maintenance work during which

the compressor needs to be operational. Ensure that all persons are at a safe distance from the danger area.

– Ensure that work on electrical equipment is carried out by qualified electri-

cians only.

– Working on current-carrying parts and devices is prohibited. Exceptions

are governed by the appropriate national regulations.

– Before starting work on the electrical system, the power supply must be

switched off and a safeguard must be provided to prevent it from being unintentionally switched on again. Immediately after finishing the work, all dismantled 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 reporting any changes (including in operational behaviour).

– When the automatic restart mode (auto-restart) is activated, the compres-

sor will start up automatically following a power failure. This is conditional upon: The network pressure being lower than the set switch-on pressure.

Accident prevention regulations

Operating instructions for S 40-3...S 150-3 series screw compressors Page 5

The operator of a compressor station is responsible for ensuring that it is properly installed, operated and maintained.

If the compressor system is operated outside the Federal Republic of Germany, the accident prevention regulations of the country where the compressor is operated must be observed, in addition to the information contained in these operating instructions. In the event that measures are required above and beyond the legal regulations specified in the Federal Republic of Germany or the information contained in these operating instructions, then it is essential that these are carried out prior to commissioning the compressor plant.

General information 1.2 Introduction

1.2 Introduction

The purpose of these operating instructions is to familiarise the user with the operation and all uses and features of the compressor.

These operating instructions contain important information on how to operate the compressor safely, economically and according to its intended use. Observing these operating instructions will help to prevent danger, reduce repair costs and downtimes and increase the reliability and service life of the compressor. They contain important information on the necessary maintenance and repair work, assists in the event of faults and contains information 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 – Transport

The compressor and its additional equipment must not be installed and commissioned until the operating instructions have been read and understood.

These operating instructions are intended to complement user instructions based on existing national accident prevention and environmental protection regulations.

In the illustrations, the compressor is shown in part without safety covers or safety devices to provide a better view. However, operating the compressor without these components is prohibited!

Page 6 Operating instructions for S 40-3...S 150-3 series screw compressors

General information 1.2 Introduction

Symbols used

In these operating instructions attention is drawn to important safety advice and tips with the following symbols:

WARNING: Risk of injury!

This symbol warns of danger to life and limb of the machine operator or other persons.

WARNING!

This 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 tips on saving energy and prolonging the life of the compressor through careful use.

Warning signs on the compressor

NOTICE!

All warning signs on the compressor and in its surroundings must be kept in a legible condition at all times. Missing or damaged signs must be replaced at once!

The following warning signs are fitted on the compressor:

Operating instructions for S 40-3...S 150-3 series screw compressors Page 7

General information 1.2 Introduction

S 40-3...S 150-3, part 1, front (outside):

Page 8 Operating instructions for S 40-3...S 150-3 series screw compressors

General information 1.2 Introduction

S 40-3...S 150-3, part 2, front (outside/inside):

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 3, front (inside):

S 40-3...S 150-3, part 4, rear panel (outside/inside):

Page 10 Operating instructions for S 40-3...S 150-3 series screw compressors

General information 1.2 Introduction

S 40-3...S 150-3, part 5 and 6, (inside/top):

Operating instructions for S 40-3...S 150-3 series screw compressors Page 11

General information 1.2 Introduction

dde

S 40-3...S 150-3, part 7 and 8, sides (outside/inside):

Page 12 Operating instructions for S 40-3...S 150-3 series screw compressors

General information 1.2 Introduction

Intended use

WARNING!

BOGE compressors, including their accessory equipment, are exclusively intended for the compression of air in industrial applications. The air taken in must not contain any explosive or chemically unstable gases or vapours. Do not exceed the specified end of compression temperature.

BOGE compressors are designed for stationary operation. Ensure that they are installed and operated in dry and clean rooms only.

The emergency stop device of the compressor (emergency stop switch/ button) is exclusively intended to switch off the compressor in case of emergency.

Operation and control are designed to be carried out by trained and authorised operators.

Foreseeable misuse

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 allow it to come into contact with foods, if it was treated appropriately beforehand.

This BOGE compressor is not explosion-protected. Do not operate in explosive areas or in a potentially explosive atmosphere!

Do not operate the compressor in rooms in which extreme dust, toxic or flammable vapours and gases may occur.

The emergency stop device of the compressor (emergency stop switch/button) must not be used as a normal means of switching the compressor off. Use the OFF button to switch the compressor off normally.

The following is not permitted: – Compressing other media than those specified as the intended use or air

containing contaminants. – Exceeding the end of compression pressure indicated on the type plate. – Altering the safety devices and safety covers, or putting them out of oper-

ation. – Removing or painting over signs and symbols on the compressor. – Operation of the compressor by unauthorised or untrained persons.

Transport damage

Operating instructions for S 40-3...S 150-3 series screw compressors Page 13

BOGE does not accept any liability for breakage or transport damage. Please inspect the compressor immediately after delivery and direct damage claims to the last haulier – even if the packaging is not damaged! To safeguard claims against the haulier we recommend leaving the machine, devices and packing material in the same condition they were in when the damage was detected.

In the event of any other complaints, please inform us within six days of the arrival of the delivery.

General information 1.2 Introduction

Data on the rating plate

Enter the details for your compressor from the rating plate or enclosed data sheet in the illustration below.

This will ensure that in the event of enquiries, you will always have the most important 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 compressor to prevent any delays:

– Type – Year of manufacture – Machine number

WARNING!

Only BOGE service technicians or persons authorised by BOGE in writing may repair or modify the compressor during the warranty period. Otherwise all warranty claims will expire!

Page 14 Operating instructions for S 40-3...S 150-3 series screw compressors

Product description 2.1 Technical data

Part 2: Product description

2.1 Technical data

Technical data S 40-3...S 100-3, part 1

Type S 40-3 S 50-3 S 60-3 S 61-3 S 75-3 S 100-3

Dimensions

- Height (silenced) [inch] 57.0 57.0 57.0 57.2 57.2 57.2

- Height (super silenced) [inch] - 76.5 76.5 76.7 76.7 76.7

- Width (silenced/super silenced) [inch] 63.6 63.6 63.6 80.5 80.5 80.5 – Depth [inch] 38.9 38.9 38.9 41.9 41.9 41.9

Weight

– silenced [lbs.] 1856 1858 2191 2601 2778 2994 – super silenced [lbs.] - 1924 2257 2712 2888 3104

Max. sound pressure level [±3 dB(A)] – silenced / super silenced [dB(A)] 64 / - 73 / 71 74 / 72 77 / 71 79 / 73 80 / 73

Measurement surface – silenced / super silenced [dB(A)] 15 / - 15 / 16 15 / 16 16 / 17 16 / 17 16 / 17

Air cooling

Sound power level – silenced / super silenced [dB(A)] 79 / - 88 / 87 89 / 88 93 / 88 95 / 90 96 / 90

Max. sound pressure level [±3 dB(A)] – silenced / super silenced [dB(A)] 63 / - 72 / 70 73 / 71 76 / 70 78 / 72 79 / 72

Measurement surface – silenced / super silenced [dB(A)] 15 / - 15 / 16 15 / 16 16 / 17 16 / 17 16 / 17

Sound power level

Water cooling

– 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: – p

= 100 psig [cfm]

max

– p

= 115 psig [cfm]

max

– p

= 125 psig [cfm]

max

– p

= 150 psig [cfm]

max

= 190 psig [cfm]

– p

max

Drive motor

Rated power [Hp] 40 50 60 60 74 101 Rated speed – 60 Hz [rpm] 3600 3600 3600 3600 3600 3600

Protection type IP TEFC TEFC TEFC TEFC TEFC TEFC ISO class FFFFFF

Electrical connection

Mains voltage compressor

Frequency

Fuse protection for 208 V Fuse protection for 230 V Fuse protection for 460 V Fuse protection for 575 V

Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.

Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies.

[V]

[Hz]

[A]

[A] [A] [A]

192.24 244.83 269.10 286.76 352.02 474.70

183.97 228.81 257.76 272.95 336.86 451.97

167.02 204.80 230.57 240.46 298.02 386.64

140.18 175.14 195.97 207.98 256.35 335.80

208 / 230 /

460 / 575

230 / 460 / 575 460 / 575 460 / 575 460 / 575 460 / 575

60 60 60 60 60 60 150----125 175 - - - -

60 70 90 90 125 150

50 60 70 70 90 125

Operating instructions for S 40-3...S 150-3 series screw compressors Page 15

Product description 2.1 Technical data

Technical data S 101-3...S 150-3, part 1

Typ e S 101-3 S 125-3 S 150-3

Dimensions

- Height (silenced) [inch] 69.3 69.3 69.3

- Height (super silenced) [inch] 88.8 88.8 88.9

- Width (silenced/super silenced) [inch] 95.1 95.1 95.1 – Depth [inch] 51.8 51.8 51.8

Weight

– silenced [lbs.] 4513 4557 4700 – super silenced [lbs.] 4645 4689 4833

Max. sound pressure level [±3 dB(A)] – silenced / super silenced [dB(A)] 76 / 72 79 / 74 79 / 74

Measurement surface – silenced / super silenced [dB(A)] 17 / 18 17 / 18 17 / 18

Air cooling

Sound power level – silenced / super silenced [dB(A)] 93 / 90 96 / 92 96 / 92

Max. sound pressure level [±3 dB(A)] – silenced / super silenced [dB(A)] 75 / 71 78 / 73 78 / 73

Measurement surface – silenced / super silenced [dB(A)] 17 / 18 17 / 18 17 / 18

Sound power level

Water cooling

– 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: – p

= 100 psig [cfm]

max

– p

= 115 psig [cfm]

max

– p

= 125 psig [cfm]

max

– p

= 150 psig [cfm]

max

– p

= 190 psig [cfm]

max

Drive motor

Rated power [Hp] 101 121 147 Rated speed – 60 Hz [rpm] 3600 3600 3600

Protection type IP TEFC TEFC TEFC ISO class F F F

Electrical connection

Mains voltage compressor Frequency

Fuse protection for 208 V Fuse protection for 230 V Fuse protection for 460 V Fuse protection for 575 V

Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.

Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies.

[V]

[Hz]

[A]

[A] [A] [A]

504.78 565.29 682.58

483.04 540.95 649.70

421.25 519.41 575.55

349.57 432.55 501.40

460 / 575 460 / 575 460 / 575

60 60 60

---

--150 175 200 125 150 175

Page 16 Operating instructions for S 40-3...S 150-3 series screw compressors

Product description 2.1 Technical data

Technical data S 40-3...S 100-3, part 2

Type S 40-3 S 50-3 S 60-3 S 61-3 S 75-3 S 100-3

Oil filling quantity

Oil receiver volume [gallon] 12.15 12.15 12.15 18.76 18.76 18.76 Total oil filling quantity [gallon] 7.40 7.40 7.40 11.10 11.10 11.10 Oil topping up quantity between min. + max. [gallon] 1.59 1.59 1.59 2.11 2.11 2.11

Intake air temperature

– min. [°F] + 41 + 41 + 41 + 41 + 41 + 41 – max. [°F] + 104 + 104 + 104 + 104 + 104 + 104

Cooling air requirement – free-standing installation [cfm] 6467 7651 7651 7651 9418 10830 – with supply and exhaust duct [cfm] 3237 3825 3825 3825 4709 5415 – free fan compression [Pa] 20 60 60 60 60 60

Air cooling

Cooling air requirement – free-standing installation [cfm] 1200 1200 1200 1200 1200 1200 – with supply and exhaust duct [cfm] 600 600 600 600 600 600

Required cooling water quantity – delta t = 15 K [cfm] 0.96 1.18 1.44 1.44 1.77 2.41 – delta t = 30 K [cfm] 0.48 0.59 0.72 0.72 0.88 1.20 Max. cooling 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

Water cooling

– 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

(factory settings) – p

= 100 psig: Switch-off press. p

max

– p

= 115 psig: Switch-off press. p

max

– p

= 125 psig: Switch-off press. p

max

= 150 psig: Switch-off press. p

– p

max

= 190 psig: Switch-off press. p

– p

max

Safety valve

Activation pressure at:

= 100 psig [psig]

– p

max

– p

= 115 psig [psig]

max

– p

= 125 psig [psig]

max

– p

= 150 psig [psig]

max

– p

= 190 psig [psig]

max

Compressors for other operating pressures p

Switch-on press. p

[psig]

max

[psig]

min

[psig]

max

[psig]

min

[psig]

max

[psig]

min

[psig]

max

[psig]

min

max

min

[psig] [psig]

min

= p

100 100 100 100 100 100

85 85 85 85 85 85 115 11 5 11 5 11 5 115 11 5 100 100 100 100 100 100 125 125 125 125 125 125 110 11 0 11 0 11 0 110 11 0

150 150 150 150 150 150 135 135 135 135 135 135

190 190 190 190 190 190 175 175 175 175 175 175

160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 160 203 203 203 203 203 203

–15 psig.

max

Operating instructions for S 40-3...S 150-3 series screw compressors Page 17

Product description 2.1 Technical data

Technical data S 101-3...S 150-3, part 2

Typ e S 101-3 S 125-3 S 150-3

Oil filling quantity

Oil receiver volume [gallon] 31.70 31.70 31.70 Total oil filling quantity [gallon] 17.17 17.17 17.17 Oil topping up quantity between min. + max. [gallon] 2.64 2.64 2.64

Intake air temperature

– min. [°F] + 41 + 41 + 41 – max. [°F] + 104 + 104 + 104

Cooling air requirement – free-standing installation [cfm] 11772 18834 18834 – with supply and exhaust duct [cfm] 5886 9417 9417 – free fan compression [Pa] 60 60 60

Air cooling

Cooling air requirement – free-standing installation [cfm] 2000 2000 2000 – with supply and exhaust duct [cfm] 1000 1000 1000

Required cooling water quantity – delta t = 15 K [cfm] 2.41 2.88 3.53 – delta t = 30 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

Water cooling

– 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

(factory settings) – p

= 100 psig: Switch-off press. p

max

– p

= 115 psig: Switch-off press. p

max

– p

= 125 psig: Switch-off press. p

max

= 150 psig: Switch-off press. p

– p

max

= 190 psig: Switch-off press. p

– p

max

Safety valve

Activation pressure at:

= 100 psig [psig]

– p

max

– p

= 115 psig [psig]

max

– p

= 125 psig [psig]

max

– p

= 150 psig [psig]

max

– p

= 190 psig [psig]

max

Compressors for other operating pressures p

Switch-on press. p

[psig]

max

[psig]

min

[psig]

max

[psig]

min

[psig]

max

[psig]

min

[psig]

max

[psig]

min

max

min

[psig] [psig]

min

= p

–15 psig.

max

100 100 100

85 85 85 115 115 115 100 100 100 125 125 125 110 11 0 11 0

150 150 150 135 135 135

190 190 190 175 175 175

160 160 160 160 160 160 160 160 160 160 160 160 203 203 203

Page 18 Operating instructions for S 40-3...S 150-3 series screw compressors

Product description 2.1 Technical data

Technical Data SF 60-3...SF 150-3, part 1

Type SF 60-3 SF 100-3 SF 150-3

Dimensions

- Height (silenced) [inch] 57.0 57.2 69.3

- Height (super silenced) [inch] 76.5 76.7 88.9

- Width (silenced/super silenced) [inch] 65.7 80.5 95.1

- Depth [inch] 39.4 41.9 51.8

Weight

– silenced [lbs.] 2394 3060 4850 – super silenced [lbs.] 2460 3170 4982

Max. sound pressure level [±3 dB(A)] – silenced / super silenced [dB(A)] 74 / 72 80 / 73 79 / 74

Measurement surface – silenced / super silenced [dB(A)]

Air cooling

Sound power level – silenced / super silenced [dB(A)] 89 / 88 96 / 90 96 / 92

Max. sound pressure level [±3 dB(A)] – silenced / super silenced [dB(A)] 73 / 71 79/ 72 78 / 73

Measurement surface – silenced / super silenced [dB(A)] 15 / 16 16 / 17 17 / 18

Sound power level

Water cooling

– 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: – p

= 100 psig [cfm]

max

– p

= 115 psig [cfm]

max

– p

= 125 psig [cfm]

max

– p

= 150 psig [cfm]

max

– p

= 190 psig [cfm]

max

Drive motor

Rated power [Hp] 60 60 60 Rated speed – 60 Hz [rpm] 3600 3600 3600

Protection type IP TEFC TEFC TEFC ISO-class F F F

Electrical connection

Mains voltage compressor Frequency

Fuse protection for 460 V Fuse protection for 575 V

Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.

Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies.

[A]

[V]

[Hz]

[A]

15 / 16 16 / 17 17 / 18

58.24 – 269.10 119.79 – 474.70 172.13 – 682.58

55.79 – 257.76 114.05 – 451.97 163.84 – 649.70

50.85 – 230.57 101.69 – 386.64 150.77 – 575.55

42.02 – 195.97 88.63 – 335.80 119.70 – 501.40

460 460 460

60 60 60 90 150 200

---

Operating instructions for S 40-3...S 150-3 series screw compressors Page 19

Product description 2.2 Operating principle of compressor

Technical Data SF 60-3...SF 150-3, part 2

Type SF 60-3 SF 100-3 SF 150-3

Oil filling quantity

Oil receiver volume [gallon] 12.15 18.76 31.70 Total oil filling quantity [gallon] 7.40 11.10 17.17 Oil topping up quantity between min. + max. [gallon] 1.59 2.11 2.64

Intake air temperature

– min. [°F] + 41 + 41 + 41 – max. [°F] + 104 + 104 + 104

Cooling air requirement

– free-standing installation [cfm] 7651 10830 18834 – with supply and exhaust duct [cfm] 3825 5415 9417

Air cool-

- free fan pressure [Pa] 60 60 60

Cooling air requirement

– free-standing installation [cfm] 1200 1200 2000 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

Water cooling

– 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

(factory settings)

= 100 psig: Switch-off press. p

– p

max

Switch-on press. p

– p

= 115 psig: Switch-off press. p

max

Switch-on press. p

– p

= 125 psig: Switch-off press. p

max

Switch-on press. p

– p

= 150 psig: Switch-off press. p

max

Switch-on press. p

– p

= 190 psig: Switch-off press. p

max

Switch-on press. p

Safety valve

Activation pressure at:

= 100 psig [psig]

– p

max

– p

= 115 psig [psig]

max

– p

= 125 psig [psig]

max

– p

= 150 psig [psig]

max

– p

= 190 psig [psig]

max

Compressors for other operating pressures p

[psig]

max

[psig]

min

[psig]

max

[psig]

min

max

min

max

min

max

min

[psig] [psig] [psig] [psig] [psig] [psig]

min

= p

– 7 psig.

max

100 100 100

93 93 93 115 115 115

108 108 108 125 125 125

118 118 118 150 150 150 143 143 143 190 190 190 183 183 183

160 160 160 160 160 160 160 160 160 160 160 160 203 203 203

2.2 Operating principle of compressor

Functional principle of the air end

Page 20 Operating instructions for S 40-3...S 150-3 series screw compressors

The air end operates according to the displacement principle. In the housing, the main and secondary rotors are driven by means of an electric motor and V-belts.

Product description 2.2 Operating principle of compressor

Both screws have screw-shaped profiles, intermeshing without contact. Together with the housing wall, these rotors form chambers which gradually reduce in size along the direction of air flow. Rotation of the rotors causes the air taken in to be compressed to the final pressure in the chambers.

During compression oil is continuously injected into the air end. This has a cooling, sealing and lubricating function.

Air circuit

Fig. 2.1: Components of the air circuit

1 Intake filter

The intake filter cleans the air suctioned by the air end.

2 Intake regulator

The intake regulator opens (load operation) or closes (idling operation or standstill) the suction 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 minimum pressure non-return valve does not open until the system pressure has increased to 51 psig. This causes a rapid build-up of the system pressure and ensures lubrication in the starting phase. Once the compressor has been switched off, the check valve prevents the compressed air from flowing back out of the mains line.

7 Compressed air aftercooler (air cooled or water cooled)

The compressed air is cooled in the compressed air aftercooler, causing the water contained in the air to condensate.

8 Stop valve

The screw compressor can be isolated from the mains using the stop valve.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 21

Product description 2.2 Operating principle of compressor

Oil circuit

The oil injected into the air end has the following function: – It dissipates the compression heat (cooling). – It seals the gaps between the rotors and between the rotors and the hous-

ing.

– It lubricates the bearings.

Fig. 2.2: Components of the oil circuit

1 Compressed air-oil vessel

The oil separated from the compressed air through the force of gravity collects in the compressed air-oil vessel. The system 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 operating temperature.

4 Oil filter

The oil filter traps impurities in the oil.

5 Air end

The injected oil returns to the compressed air-oil vessel together with the compressed air. This is separated through gravity.

6 Drainage line

The air end suctions the residual oil which collects in the oil separator back into the oil circuit via a drainage line.

Page 22 Operating instructions for S 40-3...S 150-3 series screw compressors

Product description 2.3 Compressor control

2.3 Compressor control

Network pressure

Operating states

Operating modes

For the compressor, the pressure downstream of the non-return valve is known as the network pressure. The control system switches the compressor on and off during operation depending on the network pressure.

All screw compressor controls are based on three basic operating states:

1. Load operation

– The compressor delivers its maximum amount of compressed air. – It consumes its maximum amount of energy.

2. Idling operation

– The compressor runs but does not deliver any compressed air. – It consumes approx. 75% less energy than in load operation. – When compressed air is required, it switches to load operation with out

delay.

– Idling operation reduces switching frequencies which can damage 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.

The two most important operating modes are achieved by combining the three operating states:

1. Intermittent operation

In intermittent operation the energy balance is perfect. – The compressor operates in load operation. – Upon reaching the switch-off pressure p

the compressor switches

max

to standstill. It does not consume any energy.

– Once the pressure has dropped to the switch-on pressure p

min

the

compressor switches back to load operation.

2. Continuous operation

Continuous operation limits the drive motor switching cycles and reduces wear to the system.

– The compressor operates in load operation. – Upon reaching the switch-off pressure p

the compressor switches

max

to idling operation.

– Once the pressure has dropped to the switch-on pressure p

min

the

compressor switches from idling operation back to load operation.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 23

Product description 2.4 Control devices

Controlled operation (frequency control)

Short operating times

If the pressure has dropped below the switch-on pressure p

the compressor

min

starts and operates in load operation. Once the operation pressure p

has been exceeded the control is activated

target

and reduces the speed. If the pressure has dropped below the operating pressure p

the control is

target

activated and increases the speed. Upon reaching the switch-off pressure p

the compressor switches to idling-

max

operation. The settings for p

min

and p

are effected by the parameterisation of the BASIC/

max

FOCUS. For the BASIC control the setting for p

is effected at the potentiometer R3

target

in the compressor switch cabinet. For the FOCUS control the setting for p

is effected via parameterisation of

target

the control.

WARNING!

During short operating times, the compressor does not reach its operating temperature. It operates below the dew point. The condensate generated due to physical causes mixes with the oil. The lubricating ability of the oil is reduced. This leads to damage to the air end. It is of utmost importance to consult BOGE if you operate your system with short operating times.

Operating pressure transmitter

2.4 Control devices

The operating pressure transmitter (1) controls the operation of the compressor within the set switching limits.

Fig. 2.3: Operating pressure transmitter

Switch-on pressure p

If the network pressure drops to the set switch-on pressure

, the compressor switches

min

on.

Switch-off pressure p

If the network pressure increases to the switch-off pressure p

, the compres-

max

sor either switches off (intermittent operation) or switches to idling operation (continuous operation).

min

max

Page 24 Operating instructions for S 40-3...S 150-3 series screw compressors

Product description 2.5 Safety and monitoring devices

Proportional controller (optional accessory for S series)

General information

The proportional controller is an additional control device intervening in the sequences of the intake regulator.

The intake regulator only opens as far as necessary to supply the current compressed air requirement. Thus the compressor saves compression energy.

A compressor with proportional controller is able to supply its ’delivered quantity variable between 0% and 100%. However, the energy consumption does not reduce accordingly. Therefore, a control is only practical between 50% and 100% of the delivered quantity.

The proportional controller is factory set to a delivered quantity between 50% and 100% of the compressor capacity.

The proportional controller closes when the desired delivered quantity has dropped below 50% of the compressor capacity. The compressor then operates in idling operation (continuous operation) or switches off (intermittent operation).

2.5 Safety and monitoring devices

The safety devices guarantee a high degree of operational safety, in connection with the BOGE monitoring system.

When one of the safety devices responds, the control system reacts as follows:

– The compressor is immediately switched off. – A flashing fault number in the left field of the display indicates the cause of

the fault.

Safety temperature limiting device

WARNING: Risk of injury!

Do not operate the compressor without built-in safety devices! Do not dismantle the safety devices or put them out of operation!

The following monitoring devices are standard for BOGE control systems:

The safety temperature limiting device switches the compressor off as soon as the maximum permissible final compression temperature has been reached. If the temperature drops below the minimum temperature, the compressor will not start. In the event that the safety temperature limiting device intervenes in compressor operation:

– Switch off the compressor (OFF button). – Acknowledge fault. – Rectify the fault. – Switch on the compressor (ON-button).

Operating instructions for S 40-3...S 150-3 series screw compressors Page 25

Product description 2.5 Safety and monitoring devices

Safety valve

Monitoring the drive and fan motor

Safety valve (1) on the compressed air/oil vessel prevents the maximum admissible pressure being exceeded.

Fig. 2.4: Safety valve

WARNING: Risk of injury!

When the maximum pressure is exceeded (e.g. incorrect setting of the operating pressure switch), the entire delivery volume of the compressor is ejected!

The drive motor is monitored by PTC resistors. The fan motor is monitored by overcurrent/overload release units.

Rotational direction monitoring (optional accessory)

System pressure buildup (optional accessory)

The pressure switch checks the rotational direction of the drive motor each time the system starts up.

The system pressure build-up unit monitors the system pressure build-up when the compressor starts up.

Page 26 Operating instructions for S 40-3...S 150-3 series screw compressors

Product description 2.6 Water cooling

2.6 Water cooling

Water cooling

Serial connection

Parallel connection

BOGE screw compressors are available in water or air-cooled design. In the standard version, the oil and compressed air aftercoolers are connected

in series on the water side. A parallel connection is possible as an option.

Fig. 2.5: Serial connection

Fig. 2.6: Parallel connection

1 Cooling 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 cooling unit 5 Compressed air aftercooler

The water cooling units are designed for specific standard cooling water quantities, temperatures and pressures (see "Technical data"). For individually fluctuating values, they are designed according to the specified order data.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 27

Product description 2.7 Cooling water

2.7 Cooling water

Water connection (for water cooling)

Cooling water quality

The cooling water must have the following properties: Electrical conductivity – > 50 μS/cm at pH-value 7 – 9

Carbonate hardness (CaCO

) – < 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".

The cooling units are fitted with non-ferrous heat exchangers, as standard. To avoid damage to these components and to guarantee long term functionality, ensure that the substances contained in the cooling water used do not exceed the following values.

Substances Symbol max. admissible concentration [mg/l]

Ammonia NH

< 2.0

Chloride < 158°F Cl 100 Free chlorine Cl < 0.5 Iron Fe < 0.2 Free agressive carbon dioxide CO

< 20

Manganese Mn < 0.1 Nitrate NO

Oxygen O Silicon oxide SiO Sulphate SO

< 100 < 2 < 8 < 60

Total dissolved substances TDS < 30

Tab. 2.1: Maximum admissible concentration of the substances

NOTICE!

If the specified limit values are exceeded, use cooling units made of other materials.

Please consult BOGE's service department.

WARNING!

If the cooling water data changes, the cooling units may have to be reconfigured. Incorrectly configured cooling units may cause malfunctions and cause the compressor to switch off!

Please consult BOGE.

Page 28 Operating instructions for S 40-3...S 150-3 series screw compressors

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 regulations when transporting the compressor. BOGE accepts no liability for damage caused by improper transport!

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 Technical 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 dimensioned 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 compressor!

The compressor is delivered filled with oil. Do not tilt during 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

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).

Fig. 3.1: Transport with forklift truck

Operating instructions for S 40-3...S 150-3 series screw compressors Page 29

Installation 3.1 Transport and storage

Crane transport

WARNING!

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

– Lift the compressor only with the transport pallet provided. – Protect the compressor with shoring (refer to arrows in the illustration). – Remove the shoring and transport blocks. – Use only suitable lifting straps with a minimum length of approx. 315 inch-

es!

Place the loops of the lifting strap underneath the compressor transport pallet provided 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.

Intermediate storage

Fig. 3.2: Crane transport

In case the compressor is not installed immediately after delivery, it must be stored in a sheltered location. It must be ensured that during the intermediate storage neither dust nor humidity can get enter.

NOTICE!

In the case of intermediate storage, please observe the specifications and directions on the permissible environmental influences (see section entitled "3.2 Compressor room").

We do not accept any liability for damage occurring as a consequence of improper storage!

In the event of extended intermediate storage you should consult BOGE's service department.

Following intermediate storage of more than two months, please observe the instructions for commissioning after an extended standstill (see section entitled "3.5 Commissioning").

Page 30 Operating instructions for S 40-3...S 150-3 series screw compressors

Installation 3.2 Compressor room

3.2 Compressor room

Installation conditions for horizontal or freestanding compressed air receivers

WARNING!

– Protect compressed air receivers from damage due to mechanical effects

(e.g. falling objects).

– Ensure that the compressed air receiver and its equipment can be oper-

ated from a safe location. – Provide safety areas and maintain safety clearances. – Ensure that the compressed 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 maintenance areas which must be provided. – Ensure that the factory label is clearly visible. – Ensure that compressed air receivers are adequately protected against

corrosion. – Only use the compressed air receiver for compressors operating with cut-

in and cut-out mode if the pressure fluctuation range amounts to Δp ≤ 20%

of the maximum operating pressure.

Installation surface

A level industrial floor without foundation is adequate for the installation of the compressor. No special fastening elements are required.

WARNING!

Make sure that external vibrations or shock are not able to impact on the compressor station.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 31

Installation 3.2 Compressor room

Fire protection

Sound protection

The following applies to rooms in which compressors with oil injection cooling are to be installed:

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.

Requirements of fire protected compressor rooms: – Walls, ceilings, floor and doors must be designed in fire protection class

F30 or higher.

– Flammable liquids must never be stored in the compressor room. – The floor around the compressor must be made of non-flammable material. – Leaking oil must not be able to spread out over the floor. – No inflammable materials must be located within a radius of at least

118 inches around the compressor.

– No inflammable machine parts, such as cable ducts, may run overhead of

the compressor.

Only install compressors in workrooms if the sound pressure level of their measurement surfaces does not exceed 85 dB (A).

Admissible ambient temperatures

The compressor room must be clean, dry, cool and free of dust.

Admissible ambient temperatures (see also "Technical data“).

Maximum ambient temperature (for air cooling): + 104°F Minimum ambient temperature: + 41°F

WARNING!

Failure to observe the admissible ambient temperature may lead to the following problems:

– The compressor will switch off when the admissible final compression

temperature is exceeded or undercut.

– Pipe lines and valves will freeze up at low temperatures. – Damage due to the reduced lubricating ability of the compressor oil.

Measures to be taken to ensure that the admissible ambient temperatures are maintained:

– Avoid any pipe lines or units radiating heat in the vicinity of the compres-

sor, or insulate them well.

– Never install the compressor in the cooling air flow of other machines. – Provide the supply air openings with adjustable louvres to ensure that

temperatures do not go below the minimum temperature in winter.

– Use the anti-freeze function (only in "ready for operation" mode).

Page 32 Operating instructions for S 40-3...S 150-3 series screw compressors

Installation 3.2 Compressor room

Frost protection

Ventilation

The compressor must be installed so that it is frost-protected. The BOGE antifreeze device is a standard feature. It protects the safety devices from freezing up at ambient temperatures up to 14°F.

If the following instructions are not observed, the admissible final compression temperature may be exceeded. In this case, the compressor will switch off automatically

WARNING!

Arrange the compressor intake openings or ducts in such a way that dangerous admixtures (e.g. explosive or chemically unstable materials) cannot be drawn in.

Ventilation openings (free-standing installation)

– Arrange supply air openings close to the floor. – Arrange exhaust air openings in the ceiling or at the top of the wall. – The required cross sections for the supply openings (as well as for the flaps

and weather protection grids) are indicated in the table.

Supply and exhaust 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 summer, the fans must be designed as follows:

– The capacity of the fan must be approx. 10 - 15% greater than the sum of

the total amount of cooling air required for all the machines that are oper-

ated in the room. – For free-standing installation, the cooling air requirement specified in the

table corresponds to the required fan capacity.

Supply air filter

– Equip the compressor with supply air filter mats if the compressor room is

contaminated with dust (option).

Operating instructions for S 40-3...S 150-3 series screw compressors Page 33

Installation 3.2 Compressor room

Cooling air requirement

Please refer to the following table for the cooling air requirement and size of the supply air openings for your compressor Ensure that flaps and weather protection grids have the necessary free cross section. We generally recommend contacting a specialist company for performing the duct construction work and planning.

Type Drive

Air cooling

Water cooling

rating

Cooling air

requirement

for free

standing unit

Necessary

inlet opening

for free

standing unit

Cooling air

requirement

for instal-

lation with

Necessary

free duct

cross-

section

Cooling air

requirement

for free

standing unit

Necessary

inlet opening

standing unit

ducting

[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

for free

S 101-3 101 11772 27.0 5886 8.0 2000 4.9

S 125-3 121 18834 44.0 9417 12.7 2000 4.9

S 150-3 147 18834 44.0 9417 12.7 2000 4.9

SF 60-3 60 7651 17.5 3825 5.2 1200 2.7

SF 100-3 101 10830 25.0 5415 7.4 1200 2.7

SF 150-3 147 18834 44.0 9417 12.7 2000 4.9

The cooling air requirement is based on a 7°F-difference between the ambient temperature and the outside temperature.

Table 3.1: Cooling air demand, cross-sections of openings and ducts required

Page 34 Operating instructions for S 40-3...S 150-3 series screw compressors

Installation 3.2 Compressor room

Ventilation possibilities

Condensate disposal

Fig. 3.3: Ventilation possibilities

A Supply and exhaust air openings in the outside walls

(free-standing installation) B Supported by exhaust air fan C Exhaust air duct into the open D Exhaust air duct with recirculation flap

Hot exhaust air is mixed with the cold ambient air, as required. Thus pre-

venting the plant from freezing up at temperatures below freezing.

E Using the hot exhaust air for heating

In the winter, the hot exhaust air is used for heating rooms.

In summer it is directed into the open.

The air taken in contains water in form of vapour, which turns into condensation 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 recommends using an oil/water separator.

The BOGE oil/water separator is used to separate the oil from the condensate. The cleaned water can be fed directly into the public sewage system. The oil is collected in a separate container. Dispose of the oil according to environmental regulations. If the oil emulsifies due to special operating conditions, use an emulsion cracking plant.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 35

Installation 3.3 Installation

3.3 Installation

General information

BOGE compressor units are supplied ready for connection. Only the work described in the following paragraphs needs to be carried out during the installation.

WARNING!

Any installation work must only be carried out by appropriately trained persons or specialists (BOGE service personnel).

Lay all energy supply lines in a trip-proof and barrier-free manner so that potential accidents are avoided!

Prior to delivery, each compressor is subjected to a trial run in the factory. It is carefully tested and set. However, the possibility of damage occurring during transport cannot be excluded.

– Please inspect the compressor immediately after delivery and direct dam-

age claims to the last haulier – even if the packing is not damaged! To safeguard claims against the haulier we recommend leaving the machine, devices and packing material in the same condition as they were in when the damage was detected.

– Prior to commissioning, check the compressor for external damage due to

transport.

– Observe the compressor very closely during commissioning and the follow-

ing trial run.

– If malfunctions occur, switch off the compressor immediately and inform

the BOGE's service department.

Checking the scope of delivery

Installing the compressor

The scope of delivery depends on your order. Prior to commissioning, please check whether all the 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

1. Remove the packaging around and inside the compressor.

WARNING!

The compressor may only be set in operation if the rubber feet have been fitted! If the feet have been removed for transportation, it is essential that they be fitted again before the compressor is set in operation!

2. Install the compressor and align it horizontally. The compressor must stand firmly on the ground on all feet.

Page 36 Operating instructions for S 40-3...S 150-3 series screw compressors

Installation 3.3 Installation

Connecting the compressor to the compressed air network

Connecting the cooling water (optional accessory)

– Connect the compressor to the compressed air network or a compressed

air receiver. For this, use a BOGE high pressure hose.

NOTICE!

Do not install a non-return valve in the pressure line. The compressor is already equipped with a non-return valve.

WARNING: Risk of injury!

Risk of injury due to pressurised water when connecting the cooling water system!

Close external water mains prior to connection! The connection must only be carried out by authorised and qualified person-

nel!

The pipework for the cooling water circuit in the compressor was fully installed in the factory.

Only the following work must be performed during installation:

1. Check, whether the water supply has the required data, see “ Water con-

nection (for water cooling)“.

2. and whether the cooling water quality is adequate (see " Cooling water

quality").

3. Connect the cooling water supply and discharge line to the water supply

(cf. dimensioned 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 sediment collecting. Pore width: max. 0.02 inch.

– Expansion vessel and safety valve

WARNING!

If the stop valves in the supply and discharge lines are simultaneously closed in a closed cooling system, an enclosed chamber will result. If the water heats up in this room, it will expand and the pressure will increase.

Install an expansion vessel and a safety valve to prevent damage to the cooling units.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 37

Installation 3.3 Installation

Removing the transport securing bolts

Activating the belt tensioning device

The drive unit frame is bolted to the basic frame for transport. To remove the transport securing bolts:

1. Remove the four bolts (1) and (2) marked in red (two on each long side) together with their spacer sleeves.

Fig. 3.4: Removing the transport securing bolts

The V-belts are slackened for transport. Activate the GM belt tensioning device prior to commissioning by lowering the

motor plate.

1. Hold the bolt head (1) with a spanner to prevent it from turning.

2. Turn the counternut (2) upwards in an anticlockwise direction until it is against the bolt head.

Checking the oil level

The belt tensioning device is activated. It automatically sets the correct V-belt tension in every operating mode.

Fig. 3.5: Activating the belt tension

BOGE compressors are supplied with a full oil filling. Prior to commissioning, check the oil level as described in the section entitled

"Maintenance".

Page 38 Operating instructions for S 40-3...S 150-3 series screw compressors

Installation 3.4 Electrical connection

3.4 Electrical connection

DANGER: High voltage!

Ensure that work on the electrical equipment of the compressor is only carried 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 supply company regarding the load rating of your power supply.

Before starting any work:

1. Disconnect the compressor from all electric power sources using the circuit breaker.

2. Take preventive action to prevent the current from being inadvertently switched back on.

3. Check to ensure that all current-carrying parts are zero-potential.

4. Earth and short-circuit.

5. Cover or shield adjacent current-carrying parts.

DANGER: High voltage!

If the drive has a frequency converter (SF): – Wait until the fan has stopped and all indicator LEDs have gone off after

switching off the power supply.

– Wait another 5 minutes before starting work. Do not open any guards or safety covers until this time has elapsed.

Power disconnecting device

Each compressor unit must be equipped with a power disconnecting device.

Rated voltage

The data of your mains supply (operating voltage, control voltage, type of current, frequency,...) must be identical with the data on the rating plate on the switch cabinet.

In the event of deviations, please contact BOGE's service department or your supplier.

Please refer to the section on "Technical data" for details of the fuses required.

Connecting the leads

– Check to ensure that all terminals in the switch cabinet are firmly tightened.

If necessary, retighten the screw connections.

– Route the lead cable through the PG screw connection – Connect leads L1, L2, L3, N, Pe (PEN) firmly to the power supply terminal.

A clockwise rotational field must be created.

– After the first 50 operating hours, retighten the electrical connections.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 39

Installation 3.5 Commissioning

Drive with frequency converter

DANGER: High voltage!

Depending upon operational conditions, electrical drive systems with a frequency converter may have an earth leakage current above 10 mA.

Therefore the required precautions must be taken as soon as the compressor is electrically connected.

A permanently installed connection is required. One or more of the following qualifications for the protective earth conductor

must be fulfilled:

1. The protective earth conductor must have a minimum cross-section of 10 mm

2. If the protective conductor has a minimum cross-section of less than 10 mm must be provided up to the point at which the protective conductor has a minimum cross-section of more than 10 mm

3. Automatic interruption of the power supply if the conductivity of the protective earth conductor is lost.

Cu along the whole of its length.

Cu, a second conductor with at least the same cross-section

Please observe any additional national rules and regulations.

WARNING: Risk of injury!

Prior to any work on the compressor:

1. Press the emergency stop button, disconnect the power supply using the mains disconnection device and affix a padlock to prevent it from being switched on again unintentionally.

2. Check to ensure that all conducting machine parts are voltage free.

3. Depressurise all areas under pressure.

Never omit a single safety step! Otherwise, you will risk injuries due to restarting, electric shock or self-releasing parts.

WARNING!

If the automatic restart (Auto-Restart) is activated, the compressor may restart automatically after a voltage failure

This is conditional upon: The net pressure being lower than the set switchon pressure.

3.5 Commissioning

NOTICE!

We recommend drawing up a commissioning certificate in which the test results during the commissioning process can be recorded.

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

Installation 3.5 Commissioning

WARNING: Risk of injury!

Commissioning must only be carried out by authorised and qualified personnel with the necessary experience!

Always wear protective gloves when working on the compressor to avoid bruising fingers or hands while opening or closing components!

Check installation requirements

WARNING!

Make sure that the compressor is installed in compliance with the installation requirements!

Prior to starting up the compressor for the first time, check to ensure whether the transport securing device was removed correctly and the GM-belt tensioning device was activated (see chapter "3.3 Installation")!

Record the test results in the commissioning certificate.

Checking the rotational direction of drive and fan motor

WARNING!

Always check the rotational direction of the drive and fan motor prior to commissioning.

Even brief operation in the wrong direction of rotation (more than approx. 5 seconds) may cause the total destruction of the air end!

Record the test results in the commissioning certificate.

WARNING!

Ensure that the rotational direction coincides with the rotational direction arrow on the air end.

1. Re-enable the mains disconnecting device.

2. Switch the compressor on and immediately off again to check the rota-

tional direction.

Change direction of rotation

WARNING: Risk of injury!

Press the emergency stop switch/button, disable the mains disconnection device and secure it with a padlock to prevent it from being switched on again inadvertently.

– Interchange two phases (L1, L2 or L3) in the power cable.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 41

Installation 3.5 Commissioning

Check compressed air outlet for leak tightness

WARNING: Risk of injury!

Work on the compressed air 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!

1. Re-enable the mains disconnecting device.

2. To conduct the inspection, switch on the compressor and check the compressed air outlet for tightness

3. Switch the compressor off.

Opening the stop valves

Checking for leaks

WARNING: Risk of injury!

Press the emergency stop switch/button, disable the mains disconnection device and secure it with a padlock to prevent it from being switched on again inadvertently.

– If necessary: have any leakages remedied by experienced expert person-

nel.

Record the test results in the commissioning certificate.

Open ball valve at the compressor output. For water cooling: Open the stop valve at the water inlet.

WARNING: Risk of injury!

In case of leakages in the cooling water and/or oil circuit there is a risk of slipping or falling due to cooling water or oil spills!

Have all connections of the oil or water cooling circuit checked for leakages by authorised and qualified personnel!

During the inspection, slip-resistant safety shoes and protective clothing must be worn!

Undertake the following to prevent leaks: – Check the screw connections of the ducting and retighten, if necessary. – Check to ensure that the oil filter and oil separator are hand tight seated.

Page 42 Operating instructions for S 40-3...S 150-3 series screw compressors

Installation 3.5 Commissioning

Conduct trial run

Commissioning following extended stoppages

1. Re-enable the mains disconnecting device.

2. Use ON button on compressor control to switch on compressor.

Æ Compressor starts operating. Æ When the factory-set switch-off pressure is reached, the compressor

cuts off automatically.

3. Check network pressure on control display.

4. If necessary, reset operating pressure (pressure target value).

Æ The compressor is ready for operation. Æ For control function see control display.

5. Switch off compressor after several hours of trial operation under maximum

working load.

Record the test results in the commissioning certificate.

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!

WARNING!

Only fill the suction controller with the grade of oil used to operate the compressor.

Never mix different grades or brands of oil.

WARNING: Risk of injury!

Press the emergency stop button, disconnect the power supply using the mains disconnection device and affix a padlock to prevent it from being switched on again unintentionally.

1. Unscrew the plug from the suction controller (1).

Fig. 3.6: Suction controller

Operating instructions for S 40-3...S 150-3 series screw compressors Page 43

Installation 3.6 Dismantling

The following compressor oil quantities must be filled into the suction controller:

Model Compressor oil quantity [gallon]

S 40-3...S 60-3, SF 60-3 approx. 0.13

S 61-3...S 100-3, SF 100-3 approx. 0.66

S 101-3...S 150-3, SF 150-3 approx. 1.32

Tab. 3.2: Compressor oil quantities

2. Screw plug back in again.

3. Turn compressor stage using the pulley by hand 5- to 10 times to spread the oil evenly.

3.6 Dismantling

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 qualified personnel with the necessary experience!

DANGER: High voltage!

All work on the electrical installation must only be carried out by authorised and skilled electricians!

Prior to starting the work, the power cable to the switch cabinet must be disconnected from the mains and measures taken to prevent it from being switched on again unintentionally!

Page 44 Operating instructions for S 40-3...S 150-3 series screw compressors

Faults 4.1 General information

Part 4: Faults 4.1 General information

The tables on the following pages give information on the possible causes of operating faults and action which can be taken to rectify them (please also refer to the operating instructions for the compressor control).

WARNING!

Ensure that any work undertaken to rectify faults is carried out by qualified personnel or specialists only .

Ensure that components which have a safety function are adjusted, repaired or replaced only by BOGE service personnel.

Please contact BOGE's service department at the following telephone number if you have any questions.

Telephone: +1-770-874-1570

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.

4.2 General faults

Fault Possible cause Rectification

Not delivered, no pressure build-up, max. pressure 7 psig

System components in the compressor are leaking

Minimum pressure valve is faulty

Solenoid venting valve does not close

Suction regulator does not open Suction regulator or solenoid valve is defective; check and replace,

Check oil and compressed air lines inside the compressor; tighten and/or reseal screw connections, if necessary

Close ball valve and check whether pressure builds up; if so, open ball valve again immediately; replace minimum pressure valve

Check solenoid valve and replace, if necessary

if necessary

V-belts are torn Fit new v-belts

Operating instructions for S 40-3...S 150-3 series screw compressors Page 45

Faults 4.2 General faults

Fault Possible cause Rectification

Compressor system does not start up

Oil in suction filter Minimum pressure non-return

Excessive oil consumption

No electric power to compressor Check electrical connection

Fuses are defective Check the mains fuses and control fuses and replace if necessary

Compressor system has not vented properly

Voltage fluctuations in the electrical mains power supply

Compressor oil is very viscous due to low ambient temperature

valve is leaking

Suction regulator is leaking Check the suction controller and replace, if necessary

Cutout triggered by emergencyoff switch

Drain line is blocked Dismantle and clean drain line

Defective oil separator element Check oil separator and replace, if necessary

Check unloading valve and replace, if necessary

Ensure constant voltage

Heat up the compressor system (additional heater available as an optional accessory)

Check the minimum pressure non-return valve and replace, if necessary

Normally switched off with O-key

Oil filling level too high Drain off oil

Safety valve blows Operating pressure setting

altered from original setpoint

Defective safety valve Replace safety valve

System pressure does not decrease when switching off

Venting valve does not open Check venting valve and replace, if necessary

Non-return valve is leaking Examine non-return valve and replace, if necessary

Set operating pressure to maximum permissible pressure of the screw compressor

Page 46 Operating instructions for S 40-3...S 150-3 series screw compressors

Accessory equipment 5.1 BOGE Duotherm BPT

Part 5: Accessory equipment

Function

Installation

5.1 BOGE Duotherm BPT

The heat recovery system BOGE Duotherm BPT utilizes the heat energy released during compression to produce hot water free of charge (e.g. for production systems or to supply a heater).

The plate heat exchanger is connected in the main stream of the hot oil. It consists of stainless steel plates which are soldered together. These form two separate ducting systems. Compressor oil and water run through these ducts with opposite directions of flow. The hot oil transfers its heat to the colder water through the plates.

As a rule, the plate heat exchanger is installed in the compressor in the factory and comes equipped with all the necessary pipework. Only the following work needs to be carried out during installation:

– Connect the supply and discharge water pipelines to the pipeline system.

Route the pipelines to prevent stresses and vibrations from being transmitted 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 exchanger to be removed easily

– Expansion vessel and safety valve.

WARNING!

If the stop valves in the water supply and discharge lines are closed simultaneously, an enclosed space is created. If the water in this space is heated, it expands and the pressure increases.

An expansion vessel and safety valve must therefore be installed to prevent the plate heat exchanger from becoming damaged.

– Dirt trap (pore size: max. 0.02 inch).

The dirt trap at the water inlet protects the plate heat exchanger against dirt deposits if the water is very dirty.

– Flushing connections

The flushing connections serve to clean the plate heat exchanger.

Free-standing installation

The plate heat exchanger may also be installed as a free-standing unit or retrofitted by the customer.

Normally, the plate heat exchanger is held in place by the pipelines. However, when installing larger types of heat exchanger, the customer may have to provide a bracket.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 47

Accessory equipment 5.1 BOGE Duotherm BPT

Commissioning

Maintenance

Proceed as follows during commissioning: – Check oil level in the oil circuit. If necessary, top up with oil. – Slowly open the stop valves in the water supply and discharge line. – Avoid pressure hammers! – Vent the pipelines.

Limescale, oxides as well as grease or oil will be deposited in the ducts in the plate heat exchanger during operation Regular cleaning will prevent thick deposits clogging individual ducts of the plate heat exchanger.

Cleaning intervals

Excessively soiled or hard water: 6 months Moderately soiled water, surface water: 1 year Lightly soiled water: 3 years

Recommended cleaning agents

Grease or oil deposits: Paraffin Oxide or limescale deposits: formic acid, acetic acid or citric acid

WARNING!

Always observe the instructions of the cleaning agent manufacturer!

Cleaning 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 flushing, rinse the plate heat exchanger thoroughly with water

(e.g. using a pressure washer).

Enhance the cleaning action by the following measures:

– Use a larger mass flow rate than for standard operation. – Flush the cleaning agent through the plate heat exchanger in the opposite

direction to standard operation.

Allow to react (tenacious soiling): – Dismantle plate heat exchanger. – Fill plate heat exchanger with one of the above-mentioned cleaning agents. – Allow the cleaning agent to act for at least six hours. Point the connections

upward to allow any gases that may occur to escape.

Page 48 Operating instructions for S 40-3...S 150-3 series screw compressors

Accessory equipment 5.2 BOGE Duotherm BSW

– After cleaning, rinse the plate heat exchanger thoroughly with water (e.g.

using a pressure washer).

NOTICE!

If the cleaning measures specified above are not sufficient, you should have the exchanger cleaned by a service company. Boge's service department will recommend contracting companies on request.

5.2 BOGE Duotherm BSW

Function

The safety heat exchanger BOGE Duotherm Plus BSW is approved for drinking water. It is integrated in the main stream of the hot compressor oil. The additional safety it provides in comparison with the plate heat exchanger results from the following measures:

– Separation of the circuits

In this heat exchanger, the oil and water circuits are completely separated by a confining liquid. The confining liquid transmits the heat. In the event of heat exchanger damage, this prevents the oil 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).

NOTICE!

Set the pressure control device to a value at least 20% lower than the minimum pressure of the media used.

Operating conditions

Minimum water pressure: 7.25 psig Maximum water pressure: 232 psig Maximum oil pressure: 232 psig Maximum pressure of the confining liquid: 145 psig Maximum temperature (oil and water): +212 °F

NOTICE!

Exceeding the maximum temperature will result in malfunctioning. A false alarm will be triggered.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 49

Accessory equipment 5.2 BOGE Duotherm BSW

Commissioning

Maintenance

Proceed as follows during commissioning: – Check the oil level in the oil circuit. – Gradually open the valves on the water side. – Avoid pressure hammers! – Vent the pipelines. – Any residual air contained in the heat exchanger will be carried along by

the media conveyed and will escape through the system.

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 risk!

If confining liquid escapes as a result of damage, send the heat exchanger to BOGE for repair.

Page 50 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.1 Safety instructions for maintenance

Part 6: Maintenance 6.1 Safety instructions for maintenance

WARNING!

Ensure that maintenance work is only carried out by qualified professionals or appropriately trained persons.

– Prior to starting any maintenance work, always take the compressor out

of operation as described in these operating instructions before removing any safety covers or safety devices. Refit the safety covers or safety devices 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 maintenance work.

– With an activated automatic restart (Auto-Restart) the compressor may

restart automatically after a voltage failure. Prerequisite: The net pressure is lower than the set switch-on pressure.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 51

Maintenance 6.1 Safety instructions for maintenance

WARNING: Risk of injury!

Always adhere to the prescribed operating method described below for all maintenance work. Never omit a single safety step!

Otherwise you will risk injury from restarting, electric shock or parts which may fly off.

Prior to all maintenance work:

1. Switch off the compressor using the OFF button.

2. Press Emergency Stop button.

3. Open mains disconnection device and secure against unintentional switch on by means of a padlock.

4. Fix a warning label to the control and fill in the name of the person responsible who is authorized to switch on the machine again.

5. Check to ensure that all machine elements are definitely currentless.

6. Prior to starting work 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 further.

Any possibly existing air will escape. The system pressure gauge will indicate a pressure of 0 psig.

– Once the residual air has completely escaped from the system,

firmly retighten the knurled nut.

9. Remove all safety cladding necessary to perform the maintenance work.

Once the maintenance work has been concluded:

10.Reattach all removed safety cladding.

11.Open the ball valve at the compressed air outlet.

12.Prior to switching on again, check whether anyone else is working on the compressor.

13.Remove warning sign not until then and release mains disconnecting device.

14.Unlock Emergency Stop button.

Page 52 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.2 The BOGE maintenance concept

6.2 The BOGE maintenance concept

Through the compressor control, your compressor has an integrated monitoring system which sends you a maintenance message in good time to inform you about any important maintenance work that needs to be carried out.

The essential maintenance intervals for the compressor are set in the control by BOGE service personnel during commissioning, depending upon the environmental 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 a year.

NOTICE!

Maintenance contract! Enter into a maintenance contract with BOGE. BOGE's service department will maintain your compressor professionally at

regular intervals. Besides retaining your warranty entitlement, it will ensure maximum safety and reliability for your compressed air supply.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 53

Maintenance 6.2 The BOGE maintenance concept

List of maintenance and service work

S 40-3...S 150-3

Fig. 6.1: Maintenance work S 40-3...S 150-3

1 Check pressure / 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 change 11 (Lubricate motor bearings)

Page 54 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.2 The BOGE maintenance concept

Maintenance intervals

Maintenance work Page

The maintenance intervals specified in the following table refer to average operation and ambient conditions.

Extreme conditions may require shorter maintenance intervals. The first table contains maintenance and repair work that should be carried out

by the customer himself at regular intervals between the annual service carried out by BOGE service personnel. The intervals between this maintenance work are shorter (weekly / monthly / every 1,500 operating hours).

The maintenance intervals specified in the second table are longer (every 3,000 / 9,000 operating hours, or once a year / every two years). To retain your warranty entitlement, BOGE recommends that you have this work carried out by BOGE service personnel.

NOTICE!

Note down any maintenance work completed in the table on the last page. This will facilitate troubleshooting by BOGE's service department.

Maintenance 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.

Weekly:

Check compressor for leaks - visual inspection –

Check final compression temperature (target value: 158...212°F) Control

Check system relief on system pressure display (target value 0 – 22 psig) Control

Check and if necessary change supply air filter (optional accessory) 59

Monthly:

Check function of emergency stop button Control

Check and if necessary adjust operating pressure Control

Check that screw connections on the compressor are fully tightened –

Clean suction filter 60

Check oil level and top up as required 61

Every 1,500 operating hours:

Clean oil cooler 62

Check that the electrical connections are fully tightened –

Table 6.1: Maintenance work between service intervals

Operating instructions for S 40-3...S 150-3 series screw compressors Page 55

Maintenance 6.2 The BOGE maintenance concept

Maintenance work at fixed service intervals

To retain your warranty entitlement, BOGE recommends that you have the following maintenance and repair work carried out by certified BOGE service personnel using original spare parts. For the regular intervals, maintenance kits are available in the form of "servicepacs" and "cairpacs" which contain the maintenance and wear parts necessary (except V-belt).

WARNING!

If you use a different oil instead of Syprem S: it is essential that you contact the BOGE service department to determine the required oil change intervals.

Maintenance work (BOGE service personnel) Page

Every 3,000 operating hours

Check compressor for leaks –

Change the suction filter cartrigde (after it has been cleaned twice + every 3,000 operating hours) 64

(or once a year):

Check the minimum pressure valve and repair if necessary with the repair kit –

Have the safety valve checked (by BOGE service personnel only) 64

Check the oil regulator and repair if necessary with the repair kit

Change nozzle with dirt trap (only up to S(F) 60-3) –

Change oil filter

Change oil separator

Check V-belt 67

Every 9,000 operating hours

(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

Special maintenance intervals (see also page 73 onwards):

Flush out oil circuit Maintenance interval:

– If oil strongly contaminated. – Before changing the type of oil.

–

Lubricate / replace drive motor bearings (for motors with no lubrication device)

For details of the lubrication/replacement intervals (for motors with no lubrication device): See the information given on the type plate of the drive motor.

Have proportional regulation (optional accessory) checked every 3,000 operating hours

If the compressor is not used very often, the maintenance must be carried out at the intervals specified weekly/monthly/once a year/every 2 years) irrespective of the number of operating hours.

The specified intervals apply only when using BOGE Syprem S compressor oil. If a different oil is used, different intervals will apply! Other service life periods may also be possible depending on the ambient temperature. In this case have the oil analysed by your BOGE customer service!

Table 6.2: Maintenance work at fixed service intervals

Page 56 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.2 The BOGE maintenance concept

General information concerning the lubricants used

WARNING: Risk of injury!

Oil presents a potential danger to health and environment due to their additives.

– Avoid contact with skin and eyes.

Wear protective gloves made of resistant synthetic material.

Wash yourself thoroughly after contact with oils. – Do not inhale the fumes or mist. – Protect your environment.

Ensure that no oil is spilt. – Do not eat or drink when working with oils. – Fire, naked flames and smoking is strictly prohibited when handling oil. Read and observe the information in the relevant safety data sheets!

We recommend using only oil according to the following specification:

– Viscosity range of 55 cSt at 104°F. – Minimum viscosity at 212°F of 8 cSt. – Maximum viscosity at 32°F of 1,000 cSt. – Excellent oxidation stability: Meets requirements of Pneurop oxidation test. – Antifoam – additives. – Additives to prevent residue formation. – Compatibility with all used sealing materials like Neoprene, FPM, PTFE,

FKM (Viton) and acrylic and epoxy resin paints. – Flash point > 446°F. – Additives for excellent demulsifying properties. – Additives for corrosion protection of metallic surfaces. – 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 ability.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 57

Maintenance 6.3 Maintenance work between scheduled services

Disposal of used operating material

WARNING!

The handling and disposal of mineral oils is subject to legal regulations. It is an offence not to ensure correct and safe disposal of old oil!

Please instruct one of the known service companies to dispose of used operating materials or deliver them to an authorized disposal point

Observe 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!

Pressure hoses

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 leakages! Check the service life

of the hoses and replace them in due time! As replacement only use original spare parts released by BOGE! Used pressure hoses are not permitted as a replacement!

Spare and wearing parts

WARNING!

Only use original spare parts, compressor oils and operating materials releasedby BOGE for repair and maintenance work.

BOGE is not liable for any damage resulting from the use of other spare parts or operating materials.

WARNING!

If the nozzle and dirt trap are clogged with dirt, this can considerably increase oil consumption (only up to S(F) 60-3)!

6.3 Maintenance work between scheduled services

The following sections contain a description of the maintenance work to be carried out between (annual) services. This work is listed on page 55. Perform the work at the intervals specified.

Page 58 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.3 Maintenance work between scheduled services

Weekly: Inspect / replace supply air filter (optional accessory)

Check the function of the optional supply air filter mats:

– 1x monthly, but at least every 500 operating hours. – If the air intake is very contaminated, this should be carried out at more

frequent intervals.

Change the supply air filter mats: – If a dirt crust has become deposited on the filter mats. – If the final compression temperature rises to 7.2° to 9°F above the target

value (the dirt crust on the filter mat prevents the provision of an adequate

cooling air supply).

NOTICE!

Keep a packet of spare filter mats in reserve at all times!

Changing the supply air filter mats

1. Switch off the compressor with the OFF button.

WARNING: Risk of injury!

Press the emergency stop button, use the mains disconnection device to isolate the compressor from the power supply and fix a padlock to prevent the power from being switched on again unintentionally.

WARNING: Risk of injury!

Caution: Beware of the danger of sustaining cuts from sharp sheet metal parts on the filter mat.

It is essential that you wear protective gloves!

2. Draw the filter mat (1) upwards out of its holder.

3. Insert a new mat in the holder.

Fig. 6.2: Changing the supply air filter mats

Operating instructions for S 40-3...S 150-3 series screw compressors Page 59

Maintenance 6.3 Maintenance work between scheduled services

Monthly: Clean the suction filter

Clean the suction filter to remove dirt: – 1x monthly, but at least every 500 operating hours. – If the air intake is very contaminated, this should be carried out at more

frequent intervals.

Removing the filter cartridge

1. Switch off the compressor with the OFF button.

WARNING: Risk of injury!

2. Remove the cover on the maintenance side.

3. Undo the clips (1) on the filter housing.

4. Remove the lid (2) of the filter housing.

5. Take out the filter cartridge (3).

Fig. 6.3: Taking the suction filter out

Cleaning the filter cartridge

WARNING!

Do not clean filter cartridges in liquids. Do not use any hard objects when cleaning to avoid damaging the filter paper. If damage is detected or the filter cartridge has already been cleaned twice,

the filter cartridge must be replaced with a new one.

1. Tap on the filter cartridge using the palm of your hand to knock out any coarse dust.

2. Blow out fine dust from the inside to the outside using dry compressed air (maximum pressure 72 psig).

3. Clean 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.

Page 60 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.3 Maintenance work between scheduled services

Monthly: Check oil level / top up with oil if necessary

Check the oil level:

– Before using the compressor for the first time: – After this, once a month.

Top up with oil: – If the oil level has sunk below the "min" mark (see diagram in figure below).

WARNING!

Always use the same oil type when topping up. Never mix different oil types and brands.

Check oil level / top up with oil if necessary

1. Switch off the compressor with the OFF button.

WARNING: Risk of injury!

2. Closing the ball valve at the compressed air outlet.

3. Remove the cover on the maintenance side.

4. Vent compressor fully (as described at the start of this section).

5. Wait approx. 3 minutes to permit the oil to settle.

WARNING: Risk of injury!

Danger of burning due to hot oil! Always wear your compulsory personal protective equipment when working

on the compressor!

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 outlet.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 61

Maintenance 6.3 Maintenance work between scheduled services

Fig. 6.4: Checking the oil level, topping up with oil

Every 1,500 operating hours: Clean the oil cooler (air cooling)

Clean the air/oil cooler:

– After 1,500 operating hours.

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 soiling of the cooling unit leads to an increased temperature in the oil circuit.

Cleaning the compressed air/oil cooler

1. Switch off the compressor with the OFF button.

WARNING: Risk of injury!

2. Remove the right side of the sound insulation hood.

3. Remove the maintenance opening on the cooling air duct box.

WARNING!

Do not use sharp objects to clean the cooler! Sharp objects could damage the cooler.

4. Remove accumulated dirt with a fibre brush.

5. Blow out the dirt with compressed air (1) in the opposite direction to the normal cooling air flow (see figure below).

Page 62 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.4 Maintenance work at fixed service intervals

6. Extract the blown out dirt directly with an industrial vacuum cleaner (2) (see

the figure below).

7. Screw the maintenance opening on again onto the cooling air duct box.

8. Put right side of the sound insulation hood back on again.

Fig. 6.5: Cleaning the compressed air/oil cooler

Every 1,500 operating hours: Clean the oil cooler / air cooler (water cooling)

NOTICE!

If the cooling unit is excessively soiled (cleaning is no longer possible with compressed air), have it disassembled and cleaned by BOGE customer service.

Clean the oil cooler and the air cooler in the case of water cooling:

– After 1,500 operating hours. – In the event of excessive lime deposits and dirt.

NOTICE!

The service life of the cooler depends on the level of contamination and hardness of the cooling water. In the event of excessive contamination, check the cooling unit correspondingly earlier.

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 BOGE service personnel using original spare parts.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 63

Maintenance 6.4 Maintenance work at fixed service intervals

Every 3,000 operating hours / once a year: Change the suction filter cartridge

Every 3,000 operating hours / once a year: Have safety valve checked

Change the suction filter cartridge: – If it is damaged. – After it has been cleaned twice. – Depending on the level of dirt, either after 3,000 operating hours or once a

year during the annual service.

Changing filter cartridge

1. Switch off the compressor with the OFF button.

WARNING: Risk of injury!

2. Take out old filter cartridge (as described in “Removing the filter cartridge” on page 60).

3. Insert new filter cartridge (as described in “Fitting the filter cartridge” on page 60 ).

Every 3,000 operating hours / once a year: Change the oil filter

WARNING: Risk of injury!

Have the function of the safety valve checked by BOGE service personnel only.

Interval: After approx. 3,000 operating hours, but at least once a year.

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!

Page 64 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.4 Maintenance work at fixed service intervals

2. Close ball valve at the compressed air outlet.

3. Remove the cover on the maintenance side.

4. Vent the compressor fully (as described at the beginning of this section).

5. Wait approx. 3 minutes to allow the oil to settle.

WARNING: Risk of injury!

Danger of burning due to hot oil! Wear protective gloves while working!

6. Unscrew dirty oil filter (3) by hand or with a strap wrench in the direction

shown by the arrows on the oil filter (see illustration below). 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.

WARNING!

Do not use tools to screw on the new oil filter! You might damage the oil filter or its sealing ring. A hand-tight fit of the oil filter is sufficient.

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 until it reaches the operating

temperature.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 65

Maintenance 6.4 Maintenance work at fixed service intervals

13.Switch the compressor off with the OFF button.

WARNING: Risk of injury!

14.Check the oil filter again for leaks and tighten by hand, if necessary (procedure as described above).

15.Check oil level. If necessary, top up with oil to offset any losses.

Every 3,000 operating hours / once a year: Change the oil separator

Change the oil separator: – If the difference between network and system pressure exceeds 11 psig. – If warning message "8" appears on the control system display (if option is

installed).

– After 3,000 operating hours, but not less than once a year.

WARNING: Risk of injury!

If the prescribed maintenance intervals are not observed, the oil separators might become blocked In this case, the differential pressure will increase until the safety valve blows.

1. Switch the compressor off with the OFF button.

WARNING: Risk of injury!

2. Close ball valve at the compressed air outlet.

3. Remove cladding on the maintenance side.

4. Vent compressor fully (as described at the start of this section).

5. Wait approx. 3 minutes to allow the oil to settle.

WARNING: Risk of injury!

Danger of burning due to hot oil! Wear protective gloves while working!

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

Page 66 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.4 Maintenance work at fixed service intervals

Fig. 6.7: Change the oil separator

7. Lightly oil the sealing rings of the new oil separator.

8. Screw in new oil separators by hand.

Every 3,000 operating hours / once a year: Check V-belt

WARNING!

Do not use tools to screw in the new oil separators! You might damage the oil separators or their sealing rings. A hand tight seating of the oil separators is sufficient

9. Put the cover back on on the maintenance side

10.Open ball valve at the compressed air outlet.

11.Switch the compressor on and let it heat up until it reaches the operating

temperature.

12.Switch the compressor off with the OFF button.

WARNING: Risk of injury!

13.Check the oil separator for leaks once again and tighten by hand if neces-

sary (procedure as described above).

Check the V-belt: – After 3,000 operating hours, but at least once a year to look for signs of

damage.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 67

Maintenance 6.4 Maintenance work at fixed service intervals

Every 9,000 operating hours: Change V-belt

Change the V-belt:

– If damage is visible. – After 9,000 operating hours.

Change the V-belt:

1. Switch off the compressor with the OFF button.

WARNING: Risk of injury!

2. Remove the cover on the maintenance side.

3. Remove the belt guard.

To release the tension on the V-belt:

4. Secure screw head (3) of the tensioning device with a spanner to prevent it from turning.

5. Turn locknut (4) clockwise.

6. Raise the motor in the direction shown by the arrow (5) until the V-belts are fully slackened.

Fig. 6.8: Changing the V-belt

7. Remove the slackened belts from the belt pulleys.

8. Fit new V-belts on the belt pulleys on the motor and compressor.

WARNING!

The new V-belts must be exactly the same length. Only change the V-belts as a complete set!

To tension the V-belt:

9. Lower the motor again. For 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.

Page 68 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.4 Maintenance work at fixed service intervals

Settings of the GM-drive systems with standard motors (60 Hz)

As to the setting value for the corresponding motor we refer to the table below.

Type Pressure

[psig]

S 40-3 100 / 115 / 125 / 150 / 190 3.9 / 3.9 / 3.9 / 3.9 / 3.7

S 50-3 100 / 115 / 125 / 150 / 190 4.0 / 4.0 / 4.0 / 4.1 / 3.9

S 60-3 100 / 115 / 125 / 150 / 190 4.3 / 4.4 / 4.4 / 4.4 / 4.4

S 61-3 100 / 115 / 125 / 150 / 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 / 6.1 / 5.7 / 5.2

Tab. 6.4: Settings with standard motors

Setting

+ 0 / – 0.04

[inch]

NOTICE!

The settings shown in the table are fixed by the manufacturer and may not be changed. Slight deviations are allowed and compensated by the GM drive system.

The current settings are also shown on the GM drive system. With special versions the settings on the sticker may deviate from the standard values.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 69

Maintenance 6.4 Maintenance work at fixed service intervals

Every 9,000 operating hours / every 2 years: Oil change

Change the oil:

– In the case of Syprem S:

After 9,000 operating hours, but after two years at the latest.

WARNING!

If you use a different oil instead of Syprem S: it is essential that you contact the BOGE service department to determine the required oil change intervals.

NOTICE!

The service life of the oil, the oil filter and oil separators is reduced under the following conditions:

– When the compressor is operated at extreme ambient temperatures. – When the intake air is extremely contaminated.

Oil change (see also Figs. 6.9 to 6.11):

Before changing the oil, an air cushion must be built up. The combined compressed air/oil receiver is located at the lowest point of the system. Therefore, a light air cushion (approx. 22 psig system pressure) must be applied to drain the oil. This pressure forces the oil through the drain hose into a suitable collecting vessel. To build up an air cushion:

1. Switch the compressor off with the OFF button.

2. Remove the cover on the maintenance side.

3. Place the end of the oil drain hose into a suitable collecting vessel (6).

4. Remove the cap nut (5) from the switch cabinet.

5. Close off the vent hole of the solenoid valve with the cap nut.

WARNING!

Never use any tools to screw on the cap nut! They might damage the solenoid valve.

WARNING: Risk of injury!

Danger of burning due to hot oil! Always wear protective gloves when working on the compressor!

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: Risk of injury!

Page 70 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.4 Maintenance work at fixed service intervals

To drain off the old oil:

7. Slowly open the stop valve.

8. The pressure of the air cushion forces the oil into the collecting vessel.

9. Once the compressed air/oil receiver has been completely drained, close

the stop valve.

10.Remove the cap nut from the solenoid valve.

11.Unscrew the oil plug (7) on the compressed air/oil cooler.

12.Drain off residual oil (max. 1.3 gallons) into a suitable container.

13.Reinsert the oil plug.

14.Change oil filter (procedure as described above).

15.Change oil separators (procedure as described above).

To fill up with new oil:

16.Fill up to the edge of the thread of the filling socket (max.) (procedure as

described above).

WARNING!

After each oil change you have to fill a small quantity of oil into the suction controller before starting the compressor.

For oil quantity and procedure see section entitled “Commissioning following extended stoppages”, page 43.

WARNING!

Always fill with the same oil type as previously used. Never mix different oil types and brands.

The oil circuit must be flushed through prior to changing the oil type.

17.Reattach the cover on the maintenance side.

18.Conduct trial run.

19.Switch the compressor off with the OFF button.

WARNING: Risk of injury!

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.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 71

Maintenance 6.4 Maintenance work at fixed service intervals

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

Maintenance 6.5 Special maintenance work

6.5 Special maintenance work

Flush out oil circuit

Drive motors with permanent lubrication

Flushing the oil circuit with clean oil becomes necessary: – When the oil is excessively soiled. – Prior to changing the oil type.

WARNING!

Detailed information on flushing with BOGE oils can be obtained from the following service numbers:

Telephone: +1-770-874-1570

Telephone: +49 5206 601-140

The bearings of the drive motors are generally provided with a maintenance free permanent lubrication.

Under normal operating conditions (refrigerant temperature max. 104°F, continuous operation) the bearings are maintenance free for the entire service life.

The service life decreases or increases as thermal stress increases or decreases (due to increased or reduced refrigerant temperature).

WARNING!

Have BOGE service dismantle the bearings and install new bearings once the specified service life has expired.

Drive motors with lubrication device

Motors with lubricating devices are easily recognised by the two grease nipples on the top of the cover. Additionally stickers on the compressor refer to the lubricating device (see illustration below).

Fig. 6.12: Grease nipples of the lubricating device

Operating instructions for S 40-3...S 150-3 series screw compressors Page 73

Maintenance 6.5 Special maintenance work

Check to determine which motor is integrated in your compressor and service the motor accordingly. Lubricate the bearings of the drive motor at the prescribed intervals so as not to sustain damage due to lack of lubricant.

On motors with lubricating devices, regular greasing forms part of the scope of maintenance. The lubrication intervals, quantity and type of grease are given on the type plate or a separate plate. For lubrication, the required quantity is pressed through the nipple into the bearing with a grease gun while the compressor is running.

Drive motors 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 compressor 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 cladding may not be removed.

WARNING!

Always use the same type of grease for lubrication. The lubricating ability can be sharply reduced if different types of greases are mixed.

If you intend to use a different type of grease: – Have the bearings removed and thoroughly cleaned by BOGE service

personnel prior to filling with new grease.

Please always observe the specified lubrication intervals and quantities of grease.

Over-greasing and an excess of lubricant can also destroy the bearings.

Page 74 Operating instructions for S 40-3...S 150-3 series screw compressors

Maintenance 6.5 Special maintenance work

Have proportional regulation checked (Optional accessory for S series)

Check:

– After approx. 3,000 operating hours, but at least once a year.

1. Setting the operating pressure sensor

Switch-on pressure:p Switch-off pressure:p

= Final compression pressure – 15 psig.

min

= Final compression pressure.

max

2. Setting the proportional controller

Displace the control range of the proportional controller by turning cap (1).

– Increase pressure level: Turn cap

clockwise.

– Reduce pressure level: Turn cap anti-

clockwise.

Fig. 6.13: Setting the proportional controller

NOTICE!

Always set the proportional controller higher than the lowest operating pressure value (p

min

3. Pressure switch for infinitely variable capacity control

The low pressure switch for the infinitely variable capacity control limits the reduction of the quantity delivered and switches the compressor to idling mode or off completely if the quantity delivered falls below 50%.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 75

Maintenance 6.6 Spare parts and accessory equipment

6.6 Spare parts and accessory equipment

List of spare and wear parts (for maintenance)

Designation

Filter mat for supply air filter (optional accessory)

BOGE Syprem S special lubricant for screw compressors

Set of V-belts

Lubricant for drive motor bearings

servicepac 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)

List of available accessory equipment

Solenoid valve

Designation

Accessory equipment for compressed air treatment

Oil/water separator

Frost protection device

Condensate drain

BOGE DUOTHERM BPT Plate heat exchanger

BOGE DUOTHERM-PLUS BSW Safety heat exchanger

WARNING!

When ordering, please specify the data on the rating plate: –Type – Year of manufacture – Machine number

Page 76 Operating instructions for S 40-3...S 150-3 series screw compressors

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.

Operating instructions for S 40-3...S 150-3 series screw compressors Page 77

Appendix 7.1 Flow chart

Air cooled version, standard

Page 78 Operating instructions for S 40-3...S 150-3 series screw compressors

Appendix 7.1 Flow chart

101 Intake air INLET 102 Compressed air OUTLET

1 Suction filter 2 Maintenance display (from 41 Hp) 3 Vacuum switch (for suction filter monitoring) * 4 Suction controller 5 Ventilation and regulation control valve 7 Drive motor 8 Compressor air end

9 Sensor for final compression temperature 10 Combined compressed air/oil receiver 11 Oil separator 12 Safety valve 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 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 3/2-way solenoid valve for proportional controller

(for standard control, throughput here) * 37 Free air delivery display for proportional controller * 42 3/2-way solenoid valve for suction controller regulation * 43 Double non-return valve (items 42 + 43 = rapid-start valve) * 44 Double non-return valve (monitoring of rotational direction) *

* Optional accessory

Operating instructions for S 40-3...S 150-3 series screw compressors Page 79

Appendix 7.1 Flow chart

Water cooled version, serial connection – parallel connection

Parallel connection * Series-connected circuit

Page 80 Operating instructions for S 40-3...S 150-3 series screw compressors

Appendix 7.1 Flow chart

101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET

9 Sensor for final compression temperature 10 Combined compressed air/oil receiver 11 Oil separator 12 Safety valve 15 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 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 control, throughput here) * 32 2/2-way solenoid valve 33 Control valve water supply (preadjusted) 34 Control valve water supply (preadjusted) 37 Free air delivery display for proportional controller * 42 3/2-way solenoid valve for suction control regulation * 43 Double non-return valve (items 42 + 43 = rapid-start valve) * 44 Double non-return valve (monitoring of rotational direction) *

* Optional accessory

To be provided by customer:

35 Dirt trap 36 Stop valve

Operating instructions for S 40-3...S 150-3 series screw compressors Page 81

Appendix 7.1 Flow chart

101

102

Air cooled version, frequency controlled

Page 82 Operating instructions for S 40-3...S 150-3 series screw compressors

Appendix 7.1 Flow chart

101 Intake air INLET 102 Compressed air OUTLET

1 Suction filter 2 Maintenance display 3 Vacuum switch (for suction filter monitoring) * 4 Suction controller 5 Ventilation and regulation control valve 6 Pressure switch (for rotational direction, system relief and V-belt monitoring) * 7 Drive motor 8 Compressor air end

9 Final compression temperature display and switch 10 Combined compressed air/oil receiver 11 Oil separator 12 Safety valve 13 Differential 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 24 Pressure sensor, compressor network pressure

24.1 Pressure gauge (system pressure) 25 Stop valve, compressed air outlet 26 Pressure sensor for network pressure (frequency converter) 27 Stop valve, oil drainage

27.1 Stop valve, oil drainage (oil cooler, 102 - 340 Hp) 28 Non-return valve drainage line (up to 102 Hp) 31 3/2-way solenoid valve

* Optional accessory

Operating instructions for S 40-3...S 150-3 series screw compressors Page 83

Appendix 7.1 Flow chart

101

102

104

103

Water cooled version, serial connection – frequency controlled

Page 84 Operating instructions for S 40-3...S 150-3 series screw compressors

Appendix 7.1 Flow chart

101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET

1 Suction filter 2 Maintenance display 3 Vacuum switch (for suction filter monitoring) * 4 Suction controller 5 Air relief and regulation control valve 6 Pressure switch (for rotational direction, system relief and V-belt monitoring) * 7 Drive motor 8 Compressor air end

9 Final compression temperature display and switch 10 Combined compressed air/oil receiver 11 Oil separator 12 Safety 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 Operating pressure switch 24 Pressure gauge 25 Stop valve, compressed air outlet 26 Pressure sensor for network pressure (frequency converter) 27 Stop valve, oil drainage 28 Non-return valve drainage line (up to 102 Hp) 31 3/2-way solenoid valve 32 2/2-way solenoid valve

34.1 Bypass valve *

* Optional accessory

To be provided by customer:

35 Dirt trap 36 Stop valve

Operating instructions for S 40-3...S 150-3 series screw compressors Page 85

Appendix 7.1 Flow chart

BOGE Duotherm BPT plate heat 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 86 Operating instructions for S 40-3...S 150-3 series screw compressors

Appendix 7.1 Flow chart

BOGE Duotherm-Plus BSW safety heat exchanger

101 Compressed air OFF 102 Feed line 103 Return line

1 Suction filter 4 Suction controller

Operating instructions for S 40-3...S 150-3 series screw compressors Page 87

Appendix 7.2 List of maintenance and service work

7.2 List of maintenance and service work

RemarksOil/water

Filter

Drain

separator

Motor

mainte-

unit

Cooling

Oil

separator

Oil-

level

Oil

filter

Intake

rature

Tempe-

System

pressure

nance

cleaning

Please record any maintenance work you have completed in the appropriate column

Network

pressure

hours

Operating

Date

Page 88 Operating instructions for S 40-3...S 150-3 series screw compressors

** C = Check

* Cl = Cleaning

** Ch = Change

* Ch = Change

Appendix 7.2 List of maintenance and service work

RemarksOil/water

Filter

Drain

separator

Motor

mainte-

unit

Cooling

Oil

separator

Oil-

level

Oil

filter

Intake

rature

Te m p e -

System

pressure

Please record any maintenance work you have completed in the appropriate column

nance

cleaning

Network

pressure

hours

Operating

Date

Operating instructions for S 40-3...S 150-3 series screw compressors Page 89

** C = Check

* Cl = Cleaning

** Ch = Change

* Ch = Change

Appendix 7.2 List of maintenance and service work

RemarksOil/water

Filter

Drain

separator

Motor

mainte-

unit

Cooling

Oil

separator

Oil-

level

Oil

filter

Intake

rature

Te m p e -

System

pressure

Please record any maintenance work you have completed in the appropriate column

nance

cleaning

Network

pressure

hours

Operating

Date

Page 90 Operating instructions for S 40-3...S 150-3 series screw compressors

** C = Check

* Cl = Cleaning

** Ch = Change

* Ch = Change

Boge S 100-3, S 61-3, S 101-3, S 125-3, S 150-3 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General information 1.1 General safety instructions

Safety instructions for compressor operation

1.1 General safety instructions

Special hazard warnings

Dangers of electricity

Obligations of the operator

Personnel requirements

Personal protective equipment

Safety instructions for maintenance and repair of the compressor

Accident prevention regulations

1.2 Introduction

Symbols used

Warning signs on the compressor

Intended use

Foreseeable misuse

Transport damage

Data on the rating plate

Service

Product description 2.1 Technical data

2.1 Technical data

2.2 Operating principle of compressor

Functional principle of the air end

Air circuit

Oil circuit

2.3 Compressor control

Network pressure

Operating states

Operating modes

Controlled operation (frequency control)

Short operating times

Operating pressure transmitter

2.4 Control devices

Proportional controller (optional accessory for S series)

General information

2.5 Safety and monitoring devices

Safety temperature limiting device

Safety valve

Monitoring the drive and fan motor

Rotational direction monitoring (optional accessory)

2.6 Water cooling

Water cooling

Serial connection

Parallel connection

2.7 Cooling water

Water connection (for water cooling)

Cooling water quality

Installation 3.1 Transport and storage

Part 3: Installation 3.1 Transport and storage

General information

How to transport the compressor

Intermediate storage

3.2 Compressor room

Installation surface

Fire protection

Sound protection

Admissible ambient temperatures

Frost protection

Ventilation

Cooling air requirement

Ventilation possibilities

Condensate disposal

3.3 Installation

General information

Checking the scope of delivery

Removing the transport securing bolts

Activating the belt tensioning device

Checking the oil level

3.4 Electrical connection

3.5 Commissioning

Check installation requirements

Checking the rotational direction of drive and fan motor

Check compressed air outlet for leak tightness

Opening the stop valves

Checking for leaks

Conduct trial run

3.6 Dismantling