Home

Operating instructions

1. m 5 H H 11 31 th 28 9 23 l 4 u 12 21 C lt gt D E NR NH S x Y 20 af 24 PH 2 l A 16 No 18 ae X 19 l A 26 To ID 22475 25 Page 94 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Flow chart 10 102 Oo co DO A O Nad N 24 1 25 26 27 27 1 28 3 Intake air INLET Compressed air OUTLET Suction filter Maintenance display Vacuum switch for suction filter monitoring Suction controller Ventilation and regulation control valve Pressure switch for rotational direction system relief and V belt monitoring Drive motor Compressor air end Final compression temperature display and switch Combined compressed air oil receiver Oil separator Safety valve Differential pressure switch for oil separator monitoring System pressure switch for system pressure build up and monitoring Safety pressure switch for pressure limitation Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure non return valve Compressed air aftercooler Operating pressure switch Pressure sensor compressor n
2. C gt D w w w w B B gt 4 pi E Fig 3 3 Ventilation possibilities A Supply and exhaust air openings in the outside walls free standing installation B Supported by exhaust air fan 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 preventing the plant from freezing up at temperatures below freez ing 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 Oo Operating instructions for S 31 3 S 150 3 series screw compressors Page 39 Installation Installation Condensate disposal The air taken in contains water in form of vapour which turns into condensa tion during compression Attention The condensate contains oil Never dispose of it in the public sewage system without prior treatment exception to this the built up condensate of com pressors of the BLUEKAT series does not contain any residual oil The con densate is to be treated as industrial water Strictly observe the effluent disposal laws of your local authorities Comply with the Water Act BOGE recommends using an oil water separator not for compressors in the BLUEKAT series The BOGE oil water separator is used to separate the oil from the conden sate The cleaned water can be fed directly into the publ
3. ssssssssssssssssssee 40 Checking the scope of delivery ssseee 41 Installing the compressor ssese mme 41 Connecting the compressor to the compressed air network 41 Connecting the cooling water optional accessory 41 Page IV Operating instructions for S 31 3 S 150 3 series screw compressors Contents 3 4 3 5 3 6 Part 4 4 1 Faults 4 2 4 3 Part 5 5 1 Accessory equipment 5 2 Part 6 6 1 Maintenance 6 2 Removing the transport securing bolts ssssssssss 42 Activating the belt tensioning device sseeeeeee 42 Checking the oil level errs aroia AEA AAA REER 43 Electrical connectlon iternm RREREE 43 Commissioninjg rmn Rer 45 Check installation requirements sss 45 Checking the rotational direction of drive and fan motor 45 Check compressed air outlet for leak tightness 46 Opening the stop valves sssssssssssseseeeeenees 47 Checking for leaks dottor ee te be den 47 Conduct trial Un iie ertet e epe t petam iaee 47 Commissioning following extended stoppages 48 Refrigerant compressed air dryer oo eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 49 Dismantling tenetur tercer ttp Een 50 General information
4. AA Caution Dismantling the compressor must only be carried out byauthorised and qual ified personnel with the necessary experience Observe all information in the attached operation instructions regarding safe dismantling of the refrigerant compressed air dryer and safe disposal of the refrigerant 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 The converter needs to entirely cool down prior to restarting operation only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Page 50 Operating instructions for S 31 3 S 150 3 series screw compressors Faults General information 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 re fer to the operating instructions for the compressor control Caution 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 This applies in particular to any work carried out on the integrated
5. General information EB General safety instructions 1 1 General safety instructions Caution 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 Safety instructions for compressor operation 1 Ensure that no commissioning and maintenance work on the compressor is undertaken until these operating instructions have been read and under stood 2 Only use the compressor for its intended use as described in these oper ating 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 ob served 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 com pressor 6 Toavoid dangers from debris or parts lying around the working a
6. Water connection for water cooling Cooling water quality 2 8 Cooling water The cooling water must have the following properties Electrical conductivity gt 50 uS cm at pH value 7 9 Carbonate hardness CaCO 15 dH Total hardness 21 dH Cooling water pressure max 10 0bar min 2 0 bar Cooling water inlet temperature max 30 C min 5 C 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 lt 70 C Cl 100 Free chlorine Cl lt 0 5 Iron Fe 0 2 Free agressive carbon dioxide CO lt 20 Manganese Mn lt 0 1 Nitrate NO lt 100 Oxygen O lt 2 Silicon oxide SiO lt 8 Sulphate SO 60 Total dissolved substances TDS lt 30 Table 2 2 Maximum admissible concentration of the substances Note If the specified limit values are exceeded use cooling units made of other materials Please consult BOGE s service department Attention If the cooling water data changes the cooling units may have to be reconfig ured Incorrectly configured cooling units may cause malfunctio
7. Clean the air oil cooler After 1 500 operating hours Inthe case of compressors in the BLUEKAT series once a year by BOGE service personnel during the annual service Ry Note The service life of the compressed air oil cooling unit depends on the degree of soiling dust oil vapour of the suctioned cooling air Extreme external soil ing of the cooling unit leads to an increased temperature in the oil circuit Cleaning the compressed air oil cooler 1 Switch off the compressor with the OFF button Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT 2 Remove the right side of the sound insulation hood 3 Remove the maintenance opening on the cooling air duct box Attention 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 outthe dirt with compressed air 1 in the opposite direction to the nor mal cooling air flow see figure below Operating instructions for S 31 3 S 150 3 series screw compressors Page 73 Maintenance EN Maintenance work during scheduled services 6 Extractthe blown out dirt directly with
8. e The BOGE maintenance concept Caution Risk of injury Oil presents a potential danger to health and environment due to their addi tives 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 Fire naked flames and smoking is strictly prohibited when handling oil We recommend using only oil according to the following specification Viscosity range of 55 mm s at 40 C Minimum viscosity at 100 C of 8 mm s Maximum viscosity at 0 C of 1 000 mm s Compliance with FZG test according to DIN ISO 14635 1 with failure load stage 10 Test Method A 8 3 90 min 10 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 gt 230 C 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 Meets VDL requirements DIN 51 506 for lube oils including Pneurop test Or you use BOGE compressor oil Syprem S Attention Never mix different oil types and brands T
9. 2 5 S D 101 3 S D 150 3 S D F 150 3 approx 5 0 Tab 3 2 Compressor oil quantity 2 Screw plug back in again 3 Turn compressor stage using the pulley by hand 5 to 10 times to spread the oil evenly Note 35 In the case of screw compressors of the BLUEKAT series please note that in the event of prolonged operational shutdowns for several days during which the compressor station is disconnected from the power supply restart ing the compressor requires a preheating phase of 15 to 45 minutes since the converter has completely cooled down Refrigerant compressed Before commissioning the refrigerant compressed air dryer read the attached air dryer operating instructions Caution Risk of injury Maintenance work and repairs to the refrigerant compressed air dryer SD SDF may be carried out only by BOGE service personnel with the relevant specialist training Failure to comply with this requirement can result in physical injury and in damage to the compressor system Observe the Safety instructions for maintenance and repair of the dryer SD SDF on page 6 when dealing with the refrigerants used Operating instructions for S 31 3 S 150 3 series screw compressors Page 49 Installation Dismantling 3 6 Dismantling Ry Note To avoid danger when dismantling the compressor please consult BOGE s service department Telephone 49 5206 601 140
10. 3000 3000 3000 60 Hz min 3600 3600 3600 3600 Protection type IP 55 55 55 55 Design IMB 3 3 3 3 ISO class F F F F Electrical connection Mains voltage IM 400 400 400 400 Frequency Hz 50 50 50 50 Recommended fuse protection A 100 125 125 125 Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fusible cutouts gL gG or circuit breakers with C characteristic only 2 3 Operating instructions for S 31 3 S 150 3 series screw compressors Page 19 Product description 22 Operating principle of compressor Technical Data S 40 3 BLUEKAT S 60 3 BLUEKAT part 2 Type S 40 3 BLUEKAT S 50 3 BLUEKAT S 60 3 BLUEKAT SF 60 3 BLUEKAT Oil filling quantity Oil receiver volume i 46 46 46 46 Total oil filling quantity i 28 28 28 28 Oil topping up quantity between min max i 6 6 6 6 Intake air temperature min P 5 5 5 5 max P 40 40 40 40 Cooling air requirement free standing installation m h 9000 13000 13000 13000 3 with supply and exhaust duct m h 4500 6500 6500 6500 3 free fan pressure Pa 20 60 60 60 free fan pressure mm WS 2 6 6 6 Cooling air requirement free standing installation m h 2000 2000 2000 2000 with supply and exhaust duct m h 100
11. 5 5 max 40 40 40 40 40 40 gt Cooling air requirement free standing installation m h 13000 13000 18400 18400 32000 32000 3 with supply and exhaust duct m h 6500 6500 9200 9200 16000 16000 mU free fan pressure Pa 60 60 60 60 60 60 free fan pressure mm WS 6 6 6 6 6 6 Cooling air requirement free standing installation m h 2000 2000 2000 2000 3400 3400 with supply and exhaust duct m h 1000 1000 1000 1000 1700 1700 Required cooling water quantity delta t 15K m h 2 450 2 450 4 090 4 090 6 000 6 000 delta t 30K m h 1 225 1 225 2 045 2 045 3 000 3 000 Max cooling water quantity m h 3 5 3 5 4 2 4 2 9 0 9 0 o Cooling water inlet temperature s min E 5 5 5 5 5 5 max P 30 30 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 45 45 Cooling water pressure min bar 2 2 2 2 2 2 max bar 10 10 10 10 10 10 Operating pressure transmitter factory settings Pmax 8bar Switch off press Pmax bar 8 8 8 8 8 8 Switch on press p bar 7 5 7 5 7 5 7 5 7 5 7 5 Pmax 10 bar Switch off press p bar 10 10 10 10 10 10 Switch on press Prin bar 9 5 9 5 9 5 9 5 9 5 9 5 Pmax 13bar Switch off press Prax bar 13 13 13 13 13 13 Switch on press Prin bar 12 5 12 5 12 5 12 5 12 5 12 5 Safety valve Activation pressure at p 7 8bar bar 11 11 11 11 11 11 Prax 10 bar bar 11 11 11 11 11 11 Prax 13 bar bar 14 14 14 14 1
12. 6 7 1 7 2 7 3 Maintenance work between scheduled services 70 Weekly Inspect replace supply air filter optional accessory 70 Monthly Clean the suction filter 71 Monthly Check oil level top up with oil if necessary 72 Every 1 500 operating hours Clean the oil cooler air cooling 73 Every 1 500 operating hours Clean the oil cooler air cooler water cooling zeren nora a a mmn 74 Maintenance work during scheduled services 74 Every 3 000 operating hours once a year Change the suction filter cartridge eese 75 Every 3 000 operating hours once a year Have safety valve checked ssssssseeeee eene 75 Every 3 000 operating hours once a year Change the oil filter 75 Every 3 000 operating hours once a year Change the oil separator ssssse e 77 Every 3 000 operating hours once a year Check V belt 78 Every 9 000 operating hours Change V belt 79 Every 9 000 operating hours every 2 years Oil change 81 Special maintenance work eese 84 Flush out ol Circult scene ott ode eta entes 84 Drive motors with permanent lubrication sussseusssses 84 Drive motors with lubrication device sssssssssssssss 84 Drive motors with automatic lubricati
13. 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 regulations e g DIN VDE 0105 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 un intentionally switched on again Immediately after finishing the work all dis mantled covers and safety devices must be refitted The machine operator is responsible for inspecting the compressor daily for externally visible damage and defects and for immediately 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 Operating instructions for S 31 3 S 150 3 series screw compressors Page 5 General information Safety instructions for maintenance and repair of integrated converter BLUEKAT series EB General safety instructions AA Caution Maintenance and repair work on the integrated converter in the S 40 3 BLUEKAT S 60 3 BLU
14. S 150 3 series screw compressors Page 43 Installation Electrical connection 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 Note In the case of the screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT the power supply to the integrated converter is provided through the electri cal connection for the compressor Drive with frequency converter Danger High voltage Depending upon operational conditions electrical drive systems with a fre quency converter may have an earth leakage current above 10 mA Therefore the required precautions according to EN 60204 1 2007 and EN 50178 1998 must be taken as soon as the compressor is electrically con nected 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 Cu along the whole of its length 2 If the protective conductor has a minimum cross section of less than 10 mm Cu hat a second conductor with at least the same cross se
15. after two years at the latest Attention If you use a different oil instead of Syprem S itis essential that you contact the BOGE service department to determine the required oil change intervals Note 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 11 to 6 13 Before changing the oil an air cushion must be built up The combined com pressed air oil receiver is located at the lowest point of the system Therefore a light air cushion approx 1 5 bar system pressure must be applied to drain the oil This pressure forces the oil through the drain hose into a suitable col lecting vessel To build up an air cushion 1 Switch the compressor off with the OFF button Remove the cover on the maintenance side Place the end of the oil drain hose into a suitable collecting vessel 6 Remove the cap nut 5 from the switch cabinet Close off the vent hole of the solenoid valve with the cap nut oar OMN Attention Never use any tools to screw on the cap nut They might damage the solenoid valve Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Operating instructions for S 31 3 S 150 3 series screw
16. automatically blocked The temperature inside the converter starts dropping Both heating and com pressor do not automatically restart operation due to temperature failure Use converter temperature control to restart Also see Converter faults BLUEKAT series on page 53 Caution Restart of compressor station only after consultation with your local BOGE distribution partner or BOGE service personnel It is imperative to determine the cause of the failure prior to restarting the compressor station Additional Monitoring Devices Additional monitoring devices are located on the switch cabinet of the integrat ed converter S 40 3 BLUEKAT S 60 3 BLUEKAT These include a temper ature control unit with display serving to retrieve temperature information on the converter In addition there are three indicator lights on the switch cabinet serving to indicate the operating state of the converter Page 28 Operating instructions for S 31 3 S 150 3 series screw compressors Product description EB Safety and monitoring devices o m vue ES N N OOO Fig 2 6 Switch cabinet with monitoring devices 1 Switch cabinet lock 2 Temperature control 3 Indicator lamp Operation Betrieb green 4 Indicator lamp Preheating Aufheizen yellow 5 Indicator lamp Alarm St rung red The display of the temperature control unit allows you to recall the following temperature informa
17. converter in screw compressors of the BLUEKAT series Please contact BOGE s service department at the following telephone num ber if you have any questions Telephone 49 5206 601 140 4 2 General faults Fault Possible cause Rectification Not delivered no pressure build up max pressure 0 5 bar System components in the com pressor are leaking Check oil and compressed air lines inside the compressor tighten and or reseal screw connections if necessary Minimum pressure valve is faulty Close ball valve and check whether pressure builds up if so open ball valve again immediately replace minimum pressure valve Solenoid venting valve does not close Check solenoid valve and replace if necessary Suction regulator does not open Suction regulator or solenoid valve is defective check and replace if necessary V belts are torn Fit new v belts Compressor system does not start up af 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 Check unloading valve and replace if necessary Voltage fluctuations in the elec trical mains power supply Ensure constant voltage in accordance with IEC 38 Compressor oil is very viscous due to low ambient temperature Heat up the compressor system additional heater av
18. frequencies are specified on a plate in the switch cabinet The refrigerant air dryer requires 230 V 50 Hz Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fusible cutouts gL gG or circuit breakers with C characteristic only Page 14 Operating instructions for S 31 3 S 150 3 series screw compressors Product description Technical data Technical data S 31 3 100 3 SD 40 3 SD 100 3 part 2 Type 31 3 S 40 3 S 50 3 S 60 3 S 61 3 S 75 3 S 90 3 S 100 3 yp SD 40 3 SD 50 3 SD 60 3 SD 61 3 SD 75 3 SD90 3 SD 100 3 Oil filling quantity Oil receiver volume i 46 46 46 46 71 71 71 71 Total oil filling quantity i 28 28 28 28 42 42 42 42 Oil topping up quantity between min max i 6 6 6 6 8 8 8 8 Intake air temperature min F 5 5 5 5 5 5 5 5 max C 40 40 40 40 40 40 40 40 E Cooling air requirement free standing installation m h 9000 11000 13000 13000 13000 16000 17200 18400 3 with supply and exhaust duct m h 4500 5500 6500 6500 6500 8000 8600 9200 ae free fan compression Pa 20 20 60 60 60 60 60 60 free fan pressure mm WS 2 2 6 6 6 6 6 6 Cooling air requirement free standing installation m h 2000 2000 2000 2000 2000 2000 2000 2000 with supply and exhaust duct m h 1000 1000 1000 1000 1000 1000 1000 1000 Requir
19. in the presence of flames and electric arcs 9 The products of this decomposition are toxic 10 Before welding or soldering work is carried out on refrigerant systems the refrigerant must first be removed 11 A strong smell indicates that the refrigerant is decomposing Leave the room immediately Ventilate the room well The operator of a compressor station is responsible for ensuring that it is prop erly installed operated and maintained Prior to commissioning operators in the Federal Republic of Germany must have read the currently valid regulations of the German federation of statutory accident insurance institutions for the industrial sector Among other regula tions the German Ordinance on Industrial Safety and Health BetrSichV in particular is applicable The regulations can be obtained from the following locations German federation of statutory accident insurance institutions for the industrial sector Berufsgenossenschaft Carl Heymanns Verlag KG Luxemburger Strafe 449 D 50939 K ln pub lisher Beuth Verlag GmbH Burggrafenstraf e 6 D 10787 Berlin publisher If the compressor system is operated outside the Federal Republic of Germa ny 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 be yond the legal regulations specifie
20. 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 envi ronmental conditions This enables the most important maintenance work to be carried out regularly and so achieve a sustainable effect in order to reduce compressor wear to a minimum and guarantee a long life Maintenance through Have your compressor inspected and maintained in a full service by BOGE BOGE customer service customer service every 3 000 operating hours or once a year Note 35 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 31 3 S 150 3 series screw compressors Page 61 Maintenance e The BOGE maintenance concept List of maintenance and S 31 3 S 150 3 service work Fig o AN OW 10 11 6 1 Maintenance work S 31 3 S 150 3 Check pressure final compressor temperature system relief emer gency stop button Check change if necessary supply air filter Check suction filter Clean filter and cartridge Change filter cartridge Check oil level Top up oil Clean compressed air oil cooler externally Change
21. return valve 56 Thermocouple 22 Compressed air aftercooler 57 Thermocouple 23 Pressure sensor for system pressure 58 Pressure retaining shut off valve 24 Network pressure compressor DHSV 25 Stop valve comatesres air outlet 59 DHSV solenoid valve 27 Stop valve oil drainage 60 Gauge 28 Non return valve drainage line 61 Relief ball valve up to 75 kW 62 Condensate discharge valves 29 Proportional controller 3 automatic 30 Differential pressure switch for pro portional controller cfe 31 3 2 way solenoid valve for propor Opupnalacoessory tional controller for standard control throughput here Operating instructions for S 31 3 S 150 3 series screw compressors Page 101 Appendix Flow chart BLUEKAT series water cooled version serial connection Page 102 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET 1 Suction filter 31 3 2 way solenoid valve for propor 2 Maintenance display from 30 kW tional controller for standard control 3 Vacuum switch Doug p here for suction filter monitoring 32 2 2 way solenoid valve 4 Suction controller 35 Dirttrap 5 Air relief and regulation control valve 36 Stop valve 7 Drive motor 37 Free air delivery display for propor tional controller 8 Compressor air end 42 3 2 way solenoid valve for suction 9 Senso
22. 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 13 Switch the compressor off with the OFF button Page 76 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN Maintenance work during scheduled services Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Every 3 000 operating hours once a year Change the oil separator 14 Check the oil filter again for leaks and tighten by hand if necessary proce dure as described above 15 Check oil level If necessary top up with oil to offset any losses Change the oil separator Ifthe difference between network and system pressure exceeds 0 8 bar 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 Caution 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 t
23. six days of the arrival of the delivery Operating instructions for S 31 3 S 150 3 series screw compressors Page 11 General information E Introduction Data on the rating plate Service 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 EHEOGE Type Series Machine no Delivery volume max m min Final compression pressure bar Motor speed min Motor rating kW Postfach 100713 D 33507 Bielefeld Fax 05206 601 200 www boge com info boge com C C Otto Boge StraBe 1 7 D 33739 Bielefeld Telefon 05206 601 0 Fig 1 1 Data on the rating plate Please do not hesitate to contact BOGE service if you have any questions Please call Telephone 49 5206 601 140 If you have any queries please always specify the following data for your com pressor to prevent any delays Type Year of manufacture Machine number Attention 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 12 Operating instructions for S 31 3 S 150 3 series screw compressors Product description Technical data 2 1 Technical data Technical data S 31 3 S 100 3 SD 4
24. standing unit lation with section standing unit standing unit ducting kW m h m m h m m h m S 31 3 22 9 000 1 10 4 500 0 35 2 000 0 25 S 40 3 SD 40 3 30 11 000 1 35 5 500 0 42 2 000 0 25 S 50 3 SD 50 3 37 13 000 1 60 6 500 0 48 2 000 0 25 aes n 45 13 000 1 60 6 500 048 2 000 0 25 S 75 3 SD 75 3 55 16 000 2 00 8 000 0 59 2 000 0 25 S 90 3 SD 90 3 65 17 200 2 15 8 600 0 64 2 000 0 25 S 100 3 SD 100 3 T5 18 400 2 30 9 200 0 68 2 000 0 25 S 101 3 SD 101 3 75 20 000 2 50 10 000 0 74 3 400 0 45 S 125 3 SD 125 3 90 32 000 4 00 16 000 1 18 3 400 0 45 S 150 3 SD 150 3 110 32 000 4 00 16 000 1 18 3 400 0 45 SF 60 3 SDF 60 3 45 13 000 1 60 6 500 0 48 2 000 0 25 SF 100 3 SDF 100 3 T5 18 400 2 30 9 200 0 68 2 000 0 25 SF 150 3 SDF 150 3 110 32 000 4 00 16 000 1 18 3 400 0 45 S 40 3 BLUEKAT 30 11 000 1 35 5 500 0 42 2 000 0 25 S 50 3 BLUEKAT 37 13 000 1 60 6 500 0 48 2 000 0 25 S 60 3 BLUEKAT 45 13 000 1 60 6 500 0 48 2 000 0 25 SF 60 3 BLUEKAT 45 13 000 1 60 6 500 0 48 2 000 0 25 The cooling air requirement is based on a 4 C difference between the ambient temperature and the outside temperature Table 3 1 Cooling air demand cross sections of openings and ducts required Page 38 Operating instructions for S 31 3 S 150 3 series screw compressors Installation EB Compressor room 3 2 Ventilation possibilities m B J Z A JL I B sy 2 ud E I J m m
25. 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 respon sible 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 31 3 S
26. the converter The BLUEKAT converter must only be disconnected from the power supply for the purpose of maintenance and or repair Note 35 When using the compressor control to switch off the compressor the heater for the converter remains in operation This avoids prolonged preheating phases before the next load operation Commissioning follow If an extended stoppage is scheduled you should contact BOGE s service ing extended stoppages 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 Caution 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 Attention N Only fill the suction controller with the grade of oil used to operate the com pressor Never mix different grades or brands of oil 1 Unscrew the plug from the suction controller 1 f Fig 3 6 Suction controller Page 48 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Commissioning The following compressor oil quantities must be filled into the suction control ler Model Compressor oil quantity I S D 31 3 S D 60 3 S D F 60 3 BLUEKAT Modelle approx 0 5 S D 61 3 S D 100 3 S D F 100 3 approx
27. 0 1000 1000 1000 Required cooling water quantity delta t 15K m h 1 630 2 010 2 450 2 450 om delta t 30 K m h 0 815 1 005 1 225 1 225 Max cooling water quantity m 3 5 3 5 35 3 5 o 2 Cooling water inlet temperature eo amp min 5 5 5 5 _ max C 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 Cooling water pressure min bar 2 2 2 2 max bar 10 10 10 10 Operating pressure transmitter 1 factory settings p 7 8bar Switch off press Prax bar 8 8 8 8 Switch on press Prin bar 7 T 7 7 Pmax 10 bar Switch off press Pmax bar 10 10 10 10 Switch on press Prin bar 9 9 9 9 Prax 13 bar Switch off press Pmax bar 13 13 13 13 Switch on press p bar 12 12 12 12 Safety valve Activation pressure at Prax 8bar bar 11 11 11 11 Prax 10 bar bar 11 11 11 11 Prax 13 bar bar 14 14 14 14 1 Functional principle of the air end Compressors for other operating pressures Prin Pmax 1 bar 2 2 Operating principle of compressor 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 Page 20 Operating instructions for S 31 3 S 150 3 series screw compressors Product description EN Operating principle of compressor Both screws have screw shaped profiles intermeshing without contact To
28. 0 3 SD 100 3 part 1 Type 31 3 S 40 3 S 50 3 S 60 3 S 61 3 S 75 3 S 90 3 S 100 3 yp SD 40 3 SD 50 3 SD 60 3 SD 61 3 SD 75 3 SD90 3 SD 100 3 Dimensions Height silenced mm 1450 1450 1450 1450 1450 1450 1450 1450 Height silenced SD mm 1665 1665 1665 1950 1950 1950 1950 Height super silenced mm 1950 1950 1950 1950 1950 1950 1950 1950 Width silenced super silenced mm 1620 1620 1620 1620 2000 2000 2000 2000 Depth mm 990 990 990 990 1065 1065 1065 1065 Weight silenced kg 750 842 970 843 971 994 1122 1180 1330 1260 1430 1328 1498 1358 1528 super silenced kg 780 872 1000 873 1001 1024 1152 1230 1380 1310 1480 1378 1548 1408 1578 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 2 silenced super silenced dB A 64 64 73 71 74 72 TIT 79 73 79 73 80 73 8 Measurement surface c silenced super silenced dB A 15 15 15 16 15 16 16 17 16 17 16 17 16 17 Sound power level silenced super silenced dB A 79 79 88 87 89 88 93 88 95 90 95 90 96 90 Max sound pressure level 3 dB A c accord to DIN EN ISO 2151 2009 silenced super silenced dB A 63 63 72 70 73 71 76 70 78 72 78 72 79 72 8 Measurement surface silenced super silenced dB A 15 15 15 16 15 16 16 17 16 17 16 17 16 17 Sound power level silenced super silenced dB A 78 78 8
29. 0 4 64 18 44 4 64 18 44 Prax 10 bar m min 1 43 6 53 1 43 6 53 2 58 11 00 2 58 11 00 4 27 16 25 4 27 16 25 Prax 13 bar m min 1 19 5 67 1 19 5 67 2 09 9 53 2 09 9 53 2 97 14 25 2 97 14 25 Drive motor Rated power kW 45 45 75 75 110 110 Rated speed 50 Hz min 3000 3000 3000 3000 3000 3000 Protection type IP 55 55 55 55 55 55 Design IMB 3 3 3 3 3 3 ISO class F F F F F F Electrical connection Mains voltage IV 400 400 400 400 400 400 Frequency Hz 50 50 50 50 50 50 Recommended fuse protection A 125 125 200 200 250 250 Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet The refrigerant air dryer requires 230 V 50 Hz 9 Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fusible cutouts gL gG or circuit breakers with C characteristic only Operating instructions for S 31 3 S 150 3 series screw compressors Page 17 Product description Technical data Technical Data SF 60 3 SF 150 3 SDF 60 3 SDF 150 3 part 2 Type SF 60 3 SDF 60 3 SF 100 3 SDF 100 3 SF 150 3 SDF 150 3 Oil filling quantity Oil receiver volume i 46 46 71 71 120 120 Total oil filling quantity i 28 28 42 42 65 65 Oil topping up quantity between min max l 6 6 8 8 10 10 Intake air temperature min P 5 5 5 5
30. 03 103 103 97 S 50 3 SD 50 3 8 10 13 103 103 104 98 99 94 S 60 3 SD 60 3 8 10 13 120 121 121 1251 1251 126 S 61 3 SD 61 3 8 10 13 11711171115 118 117 116 S 75 3 SD 75 3 8 10 13 115 116 115 1141 113 112 S 90 3 SD 90 3 8 10 13 107 108 109 113 114 113 S 100 3 SD 100 3 8 10 13 82 83 85 80 90 90 S 101 3 SD 101 3 8 10 13 118 105 104 110 109 102 S 125 3 SD 125 3 8 10 13 128 119 93 123 1221 110 S 150 3 SD 150 3 8 10 13 141 130 117 147 136 124 SF 100 3 SDF 100 3 8 10 13 93 95 95 93 95 95 SF 150 3 SDF 150 3 8110 13 141 130 117 147 136 124 SF 60 3 SDF 60 3 8 10 13 124 95 S 40 3 BLUEKAT 8110 13 106 107 103 103 103 97 S 50 3 BLUEKAT 8 10 13 103 103 104 98 99 94 EE EEUU 8 10 13 120 121 121 125 1251 126 Tab 6 4 Settings with standard motors Page 80 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN Maintenance work during scheduled services Ry Note 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 Every 9 000 operating hours every 2 years Oil change Change the oil Inthe case of Syprem S After 9 000 operating hours but
31. 150 3 series screw compressors Page 3 General information EN General safety instructions Personnel requirements Personal protective equipment Safety instructions for maintenance and repair of the compressor 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 com pulsory personal protective equipment at all times when working on the com pressor 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 pneumatic control system and or on the cooling system of the built in dryer 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 Caution During repair and maintenance use only original spare parts compressor oils and operating materials approved by BOGE Danger High voltage When working on the electrica
32. 4 14 Compressors for other operating pressures Pirin Prax 0 5 bar Page 18 Operating instructions for S 31 3 S 150 3 series screw compressors Product description EN Technical data Technical Data S 40 3 BLUEKAT S 60 3 BLUEKAT part 1 Type S 40 3 BLUEKAT S 50 3 BLUEKAT S 60 3 BLUEKAT SF 60 3 BLUEKAT Dimensions Height super silenced mm 1950 1950 1950 1950 Width super silenced mm 2270 2270 2270 2270 Depth mm 960 960 960 960 Weight approx kg 1100 1320 1350 1400 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 2 silenced super silenced dB A 67 IT2 72 IT2 8 Measurement surface 7 silenced super silenced dB A 17 4 17 4 17 4 17 4 Sound power level silenced super silenced dB A 844 189 4 189 4 189 4 Max sound pressure level 3 dB A c accord to DIN EN ISO 2151 2009 silenced super silenced dB A 66 IT1 JTA 71 8 Measurement surface 2 silenced super silenced dB A 17 4 17 4 17 4 17 4 Sound power level silenced super silenced dB A 83 4 188 4 188 4 188 4 Compressor Max final compression temperature C 110 110 110 110 Volume flow according to Pmax 8 bar m min 5 31 6 45 7 30 1 58 7 30 Prax 10 bar m min 477 5 77 6 54 1 43 6 53 Prax 13 bar m min 3 91 4 92 5 60 1 19 5 67 Drive motor Rated power kW 30 37 45 45 Rated speed 50 Hz min 3000
33. 7 86 88 87 92 87 94 89 94 89 95 89 Compressor Max final compression temperature C 110 110 110 110 110 110 110 110 Volume flow according to Prax 8 bar m min 3 88 5 31 6 45 7 30 7 85 9 88 11 35 ish Pmax 10 bar m min 3 35 4 77 5 77 6 54 7 10 9 04 10 18 11 00 Prax 13 bar m min 2 73 3 91 4 92 5 60 6 03 5 99 7 45 8 87 9 53 Drive motor Rated power kW 22 30 37 45 45 55 65 75 Rated speed 50 Hz min 3000 3000 3000 3000 3000 3000 3000 3000 60 Hz min 3600 3600 3600 3600 3600 3600 3600 3600 Protection type IP 55 55 55 55 55 55 55 55 Design IMB 3 3 3 3 3 3 3 3 ISO class F F F F F F F F Electrical connection Mains voltage IV 400 400 400 400 400 400 400 400 Frequency Hz 50 50 50 50 50 50 50 50 Recommended fuse protection A 63 80 100 125 125 160 160 200 The refrigerant air dryer requires 230 V 50 Hz Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fusible cutouts gL gG or circuit breakers with C characteristic only Operating instructions for S 31 3 S 150 3 series screw compressors Page 13 Product description EN Technical data Technical data S 101 3 S 150 3 SD 101 3 SD 150 3 part 1 Type S 101 3 S 125 3 S 150 3 yp SD 101 3 SD 125 3 SD 150 3 Dimensions Height sil
34. BOGE AIR THE AIR TO WORK pe ROGE COMPRESSED AIR SYSTEMS Operating instructions Belt driven screw compressors Series S 31 3 S 150 3 SD 40 3 SD 150 3 SF 60 3 SF 150 3 SDF 60 3 SDF 150 3 o 40 3 5 60 3 BLUEKAT Separate manuals Compressor control Refrigerant compressed air dryer SD SDF Frequency converter SF SDF GL Systems Certi fication www boge com Operating instructions for belt driven screw compressors 31 3 22 kW S 40 3 SD 40 3 30 kW S 50 3 SD 50 3 37 kW S 60 3 SD 60 3 45 kW S 61 3 SD 61 3 45 kW S 75 3 SD 75 3 55 kW S 90 3 SD 90 3 65 kW S 100 3 SD 100 3 75kW 101 3 SD 101 3 75KW S 125 3 SD 125 3 90 kW S 150 3 SD 150 3 110 kW SF 60 3 SDF 60 3 45 kW SF 100 3 SDF 100 3 75 kW SF 150 3 SDF 150 3 110 kW S 40 3 BLUEKAT 30 kW S 50 3 BLUEKAT 37 kW SISF 60 3 BLUEKAT 45 kW BOGE KOMPRESSOREN Otto Boge GmbH amp Co KG Postfach 10 07 13 33507 Bielefeld Otto Boge Strake 1 7 33739 Bielefeld Phone 49 5206 601 0 Fax 49 5206 601 200 Mail info boge com Net www boge com Translation of the original operating instructions according to the EU Machinery Directive 2006 42 EC Issue 04 2014 No 596 1239 01 Nominal charge 5 00 Operating instructions for S 31 3 S 150 3 series screw compressors Page Contents ns Contents Part 1 1 1 Ge
35. Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Operating instructions for S 31 3 S 150 3 series screw compressors Page 75 Maintenance EN Maintenance work during scheduled services Close ball valve at the compressed air outlet Remove the cover on the maintenance side Vent the compressor fully as described at the beginning of this section Wait approx 3 minutes to allow the oil to settle ao BR 0 N Caution 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 gt Catch the draining oil and dispose of it properly in line with environmen tal regulations Fig 6 8 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 Attention 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
36. EKAT series must be carried out by specially trained BOGE service personnel only Failure to observe this can result in physical injury and damage to the com pressor system Safety instructions for maintenance and repair of the dryer SD SDF AA Caution Maintenance work and repairs to the refrigerant compressed air dryer SD SDF may be carried out only by BOGE service personnel with the relevant specialist training Failure to comply with this requirement can result in physical injury and in damage to the compressor system The operator user must comply with the existing national occupational oper ational and safety regulations Existing internal works regulations must also be observed 1 No safety or protection equipment may be altered adjusted or removed from the dryer either permanently or temporarily 2 Use only the correct tools for maintenance and repair work Use only original spare parts oO 4 The system must be switched off and disconnected from the mains power supply before any maintenance or repair works are carried out Take steps to ensure that the dryer cannot be switched back on again inadvertently 5 Before removing any pressurised parts of the dryer actively disconnect all pressure sources from the dryer and vent the dryer to release the pressure 6 Do not use flammable cleaning agents to clean the equipment 7 Always pay meticulous attention to cleanliness when car
37. F button Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Closing the ball valve at the compressed air outlet Remove the cover on the maintenance side Vent compressor fully as described at the start of this section Wait approx 3 minutes to permit the oil to settle oo BR 0 N Caution 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 gt 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 Page 72 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance Maintenance work between scheduled services Every 1 500 operating hours Clean the oil cooler air cooling Fig 6 6 Checking the oil level topping up with oil
38. IBWOY JOLIOAUOD duo JOJO DBuijoo IIO IIO llO ayejul eduio uejs g XiowjeN Bureiedo ajeq uwinjoo ojeudoadde y ui pejojduio2 oAeu no yom o2ueuojuieui Aue pJ0294 oSeojd Page 107 Operating instructions for S 31 3 S 150 3 series screw compressors 7 3 List of maintenance and service work Appendix abuey 49 abuey 49 3994 I xx Buea 2 x uleq 49 J4 Jojesedas aoueu JejeMIIO aQueu Buiuee o ee 7 ajujeul JeKup Jie ejuieui jun Jojesedas Jang JOR Joy ainjel ainssaid eunsseid sunoy syew y JOLIOAUOD duio JOJO Duijoo IIO IIO llO yeju eduio uejs g XiowjeN Burgejedo ajeq uuuinjoo ejeudoudde y ui pajajduiod aney noA yiom o2ueuojuieul Aue pJ0294 aSedjd Operating instructions for S 31 3 S 150 3 series screw compressors Page 108 7 3 List of maintenance and service work Appendix abuey 49 abuey y9 399u I xx Buea z 2 x ulelq JOVI Jojesedas aoueu JAJOM IIO aqueu Buiuee o x ajuieul JeKup ste ojuieui jun Jojesedas Jang Jojllj Joy aunjel ainssaid ainsseid sunoy SXIeulaM JOLIOAUOD dwog JOJO DBuijoo IIO IIO llO ayejul eduio uejs g XiowjeN Burejedo ajeq uuinjoo ejeudoaudde ay ui pojo duio2 aney no yiom o2ueuojuie
39. LET 1 Suction filter 30 Differential pressure switch for w N Oo OoOnN oO A 20 2 22 23 24 25 27 28 29 Maintenance display from 30 kW Vacuum switch for suction filter monitoring Suction controller Air relief and regulation control valve Drive motor Compressor air end Sensor for final compression tem perature Combined compressed air oil receiver Oil separator Safety valve Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure non return valve Compressed air aftercooler Pressure sensor network pressure Pressure gauge Stop valve oil drainage Stop valve oil drainage non return valve drainage line up to 75 kW Proportional controller 31 37 42 43 44 50 51 52 53 54 55 56 57 58 59 60 6 62 proportional controller 3 2 way solenoid valve for propor tional controller for standard control throughput here Free air delivery display for propor tional controller 3 2 way solenoid valve for suction control regulation Double non return valve items 42 43 rapid start valve Double non return valve Monitoring of rotational direction Filter Safety valve Heat exchanger Converter Heating cartridge with thermocouple Thermocouple Thermocouple Thermocouple Pressure retaining shut off valve DHSV DHSV solenoid val
40. OGE s service department Page 40 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Installation 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 Attention The compressor may only be set in operation if the rubber feet have been fitted Ifthe feet have been removed for transportation it is essential that they be fitted again before the compressor is set in operation Connecting the com pressor to the com pressed air network 2 Install the compressor and align it horizontally The compressor must stand firmly on the ground on all feet Connect the compressor to the compressed air network or a compressed air receiver For this use a BOGE high pressure hose Ry Note Do not install a non return valve in the pressure line The compressor is already equipped with a non return valve Connecting
41. Oil receiver volume i 120 120 120 Total oil filling quantity i 65 65 65 Oil topping up quantity between min max i 10 10 10 Intake air temperature min P 5 5 5 max C 40 40 40 Cooling air requirement free standing installation m 20000 32000 32000 8 with supply and exhaust duct m 10000 16000 16000 E free fan compression Pa 60 60 60 free fan pressure mm WS 6 6 6 Cooling air requirement free standing installation m h 3400 3400 3400 with supply and exhaust duct m h 1700 1700 1700 Required cooling water quantity delta t 15K m h 4 090 4 900 6 000 o deltat 30K m h 2 045 2 450 3 000 Max cooling water quantity m h 9 0 9 0 9 0 o 2 Cooling water inlet temperature o s amp min F 5 5 5 _ max C 30 30 30 Cooling water outlet temperature max C 45 45 45 Cooling water pressure min bar 2 2 2 max bar 10 10 10 Operating pressure sensor factory settings Pmax 8 bar Switch off press Prax bar 8 8 8 Switch on press Prin bar 7 7 7 Prax 10 bar Switch off press Pmax bar 10 10 10 Switch on press p bar 9 9 9 Prax 13 bar Switch off press Pmax bar 13 13 13 Switch on press Prin bar 12 12 12 Safety valve Activation pressure at Prax 8 bar bar 11 11 11 Pmax 10 bar bar 11 11 11 Pmax 13 bar bar 14 14 14 1 Compressors for other operating pressures Prin Pmax 1 bar Pa
42. able for any damage resulting from the use of other spare parts or operating materials Attention If the nozzle and dirt trap are clogged with dirt only up to S DF 60 3 incl BLUEKAT this can considerably increase oil consumption Operating instructions for S 31 3 S 150 3 series screw compressors Page 69 Maintenance Maintenance work between scheduled services 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 in table on page 65 Perform the work at the intervals specified Weekly Inspect replace Check the function of the optional supply air filter mats supply air filter 1x monthly but at least every 500 operating hours optional accessory If the air intake is very contaminated this should be carried out at more frequent intervals Change the supply air filter mats Ifa dirt crust has become deposited on the filter mats Ifthe final compression temperature rises to 4 to 5 C above the target value the dirt crust on the filter mat prevents the provision of an adequate cooling air supply Note 35 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 Caution Risk of injury Press the emergency stop button use the mains disco
43. ailable as an optional accessory Converter fault see Converter faults BLUEKAT series on page 53 Operating instructions for S 31 3 S 150 3 series screw compressors Page 51 Faults General faults Fault Possible cause Rectification Oil in suction filter Minimum pressure non return valve is leaking Check the minimum pressure non return valve and replace if necessary Suction regulator is leaking Check the suction controller and replace if necessary Cutout triggered by emergency off switch Normally switched off with O key Excessive oil consump tion Drain line is blocked Dismantle and clean drain line Defective oil separator element Check oil separator and replace if necessary Oil filling level too high Drain off oil Safety valve blows Operating pressure setting altered from original setpoint Set operating pressure to maximum permissible pressure of the screw compressor 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 Page 52 Operating instructions for S 31 3 S 150 3 series screw compressors Faults Converter faults BLUEKAT series 4 3 Converte
44. an industrial vacuum cleaner 2 see the illustration 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 iam Fig 6 7 Cleaning the compressed air oil cooler Note 35 If the cooling unit is excessively soiled cleaning is no longer possible with compressed air have it disassembled and cleaned by BOGE customer service Every 1 500 operating Clean the oil cooler and the air cooler in the case of water cooling hours Clean the oil After 1 500 operating hours cooler air cooler n the event of excessive lime deposits and dirt water cooling Note 35 The service life of the cooler depends on the level of contamination and hard ness 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 during scheduled services The following sections contain a description of the maintenance work to be carried out between annual services This work is listed in table on page 66 To retain your warranty entitlement BOGE recommends that you have this work carried out by certified BOGE service personnel using original spare parts Page 74 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN Maintenance work during scheduled servic
45. aring protection at noise levels of over 80 dB A Page 2 Operating instructions for S 31 3 S 150 3 series screw compressors General information EB 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 de fects repaired immediately Have all electrical equipment and fixed electrical installations checked by a professional electrician at least every 4 years Any modifications made after testing must comply with DIN EN 60204 1 2007 Check all safety devices on the machine at regular intervals to ensure they work properly Only use original fuses Obligations of the The operator is obliged to operator 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
46. ator lamp Meaning The temperature inside the converter is below the temperature Preheating Aufheizen which is needed to release compressed air production The in yellow dicator lamp does not indicate whether the heating is functioning properly or is in the process of heating As soon as the necessary temperature inside the converter is reached for enabling compressed air production the yellow in Operation Betrieb vir green dicator lamp extinguishes before the green lamp lights up Atthe same time the compressor initialises compressed air produc tion Alarm St rung The indicator lamp Alarm St rung lights up in case of red overtemperature inside the converter Table 2 1 Indicator lamps Meanings Safety valve 1 on the com pressed air oil vessel pre vents the maximum admissi ble pressure being exceeded Fig 2 7 Safety valve Caution Risk of injury When the maximum pressure is exceeded e g incorrect setting of the oper ating pressure switch the entire delivery volume of the compressor is ejected Monitoring the drive and fan motor Rotational direction monitoring optional accessory System pressure build up optional accessory The drive motor is monitored by PTC resistors The fan motor is monitored by overcurrent overload release units The pressure switch checks the rotational direction of the drive motor each time the system starts up The syst
47. by a service company Boge s service department will recommend contracting companies on request Page 56 Operating instructions for S 31 3 S 150 3 series screw compressors Accessory equipment EN BOGE Duotherm BSW Function 5 2 BOGE Duotherm BSW The safety heat exchanger BOGE Duotherm Plus BSW is approved for drink ing water It is integrated in the main stream of the hot compressor oil The ad ditional 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 dam age 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 proc essed e g alarm switching off the system Note Set the pressure control device to a value at least 2096 lower than the mini mum pressure of the media used Operating conditions Ry Minimum water pressure 0 5 bar Maximum water pressure 16 bar Maximum oil pressure 16 bar Maximum pressure of the confining liquid 10 bar Maximum temperature oil and water 100 C Note Exce
48. c 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 Jt 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 Page 24 Operating instructions for S 31 3 S 150 3 series screw compressors Product description EN Compressor control Operating modes Compressed air pro duction control BLUEKAT series 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 Pmax the compressor switches to standstill It does not consume any energy Once the pressure has dropped to the switch on pressure p the compressor switches back to load operation 2 Continuous operation Continuous operation limits the drive motor switching cycles and reduces wea
49. cating 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 quan tity is pressed through the nipple into the bearing with a grease gun while the compressor is running Drive motors with Read the attached operating instructions carefully before putting the automatic automatic lubricating lubrication device into operation equipment Caution Risk of injury Always exercise great caution when lubricating the bearings with the com pressor running and observe all safety precautions Never put your hand in the area of the V belt and the fan wheel Fitted safety devices and cladding may not be removed Attention 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 Operating instructions for S 31 3 S 150 3 series screw compressors Page 85 Maintenance EB Special maintenance work Have proportional regu lation checked Optional accessory for S ser
50. ck into the oil circuit via a drainage line Page 22 Operating instructions for S 31 3 S 150 3 series screw compressors Product description BLUEKAT operation principle 2 3 BLUEKAT operation principle The screw compressors of the BLUEKAT series S 40 3 BLUEKAT S 60 3 BLUEKAT are equipped with an integrated converter for catalytic separation of oil residues contained in the compressed air During the oxidation process the converter serves to break up residual oil particles from the air compressed by the compressor into carbon dioxide and water The treated compressed air is classified as oil free class 0 according to DIN ISO 8573 1 Converter control Compressor control a i Compressor Converter Fig 2 3 Overview BLUEKAT compressor grey section with integrated con verter As for the screw compressors of the BLUEKAT series the converter is in stalled downstream of the compressor Prior to the oil separation process the compressed produced by compressor 1 is first heated up in plate heat ex changer 2 see figure below After escaping from the plate heat exchanger the heated compressed air is fed into converter 3 which is filled with catalytic material The catalytic material is kept at operating temperature 200 C by means of an electrically powered heating At the same time the heating also heats up the incoming compressed air Due to the heat build up the oil particles in the compressed air a
51. compressed air aftercooler causing the water contained in the air to condensate Stop valve The screw compressor can be isolated from the mains using the stop valve Operating instructions for S 31 3 S 150 3 series screw compressors Page 21 Product description E Operating principle of compressor Cil circuit The oil injected into the air end has the following function Fig 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 2 2 Components of the oil circuit Compressed air oil vessel The oil separated from the compressed air through the force of gravity col lects in the compressed air oil vessel The system pressure forces it out of the vessel into the air end 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 Oil cooler air or water cooled The oil cooler cools down the hot oil to operating temperature Cil filter The oil filter traps impurities in the oil Air end The injected oil returns to the compressed air oil vessel together with the compressed air This is separated through gravity Drainage line The air end suctions the residual oil which collects in the oil separator ba
52. compressor starts and operates in load operation Once the operation pressure Page has been exceeded the control is activated and reduces the speed If the pressure has dropped below the operating pressure p the control is activated and increases the speed Upon reaching the switch off pressure Pmax the compressor switches to idling operation The settings for p and Pmax are effected by the parameterisation of the BASIC FOCUS For the BASIC control the setting for Paget is effected at the potentiometer R3 in the compressor switch cabinet For the FOCUS control the setting for p is effected via parameterisation of the control Attention 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 and to the integrated converter BLUEKAT series It is of utmost importance to consult BOGE if you operate your system with short operating times Page 26 Operating instructions for S 31 3 S 150 3 series screw compressors Product description Control devices Operating pressure transmitter Proportional controller optional accessory for S series General information 2 5 Control devices The operating pressure transmitter 1 controls the operation of the compres sor within the s
53. compressors Page 81 Maintenance EN Maintenance work during scheduled services 6 During the output phase press the OFF button on the compressor and after approx 3 seconds or after a residual pressure of 2 bar shut down the compressor with the emergency stop button Caution Risk of injury 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 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 5 litres 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 Attention 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 3 5 Commissioning Commissioning following extended s
54. ction 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 pro tective earth conductor is lost Please observe any additional national rules and regulations Caution 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 4 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Never omit a single safety step Otherwise you will risk injuries due to restart ing electric shock or self releasing parts Page 44 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Commissioning Caution If the automatic restart Auto Restart is activated the compressor may re start automatically after a voltage failure This is conditional upon The net pressure being lower than the set switch on pressure 3 5 Commissioning Note We recommend drawing up a commissioning certificate in which the test results during the commissioning process can be recorded Caution Risk of injury Co
55. d 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 Operating instructions for S 31 3 S 150 3 series screw compressors Page 7 General information E Introduction Symbols used 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 Ob serving these operating instructions will help to prevent danger reduce repair costs and downtimes and increase the reliability and service life of the com pressor 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 com missioned u
56. e kept in a legible condition at all times Missing or damaged signs must be replaced at once gt oD The following symbols and warning signs are fitted on the compressor Warning Hot surfaces Do not touch Warning Remote controlled unit Can start up without warning Notice Machine operators must read operating instructions for users Prohibited NEVER open valve before air hose is connected to compressed air system Warning of injury to hands Work on the belt drive must only be carried out when the compressor is not running and safeguards are in place to prevent it from starting up Operating instructions for S 31 3 S 150 3 series screw compressors Page 9 General information E Introduction Intended use Caution 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 but ton is exclusively intended to switch off the compressor in case of emergen Cy Operation and control are designed to be carried out by trained and author ised operators Foreseeab
57. ed cooling water quantity delta t 15 K m h 1 200 1 630 2 010 2 450 2 450 3 000 3 540 4 090 o delta t 30K m h 0 600 0 815 1 005 1 225 1 225 1 500 1 770 2 045 Max cooling water quantity m h 3 5 3 5 3 5 3 5 4 2 4 2 4 2 4 2 o 2 Cooling water inlet temperature min i 5 5 5 5 5 5 5 5 _ max C 30 30 30 30 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 45 45 45 45 Cooling water pressure min bar 2 2 2 2 2 2 2 2 max bar 10 10 10 10 10 10 10 10 Operating pressure sensor factory settings p 4 7 8bar Switch off press Pmax bar 8 8 8 8 8 8 8 8 Switch on press Prin bar 7 7 T 7 7 7 7 Pmax 10 bar Switch off press Prax bar 10 10 10 10 10 10 10 10 Switch on press p bar 9 9 9 9 9 9 9 9 Pmax 13 bar Switch off press Prax bar 13 13 13 13 13 13 13 13 Switch on press Prin bar 12 12 12 12 12 12 12 12 Safety valve Activation pressure at Pmax 8 bar bar 11 11 11 11 11 11 11 11 Pmax 7 10 bar bar 11 11 11 11 11 11 11 11 Prax 13 bar bar 14 14 14 14 14 14 14 14 Compressors for other operating pressures Prin Prax 1 bar Operating instructions for S 31 3 S 150 3 series screw compressors Page 15 Product description Technical data S 101 3 S 150 3 SD 101 3 SD 150 3 part 2 Technical data Type S 101 3 S 125 3 S 150 3 yp SD 101 3 SD 125 3 SD 150 3 Oil filling quantity
58. eding the maximum temperature will result in malfunctioning A false alarm will be triggered Commissioning 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 Operating instructions for S 31 3 S 150 3 series screw compressors Page 57 Accessory equipment E BOGE Duotherm BSW Maintenance The safety circuit including the pressure control device and the expansion vessel forms a closed maintenance free system Attention 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 58 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN Safety instructions for maintenance 6 1 Safety instructions for maintenance Caution 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 dev
59. eese nnne 51 General faU S ene eau en teres 51 Converter faults BLUEKAT series eeeeeeee 53 BOGE Duotherm BPT 0 cccceseeeeeeeeeeeeeeeeeeeeeseeeeeeeseeneeneeseeeeeeeens 55 FUMCUON zr demi i dte b c e etate o duet muse 55 Installation ioci oon Hee De re ERA E ete ee Dopo ae tt 55 Commissioning a araea Ta eA EEA eene ennemis 55 Maintenance c cccceceeceeeeeceeeeeececeeaeeaeeeceeeeeeeseesetenesensanaeeees 56 BOGE Duotherm BSW cccccececeeeeseeeeeeeeeeeeeeeeeeeeeeeseseeneeeeeeeeeees 57 ined EE 57 Gomnmnlislonlhg i rire hoc t rr Ede deed tae RR 57 Maintenance iii cr rte iieii aeiiae Le deo Ye eee Toa Pages 58 Safety instructions for maintenance eeeee 59 The BOGE maintenance concept eeeeeeesees 61 Maintenance through BOGE customer service 61 List of maintenance and service work sssseeen 62 Maintenance intervals cssssssssseseeemm 65 General information concerning the lubricants used 68 Disposal of used operating material ssssssssss 69 Pressure hoses xcii dr ra rege e da ieu hann Fe Ue eR ped 69 Spare and wearing parts sssssssssssssseeeeneneee 69 Operating instructions for S 31 3 S 150 3 series screw compressors Page V Contents Part 7 Appendix 6 3 6 4 6 5 6
60. em pressure build up unit monitors the system pressure build up when the compressor starts up Page 30 Operating instructions for S 31 3 S 150 3 series screw compressors Product description Water cooling Water cooling Serial connection Parallel connection 2 7 Water cooling 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 2 3 1 Fig 2 8 Serial connection 4 m T lt gt PN 2 3 1 Fig 2 9 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 6 mm 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 individ ually fluctuating values they are designed according to the specified order data Operating instructions for S 31 3 S 150 3 series screw compressors Page 31 Product description Cooling water
61. enced mm 1760 1760 1760 Height silenced SD mm 2255 2255 2255 Height super silenced mm 2255 2255 2255 Width silenced super silenced mm 2365 2365 2365 Depth mm 1315 1315 1315 Weight silenced kg 2047 2213 2067 2233 2132 2298 super silenced kg 2107 2273 2127 2293 2192 2358 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 silenced super silenced dB A 76 72 79 74 79 74 8 Measurement surface 7 silenced super silenced dB A 17 18 17 18 17 18 Sound power level silenced super silenced dB A 93 90 96 92 96 92 Max sound pressure level 3 dB A c accord to DIN EN ISO 2151 2009 silenced super silenced dB A 75 71 78 73 76 73 S Measurement surface l silenced super silenced dB A 17 18 17 18 17 18 Sound power level silenced super silenced dB A 92 89 95 91 93 91 Compressor Max final compression temperature C 110 110 110 Volume flow according to p 7 8 bar m min 13 90 15 75 18 44 Prax 10 bar m min 12 05 14 25 16 25 Prax 13 bar m3 min 11 10 11 80 14 25 Drive motor Rated power kW 75 90 110 Rated speed 50 Hz min 3000 3000 3000 60 Hz min 3600 3600 3600 Protection type IP 55 55 55 Design IMB 3 3 3 ISO class F F F Electrical connection Mains voltage M 400 400 400 Frequency Hz 50 50 50 Recommended fuse protection A 200 250 250 Standard equipment Mains voltages and
62. er INLET Water OUTLET Suction filter Maintenance display Vacuum switch for suction filter monitoring Suction controller Air relief and regulation control valve Pressure switch for rotational direction system relief and V belt monitoring Drive motor Compressor air end Final compression temperature display and switch Combined compressed air oil receiver Oil separator Safety valve Differential pressure switch for oil separator monitoring System pressure switch for system pressure build up and monitoring Safety pressure switch for pressure limitation Thermostatic oil control valve Oil cooler Cil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure non return valve Compressed air aftercooler Operating pressure switch Pressure gauge Stop valve compressed air outlet Pressure sensor for network pressure frequency converter Stop valve oil drainage Non return valve drainage line up to 75 kW 3 2 way solenoid valve 2 2 way solenoid valve Bypass valve Optional accessory To be provided by customer 35 36 Dirt trap Stop valve Operating instructions for S 31 3 S 150 3 series screw compressors Page 97 Flow chart BLUEKAT series air cooled version Appendix Operating instructions for S 31 3 S 150 3 series screw compressors Page 98 Appendix Flow chart 101 Intake air INLET 102 Compressed air OUT
63. es Every 3 000 operating hours once a year Change the suction filter cartridge Change the suction filter cartridge Ifit 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 Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Every 3 000 operating hours once a year Have safety valve checked 2 Take out old filter cartridge as described in Removing the filter cartridge on page 71 3 Insert new old filter cartridge as described in Fitting the filter cartridge on page 71 Caution Risk of injury Have the function of the safety valve checked by BOGE service personnel only Every 3 000 operating hours once a year Change the oil filter 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
64. et switching limits Switch on pressure Prin If the network pressure drops to the set switch on pressure Pmi the compressor switches on Switch off pressure Pax If the network pressure in creases to the switch off pressure Pmax the compres Sor either switches off inter mittent operation or switches to idling operation continu ous operation Fig 2 5 Operating pressure transmitter 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 com pressed air requirement Thus the compressor saves compression energy A compressor with proportional controller is able to supply its delivered quan tity variable between 0 and 100 However the energy consumption does not reduce accordingly Therefore a control is only practical between 5096 and 100 of the delivered quantity The proportional controller is factory set to a delivered quantity between 50 and 10096 of the compressor capacity The proportional controller closes when the desired delivered quantity has dropped below 50 of the compressor capacity The compressor then oper ates in idling operation continuous operation or switches off intermittent op eration 2 6 Safety and monitoring devices The safety devices guarantee a high degree of operational safety in connec tion with the BOGE monitoring system When one of t
65. etwork pressure Pressure gauge system pressure Stop valve compressed air outlet Pressure sensor for network pressure frequency converter Stop valve oil drainage Stop valve oil drainage oil cooler 75 250 kW Non return valve drainage line up to 75 kW 3 2 way solenoid valve Optional accessory Operating instructions for S 31 3 S 150 3 series screw compressors Page 95 Appendix Flow chart Water cooled version serial connection frequency controlled H 5 ZEN 11 31 i 28 LS 23 9 7 L be 4 bia 12 21 O 10 2 J E Y 20 24 5 AO 16 P y We Ty LN P 26 Ts ft ho om 25 104 32 36 35 gt gt lt 103 a Page 96 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Flow chart 10 102 103 104 Oo OND Oo FP WD N 99 34 1 Intake air INLET Compressed air OUTLET Wat
66. f 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 31 3 S 150 3 series screw compressors Page 37 Installation 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 recom mend contacting a specialist company for performing the duct construction work and planning Type Drive Air cooling Water cooling iu Cooling air Necessary Cooling air Necessary Cooling air Necessary requirement inletopening requirement free duct requirement inletopening for free for free for instal cross for free for free standing unit
67. for S 31 3 S 150 3 series screw compressors Appendix BOGE Duotherm BPT plate heat exchanger 101 102 103 Flow chart Compressed air OUTLET Feed line Return line Suction filter Suction controller Compressor air end Combined compressed air oil receiver Oil separator Thermostatic oil control valve Oil cooler Oil filter Minimum pressure non return valve Compressed air aftercooler Heat exchanger Operating instructions for S 31 3 S 150 3 series screw compressors Page 105 Appendix BOGE Duotherm Plus BSW safety heat exchanger Flow chart 101 102 103 10 11 16 17 18 21 22 51 52 53 Compressed air OFF Feed line Return line Suction filter Suction controller Compressor air end Combined compressed air oil receiver Oil separator Thermostatic oil control valve Oil cooler Oil filter Minimum pressure non return valve Compressed air aftercooler Safety heat exchanger Pressure monitor for leakage Compensation vessel Page 106 Operating instructions for S 31 3 S 150 3 series screw compressors 7 3 List of maintenance and service work Appendix 7 3 List of maintenance and service work abuey 49 abuey y9 399u I xx Buuee z 2 x ulelq JOVI Jojyesedas aoueu JEMO vueu Buiuee o TN ojujeul JeKup ste ojuieui jun Jojesedas Jang JOA JO anjel ainssaid ainssaid sunoy SY
68. ge 16 Operating instructions for S 31 3 S 150 3 series screw compressors Product description EN Technical data Technical Data SF 60 3 SF 150 3 SDF 60 3 SDF 150 3 part 1 Type SF 60 3 SDF 60 3 SF 100 3 SDF 100 3 SF 150 3 SDF 150 3 Dimensions Height silenced mm 1450 1730 1450 1950 1765 1765 Height silenced mm 1950 1950 1950 1950 2260 2260 Width silenced super silenced mm 1670 1670 2000 2000 2370 2370 Depth mm 990 990 1065 1065 1315 1315 Weight silenced kg 1057 1122 1388 1538 2200 2366 super silenced kg 1087 1152 1438 1588 2260 2426 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 B silenced super silenced dB A 74 72 74 72 74 72 80 73 79 74 79 74 8 Measurement surface c silenced super silenced dB A 15 16 15 16 16 17 16 17 17 18 17 18 Sound power level silenced super silenced dB A 89 88 89 88 98 90 96 90 96 92 96 92 Max sound pressure level 3 dB A c accord to DIN EN ISO 2151 2009 silenced super silenced dB A 73 71 79 72 78 73 8 Measurement surface i 2 silenced super silenced dB A 15 16 16 17 1718 Sound power level silenced super silenced dB A 88 87 95 89 95 91 Compressor Max final compression temperature C 110 110 110 110 110 110 Volume flow according to Pmax 8 bar m min 1 58 7 30 1 58 7 30 2 91 12 80 2 91 12 8
69. gether 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 3 4 5 di o We T _ T 8 7 i Fig 2 1 Components of the air circuit Intake filter The intake filter cleans the air suctioned by the air end 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 Air end The air end compresses the air which is sucked in Compressed air oil separator vessel The compressed air separates from the oil under the force of gravity in the compressed air oil vessel Oil separator The oil separator separates the residual oil contained in the compressed air Minimum pressure non return valve The minimum pressure non return valve does not open until the system pressure has increased to 3 5 bar 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 com pressed air from flowing back out of the mains line Compressed air aftercooler air cooled or water cooled The compressed air is cooled in the
70. h dirt trap only up to S DF 60 3 incl BLUEKAT 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 DF 60 3 incl BLUEKAT Solenoid valve Replacement parts for converter BLUEKAT series Note 35 Stocks of spare parts are continuously updated by BOGE If you need any replacement parts for the converter in the BLUEKAT series please contact your local BOGE field representative or your nearest BOGE contracting com pany Or contact your BOGE spare parts service Telephone 49 5206 601 120 Operating instructions for S 31 3 S 150 3 series screw compressors Page 87 Maintenance EN Spare parts and accessory equipment List of available acces sory equipment 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 Attention When ordering please specify the data on the rating plate Type Year of manufacture Machine number Page 88 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Directives and standards complied with 7 1 Directives and standards complied w
71. he OFF button Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Close ball valve at the compressed air outlet Remove cladding on the maintenance side Vent compressor fully as described at the start of this section c RON Wait approx 3 minutes to allow the oil to settle Caution 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 gt Catch the draining oil and dispose of it properly in line with environmen tal regulations Operating instructions for S 31 3 S 150 3 series screw compressors Page 77 Maintenance EN Maintenance work during scheduled services Fig 6 9 Change the oil separator 7 Lightly oil the sealing rings of the new oil separator 8 Screw in new oil separators by hand Attention 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 com
72. he additives may be incompatible It may lead to foam formation premature ageing or loss of lubricating ability Page 68 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EB The BOGE maintenance concept Disposal of used oper ating material Attention 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 oper ating 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 caf A Spare and wearing parts AA Caution 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 Caution Only use original spare parts compressor oils and operating materials re leasedby BOGE for repair and maintenance work BOGE is not li
73. he safety devices responds the control system reacts as fol lows The compressor is immediately switched off A flashing fault number in the left field of the display indicates the cause of the fault Operating instructions for S 31 3 S 150 3 series screw compressors Page 27 Product description EN Safety and monitoring devices Caution 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 Safety temperature limiting device Safety temperature limiter on the integrated converter BLUEKAT series 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 The safety temperature limiter on the integrated converter S 40 3 BLUEKAT S 60 3 BLUEKAT serves to switch off the heating when the temperature in the converter runs too high limit value 250 C In such a case the compressor s release for compressed air production is
74. ic 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 General information 3 3 Installation BOGE compressor units are supplied ready for connection Only the work de scribed in the following paragraphs needs to be carried out during the installa tion Caution Any installation work must only be carried out by appropriately trained per sons 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 safe guard claims against the haulier we recommend leaving the machine de vices 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 B
75. ices Refit the safety covers or safety de vices immediately after completion of the maintenance work Heavy components may only be lifted up by various persons in due con sideration of the local industrial safety regulations Only use original spare parts compressor oils and operating materials released by BOGE for the 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 31 3 S 150 3 series screw compressors Page 59 Maintenance EN Safety instructions for maintenance Caution 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 respon sible 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 50 C 7 Al
76. ies Check After approx 3 000 operating hours but at least once a year 1 Setting the operating pressure sensor Switch on pressure p Final compression pressure 1 bar Switch off pressure p Final compression pressure 2 Setting the proportional controller Displace the control range of the propor tional controller by turning cap 1 ncrease pressure level Turn cap clockwise Reduce pressure level Turn cap anti clockwise Fig 6 15 Setting the proportional controller Note Always set the proportional controller higher than the lowest operating pres sure value p 3 Pressure switch for infinitely variable capacity control The low pressure switch for the infinitely variable capacity control limits the re duction of the quantity delivered and switches the compressor to idling mode or off completely if the quantity delivered falls below 50 Page 86 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN 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 wit
77. ils 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 Ap lt 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 Attention Make sure that external vibrations or shock are not able to impact on the compressor station particularly where compressors of the BLUEKAT series with integrated converter are concerned Operating instructions for S 31 3 S 150 3 series screw compressors Page 35 Installation Compressor room Fire protection The following applies to rooms in which compressors with oil injection cooling are to be installed Caution For compressors with motor ratings exceeding 40 kW and for com pressors of the BLUEKAT series ensure that the compressor room is equipped with special fire protection Install compressors with motor ratings exceeding 100 kW 100 kW in a separate fire protected room Sound protection Admissible ambient temperatures Requirements of fire protected compressor rooms Walls ceilings floor and doors mus
78. ing hours or once a year Have electric cable connection inspected for tight fit and have connection checked Have parameter settings on control checked Visual check of converter for damage or corrosion Full functional check Replacement of inserts in module for variable volume flow and particle filter after inspection and according to manufacturer s specifications if available After 20 000 operating hours after 3 years at the latest Air quality check After 5 years Replacement of electrical components electrical kit Converter replacement 1 If the compressor is not used very often the maintenance must be carried out at the intervals specified weekly monthly once a year every 3 years irrespective of the number of operating hours Table 6 3 Maintenance work on the converter Note 35 In the event that the converter needs to be replaced the old converter can be returned to BOGE for disposal or recycling If this is not possible we recommend that the old converter is handed over to a waste disposal contractor in its complete undismantled state for dis posal or recycling purposes Please contact BOGE s service department if you have any queries regard ing disposal Telephone 49 5206 601 140 Operating instructions for S 31 3 S 150 3 series screw compressors Page 67 Maintenance General information concerning the lubri cants used
79. ions to the compressor 14 Never start the compressor if one or more parts e g cable plug are dam aged 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 and the BLUEKAT converter are pressure equipment and require testing in accordance with national standards 17 To avoid damage special precautions must be taken during re commis sioning of compressors with a frequency control if the frequency converter has been disconnected from the power supply for a lengthy period of time gt 12 months In this case please contact the BOGE s service department 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 Caution 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 com pressor must ALWAYS be operated with its housing closed Wear addi tional he
80. ith The compressor conforms to the following guidelines and standards Guidelines Machinery Directive 2006 42 EC Pressure Equipment Directive 97 23 EC EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Simple Pressure Vessels Directive 2009 105 EC Applied harmonized standards DIN EN 1012 1 2011 DIN EN ISO 12100 2011 DIN EN 60204 1 VDE 0113 1 2007 DIN EN 61000 6 2 VDE 0839 6 2 2006 DIN EN 61000 6 4 VDE 0839 6 4 2007 7 2 Flow chart On the following pages you will find the individual flow charts for the different machine types and components Operating instructions for S 31 3 S 150 3 series screw compressors Page 89 Appendix Flow chart Air cooled version standard Page 90 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Flow chart 101 102 Oo On oO FB WO DY N 99 37 42 43 44 Intake air INLET Compressed air OUTLET Suction filter Maintenance display from 30 kW Vacuum switch for suction filter monitoring Suction controller Ventilation and regulation control valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil receiver Oil separator Safety valve Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressu
81. iver Oil separator Safety valve Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure non return valve Compressed air aftercooler Pressure sensor system pressure Pressure sensor network pressure Stop valve compressed air outlet Stop valve oil drainage Non return valve drainage line up to 75 kW Proportional controller Differential pressure switch for proportional controller 3 2 way solenoid valve for suction control regulation for standard control throughput here 2 2 way solenoid valve Control valve water supply preadjusted Control valve water supply preadjusted Free air delivery display for proportional controller 3 2 way solenoid valve for suction control regulation Double non return valve items 42 43 rapid start valve Double non return valve monitoring of rotational direction Optional accessory To be provided by customer 35 36 Dirt trap Stop valve Operating instructions for S 31 3 S 150 3 series screw compressors Page 93 Appendix Flow chart Air cooled version frequency controlled
82. k 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 Attention required oil change intervals If you use a different oil instead of Syprem S itis essential that you contact the BOGE service department to determine the Maintenance work BOGE service personnel Page Every 3 000 operating hours or once a year Check compressor for leaks Change the suction controller after it has been cleaned twice every 3 000 operating hours 65 Check the minimum pressure valve and repair if necessary with the repair kit Have the safety valve checked by BOGE service personnel only 65 Check the oil regulator and repair if necessary with the repair kit B Change nozzle with dirt trap only up to S DF 60 3 incl BLUEKAT Change oil filter 65 Change oil separator 65 Check V belt 65 Every 9 000 operating hours or every 2 years Check change V belt 65 Check the suction controller and if necessary replace or repair with the repair kit Check solenoid valve and replace if necessary Change oil 81 Special maintenance intervals see also page 65 onwards Flush out oil circuit Maintenance interval If oil strongly contaminated Before changing the type of oi
83. l Lubricate drive motor bearings lubrication replacement for motors with no automatic lubrication device For details of the lubrication replacement inter vals for motors with no automatic 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 1 number of 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 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 66 Operating instructions for S 31 3 150 3 series screw compressors Maintenance EN The BOGE maintenance concept Converter maintenance intervals S 40 3 S 60 3 BLUEKAT Caution Maintenance and repair work on integrated converter of the S 40 3 BLUE KAT S 60 3 BLUEKAT series must be carried out by specially trained BOGE service personnel only Failure to observe this may cause physical injury and damage to the com pressor station Maintenance work Every 3 000 operat
84. l change Lubricate motor bearings S 40 3 BLUEKAT S 60 3 BLUEKAT Converter Caution Maintenance and repair work on integrated converter ofthe S 40 3 BLUEKAT S 60 3 BLUEKAT series may be carried out by spe cially trained BOGE service personnel only Failure to observe this may cause physical injury and damage to the com pressor station Page 64 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN The BOGE maintenance concept Maintenance intervals 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 car ried out by BOGE service personnel The intervals between this maintenance work are shorter weekly monthly every 1 500 operating hours The intervals between the maintenance and repair work specified in the sec ond 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 The maintenance work in the third table applies only to the converter in the BLUEKAT series S 40 3 BLUEKAT S 60 3 BLUEKAT and will also be car ried out by BOGE se
85. l system be aware of the constant danger of contact with live parts To prevent danger the mains connection must be equipped with an auto matic circuit breaker The automatic circuit breaker must comply with the requirements of DIN EN 60204 1 2007 Page 4 Operating instructions for S 31 3 S 150 3 series screw compressors General information EB General safety instructions A ON co NOD Ci 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 Switch off the compressor using the OFF button Press the emergency stop button Disconnect the compressor from all electric power sources using the circuit breaker Take preventive action to prevent the current from being inadvertently switched back on Check to ensure that all current carrying parts are zero potential Earth and short circuit Cover or shield adjacent current carrying parts 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 Disconnect the compressor from the compressed air network relieve or block pressure lines 10 Allow converter to cool off for several hours applies to screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT only
86. le misuse Caution 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 flam mable vapours and gases may occur The emergency stop device of the compressor emergency stop switch but ton 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 Page 10 Operating instructions for S 31 3 S 150 3 series screw compressors General information E Introduction Intended use of the inte In accordance with its intended purpose the BLUEKAT converter is exclusively grated conve
87. low converter to cool off for several hours only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT 8 Separate the compressor from the compressed air network by closing the ball valve at the compressed air outlet 9 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 bar Once the residual air has completely escaped from the system firmly retighten the knurled nut 10 Remove all safety cladding necessary to perform the maintenance work Once the maintenance work has been concluded 11 Reattach all removed safety cladding 12 Open the ball valve at the compressed air outlet 13 Prior to switching on again check whether anyone else is working on the compressor 14 Remove warning sign not until then and release mains disconnecting device 15 Unlock Emergency Stop button Page 60 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN The BOGE maintenance concept 6 2 The BOGE maintenance concept Through the compressor control your compressor has an integrated monitor ing system which sends you a maintenance message in good time to inform you about any important maintenance work that
88. lve must therefore be installed to prevent the plate heat exchanger from becoming damaged Dirt trap pore size max 0 6 mm 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 Commissioning Free standing installation The plate heat exchanger may also be installed as a free standing unit or ret rofitted 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 pro vide a bracket 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 Operating instructions for S 31 3 S 150 3 series screw compressors Page 55 Accessory equipment ES BOGE Duotherm BPT Maintenance 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 o
89. mmissioning certificate For S 40 3 BLUEKAT S 60 3 BLUEKAT 1 Re enable the mains disconnecting device 2 Use the ON button on the compressor control to switch on the compressor gt The integrated converter starts preheating The yellow indicator lamp Preheating Aufheizen on the switch cabinet of the converter lights up The compressor remains in the operational availability standby mode gt After approx 15 to 45 minutes depending on the residual heat inside the converter and the ambient temperature the converter reaches its operating temperature release temperature The yellow indicator lamp extinguishes and the green indicator lamp Operation Betrieb lights up As soon as the switch on pressure is achieved the control system allows the compressor to switch to load operation The compressor will now start to produce compressed air while the con verter is ready for treating the compressed air 3 Switch off the compressor after several hours of trial operation under max imum working load Operating instructions for S 31 3 S 150 3 series screw compressors Page 47 Installation Commissioning Record the test results in the commissioning certificate Attention Risk of damage to integrated converter by switching the equipment on and off Do not switch off BLUEKAT converter but always leave it in standby mode even with the compressor switched off to maintain the operating tempera ture of
90. mmissioning must only be carried out by authorised and qualified person nel 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 Attention 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 the belt ten sioning 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 Attention Always check the rotational direction of the drive and fan motor prior to com missioning Even brief operation in the wrong direction of rotation more than approx 5 seconds may cause the total destruction of the air end Record the test results in the commissioning certificate Operating instructions for S 31 3 S 150 3 series screw compressors Page 45 Installation Commissioning Caution 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
91. nd di rectionson the permissible environmental influences see section entitled 3 2 Compressor room Installation conditions for horizontal or free standing compressed air receivers 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 enti tled 3 5 Commissioning Page 34 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Installation conditions for horizontal or free standing compressed air receivers Compressor room 3 2 Compressor room Caution 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 deta
92. neral safety instructions eeeceeeeeeeeeeeeeeeeeseeneeeeeeeeeees 1 General information Safety instructions for compressor operation sss 1 Special hazard warnings sssess ee 2 Dangers of electricity etori a nennen ener 3 Obligations of the operator sssssmm 3 Personnel requirements sssssssssseseenenennens 4 Personal protective equipment sssssssssssse 4 Safety instructions for maintenance and repair of the compressor 4 Safety instructions for maintenance and repair of integrated converter BLUEKAT series ssssss tnaeeeeereae 6 Safety instructions for maintenance and repair of the dryer SDISDEJa ttti miei mim On ie 6 Accident prevention regulations seen 7 1 2 Introduction eee couceesegtvecdereeeedeuenctesttc2iereesecpusactesss 8 Symbols used peer ciat 8 Symbols on the compressor ssssssee 9 Intended USC is sic ceret eame c e exdep o ede arredo ddr 10 Foreseeable misuse 2 cceeeeedeceeeteeeeneeeseedeceneeseneteneeesentenenerees 10 Intended use of the integrated converter BLUEKAT series 11 Transport damage senssa taria e een nennen nenne 11 Data on the rating plate sssssss 12 SENICE im mE Ht e ee 12 Part 2 2 1 Technical data eese trennen nre nti nente inni tr inne 13 Product description 2 2 Operating
93. ng optional accessory 30 System pressure build up optional accessory 30 Water cooling mem 31 Water Cooling eorne raaa etii ee oet Dea A AA 31 Serial connection esses enne 31 Parallel connection nsi e a a aaee 31 Cooling Water n crore eene 32 Water connection for water cooling eeeeeeees 32 Cooling water quality sseeen enn 32 Transport and storage esee enne 33 General information ssssssssssssssssemee 33 How to transport the compressor sssssseeeeeeeeees 33 Intermediate storage sssssseee eme 34 Compressor room 5 iet ede endete ee ree munie tace 35 Installation conditions for horizontal or free standing compressed air tecelVers oi eie tre eee o Pet dent d tM Ded er tse 35 Installation surface ssssssssssseeeeeee nsere e ne 35 Fire protectio onai ai dec or teet lette aite vada opinor Pedal 36 Sound protection 36 Admissible ambient temperatures ssssssseseseeeses 36 Frost protection uoce o idm ete ar x redd 37 MEDIE 37 Cooling air requirement ssssssee eme 38 Ventilation possibilities sesessem 39 Condensate disposal eut leet ise tt lade e cree texte daa 40 Installation retten entre enter rR rna eR rn mua Ern Raus 40 General information
94. ng equipment 85 Have proportional regulation checked Optional accessory for SD SOMOS 86 Spare parts and accessory equipment uus 87 List of spare and wear parts for maintenance 87 Replacement parts for converter BLUEKAT series 87 List of available accessory equipment ssssssssssss 88 Directives and standards complied with 89 Elow chatt ete no reisis 89 Air cooled version standard ccccccccesesceeeeeecessseeeeeceaeeeeeeneanes 90 Water cooled version serial connection parallel connection 92 Air cooled version frequency controlled seesessssss 94 Water cooled version serial connection frequency controlled 96 BLUEKAT series air cooled version esseeeeeeeee 98 BLUEKAT series water cooled version parallel connection 100 BLUEKAT series water cooled version serial connection 102 SD SDP itive oe dairies Se is ee wa TOE AA AAN 104 BOGE Duotherm BPT plate heat exchanger ssss 105 BOGE Duotherm Plus BSW safety heat exchanger 106 List of maintenance and service work 107 Page VI Operating instructions for S 31 3 S 150 3 series screw compressors
95. nnection device to iso late the compressor from the power supply and fix a padlock to prevent the power from being switched on again unintentionally Caution 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 Drawthe filter mat 1 upwards out of its holder 3 Insert a new mat in the holder Fig 6 4 Changing the supply air filter mats Page 70 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance Maintenance work between scheduled services Monthly Clean the suction filter Clean the suction controller to remove dirt 1x monthly but at least every 500 operating hours Ifthe 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 Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT 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 outthe filter ca
96. ns and cause the compressor to switch off Please consult BOGE Page 32 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Transport and storage 3 1 Transport and storage General information Please observe the generally accepted safety and accident prevention regu lations when transporting the compressor BOGE accepts no liability for dam age caused by improper transport Attention The transport of the compressor must only be carried out by adequately in structed 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 Technical data on page 13 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 in tended 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 Using forklift truck or lifting cart compressor Attention Improper tran
97. ntil 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 In these operating instructions attention is drawn to important safety advice and tips with the following symbols Caution Risk of injury This symbol warns of danger to life and limb of the machine operator or other persons Attention 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 Page 8 Operating instructions for S 31 3 S 150 3 series screw compressors General information E Introduction Ry Note This symbol indicates information and tips on saving energy and prolonging the life of the compressor through careful use Symbols on the com pressor Ry Note All warning signs on the compressor and in its surroundings must b
98. of rotation Caution 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 Allow the converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Check compressed air outlet for leak tightness Interchange two phases L1 L2 or L3 in the power cable Caution 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 com pressed air outlet for tightness 3 Switch the compressor off Caution 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 Allow the converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT f necessary have any leakages remedied by experienced expert person nel Record the test results in the commissioning ce
99. oil filter Change oil separator Check change V belt After extended stoppages Fill the suction controller with oil Oil change Lubricate motor bearings Page 62 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN The BOGE maintenance concept Refrigerant compressed air dryer at SD 40 3 SD 150 3 Fig 6 2 SD 40 3 SD 150 3 1 Refrigerant compressed air dryer Caution Maintenance work and repairs to the refrigerant compressed air dryer SD SDF may be carried out only by BOGE service personnel with the relevant specialist training Failure to comply with this requirement can result in physical injury and in damage to the compressor system Operating instructions for S 31 3 S 150 3 series screw compressors Page 63 Maintenance e The BOGE maintenance concept S 40 3 BLUEKAT S 60 3 BLUEKAT compressor 6 3 Maintenance work for S 40 3 BLUEKAT S 60 3 BLUEKAT Check pressure final compressor temperature system relief emer gency stop button 2 Check change supply air filter optional accessory 3 Check suction filter o o Oo Ci 10 11 Clean filter and cartridge Change filter cartridge Check oil level Top up oil Clean compressed air oil cooler externally Change oil filter Change oil separator Check change V belt After extended stoppages Fill the suction controller with oil Oi
100. oiled Prior to changing the oil type Attention Detailed information on flushing with BOGE oils can be obtained from the fol lowing service number Telephone 49 5206 601 140 Drive motors with per manent lubrication The bearings of the drive motors are generally provided with a maintenance free permanent lubrication Under normal operating conditions refrigerant temperature max 40 C con tinuous operation the bearings are maintenance free for the entire service life The service life decreases or increases as thermal stress increases or de creases due to increased or reduced refrigerant temperature Attention Have BOGE service dismantle the bearings and install new bearings once the specified service life has expired Drive motors with lubri cation device Motors with lubricating devices are easily recognised by the two grease nip ples on the top of the cover Additionally stickers on the compressor refer to the lubricating device see illustration below Fig 6 14 Grease nipples of the lubricating device Page 84 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EB 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 pre scribed intervals so as not to sustain damage due to lack of lubricant On motors with lubri
101. ove 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 Turnlocknut 4 clockwise 6 Raise the motor in the direction shown by the arrow 5 until the V belts are fully slackened c Fig 6 10 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 Attention 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 gt The V belts are automatically correctly tensioned by the BOGE GM drive system Operating instructions for S 31 3 S 150 3 series screw compressors Page 79 Maintenance Maintenance work during scheduled services 11 Fit belt protection 12 Put the cover back on on the maintenance side Settings of the GM drive systems with standard motors blue As to the setting value for the corresponding motor we refer to the table below sealed Type Pressure Setting Setting bar mm 50 Hz mm 60 Hz S 31 3 8 10 13 108 107 106 S 40 3 SD 40 3 8 10 13 106 107 1
102. pressed 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 Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT 13 Check the oil separator for leaks once again and tighten by hand if neces sary procedure as described above Every 3 000 operating Check the V belt hours once a year After 3 000 operating hours but at least once a year to look for signs of Check V belt damage Page 78 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN Maintenance work during scheduled services Every 9 000 operating Change the V belt hours Change V belt f damage is visible After 9 000 operating hours Change the V belt 1 Switch off the compressor with the OFF button Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT 2 Rem
103. principle of compressor eeueesse 20 Functional principle of the air end 20 PAN igrer eiu P P PR EIE 21 OIL CIEGUI 2 Ae coo ete dia se 22 2 3 BLUEKAT operation principle seeeeeeeeeeeeee 23 2 4 Compressor control 5 5 rere ette nene Ste ERE RUE 24 Network DressUure 5 Eee dent ien oaaao eaaa 24 Operating states eiiie a A a a adea iR 24 Operating modes aeieeiaii iae dd ca ie ee died 25 Compressed air production control BLUEKAT series 25 Controlled operation frequency control sssesssss 26 Short operating UMES oier een EEEE netten ennt 26 Operating instructions for S 31 3 S 150 3 series screw compressors Page Ill Contents Part 3 Installation 2 5 2 6 2 7 2 8 3 1 3 2 3 3 Gontrol devices eene 27 Operating pressure transmitter sssssssssssseeee 27 Proportional controller optional accessory for S series 27 Safety and monitoring devices eene 27 General information ssssssssssssssssssse 27 Safety temperature limiting device nessen 28 Safety temperature limiter on the integrated converter BLWEKAT series erae te e eder e ide ee etes 28 Safety valves cete LU ERU HU EP dx 30 Monitoring the drive and fan motor sssseeee 30 Rotational direction monitori
104. r faults BLUEKAT series Fault Possible cause Rectification Converter fault com pressor does not start af Incorrect converter temperature settings Settings of converter temperature controller to be checked by BOGE service personnel and to be reparameterised if necessary No temperature build up inside converter Have converter heater checked by BOGE service personnel and repaired replaced if necessary Converter faulty Have converter checked by BOGE service personnel and replaced if necessary Converter fault com pressor unexpectedly discontinues com pressed air production and fails to restart auto matically af Temperature inside converter too high excess temperature Have converter converter temperature controller heater checked by BOGE service personnel and repaired replaced if necessary Temperature drop inside con verter and prolonged under temperature Have converter heater checked by BOGE service personnel and repaired replaced if necessary Converter fault exces sively long time until compressed air produc tion is enabled af Temperature build up inside converter insufficient Have converter heater checked by BOGE service personnel and repaired replaced if necessary Operating instructions for S 31 3 S 150 3 series screw compressors Page 53 Accessory equipment ES BOGE Duotherm BPT Function Installa
105. r for final compression tem ds control regulation perature 10 Combined compressed air oil P DOBIE DOR TON VG P 42 items 42 43 rapid start valve receiver 44 Double non return valve 11 Oil separator n fos ihn ty monitoring of rotational direction id yeNe 50 Filter 6 rermpstalle oil control valve 51 Safety valve ROSA 52 Heat exchanger oi Mier 53 Converter 19 Direremial e SW 54 Heating cartridge with thermocouple for oil filter monitoring 20 Oil throttle 55 Thermocouple T 56 Thermocouple 21 Minimum pressure non return valve 57 Thermocouple 22 Compressed air aftercooler 58 Pressure retaining shut off valve 23 Pressure sensor for system pressure DHSV 24 Network pressure compressor 59 DHSV solenoid valve 25 Stop valve compressed air outlet A aoa 60 Pressure gauge F Stop valve ol Granade 61 Relief ball valve 28 Non return valve drainage line 62 Condensate discharge valves up to 75 kW automatic 29 Proportional controller 30 Differential pressure switch for pro portional controller Optional accessory Operating instructions for S 31 3 S 150 3 series screw compressors Page 103 Appendix Flow chart SD SDF 101 on rk N 25 101 Compressed air OUTLET Screw compressor see also flow diagram Cyclone separator Refrigerant compressed air dryer Bypass Drain Condensate Non return valve compressed air exhaust Page 104 Operating instructions
106. r oil deposits Paraffin Oxide or limescale deposits formic acid acetic acid or citric acid Attention 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 After cleaning rinse the plate heat exchanger thoroughly with water e g using a pressure washer Note If the cleaning measures specified above are not sufficient you should have the exchanger cleaned
107. r to the system The compressor operates in load operation Upon reaching the switch off pressure Pmax the compressor switches to idling operation Once the pressure has dropped to the switch on pressure p the compressor switches from idling operation back to load operation Attention Risk of damage to integrated converter by switching the equipment on and off Do not switch off BLUEKAT converter but always leave it in standby mode even with the compressor switched off to maintain the operating tempera ture of the converter The BLUEKAT converter must only be disconnected from the power supply for the purpose of maintenance and or repair As for compressors of the BLUEKAT series S 40 3 BLUEKAT S 60 3 BLUE KAT the compressed air production depends on the operating state of the integrated converter After connection of the compressor to the power supply the integrated con verter will start the preheating phase in order to reach its operating tempera ture approx 200 C As long as the converter has not reached its operating temperature the control system of the compressor will block compressed air production since the oil separation process in the converter is unable to start as yet meaning that no oil free compressed air would be available The compressor is in the opera tional availability standby mode see Operating states page 24 Operating instructions for S 31 3 S 150 3 series
108. re able to react with the catalytic material When impacting on the catalyst surface the oil particles hydrocarbons are completely burnt oxidized The heated oil free compressed air is fed back to plate heat exchanger 2 af ter the treatment process While being in the plate heat exchanger it releases part of its heat energy to the compressed air still to be treated flowing from the compressor into the plate heat exchanger which is now able to heat up pri or to the oxidation process while the already treated compressed air cools off at the same time In order to further cool off it is then fed into an aftercooler 4 The compressed air escapes at a temperature of 30 35 C and can be fed into a compressed air receiver for further use The condensate which is built up in the compressed air receiver conforms to industrial water quality and may be discharged accordingly Operating instructions for S 31 3 S 150 3 series screw compressors Page 23 Product description EN Compressor control Network pressure Operating states 4 Compressed air outlet Fig 2 4 BLUEKAT functional diagram including compressed air flow direction 2 4 Compressor control 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 basi
109. re non return valve Compressed air aftercooler Pressure sensor for system pressure Pressure sensor for network pressure Stop valve compressed air outlet Stop valve oil drainage Non return valve drainage line up to 75 kW Proportional controller Differential pressure switch for proportional controller 3 2 way solenoid valve for proportional controller for standard control throughput here Free air delivery display for proportional controller 3 2 way solenoid valve for suction controller regulation Double non return valve items 42 43 rapid start valve Double non return valve monitoring of rotational direction Optional accessory Operating instructions for S 31 3 S 150 3 series screw compressors Page 91 Appendix Flow chart Water cooled version serial connection parallel connection Parallel connection Series connected circuit Page 92 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Flow chart 10 102 103 104 Oo ON oO FP WD N wo 32 33 34 37 42 43 44 Intake air INLET Compressed air OUTLET Water INLET Water OUTLET Suction filter Maintenance display from 30 kW Vacuum switch for suction filter monitoring Suction controller Ventilation and regulation control valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil rece
110. rea of the compressor must always be kept tidy and clean 7 Always squat when working on components mounted at low height never stoop When working on components mounted higher up always stand up right and erect 8 Do not exceed the limit value for the end of compression pressure specified on the type plate 9 Do not 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 in structions when dismantling the safety covers or safety devices for repair or maintenance work Reattach and close all covers and safety devices im mediately 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 31 3 S 150 3 series screw compressors Page 1 General information EN General safety instructions Special hazard warnings 13 Undertake conversions and modifications to the compressor only with the prior approval of BOGE and in compliance with all relevant safety regula tions The manufacturer is not liable for damages resulting from unauthor ised modificat
111. rter designed for the treatment of compressed air in screw compressors by which BLUEKAT series the hydrocarbons contained in the air are catalytically oxidized The catalytic converter operating temperature in the catalyst bed should be approx 200 C 5 in the continuous flow mode In order to avoid prolonged preheating phases and delays in compressed air production the compressor station should not be unplugged too often Only hydrocarbon based oils synthetic or mineral may be used as compres sor lubricants All lifetime specifications are based on a maximum additive con tent of 596 Silicon based oils must not be used Note 35 Any modifications not authorized by BOGE to the control and the switch cab inet layout of the converter will invalidate all warranty claims against BOGE Note 35 Opening and replacement of the converter by any personnel not authorised or trained by BOGE will result in immediately invalidate all warranty claims against BOGE Transport damage 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
112. rtificate Page 46 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Commissioning Opening the stop valves Checking for leaks Open ball valve at the compressor output For water cooling Open the stop valve at the water inlet Caution Risk of injury In case of leakages in the cooling water and or oil circuit there is a risk of slip ping 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 Conduct trial run 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 1 Re enable the mains disconnecting device 2 Use ON button on compressor control to switch on compressor gt Compressor starts operating gt 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 The compressor is ready for operation For control function see control display 5 Switch off compressor after several hours oftrial operation under maximum working load Record the test results in the co
113. rtridge 3 Fig 6 5 Taking the suction filter out Cleaning the filter cartridge Attention 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 5 bar 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 Operating instructions for S 31 3 S 150 3 series screw compressors Page 71 Maintenance 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 Ifthe oil level has sunk below the min mark see diagram in Fig 6 6 Attention 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 OF
114. rvice personnel Note 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 Maintenance work Page Weekly Check compressor for leaks visual inspection Check final compression temperature target value 70 100 C Control Check system relief on system pressure display target value 0 1 5 bar Control Check and if necessary change supply air filter optional accessory 65 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 65 Check oil level and top up as required 65 Every 1 500 operating hours Clean oil cooler 65 Check that the electrical connections are fully tightened Table 6 1 Maintenance work between service intervals Operating instructions for S 31 3 S 150 3 series screw compressors Page 65 Maintenance e 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 wor
115. rying out mainte nance or repair work Cover the components and any exposed openings with a clean cloth paper or adhesive strips to keep out dirt 8 Never attempt to weld a pressure vessel or change it in any way 9 Make sure that no tools loose parts or suchlike are left in the unit Page 6 Operating instructions for S 31 3 S 150 3 series screw compressors General information EB General safety instructions Accident prevention regulations Handling refrigerants 1 Wear safety glasses and protective gloves 2 Do not allow liquid refrigerants to come into contact with the skin as this causes frostbite 3 Do not breathe in any refrigerant vapours 4 Ventilate the workroom well to prevent the build up of higher concentra tions Simply opening windows and doors may not be sufficient The air must be extracted directly from the interface if possible or at floor level 5 Do not smoke Refrigerants can decompose when exposed to the glow of a cigarette The resulting substances are toxic and should never be inhaled 6 Do not allow refrigerants to escape during repair or filling procedures 7 f concentrations of refrigerants should appear suddenly due to a burst pipe for example leave the room immediately and do not re enter until the room has been adequately ventilated 8 Welding and soldering work to refrigerating systems may be carried out only in well ventilated rooms Refrigerants decompose
116. screw compressors Page 25 Product description EN Compressor control As soon as the integrated converter has reached its operating temperature approx 200 C it switches from the preheating phase into the operation mode while automatically transmitting this information onto the control system of the compressor As soon as the switch on pressure is achieved the control system allows the compressor to switch to load operation see Operating states page 24 The compressor will now start to produce compressed air while the converter is ready for treatment of the compressed air If the integrated converter exceeds its operating temperature overtempera ture the heating of the converter switches off automatically This information is transmitted to the compressor control system which blocks the compres sor s release for compressed air production and puts it back into the opera tional availability standby mode Ry Note Automatic switching of the compressor availability state when reaching thes witch off pressure is effected irrespectively of the operating state of the con verter as with compressors without integrated converter The compressor either switches into the operational availability standby mode or back into the idle mode and stops producing compressed air Controlled operation frequency control Short operating times If the pressure has dropped below the switch on pressure p the
117. sportation 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 illustra tion Fig 3 1 Transport with forklift truck Operating instructions for S 31 3 S 150 3 series screw compressors Page 33 Installation Transport and storage Crane transport Attention 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 8 metres Intermediate storage Place the loops of the lifting strap under neath the compressor transport pallet pro vided from one head end to the other The loops of the lifting straps must not be attached to the suction filter Furthermore they must not be attached to the lug on the motor 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 Ry Note In the case of intermediate storage please observe the specifications a
118. t 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 3 me tres around the compressor Noinflammable 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 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 40 C Minimum ambient temperature 5 C Attention Failure to observe the admissible ambient temperature may lead to the fol lowing 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 tempera tures 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 suppl
119. t 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 cir cuit 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 SDF 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 according to DIN EN 60204 1 2007 Rated voltage The data of your mains supply operating voltage control voltage type of cur rent 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 Operating instructions for S 31 3
120. the cooling water optional acces sory Caution 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 qual ity 3 Connect the cooling water supply and discharge line to the water supply cf dimensioned drawing Operating instructions for S 31 3 S 150 3 series screw compressors Page 41 Installation Installation The following additional components must be provided by the customer when installing the water cooling unit Dirttrap The dirt trap at the cooling water inlet protects the cooling units against sed iment collecting Pore width max 0 6 mm Expansion vessel and safety valve Attention 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 pre
121. tion The actual value top and the target value below of the temperature in C inside the converter are shown in the display as standard Pressing the green button once causes the container bed temperature in C to be displayed Pressing the green button twice causes the current control mode to be dis played Pressing the green button three times causes the heating performance in 96 to be displayed Pressing the green button four times causes the state of the self optimi sation to be displayed Pressing the green button five times causes the idle target value in C to be displayed Pressing the green button again enables you to return to the standard dis play Pressing the reset button enables you to immediately return to the stand ard display Caution The settings of the temperature control are completely programmed at the factory Any changes to the presettings for the temperature and other parameters may only be carried out by BOGE or after consultation with BOGE by BOGE authorized service personnel Any unauthorized changes to the parameters may cause damage to the compressor station or result in reduction of the compressed air quality Operating instructions for S 31 3 S 150 3 series screw compressors Page 29 Product description Safety and monitoring devices Safety valve Lighting of the indicator lamps serves to indicate Indic
122. tion 5 1 BOGE Duotherm BPT The heat recovery system BOGE Duotherm BPT utilizes the heat energy re leased during compression to produce hot water free of charge e g for pro duction systems or to supply a heater The plate heat exchanger is connected in the main stream of the hot oil It con sists 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 transmit ted to the heat exchanger Provide venting and draining facilities The customer must provide the following components for installation Stop valves Stop valves in the water supply and discharge lines enable the heat ex changer to be removed easily Expansion vessel and safety valve Attention If the stop valves in the water supply and discharge lines are closed simul taneously an enclosed space is created If the water in this space is heated it expands and the pressure increases An expansion vessel and safety va
123. toppages Attention 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 Caution Risk of injury 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 Allow converter to cool off only screw compressors S 40 3 BLUEKAT S 60 3 BLUEKAT Page 82 Operating instructions for S 31 3 S 150 3 series screw compressors Maintenance EN Maintenance work during scheduled services 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 Yin NWT D Fig 6 13 Drain off residual oil from compressed air oil cooler Operating instructions for S 31 3 S 150 3 series screw compressors Page 83 Maintenance EB Special maintenance work Flush out oil circuit 6 5 Special maintenance work Flushing the oil circuit with clean oil becomes necessary When the oil is excessively s
124. ul Aue pJ0284 SL jd Page 109 Operating instructions for S 31 3 S 150 3 series screw compressors 7 3 List of maintenance and service work Appendix abuey 49 abuey 49 3994 I xx Buea 2 x uleq 49 J4 Jojesedas aoueu JejeMIIO aQueu Buiuee o ee 7 ajujeul JeKup Jie ejuieui jun Jojesedas Jang JOR Joy ainjel ainssaid eunsseid sunoy syew y JOLIOAUOD duio JOJO Duijoo IIO IIO llO yeju eduio uejs g XiowjeN Burgejedo ajeq uuuinjoo ejeudoudde y ui pajajduiod aney noA yiom o2ueuojuieul Aue pJ0294 aSedjd Operating instructions for S 31 3 S 150 3 series screw compressors Page 110
125. ve Gauge Relief ball valve Condensate discharge valves automatic Optional accessory Operating instructions for S 31 3 S 150 3 series screw compressors Page 99 Appendix Flow chart BLUEKAT series water cooled version parallel connection Page 100 Operating instructions for S 31 3 S 150 3 series screw compressors Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET 1 Suction filter 32 2 2 way solenoid valve 2 Maintenance display from 30 kW 33 Regulating valve water supply 3 Vacuum switch preset for suction filter monitoring 34 Regulating valve water supply 4 Suction controller preset 5 Air relief and regulation control valve 35 Dirttrap 7 Drive motor 36 Stop valve 8 Compressor air end 37 Free air delivery display for propor tional controller 9 Sensor for final compression tem perature 42 3 2 way solenoid c for suction 10 Combined compressed air oil contol regulation receiver 43 Double non return valve 11 Oil separator items 42 43 rapid start valve 44 Double non return valve 12 Safety valve Me Qum uteg Monitoring of rotational direction 16 Thermostatic oil control valve i 50 Filter al euch 51 Safety valve rod 52 Heat exchanger 19 Differential pressure switch CRAS 53 Converter for oil filter monitoring l 20 Oil throttle 54 Heating cartridge with thermocouple m 55 Thermocouple 21 Minimum pressure non
126. vent damage to the cooling units Removing the transport securing bolts Activating the belt ten sioning 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 c RC la Py m q 1 Hold the bolt head 1 with a spanner to prevent t it from turning ic 274 mc do H 2 Turn the counternut 2 Pre M p i upwards in an anticlock mm E wise direction until it is i against the bolt head 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 Page 42 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Electrical connection Checking the oil level BOGE compressors are supplied with a full oil filling Prior to commissioning check the oil level as described in the section entitled Maintenance 3 4 Electrical connection Danger High voltage Ensure that work on the electrical equipment of the compressor is only car ried out by authorised electricians Observe curren
127. y 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 36 Operating instructions for S 31 3 S 150 3 series screw compressors Installation Compressor room Frost protection Ventilation The compressor must be installed so that it is frost protected The BOGE anti freeze device is a standard feature It protects the safety devices from freezing up at ambient temperatures up to 10 C If the following instructions are not observed the admissible final com pression temperature may be exceeded In this case the compressor will switch off automatically Caution Arrange the compressor intake openings or ducts in such a way that danger ous 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 4 m s Never position cooling air ducts directly on the compressor Always use a compensator to avoid distortion and the transfer o

Operating instructions

Contents

Download Pdf Manuals

Related Search

Related Contents