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Operating instructions

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2. ssss eme 2 Dangers of electricity ne rennen nnns 3 Safety instructions for maintenance and repair of the compressor 3 Safety instructions for maintenance and repair of integrated converter SLF 40 3 BLUEKAT seem 4 Safety instructions for maintenance and repair of the dryer SLDF 5 Obligations of the operator ssssse 6 Personnel requirements sssssssssseseeee eene 7 Personal protective equipment sssssssssssss 7 Accident prevention regulations see 7 Initrod ctlon enitn are tti o eroe aaan aaa Feds eaa Ee te tine aves 8 Symbols used iiis uide did tenait see di den dian 8 Symbols on the compressor sssssssem e 9 Intended use itae erect Rae duree ede e REED tg 10 Foreseeable misuse eese enenatis 10 Intended use of the integrated converter SLF 40 3 BLUEKAT 11 Transport damage escrin eene nennen nnns 11 Data on the rating plate ssssss 12 SON C PLUR 12 Technical data sirpis n inen ette tree nne ind 13 Operating principle of compressor eeueesse 16 Functional principle of the air end ssssssssssssss 16 AICI CU Ibex HP TE 17 or Felres SES 18 BLUEKAT operation principle eeeeeeeeeeeeeee 19 Compressor control ar r arrea a me eaae aeia ahaaa ie AE Ean EE Eana 20 Network
3. 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 SLF 40 3 BLUEKAT BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 69 Maintenance Maintenance work between scheduled services 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 out the dirt with compressed air 1 in the opposite direction to the normal cooling air flow see figure below 6 Extract the blown out dirt directly with 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 uu E un al NK i Fig 6 7 Cleaning the compressed air oil cooler Ry Note If the cooling unit is excessively soiled cleaning is no longer possible with compressed air have it disassembled and cleaned by BOGE service per sonnel Every 1 500 operating hours Clean the oil cooler air cooler water cooling Clean the
4. Every 9 000 operating hours or every 2 years Check the suction controller and if necessary replace or repair with the repair kit Check solenoid valve and replace if necessary Change oil 75 Special maintenance intervals see also page 78onwards Flush out oil circuit Maintenance interval If oil strongly contaminated Before changing the type of oil Lubricate Replace drive motor bearings For details of the lubrication replacement inter for motors with no automatic lubrication device vals for motors with no automatic lubrication device See the information given on the type plate of the drive motor 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 2 years irrespective of the number of operating hours The specified intervals apply only when using BOGE Syprem S compressor oil If a different oil is used different intervals will apply Other service life periods may also be possible depending on the ambient temperature In this case have the oil analysed by your BOGE customer service Table 6 2 Maintenance work at fixed service intervals Page 62 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance EN BOGE maintenance concept Converter maintenance work for SLF 40 3 BLUEKAT Caution Maintenance and repair work on the integra
5. 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 Exceeding the maximum temperature will result in malfunctioning A false alarm will be triggered BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 53 Accessory equipment E BOGE Duotherm BSW Commissioning Maintenance Proceed as follows during commissioning Check the oil level in the oil circuit Gradually open the valves on the water side Avoid pressure hammers Vent the pipelines Any residual air contained in the heat exchanger will be carried along by the media conveyed and will escape through the system The safety circuit including the pressure control device and the expansion vessel forms a closed maintenance free system 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 54 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance EN Safety instructions for maintenance 6 1 Safety instructions for maintenance Caution Ensure that maintenance work is only carried out by qualified profess
6. 3 minutes to allow the oil to settle Page 68 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance Maintenance work between scheduled services Caution Risk of injury Danger of burning due to hot oil Always wear your compulsory personal protective equipment when working on the compressor Every 1 500 operating hours Clean the oil cooler air cooling 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 o he Fig 6 6 Checking the oil level topping up with oil Clean the air oil cooler After 1 500 operating hours For SLF 40 3 BLUEKAT 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
7. 70 79173 80174 81 75 76172 79174 8 Measurement surface E silenced super silenced dB A 15 15 16 17 16 17 16 17 17 18 17118 Sound power level silenced super silenced dB A 821 85 95 90 96 91 97192 93190 96 92 Max sound pressure level 3 dB A o accord to DIN EN ISO 2151 2009 silenced super silenced dB A 66 69 78172 79173 80 74 72170 72170 3 Measurement surface E silenced super silenced dB A 15 15 16 17 16 17 16 17 17118 17118 Sound power level silenced super silenced dB A 81 841 94189 95190 96 91 89 88 89 88 Compressor Max final compression temperature C 110 110 110 110 110 110 110 Volume flow according to ISO 1217 Annex C at p 7 8 bar m min 1 20 3 87 1 30 5 31 2 30 7 16 2 40 7 90 2 20 9 60 5 10 13 96 4 98 15 70 Prax 10 bar m min 1 30 4 75 2 25 6 43 2 30 7 00 2 10 8 50 4 94 12 25 4 93 14 93 Prax 13 bar m min 1 26 4 21 2 12 5 18 2 14 5 78 2 18 7 26 3 68 10 09 4 79 12 80 Drive motor Rated power kW 22 30 37 45 55 75 90 Rated speed 50 Hz min 3000 3000 1500 3000 1500 3000 1500 3000 1500 3000 Protection type IP 55 55 55 55 55 55 55 Design IMB 35 35 35 35 35 35 35 ISO class F F F F F F F Electrical connection Mains voltage IV 400 400 400 400 400 400 400 Frequency Hz 50 50 50 50 50 50 50 Recommended fuse protection A 63 80 100 125 160 200 250 Standard equipment Mains v
8. 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 Installation Commission ing following extended stoppages 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 SLF 40 3 BLUEKAT 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 Page 76 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance Maintenance work during scheduled services Ai TON Ha Fig 6 10 Solenoid valve on the suction controller with the cap nut screwed on ee rain off Fig 6 12 Drain off residual oil f
9. Optional accessory To be provided by customer 35 36 Dirt trap Stop valve BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 85 Appendix Flow chart SLF 40 3 BLUEKAT air cooled version frequency controlled Page 86 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET 1 Suction filter 24 Pressure transmitter for network 2 Maintenance display pressure 3 Suction filter monitoring 25 Stop valve for compressed air outlet 4 Suction regulator 27 Oil drain 5 Unloading valve 28 Non return valve for drainage line 5 1 Suction regulator control valve 50 Filter 6 Rotational direction monitoring with 51 Safety valve double non return valve 52 Heat exchanger 7 Drive motor 53 Converter 8 Compressor air end 54 Heating cartridge with thermocouple 9 Sensor for final compression tem 55 Thermocouple perature 56 Thermocouple 10 Combined compressed air oil receiver 57 Thermocouple 11 Oil separator 58 Pressure retaining shut off valve 12 Safety valve DHSV 13 Quick start valve 59 DHSV solenoid valve 16 Thermostatic oil control valve 60 Pressure gauge 17 Oil cooler 61 Relief ball valve 18 Oil filter 62 Condensate discharge valves 21 Minimum pressure non return valve automatic 22 Compressed air aftercooler 23 Pressure transmitter for system Optional accessory pressure BOGE
10. 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 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 75 Maintenance EN Maintenance work during scheduled services 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
11. 25 SLF 75 3 55 14 000 1 80 7 000 0 59 2 000 0 25 SLF 101 3 75 20 000 2 50 10 000 0 74 3 400 0 45 SLF 125 3 90 32 000 4 00 16 000 1 18 3 400 0 45 SLF 40 3 BLUEKAT 30 11 000 1 35 5 500 0 42 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 34 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Compressor room Ventilation possibilities Fig 3 3 Ventilation possibilities A Supply and exhaust air openings in the outside walls free standing installation B Supported by exhaust air fan C Exhaust air duct into the open D Exhaust air duct with recirculation flap Hot exhaust air is mixed with the cold ambient air as required Thus pre venting the plant from freezing up at temperatures below freezing E Using the hot exhaust air for heating In the winter the hot exhaust air is used for heating rooms In summer it is directed into the open BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 35 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 Neve
12. 4 Vent compressor fully as described at the start of this section 5 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 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 Page 72 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance EN Maintenance work during scheduled services 10 Put the cover back on on the maintenance side 11 Open ball valve at the compressed air outlet 12 Switch the compressor on and let it heat up until it reaches the operating temperature 13 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 uni
13. BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description EN Operating principle of compressor Both screws have screw shaped profiles intermeshing without contact Together with the housing wall these rotors form chambers which gradually reduce in size along the direction of air flow Rotation of the rotors causes the air taken in to be compressed to the final pressure in the chambers During compression oil is continuously injected into the air end This has a cooling sealing and lubricating function we WEN 8 7 6 ast W Air circuit 1 b 2 Fig 2 1 Components of the air circuit Intake filter The intake filter cleans the air suctioned by the air end 2 Intake regulator The intake regulator opens load operation or closes idling operation or standstill the suction line depending on the operating condition of the compressor 3 Air end The air end compresses the air which is sucked in 4 Compressed air oil separator vessel The compressed air separates from the oil under the force of gravity in the compressed air oil vessel 5 Oil separator The oil separator separates the residual oil contained in the compressed air 6 Minimum pressure non return valve The minimum pressure non return valve does not open until the system pressure has increased to 3 5 bar This causes a rapid build up of the sys tem pressure and ensures lubrication in the starting
14. Bielefeld Fax 05206 601 200 www boge com info boge com Fig 1 1 Data on the rating plate Service Please do not hesitate to contact BOGE service if you have any questions Please call Telephone 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description Technical data SLF 30 3 SLF 125 3 part 1 Technical data 2 1 Technical data SLF 30 3 SLF 40 3 Type SLDF 30 3 SLDF 40 3 SLF 51 3 SLF 61 3 SLF 75 3 SLF 101 3 SLF 125 3 Dimensions Height silenced mm 1442 1729 1442 1729 1453 1453 1453 1759 1759 Height super silenced mm 1949 1949 1949 2255 2255 Width mm 1880 1973 1880 1973 2043 2043 2043 2414 2414 Depth mm 985 985 1065 1065 1065 1315 1315 Weight silenced kg 775 899 845 1055 1250 1380 1498 2112 2162 super silenced kg 1300 1430 1548 2172 2222 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 silenced super silenced dB A 671
15. Clean oil cooler 69 Check that the electrical connections are fully tightened Table 6 1 Maintenance work between service intervals BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 61 Maintenance e BOGE maintenance concept Maintenance work at fixed service intervals To retain your warranty entitlement BOGE recommends that you have the fol lowing maintenance and repair work carried out by certified BOGE service per sonnel 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 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 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 71 Check the minimum pressure valve and repair if necessary with the repair kit Have the safety valve checked by BOGE service personnel only 71 Check the oil regulator and repair if necessary with the repair kit Change nozzle with dirt trap only SL D F 30 3 SL D F 40 3 incl BLUEKAT Change oil filter 71 Change oil separator 73
16. Maintenance work SLF 30 3 SLF 125 3 Check pressure final compressor temperature system relief emer gency stop button Check change supply air filter Check change supply air filters optional accessory Check suction filter Clean filter and insert Change filter insert Check oil level Top up oil Clean compressed air oil cooler externally Change oil filter Change oil separator After extended stoppages Fill the suction regulator with oil Oil change Lubricate motor bearings SL D F 30 3 SLF 51 3 SLF 101 3 Automatic lubrication SL D F 40 3 SLF 61 3 SLF 75 3 SLF 125 3 Page 58 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance 62 BOGE maintenance concept Refrigerant compressed air dryer at SLDF 30 3 SLDF 40 3 Fig 6 2 SLDF 30 3 SLDF 40 3 1 Refrigerant compressed air dryer Caution Maintenance work and repairs to the refrigerant compressed air dryer SLDF may be carried out only by BOGE service personnel with the relevant spe cialist training Failure to comply with this requirement can result in physical injury and in damage to the compressor system BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 59 Maintenance e BOGE maintenance concept SLF 40 3 BLUEKAT compressor Fi lt n g O OONO 6 3 Maint
17. 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 available as an optional accessory Converter fault See Converter faults SLF 40 3 BLUEKAT on page 49 Cil in suction filter Minimum pressure non return valve is leaking Check the minimum pressure non return valve and replace if neces sary 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 Unloading valve does not open Check unloading valve and replace if necessary Non return valve is leaking Examine non return v
18. 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 81 Appendix Flow chart Air cooled version frequency controlled 29 Page 82 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Appendix Flow chart 101 102 on OMAN OA Oc RO NN Intake air INLET Compressed air OUTLET Suction filter Maintenance display Suction filter monitoring Suction regulator Unloading valve Suction regulator control valve Rotational direction monitoring with double non return valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil receiver Oil separator Safety valve Quick start valve Thermostatic oil control valve Oil cooler Oil filter Minimum pressure non return valve Compressed air aftercooler Pressure transmitter for
19. 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 until the operating instructions have been read and understood These operating instructions are intended to complement user instructions based on existing national accident prevention and environmental protection regulations In the illustrations the compressor is shown in part without safety covers or safety devices to provide a better view However operating the compressor without these components is prohibited 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 d
20. maintenance and or repair Ry Note 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 ing extended stoppages If an extended stoppage is scheduled you should contact BOGE s service department beforehand Following an extended stoppage of more than 2 months fill a small amount of oil into the suction controller prior to starting the compressor Attention Only fill the suction controller with the grade of oil used to operate the com pressor Never mix different grades or brands of oil AN 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 Allow converter to cool off only SLF 40 3 BLUEKAT 1 Unscrew the plug from the suction controller 1 4 Fig 3 5 Suction controller Page 44 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Commissioning The following compressor oil quantities must be filled into the suction control ler Model Compressor oil quantity I SL D F 30 3 SL D F 40 3 SLF 40 3 BLUEKAT approx 0 5 SLF 51 3 SLF 75 3 approx 2 5 SLF 101 3 SLF 125 3 approx 5 0 Ta
21. oil cooler and the air cooler in the case of water cooling After 1 500 operating hours Inthe event of excessive lime deposits and dirt Ry Note 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 Page 70 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance EN Maintenance work during scheduled services Every 3 000 operating hours once a year Change the suction filter cartridge 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 62 To retain your warranty entitlement BOGE recommends that you have this work carried out by certified BOGE service personnel using original spare parts 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 f
22. phase Once the com pressor has been switched off the check valve prevents the compressed air from flowing back out of the mains line 7 Compressed air aftercooler air cooled or water cooled The compressed air is cooled in the compressed air aftercooler causing the water contained in the air to condensate 8 Stop valve The screw compressor can be isolated from the mains using the stop valve BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 17 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 impurit
23. 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 General information E Introduction Intended use of the In accordance with its intended purpose the BLUEKAT converter is exclusively integrated converter designed for the treatment of compressed air in screw compressors by which SLF 40 3 BLUEKAT 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 au
24. system pressure Pressure transmitter for network pressure Stop valve for compressed air outlet Oil drain Non return valve for drainage line Cyclone separator with condensate drain and refrigerant compressed air dryer with condensate drain Optional accessory BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 83 Appendix Flow chart Water cooled version series connection frequency controlled 104 lt 3 36 33 m o 25 43 gt PUT Tq 4 V 102 Page 84 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Appendix Flow chart 10 102 103 104 on OMAN DOA Oi RO NN Intake air INLET Compressed air OUTLET Water INLET Water OUTLET Suction filter Maintenance display Suction filter monitoring Suction regulator Unloading valve Suction regulator control valve Rotational direction monitoring with double non return valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil receiver Oil separator Safety valve Quick start valve Thermostatic oil control valve Oil cooler Oil filter Minimum pressure non return valve Compressed air aftercooler Pressure transmitter for system pressure Pressure transmitter for network pressure Stop valve for compressed air outlet Oil drain Non return valve for drainage line 2 2 way solenoid valve water valve
25. that external vibrations or shock are not able to impact on the compressor station particularly where the SLF 40 3 BLUEKAT compressor with integrated converter is concerned 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 the SLF 40 3 BLUEKAT compressor 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 31 Installation Compressor room Sound protection Requirements of fire protected compressor rooms Walls ceilings floor and doors must be designed in fire protection class F30 or higher Flammable liquids must never be stored in the compressor room The floor around the compressor must be made of non flammable material Leaking oil must not be able to spread out over the floor No inflammable materials must be located within a radius of at least 3 me tres around the compressor No inflammable machine parts such as cable ducts may run overhead of the compressor Only install compressors in workrooms if the sound pressure level of their measurement surfaces does not exceed 85 dB A Caution Risk of i
26. to 5 C above the target value the dirt crust on the filter mat prevents the provision of an adequate cooling air supply Note Keep a packet of spare filter mats in reserve at all times Changing supply air filter mat on switch cabinet standard supply 1 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 Remove the cover 1 see fig 6 4 a Take out the filter Insert a new filter Put the cover 1 back on oa BR 0 N Changing supply air filter mats on compressor optional accessory 1 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 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 Page 66 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance Maintenance work between scheduled services 2 Draw the filter mats 2 upwards out of their holder
27. 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 SLF 40 3 BLUEKAT compressor and will also be carried out by BOGE service 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 66 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 67 Check oil level and top up as required 68 Every 1 500 operating hours
28. 3 000 4 090 4 900 5 deltat 30K m h 0 600 0 815 1 005 1 225 1 500 2 045 2 450 o Max cooling water quantity m h 3 5 3 5 3 5 4 2 42 9 0 9 0 o Cooling water inlet temperature B min P 5 5 5 5 5 5 5 g max i 30 30 30 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 45 45 45 Cooling water pressure min bar 2 2 2 2 2 2 2 max bar 10 10 10 10 10 10 10 Operating pressure transmitter factory settings Pmax 8 bar Switch off press Prax bar 8 8 8 8 8 8 8 Switch on press Pin bar 7 5 7 5 7 5 7 5 7 5 7 5 7 5 Pmax 10 bar Switch off press Pmax bar 10 10 10 10 10 10 Switch on press p bar 9 5 9 5 9 5 9 5 9 5 9 5 Pmax 13 bar Switch off press Pmax bar 13 x Switch on press p bar 12 5 Safety valve Activation pressure at Prax 8 bar bar 14 14 14 14 14 14 14 Prax 10 bar bar 14 14 14 14 14 14 Prax 13 bar bar 14 1 Compressors for other operating pressures Prin Pmax 0 5 bar Page 14 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description EN Technical data Technical data SLF 40 3 BLUEKAT part 1 Type SLF 40 3 BLUEKAT Dimensions Height mm 1955 Width mm 2470 Depth mm 970 Weight kg 1171 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 200
29. 5 3 Maintenance EN Spare parts and accessory equipment Drive motors with auto matic lubrication Read the attached operating instructions carefully before putting the automatic lubrication device into operation 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 the fan wheel Fitted safety devices and cladding may not be re moved 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 List of spare and wear parts for maintenance 6 6 Spare parts and accessory equipment Designation Filter mat for supply air filter optional accessory BOGE Syprem S special lubricant for screw compressors Lubricant for drive motor bearings servicepac for oil air service Oil filter oil separator suction filter cartridge gaskets nozzle with dirt trap only SL D F 30 3 SL D F 40 3 incl BLUEKAT cairpac 3000 Full maintenance
30. 9 silenced dB A 70 8 Measurement surface l silenced dB A 17 4 Sound power level silenced dB A 87 4 Max sound pressure level 3 dB A c accord to DIN EN ISO 2151 2009 silenced dB A 69 8 Measurement surface el silenced dB A 17 4 Sound power level silenced dB A 86 4 Compressor Max final compression temperature C 110 Volume flow according to ISO 1217 Annex C at Pmax 8 bar m min 1 30 5 31 Pmax 10 bar m min 1 30 4 75 Prax 13 bar m min 1 30 4 01 Drive motor Rated power kW 30 Rated speed 50 Hz min 3000 Protection type IP 55 Design IMB 35 ISO class F Electrical connection Mains voltage V 400 Frequency Hz 50 Recommended fuse protection A 100 2 3 4 Standard equipment Mains voltages and 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 9G or circuit breakers with C characteristic only BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 15 Product description LE Operating principle of compressor Functional principle of the air end Technical data SLF 40 3 BLUEKAT part 2 Type SLF 40 3 BLUEKAT Oil filling quantity Oil receiver volume i 46 Total oil filling qu
31. BOGE AIR THE AIR TO WORK m PROGE COMPRESSED AIR SYSTEMS Operating instructions Direct coupled screw compressors Series SLF 30 3 SLF 125 3 SLDF 30 3 SLDF 40 3 SLF 40 3 BLUEKAT Separate manuals Compressor control Frequency converter Refrigerant compressed air dryer SLDF ISO 9001 ISO 14001 GL Systems Certification www boge com Operating instructions for direct coupled screw compressors SLF 30 3 SLDF 30 3 SLF 40 3 SLDF 40 3 SLF 51 3 SLF 61 3 SLF 75 3 SLF 101 3 SLF 125 3 SLF 40 3 BLUEKAT BOGE KOMPRESSOREN Otto Boge GmbH amp Co KG Postfach 10 07 13 33507 Bielefeld Otto Boge Strafke 1 7 33739 Bielefeld Phone 49 5206 601 0 Fax 49 5206 601 200 Mail info boge com Net www boge com 22 kW 30 kW 37 kW 45 kW 55 kW 75 kW 90 kW 30 kW Translation of the original operating instructions according to the EU Machinery Directive 2006 42 EC Issue 05 2014 No 596 1240 01 Nominal charge 5 00 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page Contents ns Contents Part 1 1 1 General information 1 2 Part 2 2 1 Product description 25 2 3 2 4 General safety instructions ccccesesseeeeeeeeseneeeeeseeeeeeeeeeeeeeeenens 1 Safety instructions for compressor operation ssss 1 Special hazard warnings
32. F 125 3 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 clean dry 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 Foreseeable 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
33. F 40 3 BLUEKAT air cooled version frequency controlled 86 SLF 40 3 BLUEKAT water cooled version series connection frequency controlled niei ai i eme 88 SLDF 30 3 SLDF 40 3 aaar a aa a a a eeta aaa nnne 90 List of maintenance and service work 91 Page VI BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 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 1 Ensure that no commissioning and maintenance work on the compressor compressor operation 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 operat ing 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 a
34. a eilo a AEEA re eS Ree Pe etre ee oer E LAS M EM 51 Installation eats ae a i RR Lee ee 51 COMMISSIONING e 52 Maintenance iced anced nee dade Lannea hx ded ade e die aD en ad aud 52 BOGE Duotherm BSW eene 53 epe Ert 53 COMMISSIONING ss rh E RP E RIF 54 Maintenance decet themit dieu 54 Safety instructions for maintenance eee 55 BOGE maintenance concept ccecceeeeeeeeeeeeeeeeeneeneeeeeeeeeeees 57 Maintenance through BOGE customer service 57 List of maintenance and service work ssssssseeeee 58 Maintenance intervals cssssssssssseeeemm 61 General information concerning the lubricants used 64 Disposal of used operating material ccceeeeeeeeeeeeeceeeeeeeeeees 65 Pressure NOSOS eret nt ni CR IEEE 65 Spare and wear parts ssssssssssssssssssseeeee ene 65 Maintenance work between scheduled services 66 Weekly Check change supply air filters ssssss 66 Monthly Clean suction filter 67 Monthly Check oil level top up with oil if necessary 68 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page V Contents 6 4 6 5 6 6 Part 7 7 1 A ndix ppe 7 2 7 3 Every 1 500 operating hours Clean the oil cooler air cooling 69 Ev
35. al 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 SLF 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 Connecting the leads Checkto ensure that all terminal
36. allet 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 provided from one head end to the other The loops of the lifting straps must not be attached to the suction filter Furthermore they must not be attached to the lug on the motor 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 and directionson 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 en titled 3 5 Commissioning Page 30 BOGE operating instructions for screw compressors Se
37. alve and replace if necessary Page 48 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Faults Converter faults SLF 40 3 BLUEKAT 4 3 Converter faults SLF 40 3 BLUEKAT Faults 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 dis continues compressed air production and fails to restart automatically 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 failure time period until release for compressed air produc tion excessively long af Temperature build up inside converter insufficient Have converter heater checked by BOGE service personnel
38. am of the non return valve is known as the network pressure The control system switches the compressor on and off during operation depending on the network pressure All screw compressor controls are based on three basic operating states 1 Load operation The compressor delivers its speed dependent maximum amount of compressed air It consumes its speed dependent maximum energy 2 Idling operation The compressor runs but does not deliver any compressed air It consumes approx 75 less energy than in load operation When compressed air is required it switches to load operation with out delay Idling operation reduces switching frequencies which can damage the drive motor and reduces wear of the system 3 Standstill ready for operation The compressor is standing still but ready for operation When compressed air is required it switches automatically to load operation Page 20 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description EN Compressor control Operating modes Compressed air production control SLF 40 3 BLUEKAT 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 stand
39. an 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 Stra e 449 D 50939 K ln publisher Beuth Verlag GmbH BurggrafenstraRe 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 specified in the Federal Republic of Germany or the information contained in these operating instructions then it is essential that these are carried out prior to commissioning the compressor plant BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 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
40. and repaired replaced if necessary BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 49 Accessory equipment ES BOGE Duotherm BPT Function Installation 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 must be performed 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 valve
41. anger 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 General information KA 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 be 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 coupling must only be carried out when the compressor is not running and safeguards are in place to prevent it from starting up BOGE operating instructions for screw compressors Series SLF 30 3 SL
42. antity I 28 Oil topping up quantity between min max l 6 Intake air temperature min C 5 max C 40 Cooling air requirement free standing installation m h 9000 8 with supply and exhaust duct m h 4500 ac free fan pressure Pa 20 free fan pressure mm WS 2 Cooling air requirement free standing installation m h 2000 with supply and exhaust duct m h 1000 S Required cooling water quantity delatz 15K m h 1 630 i 5 deltat 30K mh 0 815 Max cooling water quantity m h 4 2 a Cooling water inlet temperature 2 min C 5 8 max C 30 5 Cooling water outlet temperature max C 45 Cooling water pressure min bar 2 max bar 10 Operating pressure transmitter 1 factory settings Prax 8bar Switch off press Prax bar 8 Switch on press Prin bar 7 5 Pmax 10 bar Switch off press Prax bar 10 Switch on press Prin bar 9 5 Pmax 13 bar Switch off press Prax bar 13 Switch on press Prin bar 12 5 Safety valve Activation pressure at Pmax 8 bar bar 14 Prax 10 bar bar 14 Pmax 13 bar bar 14 Compressors for other operating pressures Prin Pmax 0 5 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 Page 16
43. ble 3 2 Compressor oil quantities 2 Screw the plug back in again 3 Turn compressor stage using the coupling by hand 5 to 10 times to spread the oil evenly Note 35 In the case of SLF 40 3 BLUEKAT screw compressors please note that in the event of prolonged operational shutdowns for several days during which the compressor station is disconnected from the power supply restarting the compressor requires a preheating phase of 15 to 45 minutes since the con verter 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 SLDF 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 SLDF on page 5 when dealing with the refrigerants used BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 45 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 AA Caution Dismantling the compressor must only b
44. d 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 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 37 Installation Installation Only the following work must be performed during installation 1 Check whether the water supply has the required data see Water connec tion 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 The f
45. e 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 dis connected 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 SLF 40 3 BLUEKAT Page 46 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 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 compressors Please contact BOGE s service department at the following telephone num ber if you have any questions 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 w
46. e indi cator lights go out 5 Fixa warning label to the control and fill in the name of the person respon sible who is authorised to switch on the machine again 6 Wait 5 minutes 7 Check to ensure that all machine elements are definitely currentless 8 Prior to starting work let cool down all hot components of the compressor to 50 C 9 Allow converter to cool off for several hours only SLF 40 3 BLUEKAT 10 Separate the compressor from the compressed air network by closing the ball valve at the compressed air outlet 11 Vent the compressor To this effect open the safety valve on the combined compressed air oil receiver as follows Turn the knurled nut anti clockwise until you can feel a resilient re sistance 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 12 Remove all safety cladding necessary to perform the maintenance work Once the maintenance work has been concluded 13 Reattach all removed safety cladding 14 Open the ball valve at the compressed air outlet 15 Prior to switching on again check whether anyone else is working on the compressor 16 Remove warning sign not until then and release mains disconnecting device 17 Unlock Emergency Stop button Page 56 BOGE operating instructions for sc
47. ea 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 Page 6 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 General information EB General safety instructions Personnel requirements Per
48. ed 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 eject ed Monitoring the drive and fan motor Rotational direction monitoring optional accessory Safety pressure switch 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 safety pressure switch prevents the maximum admissible system pres sure from being exceeded The switch off pressure is lower than the activation pressure for the safety valve The system pressure build up unit monitors the system pressure build up when the compressor starts up Page 26 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description Water cooling Serial connection Parallel connection Water cooling 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 4 5 2 3 1 Fig 2 8 Serial connection Fig 2 9 Parallel connection 1 C
49. ed converter SLF 40 3 BLUEKAT Switch off the compressor using the OFF button 2 Press the emergency stop button coo NOA 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 machine 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 SLF 40 3 BLUEKAT only 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 elec tricians 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 unintentionally switched on again Immediately after finishing the work all dismantled c
50. enance work for SLF 40 3 BLUEKAT Check pressure final compressor temperature system relief emer gency stop button Check change supply air filter Check change supply air filters optional accessory Check suction filter Clean filter and insert Change filter insert Check oil level Top up oil Clean compressed air oil cooler externally Change oil filter Change oil separator After extended stoppages Fill the suction regulator with oil Oil change Automatic lubrication SLF 40 3 BLUEKAT Converter Caution Maintenance and repair work on the integrated converter of the SLF 40 3 BLUEKAT series must be carried out by specially trained BOGE service per sonnel only Failure to comply with this requirement can result in physical injury and in damage to the compressor system Page 60 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance EN 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
51. er 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 When working on the coupling there is a risk of injury through crushing shearing or by being drawn in or getting caught Work on the coupling must only be carried out when the compressor is at a standstill Reattach all covers screw connections and safety devices immediately upon comple tion of the repair or maintenance work 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 addition al hearing protection at noise levels of over 80 dB A Page 2 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 General information EB General safety instructions Dangers of electricity Danger High voltage Persons working on the electrical equipment of the compressor are exposed 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 regu
52. ery 1 500 operating hours Clean the oil cooler air cooler Water cooling 5 eoi fir rr Rp Un Pob cr Peter PUR Dex eR TR 70 Maintenance work during scheduled services 71 Every 3 000 operating hours once a year Change the suction filter cartridge eeeeee 71 Every 3 000 operating hours once a year Have safety valve checked sssssssss eee 71 Every 3 000 operating hours once a year Change the oil filter 71 Every 3 000 operating hours once a year Change the oil separator ssssssenn e 73 Every 9 000 operating hours every 2 years Oil change 75 Special maintenance work eese 78 Flush out oil circuit 78 Drive motors with lubrication device ssssssssssssss 78 Drive motors with automatic lubrication seeesssssusss 79 Spare parts and accessory equipment sus 79 List of spare and wear parts for maintenance 79 Spare parts for converter SLF 40 3 BLUEKAT 80 List of available accessory equipment sssssssssss 80 Directives and standards complied with 81 dl Edi ED 81 Air cooled version frequency controlled seesessssss 82 Water cooled version series connection frequency controlled 84 SL
53. es 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 Syprem S compressor oil Attention Never mix different oil types and brands The additives may be incompatible It may lead to foam formation premature ageing or loss of lubricating ability Page 64 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Maintenance EN 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 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 lea
54. han 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 33 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 pro tection grids have the necessary free cross section We generally recommend contacting a specialist company for performing the duct construction work and planning Type Drive rating Air cooling Water cooling Cooling air Necessary Coolingair Necessary Cooling air Necessary requirement inlet require free duct requirement inlet for free opening ment for cross for free opening standing for free installation section standing for free unit standing with ducting unit standing unit unit kW m h m m h m7 m m SLF 30 3 SLDF 30 3 22 9 000 1 10 4 500 0 35 2 000 0 25 SLF 40 3 SLDF 40 3 30 11 000 1 35 5 500 0 42 2 000 0 25 SLF 51 3 37 11 000 1 35 5 500 0 42 2 000 0 25 SLF 61 3 45 13 000 1 60 6 500 0 48 2 000 0
55. ies 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 back into the oil circuit via a drainage line Page 18 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description BLUEKAT operation principle 2 3 BLUEKAT operation principle The screw compressor SLF 40 3 BLUEKAT is 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 Compressor control fy D Converter control Compressor Converter Fig 2 3 Overview BLUEKAT compressor grey section with integrated con verter In the screw compressors of the BLUEKAT series the converter is installed downstream of the compressor Prior to the oil separation process the com pressed produced by compressor 1 is first heated up in plate heat exchanger 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 kep
56. ion 1 Switch off the compressor OFF button 2 Acknowledge fault 3 Rectify the fault 4 Switch on the compressor ON button BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 23 Product description EN Safety and monitoring devices Safety temperature limiter on the integrated converter SLF 40 3 BLUEKAT The safety temperature limiter on the integrated converter SLF 40 3 BLUE KAT 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 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 SLF 40 3 BLUEKAT on page 49 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 SLF 40 3 BLUEKAT These include a temperature control unit with display serving to retrieve temperature information on the converter In addition there are three indicator light
57. ionals or appropriately trained persons Prior to starting any maintenance work always take the compressor out of operation as described in these operating instructions before removing any safety covers or safety devices Refit the safety covers or safety 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 55 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 injuries due to restarting electric shock or self releas ing parts Prior to all maintenance work 1 Switch off the compressor using the OFF button 2 Press the emergency stop button 3 Open mains disconnection device and secure against unintentional switch on by means of a padlock 4 After disconnecting the power supply wait until the fan stops and th
58. ipment may be altered adjusted or removed from the dryer either permanently or temporarily 2 Use only the correct tools for maintenance and repair work 3 Use only original spare parts 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 carrying 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 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 decomp
59. juieul jun Jojesedas Jana Joy JO aun ainssaid eunsseid sunoy SYJEUI0M JejeAuo Jre duo JOJO Buljoo9 IO IO IIO exyejuJ BJeduie wass XiowjeN Buyjeiado aeq uuuinjoo jendodde y ui p j ajdwo aney no yiom o2ueuojuieul Aue p10391 SL jd BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 92 7 3 List of maintenance and service work Appendix oDueu 49 abuey 49 4990 O sy Bujuealy z I2 uleg 4 ll4 JojeJed s eoueu JOJEMIIO eoueu Buiuee o m x ejuieul JeKup ejuieul jun Jojesedas Jana JO JO aun ainssaid ainssaid sunoy SYIEWUOY JejeAuo Jre duo JOJO Buljoo9 IIO IO IIO exeju BJeduie wash XioMjeN Bugeredo ejeq uuuinjoo ejeudoudde ay ui poyo duio2 oAeu no yom o2ueuojuieul Aue pJ0294 SL jd Page 93 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 7 3 List of maintenance and service work Appendix abuey 49 abuey Yd 4990 O vx Bujuealy 10 ulelq 49 l4 Joje4edas eoueu JOJEMIIO eoueu Buiuee o Tm ejuieul JeKup ejuieul jun Jojesedas Jana Joy JO aun ainssaid eunsseid sunoy SYJEUI0M JejeAuo Jre duo JOJO Buljoo9 IO IO IIO exyejuJ BJeduie wass XiowjeN Buyjeiado aeq
60. kages Check the service life of the hoses and replace them in due time As replacement only use original spare parts released by BOGE Used pressure hoses are not permitted as a replacement Spare and wear parts AA Caution Only use original spare parts compressor oils and operating materials re leasedby BOGE for repair and maintenance work BOGE is not liable 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 SL D F 30 3 SL D F 40 3 incl BLUEKAT this can considerably increase oil consumption BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 65 Maintenance Maintenance work between scheduled services Weekly Check change supply air filters 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 61 Perform the work at the intervals specified Check the function of the supply air filter mats 1x monthly but at least every 500 operating hours Ifthe air intake is very contaminated this should be carried out at more fre quent intervals Change the supply air filter mats Ifa dirt crust has become deposited on the filter mats Ifthe final compression temperature rises to 4
61. kit for 3 000 operating hour service Oil filter oil separator suction filter cartridge gaskets repair kit oil regu lator repair kit nozzle with dirt trap only SL D F 30 3 SL D F 40 3 incl BLUEKAT Solenoid valve BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 79 Maintenance Spare parts for converter SLF 40 3 BLUEKAT EH Spare parts and accessory equipment Ry Note Stocks of spare parts are continuously updated by BOGE If you need any spare parts for the converter in the SLF 40 3 BLUEKAT screw compressor please contact your local BOGE field representative or your nearest BOGE service partner Or contact your BOGE spare parts service Telephone 49 5206 601 120 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 80 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Appendix Directives and standards complied with 7 1 Directives and standards complied with The compressor conforms to the following directives
62. lar 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 Safety instructions for maintenance and repair of the compressor 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 electrical 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 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 3 General information EN General safety instructions Safety instructions for maintenance and repair of integrat
63. nection siii ieie eai aaeain eaii 27 Parallel connection sssssssssssssseseeeeennennnee 27 Cooling water eere eren nsn RNAn EAE 28 Water connection for water cooling eeeees 28 Cooling water quality sssseeeeene menn 28 Transport and storage eseeeeeeeeeeneee nnn 29 General information ssssssssssssssseme 29 How to transport the compressor sssssseseeeeenes 29 Intermediate storage ssssse eme 30 Compres S r FOOIm ra nee eec HE e Prnt hate exo nre eR 31 Installation conditions for horizontal or free standing compressed air TecelVers cione nadie eee tata ghectadetedien te t ett dieere ties 31 Installation surface iiec Lcd deed ete 31 Fire protection seed ot ette md eerta di 31 Sound protection emen 32 Admissible ambient temperatures sssssssssesseeses 32 Frost protection cete eel etim Re dee 33 Mu 33 Cooling air requirement sssssssee enne 34 Ventilation possibilities sssemmm 35 Condensate disp sal Z seie an a a aaa i aaia 36 O On is EAT T T M 36 General information ccecceceeeeeccecceeeeeeeeeeeseeeeccaeaaecaeeeeeeeeeeeeees 36 Checking the scope of delivery ssseee 37 Installing the compressor ssseemm em 37 Connecting the compressor to the compre
64. network 35 Dirttrap pressure 36 Stop valve BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 89 Appendix Flow chart SLDF 30 3 SLDF 40 3 ey x gu 101 a 4 101 Compressed air OUTLET Screw compressor see also flow diagram Cyclone separator Refrigerant compressed air dryer Bypass Drain Condensate 25 Non return valve for compressed air exhaust ce c Bc N Page 90 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 7 3 List of maintenance and service work Appendix 7 3 List of maintenance and service work abuey uy abuey y9 498UD 2 w Bujueej 1D x ueg 49 Jojejedas aoueu JOJEM IIO aoueu Bulueajo E ojuieui JeKup ojuieui jun Jojesedas Jang JO JOA ain ainssaid ainssaid sunoy syew y J y auog Jle duio JO OW DBuijoo IIO IIO IIO oxeju eJeduio wajsfS XiowjeN Burgejedo ajeq uwinjoo ojeudoadde ay ui pejojduio2 oAeu no yom o2ueuojuieui Aue pJ02904 oSeojd Page 91 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 7 3 List of maintenance and service work Appendix abuey 49 abuey Yd 4990 O vx Bujuealy 10 ulelq 49 l4 Joje4edas eoueu JOJEMIIO eoueu Buiuee o Tm ejuieul JeKup e
65. njury A sound pressure level of more than 80 dB A can permanently damage the hearing of persons constantly working near the compressor Persons such as these must wear hearing protection while working near the compressor Admissible ambient temperatures The compressor room must be clean dry cool and free of dust Admissible ambient temperatures see also Technical data Maximum ambient temperature for air cooling 40 C Minimum ambient temperature 5C 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 supply air openings with adjustable louvres to ensure that temperatures do not go below the minimum temperature in winter Use the anti freeze function only in ready for operation mode Page 32 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Compresso
66. ntentionally Allow converter to cool off only SLF 40 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 pro cedure 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 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 SLF 40 3 BLUEKAT Close 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 allow the oil to settle oa A O N Caution Risk of injury Danger of burning due to hot oil Wear p
67. ollowing additional components must be provided by the customer when installing the water cooling unit Dirt trap The dirt trap at the cooling water inlet protects the cooling units against sed iment collecting Pore width max 0 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 prevent damage to the cooling units Removing the transport securing bolts Checking the oil level The drive unit frame is bolted to the basic frame for transport To remove the transport securing bolts Remove the four bolts 1 and 2 marked in red two on each long side together with their spac er sleeves Fig 3 4 Removing the transport securing bolts BOGE compressors are supplied with a full oil filling Prior to commissioning check the oil level as described in the section entitled Maintenance Page 38 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Electrical connection 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 current national and internation
68. oltages and 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 13 Product description Technical data Technical data SLF 30 3 SLF 125 3 part 2 SLF 30 3 SLF 40 3 Type yp SLDF 30 3 SLDF 40 3 SLF 51 3 SLF 61 3 SLF 75 3 SLF 101 3 SLF 125 3 Oil filling quantity Oil receiver volume i 46 46 71 71 71 120 120 Total oil filling quantity i 28 28 42 42 42 65 65 Oil topping up quantity between min max i 6 6 8 8 8 10 10 Intake air temperature min P 5 5 5 5 5 5 5 max C 40 40 40 40 40 40 40 Cooling air requirement free standing installation m 9000 9000 11000 13000 14000 20000 32000 3 with supply and exhaust duct m 4500 4500 5500 6500 7000 10000 16000 free fan pressure Pa 20 20 60 60 60 60 60 free fan pressure mm WS 2 2 6 6 6 6 6 Cooling air requirement free standing installation m h 2000 2000 2000 2000 2000 2000 3400 with supply and exhaust duct m h 1000 1000 1000 1000 1000 1000 1700 E Required cooling water quantity 3 delta t 15K m h 1 200 1 630 2 010 2 450
69. ooling 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 width 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 individually fluctuating values they are designed according to the specified order data BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 27 Product description ER Cooling water 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 lt 21 dH Cooling water pressure max 10 0 bar 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
70. operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 87 Appendix Flow chart SLF 40 3 BLUEKAT water cooled version series connection frequency controlled Page 88 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET 1 Suction filter 25 Stop valve compressed air outlet 2 Maintenance display 27 Oil drain 3 Suction filter monitoring 28 Non return valve for drainage line 4 Suction regulator 32 2 2 way solenoid valve 5 Unloading valve water valve 5 1 Suction regulator control valve 90 Filter 6 Rotational direction monitoring with 91 Safety valve double non return valve 52 Heat exchanger 7 Drive motor 53 Converter 8 Compressor air end 54 Heating cartridge with thermocouple 9 Sensor for final compression tem 55 Thermocouple perature 56 Thermocouple 10 Combined compressed air oil receiver 57 Thermocouple 11 Oil separator 58 Pressure retaining shut off valve 12 Safety valve DHSV 13 Quick start valve 59 DHSV solenoid valve 16 Thermostatic oil control valve 60 Pressure gauge 17 Oil cooler 61 Relief ball valve 18 Oil filter 62 Condensate discharge valves 21 Minimum pressure non return valve automatic 22 Compressed air aftercooler 23 Pressure transmitter for system Optional accessory pressure To be provided by customer 24 Pressure transmitter for
71. ork carried out on the integrated converter in SLF 40 3 BLUEKAT screw Telephone 49 5206 601 140 Danger High voltage Before starting any work to remedy faults Press the emergency stop button use the mains disconnection device to iso late the compressor from the power supply and fix a padlock to prevent the power from being switched on again unintentionally Allow converter to cool off only SLF 40 3 BLUEKAT 4 2 General faults Fault Possible cause Rectification Not delivered no pressure build up max pressure 0 5 bar af 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 unloading 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 47 Faults La General faults Fault Possible cause Rectification Motor doesn t start up No electric power to compressor Check electrical connection Fuses are defective Check the mains fuses and control fuses
72. ors Series SLF 30 3 SLF 125 3 Maintenance EN Maintenance work during scheduled services Every 9 000 operating Change the oil hours every 2 years Inthe case of Syprem S Oil change After 9 000 operating hours but 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 35 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 10 to 6 12 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 o BR 0 N Attention Never use any tools to screw on the cap nut
73. ose 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 If 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 in the presence of flames and electric arcs BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 5 General information Obligations of the operator 9 EN General safety instructions 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 is obliged to operate the compressor only if it is in perfect technical working order provide an automatic cutout device for disconnecting the electrical power supply in the event of a fault to prevent hazards due to electricity check the emergency stop device for the compressor regularly to ensure that nothing is missing and that it works properly assess the hazards of the machine workstations in his ar
74. otherm BSW 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 Ry Note If the cleaning measures specified above are not sufficient you should have the exchanger cleaned by a service company Boge s service department will recommend contracting companies on request 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 addi tional 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 processed e g alarm switching off the system Note Set the pressure control device to a value at least 20 lower than the mini mum pressure of the media used Operating conditions
75. overs 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 net pressure being lower than the set switch on pressure Caution Maintenance and repair work on the integrated converter of the SLF 40 3 BLUEKAT series must be carried out by specially trained BOGE service per sonnel only Failure to observe this may cause physical injury and damage to the com pressor station Page 4 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 General information EB General safety instructions Safety instructions for maintenance and repair of the dryer SLDF Caution Maintenance work and repairs to the refrigerant compressed air dryer SLDF 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 equ
76. preSSure ccccccecceceeeeeeeseeecenceeaeeeeeeeeeeeeeeseesessensnneaeess 20 Operating states seiiiiseseeiieidee ee ieddt eene 20 Operating ModS neniel rasade erani ae a ira 21 Compressed air production control SLF 40 3 BLUEKAT 21 Controlled operation frequency Control sssessssss 22 Short operating maS sorrera arna er ede EE 22 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page Ill Contents Part 3 Installation 2 5 2 6 2 7 2 8 3 1 3 2 3 3 Gontrol devices eene ieri herein 23 Operating pressure transmitter 0 ccccceceeeeeeeeeseeeeecceeeeeeeeeeeeees 23 Safety and monitoring devices eene 23 General information ssssssssssssesseem 23 Safety temperature limiting device ereere 23 Safety temperature limiter on the integrated converter SLF 40 3 BLUEKAT Jao crierai eee e i its 24 Safety VaN E urean un ee Dae de OR a 26 Monitoring the drive and fan motor sssseeee 26 Rotational direction monitoring optional accessory 26 Safety pressure switch optional accessory ssesss 26 System pressure build up optional accessory 26 Water cooling eterne erret sevedescersesvetscaee 27 Water cooll ig erret ree AREE ERR RR LATS 27 Serial con
77. 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 Checking 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 see chapter Installa tion on page 36 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 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 rotational direction BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 41 Installation Commissioning Change direction of rotation Caution Risk of injury Press the emergency stop switch button disable
78. r dispose of it in the public sewage system without prior treatment exception to this the built up condensate from the SLF 40 3 BLUEKAT compressor 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 the SLF 40 3 BLUEKAT compressor The BOGE oil water separator is used to separate the oil from the conden sate The cleaned water can be fed directly into the public sewage system The oil is collected in a separate container Dispose of the oil according to environmental regulations If the oil emulsifies due to special operating conditions use an emulsion cracking plant 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 po tential 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 comp
79. r inlet Page 42 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Commissioning Checking for leaks 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 Conducting 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 the ON button on the compressor control to switch on the 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 f necessary reset operating pressure pressure target value gt The compressor is ready for operation gt 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 commissioning certificate For SLF 40 3 BLUEKAT 1 Re enable the mains disconnecting device 2 U
80. r 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 of vibrations Fans Ensure that the heated exhaust air is not taken in again If necessary the heated air must be extracted by fans To ensure perfect cooling even at higher temperatures in the summer the fans must be designed as follows The capacity of the fan must be approx 10 15 greater t
81. re 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 area of the compressor must always be kept tidy and clean 7 Always squat when working on components mounted at low height never stoop When working on components mounted higher up always stand up right and erect 8 Do not exceed the limit value for the end of compression pressure specified on the type plate 9 Do not 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 BOGE operating instr
82. ressor 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 BOGE s service department Page 36 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Installation Checking the scope of delivery Installing the compres sor 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 remove
83. rew compressors Series SLF 30 3 SLF 125 3 Maintenance 62 BOGE maintenance concept 6 2 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 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 57 Maintenance e BOGE maintenance concept List of maintenance SLF 30 3 SLF 125 3 and service work Fig 1 Co O O ON OD n 12 6 1
84. ries SLF 30 3 SLF 125 3 Installation Compressor room 3 2 Compressor room Installation conditions for horizontal or free standing compressed air receivers 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 Ensurethatthe compressed air receiver is easily accessible from all sides for periodic testing Refer to the attached dimensioned drawing for de tails 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
85. rom compressed air oil cooler BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 77 Maintenance EB Special maintenance work 6 5 Special maintenance work Flush out oil circuit Flushing the oil circuit with clean oil becomes necessary When the oil is excessively soiled 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 lubri Motors with lubricating devices are easily recognised by the two grease nip cation device ples on the top of the cover Additionally stickers on the compressor refer to the lubricating device see illustration below Fig 6 13 Grease nipples of the lubricating device 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 lubricating devices regular greasing forms part of the scope of maintenance The lubrication intervals quantity and type of grease are giv en on the type plate or a separate plate For lubrication the required quantity is pressed through the nipple into the bearing with a grease gun while the com pressor is running Page 78 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 12
86. rom the power supply and fix a padlock to prevent the power from being switched on again unintentionally Allow converter to cool off only SLF 40 3 BLUEKAT Every 3 000 operating hours once a year Have safety valve 2 Take out old filter cartridge as described in Removing the filter cartridge on page 67 3 Insert new old filter cartridge as described in Fitting the filter cartridge on page 68 checked Caution Risk of injury Have the function of the safety valve checked by BOGE service personnel only Interval After approx 3 000 operating hours but at least once a year Every 3 000 operating Change the oil filter hours 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 71 Maintenance EN Maintenance work during scheduled services Changing the oil filter 1 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 SLF 40 3 BLUEKAT 2 Close ball valve at the compressed air outlet 3 Remove the cover on the maintenance side
87. rotective gloves while working BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 73 Maintenance EN Maintenance work during scheduled services 6 Unscrew soiled oil separators 4 by hand or use a strap wrench turning anti clockwise see figure below gt Catch the draining oil and dispose of it properly in line with environmen tal regulations 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 compressed air outlet 11 Switch the compressor on and let it heat up until it reaches the operating temperature 12 Switch the compressor off with the OFF button 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 SLF 40 3 BLUEKAT 13 Check the oil separator for leaks once again and tighten by hand if neces sary procedure as described above Page 74 BOGE operating instructions for screw compress
88. rvice department if you have any queries regard ing disposal Telephone 49 5206 601 140 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 63 Maintenance General information concerning the lubri cants used e 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 Do not eat or drink when working with oils Fire naked flames and smoking is strictly prohibited when handling oil Read and observe the information in the relevant safety data sheets We recommend using only oil according to the following specification Viscosity range of 55 mm s at 40 C Minimum viscosity at 100 C of 8 mm s Maximum viscosity at 0 C of 1 000 mm7 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 Additiv
89. s 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 39 Installation Electrical connection Ry Note In the case of the screw compressor SLF 40 3 BLUEKAT the power supply to the integrated converter is provided through the electrical 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 section must be provided
90. s 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 valve 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 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 51 Accessory equipment ES BOGE Duotherm BPT Commissioning Maintenance Proceed as follows during commissioning Check oil level in the oil circuit If necessary top up with oil Slowly open the stop valves in the water supply and discharge line Avoid pressure hammers Ventthe pipelines Limescale oxides as well as grease or oil will be deposited in the ducts in the plate heat exchanger during operation Regular cleaning will prevent thick deposits clogging individual d
91. s on the switch cabinet serving to indi cate the operating state of the converter OOG 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 Page 24 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description EN Safety and monitoring devices The display of the temperature control unit allows you to recall the following temperature information 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 standard display Caution The settings of the temperature control are comple
92. se 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 43 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 the converter The BLUEKAT converter must only be disconnected from the power supply for the purpose of
93. see fig 6 4 b 3 Insert new filter mats in the holder a Switch cabinet b Changing supply air filters optional accessory Fig 6 4 Changing the supply air filter mats Monthly Clean suction Clean the suction controller to remove dirt filter 1x monthly but at least every 500 operating hours Ifthe air intake is very contaminated this should be carried out at more fre quent 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 SLF 40 3 BLUEKAT 2 Remove the cover on the maintenance side 3 Undo the clips 1 on the fil ter housing 4 Remove the lid 2 of the fil ter housing 5 Take out the filter cartridge 3 Fig 6 5 Taking the suction filter out BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 67 Maintenance Maintenance work between scheduled services 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 mu
94. sonal protective equipment Accident prevention regulations 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 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 Germ
95. ssed air network 37 Connecting the cooling water optional accessory 37 Removing the transport securing bolts ssessss 38 Checking the oil level esee 38 Page IV BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 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 6 3 Electrical COMMECtION cccceeeeenteeeeeeeeneeeeeseceeeeeeeseeeneeeenseeeneneenss 39 Comimissioning 1 REED eR er ES 41 Checking installation requirements seeeeeeee 41 Checking the rotational direction of drive and fan motor 41 Checking compressed air outlet for leak tightness 42 Opening the stop valves ssssssssssssseeeeeenee 42 Checking for leaks rninn daed iaaa 43 GConductirig iral Tn soit eerte greens EN AAE EAEE veda 43 Commissioning following extended stoppages 44 Refrigerant compressed air dryer sss 45 Dismantling erre eene 46 General information eese ensem 47 General faults lere rra s rria TEA 47 Converter faults SLF 40 3 BLUEKAT eee 49 BOGE Duotherm BPT 2 cccceseeeseeeeeeeceeeeeeeeeeeeeeeeeeeeneaneeeeeeeeeeens 51 Ul
96. st be replaced with a new one Monthly Check oil level top up with oil if necessary 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 element 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 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 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 SLF 40 3 BLUEKAT 2 Close ball valve at the compressed air outlet 3 Remove the cover on the maintenance side 4 Vent compressor fully as described at the start of this section 5 Wait approx
97. still 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 wear 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 For S 40 3 BLUEKAT screw compressors the compressed air production de pends 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 ye
98. substances contained in the cooling water used do not exceed the following values Substances Symbol max admissible concentration mg l Ammonia NH 20 Chloride lt 70 C Cl 100 Free chlorine Cl lt 0 5 Iron Fe 02 Free agressive carbon dioxide CO 20 Manganese Mn 0 1 Nitrate NO 100 Oxygen O lt 2 Silicon oxide SiO lt 8 Sulphate SO 60 Total dissolved substances TDS 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 malfunctions and cause the compressor to switch off Please consult BOGE Page 28 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 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 tr
99. t 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 are 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 after the treatment process While 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 prior 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 19 Product description EN Compressor control Network pressure Operating states 4 gt Compressed air outlet Fig 2 4 BLUEKAT functional diagram including compressed air flow direction 2 4 Compressor control For the compressor the pressure downstre
100. t meaning that no oil free compressed air would be available The compressor is in the opera tional availability standby mode see Operating states on page 20 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 on page 20 The compressor will now start to produce compressed air while the converter is ready for treatment of the compressed air BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 21 Product description EN Compressor control 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 a
101. ted converter of the SLF 40 3 BLUEKAT compressor must be carried out by specially trained BOGE serv ice personnel only Failure to observe this may cause physical injury and damage to the com pressor station Maintenance work Every 3 000 operating 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 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 Tab 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 se
102. tely 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 Lighting of the indicator lamps serves to indicate Indicator lamp Meaning The temperature inside the converter is below the temperature Preheating Aufheizen which is needed to release compressed air production The indi yellow cator 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 Operation Betrieb reached for enabling compressed air production the yellow indi green cator lamp extinguishes before the green lamp lights up At the same time the compressor initialises compressed air production 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 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 25 Product description Safety and monitoring devices Safety valve Safety valve 1 on the com pressed air oil vessel prevents the maximum admissible pres sure from being exceed
103. the mains disconnection device and secure it with a padlock to prevent it from being switched on again inadvertently Allow converter to cool off only SLF 40 3 BLUEKAT Checking compressed air outlet for leak tight ness Interchange two phases L1 L2 or L3 in the motor 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 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 SLF 40 3 BLUEKAT Opening the stop valves 4 If necessary have any leakages remedied by experienced expert person nel Record the test results in the commissioning certificate Open ball valve at the compressor output For water cooling Open the stop valve at the wate
104. thorized 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 as they were in when the damage was detect ed In the event of any other complaints please inform us within six days of the arrival of the delivery BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 11 General information E Introduction Data on the rating plate Enter the details for your compressor from the rating plate or enclosed data sheet in the following illustration 1 1 This will ensure that in the event of enquiries you will always have the most important data to hand gt BOGE Type Series Machine no Delivery volume max m min Final compression pressure bar Motor speed min Motor rating kW Otto Boge StraBe 1 7 D 33739 Bielefeld Telefon 05206 601 0 Postfach 100713 D 33507
105. tter 1 controls the operation of the compres sor within the set switching limits gast 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 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 the 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 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 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 operat
106. uck 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 transportation can damage the compressor During transport the safety covers must not be subjected to any forces or loads Ensure that the forks are underneath the base frame of the compressor see illustra tion 1 Fig 3 1 Transport with forklift truck BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Page 29 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 p
107. uctions for screw compressors Series SLF 30 3 SLF 125 3 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 modifications 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 depart ment 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 dang
108. ucts of the plate heat exchanger Cleaning intervals Excessively soiled or hard water 6 months Moderately soiled water surface water 1 year Lightly soiled water 3 years Recommended cleaning agents Grease or oil deposits Paraffin Oxide or limescale deposits formic acid acetic acid or citric acid 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 Page 52 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Accessory equipment ES BOGE Du
109. 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 SLF 40 3 BLUEKAT Never omit a single safety step Otherwise you will risk injuries due to restart ing electric shock or self releasing parts Caution If the automatic restart Auto Restart is activated the compressor may restart automatically after a voltage failure This is conditional upon The net pressure being lower than the set switch on pressure Page 40 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Installation Commissioning 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 Commissioning must only be carried out by authorised and
110. vailability 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 pin the compressor starts and operates in load operation Once the operation pressure p 4 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 FOCUS 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 SLF 40 3 BLUEKAT It is of utmost importance to consult BOGE if you op erate your system with short operating times Page 22 BOGE operating instructions for screw compressors Series SLF 30 3 SLF 125 3 Product description EX Control devices Operating pressure transmitter General information 2 5 Control devices The operating pressure transmi

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