Service Manual US-S 40-3... S 150-3
Service Manual US-S 40-3... S 150-3
Service Manual US-S 40-3... S 150-3
Belt-driven
screw compressors
Series
S 40-3...S 150-3
SF 60-3...SF 150-3
Separate manuals:
Compressor control
Frequency converter (SF)
Operating instructions
for belt-driven
screw compressors
BOGE KOMPRESSOREN
Postfach 10 07
33507 Bielefeld
Otto-Boge-Straße 1-7
33739 Bielefeld
Issue: 07 / 2013
No. 596.1252.18
Contents
1.2 Introduction..................................................................................... 6
Symbols used ................................................................................... 7
Warning signs on the compressor .................................................... 7
Intended use ................................................................................... 13
Foreseeable misuse ....................................................................... 13
Transport damage .......................................................................... 13
Data on the rating plate .................................................................. 14
Service............................................................................................ 14
Operating instructions for S 40-3...S 150-3 series screw compressors Page III
Contents
3.3 Installation..................................................................................... 36
General information ........................................................................ 36
Checking the scope of delivery ....................................................... 36
Installing the compressor ................................................................ 36
Connecting the compressor to the compressed air network........... 37
Connecting the cooling water (optional accessory) ........................ 37
Removing the transport securing bolts ........................................... 38
Activating the belt tensioning device............................................... 38
Checking the oil level ...................................................................... 38
WARNING!
Failure to observe the following safety instructions can lead to injuries and
damage to the compressor.
Observe the general safety and accident prevention regulations in addition
to the information in these operating instructions!
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 oper-
ating instructions.
3. The owner must ensure,
– that only appropriately trained and authorised personnel work on this
compressor,
– that persons whose ability to react is restricted due to the misuse of
e.g. drugs, alcohol, medication etc., are prevented from working on
this compressor,
– that operating, maintenance and repair personnel is fully conversant
with all safety instructions, and that these safety instructions are ob-
served,
– that the compressor is only operated if it is in safe working order.
4. Avoid any way of working which may impair the safety of the compressor.
5. Always wear your compulsory personal protective equipment as protection
against injuries from sharp corners or edges when working on the com-
pressor.
6. To avoid dangers from debris or parts lying around, the working area of the
compressor must always be kept tidy and clean.
7. Always squat when working on components mounted at low height, never
stoop. When working on components mounted higher up, always stand up-
right and erect.
8. Do not exceed the limit value for the end of compression pressure specified
on the type plate.
9. Do not 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.
Special hazard warnings – Always wear your compulsory personal protective equipment when work-
ing on pressure pipes and connections!
– A protective grid serves to prevent you from accidentally reaching into the
impeller in the cooling fan.
– 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)!
Dangers of electricity
Personnel requirements 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!
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.
WARNING!
During repair and maintenance, use only original spare parts, compressor
oils and operating materials approved by BOGE.
Accident prevention The operator of a compressor station is responsible for ensuring that it is prop-
regulations erly installed, operated and maintained.
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.
1.2 Introduction
The purpose of these operating instructions is to familiarise the user with the
operation and all uses and features of the compressor.
These operating instructions contain important information on how to operate
the compressor safely, economically and according to its intended use. Ob-
serving these operating instructions will help to prevent danger, reduce repair
costs and downtimes and increase the reliability and service life of the com-
pressor. They contain important information on the necessary maintenance
and repair work, assists in the event of faults and contains information on spare
and wear parts.
These operating instructions must be available at all times to the compressor
operating personnel at the place of use.
The operating instructions must be carefully read and applied by all persons
authorised to undertake the following work on the compressor:
– Operation, including fault rectification and daily care
– Servicing (maintenance, inspection, repairs)
– Commissioning
– Transport
The compressor and its additional equipment must not be installed and com-
missioned 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!
Symbols used In these operating instructions attention is drawn to important safety advice
and tips with the following symbols:
WARNING!
This symbol warns of danger to life and limb of the machine operator or other
persons or dangers which might destroy or damage the compressor.
NOTICE!
This symbol indicates information and tips on saving energy and prolonging
the life of the compressor through careful use.
NOTICE!
All warning signs on the compressor and in its surroundings must be kept in
a legible condition at all times. Missing or damaged signs must be replaced
at once!
hidden
Intended use
WARNING!
BOGE compressors, including their accessory equipment, are exclusively
intended for the compression of air in industrial applications. The air taken
in must not contain any explosive or chemically unstable gases or vapours.
Do not exceed the specified end of compression temperature.
BOGE compressors are designed for stationary operation.
Ensure that they are installed and operated in dry and clean rooms only.
The emergency stop device of the compressor (emergency stop switch/
button) is exclusively intended to switch off the compressor in case of emer-
gency.
Operation and control are designed to be carried out by trained and author-
ised operators.
Foreseeable misuse
WARNING!
Never direct the compressed air generated towards persons.
This can be life-threatening!
Oil is injected into the pressure chambers of the compressor.
Only use the compressed air generated for breathing purposes, or allow it to
come into contact with foods, if it was treated appropriately beforehand.
This BOGE compressor is not explosion-protected.
Do not operate in explosive areas or in a potentially explosive atmosphere!
Do not operate the compressor in rooms in which extreme dust, toxic or flam-
mable vapours and gases may occur.
The emergency stop device of the compressor (emergency stop switch/but-
ton) must not be used as a normal means of switching the compressor off.
Use the OFF button to switch the compressor off normally.
The following is not permitted:
– Compressing other media than those specified as the intended use or air
containing contaminants.
– Exceeding the end of compression pressure indicated on the type plate.
– Altering the safety devices and safety covers, or putting them out of oper-
ation.
– Removing or painting over signs and symbols on the compressor.
– Operation of the compressor by unauthorised or untrained persons.
Transport damage BOGE does not accept any liability for breakage or transport damage. Please
inspect the compressor immediately after delivery and direct damage claims
to the last haulier – even if the packaging is not damaged! To safeguard claims
against the haulier we recommend leaving the machine, devices and packing
material in the same condition they were in when the damage was detected.
In the event of any other complaints, please inform us within six days of the
arrival of the delivery.
Data on the rating plate Enter the details for your compressor from the rating plate or enclosed data
sheet in the illustration below.
This will ensure that in the event of enquiries, you will always have the most
important data to hand.
Service Please do not hesitate to contact BOGE service if you have any questions.
Please call:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
If you have any queries, please always specify the following data for your com-
pressor to prevent any delays:
– Type
– Year of manufacture
– Machine number
WARNING!
Only BOGE service technicians or persons authorised by BOGE in writing
may repair or modify the compressor during the warranty period. Otherwise
all warranty claims will expire!
Measurement surface
– silenced / super silenced [dB(A)] 15 / - 15 / 16 15 / 16 16 / 17 16 / 17 16 / 17
Sound power level
– silenced / super silenced [dB(A)] 79 / - 88 / 87 89 / 88 93 / 88 95 / 90 96 / 90
Max. sound pressure level [±3 dB(A)]
– silenced / super silenced [dB(A)] 63 / - 72 / 70 73 / 71 76 / 70 78 / 72 79 / 72
Water cooling
Measurement surface
– silenced / super silenced [dB(A)] 15 / - 15 / 16 15 / 16 16 / 17 16 / 17 16 / 17
Sound power level
– silenced / super silenced [dB(A)] 78 / - 87 / 86 88 / 87 92 / 87 94 / 89 95 / 89
Compressor
Max.final compression temperature [°F] + 230 + 230 + 230 + 230 + 230 + 230
Volume flow according to
ISO 1217 appendix C at:
– pmax = 100 psig [cfm] 192.24 244.83 269.10 286.76 352.02 474.70
– pmax = 115 psig [cfm] 183.97 228.81 257.76 272.95 336.86 451.97
– pmax = 125 psig [cfm] 183.97 228.81 257.76 272.95 336.86 451.97
– pmax = 150 psig [cfm] 167.02 204.80 230.57 240.46 298.02 386.64
– pmax = 190 psig [cfm] 140.18 175.14 195.97 207.98 256.35 335.80
Drive motor
Rated power [Hp] 40 50 60 60 74 101
Rated speed
– 60 Hz [rpm] 3600 3600 3600 3600 3600 3600
Protection type IP TEFC TEFC TEFC TEFC TEFC TEFC
ISO class F F F F F F
Electrical connection
208 / 230 /
Mains voltage compressor 1) [V] 230 / 460 / 575 460 / 575 460 / 575 460 / 575 460 / 575
460 / 575
Frequency 1) [Hz] 60 60 60 60 60 60
Fuse protection for 208 V 2) [A] 150 - - - - -
Fuse protection for 230 V 2) [A] 125 175 - - - -
Fuse protection for 460 V 2) [A] 60 70 90 90 125 150
Fuse protection for 575 V 2) [A] 50 60 70 70 90 125
1)
Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.
2)
Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies.
Measurement surface
– silenced / super silenced [dB(A)] 17 / 18 17 / 18 17 / 18
Sound power level
– silenced / super silenced [dB(A)] 93 / 90 96 / 92 96 / 92
Max. sound pressure level [±3 dB(A)]
– silenced / super silenced [dB(A)] 75 / 71 78 / 73 78 / 73
Water cooling
Measurement surface
– silenced / super silenced [dB(A)] 17 / 18 17 / 18 17 / 18
Sound power level
– silenced / super silenced [dB(A)] 92 / 89 95 / 91 95 / 91
Compressor
Max.final compression temperature [°F] + 230 + 230 + 230
Volume flow according to
ISO 1217 appendix C at:
– pmax = 100 psig [cfm] 504.78 565.29 682.58
– pmax = 115 psig [cfm] 483.04 540.95 649.70
– pmax = 125 psig [cfm] 483.04 540.95 649.70
– pmax = 150 psig [cfm] 421.25 519.41 575.55
– pmax = 190 psig [cfm] 349.57 432.55 501.40
Drive motor
Rated power [Hp] 101 121 147
Rated speed
– 60 Hz [rpm] 3600 3600 3600
Protection type IP TEFC TEFC TEFC
ISO class F F F
Electrical connection
Mains voltage compressor 1) [V] 460 / 575 460 / 575 460 / 575
Frequency 1) [Hz] 60 60 60
Fuse protection for 208 V 2) [A] - - -
Fuse protection for 230 V 2) [A] - - -
Fuse protection for 460 V 2) [A] 150 175 200
Fuse protection for 575 V 2) [A] 125 150 175
1)
Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.
2)
Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies.
Max. cooling water quantity [cfm] 2.1 2.1 2.1 2.5 2.5 2.5
Cooling water inlet temperature
– min. [°F] + 41 + 41 + 41 + 41 + 41 + 41
– max. [°F] + 86 + 86 + 86 + 86 + 86 + 86
Cooling water outlet temperature
– max. [°F] + 113 + 113 + 113 + 113 + 113 + 113
Cooling water pressure
– min. [psig] 30 30 30 30 30 30
– max. [psig] 145 145 145 145 145 145
Measurement surface 15 / 16 16 / 17 17 / 18
– silenced / super silenced [dB(A)]
Sound power level
– silenced / super silenced [dB(A)] 89 / 88 96 / 90 96 / 92
Max. sound pressure level [±3 dB(A)]
– silenced / super silenced [dB(A)] 73 / 71 79/ 72 78 / 73
Water cooling
Measurement surface
– silenced / super silenced [dB(A)] 15 / 16 16 / 17 17 / 18
Sound power level
– silenced / super silenced [dB(A)] 88 / 87 95 / 89 95 / 91
Compressor
Max. final compression temperature [°F] + 230 + 230 + 230
Volume flow according to
ISO 1217 appendix C at:
– pmax = 100 psig [cfm] 58.24 – 269.10 119.79 – 474.70 172.13 – 682.58
– pmax = 115 psig [cfm] 55.79 – 257.76 114.05 – 451.97 163.84 – 649.70
– pmax = 125 psig [cfm] 55.79 – 257.76 114.05 – 451.97 163.84 – 649.70
– pmax = 150 psig [cfm] 50.85 – 230.57 101.69 – 386.64 150.77 – 575.55
– pmax = 190 psig [cfm] 42.02 – 195.97 88.63 – 335.80 119.70 – 501.40
Drive motor
Rated power [Hp] 60 60 60
Rated speed
– 60 Hz [rpm] 3600 3600 3600
Protection type IP TEFC TEFC TEFC
ISO-class F F F
Electrical connection
Mains voltage compressor 1) [V] 460 460 460
Frequency 1) [Hz] 60 60 60
Fuse protection for 460 V 2) [A] 90 150 200
Fuse protection for 575 V 2) [A] - - -
1)
Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.
2)
Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies.
Functional principle of The air end operates according to the displacement principle. In the housing,
the air end the main and secondary rotors are driven by means of an electric motor and
V-belts.
Air circuit
1 Intake filter
The intake filter cleans the air suctioned by the air end.
2 Intake regulator
The intake regulator opens (load operation) or closes (idling operation or
standstill) the suction line depending on the operating condition of the
compressor.
3 Air end
The air end compresses the air which is sucked in.
4 Compressed air-oil separator vessel
The compressed air separates from the oil under the force of gravity in the
compressed air/oil vessel.
5 Oil separator
The oil separator separates the residual oil contained in the compressed
air.
6 Minimum pressure non-return valve
The minimum pressure non-return valve does not open until the system
pressure has increased to 51 psig. This causes a rapid build-up of the
system pressure and ensures lubrication in the starting phase. Once the
compressor has been switched off, the check valve prevents the com-
pressed 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.
Oil circuit The oil injected into the air end has the following function:
– It dissipates the compression heat (cooling).
– It seals the gaps between the rotors and between the rotors and the hous-
ing.
– It lubricates the bearings.
Network pressure For the compressor, the pressure downstream of the non-return valve is known
as the network pressure. The control system switches the compressor on and
off during operation depending on the network pressure.
Operating states All screw compressor controls are based on three basic operating states:
1. Load operation
– The compressor delivers its maximum amount of compressed air.
– It consumes its maximum amount of energy.
2. Idling operation
– The compressor runs but does not deliver any compressed air.
– It consumes approx. 75% less energy than in load operation.
– When compressed air is required, it switches to load operation with out
delay.
– Idling operation reduces switching frequencies which can damage the
drive motor, and reduces wear of the system.
3. Standstill ready for operation
– The compressor is standing still but ready for operation.
– When compressed air is required, it switches automatically to load
operation.
Operating modes The two most important operating modes are achieved by combining the three
operating states:
1. Intermittent operation
In intermittent operation the energy balance is perfect.
– The compressor operates in load operation.
– Upon reaching the switch-off pressure pmax the compressor switches
to standstill. It does not consume any energy.
– Once the pressure has dropped to the switch-on pressure pmin 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 pmin the
compressor switches from idling operation back to load operation.
Controlled operation If the pressure has dropped below the switch-on pressure pmin the compressor
(frequency control) starts and operates in load operation.
Once the operation pressure ptarget has been exceeded the control is activated
and reduces the speed.
If the pressure has dropped below the operating pressure ptarget the control is
activated and increases the speed.
Upon reaching the switch-off pressure pmax the compressor switches to idling-
operation.
The settings for pmin and pmax are effected by the parameterisation of the BASIC/
FOCUS.
For the BASIC control the setting for ptarget is effected at the potentiometer R3
in the compressor switch cabinet.
For the FOCUS control the setting for ptarget is effected via parameterisation of
the control.
WARNING!
During short operating times, the compressor does not reach its operating
temperature. It operates below the dew point. The condensate generated
due to physical causes mixes with the oil. The lubricating ability of the oil is
reduced. This leads to damage to the air end. It is of utmost importance to
consult BOGE if you operate your system with short operating times.
Operating pressure The operating pressure transmitter (1) controls the operation of the compres-
transmitter sor within the set switching limits.
Proportional controller The proportional controller is an additional control device intervening in the
(optional accessory for sequences of the intake regulator.
S series) The intake regulator only opens as far as necessary to supply the current com-
pressed air requirement. Thus the compressor saves compression energy.
A compressor with proportional controller is able to supply its ’delivered quan-
tity variable between 0% and 100%. However, the energy consumption does
not reduce accordingly. Therefore, a control is only practical between 50% and
100% of the delivered quantity.
The proportional controller is factory set to a delivered quantity between 50%
and 100% of the compressor capacity.
The proportional controller closes when the desired delivered quantity has
dropped below 50% of the compressor capacity. The compressor then oper-
ates in idling operation (continuous operation) or switches off (intermittent op-
eration).
General information The safety devices guarantee a high degree of operational safety, in connec-
tion with the BOGE monitoring system.
When one of the safety devices responds, the control system reacts as fol-
lows:
– The compressor is immediately switched off.
– A flashing fault number in the left field of the display indicates the cause of
the fault.
The following monitoring devices are standard for BOGE control systems:
Safety temperature The safety temperature limiting device switches the compressor off as soon as
limiting device the maximum permissible final compression temperature has been reached.
If the temperature drops below the minimum temperature, the compressor will
not start. In the event that the safety temperature limiting device intervenes in
compressor operation:
– Switch off the compressor (OFF button).
– Acknowledge fault.
– Rectify the fault.
– Switch on the compressor (ON-button).
Rotational direction The pressure switch checks the rotational direction of the drive motor each
monitoring (optional time the system starts up.
accessory)
System pressure build- The system pressure build-up unit monitors the system pressure build-up
up (optional accessory) when the compressor starts up.
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.
Serial connection
Parallel connection
Water connection The cooling water must have the following properties:
(for water cooling) Electrical conductivity – > 50 μS/cm at pH-value 7 – 9
Carbonate hardness (CaCO3) – < 15° dH
Total hardness – < 21° dH
Cooling water pressure – max. 145 psig
– min. 30 psig
Cooling water inlet temperature – max. +86 °F
– min. + 41 °F
Max. cooling water quantity – see "Technical data".
Cooling water quality The cooling units are fitted with non-ferrous heat exchangers, as standard. To
avoid damage to these components and to guarantee long term functionality,
ensure that the substances contained in the cooling water used do not exceed
the following values.
NOTICE!
If the specified limit values are exceeded, use cooling units made of other
materials.
Please consult BOGE's service department.
WARNING!
If the cooling water data changes, the cooling units may have to be reconfig-
ured. Incorrectly configured cooling units may cause malfunctions and cause
the compressor to switch off!
Please consult BOGE.
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!
WARNING!
The transport of the compressor must only be carried out by adequately
instructed and authorised personnel!
The capacity of the lifting gear (lifting cart or forklift truck) must correspond
atleast to that of the compressor / the system (see section entitled 2.1 Tech-
nical data)!
Note the position of the centre of gravity prior to lifting the compressor!
The position of the centre of gravity is specified both in the attached dimen-
sioned drawing and on the compressor packaging.
Any loose or pivoting parts must be removed before lifting the unit.
Lifting rings on individual components (such as electric motors) are only
intended for lifting individual components, not for lifting the entire compres-
sor!
The compressor is delivered filled with oil. Do not tilt during transport!
WARNING!
Improper transportation can damage the compressor. During transport, the
safety covers must not be subjected to any forces or loads.
Crane transport
WARNING!
Improper transportation can damage the compressor. During transport, the
safety covers must not be subjected to any forces or loads.
– Lift the compressor only with the transport pallet provided.
– Protect the compressor with shoring (refer to arrows in the illustration).
– Remove the shoring and transport blocks.
– Use only suitable lifting straps with a minimum length of approx. 315 inch-
es!
Intermediate storage In case the compressor is not installed immediately after delivery, it must be
stored in a sheltered location. It must be ensured that during the intermediate
storage neither dust nor humidity can get enter.
NOTICE!
In the case of intermediate storage, please observe the specifications and
directions on the permissible environmental influences (see section entitled
"3.2 Compressor room").
We do not accept any liability for damage occurring as a consequence of
improper storage!
In the event of extended intermediate storage you should consult BOGE's
service department.
Following intermediate storage of more than two months, please observe the
instructions for commissioning after an extended standstill (see section en-
titled "3.5 Commissioning").
Installation conditions
for horizontal or free-
standing compressed
air receivers
WARNING!
– Protect compressed air receivers from damage due to mechanical effects
(e.g. falling objects).
– Ensure that the compressed air receiver and its equipment can be oper-
ated from a safe location.
– Provide safety areas and maintain safety clearances.
– Ensure that the compressed air receiver stands securely. It must also not
shift or tilt due to external forces. This also includes the additional weight
exerted during pressure testing!
– The compressed air receiver must not be bolted to the floor.
– Ensure that the compressed air receiver is easily accessible from all sides
(for periodic testing). Refer to the attached dimensioned drawing for
details of the operating and maintenance areas which must be provided.
– Ensure that the factory label is clearly visible.
– Ensure that compressed air receivers are adequately protected against
corrosion.
– Only use the compressed air receiver for compressors operating with cut-
in and cut-out mode if the pressure fluctuation range amounts to Δp ≤ 20%
of the maximum operating pressure.
Installation surface A level industrial floor without foundation is adequate for the installation of the
compressor. No special fastening elements are required.
WARNING!
Make sure that external vibrations or shock are not able to impact on the
compressor station.
Fire protection The following applies to rooms in which compressors with oil injection cooling
are to be installed:
WARNING!
– For compressors with motor ratings exceeding 54 Hp ensure that the
compressor room is equipped with special fire protection.
– Install compressors with motor ratings exceeding 134 Hp in a separate
fire protected room.
Sound protection Only install compressors in workrooms if the sound pressure level of their
measurement surfaces does not exceed 85 dB (A).
Admissible ambient The compressor room must be clean, dry, cool and free of dust.
temperatures
Admissible ambient temperatures (see also "Technical data“).
Maximum ambient temperature (for air cooling): + 104°F
Minimum ambient temperature: + 41°F
WARNING!
Failure to observe the admissible ambient temperature may lead to the 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.
Frost protection 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 14°F.
Ventilation 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
WARNING!
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.
Fans
Ensure that the heated exhaust air is not taken in again.
If necessary, the heated air must be extracted by fans.
To ensure perfect cooling even at higher temperatures in the summer, the fans
must be designed as follows:
– The capacity of the fan must be approx. 10 - 15% greater than the sum of
the total amount of cooling air required for all the machines that are oper-
ated in the room.
– For free-standing installation, the cooling air requirement specified in the
table corresponds to the required fan capacity.
Cooling air requirement Please refer to the following table for the cooling air requirement and size of
the supply air openings for your compressor Ensure that flaps and weather
protection grids have the necessary free cross section. We generally recom-
mend contacting a specialist company for performing the duct construction
work and planning.
Table 3.1: Cooling air demand, cross-sections of openings and ducts required
Ventilation possibilities
Condensate disposal The air taken in contains water in form of vapour, which turns into condensa-
tion during compression.
WARNING!
The condensate contains oil. Never dispose of it in the public sewage system
without prior treatment.
Strictly observe the effluent disposal laws of your local authorities. Comply
with the Water Act!
BOGE recommends using an oil/water separator.
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.
3.3 Installation
General information BOGE compressor units are supplied ready for connection. Only the work
described in the following paragraphs needs to be carried out during the in-
stallation.
WARNING!
Any installation work must only be carried out by appropriately trained per-
sons or specialists (BOGE service personnel).
Lay all energy supply lines in a trip-proof and barrier-free manner so that
potential accidents are avoided!
Prior to delivery, each compressor is subjected to a trial run in the factory.
It is carefully tested and set. However, the possibility of damage occurring
during transport cannot be excluded.
– Please inspect the compressor immediately after delivery and direct dam-
age claims to the last haulier – even if the packing is not damaged! To safe-
guard claims against the haulier we recommend leaving the machine, de-
vices and packing material in the same condition as they were in when the
damage was detected.
– Prior to commissioning, check the compressor for external damage due to
transport.
– Observe the compressor very closely during commissioning and the follow-
ing trial run.
– If malfunctions occur, switch off the compressor immediately and inform
the BOGE's service department.
Installing the compres- 1. Remove the packaging around and inside the compressor.
sor
WARNING!
The compressor may only be set in operation if the rubber feet have been
fitted! If the feet have been removed for transportation, it is essential that they
be fitted again before the compressor is set in operation!
2. Install the compressor and align it horizontally. The compressor must stand
firmly on the ground on all feet.
Connecting the com- – Connect the compressor to the compressed air network or a compressed
pressor to the com- air receiver.
For this, use a BOGE high pressure hose.
pressed air network
NOTICE!
Do not install a non-return valve in the pressure line.
The compressor is already equipped with a non-return valve.
The pipework for the cooling water circuit in the compressor was fully installed
in the factory.
WARNING!
If the stop valves in the supply and discharge lines are simultaneously closed
in a closed cooling system, an enclosed chamber will result. If the water
heats up in this room, it will expand and the pressure will increase.
Install an expansion vessel and a safety valve to prevent damage to the
cooling units.
Removing the transport The drive unit frame is bolted to the basic frame for transport. To remove the
securing bolts transport securing bolts:
Checking the oil level BOGE compressors are supplied with a full oil filling.
Prior to commissioning, check the oil level as described in the section entitled
"Maintenance".
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.
Never omit a single safety step! Otherwise, you will risk injuries due to restart-
ing, electric shock or self-releasing parts.
WARNING!
If the automatic restart (Auto-Restart) is activated, the compressor may re-
start automatically after a voltage failure
This is conditional upon: The net pressure being lower than the set switch-
on pressure.
3.5 Commissioning
NOTICE!
We recommend drawing up a commissioning certificate in which the test
results during the commissioning process can be recorded.
Check installation
requirements
WARNING!
Make sure that the compressor is installed in compliance with the installation
requirements!
Prior to starting up the compressor for the first time, check to ensure whether
the transport securing device was removed correctly and the GM-belt ten-
sioning device was activated (see chapter "3.3 Installation")!
Record the test results in the commissioning certificate.
WARNING!
Always check the rotational direction of the drive and fan motor prior to com-
missioning.
Even brief operation in the wrong direction of rotation (more than approx.
5 seconds) may cause the total destruction of the air end!
Record the test results in the commissioning certificate.
WARNING!
Ensure that the rotational direction coincides with the rotational direction
arrow on the air end.
1. Re-enable the mains disconnecting device.
2. Switch the compressor on and immediately off again to check the rota-
tional direction.
Opening the stop valves Open ball valve at the compressor output.
For water cooling: Open the stop valve at the water inlet.
Commissioning follow- If an extended stoppage is scheduled, you should contact BOGE's service
ing extended stoppages department beforehand.
Following an extended stoppage of more than 2 months, fill a small amount of
oil into the suction controller prior to starting the compressor!
WARNING!
Only fill the suction controller with the grade of oil used to operate the com-
pressor.
Never mix different grades or brands of oil.
The following compressor oil quantities must be filled into the suction control-
ler:
3.6 Dismantling
NOTICE!
To avoid danger when dismantling the compressor, please consult BOGE's
service department:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
WARNING!
Dismantling the compressor must only be carried out by authorised and qual-
ified personnel with the necessary experience!
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).
WARNING!
Ensure that any work undertaken to rectify faults is carried out by qualified
personnel or specialists only .
Ensure that components which have a safety function are adjusted, repaired
or replaced only by BOGE service personnel.
Please contact BOGE's service department at the following telephone num-
ber if you have any questions.
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
Not delivered, System components in the com- Check oil and compressed air lines inside the compressor; tighten
no pressure build-up, pressor are leaking and/or reseal screw connections, if necessary
max. pressure 7 psig
Minimum pressure valve is Close ball valve and check whether pressure builds up; if so, open
faulty ball valve again immediately; replace minimum pressure valve
Solenoid venting valve does not Check solenoid valve and replace, if necessary
close
Suction regulator does not open Suction regulator or solenoid valve is defective; check and replace,
if necessary
Compressor system has not Check unloading valve and replace, if necessary
vented properly
Compressor oil is very viscous Heat up the compressor system (additional heater available as an
due to low ambient temperature optional accessory)
Oil in suction filter Minimum pressure non-return Check the minimum pressure non-return valve and replace,
valve is leaking if necessary
Suction regulator is leaking Check the suction controller and replace, if necessary
Excessive oil consump- Drain line is blocked Dismantle and clean drain line
tion
Defective oil separator element Check oil separator and replace, if necessary
Safety valve blows Operating pressure setting Set operating pressure to maximum permissible pressure of the
altered from original setpoint screw compressor
System pressure does Venting valve does not open Check venting valve and replace, if necessary
not decrease when
switching off Non-return valve is leaking Examine non-return valve and replace, if necessary
Function 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.
Installation As a rule, the plate heat exchanger is installed in the compressor in the factory
and comes equipped with all the necessary pipework. Only the following work
needs to be carried out during installation:
– Connect the supply and discharge water pipelines to the pipeline system.
Route the pipelines to prevent stresses and vibrations from being transmit-
ted to the heat exchanger.
– Provide venting and draining facilities.
WARNING!
If the stop valves in the water supply and discharge lines are closed simul-
taneously, an enclosed space is created. If the water in this space is heated,
it expands and the pressure increases.
An expansion vessel and safety valve must therefore be installed to prevent
the plate heat exchanger from becoming damaged.
– Dirt trap (pore size: max. 0.02 inch).
The dirt trap at the water inlet protects the plate heat exchanger against
dirt deposits if the water is very dirty.
– Flushing connections
The flushing connections serve to clean the plate heat exchanger.
Free-standing installation
The plate heat exchanger may also be installed as a free-standing unit or 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.
Maintenance Limescale, oxides as well as grease or oil will be deposited in the ducts in the
plate heat exchanger during operation
Regular cleaning will prevent thick deposits clogging individual ducts of the
plate heat exchanger.
Cleaning intervals
Excessively soiled or hard water: 6 months
Moderately soiled water, surface water: 1 year
Lightly soiled water: 3 years
WARNING!
Always observe the instructions of the cleaning agent manufacturer!
Cleaning methods
Flushing:
– First close all stop valves in the supply lines.
– Close all stop valves in the discharge lines.
– Wait until the plate heat exchanger has cooled down.
– Open the flushing connections and drain the plate heat exchanger.
– Flush out the plate heat exchangers.
For this purpose, pump one of the above mentioned cleaning agents
through the plate heat exchangers for an extended period of time.
– After flushing, rinse the plate heat exchanger thoroughly with water
(e.g. using a pressure washer).
– After cleaning, rinse the plate heat exchanger thoroughly with water (e.g.
using a pressure washer).
NOTICE!
If the cleaning measures specified above are not sufficient, you should have
the exchanger cleaned by a service company. Boge's service department will
recommend contracting companies on request.
Function The safety heat exchanger BOGE Duotherm Plus BSW is approved for drink-
ing water. It is integrated in the main stream of the hot compressor oil. The ad-
ditional safety it provides in comparison with the plate heat exchanger results
from the following measures:
– Separation of the circuits
In this heat exchanger, the oil and water circuits are completely separated
by a confining liquid.
The confining liquid transmits the heat. In the event of heat exchanger dam-
age, this prevents the oil and water from mixing.
It is impossible, therefore, for the drinking water to become contaminated.
– Pressure control device
A pressure control device responds immediately to a burst or fractured pipe
within the system, emitting a pulse which can be individually processed
(e.g. alarm, switching off the system).
NOTICE!
Set the pressure control device to a value at least 20% lower than the mini-
mum pressure of the media used.
Operating conditions
Minimum water pressure: 7.25 psig
Maximum water pressure: 232 psig
Maximum oil pressure: 232 psig
Maximum pressure of the confining liquid: 145 psig
Maximum temperature (oil and water): +212 °F
NOTICE!
Exceeding the maximum temperature will result in malfunctioning. A false
alarm will be triggered.
Maintenance The safety circuit, including the pressure control device and the expansion
vessel, forms a closed, maintenance-free system.
WARNING!
Do not open the system under any circumstances.
Opening the system will put the operation and safety of the heat exchanger
at risk!
If confining liquid escapes as a result of damage, send the heat exchanger
to BOGE for repair.
WARNING!
Ensure that maintenance work is only carried out by qualified professionals
or appropriately trained persons.
– Prior to starting any maintenance work, always take the compressor out
of operation as described in these operating instructions before removing
any safety covers or safety devices. Refit the safety covers or safety 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.
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.
NOTICE!
Maintenance contract!
Enter into a maintenance contract with BOGE.
BOGE's service department will maintain your compressor professionally at
regular intervals. Besides retaining your warranty entitlement, it will ensure
maximum safety and reliability for your compressed air supply.
Maintenance intervals The maintenance intervals specified in the following table refer to average
operation and ambient conditions.
Extreme conditions may require shorter maintenance intervals.
The first table contains maintenance and repair work that should be carried out
by the customer himself at regular intervals between the annual service car-
ried out by BOGE service personnel. The intervals between this maintenance
work are shorter (weekly / monthly / every 1,500 operating hours).
The maintenance intervals specified in the second table are longer (every
3,000 / 9,000 operating hours, or once a year / every two years). To retain your
warranty entitlement, BOGE recommends that you have this work carried out
by BOGE service personnel.
NOTICE!
Note down any maintenance work completed in the table on the last page.
This will facilitate troubleshooting by BOGE's service department.
WARNING!
If you use a different oil instead of Syprem S:
it is essential that you contact the BOGE service department to determine the
required oil change intervals.
Check the oil regulator and repair if necessary with the repair kit 2) –
Change nozzle with dirt trap (only up to S(F) 60-3) –
Change oil 2) 70
Special maintenance intervals (see also page 73 onwards):
Flush out oil circuit Maintenance interval:
– If oil strongly contaminated.
– Before changing the type of oil.
Lubricate / For details of the lubrication/replacement intervals
replace drive motor bearings (for motors with no lubrication device) (for motors with no lubrication device): See the infor-
mation given on the type plate of the drive motor.
Have proportional regulation (optional accessory) checked every 3,000 operating hours
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.
2)
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!
General information
concerning the lubri-
cants used
WARNING!
The handling and disposal of mineral oils is subject to legal regulations. It is
an offence not to ensure correct and safe disposal of old oil!
Please instruct one of the known service companies to dispose of used 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
WARNING!
Risk of injury and damage to compressor due to obsolete pressure hoses!
Never use pressure hoses beyond the prescribed service life!
Check hoses and connections regularly for leakages! Check the service life
of the hoses and replace them in due time!
As replacement only use original spare parts released by BOGE!
Used pressure hoses are not permitted as a replacement!
WARNING!
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.
WARNING!
If the nozzle and dirt trap are clogged with dirt, this can considerably increase
oil consumption (only up to S(F) 60-3)!
Weekly: Inspect / replace Check the function of the optional supply air filter mats:
supply air filter – 1x monthly, but at least every 500 operating hours.
(optional accessory) – If the air intake is very contaminated, this should be carried out at more
frequent intervals.
NOTICE!
Keep a packet of spare filter mats in reserve at all times!
WARNING!
Do not clean filter cartridges in liquids.
Do not use any hard objects when cleaning to avoid damaging the filter paper.
If damage is detected or the filter cartridge has already been cleaned twice,
the filter cartridge must be replaced with a new one.
1. Tap on the filter cartridge using the palm of your hand to knock out any
coarse dust.
2. Blow out fine dust from the inside to the outside using dry compressed
air (maximum pressure 72 psig).
3. Clean the sealing surface of the filter cartridge.
WARNING!
Always use the same oil type when topping up. Never mix different oil types
and brands.
6. Remove plug (2) of oil filling socket (1) (see figure below).
7. Check oil level.
Æ The oil level must not drop below the "min." mark (see figure below).
8. If necessary, top up with oil to the lower edge of the thread ("max." mark)
on the oil filling socket (see figure below).
9. Screw plug (2) back in (see figure below).
10.Put the cover back on on the maintenance side
11.Open ball valve at the compressed air outlet.
NOTICE!
The service life of the compressed air/oil cooling unit depends on the degree
of soiling (dust, oil vapour) of the suctioned cooling air. Extreme external soil-
ing of the cooling unit leads to an increased temperature in the oil circuit.
WARNING!
Do not use sharp objects to clean the cooler!
Sharp objects could damage the cooler.
6. Extract the blown out dirt directly with an industrial vacuum cleaner (2) (see
the figure below).
7. Screw the maintenance opening on again onto the cooling air duct box.
8. Put right side of the sound insulation hood back on again.
NOTICE!
If the cooling unit is excessively soiled (cleaning is no longer possible with
compressed air), have it disassembled and cleaned by BOGE customer
service.
Every 1,500 operating Clean the oil cooler and the air cooler in the case of water cooling:
hours: Clean the oil – After 1,500 operating hours.
cooler / air cooler – In the event of excessive lime deposits and dirt.
(water cooling)
NOTICE!
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.
2. Take out old filter cartridge (as described in “Removing the filter cartridge”
on page 60).
3. Insert new filter cartridge (as described in “Fitting the filter cartridge” on
page 60 ).
Interval: After approx. 3,000 operating hours, but at least once a year.
6. Unscrew dirty oil filter (3) by hand or with a strap wrench in the direction
shown by the arrows on the oil filter (see illustration below).
Æ Catch the draining oil and dispose of it properly in line with environmen-
tal regulations.
WARNING!
Do not use tools to screw on the new oil filter!
You might damage the oil filter or its sealing ring.
A hand-tight fit of the oil filter is sufficient.
14.Check the oil filter again for leaks and tighten by hand, if necessary (proce-
dure as described above).
15.Check oil level. If necessary, top up with oil to offset any losses.
6. Unscrew soiled oil separators (4) by hand or use a strap wrench, turning
counterclockwise (see figure below).
Æ Catch the draining oil and dispose of it properly in line with environmen-
tal regulations
WARNING!
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
13.Check the oil separator for leaks once again and tighten by hand if neces-
sary (procedure as described above).
WARNING!
The new V-belts must be exactly the same length.
Only change the V-belts as a complete set!
NOTICE!
The settings shown in the table are fixed by the manufacturer and may not
be changed. Slight deviations are allowed and compensated by the GM drive
system.
The current settings are also shown on the GM drive system. With special
versions the settings on the sticker may deviate from the standard values.
WARNING!
If you use a different oil instead of Syprem S:
it is essential that you contact the BOGE service department to determine the
required oil change intervals.
NOTICE!
The service life of the oil, the oil filter and oil separators is reduced under the
following conditions:
– When the compressor is operated at extreme ambient temperatures.
– When the intake air is extremely contaminated.
WARNING!
Never use any tools to screw on the cap nut!
They might damage the solenoid valve.
6. During the output phase, press the OFF button on the compressor, and
after approx, 3 seconds, or after a residual pressure of 29 psig, shut down
the compressor with the emergency stop button.
WARNING!
After each oil change you have to fill a small quantity of oil into the suction
controller before starting the compressor.
For oil quantity and procedure see section entitled “Commissioning following
extended stoppages”, page 43.
WARNING!
Always fill with the same oil type as previously used. Never mix different oil
types and brands.
The oil circuit must be flushed through prior to changing the oil type.
Fig. 6.9: Solenoid valve on the suction controller with the cap nut screwed on
Fig. 6.10: Drain off old oil from oil/compressed air receiver
Fig. 6.11: Drain off residual oil from compressed air/oil cooler
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.
WARNING!
Detailed information on flushing with BOGE oils can be obtained from the fol-
lowing service numbers:
Telephone: +1-770-874-1570
Telephone: +49 5206 601-140
Drive motors with per- The bearings of the drive motors are generally provided with a maintenance
manent lubrication free permanent lubrication.
Under normal operating conditions (refrigerant temperature max. 104°F, con-
tinuous operation) the bearings are maintenance free for the entire service life.
The service life decreases or increases as thermal stress increases or de-
creases (due to increased or reduced refrigerant temperature).
WARNING!
Have BOGE service dismantle the bearings and install new bearings once
the specified service life has expired.
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).
Drive motors with Read the attached operating instructions carefully before putting the automatic
automatic lubricating lubrication device into operation.
equipment
WARNING!
Always use the same type of grease for lubrication. The lubricating ability can
be sharply reduced if different types of greases are mixed.
If you intend to use a different type of grease:
– Have the bearings removed and thoroughly cleaned by BOGE service
personnel prior to filling with new grease.
Please always observe the specified lubrication intervals and quantities of
grease.
Over-greasing and an excess of lubricant can also destroy the bearings.
NOTICE!
Always set the proportional controller higher than the lowest operating pres-
sure value (pmin)!
Set of V-belts
cairpac 3000 –
Full maintenance kit for 3,000 operating hour service:
Oil filter, oil separator, suction filter cartridge, gaskets (repair kit),
oil regulator (repair kit), nozzle with dirt trap (only up to S(F) 60-3)
Solenoid valve
Oil/water separator
Condensate drain
WARNING!
When ordering, please specify the data on the rating plate:
– Type
– Year of manufacture
– Machine number
On the following pages you will find the individual flow charts for the different
machine types and components.
1 Suction filter
2 Maintenance display (from 41 Hp)
3 Vacuum switch (for suction filter monitoring) *
4 Suction controller
5 Ventilation and regulation control valve
7 Drive motor
8 Compressor air end
9 Sensor for final compression temperature
10 Combined compressed air/oil receiver
11 Oil separator
12 Safety valve
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
19 Differential pressure switch (for oil filter monitoring) *
20 Oil throttle
21 Minimum pressure non-return valve
22 Compressed air aftercooler
23 Pressure sensor for system pressure
24 Pressure sensor for network pressure
25 Stop valve, compressed air outlet
27 Stop valve, oil drainage
28 Non-return valve drainage line (up to 102 Hp)
29 Proportional controller *
30 Differential pressure switch for proportional controller *
31 3/2-way solenoid valve for proportional controller
(for standard control, throughput here) *
37 Free air delivery display for proportional controller *
42 3/2-way solenoid valve for suction controller regulation *
43 Double non-return valve (items 42 + 43 = rapid-start valve) *
44 Double non-return valve (monitoring of rotational direction) *
* Optional accessory
1 Suction filter
2 Maintenance display (from 41 Hp)
3 Vacuum switch (for suction filter monitoring) *
4 Suction controller
5 Ventilation and regulation control valve
7 Drive motor
8 Compressor air end
9 Sensor for final compression temperature
10 Combined compressed air/oil receiver
11 Oil separator
12 Safety valve
15 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
19 Differential pressure switch (for oil filter monitoring) *
20 Oil throttle
21 Minimum pressure non-return valve
22 Compressed air aftercooler
23 Pressure sensor system pressure
24 Pressure sensor network pressure
25 Stop valve, compressed air outlet
27 Stop valve, oil drainage
28 Non-return valve drainage line (up to 102 Hp)
29 Proportional controller *
30 Differential pressure switch for proportional controller *
31 3/2-way solenoid valve for suction control regulation *
(for standard control, throughput here) *
32 2/2-way solenoid valve
33 Control valve water supply (preadjusted)
34 Control valve water supply (preadjusted)
37 Free air delivery display for proportional controller *
42 3/2-way solenoid valve for suction control regulation *
43 Double non-return valve (items 42 + 43 = rapid-start valve) *
44 Double non-return valve (monitoring of rotational direction) *
* Optional accessory
To be provided by customer:
35 Dirt trap
36 Stop valve
101
102
1 Suction filter
2 Maintenance display
3 Vacuum switch (for suction filter monitoring) *
4 Suction controller
5 Ventilation and regulation control valve
6 Pressure switch (for rotational direction, system relief and V-belt monitoring) *
7 Drive motor
8 Compressor air end
9 Final compression temperature display and switch
10 Combined compressed air/oil receiver
11 Oil separator
12 Safety valve
13 Differential pressure switch (for oil separator monitoring) *
13 System pressure switch (for system pressure build-up and monitoring) *
15 Safety pressure switch (for pressure limitation) *
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
19 Differential pressure switch (for oil filter monitoring) *
20 Oil throttle
21 Minimum pressure non-return valve
22 Compressed air aftercooler
23 Operating pressure switch
24 Pressure sensor, compressor network pressure
24.1 Pressure gauge (system pressure)
25 Stop valve, compressed air outlet
26 Pressure sensor for network pressure (frequency converter)
27 Stop valve, oil drainage
27.1 Stop valve, oil drainage (oil cooler, 102 - 340 Hp)
28 Non-return valve drainage line (up to 102 Hp)
31 3/2-way solenoid valve
* Optional accessory
101
104
103
102
1 Suction filter
2 Maintenance display
3 Vacuum switch (for suction filter monitoring) *
4 Suction controller
5 Air relief and regulation control valve
6 Pressure switch (for rotational direction, system relief and V-belt monitoring) *
7 Drive motor
8 Compressor air end
9 Final compression temperature display and switch
10 Combined compressed air/oil receiver
11 Oil separator
12 Safety valve
13 Differential pressure switch (for oil separator monitoring) *
14 System pressure switch (for system pressure build-up and monitoring) *
15 Safety pressure switch (for pressure limitation) *
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
19 Differential pressure switch (for oil filter monitoring) *
20 Oil throttle
21 Minimum pressure non-return valve
22 Compressed air aftercooler
23 Operating pressure switch
24 Pressure gauge
25 Stop valve, compressed air outlet
26 Pressure sensor for network pressure (frequency converter)
27 Stop valve, oil drainage
28 Non-return valve drainage line (up to 102 Hp)
31 3/2-way solenoid valve
32 2/2-way solenoid valve
34.1 Bypass valve *
* Optional accessory
To be provided by customer:
35 Dirt trap
36 Stop valve
1 Suction filter
4 Suction controller
8 Compressor air end
10 Combined compressed air/oil receiver
11 Oil separator
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
21 Minimum pressure non-return valve
22 Compressed air aftercooler
50 Heat exchanger
BOGE Duotherm-Plus
BSW safety heat
exchanger
1 Suction filter
4 Suction controller
8 Compressor air end
10 Combined compressed air/oil receiver
11 Oil separator
16 Thermostatic oil control valve
17 Oil cooler
18 Oil filter
21 Minimum pressure non-return valve
22 Compressed air aftercooler
51 Safety heat exchanger
52 Pressure monitor for leakage
53 Compensation vessel
Page 88
Date Operating Network System Tempe- Intake Oil Oil- Oil Cooling Motor Oil/water Remarks
hours pressure pressure rature filter filter level separator unit mainte- separator
Appendix
* Cl = Cleaning ** C = Check
* Ch = Change ** Ch = Change
Date Operating Network System Tempe- Intake Oil Oil- Oil Cooling Motor Oil/water Remarks
hours pressure pressure rature filter filter level separator unit mainte- separator
Appendix
* Cl = Cleaning ** C = Check
* Ch = Change ** Ch = Change
Page 89
Please record any maintenance work you have completed in the appropriate column
Page 90
Date Operating Network System Tempe- Intake Oil Oil- Oil Cooling Motor Oil/water Remarks
hours pressure pressure rature filter filter level separator unit mainte- separator
Appendix
* Cl = Cleaning ** C = Check
* Ch = Change ** Ch = Change