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Operating instructions

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1. eee 50 Clean or change suction filter sseene 50 Cleaning the filter cartridge 51 Changing the supply air filter mats option een 51 Lubricate drive motor bearings ses 52 Drive motors with permanent lubrication cecceeeeeeeeeeees 52 BOGE Operating instructions for SL 270 SL 481 series screw compressors Page V Index 6 4 Part 7 7 1 A ndi PREIS 72 7 3 Drive motors with lubrication device ssssssssss 53 Checking the oil level topping up oil sesssseeeeses 54 Changing the oil fter iriri irainei Anr mm 56 Changing the oil separator sssssee 58 Oil cliange ee ne rte egere RR o ERE 59 Flushing the oil circuit ssenmm nenn 62 Cleaning the compressed air oil cooling unit air cooling 63 Cleaning the oil cooling unit water cooling 64 Proportional controller option se 64 Checking the safety valve uneessnneeennsssnnnnnnnsnnnnnnnnnnnnnnnnnnn nn 65 Spare parts and optional equipment 66 List of spare and wearing parts for maintenance 66 List of available optional equipment u nennen 66 Guidelines and standards complied with 67 Flow chart
2. Index a 2 5 Safety and monitoring devices eeeeeenee 16 General inp ERR epe en iaa t s 16 Safety temperature limiting device u nennen nennen 17 Safety valve xit tme t e rete dte eens ence dert 17 Monitoring the drive and fan motor sssseesee 17 Rotational direction monitoring option nennen 17 Safety pressure switch option ssseene 17 System pressure build up option ssssessssssss 17 2 6 Water coolirig terere tree rentre 18 Water Cooling sss xin tod eh ti bid aides 18 Serial connection sss ene 18 Parallel connection cccecceceeeeeeeeeeeeeeeaaeaaeceeeeeeeeeetteetenntnaeees 18 2 7 Cooling water ecceit tenere ernennen 19 Water connection for water cooling 19 Cooling water quality essem 19 Part 3 3 1 Transport and storage esee 21 Installation General an nautica ce ath oe d 21 Transport possibilities ssssssemRRRRI 21 Intermediate storage ssssssssssssse eene 22 3 2 Compressor roOom ereciieectcre cene nage dne denota a enn nna 23 Installation maintenance conditions and application for com pressed air receivers arranged below or separately 23 Installation surface sss 23 Eiteprotectiori scrobe Ure NE ates 23 Sound
3. If necessary top up with oil to the lower edge of the thread max mark on the oil filling socket Screw plug back in max min A ANNAM CSS Fig 6 5 Checking the oil level topping up with oil Close sound insulation hood Reattach cladding on the maintenance side Open ball valve at the compressed air outlet Series SL 341 SL 431 SL 481 SLF 271 Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Open sound insulation hood Remove plug 1 with sealing shim 4 from the plug 2 The oil dipstick 3 is inside the document case fixed to the bunch of keys on delivery Insert oil dipstick 3 and check oil level The oil level must not drop below the min mark nor rise above the max mark see sketch BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 55 Maintenance Changing the oil filter Regular maintenance work Remove plug 2 with sealing shim 5 and refill oil if necessary Screw plug 2 with seal ing shim 5 and plug 1 with sealing shim 4 back in max min Fig 6 6 Checking the oil level topping up with oil Close sound insulation hood Reattach cladding on the maintenance side Open ball valve at the compressed air outlet Change After 3 000 operating hours howe
4. ann een 67 Air cooled version standard ccccccccsseeccececaneeceeeeaeenseeeeeeeanees 68 Air cooled version frequency controlled 70 Water cooled version serial connection parallel connection 72 Water cooled version serial connection frequency controlled 74 List of maintenance and service work 78 Page VI BOGE Operating instructions for SL 270 SL 481 series screw compressors General EN General safety instructions 1 1 General safety instructions Caution Nonobservance of the following safety instructions may lead to injuries and damage to the compressor Also observe the generally valid 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 are understood 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 authorized personnel work on this compressor that no persons work on this compressor whose ability to react is re stricted due to misuse of e g drugs alcohol medication etc thatthe operating maintenance and repair personnel has been made fully f
5. Intended use AA Caution BOGE compressors including their additional equipment are exclusively intended for the compression of air The air taken in must not contain any explosive or chemically instable gases or vapours Do not exceed the specified final compression temperature BOGE compressors are designed for stationary operation Ensure that they are only installed and operated in dry and clean rooms Operation and control are designed to be executed by trained and authorized operators Foreseeable misuse AA Caution Never direct the produced compressed air towards persons Danger to life Oil is injected into the pressure rooms of the compressor Only use the produced compressed air for breathing or let it come in contact with foods if it was treated beforehand This BOGE compressor is not explosion protected Do not operate in explosive areas or in a possibly explosive atmosphere Do not operate the compressor in rooms in which extreme dust toxic or flam mable vapours and gases may occur The following is not permitted Compression of other media than those mentioned under intended use or compression of air loaded with contaminants Exceeding the final compression pressure indicated on the type plate Altering the safety devices and safety cladding or placing them out of operation Removing or painting over signs and symbols on the compressor Operation o
6. Vent the compressor as described in the beginning of the chapter The system pressure gauge must indicate a pressure of 0 bar Wait approx 3 minutes to permit the oil to settle Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Remove cladding on the maintenance side Unscrew soiled oil separators 4 by hand or use a strap wrench turning counterclockwise see fig 6 8 Catch the draining oil and dispose of properly according to environmental regulations Lightly oil the sealing rings of the new oil separator Screw in new oil separators 4 by hand turning clockwise 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 Reattach cladding on the maintenance side Open ball valve at the compressed air outlet Switch on the compressor and heat up to operating temperature Check the oil filter for leaks once again Page 58 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Oil change Check the oil sepa
7. Maintenance EN General General information concerning the lubricants used 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 oil Fire naked flames and smoking is strictly prohibited when handling oil Please take notice of the directions in the corresponding safety data sheet We recommend using only oil according to following specification Viscosity range of 55 mm s at 40 C Minimum viscosity at 100 C of 8 mm s Maximum viscosity at 0 C of 1 000 mm s Comply to FZG test acc to DIN 51 354 with failure load stage 10 Test Method A 8 3 90 min 10 Excellent oxidation stability Meets requirements of Pneurop oxidation test Antifoam additives Additives to prevent residue formation Compatibility with all used sealing materials like Neoprene FPM PTFE FKM Viton and acrylic and epoxy resin paints Flash point gt 230 C Additives for excellent demulsifying properties Additives for corrosion protection of metallic surfaces Excellent oxidation stability Rotating bomb oxidation Test ASTM D 2272 higher than 2 400 minutes Meets VDL requirem
8. Page 14 BOGE Operating instructions for SL 270 SL 481 series screw compressors Product description Compressor control Network pressure Operating states Operating modes Short operating times 2 3 Compressor control For the compressor the pressure downstream of the check valve is termed network pressure The control system switches the compressor on and off dur ing operation depending on the network pressure All screw compressor controls are based on three basic operating states 1 Load operation The compressor delivers its maximum amount of compressed air It consumes its maximum 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 without delay Idling operation reduces switching frequencies which can damage the drive motor and reduces wear of the system 3 Standstill ready for operation The compressor is standing still but ready for operation When compressed air is required it switches automatically to load operation The two most important operating modes are achieved by combining the three operating states 1 Intermittent operation In intermittent operation the energy balance is perfect The compressor operates in load operation Upon reaching the switch off pressure Pmax the compressor
9. The delivery scope depends on your order Prior to commissioning please check whether all required parts have been provided Please check the order confirmation for any possible accessory equipment The delivery scope includes the following component parts Operating instructions Keys Electric circuit diagram in the compartment of the switch cabinet List of electrical equipment in the compartment of the switch cabinet Remove the packing material on and in the compressor Install compressor and align 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 cS Note Do not install a check valve in the pressure line The compressor is already equipped with a check valve Connecting the cooling water option Caution Risk of injury Risk of injury due to pressurized water when connecting the cooling water system Close external water mains prior to connection The connection may only be carried out by authorized qualified personnel The pipework for the cooling water circuit in the compressor is completely in stalled at the factory Only the following work must be performed during installation Check whether the water supply has the required data and whether the cooling water quality is adequate see Cooling water qua
10. 3 If the cleaning measures specified above are not sufficient you should have the exchanger cleaned by a service company Boge service will recommend contracting firms on request 5 2 BOGE Duotherm BSW Function The safety heat exchanger BOGE Duotherm Plus BSW is approved for drink ing water It is connected in the main stream of the hot compressor oil The additional safety feature in comparison to the plate heat exchanger is provided through the following measures Separation of the circuits For this heat exchanger the oil and water circuits are completely separat ed by a barrier liquid The barrier liquid transmits the heat In the event of heat exchanger dam age it prevents oil and water from mixing Thus contamination of the drink ing water is excluded Pressure monitor A pressure monitor responds immediately to a pipe rupture within the sys tem emitting a pulse which can be individually processed e g alarm Switching off the system Note 3 Set the pressure to a value at least 2096 lower than the minimum pressure of the media used Operating conditions Minimum water pressure 0 5 bar Maximum water pressure 16 bar Maximum oil pressure 16 bar Maximum pressure of the barrier liquid 10 bar Maximum temperature oil and water 100 C Note 3 Exceeding the maximum temperature will lead to malfunctions A fault alarm is triggered BOGE Operating instructions for SL 270
11. If the net pressure increases to the switch off pressure Pmax the compressor either switches off intermittent op eration or switches to idling operation continuous opera tion Fig 2 3 Operating pressure transmitter The proportional controller is an additional control device intervening in the se quences of the intake regulator The intake regulator only opens as far as necessary to supply the current com pressed air requirement Thus the compressor saves compression energy A compressor with proportional controller is able to supply its delivered quan tity variable between 0 and 100 However the energy consumption does not reduce accordingly Therefore a control is only practical between 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 2 5 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
12. 3 dB A c accord to DIN EN ISO 2151 2009 86 79 86 79 86 79 87 80 87 80 87 80 79 75 81 75 silenced super silenced dB A o 21 Rererence ee measure 18 9 1849 1849 1819 18 9 18 9 18 9 18 19 si enced super silenced dB A z Sound power level 104 98 104 98 104 08 105 99 105 99 105 99 97 94 99 94 silenced super silenced dB A Compressor max final compression temperature C 110 110 110 110 110 110 110 110 Volume flow according to ISO 1217 appendix C at Pmax 8bar m min 33 3 44 2 43 7 6 46 28 21 6 46 34 7 Pmax 10 bar m min 33 2 44 0 43 4 6 18 25 06 61 8 30 5 Pmax 13 bar m min 33 0 42 7 5 46 20 36 5 46 24 7 Drive motor Rated power kW 200 250 315 250 315 355 160 200 Rated speed 50 Hz min 3000 3000 3000 3000 3000 3000 60 Hz min 1800 1800 Protection type IP 55 55 55 55 55 55 55 55 Design IMB 35 35 35 35 35 35 35 35 ISO class F F F F F F F F Electrical connection Mains voltage V 400 400 400 400 400 400 400 400 Frequency Hz 50 50 50 50 50 50 50 50 Min fuse protection A 500 630 630 630 630 800 400 500 Recommended fuse protection A 500 630 630 630 630 800 400 500 Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Only for 400 V 50 Hz The fuse values change in the case of other mains voltages and frequencies Use fuse gL gG or circuit breaker with C charac
13. co 40 Oc BR wD option BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 71 Appendix Flow chart Water cooled version serial connection parallel connection Parallel connection Serial connection Page 72 BOGE Operating instructions for SL 270 SL 481 series screw compressors Appendix Flow chart 10 102 103 104 Oo ON oO FP WD N wo Intake air INLET Compressed air OUTLET Water INLET Water OUTLET Suction filter Maintenance display from 30 kW Vacuum switch for suction filter monitoring Intake regulator Ventilation and regulation control valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil receiver Oil separator Safety valve Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure non return valve Compressed air after cooler Pressure sensor system pressure Pressure sensor net pressure Stop valve compressed air outlet Stop valve oil drainage Check valve drainage line up to 75 kW Proportional regulator Differential pressure switch for proportional controller 3 2 way solenoid valve for prop controller passage here in case of standard control 2 2 way solenoid valve Control valve water inlet preset Control valve water inlet
14. maintenance and repair measures assists in case of malfunctions and con tains data concerning spare and wearing parts The operating instructions must be available to the compressor operating per sonnel at the place of operation at all times The operating instructions must be carefully read and applied by all persons engaged to undertake the following work on the compressor Operation including fault rectification and daily care Maintenance service inspection repair Commissioning Transport The compressor and its additional equipment must not be installed and com missioned until the operating instructions are understood These operating instructions can be supplemented with instructions on the basis of existing national regulations concerning accident prevention and envi ronmental protection In the illustrations the compressor is shown in part without safety cladding or safety devices for better visualization However operation without these com ponents is prohibited Page 6 BOGE Operating instructions for SL 270 SL 481 series screw compressors General E Introduction Symbols used In these operating instructions the most important safety notes and tips are es pecially characterized by the following symbols Caution Risk of injury This symbol indicates information warning of possible danger to life and limb of the operator or other persons Attention This s
15. preset Air delivery indicator for proportional controller 3 2 way solenoid valve forsuction controller Double check valve Pos 42 43 rapid start valve Double check valve rotational direction monitoring option To be supplied by customer 35 36 Dirt trap Stop valve BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 73 Appendix Flow chart Water cooled version serial connection frequency controlled Page 74 BOGE Operating instructions for SL 270 SL 481 series screw compressors Appendix Flow chart 10 102 103 104 on OMAN D gt Oc BR wWD Intake air INLET Compressed air OUTLET Water INLET Water OUTLET Suction filter Maintenance display Suction filter monitoring Suction controller Vent valve Suction control valve Direction of rotation monitoring with double check valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil vessel Oil separator Safety valve Rapid start valve Thermostatic oil control valve Oil cooler Oil filter Minimum pressure non return valve Compressed air after cooler Pressure transmitter system pressure Pressure transmitter net pressure Stop valve compressed air outlet Oil drainage Check valve drainage line 2 2 way solenoid valve water valve option To be supplied by customer 35 36 Dirt trap Stop
16. protection o disce LA ttp dk ee I ad AEERE 24 Admissible environmental influences ssessssssss 24 Anti freeze protection eene 25 Ventilati n i ore rii eed oni etg ree oett reu e eden EE aa 25 Cooling air requirement ssssssseee emen 26 Ventilation possibilities ssssss eI 27 Condensate disposal sssssssssssseme 28 3 3 Assembly eren eret ERR re ie ERE ER e Ree eds 28 General matita dom tentiae s 28 Checking the delivery scope sssssen e 29 Installing the compressor seme 29 Connecting the compressor to the compressed air network 29 Connecting the cooling water option 29 Removing the transport securing devices nennen 30 Checking the oil leval merenie HR Hanna tnn 30 3 4 Electrical connection na 30 Page IV BOGE Operating instructions for SL 270 SL 481 series screw compressors Index 3 5 3 6 Part 4 4 1 Faults 4 2 Part 5 5 1 Optional equipment 5 2 Part 6 6 1 Maintenance 6 2 6 3 Commissioning esee n nennen 32 Check installation requirements eccccceeeeeeeeeeeeeeestneneeeeees 32 Check rotational direction of drive and fan motor 33 Check compressed air outlet for tightness een 33 Opening the stop valve ssssssssssseeeeeennes 34 Checking for le
17. 6 10 Drain off old oil from oil compressed air receiver Filling with new oil Fill up to the edge of the thread of the filling socket max procedure as described above Attention After each oil change you have to fill a small quantity of oil into the suction controller before starting the compressor For oil quantity and procedure see chapter Commissioning Commissioning 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 prior to changing the oil type procedure as described above Reattach cladding on the maintenance side Conduct trial run Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 61 Maintenance Regular maintenance work Check the oil filters and oil separa tors for leaks and tighten by hand if necessary Check oil level procedure as de scribed above Top up oil losses if any e Fig 6 11 Drain off residual oil from compressed air oil cooler Flushing the oil circuit Flushing the oil circuit with clean oil becomes necessary When the oil is excessively soiled Prior to changing the oil type Attention When fl
18. BOGE Service Telephone 49 5206 601 0 AA Caution Dismantling of the compressor may only be carried out by experienced and authorized qualified personnel Make also sure to observe all information in the attached operation instruc tions as to a safe dismantling of the refrigeration compressed air dryer and a secure disposal of the refrigerant Caution Voltage All work on the electrical installation may only be carried out by authorized and skilled electricians Prior to starting the work the power cable to the switch cabinet must be dis connected from the mains and secured against unintentional switching on Page 36 BOGE Operating instructions for SL 270 SL 481 series screw compressors Faults General 4 1 General The tables on the following pages give information on the possible causes of operating faults and measures for their rectification please also refer to oper ating instructions of the compressor control Caution any questions Ensure that any work required to rectify faults is only carried out by trained personnel or specialists Ensure that components which have a safety function are only set repaired or exchanged by BOGE Service Please contact BOGE Service at the following telephone number if you have Telephone 49 5206 601 0 Caution Voltage Prior to any work required to rectify faults Press Emergency Stop button open ma
19. Cooling water inlet temperature min C 5 5 5 5 5 5 5 5 8 max C 30 30 30 30 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 45 45 45 45 Cooling water pressure min bar 2 2 2 2 2 2 2 2 max bar 10 10 10 10 10 10 10 10 Operating pressure transmitter 9 factory settings Pmax 8bar Switch off press Prax bar 8 8 8 8 8 8 8 8 Switch on press Prin bar 7 7 7 7 7 7 78 78 Prax 10 bar Switch off press Prex bar 10 10 10 10 10 10 10 10 Switch on press pi bar 9 9 9 9 9 9 9 8 9 8 Prax 13 bar Switch off press Prex bar 13 13 13 13 13 13 13 13 Switch on press Pirin bar 12 12 12 12 12 12 12 8 12 8 Safety valve Activation pressure at Pmax 8 bar bar 11 11 11 11 11 11 11 11 Prax 10 bar bar 11 11 11 11 11 11 11 11 Prax 13 bar bar 14 14 14 14 14 14 14 14 1 Compressors for other operating pressures Prin Pmax 1 bar Page 12 BOGE Operating instructions for SL 270 SL 481 series screw compressors Product description EN Function description Function principle of the air end Air circuit 2 2 Function description The air end operates according to the displacement principle In the housing the main and secondary screws are driven by means of an electric motor Both screws have screw shaped profiles intermeshing without contact To
20. Spare parts and optional equipment 6 4 Spare parts and optional equipment List of spare and wearing parts Designation for maintenance Filter mat for supply air filter option BOGE Syprem 8000 S special lubricant for screw compressors Lubrication for drive motor bearings Maintenace package oil filter oil separator suction filter cartridge gaskets nozzle with dirt catch Wearing part kit oil regulator intake regulator minimum pressure valve Solenoid valve List of available optional equipment Designation Optional equipment for compressed air treatment Oil water separator Frost protection device Proportional controller Automatic condensate draining unit Bekomat BOGE DUOTHERM BPT Plate heat exchanger BOGE DUOTHERM PLUS BSW Safety heat exchanger Attention When ordering please specify the data on the type plate Type Year of manufacture Machine number Page 66 BOGE Operating instructions for SL 270 SL 481 series screw compressors Appendix Guidelines and standards complied with 7 1 Guidelines and standards complied with The compressor conforms to the following guidelines and standards Guidelines and directives Machinery Directive 2006 42 EC Pressure Equipment Directive 97 23 EC EMC Directive 2004 108 EC Low Voltage Directive 2006 95 EC Simple Pressure Vess
21. after cooler air or water cooled The compressed air is cooled in the compressed air after cooler causing the water contained in the air to condensate 8 Stop valve The screw compressor may be isolated from the mains by means of the stop valve Oil circuit The oil injected into the air end has the following function It dissipates the compression heat cooling Itseals the gaps between the screws and between the screws and hous ing Itlubricates the bearings Fig 2 2 Components of the oil circuit 1 Compressed air oil vessel The oil separated from the compressed air through the force of gravity col lects in the compressed air oil vessel The system pressure forces it out of the receiver into the air end 2 Thermostatic oil control valve Depending on the oil temperature the thermostatic oil control valve either allows the oil to pass through the oil cooler or through a bypass e g in the starting phase Thus the oil constantly maintains its optimum operating temperature 3 Oil cooler air or water cooled The oil cooler cools down the hot oil to operating temperature 4 Oil filter The oil filter traps impurities in the oil 5 Air end The injected oil returns to the compressed air oil vessel together with the compressed air There it is separated through the force of gravity 6 Drainage line The air end suctions the residual oil which collects in the oil separator back into the oil circuit via a drainage line
22. consult BOGE service Attention If the cooling water data changes the cooling units may have to be rede signed Incorrectly designed cooling units may cause malfunctions and the compressor to switch off Please consult BOGE BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 19 Installation Transport and storage General 3 1 Transport and storage 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 may only be carried out by adequately in structed and authorized personnel The capacity of the lifting gear lifting cart or forklift truck must correspond at least to that of the compressor see Technical Data Mind the position of the mass centre prior to lifting the compressor The posi tion of the mass centre is specified both in the attached dimensioned drawing and on the packing of the compressor The compressor is delivered filled with oil Do not tilt during transport Transport possibilities Forklift truck or lifting cart transport Ensure that the forks are un derneath the base frame of the compressor see illustra tion Fig 3 1 Transport with forklift truck BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 21 In
23. indicates the cause of the fault Page 16 BOGE Operating instructions for SL 270 SL 481 series screw compressors Product description EH Safety and monitoring devices Caution Risk of injury Do not operate the compressor without built in safety devices Do not dismantle the safety devices or put them out of operation Safety temperature limiting device Safety valve The safety temperature limiting device switches the compressor off as soon as the max permissible final compression temperature has been reached A dropping below the minimum temperature prevents the compressor from start ing Switch off the compressor OFF button Fault is acknowledged Rectify the fault Switch on the compressor ON button Safety valve 1 on the compressed air oil vessel pre vents the maximum admissible pressure being exceed ed Fig 2 4 Safety valve Caution Risk of injury When the maximum pressure is exceeded e g incorrect setting of the oper ating pressure the entire delivery volume of the compressor is ejected Monitoring the drive and fan motor Rotational direction monitoring option Safety pressure switch option System pressure build up option The following monitoring devices are standard for BOGE control systems The drive motor is monitored by PTC resistors The fan motor is monitored by overcurrent overload release units The pressur
24. mains connection must be equipped with a dis connecting device The mains disconnecting device has to meet the requirements of DIN EN 60204 1 2007 1 Ensure that maintenance work is only carried out by appropriately trained persons 2 Ensure that setting work malfunction rectification and repair is only carried out by specialists or appropriately trained persons 3 Prior to maintenance or repair work Press Emergency Stop button Open mains disconnecting device Secure mains disconnecting device against unintentional switching on by means of a padlock Fix a warning label to the control and fill in the name of the person re sponsible who is authorized to switch on the machine again Check to ensure that all parts are currentless Disconnect the compressor from the compressed air network relieve or block pressurized lines Page 2 BOGE Operating instructions for SL 270 SL 481 series screw compressors General EB General safety instructions Special hazard warnings Exercise extreme caution during repair or maintenance work requiring the compressor to be operational Ensure that no persons are located in the hazardous area Ensure that work on the electrical equipment is only undertaken by quali fied electricians Work on parts and devices under current is prohibited Exceptions are gov erned by the appropriate regulations e g DIN VDE 0105 Prior
25. on the compressor refer to the lubricating device Please check which motor is installed in your compres sor and service it according to the respective instructions Lubricate the bear ings of the drive motor at the prescribed intervals so as not to sustain damage due to lack of lubricant Caution Risk of injury Always exercise great caution when lubricating the bearings with the com pressor running and observe all safety precautions Never put your hand in the area of the fan wheel Fitted safety devices and cladding may not be removed Attention Always use the same type of grease for lubrication The lubricating ability can be sharply reduced if different types of greases are mixed If you intend to use a different type of grease Have the bearings removed and thoroughly cleaned 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 On motors with lubrication devices regular Motorschmierung greasing forms part of the scope of mainte nance The lubrication intervals quantity and type of grease are given on the type plate or a separate plate For lubrication the required quantity is pressed through the nipple into the bearing with a grease gun while the compressor is running Fig 6 4 Grease nipples of the lubrication device BOGE Operating instructio
26. switches to standstill It does not consume any energy Once the pressure has dropped to the switch on pressure pin the com pressor 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 pin the com pressor switches from idling operation back to load operation Attention During short operating times the compressor does not reach its operating temperature It operates below the dew point The generated condensate mixes with the oil The lubricating ability of the oil is reduced This leads to damage on the air end It is of utmost importance to consult BOGE if you operate your system with short operating times BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 15 Product description Control devices Operating pressure transmitter Proportional controller option not with SLF General 2 4 Control devices The operating pressure transmitter 1 controls the operation of the compres sor within the set switching limit Switch on pressure p If the net pressure drops to the set switch on pressure Pin the compressor switches on Switch off pressure p
27. syeway JoJoW DBuioo IIO IIO IIO uogoang siadwa weIs S JON Bunesado ed suuin oo 9Al99dsa1 ou ui 4310 e2ueuojureui pajojduioo ou ojou oseajd BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 78 7 3 List of maintenance and service work Appendix abuey 49 abuey y9 10 U09 09 ax Buiuea z I2 aoueuajulew Buiuea o JojeJedos jene Jolly Jeny ainssoJd ainssoJd sunoy SXJ0U9M JoJow yun Buijoo IIO IIO IIO uoyons einjeJeduia weJs S JON Buyesado ajeq suwnjo9 BANIAdSAa BY ui YIOM e2ueuojureui pojojduioo ay 9jou aseajd Page 79 BOGE Operating instructions for SL 270 SL 481 series screw compressors List of maintenance and service work 7 3 Appendix abuey9 49 abuey 49 10 U09 09 xx Bujueal z I2 eoueuojuieu Bulueajo Jojejedos jana Joh p aunssaid aunssaid s noy Syleuay JOJOW yun Buyjooo IO IO IO uonans auneradug ways JON Bunesodo ojeg SULUNJOD 9Anoedsai BY ui YIOM e2ueuojureui pojojduioo ay 9jou aseajd BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 80
28. BOGE AIR THE AIR TO WORK gt ROGE COMPRESSED AIR SYSTEMS Operating instructions Direct driven screw compressors Series SL 270 SL 340 SL 430 SL 341 SL 431 SL481 oLF 221 SLF 271 Separate instructions Compressor control Frequency converter www boge com Operating instructions for direct driven Screw compressors SL 270 SL 340 SL 430 SL 341 SL 431 SL 481 SLF 221 SLF 271 200 kW 250 kW 315 kW 250 kW 315 kW 355 kW 160 kW 200 kW BOGE KOMPRESSOREN Postfach 10 07 13 D 33507 Bielefeld Otto Boge Stra e 1 7 D 33739 Bielefeld Fon 49 5206 601 0 Fax 49 5206 601 200 Mail info boge com Net www boge com Issue 05 2012 No 596 1005 01 Nominal price 5 00 BOGE Operating instructions for SL 270 SL 481 series screw compressors Pagel Part 1 1 1 General 1 2 Part 2 2 1 Product description 2 2 2 3 2 4 General safety instructions cese 1 Safety instructions for compressor operation nenne 1 Safety instructions for maintenance and repair of the compressor 2 Special hazard warnings ssesseen 3 Electrical energy hazards ssssssseeee ee 4 Obligations of the owner ssssssenm m 4 Personnel requirements sssssssssseeeem 5 Personal protective equipment ssssssssss
29. L 270 SL 481 series screw compressors 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 ventilator 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 room heating In summer it is directed into the open BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 27 Installation Assembly Condensate disposal The air taken in contains water in form of vapour which turns into condensa tion during compression Attention The condensate contains oil Never lead it into the public sewage system without prior treatment Pay attention to the pertaining rules and regulations of your local authorities Oil water separator The BOGE oil water separator separates the oil from the condensate The cleaned water may 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 due to special operating conditions the oil should emulsi
30. L 481 series screw compressors Page 33 Installation Commissioning Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock f necessary have leakages repaired by skilled qualified pesonnel Opening the stop valve Checking for leaks List up the test results in the commissioning certificate Open ball valve on the compressor delivery In case of water cooling Open stop valve at the water supply Caution Risk of injury In case of leakages in the oil circuit there is a certain danger to slip and fall because of oil or water spills Have all connections of the oil or water cooling circuit checked for leakages by authorized qualified personnel During the inspection slip resistant safety shoes and protective clothing are obligatory Conduct trial run Undertake the following to prevent leaks Check screw connection of the lines and retighten if necessary Check to ensure that the oil filter and oil separator are hand tight seated Close mains disconnecting device Switch on the compressor using the ON key The compressor starts When the factory set switch off pressure is reached the compressor cuts off automatically Check network pressure on control display or netpressure manometer If necessary reset operating pressure pressure target value The compres
31. SL 481 series screw compressors Page 41 Optional equipment EN BOGE Duotherm BSW Commissioning Check the oil level in the oil circuit Slowly open the valves on the water side Avoid pressure hammers Vent the pipelines Anyresidual air contained in the heat exchanger will be carried along by the respective medium and escapes via the system Maintenance The safety circuit including pressure monitor and compensation vessel forms an enclosed 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 barrier liquid escapes due to damage send the heat exchanger to BOGE for repair Page 42 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance EN Safety instructions 6 1 Safety instructions Caution Ensure that maintenance work is only carried out by specialists or appropri ately trained person Prior to starting any maintenance work always stop the compressor as described in these operating instructions prior to removing any cladding or safety devices Refit the cladding or safety devices immediately upon 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 op
32. achine parts are voltage free Depressurize all areas under pressure Never omit a single safety step Otherwise you will risk injuries due to restart ing electric shock or self releasing parts Caution When the automatic restart Auto Restart is activated the compressor will start automatically following a voltage loss Prerequisite The net pressure is lower than the set switch on pressure 3 5 Commissioning Note We recommend the drawing up of a commissioning certificate in which the test results during the commissioning process can be listed up Caution Risk of injury The commissioning may only be carried out by experienced and authorized qualified personnel Always wear protective gloves when working on the compressor to avoid bruising of fingers or hands while opening or closing components Check installation requirements Attention Make sure that the compressor is installed according to the installation requirements Prior to starting the compressor for the first time check if the transport secur ing device was duly removed see chapter 3 3 Assembly List up the test results in the commissioning certificate Page 32 BOGE Operating instructions for SL 270 SL 481 series screw compressors Installation Commissioning Check rotational direction of drive and fan motor Attention Always check the rotational directio
33. aks eiiis aN nns 34 Conduct trial Fb eim oe ee etate eere deeds 34 Commissioning following extended stoppages 35 Dismantling z iaga anaie ana ae ebenen 36 G eral Aane ET 37 Self monitoring of controls cceeeeeeeeececeeeeeeeeeeeeeeeeeseeestnnneaeeees 37 General faults erre terrier 37 BOGE Duotherm BPT eese 39 EUnctlon oa ede ttt et aie 39 Assembly rennen rennen IR 39 Commissioning Aaeeea ARAA aeiaai Eea R aaa nennen enne 40 Maintenance 2 ccccceccccceceeeeeee eee ceeaeeaeeeeeeeeeeeeeeeeeeeesnnsaeeeeeeees 40 BOGE Duotherm BSW eese 41 EUnctlOn tue eoe ood PSU PE dae ls 41 COMMISSIONING iiti ei Eoo ERO PERRA 42 Maintenance 21 4 Edere tr n Enea ne den aa a dV DV lies 42 Safety instructions uussunnsnnnnannnnnnnnannannnnnnnnnnnnnnnnnnnnnann nn 43 General en irren 45 Maintenance through BOGE service uuusssssnnneennnsssnnnnnnnnn sn 45 Review of regular maintenance work sse 45 Maintenance intervals ssssssssssseeemm 46 General information concerning the lubricants used 48 Disposal of used operating material sssssssssss 49 Pressure hoses aed cte dame Ga ree dan re 49 Spare and wearing parts sss 49 Regular maintenance work
34. amiliar with all safety instructions and that they are being ob served that the compressor is only operated in a safe operating condition 4 Avoid any operating method which may impair the safety of the compres SOr 5 Always wear your compulsory personal protective equipment as a protec tion against injuries from sharp corners or edges when working on the compressor 6 To avoid dangers from debris or parts lying around the service area of the compressor has always to be kept tiedied up 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 final compression pressure specified on the type plate 9 Do not operate the compressor without the attendant protection and safety devices Do not dismantle any built in safety devices or put them out of operation Ensure that all safety claddings and doors are closed prior to commission ing starting up the compressor and that they are not opened during oper ation 10 Place the compressor out of operation as described in these operating in structions when dismantling the safety claddings or safety devices for re pair or maintenance work Reattach and close all cladding and safety de vices immediately upon completion of the repair or maintenance work 11 Only operate the compressor using the additional equipment options
35. application for compressed air receivers arranged below or separately 3 2 Compressor room Caution Protect compressed air receivers against damage through mechanical effects e g falling objects Operate the compressed air receiver and its equipment from a safe loca tion Adhere to safety areas and safety clearances Ensure that the compressed air receiver stands securely It must not shift or tilt due to external forces This also includes the additional weight dur ing a pressure test The compressed air receiver must not be bolted to the base Ensure that the compressed air receiver is easily accessible from all sides for recurring tests For the necessary operating and maintenance areas have a look at the attached dimensioned drawings Ensure that the factory label is clearly visible Ensure that compressed air receivers are adequatly 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 x 20 of the maximum operating pressure Installation surface Fire protection A level industrial floor without foundation is adequate for the installation of the compressor No special fastening elements are required 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 ensure tha
36. are parts released by BOGE Used pressure hoses are not permitted as a replacement Caution Only use original spare parts compressor oils and operating materials re leased by 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 with dirt catch is soiled the oil consumption may increase signif icantly BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 49 Maintenance Regular maintenance work Clean or change suction filter 6 3 Regular maintenance work Cleaning 1x monthly however at least every 500 operating hours Correspondingly earlier if the air taken in is heavily soiled Change Inthe event of damage After the second cleaning Switch off the compressor with the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Removing the filter cartridge Remove cladding on the maintenance side Remove lid 1 of the filter housing Loosen nut 3 and remove filter cartridge 2 Fig 6 2 Changing the suction filter Page 50 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Cleaning the filt
37. c power to compressor Check electrical connection Fuses are defective Check the mains and control fuses replace if necessary Machine has not vented per fectly Check venting valve and replace if necessary Voltage fluctuations in the elec trical mains power 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 option Oil in suction filter Minimum pressure non return valve is leaking Check the minimum pressure check valve and replace if necessary Suction controller is leaking Check the suction controller and replace if necessary Excessive oil consumption Drain line is blocked Dismantle and clean drain line Defective oil separator element Check oil separator and replace if necessary Excessive oil filling Drain off oil Operating pressure target value maladjusted Set operating pressure to maximum permissible pressure of the Screw compressor Defective safety valve Replace safety valve System pressure does not decrease when switching off Venting valve does not open Check venting valve and replace if necessary Check valve is leaking Examine check valve and replace if necessary Page 38 BOGE Operating instructions for SL 270 SL 481 series screw compressors Optional eq
38. ce flap on the air guidance box Remove accumulated soiling with a fibre brush Attention Do not use any sharp objects for cleaning These could damage the cooling unit If the cooling unit is excessively soiled cleaning is no longer possible with compressed air have it disassembled and cleaned by BOGE service Blow down the dirt with com ON pressed air 1 in the opposite direction to the normal cool ing air flow Vacuum out the dirt using an industrial vac uum cleaner 2 S Wi we NE Zi Zu Fig 6 12 Cleaning the compressed air oil cooling unit BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 63 Maintenance Regular maintenance work Cleaning the oil cooling unit water cooling Cleaning After 1 500 operating hours however not later than after one year Inthe event of excessive lime deposits and dirt Ry Note The service life of the cooling unit depends on the degree of soiling and lime deposits in the cooling water In the event of excessive soiling check the cooling unit correspondingly earlier Proportional controller option Carry out the cleaning as described for plate heat exchangers Check After approx 3 000 operating hours however at least once a year 1 Set operating pressure sensor Switch on pressure p final compression pressure 1 bar Switch off pressure Pmax final compression p
39. connection device and secure against unintentional switch on by means of a padlock Screw cap nut 5 onto the vent hole of the solenoid valve on the suction controller by hand Slowly loosen cap nut 5 until com pressed air escapes Let off compressed air until the sys tem pressure gauge shows a resid ual pressure of approx 2 bar Tighten cap nut 5 by hand 4 Fig 6 9 Solenoid valve on the suction controller with the cap nut screwed on Draining old oil Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Place the oil drain hose into a suitable container 6 see fig 6 10 Slowly open the stop valve The pressure cushion forces the oil into the container Once the compressed air oil receiver has been completely drained close the stop valve Remove the cap nut from the solenoid valve Page 60 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Remove oil filler screw 7 on the compressed air oil cooler and drain the residual oil max 5 litres into a suitable container see fig 6 11 Reinsert the oil filler screw together with a new copper sealing ring Change oil filter procedure as de scribed above Change oil separators procedure as described above Fig
40. e 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 being exceeded The switch off pressure is below the response pressure of the safety valve The system pressure build up unit monitors the system pressure build up when the compressor starts up BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 17 Product description EB Water cooling Water cooling Serial connection Parallel connection 2 6 Water cooling BOGE screw compressors are available in water or air cooled design In the standard version the oil and compressed air after coolers are connect ed in series on the water side A parallel connection is possible as an option 2 3 1 Fig 2 5 Serial connection lt gt i3 x Fig 2 6 Parallel connection 1 Cooling water solenoid valve The cooling water solenoid valve closed the cooling water supply when the compressor switches off 2 Cooling water stop valve The compressor may be separated from the cooling water supply by means of the stop valve e g for maintenance or repair work 3 Dirt trap provided by customer The dirt trap protects the cooling unit against sedimenting Pore size max 0 6 mm 4 Oil cooling unit 5 Compressed air after cooler The water cooling units are designed for specific standard cooling water quan tities tem
41. eck compressor for leaks X IU Ud viu pressure gauge 22 i Control Check function of Emergency Stop button Control Check and if necess change supply air filter option 51 Clean oil cooler X 63 Check if electrical connections are tightened X Air circuit Check and if necessary change suction filter m 50 Change suction filter cartridge X 51 Check reset operating pressure sensor X Control Check safety valve X 65 Replace minimum pressure valve wearing parts set X Replace suction controller wearing parts set Replace solenoid valve Oil circuit Check oil level and top up as required X 54 Change oil separator 58 Change oil filter 56 Change oil X 59 Replace oil regulator wearing parts set X Replace nozzle with dirt catch X Drive Lubricate drive motor bearings See data on type plate of drive motor Replace grease in motor bearings Depending on mains frequency 50 Hz 10 000 operating hours 60 Hz 8 000 operating hours Ifthe compressor is not often used undertake the maintenance according to the specified intervals weekly monthly annually irrespective the number of operating hours 2 have the oil analyzed by your BOGE service Tab 6 1 Maintenance intervals The specified intervals only apply when BOGE compressor oil Syprem 8000 S is used The service life may differ depending on the ambient temperature In this case BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 47
42. egular intervals Only use original fuses Obligations of the owner The owner is obliged to operate the compressor only in technically perfect condition check the Emergency Stop device of the compressor regularly for com pleteness and functionality assess the hazards of the machine working places in his area of respon sibility and to issue the ensuing operating instructions to name a person responsible beeing in charge of 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 means of tech nological and organizational operation scheduling ensure a proper workplace lighting at the compressor control section ac cording to the local health and safety regulations observe the safety data sheet of the used lubricants and to customize the personnel all information as to said data sheet provide the compulsory personal protective equipment and to stipulate and check the wearing of said protective equipment on a regular basis assign the personnel responsible for various tasks and work on the ma chine instruct the personnel on a regular basis with respect to all obligations as to compressor related preservation of safety and tidiness Page 4 BOGE Operating instructions for SL 270 SL 481 series screw compressors General E General safety instructions Personnel requirements Personal protective equipme
43. els 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 SL 270 SL 481 series screw compressors Page 67 Appendix Flow chart Air cooled version standard Page 68 BOGE Operating instructions for SL 270 SL 481 series screw compressors Appendix Flow chart 10 102 o OnN oO FP WO DY N 99 Intake air INLET Compressed air OUTLET Suction filter Maintenance display from 30 kW Vacuum switch for suction filter monitoring Suction controller Ventilation and regulation control valve Drive motor Compressor air end Sensor for final compression temperature Combined compressed air oil receiver Oil separator Safety valve Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure check valve Compressed air after cooler Pressure sensor system pressure Pressure sensor network pressure Stop valve compressed air outlet Stop valve oil drainage Check valve drainage line up to 75 kW Proportional controller Differential pressure
44. ents DIN 51 506 for lube oils including Pneurop test Or you use BOGE compressor oil Syprem 8000 S The stated mainte nance intervals refer to the use of Syprem 8000 S only Syprem 8000 S can be purchased from BOGE retailers Never mix different oil types and brands The additives may be incompatible It may lead to foam formation prema ture aging or loss of lubricating ability Page 48 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance e General Disposal of used operating material Attention The handling and disposal of mineral oils is subject to legal regulations It is an offense not to ensure correct and safe disposal of old oil Please instruct one of the known service companies to dispose of used oper ating materials or deliver them to an authorized disposal point Observe the following points when disposing of old oil Never mix the oil with other material or liquids Used oil filters and oil separator cartridges require special waste treat ment and must be kept separate from normal waste Pressure hoses caf A Spare and wearing parts AA Caution Risk of injury and damage to compressor due to obsolete pressure hoses Never use pressure hoses beyond the prescribed service life Check hoses and connections regularly for leakages Check the service life of the hoses and replace them in due time As replacement only use original sp
45. er cartridge Attention Do not clean filter cartridges in liquids Do not use any hard objects when cleaning to avoid damaging the filter paper Refit a new filter cartridge in the event of damage or when it has been cleaned twice Hit on the filter cartridge using the palm of your hand to knock out coarse dust Blow outfine dust from the inside to the outside using dry compressed air maximum pressure 5 bar Clean the sealing surface of the filter cartridge Changing the supply air filter mats option Fitting a filter cartridge Insert filter cartridge into the filter housing Tighten nut Attach lid of the filter housing Attach cladding on the maintenance side Check 1x weekly however at least every 500 operating hours Correspondingly earlier if the air taken in is heavily soiled Change When a crust of dirt has accumulated on the filter mat When the final compression temperature has exceeded its set point value by 4 to 5 C The crust of dirt on the filter mat prevents an adequate cooling air supply Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 51 Maintenance Lubricate drive
46. erating 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 SL 270 SL 481 series screw compressors Page 43 Maintenance EN Safety instructions Caution Risk of injury Always adhere to the prescribed operating method described below for all maintenance work Never omit a single safety step Otherwise you will risk injury from restarting electric shock or parts which may fly off Prior to all maintenance work 1 Switch off the compressor using the OFF button 2 Press Emergency Stop button 3 Open mains disconnection device and secure against unintentional Switch on by means of a padlock 4 Fix a warning label to the control and fill in the name of the person re sponsible who is authorized to switch on the machine again 5 Check to ensure that all machine elements are definitely currentless 6 Prior to starting work let cool down all hot components of the compressor to 50 C 7 Separate the compressor from the compressed air network by closing the ball valve at the compressed air outlet 8 Vent the compressor To this effect open the safety valve on the combined compressed air oil receiver as follows Turn the knurled nut counterclockwise until you can fee
47. f the compressor by unauthorized 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 when the packing is not damaged To safeguard claims against the haulier we recommend leaving the machine devices and packing material in the same condition as they were in when the damage was detected In the event of any other complaints please inform us within six days after ar rival of the delivery BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 9 General kA Introduction Data on the type plate Service Enter the data of your compressor from the type plate or enclosed data sheet in the illustration 1 1 below This will ensure that in the event of enquiries you will always have the most important data to hand gt BOGE Type Year of construction Serial number F a d m min Final compression pressure bar Motor speed min Motor power a gt gt gt kW Otto Boge StraBe 1 7 D 33739 Bielefeld Telefon 05206 601 0 Postfach 100713 D 33507 Bielefeld Fax 05206 601 200 www boge com info boge com Fig 1 1 Data on the type plate Please do not hesitate to contact BOGE service if you have any questions Please call Telephone 49 5206 601 0 In the event of inquiries always specify the follow
48. filter cartridge Change oil filter Clean compressed air oil cooler externally Top up oil in the suction controller after an extended down time Change oil separator Check oil level Top up oil 9 Oil change 10 Lubricate motor bearings A and B side ON DOO P BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 45 Maintenance E General Maintenance intervals The maintenance intervals specified in the table are based on average oper ating and ambient conditions Extreme conditions may require shorter maintenance intervals Ry Note Note down any maintenance work in the table on the last page This will facil itate trouble shooting for BOGE service Attention Check monthly if all screw connections on the compressor are fully tight ened Oil change Please change oil and replace oil filter and nozzle with dirt catch after the first 500 operating hours Page 46 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance ES General Maintenance work Maintenance intervals in operating hours Page weekly 1 000 1 500 3 000 9 000 monthly annually annually annually every 2 years General maintenance work Check final compression temperature Control set point value 70 100 C Ch
49. fy use an emul sion cracking plant General 3 3 Assembly BOGE compressor units are supplied ready for connection Only the work de scribed in the following paragraphs needs to be carried out during the assem bly Caution Only have the installation work carried out by appropriately trained persons or specialists Lay out all energy supply lines in a trip proof and barrier free manner so that potential accidents can be avoided Prior to delivery each compressor is subjected to a trail run at the factory It is carefully tested and set However possible transport damage cannot be ex cluded Please inspect the compressor immediately after delivery and direct dam age claims to the last haulier even when the packing is not damaged To safeguard claims against the haulier we recommend leaving the machine devices and packing material in the same condition as they were in when the damage was detected Prior to commissioning check the compressor for external damage Observe the compressor very closely during commissioning and the fol lowing trial run f malfunctions occur switch off the compressor immediately and inform the BOGE Service Page 28 BOGE Operating instructions for SL 270 SL 481 series screw compressors Installation Assembly Checking the delivery scope Installing the compressor Connecting the com pressor to the com pressed air network
50. gether with the housing wall these screws form chambers which gradually reduce in size seen in air flow direction 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 having a cooling sealing and lubricating function Fig 2 1 Components of the air circuit Intake filter The intake filter cleans the air suctioned by the air end Intake regulator The intake regulator opens load operation or closes idling operation or standstill the suction line depending on the operating condition of the compressor Air end The air end compresses the suctioned air Compressed air oil vessel The compressed air separates from the oil under the force of gravity in the compressed air oil vessel Oil separator The oil separator separates the residual oil contained in the compressed air Minimum pressure check valve The minimum pressure check valve does not open until the system pres sure has increased to 3 5 bar This causes a rapid build up of the system pressure and ensures lubrication in the starting phase Once the com pressor has been switched off the check valve prevents the compressed air from flowing back out of the mains line BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 13 Product description EN Function description 7 Compressed air
51. gs screw connections and safety de vices have to be rettached During operation the compressor generates a high sound pressure level which may cause permanent hearing damage due to continuous noise stress As a rule the compressor may only be operated with its housing cover closed Make sure to additionally wear a hearing protection in case of a noise pressure level above 80 dB A BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 3 General E General safety instructions Electrical energy hazards Caution Voltage There is danger of life when working on the electrical equipment of the compressor Disconnect mains connection prior to starting to carry out works on the compressor and use padlock to secure against switching on again Only duly authorized professional electricians e g plant electricians are allowed to carry out works in the electrical area of the machine Make sure to check the electrical equipment of the compressor at regular intervals for defects such as loose connections or scorched cables and have any defects repaired immediately Make sure to have all electrical equipment and fixed electrical installa tions checked by a professional electrician at least every 4 years Any modifications that may have been carried out after examination must conform to DIN EN 60204 1 2007 Make sure to check all safety installations on the machine for proper func tioning at r
52. h that dangerous ad mixtures 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 rates in the ducts do 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 Ventilators Ensure that the heated exhaust air is not taken in again If necessary the heated air must be extracted by ventilators To ensure perfect cooling even at higher temperatures in the summer the ven tilators must be designed as follows The ventilator capacity must be rated approx 10 15 higher than the sum of the cooling air quantity required for all machines operated in the room VDMA Code of Practice sheet 4363 Ventilation of compressor rooms For free standing installation the cooling air requirement specified in the table corresponds to the required ventilator 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 SL 270 SL 481 se
53. hV is applicable The regulations are available at the following locations Berufsgenossenschaft Industrial Employers Liability Insurance Carl Heymanns Verlag KG Luxemburger Stra e 449 D 50939 K ln Beuth Verlag GmbH Burggrafenstra e 6 D 10787 Berlin For operation of the compressor plant outside the Federal Republic of Ger many the accident prevention regulations of the country where the compres sor is operated must be observed in addition to the data 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 data contained in these operating instructions then it is of utmost importance that these be carried out prior to commissioning the compressor plant BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 5 General EN Introduction 1 2 Introduction The purpose of these operating instructions is to familiarize the user with the function and all application possibilities of the compressor These operating instructions contain important information on how to operate the compressor safely economically and according to its intented use Ob serving these operating instructions will assist in avoiding danger to reduce repair costs and down times and to increase the reliability and service life of the compressor It contains important information concerning the required
54. horized electricians When connecting to the power supply observe the valid VDE DIN and EVU regulations or the local safety regulations Also observe the regulations of your local power supply company regarding the load rating of your power supply Page 30 BOGE Operating instructions for SL 270 SL 481 series screw compressors Installation Electrical connection Mains disconnecting device According to accident prevention regulation VBG 5 12 the customer is re sponsible to provide the following safety measures Compressor plants having a drive motor larger than 3 kW and current intensi ties larger than 16 amperes have to be equipped with a mains disconnecting device according to DIN EN 60204 1 2007 Please refer to the Technical data for the design and fuse rating Rated voltage The data of your mains operating voltage control voltage type of current fre quency must coincide with the data on the type plate on the switch cabinet In the event of deviations please contact the BOGE service or your supplier Connecting the leads Check to ensure that all terminals in the switch cabinet are firmly tight ened If necessary retighten the screw connections Guide the lead cable through the PG screw connection Connect the leads L1 L2 L3 N Pe PEN firmly to the power supply ter minal A clockwise rotational field must be created Retighten the electrical con
55. ient temperature 5 C Attention Nonobservance of 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 gone below Pipe lines and valves will freeze up at low temperatures Damage due to reduced lubricating ability of the compressor oil Measures to be taken to ensure that admissible ambient temperatures are observed 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 thatthe minimum temperature is not gone below in winter Use of anti freeze function only in mode Ready for operation Page 24 BOGE Operating instructions for SL 270 SL 481 series screw compressors Installation Compressor room Anti freeze protection Ventilation The compressor must be installed frost protected The BOGE anti freeze de vice 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 suc
56. ing data of your compressor to prevent any delays Type Year of manufacture Machine number Attention Only BOGE service technicians or persons authorized by BOGE in writing may repair or alter the compressor during the warranty period Otherwise all warranty claims will expire Page 10 BOGE Operating instructions for SL 270 SL 481 series screw compressors Product description Technical data 2 1 Technical data SL 270 481 and SLF 221 271 part 1 Type SL 270 SL 340 SL 430 SL 341 SL431 SL481 SLF221 SLF 271 Dimensions Height silenced mm 2145 2145 2145 2145 2145 2145 2145 2145 Height super silenced mm 2645 2645 2645 2645 2645 2645 2645 2645 Width silenced mm 3100 3100 3100 3100 3100 3100 3145 3145 Width super silenced mm 3100 3100 3100 3100 3100 3500 3145 3145 Depth mm 1910 1910 1910 1910 1910 1910 1910 1910 Weight silenced kg 3900 4500 4600 5000 5000 5600 4500 4700 super silenced kg 4000 4600 4700 5100 5100 5700 4600 4800 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 2 silenced super silenced dB A 87 80 87 80 87 80 88 81 88 81 88 81 80 76 82 76 M En qe 78 9 189 name aeng aeng aeng 18n 18119 eda level 105 99 105 99 105 99 106 100 106 100 106 100 98 95 100 95 silenced super silenced dB A Max sound pressure level
57. ins disconnection device and secure against unintentional switch on by means of a padlock Self monitoring of controls All programmed data are saved in a memory module EEPROM which can be electrically written on and erased again If an error occurs when the saved data in the EEPROM are read the control reacts as follows The compressor is switched off The corresponding fault message is displayed In this connection we refer to the separate BOGE compressor control operat ing instructions 4 2 General faults Fault Possible cause Rectification No quantity delivered no pressure build up max pressure 0 5 bar System components in the com pressor are leaking Check oil and compressed air lines inside the compressor tighten and or reseal screw connections if necessary Minimum pressure valve is defective Close ball valve and check whether pressure builds up if so open ball valve again immediately replace minimum pressure valve Electromagnetic venting valve does not close Check solenoid valve and replace if necessary Suction controller does not open Suction controller or solenoid valve is defective check and replace if necessary BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 37 Faults General faults Fault Possible cause Rectification Compressor system does not start up No electri
58. l a resilient resistance Turn the knurled nut a little further Any possibly existing air will escape The system pressure gauge will indicate a pressure of 0 bar Once the residual air has completely escaped from the system firmly retighten the knurled nut 9 Remove all safety cladding necessary to perform the maintenance work Once the maintenance work has been concluded 10 Reattach all removed safety cladding 11 Open the ball valve at the compressed air outlet 12 Prior to switching on again check whether anyone else is working on the compressor 13 Remove warning sign not until then and release power disconnecting device 14 Unlock Emergency Stop button Page 44 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance e General 6 2 General Maintenance through Have BOGE service check your compressor every 3 000 operating hours or BOGE service annually Note Maintenance agreement Enter into a maintenance agreement with BOGE BOGE service will carry out the proper maintenance on your compressor at regular intervals This guarantees maximum safety and realiability of your compressed air supply Review of regular maintenance work Fig 6 1 Review of regular maintenance work 1 Change supply air filter on the front side option 2 Check set pressure sensor 3 Check suction filter Clean filter and cartridge Change
59. lity Connect the cooling water supply and discharge line to the water supply BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 29 Installation Electrical connection The following component parts must be provided by the customer for cooling water installation Dirt traps The dirt trap at the cooling water inlet protects the cooling units against sediment 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 room 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 devices Checking the oil level The frame of the drive unit is bolted to the basic frame for transport Open flap 1 Remove the four red marked screws 2 two of each on the longitudinal side together with the space collars Fig 3 4 Removing the transport securing devices BOGE compressors are supplied with a complete oil filling Prior to commissioning start up check the oil level as described in chapter Maintenance 3 4 Electrical connection Caution Voltage Ensure that work on the electrical equipment of the compressor is only car ried out by aut
60. motor bearings Drive motors with permanent lubrication Regular maintenance work Pull filter mat 1 out of its holder from above Insert new filter mat into the holder Fig 6 3 Changing the supply air filter As a rule the bearings of the drive motors are provided with a maintenance free permanent lubrication Drive motors of some compressor series are equipped with a relubrication device These motors are easily recognised by the two grease nipples on the top of the cover Additionally signs on the compressor draw attention to the kind of motor lubrication Under normal operating conditions refrigerant temperature max 40 C conti nous operation the bearings are maintenance free for the service life Mains frequency Operating hours Oh 50Hz 10 000 60 Hz 8 000 Tab 6 2 Service life of bearings The service lives specified above are extended or shortened in the event of higher or lower thermal stress due to the higher or lower temperature of the refrigerant Attention The bearings must be replaced by BOGE service after their service life has expired Page 52 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Drive motors with lubrication device Motors with lubricating devices are easily recognised by the two grease nip ples on the top of the cover Additionally stickers
61. n of the drive and fan motor prior to com missioning initial start up Even brief operation in the wrong direction of rotation more than approx 5 seconds may cause total destruction of the air end List up the test results in the commissioning certificate Caution Ensure that the rotational direction coincides with the rotational direction ar row on the air end Close mains disconnecting device Switch the compressor on and immediately off again to check the rota tional direction Changing the rotational direction Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Interchange two phases L1 L2 or L3 in the power cable Check compressed air outlet for tightness Caution Risk of injury Work on the compressed air system may only be carried out by experienced and authorized qualified personnel Always wear protective clothing and goggles Immediately after having switched on the machine the connection of the compressed air outlet must be checked for tightness Make sure to observe an appropriate safety distance during the inspection Close mains disconnecting device To conduct the inspection switch on the compressor and check the com pressed air outlet for tightness Switch off compressor BOGE Operating instructions for SL 270 S
62. nections after the first 50 operating hours Drive with frequency converter Caution Voltage According to operational conditions electrical drive systems with frequency converter may have an earth leakage current above 10 mA Therefore the required precautions according to DIN EN 60204 1 2007 and DIN EN 50178 1998 have to be applied as soon as the compressor is elec trically connected A permanently installed connection is required One or several of the following qualifications for the protective conductor system have to be fulfilled 1 The protective conductor must have a minimum cross section of 10 mm Cu along its total length 2 If the protective conductor has a minimum cross section of less than 10 mm Cu a second conductor with at least the same cross section has to be provided up to the point from where the protective conductor has a minimum cross section of more than 10 mm 3 Automatic interruption of the supply if the continuity of the protective con ductor is lost Please observe any additional national rules and regulations BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 31 Installation Commissioning Caution Risk of injury Prior to any work on the compressor Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Check to ensure that all conducting m
63. ns for SL 270 SL 481 series screw compressors Page 53 Maintenance Regular maintenance work Checking the oil level Check topping up oil Prior to commissioning start up of the compressor Then every 1 000 operating hours however at least once a year Topping up When the oil level has dropped below the min mark see sketch Attention Always use the same oil type when topping up Never mix different oil types and brands Switch off the compressor using the OFF button Series SL 270 SL 340 SL 430 SLF 221 Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Close ball valve at the compressed air outlet Vent the compressor as described in the beginning of the chapter The system pressure gauge must indicate a pressure of 0 bar Wait approx 3 minutes to permit the oil to settle Remove cladding on the maintenance side Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Open sound insulation hood Page 54 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Remove plug of oil filling socket 1 Check oil level The oil level must not drop below the min mark
64. nt Accident prevention regulations Work on and with the compressor may only be carried out by personnel duly authorized by the owner of the compressor The personnel working on the compressor has to observe all industrial safety regulations and operating instructions properly recognize responsibilities and read and understand the operating instructions It is essential to wear the com pulsory personal protective equipment when working on the compressor In general for all work on the compressor protective clothing chemicals resistant gloves Slip resistant safety shoes and hearing protection if applicable are compulsory For special duties protective helmets for transport work with lifting gear and safety goggles when working on the compressed air system on the con trol pneumatics and or on the cooling system of the built in dryer must be worn Before starting work using oils or greases a skin protection cream must be ap plied Having finished the work a skin care product must be applied The owner of a compressor plant is responsible to ensure that it is properly installed operated and maintained Prior to commissioning owners in the Federal Republic of Germany urgently have to read the currently valid regulations of the Main Association of the In dustrial Employers Liability Insurance Apart from other regulations particular ly the Ordinance on Industrial Safety and Health BetrSic
65. peratures and pressures see Technical data page 11 For indi vidually fluctuating values they are designed according to the specified order data Page 18 BOGE Operating instructions for SL 270 SL 481 series screw compressors Product description Cooling water Water connection for water cooling Cooling water quality 2 7 Cooling water The cooling water must have the following properties Electrical conductivity gt 50 uS cm at pH value 7 9 Carbonate hardness CaCO lt 16 dH Cooling water pressure max 10 0 bar min 2 0 bar Cooling water inlet temperature min 5 C max 30 C Max cooling water quantity see Technical data The cooling units are fitted with nonferrous heat exchangers as standard To avoid damage to these components and to guarantee a long term function ensure that the substances contained in the cooling water used do not exceed the following values Substances Symbol Max admissible concentration mg l Ammonia NH 2 Chloride lt 70 C Cl 100 Free chlorine Cl 5 Iron Fe 2 Free carbon dioxide CO 20 Manganese Mn 1 Nitrate NO 100 Oxygen 0 2 Silicon oxide SiO 8 Sulphate SO 60 Totally diluted substances TDS 600 Tab 2 1 Maximum admissible concentration of the substances Note If the specified limit values are exceeded use cooling units made of other materials Please
66. rators for leaks and tighten by hand if necessary Fig 6 8 Changing the oil separators Change After 9 000 operating hours when using BOGE Syprem 8000 S however at the latest after two years For other types of oil the appropriate oil change intervals must be complied with Note The service life of the oil the oil filter and oil separators is reduced under the following conditions When the compressor is operated at extreme ambient temperatures When the intake air is extremely soiled Building up a pressure cushion The combined compressed air oil receiver is located at the lowest point of the system Therefore a light pressure cushion approx 1 5 bar system pressure must be applied to drain the oil This pressure cushion forces the oil through the drain hose into a suitable collecting vessel Use emergency stop button to switch of the compressor once the system pressure has been reached Caution Risk of injury Open mains disconnection device and secure against unintentional switch on by means of a padlock BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 59 Maintenance Regular maintenance work Attention Never use any tools to screw on the cap nut They might damage the solenoid valve The cap nut M8 is located in the storage compartment of the switch cabinet Caution Risk of injury Open mains dis
67. re an expansion vessel and safety valve must be installed to avoid damage to the plate heat exchanger Dirt trap pore size max 0 6 mm The dirt trap at the water inlet protects the plate heat exchanger against dirt deposits in the event of a high degree of water contamination Flushing connections The flushing connections serve to clean the plate heat exchanger Separate installation The plate heat exchanger may also be separately installed or retrofitted by the customer Normally the plate heat exchanger is held in place by the pipelines However when installing larger types the customer may have to provide a bracket BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 39 Optional equipment EN BOGE Duotherm BPT Commissioning Maintenance Proceed as follows during commissioning Check oil level in the oil circuit If necessary top up oil Slowly open the stop valves in the water supply and discharge line Avoid pressure hammers Vent the pipelines Lime oxides as well as grease or oil will deposit in the ducts of the plate heat exchanger during operation Regular cleaning will prevent thick deposits clogging individual ducts of the plate heat exchanger Cleaning intervals Excessively soiled and limy water 6 months Moderately soiled water surface water 1 year Lightly soiled water 3 years Recommended cleaning agents Grease or oil deposi
68. rec ommended or authorized by the manufacturer BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 1 General E General safety instructions Safety instructions for maintenance and repair of the compressor 12 Undertake conversions and modifications of the compressor only in agree ment with BOGE taking all relevant safety regulations into consideration The manufacturer is not liable for damages resulting from independent modifications on the compressor 13 Never start the compressor when one or serveral parts e g cable plug are damaged when not in perfect working order and when damage is de tected or suspected 14 Observe all safety and danger signs directly attached on the compressor 15 The compressed air oil receiver is a compression device which has to be checked according to the national rules and regulations 16 To avoid damages special precautions have to be taken during re oper ation of compressors with frequency control if the frequency converter was cut off from the power supply for a longer period of time gt 12 months In this case please contact the BOGE Service Caution Only use original spare parts compressor oils and operating materials re leased by BOGE during repair or maintenance Caution Voltage When working on the electrical system there is a constant danger of getting into contact with live parts To avoid such dangers the
69. ressure 2 Set proportional controller The control range of the proportional con troller can be moved by turning the cap 1 Increase pressure level Turn cap clockwise Decrease pressure level Turn cap anti clockwise Fig 6 13 Set proportional controller Note Always set proportional controller higher than operating pressure value Prin 3 Pressure switch for infinitely variable power control The vacuum switch for the infinitely variable power control limits the reduction of the air delivery and switches the compressor to idling or off if the air delivery falls below 50 Page 64 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Checking the safety valve Check After approx 3 000 operating hours but at least 1x yearly Check the safety valve by turning open the lock screw 1 Caution Risk of injury Take extreme care when checking the safety valve with the compressor run ning and observe all safety measures A hot air oil mixture escapes when opening Always wear protective goggles and gloves Open the lock screw 1 by turning it anti clockwise The compressed air escapes Tighten the lock screw by turning it clockwise Fig 6 14 Checking the safety valve BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 65 Maintenance EN
70. ries screw compressors Page 25 Installation Compressor room Cooling air requirement Please refer to the following table for the cooling air requirement and size of the supply air openings for your compressor Ensure that flaps and weather protection grids have the necessary free cross section We generally recom mend contacting a specialist company for performing the duct construction work and planning Type Drive rating Air cooling Water cooling Cooling air Necessary Cooling air Necessary Cooling air Necessary require inlet open require free duct require inlet open ment for ing for ment for Cross ment for ing for free stand free stand installation section free stand free stand ing unit ing unit with ducting ing unit ing unit kW m h m m h m m h m SL 270 200 56 000 7 28 000 2 1 10 000 1 25 SL 340 250 66 000 8 3 33 000 24 10 000 1 25 SL 430 315 64 000 8 3 33 000 24 10 000 1 25 SL 341 250 66 000 8 3 33 000 24 10 000 1 25 SL 431 315 66 000 8 3 33 000 24 10 000 1 25 SL 481 355 66 000 8 3 33 000 24 10 000 1 25 SLF 221 160 48 800 6 1 24 400 1 8 9 000 0 37 SLF 271 200 56 000 7 1 28 000 2 06 10 000 0 37 1 For the cooling air requirements the basis is a 4 C temperature difference between room and outside temperature Tab 3 1 Cooling air requirement necessary aperture dimensions Page 26 BOGE Operating instructions for S
71. seseee 5 Accident prevention regulations sssssssee 5 Introdu ctiOn reuerentia rhe teh Ri Ran Ine mE pDit RE 6 SYMDOIS Used 5 oro e tono ee 7 Symbols on the compressor 8 Intended Usen ce eei cet e Mi ee 9 Foreseeable misuse sss 9 Transport damage iner a e ara a eA 9 Data on the type plate ssesssssssssseemmRR 10 Set VICO 1s iicet iio abbati tee Mei cc sia dilest i iet alate as 10 Technical data T prt reri RIA EET 11 SL 270 481 and SLF 221 271 part 1 11 SL 270 481 and SLF 221 271 part 2 een 12 Function description uusuuursennennnnnannnnnnnnnnnnnnnnnnnnnnnanannnnnnnnnn 13 Function principle of the air end sess 13 pde HE 13 Qil circuit 21i eee ette ee dne edet nate 14 Compressor control uurssusnennnannnnnnnnannannnnnnnnnnnnnnnnnnnn nenn 15 Network pressure uusssnsssssennnnnnennnnnnnnnnnnnnnnnennnennennennnnnennnnnnn 15 Operating states nn tse tended adest lied 15 Operating modes 4eeeesesiseeenee esee tnnt nein tn nt 15 Short operating times ssssssessee e 15 Control devices aan anna 16 Operating pressure transmitter sssssssssseeeesee 16 Proportional controller option not with SLF 16 BOGE Operating instructions for SL 270 SL 481 series screw compressors Page III
72. sor is ready for operation For control function see control display Switch off the compressor after a trial run of several hours under maximum load List up the test results in the commissioning certificate Page 34 BOGE Operating instructions for SL 270 SL 481 series screw compressors Installation Commissioning Commissioning following extended stoppages If an extended stoppage is scheduled you should contact BOGE Service be forehand Following an extended stoppage of more than 2 months fill a small amount of oil in 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 oil grades and brands Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Unscrew plug from the suction controller 1 Fill approx 101 compres Sor oil into the suction controller Fig 3 5 Suction controller Screw in the plug again Turn compressor stage at the coupling by hand 5 to 10 times to spread the oil evenly BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 35 Installation Dismantling 3 6 Dismantling Ry Note To avoid dangers when dismantling the compressor please consult your
73. stallation Transport and storage Crane transport Attention Do not subject the safety cladding to force during transport Protect the com pressor using wooden spacers see arrows in the following illustration Remove the transport timbers Intermediate storage Only use suitable transport slings Position the slings at the ends underneath the base frame of the compressor Fig 3 2 Crane transport In case the compressor is not installed immediately after delivery it has to be stored at a sheltered location It must be ensured that during the intermediate storage neither dust nor humidity can penetrate Ry Note In case of an intermediate storage please observe the specifications and directions as to permissible environmental impacts see chapter 3 2 Com pressor room Installation maintenance conditions and application for com pressed air receivers arranged below or separately In case of a careless storage we assume no liability for consequent dam ages In the event of an extended intermediate storage you should consult BOGE Service Please observe the directions for commissioning after an extended standstill see chapter 3 5 Commissioning if the intermediate storage takes longer than two months Page 22 BOGE Operating instructions for SL 270 SL 481 series screw compressors Installation Compressor room Installation maintenance conditions and
74. switch for proportional controller 3 2 way solenoid valve for prop controller passage here in case of standard control Air delivery indicator for proportional controller 3 2 way solenoid valve for suction controller Double check valve Pos 42 43 rapid start valve Double check valve rotational direction monitoring option BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 69 Appendix Flow chart Air cooled version frequency controlled 29 Page 70 BOGE Operating instructions for SL 270 SL 481 series screw compressors Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET Suction filter Maintenance display Suction filter monitoring Suction controller Air relief valve Suction control valve Direction of rotation monitoring with double check valve Drive motor Compressor air end Sensor for final compression temperature 10 Combined compressed air oil vessel Oil separator 12 Safety valve 13 Rapid start valve 16 Thermostatic oil control valve 17 Oil cooler 18 Oil filter 21 Minimum pressure non return valve 22 Compressed air after cooler 23 Pressure transmitter system pressure 24 Pressure transmitter net pressure 25 Stop valve compressed air outlet 27 Oil drainage 28 Check valve drainage line 29 Cyclone separator with condensate drain and compressed air refrigeration dryer with condensate drain on
75. t the compressor room is equipped with special fire protection Install compressors with motor ratings exceeding 100 kW in a separate fire protected room BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 23 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 mate rial Leaking oil must not spread out over the floor Noinflammable materials must be located within a radius of at least 3 me tres around the compressor Noinflammable machine parts such as cable ducts may run overhead of the compressor Only install compressors in workrooms if the sound pressure level of their measuring surfaces does not exceed 85 dB A Caution Risk of injury A sound pressure level above 80 dB A can cause permanent hearing dam ages to persons who constantly work in close proximity of the compressor These persons must wear ear protection when working in close proximity of the compressor Admissible environmental influences The compressor room must be clean dry cool and free of dust Admissible ambient temperatures Maximum ambient temperature for air cooling 45 C Minimum amb
76. teristic only 2 3 BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 11 Product description Technical data SL 270 481 and SLF 221 271 part 2 Type SL 270 SL 340 SL 430 SL 341 SL 431 SL 481 SLF221 SLF 271 Oil filling quantities Oil receiver volume i 23 230 230 230 230 230 230 230 Total oil filling quantity 11 130 130 130 113 113 113 130 130 Oil topping up quantity between min max I 20 20 20 20 20 20 20 20 Intake air temperature min C 5 5 5 5 5 5 5 5 max C 45 45 45 45 45 45 45 45 Cooling air requirement gt free standing installation m h 56000 64000 64000 66000 66000 66000 48800 56000 3 S With Supp and exa t mh 58995 32000 32000 33000 33000 33000 24400 28000 9 Hot air quantity X free ventilator pressure Pa 60 60 60 60 60 60 60 60 free ventilator pressure mm WC 6 6 6 6 6 6 6 6 Cooling air requirement free standing installation m h 10000 10000 10000 10000 10000 10000 10000 10000 3 WIDE Suppl and exhaust mh 5000 5000 5000 5000 5000 5000 5000 5000 Hot air quantity 2 Required cooling water quantity S delta t 15 K m h 10 900 13 600 13 600 13 600 13 600 13 600 8 72 10 900 delta t 30K m h 6 800 5 450 6 800 6 800 6 800 6 800 4 36 6 800 Max cooling water quantity m h 13 6 13 6 13 6 13 6 13 6 13 6 13 6 13 6 o ER
77. to starting work on the electrical system the power supply has to be Switched off and secured against unintentional switching on again Imme diately after having finished the work all dismantled claddings and safety devices must be refitted The operator is responsible to check the compressor daily for externally visible damage and defects and to immediately report any changes in cluding operational behaviour When the automatic restart Auto Restart is activated the compressor will start automatically following a voltage loss Prerequisite The net pres sure is lower than the set switch on pressure 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 of the cooling fan Caution Risk of injury Never operate the compressor with dismantled protective grid Never oper ate the compressor with dismantled protective grid There is a constant dan ger of accidentally reaching into the impeller of 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 constant danger by bruising shearing or being seized or trapped Any servicing on the coupling may only be carried out during standstill of the compressor Immediately after having finished the work all claddin
78. ts X paraffin Oxide or lime 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 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 high pressure hose 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 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 40 BOGE Operating instructions for SL 270 SL 481 series screw compressors Optional equipment E BOGE Duotherm BSW Allow the cleaning agent to act for at least six hours Point the connection upward to allow gases to escape After cleaning rinse the plate heat exchanger thoroughly with water e g using a high pressure hose Note
79. uipment EN BOGE Duotherm BPT Function Assembly 5 1 BOGE Duotherm BPT The heat recovery system BOGE Duotherm BPT utilizes the heat energy re leased during compression to produce warm 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 com prises of stainless steel plates which are soldered together These form two separate duct systems Compressor oil and water run through these ducts with opposing flow directions The hot oil transfers its heat to the colder water via the plates As a rule the plate heat exchanger is installed into the compressor at the fac tory and comes equipped with all necessary pipework Only the following work is required during assembly Connect the supply and discharge water lines to the pipeline mains Route the pipelines to prevent transmission of stresses tension and vibra tions to the heat exchanger Provide venting and draining facilities The customer must provide the following components for assembly Stop valves Stop valves in the water supply and discharge lines enable simple removal of the heat exchanger Expansion vessel and safety valve Attention If the stop valves in the water supply and discharge lines are closed simulta neously an enclosed space is created If the water in this space is heated it expands and the pressure increases Therefo
80. ushing the oil circuit only use oil of the same brand you want to fill in afterwards Drain used oil completely procedure as described above Leave used oil filters and separators inside the compressor Fill oil compressed air receiver with clean oil up to approx one third of the complete oil quantity Close oil filling socket Let compressor run for approx 10 minutes Drain flushing oil and dispose of properly Change oil filter and oil separator cartridges procedure as described above Fill in new oil up to required oil level procedure as described above Page 62 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Cleaning the com pressed air oil cooling unit air cooling Cleaning After 1 500 operating hours however not later than after one year 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 Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Remove cladding on the maintenance side Unscrew the maintenan
81. valve BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 75 Appendix Flow chart BOGE Duotherm BPT plate heat exchanger T lt gt 101 21 102 1 101 Compressed air OUTLET 102 Return 103 Flow Suction filter 4 Intake regulator 8 Compressor air end 10 Combined compressed air oil vessel 11 Oil separator 16 Thermostatic oil control valve 17 Oil cooler 18 Oil filter 21 Minimum pressure check valve 22 Compressed air after cooler 50 Heat exchanger Page 76 BOGE Operating instructions for SL 270 SL 481 series screw compressors Appendix Flow chart BOGE Duotherm Plus BSW safety heat exchanger 101 102 103 Compressed air OUTLET Return Flow Suction filter Suction controller Compressor air end Combined compressed air oil vessel Oil separator Thermostatic oil control valve Oil cooler Oil filter Minimum pressure check valve Compressed air after cooler Safety heat exchanger Pressure monitor in case of pipe rupture Compensation vessel BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 77 7 3 List of maintenance and service work Appendix 7 3 List of maintenance and service work oDueu uo abuey u5 JOUOD 09 xx Bujuea D x 9oueu Duiueo o ejuieul un Jojejedas ang Joy Joy aun einssaJd aunssaid sunoy
82. valve at the compressed air outlet Switch on the compressor and heat up to operating temperature Subsequently check the oil filter for leaks once again and tighten by hand if necessary proceed as described before Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Check the oil filter for leaks and tighten by hand if necessary Check oil level Top up oil losses if any Fig 6 7 Changing the oil filter the photo shows the SL 340 air cooled BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 57 Maintenance Regular maintenance work Changing the oil separator Change When the difference between network and system pressure exceeds 0 8 bar When warning message 8 appears on the control system display if option is installed After 3 000 operating hours however not later than after one 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 Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock
83. ver no later than after one year With each oil change Switch off the compressor using the OFF button Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Close ball valve at the compressed air outlet Vent the compressor as described in the beginning of the chapter The system pressure gauge must indicate a pressure of 0 bar Wait approx 3 minutes to permit the oil to settle Remove cladding on the maintenance side Page 56 BOGE Operating instructions for SL 270 SL 481 series screw compressors Maintenance Regular maintenance work Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Unscrew soiled oil filter 3 by hand or use a strap wrench turning coun terclockwise see fig 6 7 Catch the draining oil and dispose of properly according to environmental regulations Fill the new oil filter 3 with compressor oil Lightly oil the sealing ring of the new oil filter Screw in new oil filter by hand turning clockwise Attention Do not use tools to screw in the new oil filter You might damage the oil filter or its sealing ring A hand tight seating of the oil filter is sufficient Reattach cladding on the maintenance side Open ball
84. ymbol indicates information warning of dangers to life and limb of the operator or other persons or dangers which might destroy or damage the compressor Caution Voltage This symbol indicates information warning of life threatening electrical volt age levels It indicates work which must be exclusively performed by skilled electricians Note This symbol indicates information and tips concerning the economical and careful operation of the compressor DD BOGE Operating instructions for SL 270 SL 481 series screw compressors Page 7 General EH Introduction Symbols on the compressor Note 3 All warning signs on the compressor and in its surrounding must always be kept in a legible condition Missing or damaged signs must be replaced at once The following symbols and warning signs are fitted on the compressor Warning Hot surfaces Do not touch Warning The unit is operated by remote control and might start without warning ag Note ILL Instructions for the operating personnel must be read Prohibited Never open the valve before the air hose connection to the compressed air network is connected Warning of hand injuries Only carry out work on the coupling if the compressor is in standstill and se cured against unintentional switching on Page 8 BOGE Operating instructions for SL 270 SL 481 series screw compressors General E Introduction

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