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Operating instructions

1. E 5 H H 11 31 AA 28 9 im a S 10 9 Mg J E ny X 20 27 24 P HS 2 DEN EN PL 16 1 18 Am EX 19 A 26 Ta lt 17 224 25 Page 92 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow chart 10 102 Oo ON DO FWD N 24 1 25 26 27 27 1 28 3 Intake air INLET Compressed air OUTLET Suction filter Maintenance display Vacuum switch for suction filter monitoring Suction controller Air relief and regulation control valve Pressure switch for rotational direction system relief and V belt monitoring Drive motor Air end Final compression temperature display and switch Combined compressed air oil receiver Oil separator Safety valve Differential pressure switch for oil separator monitoring System pressure switch for system pressure build up and monitoring Safety pressure switch for pressure limitation Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure check valve Compressed air after cooler Pressure sensor for system pressure Net
2. Expansion vessel and safety valve Attention If the stop valves in the water supply and discharge lines are closed simul taneously an enclosed space is created If the water in this space is heated it expands and the pressure increases Therefore 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 Commissioning 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 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 55 Optional features EN BOGE Duotherm BPT Maintenance 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
3. silenced super silenced dB A gu Rerergnce surface measure 17 18 17 18 17 18 18 19 18 19 18 19 18 19 18 19 amp 7 silenced super silenced dB A Bouna power eval 93 90 96 92 96 92 101 93 101 93 101 93 105 99 105 99 silenced super silenced dB A Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 72 70 73 71 73 71 79 71 79 71 79 71 86 79 86 79 silenced super silenced dB A o ee 17118 17 18 17 18 18 19 18 19 18 19 18 19 18 19 2 si enced super silenced dB A Se 89 88 90 89 90 89 97 90 97 90 97 90 104 98 104 98 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 8 bar m min 13 1 15 7 18 4 19 4 23 3 27 9 34 7 40 7 Prax 10 bar m min 11 4 13 7 16 3 17 0 20 8 25 1 30 5 37 1 Prax 13 bar m min 9 8 12 0 142 144 17 8 21 7 24 7 31 7 Drive motor Rated power kW 75 90 110 110 132 160 200 250 Rated speed 50 Hz min 3000 3000 3000 3000 1500 1500 1500 1500 60 Hz min 3600 3600 3600 3600 1800 1800 1800 1800 Protection type IP 55 23 55 23 55 23 55 23 55 23 55 23 55 23 55 23 Design IMB 3 3 3 3 3 3 3 3 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 200 250 250 250 315 400 500 630 Recommended fuse protection A 200 250 250 250 315 400
4. 1x per week for damage Change If damage is visible 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Remove cladding on the maintenance side as well as the belt protection Slacken the V belts Secure screw head 3 of the tensioning device with NW 27 spanner to prevent it from turning Turn locknut 4 clockwise Raise the motor in arrow direction 5 until the V belts are fully slackened Fig 6 7 The BOGE GM drive system Changing the V belts Remove the slackened belts from the belt pulleys Fit new V belts on the belt pulleys on the motor and compressor Attention The new V belts must be of precisely the same length Only change the V belts as a complete set Tensioning the V belts Lower the motor again For this purpose secure screw head 3 against turning then turn locknut 4 counterclockwise and lock by means of the screw head The V belts are automatically correctly tensioned by the BOGE GM drive system Fit belt protection Reattach cladding on the maintenance side Page 72 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance Regular maintenance work S
5. 99 34 1 Intake air INLET Compressed air OUTLET Water INLET Water OUTLET Suction filter Maintenance display Vacuum switch for suction filter monitoring Suction controller Air relief and regulation control valve Pressure switch for rotational direction system relief and V belt monitoring Drive motor Air end Final compression temperature display and switch Combined compressed air oil receiver Oil separator Safety valve Differential pressure switch for oil separator monitoring System pressure switch for system pressure build up and monitoring Safety pressure switch for pressure limitation Thermostatic oil control valve Oil cooler Oil filter Differential pressure switch for oil filter monitoring Oil throttle Minimum pressure check valve Compressed air after cooler Operating pressure switch Pressure gauge Stop valve compressed air outlet Pressure sensor for network pressure frequency converter Stop valve oil drainage Check valve drainage line up to 75 kW 3 2 way solenoid valve 2 2 way solenoid valve Bypass valve Option To be provided by customer 35 36 Dirt trap Stop valve BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 95 Appendix Flow chart BLUEKAT series air cooled version Page 96 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow
6. Installation Compressor room Ventilation If the following instructions are not observed the admissible final com pression temperature may be exceeded In this case the compressor will switch off automatically Caution Arrange the compressor intake openings or ducts such 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 1596 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 ins
7. Avoid any operating method which may impair the safety of the compres sor Always wear your compulsory personal protective equipment as a protec tion against injuries from sharp corners or edges when working on the compressor To avoid dangers from debris or parts lying around the service area of the compressor has always to be kept tiedied up and clean Always squat when working on components mounted at low height never stoop When working on components mounted higher up always stand upright and erect Do not exceed the limit value for the final compression pressure specified on the type plate 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 Place the compressor out of operation as described in these operating instructions when dismantling the safety claddings or safety devices for repair or maintenance work Reattach and close all cladding and safety devices immediately upon completion of the repair or maintenance work Only operate the compressor using the additional equipment options recommended or authorized by the manufacturer BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 1 General E Gener
8. 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 of the compressor by unauthorized or untrained persons BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 9 General kA Introduction Intended use of the integrated converter BLUEKAT series In accordance with its intended purpose the BLUEKAT converter is exclusively designed for the treatment of compressed air of screw compressors with the hydrocarbons contained in the air being catalytically oxidized The catalyst operating temperature in the catalyst bed should be approx 200 C 5 in the flow through mode In order to avoid prolonged preheating phases and delays in compressed air production the compressor station should not be unplugged too often Only hydrocarbon based oils synthetic or mineral may be used as compres sor lubricants All lifetime specifications are based on a max additive content of 5 Silicon based oils may not be used Ry Note Any modifications not authorized by BOGE to the control and the switch cab inet layout of the converter will result in expir
9. 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 3 General E General safety instructions Personnel requirements Personal protective equipment Safety instructio
10. BLUEKAT series Page 64 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance 62 General Maintenance work Maintenance intervals in operating hours Page weeky 1 000 1 500 3 000 9 000 monthly annually annually annually every 2 years General maintenance work Check final compression temperature Control target value 70 100 C Check compressor for leaks X 2 a ae cs pressure display y Control Check function of emergency stop button m Control Check and if necessary change supply air filter option w 69 Clean oil cooler X 82 Check if electrical connections are tightened X Air circuit Check and if necessary clean suction filter m 68 Change suction filter cartridge X 69 Replace suction controller wearing parts set X Check adjust operating pressure X Control Replace minimum pressure valve wearing parts set Replace solenoid valve X Check safety valve X 84 Oil circuit Check oil level and top up as required X 74 Replace oil regulator wearing parts set X Replace nozzle with dirt catch only through to S 100 2 SD 100 2 SF 100 2 SDF 100 2 X BLUEKAT series Change oil separator 77 Change oil filter 76 Change oil X 79 Drive Check change V belt X X 72 Lubricate drive motor bearings for details please see nameplate or enclosed ope
11. 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 quantities temperatures and pressures see Technical data For indi vidually fluctuating values they are designed according to the specified order data BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 31 Product description ER Cooling water Water connection for water cooling Cooling water quality 2 8 Cooling water The cooling water must have the following properties Electrical conductivity gt 50 uS cm at pH value 7 9 Carbonate hardness CaCO lt 16 dH Cooling water pressure max 10 0bar min 2 0 bar Cooling water inlet temperature max 5 C min 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 en sure that the substances contained in the cooling water used do not exceed the following values Substances Symbol max admissible concentration mg l Ammonia HNH 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 O 2 Silicon oxide SiO 8 Sulphate SO 60 Totally diluted
12. 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 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 machine parts are voltage free Depressurize all areas under pressure Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Never omit a single safety step Otherwise you will risk injuries due to restart ing electric shock or self releasing parts Caution With an activated automatic restart Auto Restart the compressor may re start automatically after a voltage failure Prerequisite The net pressure is lower than the set switch on pressure Page 44 BOGE Operating instructions for S 31 2 S 341 series screw compressors Installation Commissioning 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 qualifi
13. 31 2 S 341 series screw compressors Maintenance Regular maintenance work Fig 6 8 Checking the oil level topping up with oil Series S 271 and S 341 Caution Risk of injury Danger of burning due to hot oil Always wear protective gloves when working on the compressor Open safety sound insulation hood Remove plug 1 with sealing washer 4 from plug 2 see figure below You will find the dip stick 3 in the document pocket of the key ring when delivered Insert dip stick 3 and measure the oil level The oil level must neither drop below the min mark nor rise above the max mark Unscrew plug 2 with sealing washer 5 if necessary and top up with oil Screw plug 2 with sealing washer 5 and plug 1 with sealing washer 4 back in Close safety sound insulation hood Reattach clading on the maintenance side Open ball valve at the compressed air outlet Fig 6 9 Checking the oil level topping up with oil BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 75 Maintenance Regular maintenance work Changing the oil filter Change After 3 000 operating hours but no less than once a 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
14. 86 BOGE Operating instructions for S 31 2 S 341 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 Vessels Directive 2009 105 EC Applied harmonized standards DIN EN 1012 1 2011 DIN EN ISO 12100 2011 DIN EN 60204 1 VDE 0113 1 2007 DIN EN 61000 6 2 VDE 0839 6 2 2006 DIN EN 61000 6 4 VDE 0839 6 4 2007 7 2 Flow chart On the following pages you will find the individual flow charts for the different machine types and components BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 87 Appendix Flow chart Air cooled version standard Page 88 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow chart 10 102 o OnN oO FP WO DY N 99 37 42 43 44 Intake air INLET Compressed air OUTLET Suction filter Maintenance display from 30 kW Vacuum switch for suction filter monitoring Suction controller Ventilation and regulation control valve Drive motor Compressor air end Sensor for final compression temperature Combi
15. Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Check the oil separators for leaks and tighten by hand if necessary n A Fig 6 11 Changing the oil separator Page 78 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance Regular maintenance work Oil change Change After 9 000 operating hours however at the latest after two years Forother types of oil the appropriate oil change intervals must be complied with Ry 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 Switch off the compressor using the OFF button Attention Never use any tools to screw on the cap nut They might damage the solenoid valve Place oil drain hose into a suitable container 6 as described and take cap nut 5 out of the switch cabinet Press OFF button at the machine during output phase and then shut down the machi
16. Compressed air after cooler 58 Pressure retaining shut off valve 23 Pressure sensor for system pressure DHSV 24 Network pressure compressor 59 DHSV solenoid valve 25 Stop valve compressed air outlet 60 Gauge 27 Stop valve oil drainage 61 Relief ball valve 28 Check valve drainage line 62 Condensate discharge valve auto up to 75 kW matic 29 Proportional controller 30 Diff pressure switch for prop control Option ler 31 3 2 way solenoid valve for prop con troller with standard control passage here BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 99 Appendix Flow chart BLUEKAT series Water cooled version serial connection Page 100 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET 1 Suction filter 31 3 2 way solenoid valve for prop con 2 Maintenance display from 30 kW troller Anh standard control passage 3 Vacuum switch bai for suction filter monitoring 32 2 2 way solenoid valve 4 Suction controller 35 Dirttrap 5 Airrelief and regulation control valve 36 Stop valve 7 Drive motor 37 Display of f a d for prop controller 8 Airend 42 3 2 way solenoid valve for suction con trol regulation 9 Sensor for final compression tempera ture 43 Double check valve 10 Combined compressed air oil receiver Ego de te Ta pet
17. Otto Boge Stra e 1 7 D 33739 Bielefeld Telefon 05206 601 0 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 601 140 In the event of inquiries always specify the following 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 11 Product description Technical data 2 1 Technical data Technical data S 31 2 S 100 2 SD 40 2 SD 100 2 part 1 Nube 312 S 40 2 S 50 2 S 60 2 S 61 2 75 2 S 90 2 S 100 2 yp SD40 2 SD50 2 SD60 2 SD61 2 SD75 2 SD90 2 SD 100 2 Dimensions Height silenced mm 1450 1450 1450 1450 1450 1450 1450 1450 Height silenced SD mm 1665 1665 1665 1665 1910 1910 1910 1910 Height super silenced mm 1950 1950 1950 1950 1950 1950 1950 1950 Width silenced super silenced mm 1620 1620 1620 1620 2000 2000 2000 2000 Depth mm 960 960 960 960 1065 1065 1065 1065 Weight silenced kg 740 740 835 760 870 840 950 1100 1325 1180 1460 1250 1360 1290 1390 super silenced kg 770 770 86
18. S 31 2 S 341 series screw compressors Page 27 Product description EB Safety and monitoring devices Safety temperature limiter on the integrated converter BLUEKAT series The safety temperature limiter on the integrated converter S 40 2 BLUEKAT and S 50 2 BLUEKAT serves to switch off the heating when the temperature in the converter runs too high limit value 250 C In such a case the compres sor s release for compressed air production is automatically blocked The temperature inside the converter starts dropping Both heating and com pressor do not automatically restart operation due to temperature failure Use converter temperature control to restart Also see Converter failures BLUEKAT series on page 53 AA Caution Restart of compressor station only after consultation with your local BOGE distribution partner or BOGE service personnel It is imperative to determine the cause of the failure prior to restarting the compressor station Additional Monitoring Devices Additional monitoring devices are located on the switch cabinet of the inte grated converter S 40 2 BLUEKAT and S 50 2 BLUEKAT These include a temperature control unit with display serving to retrieve temperature informa tion on the converter In addition there are three indicator lights on the switch cabinet serving to indicate the operating state of the converter fo vse NN N v N Fig 2 6 Switch cabinet
19. Turn cap clockwise Reduce pressure level Turn cap coun terclockwise VAM Fig 6 17 Setting the proportional controller Ry Note Always set the proportional controller higher than the bottom operating pres sure value Prin Check safety valve 3 Pressure switch for infinitely variable capacity control The low pressure switch for the infinitely variable capacity control limits the reduction of the delivered quantity and switches the compressor in the event of less than 50 delivered quantity into idling operation or off Check After approx 3 000 operating hours however at least once a year Check safety valve by opening the screw plug 1 Caution Risk of injury Danger of scalding due to hot oil Always wear protective gloves when working on the compressor Take extreme care when checking the safety valve with the compressor running taking all safety measures into consideration A hot air oil mixture escapes when opening Open the threaded plug 1 counterclockwise The compressed air es capes Tighten the threaded plug by turning clockwise Page 84 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance EN Spare parts and optional equipment Fig 6 18 Check safety valve 6 4 Spare parts and optional equipment List of spare and wearing parts Designation for maintenance Filter mat for s
20. before removing any safety cladding or safety devices Refit the safety 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 operating materials released by BOGE for the maintenance work With an activated automatic restart Auto Restart the compressor may restart automatically after a voltage failure Prerequisite The net pressure is lower than the set switch on pressure BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 59 Maintenance EN Safety instructions Prior to all maintenance work 1 2 3 10 Once the maintenance work has been concluded 11 12 13 14 15 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 Fix a warning label to the control and fill in the name of the person re Check to ensure that all machine elements are definitely currentless Prior to starting work let cool down all hot components of the compressor Allow converter to cool off for several hours only screw compressors Separate the compressor from the compresse
21. 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 deposits 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 Allow the cleaning agentto act for at least six hours Point the connection upward to allow gases to escape Af
22. possibilities Forklift truck or lifting cart transport Ensure that the forks are underneath the base frame of the compressor see illustra tion 1 Fig 3 1 Transport with forklift truck BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 33 Installation 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 illustrations Remove the transport timbers Intermediate storage Ensure that the forks are underneath the base frame of the compressor see illustra tion 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 di rections as to permissible environmental impacts see chapter 3 2 Com pressor room Installation conditions and application for compressed air re ceivers 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
23. replacement Note In case of converter replacement you are free to either return the old used converter to BOGE or to dispose of it as scrap metal 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 Fire naked flames and smoking is strictly prohibited when handling oil Page 66 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance e General We recommend using only oil according to the following specification Disposal of used operating material Viscosity range of 55 mm s at 40 C Minimum viscosity at 100 C of 8 mm7 s Maximum viscosity at 0 C of 1 000 mm s Comply to FZG test according to DIN 51 354 with failure load stage 10 Test Method A 8 3 90 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 230 C Additives for excellent demulsifying properties Addi
24. safety sound insulation hood Vent the compressor as described in the beginning of the chapter The system pressure gauge must indicate a pressure of 0 bar Wait for approx 3 minutes to permit the oil to settle BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 77 Maintenance Regular maintenance work 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 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 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 Close safety sound insulation hood 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 separator for leaks once again procedure as described above Caution Risk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock
25. substances TDS 600 Table 2 2 Maximum admissible concentration of the substances Note If the specified limit values are exceeded use cooling units made of other materials Please consult BOGE 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 Page 32 BOGE Operating instructions for S 31 2 S 341 series screw compressors 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 the system 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 Any loose or pivoting parts are to be removed prior to lifting the unit The compressor is delivered filled with oil Do not tilt during transport Transport
26. the compressor to the power supply the integrated convert er will start the preheating phase in order to reach its operating temperature approx 200 C As long as the converter has not reached its operating temperature the control system of the compressor will block compressed air production since the oil separation process in the converter is unable to start as yet meaning that no oil free compressed air would be available The compressor is in the opera tional availability standby mode see Operating modes on page 25 As soon as the integrated converter has reached its operating temperature approx 200 C it switches from the preheating phase into the operation mode while automatically transmitting this information onto the control system of the compressor As soon as the switch on pressure is achieved the control system allows the compressor to switch to load operation see Operating modes on page 25 The compressor will now start to produce compressed air while the converter is ready for treatment of the compressed air If the integrated converter exceeds its operating temperature overtempera ture the heating of the converter switches off automatically This information is transmitted to the compressor control system which blocks the compres sor s release for compressed air production and puts it back into the opera tional availability standby mode Note Automatic switching of the compressor availabi
27. valve and replace if necessary Check valve is leaking Examine check valve and replace if necessary Page 52 BOGE Operating instructions for S 31 2 S 341 series screw compressors Faults Converter failures BLUEKAT series 4 3 Converter failures BLUEKAT series Fault Possible cause Rectification Converter failure compressor does not start af Incorrect converter temperature settings Settings of converter temperature control to be checked by BOGE service personnel and to be reparametrized if necessary No temperature build up inside converter Heating of converter to be checked by BOGE service personnel and to be repaired replaced if necessary Converter defect Converter to be checked by BOGE service personnel to be replaced if necessary Converter failure com pressor unexpectedly dis continues compressed air production and fails to automatically restart af Temperature inside converter too high overtemperature Converter converter temperature control heating to be checked by BOGE service personnel and to be repaired replaced if necessary Temperature drop inside con verter and prolonged undertem perature Converter heating to be checked by BOGE service personnel and to be repaired replaced if necessary Converter failure time period until release for compressed air produc tion excessively long af Temperatur
28. with monitoring devices 1 Switch cabinet lock 2 Temperature control 3 Indicator lamp Operation Betrieb green 4 Indicator lamp Preheating Aufheizen yellow 5 Indicator lamp Alarm St rung red Page 28 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description EN Safety and monitoring devices The display of the temperature control unit allows you to recall the following temperature information The actual value top and the target value below of the temperature in C inside the converter are shown in the display as standard Pressing the green button once causes the container bed temperature in C to be displayed Pressing the green button twice causes the current control mode to be dis played Pressing the green button three times causes the heating performance in 96 to be displayed Pressing the green button four times causes the state of the self optimiza tion to be displayed Pressing the green button five times causes the idle target value in C to be displayed Pressing the green button again enables you to return to the standard dis play Pressing the reset button enables you to immediately return to the stand ard display Caution The settings of the temperature control are completely programmed at the factory Any changes to the presettings for the temperature and other parameters ma
29. 00 0 59 2 000 0 25 S 90 2 SD 90 2 65 17 200 2 15 8 600 0 64 2 000 0 25 S 100 2 SD 100 2 75 18 400 2 30 9 200 0 68 2 000 0 25 S 101 75 20 000 2 50 10 000 0 74 3 400 0 45 S 125 90 32 000 4 00 16 000 1 18 3 400 0 45 S 150 S 151 110 32 000 4 00 16 000 1 18 3 400 0 45 S 180 132 48 800 6 10 24 400 1 74 10 000 1 25 S 220 160 48 800 6 10 24 400 2 11 10 000 1 25 S 271 200 56 000 7 00 28 000 2 50 10 000 1 25 S 341 250 64 000 8 30 33 000 2 50 10 000 1 25 SF 60 2 SDF 60 2 45 13 000 1 60 6 500 0 48 2 000 0 25 SF 100 2 SDF 100 2 75 18 400 2 30 9 200 0 68 2 000 0 25 SF 150 SDF 150 110 32 000 4 00 16 000 1 51 3 400 0 45 S 40 2 BLUEKAT 30 11 000 1 35 5 500 0 42 2 000 0 25 S 50 2 BLUEKAT 37 13 000 1 60 6 500 0 48 2 000 0 25 For the cooling air requirements the basis is a 4 C temperature difference between room and outside temperature Only with S 31 2 S 341 and SF 60 2 SF 150 Table 3 1 Cooling air requirement necessary cross sections for openings and ducts Page 38 BOGE Operating instructions for S 31 2 S 341 series screw compressors Installation EB Compressor room 3 2 Ventilation possibilities m REN AL I 31 A JL B m d ud t il J m m gt C miim s D w m exo w w m a gt eS E m 2 Fig 3 3 Ventilation possibilities A Supply and exhaust air openings in the outside walls free standing installation B Supported by exhaust air v
30. 25 dE od dt ES Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Required for the refrigeration compressed air dryer 230 V 50 Hz 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 characteristic only BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 19 Product description EB Compressor operation principle Technical data for S 40 2 BLUEKAT S 50 2 BLUEKAT part 2 Type S 40 2 BLUEKAT S 50 2 BLUEKAT Oil filling quantity Oil receiver volume i 46 46 Total oil filling quantity i 28 28 Oil topping up quantity between min max i 6 6 Intake air temperature min C 5 5 max C 40 40 RB Cooling air requirement free standing installation m h 11000 13000 8 with supply and exhaust mh 5500 6500 Ale free ventilator pressure Pa 60 60 free ventilator pressure mm WColumn 6 6 Cooling air requirement free standing installation m h 2000 2000 with supply and exhaust m h 1000 1000 Required cooling water quantity deltat 15K m h 1 630 2 010 o delta t 30 K m h 0 815 1 005 Max cooling water quantity m h 4 2 4 2 o Cooling water inlet temperature s min fc 5 5 max C 30 30 Cooling water outlet temperature max C 45 45 C
31. 5 790 900 870 980 1150 1375 1230 1510 1300 1410 1330 1440 Max sound pressure level dB A accord to DIN EN ISO 2151 2009 73 68 76 71 78 72 78 73 77171 79 73 79 73 80 73 silenced super silenced dB A 8 MAT gag 196 15 16 15 16 15 16 16 17 16 17 16 17 16 17 E Sound power lgvel 88 84 91 87 93 88 93 89 93 88 95 90 95 90 96 90 silenced super silenced dB A Max sound pressure level 3 dB A o accord to DIN EN ISO 2151 2009 72 67 75 70 77171 771 72 76 70 78 72 78 72 79 72 silenced super silenced dB A o Sure surfaca measure 15 16 15 16 15 16 15 16 16 17 16 17 16 17 16 17 g si enced super silenced dB A z Soung power level 87 83 90 86 92 87 92 88 92 87 94 89 94 89 95 89 silenced super silenced dB A Compressor max final compression temperature PC 110 110 110 110 110 110 110 110 Volume flow according to ISO 1217 appendix C at p 7 8bar m min 3 88 5 17 6 35 7 00 7 70 9 33 10 80 12 10 Pmax 10 bar m min 3 30 4 63 5 78 6 34 6 92 8 30 9 65 10 50 Pmax 13 bar m min 2 58 3 82 4 95 5 36 5 87 7 11 8 45 9 20 Drive motor Rated power kW 22 30 37 45 45 55 65 75 Rated speed 50 Hz min 3000 3000 3000 3000 3000 3000 3000 3000 60 Hz min 3600 3600 3600 3600 3600 3600 3600 3600 Protection type IP 55 23 55 23 55 23 55 23 55 23 55 23 55 23 55 23 Design IMB 3 3 3 3 3 3 3 3 ISO class F F F F F F F F Electrical connection Mains voltage V 400 400 400 400 400 400 400 400 Frequenc
32. 5 kW matic Option BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 97 Appendix Flow chart BLUEKAT series water cooled version parallel connection Page 98 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow chart 101 Intake air INLET 102 Compressed air OUTLET 103 Water INLET 104 Water OUTLET 1 Suction filter 32 2 2 way solenoid valve 2 Maintenance display from 30 kW 33 Regulating valve water supply preset 3 Vacuum switch 34 Regulating valve water supply preset for suction filter monitoring 35 Dirt trap 4 Suction controller 36 Stop valve 5 Airrelief and regulation control valve 37 Display of f a d for prop controller 7 Drive motor 42 3 2 way solenoid valve for suction con 8 Airend trol regulation 9 Sensor for final compression tempera 43 Double check valve ture Pos 42 43 rapid start valve 10 Combined compressed air oil receiver 44 Double check valve 11 Oil separator Monitoring of rotational direction 12 Safety valve 90 Filter 16 Thermostatic oil control valve 51 Safety valve 17 Oil cooler 92 Heat exchanger 18 Oil filter 53 Converter 19 Differential pressure switch 54 Heating cartridge with thermocouple for oil filter monitoring 55 Heating cartridge receiver top 20 Oil throttle 56 Heating cartridge receiver middle 21 Minimum pressure check valve 57 Heating cartridge bed temperature 22
33. 500 630 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 characteristic only Page 14 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description Technical data Technical data for S 31 2 S 100 2 SD 40 2 SD 100 2 part 2 Type 312 S 40 2 S 50 2 S 60 2 S 61 2 S 75 2 S 90 2 S 100 2 yp SD 40 2 SD 50 2 SD 60 2 SD 61 2 SD 75 2 SD90 2 SD 100 2 Oil filling quantity Oil receiver volume l 46 46 46 46 71 71 71 71 Total oil filling quantity l 28 28 28 28 42 42 42 42 Oil topping up quantity between min max 6 6 6 6 8 8 8 8 Intake air temperature min C 5 5 5 5 5 5 5 5 max C 40 40 40 40 40 40 40 40 m Cooling air requirement amp free standing installation m n 9000 11000 13000 13000 13000 16000 17200 18400 8 with supply and exhaust air duct m h 4500 5500 6500 6500 6500 8000 8600 9200 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 2000 2000 2000 2000 2000 2000 2000 2000 with supply and exhaust m h 1000 1000 1000 1000 1000 1000 1000 1000 Required cooli
34. 8 8 Switch on press Prin bar 7 7 7 7 7 7 7 T Pmax 10 bar Switch off press Paa bar 10 10 10 10 10 10 10 10 Switch on press Prin bar 9 9 9 9 9 9 9 9 p 713bar Switch offpress p bar 13 13 13 13 13 13 13 13 Switch on press Prin bar 12 12 12 12 12 12 12 12 Safety valve Activation pressure at Pmax 8 bar bar 11 11 11 11 11 11 11 11 Prax 7 10 bar bar 11 11 11 11 11 11 11 11 Prax 13 bar bar 14 14 14 14 14 14 14 14 Compressors for other operating pressures Prin Pmax 1 bar Page 16 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description Technical data for SF 60 2 SF 150 SDF 60 2 SDF 150 part 1 Technical data Type SF 60 2 SF100 2 SF 150 yp SDF 60 2 SDF 100 2 SDF 150 Dimensions Height silenced mm 1450 1450 1750 Height super silenced mm 1950 1950 2250 Width silenced super silenced mm 1620 2000 2365 Depth mm 960 1065 1335 Weight silenced kg 840 1535 2040 super silenced kg 870 1585 2100 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 78 73 80 73 79 74 silenced super silenced dB A 8 Reference surface measure 15 16 16 17 17 18 amp silenced super silenced dB A Sound power level 93 89 96 90 96 92 silenced super silenced dB A Max sound pressure level 3 dB A o accord to DIN EN ISO 2151 2009 77 72 7
35. 9 72 73 71 silenced super silenced dB A S Reference surface measure E silenced super silenced dB A 1916 19 II Sound power level silenced super silenced dB A Eu dd 30189 Compressor max final compression temperature PC 110 110 110 Volume flow according to ISO 1217 appendix C at Pmax 8bar m min 1 75 7 00 3 0 12 10 4 60 18 4 Pmax 10 bar m min 1 59 6 34 2 6 10 50 4 08 16 3 Pmax 13 bar m min 1 35 5 36 2 3 9 20 3 55 142 Drive motor Rated power kW 45 75 110 Nominal speed 60 Hz min 3600 3600 3600 Protection type IP 55 23 55 23 55 23 Design IMB 3 3 3 ISO class F F F Electrical connection Mains voltage V 400 400 400 Frequency Hz 50 50 50 Min fuse protection A 100 200 250 Recommended fuse protection A 125 200 250 2 BF gt ES Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Required for the refrigeration compressed air dryer 230 V 50 Hz 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 characteristic only BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 17 Product description EN Technical data Technical data for SF 60 2 SF 150 SDF 60 2 SDF 150 part 2 Type SF 60 2 SF 100 2 SF 150 yp
36. BOGE AIR THE AIR TO WORK we ROGE COMPRESSED AIR SYSTEMS Operating instructions Belt driven screw compressors Series S 31 2 5 341 SD 40 2 SD 150 SF 60 2 SF 150 SDF 60 2 SDF 150 S 40 2 S 50 2 BLUEKAT Separate manuals Compressor control Refrigeration compressed air dryer SD SDF Frequency converter SF SDF www boge com Operating instructions for belt driven screw compressors 31 2 40 2 SD 40 2 50 2 SD 50 2 60 2 SD 60 2 61 2 SD 61 2 75 2 SD 75 2 90 2 SD 90 2 S 100 2 SD 100 2 S 101 SD 101 S 125 SD 125 S 150 SD 150 151 S 180 220 271 341 I NN NNNNA SF 60 2 SDF 60 2 SF 100 2 SDF 100 2 SF 150 SDF 150 S 40 2 BLUEKAT S 50 2 BLUEKAT BOGE KOMPRESSOREN Postfach 10 07 13 33507 Bielefeld Otto Boge Stra e 1 7 33739 Bielefeld Fon 49 5206 601 0 Fax 49 5206 601 200 Mail info boge com Net www boge com 22 kW 30 kW 37 kW 45 kW 45 kW 55 kW 65 kW 75 kW 75 kW 90 kW 110 kW 110 kW 132 kW 160 kW 200 kW 250 kW 45 kW 75 kW 110 kW 30 kW 37 kW Issue 05 2012 No 596 1162 01 Nominal price 5 00 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page Part 1 1 1 General safety instructions cccesseeeneeeeeee eee eeeeeeeeeeeneeeeeeeeees 1 General Safet
37. IEM IIO epeui yun Jojejed s 919 Jolly Jo eJnjeJ einsseJd einsseJd s noy sSyeway JOUONUOD Jafup Je o 100W Bu1009 IIO TO IO exejul edue weIs S YIOMJON Bugesado ajeq suuinjo2 BAI IAdSaJ BY ui YIOM e2ueuojureui poajojduioo ay 9jou oseajd BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 108
38. N VDE 0105 7 Prior 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 8 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 9 When the automatic restart Auto Restart is activated the compressor will start automatically following a voltage loss Prerequisite The netpressure is lower than the set switch on pressure Safety instructions for maintenance and repair on integrated converter BLUEKAT series Caution Maintenance and repair work on integrated converter of the S 40 2 BLUEKAT and S 50 2 BLUEKAT series may be carried out by specially trained BOGE service personnel only Non observance may cause physical injuries and damage to the compressor station BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 5 General kA Introduction Accident prevention regulations The owner of a compressor plant is responsible to ensure that it is properly in stalled 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 Employer
39. SDF 60 2 SDF 100 2 SDF 150 Oil filling quantity Oil receiver volume i 46 71 120 Total oil filling quantity i 28 42 65 Oil topping up quantity between min max i 6 8 10 Intake air temperature min C 5 5 5 max C 40 40 40 Cooling air requirement free standing installation m h 13000 18400 32000 g with supply and exhaust m h 6500 9200 16000 x free ventilator pressure Pa 60 60 60 free ventilator pressure mm WColumn 6 6 6 Cooling air requirement free standing installation m h 2000 2000 3400 with supply and exhaust m h 1000 1000 1700 Required cooling water quantity deltat 15K m h 2 450 4 090 6 000 o delta t 30K m h 1 225 2 045 3 000 Max cooling water quantity m h 3 5 4 2 9 0 o Cooling water inlet temperature E min C 5 5 5 max C 30 30 30 Cooling water outlet temperature max C 45 45 45 Cooling water pressure min bar 2 2 2 max bar 10 10 10 Operating pressure transmitter factory settings Pmax 8bar Switch offpress p bar 8 8 8 Switch on press Prin bar 7 5 75 7 5 Pmax 10 bar Switch offpress p bar 10 10 10 Switch on press Prin bar 9 5 9 5 9 5 Pmax 13 bar Switch off press Prax bar 13 13 13 Switch on press Prin bar 12 5 12 5 12 5 Safety valve Activation pressure at Prax 8 bar bar 11 11 11 Prex 10 bar bar 11 11 11 Prax 13 bar bar 14 14 14 Compres
40. a padlock Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Close ball valve at the compressed air outlet Open safety sound insulation hood and take off safety warm air hood 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 Unscrew soiled oil filter 3 by hand or use a strap wrench turning counter clockwise 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 Close safety sound insulation hood 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 and close safety sound insula tion hood Open ball 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 procedure as de
41. aintenance Regular maintenance work Cleaning the com Cleaning pressed air oil cooling After 1 500 operating hours however not later than after one year unit air cooling Note 3 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Remove the cladding from the service side Unscrew the maintenance 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 Blow down the dirt with compressed air 1 in the opposite direction to the normal cooling air flow Vacuum out the dirt using an industrial vacuum cleaner 2 see Fig If the cooling unit is excessively soiled cleaning is no longer possible with compressed air have it disassembled and cleaned by BOGE service O No cleaning necessary in b P2 case of water cooling 2 f P Fig 6 15 Cleaning the compressed air oil cooling u
42. al E Introduction Intended use Caution BOGE compressors including their additional equipment are exclusively intended for the compression of air in industrial applications 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 The emergency stop device of the compressor emergency stop switch button is exclusively intended to switch off the compressor in case of emer gency Operation and control are designed to be executed by trained and authorized operators Foreseeable Misuse 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 emergency stop device of the compressor emergency stop switch button may not be used for operational tripping of the compressor Make sure to actuate the OFF button for operational tripping of the compressor
43. al safety instructions Special hazard warnings 12 Undertake conversions and modifications of the compressor only with BOGE prior approval taking all relevant safety regulations into considera tion The manufacturer is not liable for damages resulting from independ ent 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 detected or suspected 14 Observe all safety and danger signs directly attached on the compressor 15 The compressed air oil receiver and the BLUEKAT converter are pressure devices and require testing in accordance with international standards 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 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 There is a constant danger of accidentally reaching into the impeller of the cooling fan Please note that the cooling fan may run on for a certain time even afte
44. als the gaps between the screws and between the screws and hous ing It lubricates the bearings Fig 2 2 Components of the oil circuit Compressed air oil vessel The oil separated from the compressed air through the force of gravity col lects in the compressed air oil vessel The system pressure forces it out of the vessel into the air end Thermostatic oil control valve Depending on the oil temperature the thermostatic oil control valve either allows the oil to pass through the oil cooler or through a bypass e g in the starting phase Thus the oil constantly maintains its optimum operating temperature Oil cooler air or water cooled The oil cooler cools down the hot oil to operating temperature Cil filter The oil filter traps impurities in the oil Air end The injected oil returns to the compressed air oil vessel together with the compressed air Drainage line The air end suctions the residual oil which collects in the oil separator back into the oil circuit via a drainage line Page 22 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description BLUEKAT operation principle 2 3 BLUEKAT operation principle The screw compressors of the BLUEKAT series S 40 2 BLUEKAT and S 50 2 BLUEKAT are equipped with an integrated converter for catalyctic sep aration of oil residues contained in the compressed air During the oxidation process the converter serves to br
45. at vae ATO separator 44 Double check valve p Monitoring of rotational direction 12 Safety valve 50 Filter 16 Thermostatig oil control valve 51 Safety valve i A ei 52 Heat exchanger 2 Her 53 Converter ib A Ken iri 54 Heating cartridge with thermocouple 20 Oil throttle 55 Heating cartridge receiver top 21 Minimum pressure check valve 56 Heating cartridge receiver middle 22 Compressed air after cooler 57 Heating cartridge bed temperature 58 Pressure retaining shut off valve 23 Pressure sensor for system pressure DHSV 24 Network pressure compress 59 DHSV solenoid valve s Stop ih Pede air outlet 60 Gauge E Sup valva oildraiage 61 Relief ball valve a qs ps is Fanage ling 62 Condensate discharge valve auto p matic 29 Proportional controller 30 Diff pressure switch for prop control ler Option BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 101 Appendix SD SDF 101 ce c Aa n Flow chart 25 101 Compressed air OUTLET Screw compressor see also flow diagram Cyclone separator Compressed air refrigeration dryer Bypass Drain Condensate Non return valve compressed air exhaust Page 102 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix BOGE Duotherm BPT plate heat exchanger 10 102 103 Ro Flow chart DUOTHERM Compressed air OUTLET backwards forwards Suction fi
46. ation control valve Drive motor 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 Diff pressure switch for prop controller 3 2 way solenoid valve for prop controller with standard control passage here 2 2 way solenoid valve Control valve water supply preadjusted Control valve water supply preadjusted Display of f a d for prop controller 3 2 way solenoid valve for suction control regulation Double check valve Pos 42 43 rapid start valve Double check valve Monitoring of rotational direction Option To be provided by customer 35 36 Dirt trap Stop valve BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 91 Appendix Flow chart Air cooled version frequency controlled
47. ation of any warranty claims against BOGE Ry Note Opening and replacement of the converter by any personnel not authorized or trained by BOGE will result in immediate expiration of any warranty claims against BOGE Transport damage BOGE does not accept any liability for breakage or transport damage Please inspect the compressor immediately after delivery and direct damage claims to the last haulier even 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 Page 10 BOGE Operating instructions for S 31 2 S 341 series screw compressors General E Introduction Data on the type plate Service Enter the data of your compressor from the type plate or enclosed data sheet in the illustration below This will ensure that in the event of enquiries you will always have the most important data to hand 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 kW Postfach 100713 D 33507 Bielefeld Fax 05206 601 200 www boge com info boge com C C
48. ays use the same oil type when topping up Never mix different oil types and brands 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Close ball valve at the compressed air outlet Open safety sound insulation hood 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 Series S 31 2 S 220 SF 60 SDF 150 BLUEKAT series Caution Risk of injury Danger of burning due to hot oil Always wear your compulsory personal protective equipment when working on the compressor Open safety sound insulation hood Remove plug 2 of oil filling socket 1 see figure below Check oil level The oil level must not drop below the min mark If necessary top up with oil to the lower edge of the thread max mark on the oil filling socket Screw plug 2 back in Close safety sound insulation hood Reattach cladding on the maintenance side Open ball valve at the compressed air outlet Page 74 BOGE Operating instructions for S
49. cates 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 S 31 2 S 341 series screw compressors Page 7 General EH Introduction Symbols on the compressor Note 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 Note 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 Any works on the belt drive may only be carried out when the compressor is at standstill and secured against unintentional switching on poe r S Page 8 BOGE Operating instructions for S 31 2 S 341 series screw compressors Gener
50. ced This leads to damage to the air end and to the integrated converter BLUEKAT series It is of utmost importance to consult BOGE if you operate your system with short operating times Operating pressure transmitter 2 5 Control devices The operating pressure transmitter 1 controls the operation of the compres sor within the set switching limits Switch on pressure Prin If the network pressure drops to the set switch on pressure Pin the compressor switches on Switch off pressure Prax If the network pressure in creases to the switch off pressure the compres sor either switches off inter mittent operation or switches to idling operation continu ous operation Fig 2 5 Operating pressure transmitter Page 26 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description EN Safety and monitoring devices Proportional controller option for S series General The proportional controller is an additional control device intervening in the sequences of the intake regulator The intake regulator only opens as far as necessary to supply the current com pressed air requirement Thus the compressor saves compression energy A compressor with proportional controller is able to supply its delivered quan tity variable between 096 and 10096 However the energy consumption does not reduce accordingly Therefore a control is only practical betwee
51. chapter 3 5 Commissioning Page 34 BOGE Operating instructions for S 31 2 S 341 series screw compressors Installation Compressor room Installation conditions and 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 A level industrial floor without foundation is adequate for the installation of the compressor No special fas
52. chart 101 Intake air INLET 102 Compressed air OUTLET 1 Suction filter 29 Proportional controller 2 Maintenance display from 30 kW 30 Diff pressure switch for prop control 3 Vacuum switch ler for suction filter monitoring 31 3 2 way solenoid valve for prop con 4 Suction controller troller with standard control passage 5 Airrelief and regulation control valve here g 7 Drive motor 37 Display of f a d for prop controller 42 3 2 way solenoid valve for suction con 8 Airend ge trol regulation 9 d for final compression tempera 43 Double check valve T Pos 42 43 rapid start valve 10 combined compressed air oil receiver 44 Do bls check valve 11 Oil separator Monitoring of rotational direction 12 Safety valve 50 Filter 16 Thermostatic oil control valve 51 Safety valve 17 Oil cooler 52 Heat exchanger 18 Oil filter 53 Converter 19 Differential pressure Such 54 Heating cartridge with thermocouple for ollaltog mennoning 55 Heating cartridge receiver top 20 Oilthrottle l SAL ia e 56 Heating cartridge receiver middle ab Minimum i pas ENGER valve 57 Heating cartridge bed temperature eer ONISSSRO irana eaog 58 Pressure retaining shut off valve 23 Pressure sensor for system pressure DHSV 24 Network pressure compressor 59 DHSV solenoid valve 25 Stop valve compressed air outlet 60 Gauge 27 Stop valve oil drainage 61 Relief ball valve 28 Check valve drainage line 62 Condensate discharge valve auto up to 7
53. d air network by closing Vent the compressor Switch off the compressor using the OFF button Press Emergency Stop button Open mains disconnection device and secure against unintentional Switch on by means of a padlock sponsible who is authorized to switch on the maschine again to 50 C S 40 2 BLUEKAT and S 50 2 BLUEKAT the ball valve at the compressed air outlet To this effect open the safety valve on the combined compressed air oil receiver as follows Turn the knurled nut counterclockwise until you can feel a resilient resistance Turn the knurled nut a little further Any possibly existing air will escape The system pressure gauge will indicate a pressure of 0 bar Once the residual air has completely escaped from the system firmly retighten the knurled nut Remove all safety cladding necessary to perform the maintenance work Reattach all removed safety cladding Open the ball valve at the compressed air outlet Prior to switching on again check whether anyone else is working on the compressor Remove warning sign not until then and release mains disconnecting device Unlock Emergency Stop button Page 60 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance e General 6 2 General Maintenance through Have BOGE service check your compressor every 3 000 operating hours or BOGE customer service annually Note Maintenance agre
54. e Check suction filter Clean filter and cartridge Change filter cartridge Clean compressed air oil cooler externally Change oil filter Top up oil in the suction controller after an extended down time Change oil separator Check oil level Top up oil Change oil Check V belt Lubricate motor bearings Change supply air filter option Maintenance work on converter S 40 2 S 50 2 BLUEKAT Attention Maintenance and repair work on integrated converter of the S 40 2 BLUE KAT and S 50 2 BLUEKAT series may be carried out by specially trained BOGE service personnel only Non observance may cause physical injuries and damage to the compressor station BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 63 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 nozzle with dirt catch only through to S 100 2 SD 100 2 SF 100 2 SDF 100 2
55. e ete ia e eei tn itat lutei AM 56 BOGE Duotherm BSW eese nennen 57 la eoD EEEE E e E 57 COMMISSIONING 00 0 2 cece eee ceeeeee a EE A 57 Maintenances u rel NER talc ead 58 Safety instructions retener ann 59 ernicee er 61 Maintenance through BOGE customer service ss 61 Review of regular maintenance work sse 61 Maintenance intervals ssssssssseeeem 64 General information concerning the lubricants used 66 Disposal of used operating material sesenenn 67 Pressure hoses niii ete Desde i Lord oe Mu cand 68 Spare and wearing parts sss 68 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page V Index E 6 3 Regular maintenance work eene 68 Clean or change suction filter seeene 68 Cleaning the filter cartridge 69 Changing the supply air filter mats option 69 Drive motors with permanent lubrication reen 70 Drive motors with lubrication device nennen 70 Drive motors with automatic lubricating equipment 71 Changing the V belt oirro Aa TA 72 Settings of the GM drive systems with standard motors 73 Checking the oil level topping up oil eeeee
56. e build up inside converter insufficient Heating of converter to be checked by BOGE service personnel and to be repaired replaced if necessary BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 53 Optional features EN BOGE Duotherm BPT Function Installation 5 1 BOGE Duotherm BPT The heat recovery system BOGE Duotherm BPT utilizes the heat energy re leased during compression to produce 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 installation Connect the supply and discharge water lines to the pipeline mains Route the pipelines to prevent transmission of stresses tension and vibrations to the heat exchanger Provide venting and draining facilities The customer must provide the following components for installation Stop valves Stop valves in the water supply and discharge lines enable simple removal of the heat exchanger
57. e 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 Page 4 BOGE Operating instructions for S 31 2 S 341 series screw compressors General EN General safety instructions 3 Prior to maintenance or repair work Switch off the compressor using the OFF button Press Emergency Stop button Open power disconnecting device Secure power 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 maschine again Check to ensure that all parts are currentless Disconnect the compressor from the compressed air network relieve or block pressurized lines Allow converter to cool off for several hours only applies to screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT 4 Exercise extreme caution during repair or maintenance work requiring the compressor to be operational Ensure that persons keep out of reach of the hazardous area 5 Ensure that work on the electrical equipment is only executed by qualified electricians 6 Work on parts and devices under current is prohibited Exceptions are gov erned by the appropriate regulations e g DI
58. e water supply cf dimensioned drawing 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 41 Installation Installation 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 The frame of the drive unit is bolted to the basic frame for transport seeunmig bolts Remove the four red marked screws 1 and 2 two of each on the longitudinal side together with the space col lars Ensure that the forks are un derneath the base frame of the compressor see illustra tion Fig 3 4 Removing the transport securing bolts S 60 air cooled shown on this illustration Activating the belt The V belts are slackened for transport tensioning device Activate the GM belt tensioning device prior to commissioning by lowering the motor plate ym Secure bolt head 1 against turning by means of a span ner NW 27 Turn
59. eak up residual oil particles from the air com pressed by the compressor into carbon dioxide and water The treated com pressed air is classified as oil free class 0 according to DIN ISO 8573 1 Converter control Compressor control A B Compressor Converter Fig 2 3 Overview BLUEKAT compressor gray section with integrated con verter As for the screw compressors of the BLUEKAT series the converter is installed downstream of the compressor Prior to the oil separation process the com pressed produced by compressor 1 is first heated up in plate heat exchanger 2 see figure below After escaping from the plate heat exchanger the heated compressed air is fed into converter 3 which is filled with catalytic material The catalytic material is kept at operating temperature 200 C by means of an electrically powered heating At the same time the heating also heats up the incoming compressed air Due to the heat build up the oil particles in the compressed air are able to react with the catalytic material When impacting on the catalyst surface the oil particles hydrocarbons are completely burnt oxidized The heated oil free compressed air is fed back to plate heat exchanger 2 af ter the treatment process While being in the plate heat exchanger it releases part of its heat energy to the compressed air still to be treated flowing from the compressor into the plate heat exchanger which is now able to heat up pri or to
60. ed 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 re quirements Prior to starting the compressor for the first time check if the transport secur ing device was duly removed and the GM the belt tensioning device was acti vated see chapter 3 3 Installation List up the test results in the commissioning certificate Checking the rotational direction of drive and fan motor Attention Always check the rotational direction of the drive and fan motor prior to com missioning 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 45 Installation Commissioning Changing the rotational direction Caution Risk of injury Emergency stop switch button open mains disconnec
61. eeeeeeeeeceeeeeeeeeeeeeees 74 Changing the oil filter 76 Changing the oil separator 77 OM CHAN GOS ra en Ea die 79 Flushing the oil circuit 81 Cleaning the compressed air oil cooling unit air cooling 82 Cleaning the oil cooling unit water cooling 83 Proportional controller option for S series 83 Check safety valve ener knees 84 6 4 Spare parts and optional equipment 85 List of spare and wearing parts for maintenance 85 Replacement parts for converter BLUEKAT series 86 List of available optional equipment ssssssssssssss 86 Part 7 7 1 Guidelines and standards complied with 87 Appendix 7 2 Flow chart cione nete ner eee eterne arena 87 Air cooled version standard ccccccccsssscceeecaneeeeeeeaeeaseeeeeeeanees 88 Water cooled version serial connection parallel connection 90 Air cooled version frequency controlled nesen 92 Water cooled version serial connection frequency controlled 94 BLUEKAT series air cooled version sese 96 BLUEKAT series water cooled version parallel connection 98 BLUEKAT series Water cooled version serial connection 100 SD SE iet idet ede itae tek trete
62. ement 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 S 31 2 S 341 maintenance work 3 Or Fig 6 1 Maintenance works S 31 2 S 341 Check adjust pressure 2 Check suction filter Clean filter and cartridge Change 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 on PR Oo BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 61 Maintenance LE General 7 Check oil level Top up oil 8 Change oil 9 Check V belts 10 Lubricate motor bearings 11 Change supply air filter option SD 40 2 SD 150 Fig 6 2 Additional maintenance works SD 40 2 SD 150 1 Replace compressed air filter with differential pressure and filter element see separate operating instructions 2 Compressed air refrigeration dryer see separate operating instructions Page 62 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance e General Maintenance work on compressor S 40 2 S 50 2 BLUEKAT Fig 1 NO o 8 9 10 11 6 3 Maintenance works S 40 2 BLUEKAT S 50 2 BLUEKAT Check adjust pressur
63. entilator 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 S 31 2 S 341 series screw compressors Page 39 Installation Installation Condensate disposal The air taken in contains water in form of vapour which turns into condensa tion during compression Attention The condensate contains oil Never lead it into the public sewage system without prior treatment Exception The built up condensate of compressors of the BLUEKAT series does not contain any residual oil The condensate is to be treated as industrial water Strictly observe the effluent disposal laws of your local authorities Oil water separator not for compressors of the BLUEKAT series 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 emulsify use an emul sion cracking plant General 3 3 Installation BOGE compressor units are supplied ready fo
64. er 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 Spare parts list 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 Ry 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 installed 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 quality Connect the cooling water supply and discharge line to th
65. es replace if necessary Machine has not vented perfectly 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 Converter failure See Converter failures BLUEKAT series on page 53 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 51 Faults General faults Fault Possible cause Rectification Oil in suction filter Minimum pressure non return valve is leaking Check the minimum pressure check valve and replace if necessary Suction controller is leaking Check the suction controller and replace if necessary Cut out performed by emer gency off switch Cut out normally via O key 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
66. ettings of the GM drive blue As to the setting value for tge corresponding motor systems with standard we refer to the table below motors sealed Type Pressure Setting bar mm S 31 2 8 10 13 84 S 40 2 5 60 2 SD 40 2 SD 60 2 8 10 13 112 S 40 2 BLUEKAT S 50 2 BLUEKAT S 61 2 5 75 2 S 100 2 8110 13 112 SD 61 2 SD 75 2 SD 100 2 8 10 13 112 S 90 2 SD 90 2 10 13 103 S 90 2 SD 90 2 8 112 S 101 S 125 S 150 S 151 8 10 13 84 83 63 S 180 8 10 13 92 88 98 S 220 8 10 13 76192182 S 271 8110 13 102 96 122 341 8110 13 90 81 116 SF 60 2 SDF 60 2 8110 13 112 SF 100 2 SDF 100 2 SF 150 SDF 150 SEINE He Table 6 2 Settings with standard motors The settings shown in the table are fixed by the manufacturer and may not be changed Slight deviations are allowed and compensated by the GM drive sys tem The current settings are also shown on the GM drive system With special ver sions the settings on the sticker may deviate from the standard values BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 73 Maintenance Regular maintenance work Checking the oil level topping up oil Check 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 Alw
67. f the system 3 Standstill ready for operation The compressor is standing still but ready for operation When compressed air is required it switches automatically to load operation Page 24 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description EN Compressor control Operating modes Compressed air production control BLUEKAT series The two most important operating modes are achieved by combining the three operating states 1 Intermittent operation In intermittent operation the energy balance is perfect The compressor operates in load operation Upon reaching the switch off pressure Pmax the compressor switches to standstill It does not consume any energy Once the pressure has dropped to the switch on pressure Pmi the compressor switches back to load operation 2 Continuous operation Continuous operation limits the drive motor switching cycles and reduces wear to the system The compressor operates in load operation Upon reaching the switch off pressure Pmax the compressor switches to idling operation nce the pressure has dropped to the switch on pressure pin the com pressor switches from idling operation back to load operation As for compressors of the BLUEKAT series S 40 2 BLUEKAT and S 50 2 BLUEKAT the compressed air production depends on the operating state of the integrated converter After connection of
68. g waltoer enne eie ede 32 Water connection for water cooling seeenes 32 Cooling water quality eem 32 Transport and storage unneessnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnn 33 IC MIR E wa ute aaa kara AEAEE 33 Transport possibilities ccc ceeececeeeeceeceeeeeeeeeeeeteceeecaesaeeeeeeeeeenens 33 Intermediate storage emen 34 Compressor rOOim eiie serae eret ree CER ere Ce Ceca ESEE 35 Installation conditions and application for compressed air receivers arranged below or separately ssssssssssssssee 35 Installation surface sssssssssssesseeeememm 35 Fire protectionis ou ico ee moie keit 35 Sound protection cceccecceececcceee a e aes eaaa 36 Admissible ambient temperatures nennen 36 Frost protections eiecti ri A net reden 36 Mac peers eee IE DEUTET reer tre tec tre ter Cn rer et er rer ner A 37 Cooling air requirement secerni a a emen 38 Ventilation possibilities 39 Condensate disposal ssssssssssssssssee 40 Installation 2 aaa nn 40 General hiat cedet iere tata ena tede edente aep 40 Checking the delivery scope sssseem e 41 Installing the compressor sse mem 41 Connecting the compressor to the compressed air network 41 Connecting the cooling water option 41 Removing t
69. he transport securing bolts sssessss 42 Page IV BOGE Operating instructions for S 31 2 S 341 series screw compressors Index 3 4 3 5 3 6 Part 4 4 1 Faults 4 2 4 3 Part 5 5 1 Optional features 5 2 Part 6 6 1 Maintenance 6 2 Activating the belt tensioning device sseeeeee 42 Checking the oil level eee 43 Electrical connection eese nennen 43 Commissioning ccedeessteceetvacienceeseencetedevesctecceedaiteeeeeseeneteess 45 Check installation requirements ssssssssssseeess 45 Checking the rotational direction of drive and fan motor 45 Check compressed air outlet for tightness een 46 Opening the stop valve ssssssssssseseeeeneees 46 Checking for leaks Siren a a E E enn 47 Conduct trail fun a eri D HERD 47 Commissioning following extended stoppages 48 Refrigeration compressed air dryer ssssseee 49 Dismantling 2 2 2 Reken in edens 50 rnc eR 51 General faults need ret nere tenete 51 Converter failures BLUEKAT series eese 53 BOGE Duotherm BPT eese nnne 55 Function are ae a rennen ie ceeded 55 Installation 4 34 e o e E id sel a ee gta 55 COMMISSIONING 2 eret ei reme So eR ees 55 Maintenanc
70. heir rectification please also refer to oper ating instructions of the compressor control Caution Ensure that any work required to rectify faults is only carried out by qualified personnel or specialists Ensure that components which have a safety function be only set repaired or exchanged by BOGE service personnel This applies in particular to any work carried out on the integrated converter of screw compressors of the BLUEKAT series Please contact BOGE Service at the following telephone number if you have any questions Telephone 49 5206 601 140 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 V belts are torn Fit new V belts Compressor system does not start up No electric power to compressor Check electrical connection Fuses are defective Check the mains and control fus
71. imum pressure is exceeded e g incorrect setting of the oper ating pressure switch the entire delivery volume of the compressor is eject ed Monitoring the drive and fan motor Rotational direction monitoring option System pressure build up option The drive motor is monitored by PTC resistors The fan motor is monitored by overcurrent overload release units The pressure switch checks the rotational direction of the drive motor each time the system starts up The system pressure build up unit monitors the system pressure build up when the compressor starts up Page 30 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description Water cooling Water cooling Serial connection Parallel connection 2 7 Water cooling BOGE screw compressors are available in water or air cooled design In the standard version the oil and compressed air aftercoolers are connected in series on the water side A parallel connection is possible as an option 2 3 1 Fig 2 8 Serial connection 4 Ne ES Fig 2 9 Parallel connection 2 3 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
72. it Intake filter The intake filter cleans the air suctioned by the air end 2 Intake regulator The intake regulator opens load operation or closes idling operation or standstill the suction line depending on the operating condition of the compressor 3 Air end The air end compresses the sucked in air 4 Compressed air oil vessel The compressed air separates from the oil under the force of gravity in the compressed air oil vessel 5 Oil separator The oil separator separates the residual oil contained in the compressed air 6 Minimum pressure 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 7 Compressed air after cooler air cooled 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 21 Product description EN Compressor operation principle Cil circuit The oil injected into the air end has the following function It dissipates the compression heat cooling It se
73. leakages Check the service life of the hoses and replace them in due time As replacement only use original spare parts released by BOGE Used pressure hoses are not permitted as a replacement Spare and wearing parts AA 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 only through to S 100 2 SD 100 2 SF 100 2 SDF 100 2 BLUE KAT series 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Page 68 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance Cleaning the filter cartridge Regular maintenance work Removing the filter car t
74. lity state when reaching the switch off pressure is effected irrespectively of the operating state of the con verter as with compressors without integrated converter The compressor either switches into the operational availability standby mode or back into the idle mode and stops producing compressed air BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 25 Product description Control devices Controlled operation frequency control Short operating times If the pressure has dropped below the switch on pressure Pin the compressor starts and operates in load operation Once the operation pressure p 4 has been exceeded the control is activated and reduces the speed If the pressure has dropped below the operating pressure Piaget the control is activated and increases the speed Upon reaching the switch off pressure Pmax the compressor switches to idling operation The settings for p und Pmax are effected by the parameterization of the BASIC FOCUS For the BASIC control the setting for p is effected at the potentiometer R3 in the compressor switch cabinet For the FOCUS control the setting for p is effected via parameterization of the control 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 redu
75. llow indicator lamp Pre heating Aufheizen on the switch cabinet of the converter lights up The compressor remains in the operational availability standby mode After approx 15 to 45 minutes depending on the residual heat inside the converter and the ambient temperature the converter reaches its operat ing temperature release temperature The yellow indicator lamps extinguishes and the green indicator lamp op eration Betrieb lights up As soon as the switch on pressure is achieved the control system allows the compressor to switch to load operation The compressor will now start to produce compressed air while the converter is ready for treatment of the compressed air Switch off compressor after several hours of trial operation under max work load List up the test results in the commissioning certificate Ry Note When using the compressor control to switch off the compressor the heating of the converter remains in operation This serves to avoid prolonged pre heating phases before the next load operation BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 47 Installation Commissioning Commissioning If an extended stoppage is scheduled you should contact BOGE Service be following extended forehand stoppages Following an extended stoppage of more than 2 months fill a small amount of oil i
76. locknut 2 upwards by turning counterclockwise until it locks against the bolt head The belt tensioning device is activated It automatically sets the correct V belt tension in every operating mode Fig 3 5 Activating the belt tension Page 42 BOGE Operating instructions for S 31 2 S 341 series screw compressors Installation Electrical connection Checking the oil level 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 High voltage Ensure that work on the electrical equipment of the compressor is only car ried out by authorized 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 Power disconnecting device Each compressor plant has to be equipped with a power disconnecting device according to DIN EN 60204 1 2007 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 Please see Technical Data for layout of mains fuse Connecting the leads Check to e
77. lter Intake regulator Air end Combined compressed air oil receiver Oil separator Thermostatic oil control valve Oil cooler Oil filter Minimum pressure check valve Compressed air after cooler Heat exchanger BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 103 Appendix Flow chart BOGE Duotherm Plus BSW safety heat exchanger 10 102 103 o A 10 11 16 17 18 2 22 5 52 53 Compressed air OFF backwards forwards Suction filter Intake regulator Air end Combined compressed air oil receiver Oil separator Thermostatic oil control valve Oil cooler Oil filter Minimum pressure check valve Compressed air after cooler Safety heat exchanger Pressure monitor for rupture Compensation vessel Page 104 BOGE Operating instructions for S 31 2 S 341 series screw compressors 7 3 List of maintenance and service work Appendix 7 3 List of maintenance and service work abuey M eDueu M X99U Y xs Buiuee Y uleig JOA Jojejedos goueu Bujueojo S 18 em 0 He yun JojeJedes 0 8 Jay Jay eJnjel enssoJd aunssaid s noy SHICWOY siayanuog J9 up de 100W Bu1009 IIO 10 IIO ayeyu eduo uiejsAg xiowjeN Bugeiedo aeg suuinjo2 BANIAdSAaJ BY ui YIOM e2ueuojureui pojojduioo y aJOU eseajd Page 105 BOGE Operating i
78. m oil pressure 16 bar Maximum pressure of the barrier liquid 10 bar Maximum temperature oil and water 100 C Note Exceeding the maximum temperature will lead to malfunctions A fault alarm is triggered Commissioning Proceed as follows during commissioning Check the oil level in the oil circuit Slowly open the valves on the water side Prevent pressure hammers Vent the pipelines Any residual air contained in the heat exchanger will be carried along by the respective medium and escapes via the system BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 57 Optional features EN BOGE Duotherm BSW 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 58 BOGE Operating instructions for S 31 2 S 341 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
79. n 5096 and 10096 of the delivered quantity The proportional controller is factory set to a delivered quantity between 5096 and 10096 of the compressor capacity The proportional controller closes when the desired delivered quantity has dropped below 50 of the compressor capacity The compressor then oper ates in idling operation continuous operation or switches off intermittent operation 2 6 Safety and monitoring devices The safety devices guarantee a high degree of operational safety in connec tion with the BOGE monitoring system When one of the safety devices responds the control system reacts as fol lows The compressor is immediately switched off A flashing fault number in the left field of the display indicates the cause of the fault Caution Risk of injury Do not operate the compressor without built in safety devices Do not dismantle the safety devices or put them out of operation Safety temperature limiting device The following monitoring devices are standard for BOGE control systems The safety temperature limiting device switches the compressor off as soon as the 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 BOGE Operating instructions for
80. n etus reg adeo erga 102 BOGE Duotherm BPT plate heat exchanger 103 BOGE Duotherm Plus BSW safety heat exchanger 104 7 3 List of maintenance and service work 105 Page VI BOGE Operating instructions for S 31 2 S 341 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 compressor operation 1 10 11 Ensure that no commissioning and maintenance work on the compressor is undertaken until these operating instructions are understood Only use the compressor for its intended use as described in these oper ating instructions The owner must ensure that only appropriately trained and authorized personnel work on this compressor dthat no persons work on this compressor whose ability to react is restricted due to misuse of e g drugs alcohol medication etc thatthe operating maintenance and repair personnel has been made fully familiar with all safety instructions and that they are being observed that the compressor is only operated in a safe operating condition
81. n 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 suc tion controller 1 Nes Fig 3 6 Suction controller The following compressor oil quantities must be filled into the suction control ler Model Compressor oil quantity I S 31 2 5 60 2 SF 60 2 BLUEKAT models approx 0 5 S 61 2 S 100 2 SF 100 2 approx 2 5 S 101 S 150 SF 150 approx 5 0 S 151 S 220 approx 8 0 S 271 8 341 approx 10 0 Table 3 2 Compressor oil quantities Screw in plug again Page 48 BOGE Operating instructions for S 31 2 S 341 series screw compressors Installation Commissioning Turn compressor stage at the pulley by hand 5 to 10 times to spread the oil evenly Note 35 As for screw compressors of the BLUEKAT series please note that in the event of prolonged operational shutdowns for several days during which the compressor station is disconnected from the power supply restarting the compressor requires a preheating phase of 15 to 45 minutes since the con verter has completely cooled down Refrigeration Before commissioning the refrigeration compressed air dryer read attached compressed air dryer
82. nannannnnnnnnnnnnnnnnnnnnnan nn 24 Network PpreSSure ccccccccceceeeeeeeeeseeeeeeaaneeceeeeeeeeeeeeseseeesseneeaeees 24 Operating states oni nts OD eee bert one ag 24 Operating modes esisiini aari nAi tenentes 25 Compressed air production control BLUEKAT series 25 Controlled operation frequency control ssesssssss 26 Short operating times ettet 26 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page Ill Index Part 3 Installation 2 5 2 6 2 7 2 8 3 1 3 2 3 3 Control devices nou Ine elei 26 Operating pressure transmitter sess 26 Proportional controller option for S series 27 Safety and monitoring devices eene 27 General el ete pel te nd e desde Leid 27 Safety temperature limiting device sssseeeeeee 27 Safety temperature limiter on the integrated converter BEUEKAT Series recette e dide e ted 28 Safety valve iium e e dor PEU E 30 Monitoring the drive and fan motor sssseeee 30 Rotational direction monitoring option esesssss 30 System pressure build up option 30 Water cooling nene eee 31 Water coolirig meri ea kin 31 Serial connection sse enne 31 Parallel connection dn A ae a taa a 31 Coolin
83. ne using the emegency stop button after 3 seconds or if a residual pressure of 2 bar is reached Screw cap nut on the bleed aperture of the solenoid valve 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 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 Remove oil filler screw 7 on the compressed air oil cooler and drain the residual oil max 5 litres into a suitable container Reinsert the oil filler screw together with a new copper sealing ring Change oil filter procedure as described above Change oil separators procedure as described above BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 79 Maintenance Regular maintenance work 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 3 5 Commissioning Commis sioning following extended stoppages Atte
84. ned 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 Diff pressure switch for prop controller 3 2 way solenoid valve for prop controller with standard control passage here Display of F a d for prop controller 3 2 way solenoid valve for suction control regulation Double check valve Pos 42 43 rapid start valve Double check valve Monitoring of rotational direction Option BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 89 Appendix Flow chart Water cooled version serial connection parallel connection Parallel connection Serial connection Page 90 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow chart 10 102 103 104 oO ON oO FP WD N wo 32 33 34 37 42 43 44 Intake air INLET Compressed air OUTLET Water INLET Water OUTLET Suction filter Maintenance display from 30 kW Vacuum switch for suction filter monitoring Suction controller Air relief and regul
85. ng water quantity delta t 15K m h 1 200 1 630 2 010 2 450 2 450 3 000 3 540 4 090 delta t 30K m h 0 600 0 815 1 005 1 225 1 225 1 500 1 770 2 045 Max cooling water quantity m h 3 5 3 5 3 5 3 5 4 2 4 2 42 42 o Cooling water inlet temperature min Pc 5 5 5 5 5 5 5 5 ma C 30 30 30 30 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 45 45 45 45 Cooling water pressure min bar 2 2 2 2 2 2 2 2 max bar 10 10 10 10 10 10 10 10 Operating pressure sensor LU factory settings Pmax 8bar Switch offpress p bar 8 8 8 8 8 8 8 8 Switch on press Prin bar 7 7 7 7 7 7 7 7 Prax 10 bar Switch off press Prey bar 10 10 10 10 10 10 10 10 Switch on press Pin bar 9 9 9 9 9 9 9 9 Pmax 13 bar Switch off press Prex bar 13 13 13 13 13 13 13 13 Switch on press Prin bar 12 12 12 12 12 12 12 12 Safety valve Activation pressure at p 7 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 Compressors for other operating pressures Prin Pmax 1 bar BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 15 Product description EN Technical data Technical data for S 101 S 341 SD 101 SD 150 part 2 S 101 S 125 S 150 Type SD 101 SD 125 SD 150 S 151 S 180 S 220 271 341 Oil filling quantity Oil receiver vol
86. nit Page 82 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance Regular maintenance work Cleaning the oil cooling unit water cooling As for compressors of the BLUEKAT series the maintenance flap of the air cir culation box is located at the arrow marked in the following illustration IE A Fig 6 16 Cleaning the compressed air oil cooling unit S 40 2 S 50 2 BLUEKAT 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 for S series Carry out the cleaning as described for plate heat exchangers Check After approx 3 000 operating hours however at least once a year 1 Setting the operating pressure sensor Switch on pressure p Final compression pressure 1 bar Switch off pressure p Final compression pressure BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 83 Maintenance Regular maintenance work 2 Setting the proportional controller Displace the control range of the propor tional controller by turning cap 1 A Increase pressure level
87. ns for maintenance and repair of the compressor 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 applied Having finished the work a skin care product must be applied 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 mains connection must be equipped with a dis connecting device The power disconnecting devic
88. nstructions for S 31 2 S 341 series screw compressors 7 3 List of maintenance and service work Appendix abuey M abuey M 4994 M xx Duiuee 4 uie EE Jojesedas goueu Bujuego a Saas FOIEM IIO epeui yun Jojejed s 919 Jolly Jo eJnjeJ einsseJd einsseJd s noy sSyeway JOUONUOD Jafup Je o 100W Bu1009 IIO TO IO exejul edue weIs S YIOMJON Bugesado ajeq suuinjo2 BAI IAdSaJ BY ui YIOM e2ueuojureui poajojduioo ay 9jou oseajd BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 106 7 3 List of maintenance and service work Appendix abuey M abuey M YOU ax Buwesg Y uleig EE Jojesedas o2ueu Bujueojo Nas J9je H O eeu yun Jojeiedas 1943 Joy Jay anjel anss sd einsseJd s noy SYIEWOM isuenuog 194p de J0J0W Bu1009 IIO 10 IIO ayeyu eduo uiejs4g women Bugeredo aea suuinjo2 aAnoodsaij y ui YIOM e2ueuojureui pojojduioo ay ajou aseajd Page 107 BOGE Operating instructions for S 31 2 S 341 series screw compressors 7 3 List of maintenance and service work Appendix abuey M abuey M 4994 M xx Duiuee 4 uie EE Jojesedas goueu Bujuego a Saas FO
89. nsure 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 connections after the first 50 operating hours Note As for the screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT the power supply to the integrated converter is enabled by means of the electri cal connection of the compressor BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 43 Installation Electrical connection Drive with frequency converter Caution High 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 EN 60204 1 2007 and EN 50178 1998 have to be applied as soon as the compressor is electrically con nected 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 hat a second conductor with at least the same cross section
90. ntenance 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 S 31 2 S 341 series screw compressors General E Introduction Symbols used In these operating instructions the most important safety notes and tips are especially 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 symbol indi
91. ntion 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 Close safety sound insulation hood Open ball valve at the compressed air outlet 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Check the oil filters and oil separators for leaks and tighten by hand if necessary procedure as described above Check oil level procedure as described above Top up oil losses if any A N Fig 6 12 Solenoid valve on the suction controller with the cap nut screwed on Nu Page 80 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance Regular maintenance work 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 Detailed information as to the flushing with BOGE oils you can obtain from the following service number Telephone 49 5206 601 140 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 81 M
92. ompressors Installation Commissioning Checking for leaks Caution Risk of injury In case of leakages in the cooling water and or oil circuit there is a risk of slip ping or falling due to cooling water or oil spills Have all connections of the oil or water cooling circuit checked for leakages by authorized qualified personnel During the inspection slip resistant safety shoes and protective clothing are obligatory Conduct trail 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 Use ON button on compressor control to switch on compressor Compres Sor starts operating When the factory set switch off pressure is reached the compressor cuts off automatically Check network pressure on control display f necessary reset operating pressure pressure target value The compressor is ready for operation For control function see control display Switch off compressor after several hours of trial operation under max work load List up the test results in the commissioning certificate For S 40 2 BLUEKAT and S 50 2 BLUEKAT Close power disconnecting device Use ON button on compressor control to switch on compressor The integrated converter starts preheating The ye
93. ooling water pressure min bar 2 2 max bar 10 10 Operating pressure sensor factory settings p 7 8bar Switch offpress p bar 8 8 Switch on press Prin bar 7 7 Prax 10 bar Switch off press Pae bar 10 10 Switch on press Prin bar 9 9 Pmax 13 bar Switch off press Prax bar 13 13 Switch on press Prin bar 12 12 Safety valve Activation pressure at 7 Prax 8 bar bar 11 11 Prax 10 bar bar 11 11 7 Prax 13 bar bar 14 14 Compressors for other operating pressures Prin Pmax 1 bar 2 2 Compressor operation principle Function principle The air end operates according to the displacement principle In the housing of the air end the main and secondary screws are driven by means of an electric motor and V belts Page 20 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description E Compressor operation principle Air circuit Both screws have screw shaped profiles intermeshing without contact To 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 we WEN 8 7 6 ast 4 3 2 Fig 2 1 Components of the air circu
94. operating instructions Caution Risk of injury Observe all safety notes specified in the attached operating instructions when working with refrigerants BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 49 Installation Dismantling 3 6 Dismantling Ry Note To avoid dangers when dismantling the compressor please consult your BOGE Service Telephone 49 5206 601 140 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 High 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 The converter needs to entirely cool down prior to restarting operation only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Page 50 BOGE Operating instructions for S 31 2 S 341 series screw compressors Faults DH General 4 1 General The tables on the following pages give information on the possible causes of operating faults and measures for t
95. otors with lubricating devices regular greasing forms part of the scope of maintenance The lubrication intervals quantity and type of grease are given on the type plate or a separate plate For lubrication the required quan tity is pressed through the nipple into the bearing with a grease gun while the compressor is running Fig 6 6 Grease nipples of the lubricating device Drive motors with Read the attached operating instructions carefully before putting the automatic automatic lubricating lubrication device into operation equipment Caution Risk of injury Always exercise great caution when lubricating the bearings with the com pressor running and observe all safety precautions Never put your hand in the area of the V belt and the fan wheel Fitted safety devices and cladding may not be removed Attention Always use the same type of grease for lubrication The lubricating ability can be sharply reduced if different types of greases are mixed If you intend to use a different type of grease Have the bearings removed and thoroughly cleaned 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 71 Maintenance Regular maintenance work Changing the V belt Check
96. r connection Only the work de scribed in the following paragraphs needs to be carried out during the installa tion Caution Any installation work may only be carried out by appropriately trained per sons or specialists BOGE service personnel 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 excluded 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 If malfunctions occur switch off the compressor immediately and inform the BOGE Service Page 40 BOGE Operating instructions for S 31 2 S 341 series screw compressors Installation Installation Checking the delivery scope Installing the compressor Connecting the compressor to the compressed air network The delivery scope depends on your order Prior to commissioning please check wheth
97. r the compressor has been switched off 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 Page 2 BOGE Operating instructions for S 31 2 S 341 series screw compressors General EN 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 functioning at regular intervals
98. rating instructions for drive motor from 45 kW and up Replace grease in motor bearings Depending on mains frequency 50 Hz 10 000 operating hours 60 Hz 8 000 operating hours If the compressor is not often used undertake the maintenance according to the specified intervals weekly monthly annually depending on the number of operating hours MN Table 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 tempera ture In this case have the oil analyzed by your BOGE service BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 65 Maintenance LE General Converter maintenance intervals S 40 2 S 50 2 BLUEKAT Maintenance interval Maintenance work Annually BOGE service personnel Check electric cable connection for tight fit and connection Check parameter settings on control Visual check of converter for damage or corrosion Complete functional check Replacement of inserts in VS module and particle filter after inspection and according to manufacturer specifications if available After 20 000 operating hours or 3 years at the very latest BOGE service personnel Air quality check Ry After 5 years Replacement of electrical component parts electrical kit BOGE service personnel Converter
99. ridge Remove cladding on the maintenance side Remove lid 1 of the filter housing Loosen nut 3 and re move filter cartridge 2 Attention Do not clean filter cartridges in liquids Do not use any hard objects when cleaning to avoid damaging the filter pa per Refit a new filter cartridge in the event of damage or once it has been cleaned twice Tap 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 69 Maintenance Regular maintenance work Switch off the compressor with the OFF button Caution Ri
100. s Liability Insurance Apart from other regulations particular ly the Ordinance on Industrial Safety and Health BetrSichV 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 10737 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 beyond the legal regulations specified in the Federal Republic of Germany or the data contained in these operating instructions then it is of utmost impor tance that these be carried out prior to commissioning the compressor plant 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 mai
101. scribed above Page 76 BOGE Operating instructions for S 31 2 S 341 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Check the oil filter for leaks and tighten by hand if necessary Check oil level Top up oil losses if any Changing the oil separator Fig 6 10 Changing the oil filter 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 Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT Close ball valve at the compressed air outlet Open
102. sk of injury Press Emergency Stop button open mains disconnection device and secure against unintentional switch on by means of a padlock Drive motors with permanent lubrication Pull filter mat 1 out of its holder from above Insert new filter mat into the holder Fig 6 5 Changing the supply air filter As a rule the bearings of the drive motors are provided with a maintenance free permanent lubrication Under normal operating conditions refrigerant temperature max 40 C conti nous operation the bearings are maintenance free for the service life The service life decreases or increases as thermal stress increases or de creases due to increased or reduced refrigerant temperature Attention Have BOGE service dismantle the bearings and install new bearings once the specified service life has expired Drive motors with lubrication device Motors with lubricating devices are easily recognised by the two grease nip ples on the top of the cover Additionally stickers on the compressor refer to the lubricating device 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 Page 70 BOGE Operating instructions for S 31 2 S 341 series screw compressors Maintenance Regular maintenance work On m
103. sors for other operating pressures Prin Pmax 0 5 bar Page 18 BOGE Operating instructions for S 31 2 S 341 series screw compressors Product description Technical data for S 40 2 BLUEKAT S 50 2 BLUEKAT part 1 Technical data Type S 40 2 BLUEKAT S 50 2 BLUEKAT Dimensions Height super silenced mm 1950 1950 Width silenced super silenced mm 2270 2270 Depth mm 960 960 Weight kg 1100 1320 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 71 72 super silenced dB A 8 Reference surface measure 174 174 l super silenced dB A Sound power level super silenced dB A 88 4 4 Max sound pressure level 3 dB A c accord to DIN EN ISO 2151 2009 70 71 super silenced dB A o g Reference surface measure 174 174 super silenced dB A Sound power level super silenced dB A m m Compressor max final compression temperature C 110 110 Volume flow according to ISO 1217 appendix C at Prax 8 bar m min 5 01 6 16 Pmax 10 bar m min 4 49 5 61 Pmax 13 bar m min 3 71 4 80 Drive motor Rated power kW 30 37 Nominal speed 50 Hz min 3000 3000 60 Hz min 3600 3600 Protection type IP 55 55 Design IMB 3 3 ISO class F F Electrical connection Mains voltage V 400 400 Frequency Hz 50 50 Min fuse protection A 100 100 Recommended fuse protection A 100 1
104. surfaces does not exceed 85 dB A The compressor room must be clean dry cool and free of dust temperatures Admissible ambient temperatures see also Technical data Maximum ambient temperature for air cooling 400C 45 C Maximum ambient temperature S 40 2 50 2 BLUEKAT 40 C Minimum ambient 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 that the minimum temperature is not gone below in winter Use of anti freeze function only in mode Ready for operation Frost protection 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 Page 36 BOGE Operating instructions for S 31 2 S 341 series screw compressors
105. tallation 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 S 31 2 S 341 series screw compressors Page 37 Installation Compressor room Cooling air requirement Please refer to the following table for the cooling air requirement and size of the supply air openings for your compressor Ensure that flaps and weather protection grids have the necessary free cross section We generally recom mend contacting a specialist company for performing the duct construction work and planning Type Drive Air cooling Water cooling DM Cooling air Necessary Coolingair Necessary Coolingair Necessary require inlet open require free duct require inlet open ment for ing for free ment for Cross ment for ing for free free stand standing installation section free stand standing ing unit unit with ducting ing unit unit kW m h m7 m h m m h m S 31 2 22 9 000 1 10 4 500 0 35 2 000 0 25 S 40 2 SD 40 2 30 11 000 1 35 5 500 0 42 2 000 0 25 S 50 2 SD 50 2 37 13 000 1 60 6 500 0 48 2 000 0 25 S 60 2 SD 60 2 45 13 000 1 60 6 500 0 48 2 000 0 25 S 61 2 SD 61 2 45 13 000 1 60 6 500 0 48 2 000 0 25 S 75 2 SD 75 2 55 16 000 2 00 8 0
106. tening elements are required Attention Make sure that no external vibrations or shock are able to impact on the com pressor station in particular with view to compressors of the BLUEKAT se ries with integrated converter Fire protection The following applies to rooms in which compressors with oil injection cooling are to be installed Caution Forcompressors with motor ratings exceeding 40 kW and for compres sors of the BLUEKAT series ensure that 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 S 31 2 S 341 series screw compressors Page 35 Installation Compressor room Sound protection Admissible ambient 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
107. ter cleaning rinse the plate heat exchanger thoroughly with water e g using a high pressure hose Note 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 Page 56 BOGE Operating instructions for S 31 2 S 341 series screw compressors Optional features E BOGE Duotherm BSW Function 5 2 BOGE Duotherm BSW The safety heat exchanger BOGE Duotherm Plus BSW is approved for drink ing water It is 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 sepa rated 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 Set the pressure to a value at least 2096 lower than the minimum pressure of the media used Operating conditions Ry Minimum water pressure 0 5 bar Maximum water pressure 16 bar Maximu
108. the oxidation process while the already treated compressed air cools off at the same time In order to further cool off it is then fed into aftercooler 4 The compressed air escapes at a temperature of 30 35 C and can be fed into a compressed air receiver for further use The condensate which is built up in the compressed air receiver conforms to industrial water quality and may be discharged accordingly BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 23 Product description ER Compressor control Network pressure Operating states 4 Compressed air outlet Fig 2 4 BLUEKAT functional diagram including compressed air flow direction 2 4 Compressor control For the compressor the pressure downstream of the 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 with out delay Idling operation reduces switching frequencies which can damage the drive motor and reduces wear o
109. tion device and secure against unintentional switch on by means of a padlock Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT 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 com pressed 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 Caution Risk of injury Emergency stop switch button open mains disconnection device and secure against unintentional switch on by means of a padlock Allow converter to cool off only screw compressors S 40 2 BLUEKAT and S 50 2 BLUEKAT If required have any leakages remedied by experienced expert person nel Opening the stop valve List up the test results in the commissioning certificate Open ball valve on the compressor delivery For water cooling Open stop valve at the water supply Page 46 BOGE Operating instructions for S 31 2 S 341 series screw c
110. tives for corrosion protection of metallic surfaces Excellent oxidation stability Rotating bomb oxidation Test ASTM D 2272 higher than 2 400 minutes Meets VDL requirements DIN 51 506 for lube oils including Pneurop test Or you use BOGE compressor oil Syprem 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 incompat ible It may lead to foam formation premature aging or loss of lubricating ability 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 BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 67 Maintenance Regular maintenance work Pressure hoses AA Caution Risk of injury and damage to compressor due to obsolete pressure hoses Never use pressure hoses beyond the prescribed service life Check hoses and connections regularly for
111. ume i 120 120 120 188 188 188 230 230 Total oil filling quantity 11 65 65 65 100 100 100 113 113 Oil topping up quantity between min max I 10 10 10 16 16 16 20 20 Intake air temperature min C 5 5 5 5 5 5 5 5 max C 40 40 40 40 40 40 40 40 Cooling air requirement free standing installation m h 20000 32000 32000 32000 48800 48800 56000 66000 g with supply and exhaust m h 10000 16000 16000 16000 24400 24400 28000 33000 xU free ventilator pressure Pa 60 60 60 60 60 60 60 60 free ventilator pressure mm WColumn 6 6 6 6 6 6 6 6 Cooling air requirement free standing installation m h 3400 3400 3400 3400 10000 10000 10000 10000 with supply and exhaust m h 1700 1700 1700 1700 5000 5000 5000 5000 Required cooling water quantity deltat 15K m h 4 090 4 900 6 000 6 000 7 190 8 720 10 900 13 600 o delta t 30K m h 2 045 2 450 3 000 3 000 3 595 4 360 5 450 6 800 Max cooling water quantity m h 9 0 9 0 9 0 9 0 12 0 12 0 13 6 13 6 o Cooling water inlet temperature s min C 5 5 5 5 5 5 5 5 max C 30 30 30 30 30 30 30 30 Cooling water outlet temperature max C 45 45 45 45 45 45 45 45 Cooling water pressure min bar 2 2 2 2 2 2 2 2 max bar 10 10 10 10 10 10 10 10 Operating pressure sensor factory settings p 7 8bar Switch offpress p bar 8 8 8 8 8 8
112. upply air filter option BOGE Syprem 8000 S special lubricant for screw compressors Set of V belts Lubrication for drive motor bearings Maintenace package oil filter oil separator suction filter cartridge gaskets nozzle with dirt catch nozzle with dirt catch only through to S 100 2 SD 100 2 SF 100 2 SDF 100 2 BLUEKAT series Wearing part kit oil regulator intake regulator minimum pressure valve Solenoid valve BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 85 Maintenance EN Spare parts and optional equipment Replacement parts for converter BLUEKAT series Ry Note Replacement parts management is being permanently updated by BOGE If you need any replacement parts for the converter of the BLUEKAT series please contact your local BOGE field representative and or BOGE contract partner Or contact your BOGE replacement parts service Telephone 49 5206 601 120 List of available optional equipment Designation Optional equipment for compressed air treatment Oil water separator Frost protection device 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
113. work pressure compressor Pressure gauge system pressure Stop valve compressed air outlet Pressure sensor for network pressure frequency converter Stop valve oil drainage Stop valve oil drainage oil cooler 75 250 kW R ckschlagventil Drainageleitung up to 75 kW 3 2 way solenoid valve Option BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 93 Appendix Flow chart Water cooled version serial connection frequency controlled LA 5 H H y 11 Sis 28 E 7 B P 4 12 21 i i rn gt i 3 Mg y J u x Y 20 T 24 PH 2 lp Or wp EL Le A Pog Ts 17 e o 22 25 Cra 104 O 32 36 35 ES gt lt 103 I Page 94 BOGE Operating instructions for S 31 2 S 341 series screw compressors Appendix Flow chart 10 102 103 104 Oo ON DO FP WD N
114. y Hz 50 50 50 50 50 50 50 50 Min fuse protection A 50 80 80 100 100 125 160 200 Recommended fuse protection A 63 80 100 125 125 160 160 200 SE ER OGNEC X ES Standard equipment Mains voltages and frequencies are specified on a plate in the switch cabinet Required for the refrigeration compressed air dryer 230 V 50 Hz 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 characteristic only BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 13 Product description EN Technical data Technical data for S 101 S 341 SD 101 SD 150 part 1 S 101 S 125 S 150 Type yp SD 101 SD 125 SD 150 S 151 S 180 S 220 S271 341 Dimensions Height silenced mm 1750 1750 1750 2005 2005 2005 2145 2145 Height silenced SD mm 2153 2153 2153 Height super silenced mm 2250 2250 2250 2505 2505 2505 2645 2645 Width silenced super silenced mm 2365 2365 2365 2265 2565 2265 2565 2265 2565 3100 3100 Depth mm 1335 1335 1335 1585 1585 1585 1910 1910 Weight silenced kg 1960 1980 2040 3100 3200 3200 4500 5000 super silenced kg 2020 2040 2100 3200 3300 3300 4600 5100 Max sound pressure level 3 dB A accord to DIN EN ISO 2151 2009 76 72 79 74 79 74 83 74 83 74 83 74 84 77 87 80
115. y instructions for compressor operation nenn 1 Special hazard warnings ssessn 2 Electrical energy hazards sssssseee ee 3 Obligations of the owner sssse nenn nn 3 Personnel requirements ssssssssssseeeeeem 4 Personal protective equipment sssssssssseee 4 Safety instructions for maintenance and repair of the compressor 4 Safety instructions for maintenance and repair on integrated converter BLUEKAT series ssssss m 5 Accident prevention regulations eene 6 1 2 Introduction uer enden 6 Symbole Used oe eee des tides ete dose si 7 Symbols on the compressor 8 Intended se cet den n cem ette 9 Foreseeable Misuse esses ee sneeee enini nn ne annt nena 9 Intended use of the integrated converter BLUEKAT series 10 Transport damage icto e E ER EORR ER CREE NUR 10 Data on the type plate ssssssssssseeeem 11 lad 11 Part 2 2 1 Technical data ences crede Rt rere oo an aera waste Kira noa Duo rua aw nee 13 Product description 2 2 Compressor operation principle cecus 20 Function principle of the air end sssesssss 20 ACCU EE 21 eec Ln 22 2 3 BLUEKAT operation principle ceeeeseeeeeeeee 23 24 Compressor control uuurssussennnannnnnnn
116. y only be carried out by BOGE or after consultation with BOGE by BOGE authorized service personnel Any unauthorized changes to the parameters may cause damage to the com pressor station or result in reduction of the compressed air quality Lighting of the indicator lamps serves to indicate Indicator lamp Meaning The temperature inside the converter is below the temperature Preheating Aufheizen which is needed to release compressed air production The yellow indicator lamp does not indicate whether or not the heating is properly functioning or in the process of heating As soon as the temperature inside the converter is reached for Operation Betrieb release of compressed air production the yellow indicator lamp green extinguishes before the green lamp lights up At the same time the compressor initializes compressed air production The indicator lamp Alarm St rung lights up in case of over Alar n Syonung red temperature inside the converter Table 2 1 Indicator lamps Meanings BOGE Operating instructions for S 31 2 S 341 series screw compressors Page 29 Product description Safety valve Safety and monitoring devices Safety valve 1 on the com pressed air oil vessel pre vents the maximum admissi ble pressure being exceeded Broce eor n Fig 2 7 Safety valve Caution Risk of injury When the max

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