Boge S 40-3 User manual

Operating instructions
Belt-driven
screw compressors
Series
S 40-3...S 150-3
SF 60-3...SF 150-3
Separate manuals:
Compressor control
Frequency converter (SF)

Operating instructions for S 40-3...S 150-3 series screw compressors Page I
Operating instructions
for belt-driven
screw compressors
– S 40-3 (40 Hp)
– S 50-3 (50 Hp)
– S 60-3 (60 Hp)
–S 61-3 (60 Hp)
– S 75-3 (74 Hp)
– S 100-3 (101 Hp)
– S 101-3 (101 Hp)
– S 125-3 (121 Hp)
– S 150-3 (147 Hp)
– SF 60-3 (60 Hp)
– SF 100-3 (101 Hp)
–SF 150-3 (147 Hp)
BOGE KOMPRESSOREN
Postfach 10 07
33507 Bielefeld
Otto-Boge-Straße 1-7
33739 Bielefeld
Phone: [phone]
Fax: [phone]
Mail: [email protected]
Net: www.boge.com
Issue: 07 / 2013
No. 596.1252.18

Operating instructions for S 40-3...S 150-3 series screw compressors Page III
Contents
Contents
Part 1:
General information
1.1 General safety instructions ........................................................... 1
Safety instructions for compressor operation ................................... 1
Special hazard warnings................................................................... 2
Dangers of electricity ........................................................................ 3
Obligations of the operator ............................................................... 3
Personnel requirements.................................................................... 4
Personal protective equipment ......................................................... 4
Safety instructions for maintenance and repair of the compressor... 4
Accident prevention regulations........................................................ 5
1.2 Introduction..................................................................................... 6
Symbols used ................................................................................... 7
Warning signs on the compressor .................................................... 7
Intended use................................................................................... 13
Foreseeable misuse ....................................................................... 13
Transport damage .......................................................................... 13
Data on the rating plate .................................................................. 14
Service............................................................................................ 14
Part 2:
Product description
2.1 Technical data............................................................................... 15
2.2 Operating principle of compressor............................................. 20
Functional principle of the air end................................................... 20
Air circuit......................................................................................... 21
Oil circuit......................................................................................... 22
2.3 Compressor control ..................................................................... 23
Network pressure............................................................................ 23
Operating states ............................................................................. 23
Operating modes ............................................................................ 23
Controlled operation (frequency control) ........................................ 24
Short operating times...................................................................... 24
2.4 Control devices............................................................................. 24
Operating pressure transmitter ....................................................... 24
Proportional controller (optional accessory for S series) ................ 25
2.5 Safety and monitoring devices.................................................... 25
General information ........................................................................ 25
Safety temperature limiting device.................................................. 25

Contents
Page IV Operating instructions for S 40-3...S 150-3 series screw compressors
Safety valve .................................................................................... 26
Monitoring the drive and fan motor ................................................. 26
Rotational direction monitoring (optional accessory) ...................... 26
System pressure build-up (optional accessory).............................. 26
2.6 Water cooling ................................................................................ 27
Water cooling.................................................................................. 27
Serial connection ............................................................................ 27
Parallel connection ......................................................................... 27
2.7 Cooling water ................................................................................ 28
Water connection (for water cooling) .............................................. 28
Cooling water quality ...................................................................... 28
Part 3:
Installation
3.1 Transport and storage.................................................................. 29
General information ........................................................................ 29
How to transport the compressor.................................................... 29
Intermediate storage....................................................................... 30
3.2 Compressor room......................................................................... 31
Installation conditions for horizontal or free-standing compressed
air receivers .................................................................................... 31
Installation surface.......................................................................... 31
Fire protection................................................................................. 32
Sound protection............................................................................. 32
Admissible ambient temperatures .................................................. 32
Frost protection............................................................................... 33
Ventilation ....................................................................................... 33
Cooling air requirement .................................................................. 34
Ventilation possibilities.................................................................... 35
Condensate disposal ...................................................................... 35
3.3 Installation..................................................................................... 36
General information ........................................................................ 36
Checking the scope of delivery....................................................... 36
Installing the compressor................................................................ 36
Connecting the compressor to the compressed air network........... 37
Connecting the cooling water (optional accessory) ........................ 37
Removing the transport securing bolts ........................................... 38
Activating the belt tensioning device............................................... 38
Checking the oil level...................................................................... 38
3.4 Electrical connection.................................................................... 39
3.5 Commissioning............................................................................. 40
Check installation requirements...................................................... 41
Checking the rotational direction of drive and fan motor ................ 41
Check compressed air outlet for leak tightness .............................. 42

Operating instructions for S 40-3...S 150-3 series screw compressors Page V
Contents
Opening the stop valves ................................................................. 42
Checking for leaks .......................................................................... 42
Conduct trial run ............................................................................. 43
Commissioning following extended stoppages............................... 43
3.6 Dismantling ................................................................................... 44
Part 4:
Faults
4.1 General information...................................................................... 45
4.2 General faults................................................................................ 45
Part 5:
Accessory equipment
5.1 BOGE Duotherm BPT ................................................................... 47
Function.......................................................................................... 47
Installation....................................................................................... 47
Commissioning ............................................................................... 48
Maintenance ................................................................................... 48
5.2 BOGE Duotherm BSW.................................................................. 49
Function.......................................................................................... 49
Commissioning ............................................................................... 50
Maintenance ................................................................................... 50
Part 6:
Maintenance
6.1 Safety instructions for maintenance........................................... 51
6.2 The BOGE maintenance concept................................................ 53
Maintenance through BOGE customer service .............................. 53
List of maintenance and service work............................................. 54
Maintenance intervals..................................................................... 55
General information concerning the lubricants used ...................... 57
Disposal of used operating material ............................................... 58
Pressure hoses............................................................................... 58
Spare and wearing parts................................................................. 58
6.3 Maintenance work between scheduled services....................... 58
Weekly: Inspect / replace supply air filter (optional accessory) ...... 59
Monthly: Clean the suction filter...................................................... 60
Monthly: Check oil level / top up with oil if necessary..................... 61
Every 1,500 operating hours: Clean the oil cooler (air cooling)...... 62
Every 1,500 operating hours: Clean the oil cooler / air cooler
(water cooling) ................................................................................ 63
6.4 Maintenance work at fixed service intervals.............................. 63
Every 3,000 operating hours / once a year:
Change the suction filter cartridge.................................................. 64
Every 3,000 operating hours / once a year:
Have safety valve checked............................................................. 64

Contents
Page VI Operating instructions for S 40-3...S 150-3 series screw compressors
Every 3,000 operating hours / once a year:
Change the oil filter......................................................................... 64
Every 3,000 operating hours / once a year:
Change the oil separator ................................................................ 66
Every 3,000 operating hours / once a year: Check V-belt .............. 67
Every 9,000 operating hours: Change V-belt.................................. 68
Every 9,000 operating hours / every 2 years: Oil change............... 70
6.5 Special maintenance work........................................................... 73
Flush out oil circuit .......................................................................... 73
Drive motors with permanent lubrication ........................................ 73
Drive motors with lubrication device ............................................... 73
Drive motors with automatic lubricating equipment ........................ 74
Have proportional regulation checked
(Optional accessory for S series).................................................... 75
6.6 Spare parts and accessory equipment....................................... 76
List of spare and wear parts (for maintenance) .............................. 76
List of available accessory equipment ............................................ 76
Part 7:
Appendix
7.1 Flow chart...................................................................................... 77
Air cooled version, standard ........................................................... 78
Water cooled version, serial connection – parallel connection ....... 80
Air cooled version, frequency controlled......................................... 82
Water cooled version, serial connection – frequency controlled..... 84
BOGE Duotherm BPT plate heat exchanger .................................. 86
BOGE Duotherm-Plus BSW safety heat exchanger....................... 87
7.2 List of maintenance and service work........................................ 88

Operating instructions for S 40-3...S 150-3 series screw compressors Page 1
General information 1.1 General safety instructions
Part 1: General information 1.1 General safety instructions
Safety instructions for
compressor operation
1. Ensure that no commissioning and maintenance work on the compressor
is undertaken until these operating instructions have been read and under-
stood.
2. Only use the compressor for its intended use, as described in these oper-
ating instructions.
3. The owner must ensure,
– that only appropriately trained and authorised personnel work on this
compressor,
– that persons whose ability to react is restricted due to the misuse of
e.g. drugs, alcohol, medication etc., are prevented from working on
this compressor,
– that operating, maintenance and repair personnel is fully conversant
with all safety instructions, and that these safety instructions are ob-
served,
– that the compressor is only operated if it is in safe working order.
4. Avoid any way of working which may impair the safety of the compressor.
5. Always wear your compulsory personal protective equipment as protection
against injuries from sharp corners or edges when working on the com-
pressor.
6. To avoid dangers from debris or parts lying around, the working area of the
compressor must always be kept tidy and clean.
7. Always squat when working on components mounted at low height, never
stoop. When working on components mounted higher up, always stand up-
right and erect.
8. Do not exceed the limit value for the end of compression pressure specified
on the type plate.
9. Do not operate the compressor without the attendant protective equipment
and safety devices.
Do not dismantle any built-in safety devices or put them out of operation.
10.Ensure that all safety covers and doors are closed prior to commissioning/
starting up the compressor and that they are not opened during operation.
11.Place the compressor out of operation as described in these operating in-
structions, when dismantling the safety covers or safety devices for repair
or maintenance work. Reattach and close all covers and safety devices im-
mediately upon completion of the repair or maintenance work.
12.Operate the compressor only if any optional accessory equipment used is
recommended or authorised by the manufacturer.
WARNING!
Failure to observe the following safety instructions can lead to injuries and
damage to the compressor.
Observe the general safety and accident prevention regulations in addition
to the information in these operating instructions!

General information 1.1 General safety instructions
Page 2 Operating instructions for S 40-3...S 150-3 series screw compressors
13.Undertake conversions and modifications to the compressor only with the
prior approval of BOGE, and in compliance with all relevant safety regula-
tions. The manufacturer is not liable for damages resulting from unauthor-
ised modifications to the compressor.
14.Never start the compressor if one or more parts (e.g. cable, plug) are dam-
aged, or if the compressor is not in perfect working order, or if damage is
visible or suspected.
15.Observe all safety and danger signs attached to the compressor itself!
16.The compressed air/oil receiver is pressure equipment and requires testing
in accordance with national standards.
17.To avoid damage, special precautions must be taken during (re-)commis-
sioning of compressors with a frequency control if the frequency converter
has been disconnected from the power supply for a lengthy period of time
(> 12 months). In this case, please contact the BOGE's service department.
Special hazard warnings – Always wear your compulsory personal protective equipment when work-
ing on pressure pipes and connections!
– A protective grid serves to prevent you from accidentally reaching into the
impeller in the cooling fan.
– During operation, the compressor generates a high noise level which may
cause permanent hearing damage due to prolonged exposure. The com-
pressor must ALWAYS be operated with its housing closed! Wear addition-
al hearing protection at noise levels of over 80 dB(A)!
WARNING: Risk of injury!
Never operate the compressor with the protective grid removed! There is
constant danger of accidentally reaching into the impeller in the cooling fan!
Please note that the cooling fan may run on for a certain time even after the
compressor has been switched off!

Operating instructions for S 40-3...S 150-3 series screw compressors Page 3
General information 1.1 General safety instructions
Dangers of electricity
Obligations of the
operator
The operator is obliged to,
– operate the compressor only if it is in perfect technical working order,
– provide an automatic cutout device for disconnecting the electrical power
supply in the event of a fault to prevent hazards due to electricity.
– check the emergency stop device for the compressor regularly to ensure
that nothing is missing and that it works properly,
– assess the hazards of the machine workstations in his area of responsibility
and to issue specific user instructions on the basis of this,
– appoint a person who is responsible for the safe operation of the machine
as well as the coordination of all service work performed on it,
– avoid stress situations while operating the compressor by implementing
appropriate technological and organisational work preparation measures,
– ensure proper lighting at the compressor control panel in line with local
health and safety regulations,
– observe the safety data sheets for the lubricants used and make all infor-
mation specified by the data sheet accessible to personnel,
– provide the compulsory personal protective equipment and stipulate and
regularly check the wearing of this protective equipment,
– designate personnel responsible for the various types of work on the ma-
chine,
– instruct personnel on a regular basis about the extent of obligations to keep
the area around the compressor safe, tidy and in good order.
– in the event that the compressor requires to be dismantled, develop a safe
technical means of dismantling the structure, designate persons respon-
sible (for safety at work, supervision, completing the work), supervise the
dismantling work and monitor compliance with the safety precautions and
instructions drawn up,
DANGER: High voltage!
Persons working on the electrical equipment of the compressor are ex-
posed to mortal danger!
– Disconnect from the mains power supply before starting any work on the
compressor and use a padlock to prevent the power from being switched
on again.
– Only duly authorised professional electricians (e.g. plant electricians) are
permitted to carry out work on the electrical system of the machine.
– Inspect the electrical equipment of the compressor at regular intervals for
defects such as loose connections or scorched cables and have any de-
fects repaired immediately.
– Have all electrical equipment and fixed electrical installations checked by
a professional electrician at least every 4 years.
– Check all safety devices on the machine at regular intervals to ensure
they work properly.
– Only use original fuses.

General information 1.1 General safety instructions
Page 4 Operating instructions for S 40-3...S 150-3 series screw compressors
Personnel requirements Work on and with the compressor must only be carried out by personnel duly
authorised by the operator of the compressor.
The personnel working on the compressor must observe all industrial safety
regulations and user instructions, properly recognize responsibilities and have
read and understood the operating instructions. It is essential to wear the com-
pulsory personal protective equipment at all times when working on the com-
pressor!
Personal protective
equipment
During all work on the compressor,
– protective clothing,
– chemical resistant gloves,
– slip-resistant safety shoes and
– hearing protection, if applicable,
must be worn.
For special tasks,
– safety helmets (when operating lifting gear to transport equipment) and
– safety goggles (when working on the compressed air system and/or on the
pneumatic control system)
must be worn.
Before working with oils or greases, barrier cream must be applied to the skin.
After the work is finished, a skin care product must be applied.
Safety instructions for
maintenance and repair
of the compressor
– Ensure that maintenance work is carried out by suitably trained persons
only.
– Settings, fault rectification and repair work must be carried out by special-
ists or suitably trained persons only.
– Before carrying out any maintenance or repair work:
WARNING!
During repair and maintenance, use only original spare parts, compressor
oils and operating materials approved by BOGE.
DANGER: High voltage!
When working on the electrical system be aware of the constant danger of
contact with live parts!
To prevent danger, the mains connection must be equipped with an auto-
matic circuit breaker!
The automatic circuit breaker must comply with the requirements of national
regulations!

Operating instructions for S 40-3...S 150-3 series screw compressors Page 5
General information 1.1 General safety instructions
1. Switch off the compressor using the OFF button.
2. Press the emergency stop button.
3. Disconnect the compressor from all electric power sources using the circuit
breaker.
4. Take preventive action to prevent the current from being inadvertently
switched back on.
5. Check to ensure that all current-carrying parts are zero-potential.
6. Earth and short-circuit.
7. Cover or shield adjacent current-carrying parts.
8. Fix a warning label to the control and fill in the name of the person respon-
sible who is authorised to switch on the machine again.
9. Disconnect the compressor from the compressed air network (relieve or
block pressure lines).
– Exercise extreme caution during repair or maintenance work during which
the compressor needs to be operational.
Ensure that all persons are at a safe distance from the danger area.
– Ensure that work on electrical equipment is carried out by qualified electri-
cians only.
– Working on current-carrying parts and devices is prohibited. Exceptions
are governed by the appropriate national regulations.
– Before starting work on the electrical system, the power supply must be
switched off and a safeguard must be provided to prevent it from being un-
intentionally switched on again. Immediately after finishing the work, all dis-
mantled covers and safety devices must be refitted.
– The machine operator is responsible for inspecting the compressor daily
for externally visible damage and defects, and for immediately reporting
any changes (including in operational behaviour).
– When the automatic restart mode (auto-restart) is activated, the compres-
sor will start up automatically following a power failure. This is conditional
upon: The network pressure being lower than the set switch-on pressure.
Accident prevention
regulations
The operator of a compressor station is responsible for ensuring that it is prop-
erly installed, operated and maintained.
If the compressor system is operated outside the Federal Republic of Germa-
ny, the accident prevention regulations of the country where the compressor
is operated must be observed, in addition to the information contained in these
operating instructions. In the event that measures are required above and be-
yond the legal regulations specified in the Federal Republic of Germany or the
information contained in these operating instructions, then it is essential that
these are carried out prior to commissioning the compressor plant.

General information 1.2 Introduction
Page 6 Operating instructions for S 40-3...S 150-3 series screw compressors
1.2 Introduction
The purpose of these operating instructions is to familiarise the user with the
operation and all uses and features of the compressor.
These operating instructions contain important information on how to operate
the compressor safely, economically and according to its intended use. Ob-
serving these operating instructions will help to prevent danger, reduce repair
costs and downtimes and increase the reliability and service life of the com-
pressor. They contain important information on the necessary maintenance
and repair work, assists in the event of faults and contains information on spare
and wear parts.
These operating instructions must be available at all times to the compressor
operating personnel at the place of use.
The operating instructions must be carefully read and applied by all persons
authorised to undertake the following work on the compressor:
– Operation, including fault rectification and daily care
– Servicing (maintenance, inspection, repairs)
– Commissioning
– Transport
The compressor and its additional equipment must not be installed and com-
missioned until the operating instructions have been read and understood.
These operating instructions are intended to complement user instructions
based on existing national accident prevention and environmental protection
regulations.
In the illustrations, the compressor is shown in part without safety covers or
safety devices to provide a better view. However, operating the compressor
without these components is prohibited!

Operating instructions for S 40-3...S 150-3 series screw compressors Page 7
General information 1.2 Introduction
Symbols used In these operating instructions attention is drawn to important safety advice
and tips with the following symbols:
Warning signs on the
compressor
The following warning signs are fitted on the compressor:
WARNING: Risk of injury!
This symbol warns of danger to life and limb of the machine operator or other
persons.
WARNING!
This symbol warns of danger to life and limb of the machine operator or other
persons or dangers which might destroy or damage the compressor.
DANGER: High voltage!
This symbol warns of danger due to electricity.
This symbol indicates a warning of life-threatening electrical voltage levels.
It indicates work which must be performed by skilled electricians only.
NOTICE!
This symbol indicates information and tips on saving energy and prolonging
the life of the compressor through careful use.
NOTICE!
All warning signs on the compressor and in its surroundings must be kept in
a legible condition at all times. Missing or damaged signs must be replaced
at once!

General information 1.2 Introduction
Page 8 Operating instructions for S 40-3...S 150-3 series screw compressors
S 40-3...S 150-3, part 1, front (outside):

Operating instructions for S 40-3...S 150-3 series screw compressors Page 9
General information 1.2 Introduction
S 40-3...S 150-3, part 2, front (outside/inside):

General information 1.2 Introduction
Page 10 Operating instructions for S 40-3...S 150-3 series screw compressors
S 40-3...S 150-3, part 3, front (inside):
S 40-3...S 150-3, part 4, rear panel (outside/inside):

Operating instructions for S 40-3...S 150-3 series screw compressors Page 11
General information 1.2 Introduction
S 40-3...S 150-3, part 5 and 6, (inside/top):

General information 1.2 Introduction
Page 12 Operating instructions for S 40-3...S 150-3 series screw compressors
S 40-3...S 150-3, part 7 and 8, sides (outside/inside):
hidden