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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)
Control devices................24 Operating pressure transmitter ............24 Proportional controller (optional accessory for S series) ....25 Safety and monitoring devices............ 25 General information ................ 25 Safety temperature limiting device..........25 Operating instructions for S 40-3...S 150-3 series screw compressors Page III...
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Electrical connection..............39 Commissioning ................40 Check installation requirements............41 Checking the rotational direction of drive and fan motor ....41 Check compressed air outlet for leak tightness ......42 Page IV Operating instructions for S 40-3...S 150-3 series screw compressors...
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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 Operating instructions for S 40-3...S 150-3 series screw compressors Page V...
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Water cooled version, serial connection – frequency controlled..84 BOGE Duotherm BPT plate heat exchanger ........86 BOGE Duotherm-Plus BSW safety heat exchanger ....... 87 List of maintenance and service work ........88 Page VI Operating instructions for S 40-3...S 150-3 series screw compressors...
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. Operating instructions for S 40-3...S 150-3 series screw compressors Page 1...
General safety instructions 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.
(for safety at work, supervision, completing the work), supervise the dismantling work and monitor compliance with the safety precautions and instructions drawn up, Operating instructions for S 40-3...S 150-3 series screw compressors Page 3...
– 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: Page 4 Operating instructions for S 40-3...S 150-3 series screw compressors...
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. Operating instructions for S 40-3...S 150-3 series screw compressors Page 5...
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! Page 6 Operating instructions for S 40-3...S 150-3 series screw compressors...
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! The following warning signs are fitted on the compressor: Operating instructions for S 40-3...S 150-3 series screw compressors Page 7...
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General information Introduction S 40-3...S 150-3, part 1, front (outside): Page 8 Operating instructions for S 40-3...S 150-3 series screw compressors...
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General information Introduction S 40-3...S 150-3, part 2, front (outside/inside): Operating instructions for S 40-3...S 150-3 series screw compressors Page 9...
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General information Introduction S 40-3...S 150-3, part 3, front (inside): S 40-3...S 150-3, part 4, rear panel (outside/inside): Page 10 Operating instructions for S 40-3...S 150-3 series screw compressors...
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General information Introduction S 40-3...S 150-3, part 5 and 6, (inside/top): Operating instructions for S 40-3...S 150-3 series screw compressors Page 11...
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General information Introduction S 40-3...S 150-3, part 7 and 8, sides (outside/inside): Page 12 Operating instructions for S 40-3...S 150-3 series screw compressors...
– Operation of the compressor by unauthorised or untrained persons. Transport damage BOGE does not accept any liability for breakage or transport damage. Please inspect the compressor immediately after delivery and direct damage claims to the last haulier – even if the packaging is not damaged! To safeguard claims against the haulier we recommend leaving the machine, devices and packing material in the same condition they were in when the damage was detected.
This will ensure that in the event of enquiries, you will always have the most important data to hand. Fig. 1.1: Data on the rating plate Service Please do not hesitate to contact BOGE service if you have any questions. Please call: Telephone: +1-770-874-1570 Telephone: +49 5206 601-140...
Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet. Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies. Operating instructions for S 40-3...S 150-3 series screw compressors Page 15...
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Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet. Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies. Page 16 Operating instructions for S 40-3...S 150-3 series screw compressors...
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= 115 psig [psig] – p = 125 psig [psig] – p = 150 psig [psig] – p = 190 psig [psig] Compressors for other operating pressures p –15 psig. Operating instructions for S 40-3...S 150-3 series screw compressors Page 17...
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= 115 psig [psig] – p = 125 psig [psig] – p = 150 psig [psig] – p = 190 psig [psig] Compressors for other operating pressures p –15 psig. Page 18 Operating instructions for S 40-3...S 150-3 series screw compressors...
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Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet. Use fuse RK 5 only. The fuse values change in the case of other mains voltages and frequencies. Operating instructions for S 40-3...S 150-3 series screw compressors Page 19...
The air end operates according to the displacement principle. In the housing, the main and secondary rotors are driven by means of an electric motor and the air end V-belts. Page 20 Operating instructions for S 40-3...S 150-3 series screw compressors...
The compressed air is cooled in the compressed air aftercooler, causing the water contained in the air to condensate. 8 Stop valve The screw compressor can be isolated from the mains using the stop valve. Operating instructions for S 40-3...S 150-3 series screw compressors Page 21...
This is separated through gravity. 6 Drainage line The air end suctions the residual oil which collects in the oil separator back into the oil circuit via a drainage line. Page 22 Operating instructions for S 40-3...S 150-3 series screw compressors...
Upon reaching the switch-off pressure p the compressor switches to idling operation. – Once the pressure has dropped to the switch-on pressure p compressor switches from idling operation back to load operation. Operating instructions for S 40-3...S 150-3 series screw compressors Page 23...
The lubricating ability of the oil is reduced. This leads to damage to the air end. It is of utmost importance to consult BOGE if you operate your system with short operating times. 2.4 Control devices...
Do not operate the compressor without built-in safety devices! Do not dismantle the safety devices or put them out of operation! The following monitoring devices are standard for BOGE control systems: Safety temperature The safety temperature limiting device switches the compressor off as soon as the maximum permissible final compression temperature has been reached.
(optional accessory) System pressure build- The system pressure build-up unit monitors the system pressure build-up when the compressor starts up. up (optional accessory) Page 26 Operating instructions for S 40-3...S 150-3 series screw compressors...
2.6 Water cooling 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.
If the cooling water data changes, the cooling units may have to be reconfig- ured. Incorrectly configured cooling units may cause malfunctions and cause the compressor to switch off! Please consult BOGE. Page 28 Operating instructions for S 40-3...S 150-3 series screw compressors...
3.1 Transport and storage General information Please observe the generally accepted safety and accident prevention regu- lations when transporting the compressor. BOGE accepts no liability for dam- age caused by improper transport! WARNING! The transport of the compressor must only be carried out by adequately...
"3.2 Compressor room"). We do not accept any liability for damage occurring as a consequence of improper storage! In the event of extended intermediate storage you should consult BOGE's service department. Following intermediate storage of more than two months, please observe the instructions for commissioning after an extended standstill (see section en- titled "3.5 Commissioning").
A level industrial floor without foundation is adequate for the installation of the compressor. No special fastening elements are required. WARNING! Make sure that external vibrations or shock are not able to impact on the compressor station. Operating instructions for S 40-3...S 150-3 series screw compressors Page 31...
– Provide the supply air openings with adjustable louvres to ensure that temperatures do not go below the minimum temperature in winter. – Use the anti-freeze function (only in "ready for operation" mode). Page 32 Operating instructions for S 40-3...S 150-3 series screw compressors...
Installation Compressor room Frost protection The compressor must be installed so that it is frost-protected. The BOGE anti- freeze device is a standard feature. It protects the safety devices from freezing up at ambient temperatures up to 14°F. Ventilation If the following instructions are not observed, the admissible final com- pression temperature may be exceeded.
2000 The cooling air requirement is based on a 7°F-difference between the ambient temperature and the outside temperature. Table 3.1: Cooling air demand, cross-sections of openings and ducts required Page 34 Operating instructions for S 40-3...S 150-3 series screw compressors...
Water Act! BOGE recommends using an oil/water separator. The BOGE oil/water separator is used to separate the oil from the conden- sate. The cleaned water can be fed directly into the public sewage system. The oil is collected in a separate container. Dispose of the oil according to environmental regulations.
Installation Installation 3.3 Installation General information BOGE compressor units are supplied ready for connection. Only the work described in the following paragraphs needs to be carried out during the in- stallation. WARNING! Any installation work must only be carried out by appropriately trained per- sons or specialists (BOGE service personnel).
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. Operating instructions for S 40-3...S 150-3 series screw compressors Page 37...
Fig. 3.5: Activating the belt tension Checking the oil level BOGE compressors are supplied with a full oil filling. Prior to commissioning, check the oil level as described in the section entitled "Maintenance". Page 38 Operating instructions for S 40-3...S 150-3 series screw compressors...
In the event of deviations, please contact BOGE's service department or your supplier. Please refer to the section on "Technical data" for details of the fuses required.
This is conditional upon: The net pressure being lower than the set switch- on pressure. 3.5 Commissioning NOTICE! We recommend drawing up a commissioning certificate in which the test results during the commissioning process can be recorded. Page 40 Operating instructions for S 40-3...S 150-3 series screw compressors...
Press the emergency stop switch/button, disable the mains disconnection device and secure it with a padlock to prevent it from being switched on again inadvertently. – Interchange two phases (L1, L2 or L3) in the power cable. Operating instructions for S 40-3...S 150-3 series screw compressors Page 41...
Undertake the following to prevent leaks: – Check the screw connections of the ducting and retighten, if necessary. – Check to ensure that the oil filter and oil separator are hand tight seated. Page 42 Operating instructions for S 40-3...S 150-3 series screw compressors...
Record the test results in the commissioning certificate. Commissioning follow- If an extended stoppage is scheduled, you should contact BOGE's service department beforehand. ing extended stoppages Following an extended stoppage of more than 2 months, fill a small amount of...
3. Turn compressor stage using the pulley by hand 5- to 10 times to spread the oil evenly. 3.6 Dismantling NOTICE! To avoid danger when dismantling the compressor, please consult BOGE's service department: Telephone: +1-770-874-1570 Telephone: +49 5206 601-140 WARNING!
. Ensure that components which have a safety function are adjusted, repaired or replaced only by BOGE service personnel. Please contact BOGE's service department at the following telephone num- ber if you have any questions. Telephone: +1-770-874-1570...
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System pressure does Venting valve does not open Check venting valve and replace, if necessary not decrease when Non-return valve is leaking Examine non-return valve and replace, if necessary switching off Page 46 Operating instructions for S 40-3...S 150-3 series screw compressors...
Part 5: Accessory equipment 5.1 BOGE Duotherm BPT Function The heat recovery system BOGE Duotherm BPT utilizes the heat energy re- leased during compression to produce hot water free of charge (e.g. for pro- duction systems or to supply a heater).
Fill plate heat exchanger with one of the above-mentioned cleaning agents. – Allow the cleaning agent to act for at least six hours. Point the connections upward to allow any gases that may occur to escape. Page 48 Operating instructions for S 40-3...S 150-3 series screw compressors...
5.2 BOGE Duotherm BSW Function The safety heat exchanger BOGE Duotherm Plus BSW is approved for drink- ing water. It is integrated in the main stream of the hot compressor oil. The ad- ditional safety it provides in comparison with the plate heat exchanger results from the following measures: –...
Opening the system will put the operation and safety of the heat exchanger at risk! If confining liquid escapes as a result of damage, send the heat exchanger to BOGE for repair. Page 50 Operating instructions for S 40-3...S 150-3 series screw compressors...
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. Operating instructions for S 40-3...S 150-3 series screw compressors Page 51...
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12.Prior to switching on again, check whether anyone else is working on the compressor. 13.Remove warning sign not until then and release mains disconnecting device. 14.Unlock Emergency Stop button. Page 52 Operating instructions for S 40-3...S 150-3 series screw compressors...
Maintenance through Have your compressor inspected and maintained in a full service by BOGE customer service every 3,000 operating hours or once a year. BOGE customer service...
The first table contains maintenance and repair work that should be carried out by the customer himself at regular intervals between the annual service car- ried out by BOGE service personnel. The intervals between this maintenance work are shorter (weekly / monthly / every 1,500 operating hours).
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The specified intervals apply only when using BOGE Syprem S compressor oil. If a different oil is used, different intervals will apply! Other service life periods may also be possible depending on the ambient temperature. In this case have the oil analysed by your BOGE customer service! Table 6.2: Maintenance work at fixed service intervals...
– Excellent oxidation stability: Rotating bomb oxidation Test (ASTM D 2272) higher than 2,400 minutes. – Or you use BOGE compressor oil Syprem S. The stated maintenance inter- vals refer to the use of Syprem S only. – Syprem S can be purchased from BOGE retailers.
WARNING! Only use original spare parts, compressor oils and operating materials re- leasedby BOGE for repair and maintenance work. BOGE is not liable for any damage resulting from the use of other spare parts or operating materials. WARNING! If the nozzle and dirt trap are clogged with dirt, this can considerably increase oil consumption (only up to S(F) 60-3)! 6.3 Maintenance work between scheduled services...
It is essential that you wear protective gloves! 2. Draw the filter mat (1) upwards out of its holder. 3. Insert a new mat in the holder. Fig. 6.2: Changing the supply air filter mats Operating instructions for S 40-3...S 150-3 series screw compressors Page 59...
1. Insert filter cartridge (3) into the filter housing. 2. Replace the lid (2) on the filter housing. 3. Fasten the clips (1) on the filter housing. 4. Put the cover back on on the maintenance side. Page 60 Operating instructions for S 40-3...S 150-3 series screw compressors...
(see figure below). 9. Screw plug (2) back in (see figure below). 10.Put the cover back on on the maintenance side 11.Open ball valve at the compressed air outlet. Operating instructions for S 40-3...S 150-3 series screw compressors Page 61...
4. Remove accumulated dirt with a fibre brush. 5. Blow out the dirt with compressed air (1) in the opposite direction to the nor- mal cooling air flow (see figure below). Page 62 Operating instructions for S 40-3...S 150-3 series screw compressors...
The following sections contain a description of the maintenance work to be carried out at fixed service intervals. This work is listed in table 6.2 on page 56. To retain your warranty entitlement, BOGE recommends that you have this work carried out by certified BOGE service personnel using original spare parts.
/ once a year: Have safety valve checked WARNING: Risk of injury! Have the function of the safety valve checked by BOGE service personnel only. Interval: After approx. 3,000 operating hours, but at least once a year. Every 3,000 operating...
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10.Put the cover back on on the maintenance side 11.Open ball valve at the compressed air outlet. 12.Switch the compressor on and let it heat up until it reaches the operating temperature. Operating instructions for S 40-3...S 150-3 series screw compressors Page 65...
6. Unscrew soiled oil separators (4) by hand or use a strap wrench, turning counterclockwise (see figure below). Catch the draining oil and dispose of it properly in line with environmen- tal regulations Page 66 Operating instructions for S 40-3...S 150-3 series screw compressors...
Every 3,000 operating Check the V-belt: hours / once a year: – After 3,000 operating hours, but at least once a year to look for signs of damage. Check V-belt Operating instructions for S 40-3...S 150-3 series screw compressors Page 67...
9. Lower the motor again. For this purpose, secure screw head (3) against turning. 10.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. 11.Fit belt protection. 12.Put the cover back on on the maintenance side.
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Slight deviations are allowed and compensated by the GM drive system. The current settings are also shown on the GM drive system. With special versions the settings on the sticker may deviate from the standard values. Operating instructions for S 40-3...S 150-3 series screw compressors Page 69...
Oil change WARNING! If you use a different oil instead of Syprem S: it is essential that you contact the BOGE service department to determine the required oil change intervals. NOTICE! The service life of the oil, the oil filter and oil separators is reduced under the following conditions: –...
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21.If necessary, tighten the oil filter and oil separator by hand (procedure as described above). 22.Check oil level (procedure as described above). 23.If necessary, top up with oil to offset any losses. Operating instructions for S 40-3...S 150-3 series screw compressors Page 71...
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Fig. 6.9: Solenoid valve on the suction controller with the cap nut screwed on Fig. 6.10: Drain off old oil from oil/compressed air receiver Fig. 6.11: Drain off residual oil from compressed air/oil cooler Page 72 Operating instructions for S 40-3...S 150-3 series screw compressors...
Flushing the oil circuit with clean oil becomes necessary: – When the oil is excessively soiled. – Prior to changing the oil type. WARNING! Detailed information on flushing with BOGE oils can be obtained from the fol- lowing service numbers: Telephone: +1-770-874-1570 Telephone: +49 5206 601-140...
If you intend to use a different type of grease: – Have the bearings removed and thoroughly cleaned by BOGE service personnel prior to filling with new grease. Please always observe the specified lubrication intervals and quantities of grease.
The low pressure switch for the infinitely variable capacity control limits the re- duction of the quantity delivered and switches the compressor to idling mode or off completely if the quantity delivered falls below 50%. Operating instructions for S 40-3...S 150-3 series screw compressors Page 75...
Plate heat exchanger BOGE DUOTHERM-PLUS BSW Safety heat exchanger WARNING! When ordering, please specify the data on the rating plate: – Type – Year of manufacture – Machine number Page 76 Operating instructions for S 40-3...S 150-3 series screw compressors...
Appendix Flow chart Part 7: Appendix 7.1 Flow chart On the following pages you will find the individual flow charts for the different machine types and components. Operating instructions for S 40-3...S 150-3 series screw compressors Page 77...
Appendix Flow chart Water cooled version, serial connection – frequency controlled Page 84 Operating instructions for S 40-3...S 150-3 series screw compressors...
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28 Non-return valve drainage line (up to 102 Hp) 31 3/2-way solenoid valve 32 2/2-way solenoid valve 34.1 Bypass valve * * Optional accessory To be provided by customer: 35 Dirt trap 36 Stop valve Operating instructions for S 40-3...S 150-3 series screw compressors Page 85...
Appendix List of maintenance and service work 7.2 List of maintenance and service work Page 88 Operating instructions for S 40-3...S 150-3 series screw compressors...
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Appendix List of maintenance and service work Operating instructions for S 40-3...S 150-3 series screw compressors Page 89...
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Appendix List of maintenance and service work Page 90 Operating instructions for S 40-3...S 150-3 series screw compressors...
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