k3 k6 k8 k15 operating instructions - surgevessels.co.uk

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Operating instructions

Oil-free piston compressors

SeriesK 3...K 15K Booster

Separate instruction:Compressor control

Operating instructions foroil-free piston compressors

Max. pressure: 10 barK 3 ( 2.2 kW) 50 Hz (60 Hz)K 4 ( 3.0 kW) 50 Hz (60 Hz)K 6 ( 4.0 kW) 50 Hz (60 Hz)K 8 ( 5.5 kW) 50 Hz (60 Hz)K 15 (11.0 kW) 50 Hz (60 Hz)

Max. pressure: 15 barK 4 – 15 ( 3.0 kW) 50 Hz (60 Hz)K 6 – 15 ( 4.0 kW) 50 Hz (60 Hz)K 15 – 15 (11.0 kW) 50 Hz (60 Hz)

Max. pressure: 40 barK 8 – 40 ( 5.5 kW) 50 Hz (60 Hz)K 15 – 40 (11.0 kW) 50 Hz (60 Hz)

K Booster: Booster pressure 10 bar, max. pressure 40 barK 8 Booster ( 5.5 kW) 50 Hz (60 Hz)K 15 Booster (11.0 kW) 50 Hz (60 Hz)

BOGE KOMPRESSORENPostfach 10 07 13D-33507 Bielefeld

Otto-Boge-Straße 1-7D-33739 Bielefeld

Phone: +49 5206 601-0Fax: +49 5206 601-200Mail: [email protected]: www.boge.com

Issue: 05 / 2012No. 596.1028.01

Nominal price: € 5,00

BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page I

Index

Index

Part 1: General

1.1 Introduction..................................................................................... 1General ............................................................................................. 1Symbols used ................................................................................... 2Symbols on the compressor ............................................................. 3Intended use..................................................................................... 4Foreseeable Misuse ......................................................................... 4Transport damage ............................................................................ 5Data on the type plate....................................................................... 5Service.............................................................................................. 5

1.2 General safety instructions ........................................................... 6Safety instructions for compressor operation ................................... 6Safety instructions for maintenance and repair of the compressor... 7Special hazard warnings................................................................... 8Electrical energy hazards ................................................................. 9Accident prevention regulations........................................................ 9Obligations of the owner ................................................................. 10Personnel requirements.................................................................. 10Personal protective equipment ....................................................... 10

Part 2: Product description

2.1 Technical data............................................................................... 11Compressor system: maximum pressure 10 bar, 50 / 60 Hz (compressor unit)............................................................................... 11Compressor system: maximum pressure 10 bar, 50 / 60 Hz (with receiver) .................................................................................... 11Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz (compressor unit)............................................................................... 12Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz (with receiver) .................................................................................... 12Booster compressor system: max. booster pressure 10 bar, max. pressure 40 bar, 50 / 60 Hz (compressor unit) ......................... 13Booster compressor system: max. booster pressure 10 bar, max. pressure 40 bar, 50 / 60 Hz (with receiver)............................... 13

Part 3: Installation

3.1 Transport ....................................................................................... 15General ........................................................................................... 15Transport possibilities ..................................................................... 15Intermediate storage or after an extended stoppage...................... 16

BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page III

Index

3.2 The compressor room.................................................................. 17Installation conditions for compressed air receivers arranged separately ....................................................................................... 17Installation surface.......................................................................... 17Sound protection............................................................................. 17Admissible environmental influences.............................................. 18Ventilation ....................................................................................... 18Cooling air requirement .................................................................. 19Installation of the compressor ......................................................... 19Sound insulation hoods .................................................................. 19Electrical connection....................................................................... 20Condensate disposal ...................................................................... 20

3.3 Installation, assembly and commissioning................................ 20General ........................................................................................... 20Checking the delivery scope........................................................... 21Installing the compressor ................................................................ 21Assembly ........................................................................................ 22Assembly in case of booster pressure supply (K Booster) ............. 23Electrical connection....................................................................... 25Compressed air connection ............................................................ 27Prior to commissioning / start up .................................................... 28Check installation requirements...................................................... 29Checking the rotationaldirection ..................................................... 29Check compressed air outlet for tightness...................................... 30Checking for leaks (general) ........................................................... 30Conduct trial run ............................................................................. 30

3.4 Dismantling ................................................................................... 31

Part 4: Fault

4.1 General .......................................................................................... 33

4.2 Faults and fault rectification........................................................ 33Only for 2-stage compressors:........................................................ 34

Part 5: Maintenance

5.1 Safety instructions ....................................................................... 35

5.2 General .......................................................................................... 36Maintenance through BOGE service .............................................. 36Spare and wearing parts................................................................. 37Overview of regular maintenance work .......................................... 37Maintenance intervals..................................................................... 39

5.3 Regular maintenance work .......................................................... 40Intake filter: Cleaning / changing of filter cartridges........................ 40Check pre-filter / Replace filter cartridge ........................................ 41Lubricate the bearings of the drive motor ....................................... 42

Page IV BOGE Operating instructions for oil-free piston compressors, series K 3...K 15

Index

Drive motors with permanent lubrication ........................................ 42Cleaning the cooler (air cooling) ..................................................... 43Checking and setting the operating pressure (with compressor control)............................................................................................ 44Check / set operating pressure switch............................................ 44Checking the safety valve............................................................... 46

5.4 Spare parts and optional extras .................................................. 46List of spare and wearing parts (for maintenance) ......................... 46

Part 6: Appendix

6.1 Guidelines and standards complied with................................... 47

6.2 Pneumatic circuit diagrams......................................................... 47Pneumatic circuit diagram: K 3...K 15 (single stage up to 10 bar with compressor control) ....................... 48Pneumatic circuit diagram: K 3...K 8 (single stage up to 10 bar with pressure switch ventilation) ........... 49Pneumatic circuit diagram: K 4 – 15 / K 6 – 15 / K 8 – 40 / K 15 – 15/40 (two-stage 15...40 bar with compressor control) ....... 50Pneumatic circuit diagram: K 4 – 15 / K 6 – 15 (two-stage up to 15 bar with pressure switch ventilation) ............... 52Pneumatic circuit diagram: K 8 Booster and K 15 Booster booster compressors (single stage up to 40 bar with compressor control) . 54

6.3 List of maintenance and service work ....................................... 56

BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page V

General 1.1 Introduction

Part 1: General 1.1 Introduction

These operating instructions apply to:– complete machines

(compressor assembly ready for operation, incl. compressed air receiver),– incomplete machines

(compressor assembly not ready for operation, without compressed air re-ceiver).

The present operating instructions are based on a complete machine. In case of an incomplete machine, chapter „3.3 Installation, assembly and commis-sioning”, page 20 focuses in detail on the particularities of an incomplete ma-chine (assembly of required components on unit).

General 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 maintenance and repair measures, assists in case of malfunctions and con-tains data concerning spare and wearing parts.The operating instructions must be available to the compressor operating per-sonnel at the place of operation, at all times.The operating instructions must be carefully read and applied by all persons engaged to undertake the following work on the compressor:– Operation, including fault rectification and daily care – Maintenance (service, inspection, repair)– Commissioning– Transport

The compressor and its additional equipment must not be installed and com-missioned until the operating instructions are understood.These operating instructions can be supplemented with instructions on the basis of existing national regulations concerning accident prevention and envi-ronmental protection.In the illustrations, the compressor is shown in part without safety cladding or safety devices for better visualization. However, operation without these com-ponents is prohibited!

BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page 1


Symbols used In these operating instructions, important safety instructions and tips are iden-tified 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 indicates information warning of dangers to life and limb of the operator or other persons or dangers, which might destroy or damage the compressor.

Caution: Voltage!This symbol indicates information warning of life threatening electrical volt-age levels.It indicates work which must be exclusively performed by skilled electricians.

Note:This symbol indicates information and tips concerning the economical and careful operation of the compressor.

Page 2 BOGE Operating instructions for oil-free piston compressors, series K 3...K 15


Symbols on the compressor

The following symbols and warning signs are fitted 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!

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!



Intended use

Foreseeable Misuse

Caution!BOGE compressors, including their additional equipment, are exclusively intended for the compression of air for industrial purposes. The air taken in must not contain any explosive or chemically instable gases or vapours.Booster compressors of the Booster series are designed to take in the air from the compressed air network of an existing compressor system. The pre-compressed air must be available in an adequate amount and the required pressure. The suction line from the receiver needs possibly be re-dimen-sioned. The air must not contain any oil, aggressive, abrasive or combustible admixtures.As all BOGE compressors, booster compressors do not qualify for compres-sion of flammable or toxic gases. Certain gases such as nitrogen or carbon dioxide can, however, be compressed. Please contact BOGE for further de-tails on such type of applications.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/but-ton) 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.

Caution!Never direct the produced compressed air towards persons. Danger to life!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/but-ton) may not be used for operational tripping of the compressor. Make sure to actuate the OFF button for operational tripping of the compressor. 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.



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.

Data on the type plate Enter the data of your compressor from the type plate or enclosed data sheet into fig. 1.1 below.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 type plate

Service 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

��

��

��

��

��

��

�� !��"�#$%&'�((%() ��&�� *+,-+./.+#�+

0��1#++%#( &'�((,+% �� &��2 *+,-+./ .+#�-++

��34��3��&� �54��3��

4��

4��23� ��

min–1

Note:The indication "Max. input pressure" is only appropriate for Booster compres-sors of the Booster series (K 8 Booster, K 15 Booster).


General 1.2 General safety instructions

1.2 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 are understood.

2. Only use the compressor for its intended use, as described in these oper-ating instructions.

3. The owner must ensure,– that only appropriately trained and authorized personnel work on this

compressor,– that no persons work on this compressor, whose ability to react is re-

stricted due to misuse of e.g. drugs, alcohol, medication etc.,– that the operating, maintenance and repair personnel has been made

fully familiar with all safety instructions, and that they are being ob-served,

– that the compressor is only operated in a safe operating condition.4. Avoid any operating method which may impair the safety of the compres-

sor.5. Always wear your compulsory personal protective quipment as a protec-

tion against injuries from sharp corners or edges when working on the compressor.

6. To avoid dangers from debris or parts lying around, the service area of the compressor has always to be kept tiedied up and clean.

7. Always squat when working on components mounted at low height, never stoop. When working on components mounted higher up always stand upright and erect.

8. It is imperative that the limit values for the max. booster pressure and the final compression pressure marked on the type plate be not exceeded.

9. Do not operate the compressor without the attendant protection and safety devices.Do not dismantle any built-in safety devices or put them out of operation. Ensure that all safety claddings and doors are closed prior to commission-ing/starting up the compressor and that they are not opened during oper-ation.

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!

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!



10. 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.

11. Only operate the compressor using the additional equipment (options) rec-ommended or authorized by the manufacturer.

12. Undertake conversions and modifications of the compressor only in agree-ment with BOGE, taking all relevant safety regulations into consideration. The manufacturer is not liable for damages resulting from independent modifications on the compressor.

13. Never start the compressor when one or serveral parts (e.g. cable, plug) are damaged, when not in perfect working order and when damage is detected or suspected.

14. Observe all safety and danger signs directly attached on the compressor!

Safety instructions for maintenance and repair of the compressor

1. Ensure that maintenance work is only carried out by appropriately trained persons.

2. Ensure that setting work, malfunction rectification and repair is only carried out by specialists or appropriately trained persons.

3. Prior to maintenance or repair work:– Press Emergency Stop button.– Open mains disconnecting device.– Secure mains disconnecting device against unintentional switching on

by means of a padlock.– Fix a warning label to the control and fill in the name of the person re-

sponsible who is authorized to switch on the maschine again.– Check to ensure that all parts are currentless.– Disconnect the compressor from the compressed air network (relieve

or block pressurized lines). Additionaly for booster compressors: Vent booster pressure pipe lead-ing to the booster compressor.

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 mains disconnecting device has to meet the requirements of DIN EN 60204-1:2007!Check mains disconnecting device for correct function on a regular basis!



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. DIN 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 net pressure is lower than the set switch-on pressure.

Special hazard warnings – Any performance of work on pressurized system components may be car-ried out by duly qualified and specialized personnel only.

– Always wear your compulsory personal protective equipment when work-ing on pressure pipes and connections!

– Some of the component parts risk to get extremely hot during compressor operation! Prior to working on the compressor, allow all hot component parts cool down to 50°C! Make sure to always wear protective gloves dur-ing work!

– Reaching into the rotating component parts of the compressor or ejection of rotating or prestressed component parts is prevented by use of protec-tive covers. Never operate compressor with protective covers removed!

– A protective grid serves to prevent you from accidentally reaching into the impeller of the cooling fan.

– Any pipelines and/or auxiliary equipment on the compressor are designed such as to resist to any adverse operating conditions and any predictable external influences. Make sure to operate your compressor within the pa-rameters specified in the Technical Data Sheet!

– A check valve is used to prevent the admissible operating pressure from being exceeded.

CAUTION: Risk of injury!Never operate compressor with protective grid removed! There is a risk of putting your hands into the rotating impeller wheel of the cooling fan!Please note that the cooling fan may run on for a certain time even after the compressor has been switched off!

CAUTION: Risk of injury!When the maximum pressure is exceeded (e.g. incorrect setting of the oper-ating pressure value), the entire delivery volume of the compressor is eject-ed!



Electrical energy hazards

Accident prevention regulations

The owner of a compressor plant is responsible to ensure that it is properly installed, operated and maintained.Prior to commissioning, owners in the Federal Republic of Germany urgently have to read the currently valid regulations of the Main Association of the In-dustrial Employers' Liability Insurance. Apart from other regulations particular-ly the Ordinance on Industrial Safety and Health (BetrSichV) is applicable.The regulations are available at the following locations:– Berufsgenossenschaft (Industrial Employers' Liability Insurance)– Carl-Heymanns-Verlag KG, Luxemburger Straße 449, D-50939 Köln– Beuth Verlag GmbH, Burggrafenstraße 6, D-10787 BerlinFor operation of the compressor plant outside the Federal Republic of Ger-many, the accident prevention regulations of the country, where the compres-sor is operated, must be observed in addition to the data contained in these operating instructions. In the event that measures are required above and be-yond the legal regulations specified in the Federal Republic of Germany or the data contained in these operating instructions, then it is of utmost importance that these be carried out prior to commissioning the compressor plant.

Caution: Voltage!There is danger of life when working on the electrical equipment of the compressor!– Disconnect mains connection prior to starting to carry out works on the

compressor and use padlock to secure against switching on again.– Only duly authorized professional electricians (e.g. plant electricians) are

allowed to carry out works in the electrical area of the machine.– Make sure to check the electrical equipment of the compressor at regular

intervals for defects such as loose connections or scorched cables and have any defects repaired immediately.

– Make sure to have all electrical equipment and fixed electrical installa-tions checked by a professional electrician at least every 4 years.

– Any modifications that may have been carried out after examination must conform to DIN EN 60204-1:2007.

– Make sure to check all safety installations on the machine for proper func-tioning at regular intervals.

– Only use original fuses.



Obligations of the owner The owner is obliged to,– operate the compressor only in technically perfect condition,– check the Emergency Stop device of the compressor regularly for com-

pleteness and functionality,– assess the hazards of the machine working places in his area of respon-

sibility and to issue the ensuing operating instructions,– to name a person responsible beeing in charge of the safe operation of the

machine as well as the coordination of all service work performed on it,– avoid stress situations while operating the compressor by means of tech-

nological and organizational operation scheduling,– ensure a proper workplace lighting at the compressor control section ac-

cording to the local health and safety regulations,– observe the safety data sheet of the used lubricants and to customize the

personnel all information as to said data sheet,– provide the compulsory personal protective equipment and to stipulate

and check the wearing of said protective equipment on a regular basis,– assign the personnel responsible for various tasks and work on the ma-

chine,– instruct the personnel on a regular basis with respect to all obligations as

to compressor related preservation of safety and tidiness.

Personnel requirements 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!

Personal protective equipment

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 and/or con-

trol pneumatics)must be worn.

Before starting work using oils or greases a skin protection cream must be ap-plied. Having finished the work a skin care product must be applied.


Product description 2.1 Technical data

Part 2: Product description 2.1 Technical data

Compressor system: maximum pressure 10 bar, 50 / 60 Hz (compressor unit)

Mode

l

Volum

e flow

(outp

ut ra

te)ac

c. to

VDMA

4362

at 8 b

ar

Comp

ress

or sp

eed

50/60

Hz

Motor

Dime

nsion

s (W

x D

x H)

silen

ced a

ppro

x.

Dime

nsion

s (W

x D

x H)

supe

r-sile

nced

appr

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Weig

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ence

d app

rox.

Weig

htsu

per-s

ilenc

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prox

.

Max.

soun

d pre

ssur

e lev

el

acc.

to PN

8NTC

2.3

silen

ced /

supe

r sile

nced

[pmax bar] [l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg] [dB (A)]

K 3 10 244 14.64 1450/1740 2.2 1012x804x784 1312x804x784 182 189 73/70

K 4 10 328 19.68 1450/1740 3.0 1012x804x784 1312x804x784 182 189 74/71

K 6 10 466 27.96 1450/1740 4.0 1012x804x784 1312x804x784 209 216 75/72

K 8 10 648 38.88 1450/1740 5.5 1012x804x784 1312x804x784 225 232 78/75

K 15 10 1296 77.76 1450/1740 11.0 1497x806x891 2097x806x891 379 391 83/79

Compressor system: maximum pressure 10 bar, 50 / 60 Hz (with receiver)

Mode

l (with

rece

iver s

ize)

Volum

e flow

(outp

ut ra

te)ac

c. to

VDMA

4362

at 8 b

ar

Comp

ress

or sp

eed

50/60

Hz

Motor

Dime

nsion

s (W

x D

x H)

silen

ced a

ppro

x.

Dime

nsion

s (W

x D

x H)

supe

r-sile

nced

appr

ox.

Weig

htsil

ence

d app

rox.

Weig

htsu

per-s

ilenc

ed ap

prox

.

Max.

soun

d pre

ssur

e lev

el

acc.

to PN

8NTC

2.3

silen

ced /

supe

r sile

nced

[pmax bar] [l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg] [dB (A)]

K 3 – 270 10 244 14.64 1450/1740 2.2 1770x804x1346 290 297 73/70

K 4 – 270 10 328 19.68 1450/1740 3.0 1770x804x1346 290 297 74/71

K 6 – 270 10 466 27.96 1450/1740 4.0 1770x804x1346 320 327 75/72

K 8 – 270 10 648 38.88 1450/1740 5.5 1770x804x1346 330 337 78/75

K 15 – 270 10 1296 77.76 1450/1740 11.0 1770x806x1453 490 502 83/79



Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz (compressor unit)

Mode

l

Volum

e flow

(outp

ut ra

te)ac

c. to

VDMA

4362

at 12

/32 b

ar

Comp

ress

or sp

eed

50/60

Hz

Motor

Dime

nsion

s (W

x D

x H)

silen

ced a

ppro

x.

Dime

nsion

s (W

x D

x H)

supe

r-sile

nced

appr

ox.

Weig

htsil

ence

d app

rox.

Weig

htsu

per-s

ilenc

ed ap

prox

.

Max.

soun

d pre

ssur

e lev

el

acc.

to PN

8NTC

2.3

silen

ced /

supe

r sile

nced

[pmax bar] l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg] [dB (A)]

K 4 15 279 16.74 1450/1740 3.0 1012x804x784 1312x804x784 182 189 71/68

K 6 15 420 25.20 1450/1740 4.0 1012x804x784 1312x804x784 209 216 72/69

K 8 40 390 23.40 1450/1740 5.5 1012x804x784 1312x804x784 232 239 75/72

K 15 15 794 47.64 1450/1740 11.0 1497x806x891 2097x806x891 380 392 83/79

K 15 40 780 46.80 1450/1740 11.0 1497x806x891 2097x806x891 380 392 83/79

Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz (with receiver)

Mode

l (with

rece

iver s

ize)

Volum

e flow

(outp

ut ra

te)ac

c. to

VDMA

4362

at 12

/32 b

ar

Comp

ress

or sp

eed

50/60

Hz

Motor

Dime

nsion

s (W

x D

x H)

silen

ced a

ppro

x.

Dime

nsion

s (W

x D

x H)

supe

r-sile

nced

appr

ox.

Weig

htsil

ence

d app

rox.

Weig

htsu

per-s

ilenc

ed ap

prox

.

Max.

soun

d pre

ssur

e lev

el

acc.

to PN

8NTC

2.3

silen

ced /

supe

r sile

nced

[pmax bar] [l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg [dB (A)]

K 4 – 250 15 279 16.74 1450/1740 3.0 1630x804x1346 1630x804x1346 290 297 71/68

K 6 – 250 15 420 25.20 1450/1740 4.0 1630x804x1346 1630x804x1346 320 327 72/69

K 15 – 250 15 794 47.64 1450/1740 11.0 1520x806x1453 2097x806x1453 490 502 83/79

K 8 – 250 40 390 23.40 1450/1740 5.5 1630x804x1346 1630x804x1346 330 337 75/72

K 15 – 250 40 780 46.80 1450/1740 11.0 1560x806x1453 2097x806x1453 490 502 83/79




Booster compressor system: max. booster pressure 10 bar, max. pressure 40 bar, 50 / 60 Hz (compressor unit)

Mode

l

Volum

e flow

(outp

ut ra

te)ac

c. to

VDMA

4362

at 12

/32 b

ar

Comp

ress

or sp

eed

50/60

Hz

Motor

Dime

nsion

s (W

x D

x H)

silen

ced a

ppro

x.

Weig

htsil

ence

d app

rox.

Max.

soun

d pre

ssur

e lev

el

acc.

to PN

8NTC

2.3

silen

ced /

supe

r sile

nced

[pmax bar] l/min] [m3/h] [min-1] [kW] [mm] [kg] [dB (A)]

K 8 Booster 40 1160 69.60 1450/1740 5.5 1010x930x790 215 75/72

K 15 Booster 40 2320 139.20 1450/1740 11.0 1500x930x885 425 83/79

Installation 3.1 Transport

Part 3: Installation 3.1 Transport

General Please observe the generally accepted safety and accident prevention regu-lations when transporting the compressor. BOGE accepts no liability for dam-age caused by incorrect transport!

Move compressor to installation site as described in the following sections.

Transport possibilities Forklift truck or lifting carriage transport

Fig. 3.1: Transport with forklift truck

Attention!The transport of the compressor may only be carried out by adequately in-structed and authorized personnel!The capacity of the lifting gear (lifting cart or forklift truck) must correspond at least to that of the compressor (see chapter „2.1 Technical data”, page 11)!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.Lifting lugs on certain component parts (e.g. electric motor) are exclusively intended for lifting the individual parts, however not for lifting the entire com-pressor!Do not tilt the compressor during transport!

Attention!Inappropriate transport may lead to compressor damages. Do not subject the safety cladding to force during transport.

Ensure that the forks are un-derneath the base frame of the compressor (see figure).


Installation 3.1 Transport

Crane transport

Fig. 3.2: Crane transport

Intermediate storage 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.

Attention!Inappropriate transport may lead to compressor damages. Do not subject the safety cladding to force during transport. – Only lift compressor by using the supplied transport pallet.– Protect the compressor using wooden spacers (see arrows in the illus-

tration below). – Remove transport timber.– Only use suitable transport slings having a minimum length of approx.

5 metres!

Place loops of the transport slings at the head sides underneath the supplied trans-port pallet of the compressor.Neither fasten the transport slings to the suction filter nor to the eyelet on the motor.

Note!In case of an intermediate storage please observe the specifications and di-rections as to permissible environmental impacts (see chapter „3.2 The com-pressor room”, page 17).In case of a careless storage BOGE does not assume any liability for conse-quent damages!In the event of an extended intermediate storage or after an extended stop-page (6 months) you should consult BOGE-Service. In case of protracted downtimes and/or temporary storage of more than two months make sure to also observe the respective measures for commission-ing (see section „Prior to commissioning / start up”, page 28“).


Installation 3.2 The compressor room

3.2 The compressor room

Installation conditions for compressed air receivers arranged separately

Installation surface A level industrial floor without foundation is adequate for the installation of the compressor. No special fastening elements are required.

Sound protection Only install compressors in workrooms if the sound pressure level of their measuring surfaces does not exceed 85 dB (A).

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).– Ensure that the type plate is clearly visible.– Ensure that compressed air receivers are adequatly protected against

corrosion (galvanised receiver).– Only use the compressed air receiver for compressors operating with

cut-in and cut-out mode if the pressure fluctuation range amounts to Δp ≤ 20% of the maximum operating pressure.

Note!If vibrations are detected during commissioning due to an inappropriate foun-dation the owner has to install a suitable vibration damper between machine feet and foundation.Please note that even the use of vibration dampers will not prevent the ma-chine from causing mechanical residual vibrations. This fact should be drawn into account when placing sensitive equipment in the immediate neighbor-hood of the machine.



Admissible environmental influences

The compressor room must be clean, dry, cool and free of dust.

Admissible ambient temperaturesMaximum ambient temperature (for air cooling): + 40°C Minimum ambient temperature: + 5°C

Ventilation If the following instructions are not observed, the admissible final com-pression temperature may be exceeded.

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 3.1.

VentilatorsEnsure that the heated exhaust air is not taken in again.If necessary, the heated exhaust air must be extracted by ventilators. To en-sure perfect cooling even at higher temperatures in the summer, the ventila-tors must be designed as follows:– The ventilator capacity must be rated approx. 10...15% higher than the

sum of the cooling air quantity required for all machines operated in the room (VDMA Code of Practice sheet 4363 "Ventilation of compressor rooms").

– For free-standing installation, the cooling air requirement specified in the table corresponds to the required ventilator capacity.

Attention!Non-observance of the admissible ambient temperature may lead to the fol-lowing problems:– Pipelines and valves may freeze up at low temperatures.– The service life of components will fall if temperature limits are exceeded.

Measures to be taken to ensure that admissible ambient temperatures are observed:– Avoid having any heat-radiating pipelines or units in the vicinity of the

compressor, or insulate them well.– Never install the compressor in the cooling air flow of other machinery.– Provide the supply air openings with adjustable louvres to ensure that the

minimum temperature is not gone below in winter.

Caution!Arrange the compressor intake openings or ducts in such a way, that dan-gerous admixtures (e.g. explosive or chemically unstable materials) cannot be drawn in.



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.

Fig. 3.1: Cooling air requirement and necessary size of supply air opening

Installation of the compressor

– Set up the compressor in such a way, that– it can be operated and serviced without disturbances or obstructions

(see layout/space plan).– there is sufficient space at the front side (min. wall distance: 600 mm)

to suck in air. Otherwise the ventilator efficiency is affected and a prop-er cooling can no longer be guaranteed!

– The cooling air flow of a compressor must not heat up other machines.– Ensure that the heated exhaust air is not taken in again.– Please note that even the use of vibration dampers will not prevent the ma-

chine from causing mechanical residual vibrations. This fact should be drawn into account when placing sensitive equipment in the immediate neighborhood of the machine.

– Please observe the admissible surface load of the place of installation (see layout/space plan).

Sound insulation hoods Only use the original BOGE sound insulation hoods for all BOGE compres-sors. Other hoods may impair the cooling, causing serious damage!

Drive rating Required ventilator output for room ventilation

Necessary inlet opening

[kW] [m3/h] [m2]

2.2 1000 0.3

3.0 1400 0.3

4.0 1800 0.3

5.5 2270 0.3

11.0 4750 0.5

Attention!If you fail to observe the instructions on installation, as well as ventilation, the machine may be damaged and the compressed air quality may be impaired.


Installation 3.3 Installation, assembly and commissioning

Electrical connection

Condensate disposal The air taken in contains water in form of vapour, which turns into condensa-tion during compression.

3.3 Installation, assembly and commissioning

General Depending on the purchased variant, BOGE compressors will be shipped as incomplete machines or as ready-for-connection units. Only the work de-scribed in the following paragraphs needs to be carried out during installation. As to installation observe the notes in chapter „3.2 The compressor room”, page 17.

Caution: Voltage!Make sure to secure the power line to the compressor in conformity with the technical connection requirements. A power cut-out should also be provided. The installation must be carried out by a qualified specialist!

Attention!When disposing of the collected condensate, the drainage requirements of your local water authority are to be adhered to!Do not hesitate to contact us if you have any questions on this subject.

Note!We recommend the drawing up of an assembly and commissioning certifi-cate in which the test results during the assembly or commissioning process can be listed up.

CAUTION: Risk of injury!Installation and commissioning are to be carried out by duly authorized and experienced professional personnel only!Always wear protective gloves when working on the compressor to avoid bruising of fingers or hands while opening or closing components!

Caution!Only have the installation work carried out by appropriately trained persons or specialists.Lay out all energy supply lines in a trip-proof and barrier-free manner so that potential accidents can be avoided!



Prior to delivery, each compressor is subjected to a trial run at the factory. It is carefully tested and set. However, possible transport damage cannot be ex-cluded.– It is recommended that the compressor be subject to a visual inspection

immediately after receipt (damage to paintwork, oil stains or other types of damage) and that any complaints be reported to the last shipping compa-ny. In order to secure your claims for damages against the shipping com-pany we would advise you to temporarily leave the machines, equipment and packaging materials in the condition in which they were received upon determination of the 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.

Checking the delivery scope

The delivery scope depends on your order.Prior to commissioning, please check whether all required parts have been provided. Please check the order confirmation for any possible accessory equipment.The delivery scope includes the following component parts:– Operating instructions– Dimensioned drawing– Keys– Electric circuit diagram

Installing the compressor

– Remove all packing material in and around the compressor.– Install compressor and align it horizontally.– The compressor / compressed air receiver (depending on type) must stand

firmly on the ground on all feet.

Attention!During transportation, do not use intake filter as a means of transportation.



Assembly Customized compressor stations (built-in compressors, incomplete ma-chine)Customized compressor stations (machines, receivers, fittings and switch de-vices) are shipped incompletely assembled. receiver fittings, switch devices, connection piping and control lines are readied at the factory and included with the shipment.As a standard, the compressor unit is mounted on the receiver. Depending on locally available space the unit may also be placed in a different manner. At any rate, the unit should be in the proximity of the receiver. Prior to installation of your compressor please contact BOGE for further information or details on proper positioning and/or connection to existing receivers!In this conjunction, please observe related references in chapter „3.2 The compressor room”, page 17“.

Fig. 3.3: View of a customized compressor station

1 Compressor control or compressed air switch (according to type)2 Electrical connection3 Air outlet, ball check valve4 Condensate drain on compressed air receiver5 Manometer / Safety valve6 Compressor7 Elastic bearing8 Compressed air connection Compressor-Receiver9 Compressed air receiver



Assembly in case of booster pressure supply (K Booster)

Fig. 3.4: Assembly overview: Booster compressor with vertical receiver

1 Inlet pre-compressed compressed air2 Upstream compressed air receiver3 Pre-filter4 High-pressure hose (booster pressure)5 Booster compressor6 High-pressure hose (final pressure)7 Compressed air receiver8 Outlet finally compressed compressed air

: Compressed air path

Fig. 3.5: Assembly overview: Booster compressor with horizontal receiver

Booster compressors (K 8 Booster, K 15 Booster) are designed to take in pre-compressed compressed air from the network of an existing compressed air system, preferably from an upstream compressed air receiver (2) with a min. 250 liter capacity in order to reduce pulsation on the suction side. The sepa-rately enclosed pre-filter (3) is to be installed in the pre-pressure line upstream of the flexible connection / hose (4) (see pertaining illustrations 3.4 and 3.5).



Never install the filter directly on the compressor (5). Do not forget to monitor the differential pressure display of the pre-filter. The filter element has to be replaced when the differential pressure shows 0.035 bar or at least once a year. It must be checked that the size of the intake line is correct, otherwise the quantity of air delivered will be affected.If the diameter of your compressed air lines is not sufficient, a special connec-tion line must be laid from the compressed air receiver to your booster com-pressor.– Hose and pipeline for booster compressors K 8 Booster and K 15 Booster

at least DN25.Please consider that the FAD of your compressor must correspond to the booster pressure supply.

Quality of compressed air from the compressd air net

The quality of the compressed air taken in must meet certain minimum require-ments. For BOGE booster compressors the air taken in must not exceed the following maximum values for impurities:

Furthermore thr following amounts of particles (corresponding to particle size) per cubic meter of compressed air taken in must not be exceeded:

If necessary, the compressed air needs to be pretreated prior to compression by use of the booster compressor, i.e. cleaned by means of a cyclone separa-tor, pre-filter and dryer.

Attention!The booster pressures specified on the type plate are maximum pressures and must not be exceededWith higher network pressure, a reduction valve with safety valve must be connected upstream from the booster compressor.

Attention!The residual oil content of the air taken in may damage the compressor. The residual oil content must not exceed the value specified below. A pre-treat-ment of the compressed air is necessary before it is taken in!

– Oil content ≤ 0,01 mg/m³ (purity class 1)– Water content 5,90 g/m3 (Pressure dew point + 3 °C)– Inlet temperature max. 40 °C

Particle size in μm Particle amount / m³– 0.1 bis ≤ 0,5 ≤ 20 000– 0.5 bis ≤ 1,0 ≤ 400– 1.0 bis ≤ 5,0 ≤ 10



Electrical connection

Fuse protection of compressors at 400 V / 50 – 60 Hz.

Please see name plate for compressor motor output.– Use slow fuses only!– Do not use any circuit breakers!

Rated voltageThe data of your mains (operating voltage, control voltage, type of current, fre-quency,...) must be identical to the data on the type plate on the switch cabi-net.In the event of deviations, please contact the BOGE service or your supplier.

WARNING: Voltage!Ensure that work on the electrical equipment of the compressor is only car-ried out by authorized electricians.Prior to commencement of any works the power supply cable is to be switched currentless from the power supply system and to be secured against unintended connection.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.

Mains disconnecting deviceAccording to accident prevention regulation VBG 5, § 12, the customer is responsible to provide the following safety measures:Compressor plants must be fitted with a power disconnecting device accord-ing to EN 60204-1:2007The pressure switch and/or pressure sensor (when using BASIC control) are not designed as mains disconnecting device!

Rating Nominal current

Minimum prel. fuse 1) star-delta

1) Use fuse gL – gG or circuit-breaker with C-characteristic only.

Minimum prel. fuse 1)

direct

Recommended prel. fuse 1) star-delta

Recom-mended

prel. fuse 1)

direct[kW] [A] [A] [A] [A] [A]2.2 4.7...5.2 10 10 10 163.0 6.5...7.0 10 16 10 164.0 9.7...10.5 16 20 16 205.5 13.5 20 25 20 25

11.0 22...23.5 35 35 35 50



Connect power supply lines– Check to ensure that all terminals in the switch cabinet are firmly tight-

ened. If necessary, retighten the screw connections.

Fig. 3.6: Insert power supply line

Fig. 3.7: Connection power supply line

– Retighten the electrical connections after the first 50 operating hours.

Remove screw (1) on either side.Use handles to pull cover (2) upward and carefully put down the handles.Pass power supply cable through cable bushing (PG gland) (3).

Mains

Motor3 ~

Pressure switch with overcurrent release for direct connection to three-phase motor (up to 5.5 kW and max. 15 bar)

Connect the leads L1, L2, L3, N, Pe (PEN) firmly to the power supply ter-minal.A clockwise rotational field must be created.



Compressed air connection

Connect compressed air receiverIn case of a customized compressor station (incomplete machine) an elastic connection from the compressor unit to the compressed air receiver is to be established:

Fig. 3.8: Connection compressor unit - compressed air receiver

Compressed air connection for booster compressors (K Booster)

Fig. 3.9: Compressed air inlet/outlet for booster compressors

1 Compressed air inlet (fig. 3.9): The pre-compressed air was cleaned by means of the pre-filter and is taken into the booster compressor at this point via a high-pressure hose.

Connect high pressure hose (1) coming from compressor to compressed air receiver (2).(In case of a customized com-pressor station the com-pressed air receiver may be aligned other than shown in this illustration.)

(1) Compressed air inlet (from pre-filter side)

(2) Compressed air outlet

Note!At the booster compressor K 15 Booster the compressed air inlet and com-pressed air outlet are placed opposite each other on the longitudinal sides of the housing. Compressed air inlet and conmpressed air outlet are marked by red arrows as shown in fig. 3.9.



2 Compressed air outlet (figure 3.9):The compressed air is compressed to the final pressure and can now be fed into a compressed air network or compressed air receiver.

Connection to compressed air pipe network

Fig. 3.10: Connection compressor unit – compressed air receiver

Prior to commissioning / start up

Attention!Any potential residual oil in the incoming air may cause damage to the com-pressor. The residual oil content may not exceed the valued specified on page 24. Make sure to accordingly pre-treat the compressed air before enter-ing.

Connect ball check valve (1) on compressed air receiver to compressed air pipe network. Make sure to use a high pres-sure hose!(In case of a customized com-pressor station the com-pressed air receiver may be aligned other than shown in this illustration).

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!Prior to any work on the compressor:– Press Emergency Stop button, open mains disconnection device and

secure against unintentional switch on .– Check that all electrical components are not under power.– Depressurize all areas under pressure.

Additionaly for booster compressors: Vent booster pressure pipe leading to the booster compressor.

Never omit a single safety step! Otherwise, you will risk injuries due to re-starting, electric shock or self-releasing parts.



Check installation requirements

Checking the rotational-direction

K 3 – K 8: When watching the flywheel through the grid the compressor must rotate to the right, in order that the cooling air flow from the ventilator is press-ing against the compressor.

Caution!When the automatic restart (Auto-Restart) is activated, the compressor will start automatically following a voltage loss.Prerequisite: The network pressure is lower than the set switch-on pressure.

CAUTION: Risk of injury!The commissioning may only be carried out by experienced and authorized qualified personnel!Always wear protective gloves when working on the compressor to avoid bruising of fingers or hands while opening or closing components!

Attention!Make sure that the compressor is installed according to the installation re-quirements!List up the test results in the commissioning certificate.

Caution!Prior to switching on the compressor check electrical compressor connection for proper design (see chapter „Electrical connection”, page 25)!List up the test results in the commissioning certificate.

Attention!Always check the rotational direction of the drive motor prior to commission-ing/initial start up.Ensure that the directional rotation coincides with the directional rotation ar-row on the cooling air hood.List up the test results in the commissioning certificate.

Caution!Always wear safety gloves!



K 15: When looking at the fan wheel the fan itself must rotate anti-clockwise so that the fan generated cooling air flow is pushed out upward.– Close mains disconnecting device.– Switch the compressor on and immediately off again to check the rota-

tional direction.

Changing the rotational direction

– Interchange two phases (L1, L2 or L3) in the power cable.

Check compressed air outlet for tightness

– Close mains disconnecting device.– Switch on the compressor and check the compressed air outlet for tight-

ness.– Switch off compressor.

– If necessary, have leakages repaired by skilled qualified pesonnel.List up the test results in the commissioning certificate.

Checking for leaks (general)

Undertake the following to prevent leaks:– Check screw connection of the lines and retighten, if necessary.

CAUTION: Risk of injury!Press Emergency Stop button, open mains disconnection device and secure against unintentional switch on.

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!

CAUTION: Risk of injury!Open mains disconnection device and secure against unintentional switch on by means of a padlock.


Installation 3.4 Dismantling

Conduct trial run Each compressor is put through a trial run at the factory. It is carefully tested and set. However, we are unable to guarantee that no damage occurred, e.g., during transport. It is therefore necessary to conduct a trial run for a precise observation of the compressor.– Close mains disconnecting device.– Switch on the compressor.

The compressor switches off automatically once the switch-off pressure, has been reached.

– Check pressure at pressure gauge (compressed air net). If necessary, readjust pressure switch/pressure sensor (see chapter "Maintenance", section „Checking and setting the operating pressure (with compressor control)”, page 44).

– Check pressure display on the control. If necessary, reset the pressure (see separate operating instructions).

The compressor is ready for operation.

Switch off compressor after a 30-minute trial run at max. operating load.List up the test results in the commissioning certificate.

3.4 Dismantling

Note!To avoid dangers when dismantling the compressor please consult your BOGE Service:

Telephone: +49 5206 601-140

Caution!Dismantling of the compressor may only be carried out by experienced and authorized qualified personnel!Dispose of collected condensate in accordance with local regulations!

Caution: Voltage!All work on the electrical installation may only be carried out by authorized and skilled electricians!Prior to starting the work the power cable to the switch cabinet must be dis-connected from the mains and secured against unintentional switching on!


Fault 4.1 General

Part 4: Fault 4.1 General

The tables on this and on the following pages give information on the possible causes of operating faults and measures for their rectification (please also re-fer to operating instructions of the compressor control).

4.2 Faults and fault rectification

Caution!Ensure that any work required to rectify faults is only carried out by trained personnel or specialists. Ensure that components which have a safety function are only set, repaired or exchanged by BOGE Service!Please contact BOGE-Service at the following telephone number, if you have any questions.

Telephone: +49 5206 601-140

Caution: Voltage!Prior to any work required to rectify faults:Open mains disconnecting device. Secure mains disconnecting device against unintentional switching on by means of a padlock.

Fault Possible cause Rectification

Receiver safety valve blows off

Pressure switch set too high Set pressure switch to correct cut-out pressure

Safety valve displaced Check seal, if damaged have safety valve read-justed by BOGE

Air escapes from solenoid valve

Compressor not running: non-return valve leaking Clean ball and seat of non-return valve

Compressor running:

– Solenoid valve soiled Clean solenoid valve, renew seals

– Coil of solenoid valve defective Check coil and replace if necessary


Fault 4.2 Faults and fault rectification

Only for 2-stage compressors:

Compressor supplies no output or output too low

Suction filter soiled Clean suction filter

Suction and pressure valves worn or defec-tive

Replace valves

Vent valve not closing Check whether vent valve closes with compressor running; Overhaul or replace valve, as necessary

For booster compressors:

Solenoid valve on the intake side does not open – solenoid valve defective

Booster pressure too low (< 1 bar)

Replace solenoid valve

Check booster pressure



Safety valve of first stage blows off

Suction and pressure valves of the second stage defective or worn

Replace valves

Seal between valve and cylinder head defective

Replace seal

Air escapes from solenoid valve of first stage

Compressor not running: non-return valve leaking Clean ball and seat of non-return valve

Compressor running:

– Solenoid valve soiled Clean solenoid valve, renew seals

– Coil of solenoid valve defective Check coil and replace if necessary

The pneumatic vent valve of the 2nd stage blows with compressor running

Suction and pressure valves of first stage defective or worn

Replace valves

Suction filter soiled Clean suction filter

Solenoid valve of first stage defective Check solenoid valve and replace if necessary


Maintenance 5.1 Safety instructions

Part 5: Maintenance 5.1 Safety instructions

Caution!Ensure that maintenance work is only carried out by specialists or appropri-ately trained persons. Any performance of work on pressurized system components may be carried out by duly qualified and specialized personnel only.– Prior to starting any maintenance work, always stop the compressor as

described in these operating instructions prior to removing any cladding or safety devices. Refit the cladding or safety devices immediately upon completion of the maintenance work.

– Heavy components may only be lifted up by various persons in due con-sideration of the local industrial safety regulations.

– Only use original spare parts and operating materials released by BOGE for the maintenance and service work

– When the automatic restart (Auto-Restart) is activated, the compressor will start automatically following a voltage loss. Prerequisite:The net pressure is lower than the set switch-on pressure.


Maintenance 5.2 General

5.2 General

Maintenance through BOGE service

Have BOGE service check your compressor completely according to the serv-icing table (see " Maintenance intervals" on page 39).

CAUTION: Risk of injury!Always adhere to the prescribed operating method described below for all maintenance work. Never omit a single safety step!Otherwise you will risk injury from restarting, electric shock or parts which may fly off.

Prior to all maintenance work:1. Switch off the compressor using the OFF button.2. Press Emergency Stop button.3. Press Emergency Stop button, open mains disconnection device and

secure against unintentional switch on by means of a padlock.4. Fix a warning label to the control and fill in the name of the person re-

sponsible who is authorized to switch on the machine again.5. Prior to starting work let cool down all hot components of the compressor

to 50°C.6. Check to ensure that all machine elements are definitely currentless.7. Separate the compressor from the compressed air network.


8. Remove all safety cladding necessary to perform the maintenance work.

Once the maintenance work has been concluded:9. Reattach all removed safety cladding.

10. Prior to switching on again, check whether anyone else is working on the compressor.

11. Remove warning sign not until then and release mains disconnecting device.

12. Unlock Emergency Stop button.13. For booster compressors: Ensure booster pressure supply prior to re-

starting the booster compressor.

Maintenance agreementEnter into a maintenance agreement with BOGE. BOGE service will carry out the proper maintenance on your compressor at regular intervals. This guar-antees maximum safety and realiability of your compressed air supply.



Spare and wearing parts

Overview of regular maintenance work

Fig. 5.1: Overview of regular maintenance work

1 Pressure switch with hour counter (not with booster compressors)2 Check cooler for soiling / clean if necessary3 Check pressure adjustments / adjust pressure, if necessary

(compressor control)4 Check/clean both air intake filters (not with booster compressors)

Replace air intake filter cartridge (not with booster compressors)5 For booster compressors (not illustrated here):

– Check pre-filter – Replace pre-filter cartridge

Caution!Only use original spare parts approved by BOGE for repair or maintenance work.BOGE accepts no liability for damage caused by the use of other parts.



Fig. 5.2: Overview of regular maintenance work K 15

1 Check cooler for soiling / clean if necessary.2 Check pressure adjustments/adjust pressure, if necessary3 Check intake filter / clean if necessary (not with booster compressors)

Replace air intake filter cartridge (not with booster compressors)4 For booster compressors (not illustrated here):

– Check pre-filter – Replace pre-filter cartridge

Fig. 5.3: Additional service work K 3..K 8

1 Check safety valve

Fig. 5.4: Additional service work K 15

3

2

11



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.

Note!Note down all maintenance work in the table on the last pages. This will facil-itate troubleshooting for BOGE-service.

Retighten the screw connections of the electrical connections after the first 50 operating hours.1. Switch off the compressor using the OFF button.2. Press Emergency Stop button.3. Open power disconnecting device and secure against unintentional

switch on by means of a padlock.4. Check to ensure that all machine elements are definitely currentless.5. Disconnect compressed air network from the compressor.


6. Remove all necessary safety cladding to perform the maintenance work.7. Retighten the electrical connections in the switch cabinet.8. Reattach all removed safety cladding.9. Release power disconnecting device.

10. Unlock Emergency Stop button.11. For booster compressors: Ensure booster pressure supply prior to re-

starting the booster compressor.

Maintenance work Maintenance intervals in operating hours Page

monthly yearly 3.000 yearly

General maintenance work

Check function of EMERGENCY STOP pushbutton X –

Check / clean intake filter cartridge (not for booster compressors) X 40

Replace intake filter cartridge (not for booster compressors) X 41

Check pre-filter (for booster compressors) X 41

Replace pre-filter cartridge (for booster compressors) X 41

Clean cooler X 43

Check / adjust operating pressure X 44

Check safety valve X 46


Maintenance 5.3 Regular maintenance work

Tab. 5.1: Maintenance intervals

5.3 Regular maintenance work

Intake filter: Cleaning / changing of filter cartridges

Cleaning: – 1x monthly,

however, at least every 500 operating hours– Correspondingly earlier if the air taken in is heavily soiledChange: – In the event of damage– After the second cleaning.

Removing the filter cartridge

To clean or replace the filter cartridge proceed as follows:– Remove cladding on the maintenance side.– Remove the lid of the filter case.– Take out the filter cartridge.– Now the filter cartridge can be cleaned resp. replaced.

The following servicing tasks must be carried out by expert BOGE servicing personnel:

Operating hrs at 50 Hz

Operating hrs at 60 Hz

Change drive 1) 6.000 5.000

after 2 years at the latest

Replace air intake and pressure valves 6.000 5.0001) The specified servicing intervals are mean values that may be shortened or extended according to operating conditions. If installed in areas with ambient temperatures

of 30°C to 40°C the intervals are to be reduced by 1000 operating hours.

Note!This servicing is not meant for booster compressors.

CAUTION: Risk of injury!Press Emergency Stop button, open mains disconnecting device. Secure mains disconnecting device against unintentional switching on by means of a padlock.



Clean filter cartridge

– Tap the filter cartridge with your hand to knock out coarse dust.– Blow out fine dust (max. pressure 5 bar) from the inside to the outside.– Clean the sealing surfaces of the filter cartridge.

Fig. 5.5: Intake filter (1) and filter cartridge (2)

Check pre-filter / Replace filter cartridge

Check functionality of pre-filter: – 1 x per month.– Pressure display must be in the green area.

Replace filter cartridge: – after 3.000 operating hours,

however, no later than after one year.

Caution!Do not clean filter cartridges in liquids.Do not use hard objects for cleaning in order that the filter paper is not dam-aged.Replace the filter cartridge if it is damaged or has been cleaned twice.

Fitting a filter cartridgeAfter cleaning and in case of a replacement insert the cleaned resp. new filter car-tridge as follows:– Insert the filter cartridge

into the filter case.– Fasten the lid of the filter

case.– Fit the cladding on the

service side.

Note!This service is only suitable for booster compressors.

CAUTION: Risk of injury!Press Emergency Stop button, open power disconnecting device and secure against unintentional switch on by means of a padlockDisconnect compressed air supply to pre-filter. Vent all pressurized areas of the system. There must be no pressure inside high-pressure hoses, pre-filter and compressor any longer.



Replace filter cartridge as follows:

Lubricate the bearings of the drive motor

The bearings of the drive motors usually have a service-free permanent lubri-cation.

Drive motors with permanent lubrication

Under normal operating conditions (refrigerant temperature max. 40°C, con-tinuous operation) the bearings require no servicing.

Tab. 5.2: Service life of bearings

The service lives specified above are extended or shortened in the event of higher or lower thermal stress (due to the higher or lower temperature of the coolant).

– Depressurize pre-filter (cf. filter man-ual).

– Unscrew and remove bottom part of housing (1).

– Unscrew filter cartridge (2) and take out.

– Insert new filter cartridge with O ring.– Tighten filter cartridge by hand. Make

sure that the O ring is properly seated.– Check tightness of housing (cf. filter

manual).– The pre-filter is ready for operation

again.

Mains frequency Operating hours

50 Hz 18.000

60 Hz 15.000

Attention!The bearings must be replaced by BOGE-service after their service life has expired. This is done by BOGE-Service together with the scheduled service after 6.000/5.000 operating hours by installing an exchange motor. We rec-ommend the installation of a spare compressor.



Cleaning the cooler (air cooling)

Cleaning: – After 3.000 operating hours,

but no less than once a year.

– Switch off the compressor with the OFF button.

– Remove the cladding from the service side.– Clean off the collected soiling with a fibre brush (vacuum cleaner).

– Blow out any dirt with compressed air (1) against the normal flow of the cooling air.

If the cooler is very heavily soiled (i.e. a cleaning with compressed air is no longer possible), it must be dismantled and cleaned by BOGE-Service.

Fig. 5.6: Cleaning the compressed air cooler

The service life of the cooler depends on the degree of soiling (dust, oil va-pour) in the intake cooling air. Heavy external soiling of the cooler leads to an excessively high temperature in the air circuit.

CAUTION: Risk of injury!Press Emergency Stop button, open mains disconnecting device. Secure mains disconnecting device against unintentional switching on by means of a padlock.

Attention!Never use sharp objects to clean the cooler! You may damage the cooler (vacuum cleaner).



Checking and setting the operating pressure (with compressor control)

Check: – After approx. 3.000 operating hours,

but at least 1x per year.

Setting: – If the switch-on or switch-off pressure no longer matches the set point val-

ues.

Set point values (factory setting):

Switch-on pressure: pmin = final compression pressure – 2 bar at pmax. 10 bar. – 3 bar at pmax. 15 bar. – 5 bar at pmax. 40 bar.

Switch-off pressure: pmax = final compression pressure.The target values (factory setting) can be adjusted individually to the operat-ing conditions.

Check the operating pressure:– Check the switch-on and switch-off pressure on the net pressure gauge

during operation .Switch-off pressure = the pressure at which the compressor switches off.Switch-on pressure = the pressure at which the compressor automatically switches on.

Check / set operating pressure switch


but at least 1x yearly.

Setting: – If the switch-on or switch-off pressure no longer matches the set point val-

ues.

Set point values (factory setting):

Caution!Never set the operating pressure higher than the admissible final compres-sion pressure (see type plate).

Max. pressure [bar] 8 10 15

Switch-on pressure [bar] 6 8 12

Switch-off pressure [bar] 8 10 15

Attention!

Never set the operating pressure switch above the admissible final com-pression pressure (see type plate).



Check operating pressure switch:The operating pressure switch is installed on the compressor unit.– Check switch-on and switch-off pressure on the pressure gauge during

operation.Switch-off pressure = the pressure at which the compressor switches off.Switch-on pressure = the pressure at which the compressor automatically switches on.

Set operating pressure switch:

Fig. 5.7: Set pressure switch

– Re-fasten the casing of the operating pressure switch.

Caution: Voltage!Ensure that the operating pressure switch is only set by trained electricians.Live contacts may be exposed on the pressure switch.Risk of injury resulting from an electrical shock.

Attention!Ensure that the operating pressure switch is only adjusted while under pres-sure!

– Loosen fastening screws (1) and (2) to remove op-erating pressure switch housing(3).

– Take out the adjustment instructions.

– Adjust the pressure switch according to the manufacturer's instruc-tions.

– Put the instructions back into the casing.


Maintenance 5.4 Spare parts and optional extras

Checking the safety valve


but at least 1x yearly.

Check the safety valve by turning open the lock screw.

Fig. 5.8: Check safety valve

5.4 Spare parts and optional extras

List of spare and wearing parts (for maintenance)

CAUTION: Risk of injury!Take extreme care when checking the safety valve with the compressor run-ning, and observe all safety measures.Hot air escapes during opening!– Always wear protective goggles and gloves.– Open the lock screw (1) by turning it anti-clockwise.

The compressed air escapes.– Tighten the threaded plug by turning clockwise.– The safety valve is situated on the fitting support of the receiver.

Description

Intake filter / Cartridge

Pre-filter / cartridge (for booster compressors)

Please always specify the following information from the type plate when ordering:– Type– Year of manufacture– Machine number


Appendix 6.1 Guidelines and standards complied with

Part 6: Appendix 6.1 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

6.2 Pneumatic circuit diagrams

On the following pages you will find the individual pneumatic circuit diagrams for the different machine types.


Appendix 6.2 Pneumatic circuit diagrams

101 Intake air INLET102 Compressed air OUTLET

1 Intake filter2 Vacuum switch for intake filter *3 Service display *4 Compressor, stage 15 Drive motor6 Safety valve, stage 1 * 7 Cooler, stage 18 Pressure sensor, system pressure monitoring *9 Pressure sensor, net pressure

10 Non-return valve11 Elastic hose12 Solenoid valve, stage 1 (ventilation)13 Silencer, stage 1

* Option

Pneumatic circuit diagram: K 3...K 15 (single stage up to 10 bar with compressor control)




1 Intake filter2 Vacuum switch for intake filter *3 Service display *4 Compressor, stage 15 Drive motor6 Safety valve, stage 17 Cooler, stage 18 Pressure switch with ventilation9 Non-return valve

10 Elastic hose* Option

Pneumatic circuit diagram: K 3...K 8 (single stage up to 10 bar with pressure switch ventilation)



Pneumatic circuit diagram: K 4 – 15 / K 6 – 15 / K 8 – 40 / K 15 – 15/40 (two-stage 15...40 bar with compressor control)




1 Intake filter2 Vacuum switch for intake filter *3 Service display *4 Compressor, stage 15 Drive motor6 Cooler, stage 17 Compressor, stage 28 Cooler, stage 29 Safety valve, stage 2

10 Pressure sensor, system pressure monitoring *11 Pressure sensor, net pressure12 Non-return valve13 Elastic hose14 Solenoid valve, stage 1 (ventilation)15 Pneum. vent valve, stage 2 (ventilation)16 Silencer, stage 117 Silencer, stage 2

* Option



Pneumatic circuit diagram: K 4 – 15 / K 6 – 15 (two-stage up to 15 bar with pressure switch ventilation)




1 Intake filter2 Vacuum switch for intake filter *3 Service display *4 Compressor, stage 15 Drive motor6 Cooler, stage 17 Compressor, stage 28 Cooler, stage 29 Safety valve, stage 2

10 Pressure switch, system pressure monitoring *11 Pressure switch, net pressure12 Non-return valve13 Elastic hose14 Pneum. vent valve, stage 2 (ventilation)

* Option



Pneumatic circuit diagram: K 8 Booster and K 15 Booster booster compressors (single stage up to 40 bar with compressor control)




101 Intake air INLET (pre-compressed air)102 Compressed air OUTLET

1 Pre-filter, assembly on site2 flexible hose3 Electromagnetic stop valve4 Booster pressure sensor *5 Compressor6 Drive motor7 Cooler8 Electromagnetic vent valve9 Sensor - system pressure build-up *

10 Non-return valve11 Safety valve12 Net pressure sensor13 flexible hose

* Option

Appendix 6.3 List of maintenance and service work

6.3 List of maintenance and service work

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k3 k6 k8 k15 operating instructions - surgevessels.co.uk

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