Boge Screw Compressor s31 2 To s341 PDF

Operating instructions
Belt-driven
screw compressors
Series
S 31-2...S 341
SD 40-2...SD 150
SF 60-2...SF 150
SDF 60-2...SDF 150
S 40-2...S 50-2 BLUEKAT
Separate manuals:
Compressor control
Refrigeration compressed air dryer (SD / SDF)
Frequency converter (SF / SDF)
www.boge.com
for belt-driven
screw compressors
S 31-2 (22 kW)

S 40-2 / SD 40-2 (30 kW)
S 50-2 / SD 50-2 (37 kW)
S 60-2 / SD 60-2 (45 kW)
S 61-2 / SD 61-2 (45 kW)
S 75-2 / SD 75-2 (55 kW)
S 90-2 / SD 90-2 (65 kW)
S 100-2 / SD 100-2 (75 kW)
S 101 / SD 101 (75 kW)
S 125 / SD 125 (90 kW)
S 150 / SD 150 (110 kW)
S 151 (110 kW)
S 180 (132 kW)
S 220 (160 kW)
S 271 (200 kW)
S 341 (250 kW)
SF 60-2 / SDF 60-2 (45 kW)

SF 100-2 / SDF 100-2 (75 kW)
SF 150 / SDF 150 (110 kW)
S 40-2 BLUEKAT (30 kW)

S 50-2 BLUEKAT (37 kW)
BOGE KOMPRESSOREN
Postfach 10 07 13
33507 Bielefeld
Otto-Boge-Strae 1-7
33739 Bielefeld
Fon: +49 5206 601-0

Fax: +49 5206 601-200
Mail: [email protected]
Net: www.boge.com
Issue: 05 / 2012
No. 596.1162.01
Nominal price: 5,00
BOGE Operating instructions for S 31-2...S 341 series screw compressors Page I
Index
Index
Part 1: 1.1 General safety instructions ........................................................... 1

General Safety instructions for compressor operation ................................... 1
Special hazard warnings................................................................... 2
Electrical energy hazards ................................................................. 3
Obligations of the owner ................................................................... 3
Personnel requirements.................................................................... 4
Personal protective equipment ......................................................... 4
Safety instructions for maintenance and repair of the compressor... 4
Safety instructions for maintenance and repair on integrated
converter (BLUEKAT series) ............................................................ 5
Accident prevention regulations........................................................ 6
1.2 Introduction..................................................................................... 6
Symbols used ................................................................................... 7
Symbols on the compressor ............................................................. 8
Intended use ..................................................................................... 9
Foreseeable Misuse ......................................................................... 9
Intended use of the integrated converter (BLUEKAT series).......... 10
Transport damage .......................................................................... 10
Data on the type plate..................................................................... 11
Service............................................................................................ 11
Part 2: 2.1 Technical data............................................................................... 13

Product description
2.2 Compressor operation principle ................................................. 20
Function principle of the air end...................................................... 20
Air circuit ......................................................................................... 21
Oil circuit ......................................................................................... 22
2.3 BLUEKAT operation principle ..................................................... 23
2.4 Compressor control ..................................................................... 24

Network pressure............................................................................ 24
Operating states ............................................................................. 24
Operating modes ............................................................................ 25
Compressed air production control (BLUEKAT series) .................. 25
Controlled operation (frequency control) ........................................ 26
Short operating times...................................................................... 26
BOGE Operating instructions for S 31-2...S 341 series screw compressors Page III
Index
2.5 Control devices ............................................................................. 26

Operating pressure transmitter ....................................................... 26
Proportional controller (option for S series) .................................... 27
2.6 Safety and monitoring devices.................................................... 27

General ........................................................................................... 27
Safety temperature limiting device.................................................. 27
Safety temperature limiter on the integrated converter
(BLUEKAT series) .......................................................................... 28
Safety valve .................................................................................... 30
Monitoring the drive and fan motor ................................................. 30
Rotational direction monitoring (option) .......................................... 30
System pressure build-up (option) .................................................. 30
2.7 Water cooling ................................................................................ 31

Water cooling .................................................................................. 31
Serial connection ............................................................................ 31
Parallel connection ......................................................................... 31
2.8 Cooling water ................................................................................ 32

Water connection (for water cooling) .............................................. 32
Cooling water quality ...................................................................... 32
Part 3: 3.1 Transport and storage.................................................................. 33

Installation General ........................................................................................... 33
Transport possibilities ..................................................................... 33
Intermediate storage ....................................................................... 34
3.2 Compressor room......................................................................... 35

Installation conditions and application for compressed air receivers
arranged below or separately .......................................................... 35
Installation surface .......................................................................... 35
Fire protection ................................................................................. 35
Sound protection............................................................................. 36
Admissible ambient temperatures .................................................. 36
Frost protection............................................................................... 36
Ventilation ....................................................................................... 37
Cooling air requirement .................................................................. 38
Ventilation possibilities.................................................................... 39
Condensate disposal ...................................................................... 40
3.3 Installation..................................................................................... 40
General ........................................................................................... 40
Checking the delivery scope ........................................................... 41
Installing the compressor ................................................................ 41
Connecting the compressor to the compressed air network........... 41
Connecting the cooling water (option) ............................................ 41
Removing the transport securing bolts ........................................... 42
Page IV BOGE Operating instructions for S 31-2...S 341 series screw compressors
Index
Activating the belt tensioning device............................................... 42

Checking the oil level...................................................................... 43
3.4 Electrical connection.................................................................... 43
3.5 Commissioning............................................................................. 45
Check installation requirements...................................................... 45
Checking the rotational direction of drive and fan motor ................ 45
Check compressed air outlet for tightness...................................... 46
Opening the stop valve ................................................................... 46
Checking for leaks .......................................................................... 47
Conduct trail run ............................................................................. 47
Commissioning following extended stoppages............................... 48
Refrigeration compressed air dryer ................................................ 49
3.6 Dismantling ................................................................................... 50
Part 4: 4.1 General .......................................................................................... 51

Faults
4.2 General faults................................................................................ 51
4.3 Converter failures (BLUEKAT series) ......................................... 53
Part 5: 5.1 BOGE-Duotherm BPT................................................................... 55

Optional features Function .......................................................................................... 55
Installation....................................................................................... 55
Commissioning ............................................................................... 55
Maintenance ................................................................................... 56
5.2 BOGE-Duotherm BSW.................................................................. 57

Function .......................................................................................... 57
Commissioning ............................................................................... 57
Maintenance ................................................................................... 58
Part 6: 6.1 Safety instructions ....................................................................... 59

Maintenance
6.2 General .......................................................................................... 61
Maintenance through BOGE customer service .............................. 61
Review of regular maintenance work.............................................. 61
Maintenance intervals..................................................................... 64
General information concerning the lubricants used ...................... 66
Disposal of used operating material ............................................... 67
Pressure hoses............................................................................... 68
Spare and wearing parts................................................................. 68
BOGE Operating instructions for S 31-2...S 341 series screw compressors Page V
Index
6.3 Regular maintenance work .......................................................... 68

Clean or change suction filter ......................................................... 68
Cleaning the filter cartridge ............................................................. 69
Changing the supply air filter mats (option) .................................... 69
Drive motors with permanent lubrication ........................................ 70
Drive motors with lubrication device ............................................... 70
Drive motors with automatic lubricating equipment ........................ 71
Changing the V-belt ........................................................................ 72
Settings of the GM-drive systems with standard motors ................ 73
Checking the oil level, topping up oil .............................................. 74
Changing the oil filter ...................................................................... 76
Changing the oil separator.............................................................. 77
Oil change....................................................................................... 79
Flushing the oil circuit ..................................................................... 81
Cleaning the compressed air/oil cooling unit (air cooling) .............. 82
Cleaning the oil cooling unit (water cooling) ................................... 83
Proportional controller (option for S series) .................................... 83
Check safety valve.......................................................................... 84
6.4 Spare parts and optional equipment .......................................... 85

List of spare and wearing parts (for maintenance) ......................... 85
Replacement parts for converter (BLUEKAT series) ...................... 86
List of available optional equipment................................................ 86
Part 7: 7.1 Guidelines and standards complied with ................................... 87

Appendix
7.2 Flow chart...................................................................................... 87
Air cooled version, standard ........................................................... 88
Water cooled version, serial connection parallel connection ....... 90
Air cooled version, frequency controlled ......................................... 92
Water cooled version, serial connection frequency controlled.... 94
BLUEKAT series, air cooled version............................................... 96
BLUEKAT series, water cooled version, parallel connection .......... 98
BLUEKAT series, Water cooled version, serial connection .......... 100
SD / SDF....................................................................................... 102
BOGE-Duotherm BPT plate heat exchanger ................................ 103
BOGE-Duotherm-Plus BSW safety heat exchanger..................... 104
7.3 List of maintenance and service work ...................................... 105
Page VI BOGE Operating instructions for S 31-2...S 341 series screw compressors
General 1.1 General safety instructions
Part 1: General 1.1 General safety instructions
Caution!
Nonobservance of the following safety instructions may lead to injuries and
damage to the compressor.
Also observe the generally valid safety and accident prevention regulations
in addition to the information in these operating instructions!
Safety instructions for 1. Ensure that no commissioning and maintenance work on the compressor
compressor operation is undertaken until these operating instructions are understood.
2. Only use the compressor for its intended use, as described in these oper-
ating instructions.
3. The owner must ensure,
that only appropriately trained and authorized personnel work on this
compressor,
dthat no persons work on this compressor, whose ability to react is
restricted 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
observed,
that the compressor is only operated in a safe operating condition.
4. Avoid any operating method which may impair the safety of the compres-
sor.
5. Always wear your compulsory personal protective equipment as a protec-
tion against injuries from sharp corners or edges when working on the
compressor.
6. To avoid dangers from debris or parts lying around, the service area of the
compressor has always to be kept tiedied up and clean.
7. Always squat when working on components mounted at low height, never
stoop. When working on components mounted higher up always stand
upright and erect.
8. Do not exceed the limit value for the final compression pressure specified
on the type plate.
9. Do not operate the compressor without the attendant protection and safety
devices.
Do not dismantle any built-in safety devices or put them out of operation.
Ensure that all safety claddings and doors are closed prior to commission-
ing/starting up the compressor and that they are not opened during oper-
ation.
10. Place the compressor out of operation as described in these operating
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)
recommended or authorized by the manufacturer.
BOGE Operating instructions for S 31-2...S 341 series screw compressors Page 1
12. Undertake conversions and modifications of the compressor only with

BOGE prior approval, taking all relevant safety regulations into considera-
tion. The manufacturer is not liable for damages resulting from independ-
ent modifications on the compressor.
13. Never start the compressor when one or serveral parts (e.g. cable, plug)
are damaged, when not in perfect working order and when damage is
detected or suspected.
14. Observe all safety and danger signs directly attached on the compressor!
15. The compressed air/oil receiver and the BLUEKAT converter are pressure
devices and require testing in accordance with international standards.
16. To avoid damages, special precautions have to be taken during (re-) oper-
ation of compressors with frequency control, if the frequency converter
was cut off from the power supply for a longer period of time (> 12 months).
In this case please contact the BOGE-Service.
Special hazard warnings Always wear your compulsory personal protective equipment when work-
ing on pressure pipes and connections!
A protective grid serves to prevent you from accidentally reaching into the
impeller of the cooling fan.
Caution: Risk of injury!

Never operate the compressor with dismantled protective grid! There is a
constant danger of accidentally reaching into the impeller of the cooling fan!
Please note that the cooling fan may run on for a certain time even after the
compressor has been switched off!
During operation, the compressor generates a high sound pressure level

which may cause permanent hearing damage due to continuous noise
stress. As a rule, the compressor may only be operated with its housing
cover closed. Make sure to additionally wear a hearing protection in case
of a noise pressure level above 80 dB(A)!
Page 2 BOGE Operating instructions for S 31-2...S 341 series screw compressors
Electrical energy
hazards
Caution: Voltage!
There is danger of life when working on the electrical equipment of the
compressor!
Disconnect mains connection prior to starting to carry out works on the
compressor and use padlock to secure against switching on again.
Only duly authorized professional electricians (e.g. plant electricians) are
allowed to carry out works in the electrical area of the machine.
Make sure to check the electrical equipment of the compressor at regular
intervals for defects such as loose connections or scorched cables and
have any defects repaired immediately.
Make sure to have all electrical equipment and fixed electrical installa-
tions checked by a professional electrician at least every 4 years.
Any modifications that may have been carried out after examination must
conform to DIN EN 60204-1:2007.
Make sure to check all safety installations on the machine for proper
functioning at regular intervals.
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 In general for all work on the compressor

equipment protective clothing,
chemicals resistant gloves,
slip-resistant safety shoes and
hearing protection, if applicable
are compulsory.
For special duties

protective helmets (for transport work with lifting gear) and
safety goggles (when working on the compressed air system, on the con-
trol pneumatics and/or on the cooling system of the built-in dryer)
must be worn.
Before starting work using oils or greases a skin protection cream must be
applied. Having finished the work a skin care product must be applied.
Safety instructions for

maintenance and repair
of the 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 power disconnecting device has to meet the requirements of DIN EN
60204-1:2007!
1. Ensure that maintenance work is only carried out by appropriately trained

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

Switch off the compressor using the OFF button.
Press Emergency Stop button.
Open power disconnecting device.
Secure power disconnecting device against unintentional switching on
by means of a padlock.
Fix a warning label to the control and fill in the name of the person re-
sponsible who is authorized to switch on the maschine again.
Check to ensure that all parts are currentless.
Disconnect the compressor from the compressed air network (relieve
or block pressurized lines).
Allow converter to cool off for several hours (only applies to screw
compressors S 40-2 BLUEKAT and S 50-2 BLUEKAT)
4. Exercise extreme caution during repair or maintenance work requiring the
compressor to be operational.
Ensure that persons keep out of reach of the hazardous area.
5. Ensure that work on the electrical equipment is only executed by qualified
electricians.
6. Work on parts and devices under current is prohibited. Exceptions are gov-
erned by the appropriate regulations, e.g. 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.
Safety instructions for

maintenance and repair
on integrated converter
(BLUEKAT series)
Caution!
Maintenance and repair work on integrated converter of the S 40-2 BLUEKAT
and S 50-2 BLUEKAT series may be carried out by specially trained BOGE
service personnel only.
Non-observance may cause physical injuries and damage to the compressor
station.
General 1.2 Introduction
Accident prevention The owner of a compressor plant is responsible to ensure that it is properly in-
regulations stalled, operated and maintained.
Prior to commissioning, owners in the Federal Republic of Germany urgently
have to read the currently valid regulations of the Main Association of the In-
dustrial 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 Strae 449, D-50939 Kln
Beuth Verlag GmbH, Burggrafenstrae 6, D-10787 Berlin
For operation of the compressor plant outside the Federal Republic of Ger-
many, the accident prevention regulations of the country, where the compres-
sor is operated, must be observed in addition to the data contained in these
operating instructions. In the event that measures are required above and
beyond the legal regulations specified in the Federal Republic of Germany or
the data contained in these operating instructions, then it is of utmost impor-
tance that these be carried out prior to commissioning the compressor plant.
1.2 Introduction
The purpose of these operating instructions is to familiarize the user with the
function and all application possibilities of the compressor.
These operating instructions contain important information on how to operate
the compressor safely, economically and according to its intented use. Ob-
serving these operating instructions will assist in avoiding danger, to reduce
repair costs and down times and to increase the reliability and service life of
the compressor. It contains important information concerning the required
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!
Symbols used In these operating instructions the most important safety notes and tips are
especially characterized by the following symbols:

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.
Symbols on the
compressor
Note!
All warning signs on the compressor and in its surrounding must always be
kept in a legible condition. Missing or damaged signs must be replaced at
once!
The following symbols and warning signs are fitted on the compressor:
Warning!
Hot surfaces: Do not touch!
Warning!
The unit is operated by remote control, and might start without warning!
Note!
Instructions for the operating personnel must be read!
Prohibited!
Never open the valve before the air hose (connection to the compressed air
network) is connected!
Warning of hand injuries!

Any works on the belt drive may only be carried out when the compressor is
at standstill and secured against unintentional switching on!
Intended use
Caution!
BOGE compressors, including their additional equipment, are exclusively
intended for the compression of air in industrial applications. The air taken in
must not contain any explosive or chemically instable gases or vapours.
Do not exceed the specified final compression temperature.
BOGE compressors are designed for stationary operation.
Ensure that they are only installed and operated in dry and clean rooms.
The emergency stop device of the compressor (emergency stop switch/
button) is exclusively intended to switch off the compressor in case of emer-
gency.
Operation and control are designed to be executed by trained and authorized
operators.
Foreseeable Misuse
Caution!
Never direct the produced compressed air towards persons.Danger to life!
Oil is injected into the pressure rooms of the compressor.
Only use the produced compressed air for breathing or let it come in contact
with foods, if it was treated beforehand.
This BOGE compressor is not explosion protected.
Do not operate in explosive areas or in a possibly explosive atmosphere!
Do not operate the compressor in rooms in which extreme dust, toxic or flam-
mable vapours and gases may occur.
The emergency stop device of the compressor (emergency stop switch/
button) may not be used for operational tripping of the compressor. Make
sure to actuate the OFF button for operational tripping of the compressor.
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.
Intended use of the In accordance with its intended purpose the BLUEKAT converter is exclusively
integrated converter designed for the treatment of compressed air of screw compressors, with the
hydrocarbons contained in the air being catalytically oxidized.
(BLUEKAT series)
The catalyst operating temperature in the catalyst bed should be approx.
200C 5% in the flow through mode. In order to avoid prolonged preheating
phases and delays in compressed air production, the compressor station
should not be unplugged too often.
Only hydrocarbon based oils (synthetic or mineral) may be used as compres-

sor lubricants. All lifetime specifications are based on a max. additive content
of 5 %. Silicon based oils may not be used.
Note!
Any modifications not authorized by BOGE to the control and the switch cab-
inet layout of the converter will result in expiration of any warranty claims
against BOGE.
Note!
Opening and replacement of the converter by any personnel not authorized
or trained by BOGE will result in immediate expiration of any warranty claims
against BOGE.
Transport damage BOGE does not accept any liability for breakage or transport damage. Please
inspect the compressor immediately after delivery and direct damage claims
to the last haulier even when the packing is not damaged! To safeguard
claims against the haulier we recommend leaving the machine, devices and
packing material in the same condition as they were in when the damage was
detected.
In the event of any other complaints, please inform us within six days after ar-
rival of the delivery.
Data on the type plate Enter the data of your compressor from the type plate or enclosed data sheet
in the illustration below. This will ensure that in the event of enquiries, you will
always have the most important data to hand.
This will ensure that in the event of enquiries, you will always have the most
important data to hand.
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
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!
Product description 2.1 Technical data
Part 2: Product description 2.1 Technical data
Technical data S 31-2...S 100-2 / SD 40-2...SD 100-2, part 1
S 40-2 S 50-2 S 60-2 S 61-2 S 75-2 S 90-2 S 100-2

Type S 31-2
SD 40-2 SD 50-2 SD 60-2 SD 61-2 SD 75-2 SD 90-2 SD 100-2
Dimensions
Height (silenced) [mm] 1450 1450 1450 1450 1450 1450 1450 1450
Height (silenced) SD [mm] 1665 1665 1665 1665 1910 1910 1910 1910
Height (super silenced) [mm] 1950 1950 1950 1950 1950 1950 1950 1950
Width (silenced/super silenced) [mm] 1620 1620 1620 1620 2000 2000 2000 2000
Depth [mm] 960 960 960 960 1065 1065 1065 1065
Weight
silenced [kg] 740 740/835 760/870 840/950 1100/1325 1180/1460 1250/1360 1290/1390
super silenced [kg] 770 770/865 790/900 870/980 1150/1375 1230/1510 1300/1410 1330/1440
Max. sound pressure level [dB(A)]
accord. to DIN EN ISO 2151:2009 73/68 76/71 78/72 78/73 77/71 79/73 79/73 80/73
silenced / super silenced [dB(A)]
Air cooling
Reference surface measure

15/16 15/16 15/16 15/16 16/17 16/17 16/17 16/17
Sound power level
88/84 91/87 93/88 93/89 93/88 95/90 95/90 96/90
Max. sound pressure level [3 dB(A)]
Water cooling

15/16 15/16 15/16 15/16 16/17 16/17 16/17 16/17
Sound power level
87/83 90/86 92/87 92/88 92/87 94/89 94/89 95/89
Compressor
max.final compression temperature [C] 110 110 110 110 110 110 110 110
Volume flow according to
ISO 1217 appendix C at:
pmax = 8 bar [m3/min] 3.88 5.17 6.35 7.00 7.70 9.33 10.80 12.10
pmax = 10 bar [m3/min] 3.30 4.63 5.78 6.34 6.92 8.30 9.65 10.50
pmax = 13 bar [m3/min] 2.58 3.82 4.95 5.36 5.87 7.11 8.45 9.20
Drive motor
Rated power [kW] 22 30 37 45 45 55 65 75
Rated speed
50 Hz [min-1] 3000 3000 3000 3000 3000 3000 3000 3000
60 Hz [min-1] 3600 3600 3600 3600 3600 3600 3600 3600
Protection type IP 55/23 55/23 55/23 55/23 55/23 55/23 55/23 55/23
Design IMB 3 3 3 3 3 3 3 3
ISO class F F F F F F F F
Electrical connection
Mains voltage 1) 2) [V] 400 400 400 400 400 400 400 400
Frequency 1) [Hz] 50 50 50 50 50 50 50 50
Min. fuse protection 3) 4) [A] 50 80 80 100 100 125 160 200
Recommended fuse protection 3) 4) [A] 63 80 100 125 125 160 160 200
1)
Standard equipment. Mains voltages and frequencies are specified on a plate in the switch cabinet.
2)
Required for the refrigeration compressed air dryer 230 V / 50 Hz.
3)
Only for 400 V / 50 Hz. The fuse values change in the case of other mains voltages and frequencies.
4)
Use fuse gL gG or circuit-breaker with C-characteristic only.
Technical data for S 101...S 341 / SD 101...SD 150, part 1
S 101 S 125 S 150

Type S 151 S 180 S 220 S 271 S 341
SD 101 SD 125 SD 150
Dimensions
Height (silenced) [mm] 1750 1750 1750 2005 2005 2005 2145 2145
Height (silenced) SD [mm] 2153 2153 2153
Height (super silenced) [mm] 2250 2250 2250 2505 2505 2505 2645 2645
Width (silenced/super silenced) [mm] 2365 2365 2365 2265/2565 2265/2565 2265/2565 3100 3100
Depth [mm] 1335 1335 1335 1585 1585 1585 1910 1910
Weight
silenced [kg] 1960 1980 2040 3100 3200 3200 4500 5000
super silenced [kg] 2020 2040 2100 3200 3300 3300 4600 5100
Air cooling

17/18 17/18 17/18 18/19 18/19 18/19 18/19 18/19
Sound power level
93/90 96/92 96/92 101/93 101/93 101/93 105/99 105/99
Water cooling

17/18 17/18 17/18 18/19 18/19 18/19 18/19 18/19
Sound power level
89/88 90/89 90/89 97/90 97/90 97/90 104/98 104/98
Compressor
max.final compression temperature [C] 110 110 110 110 110 110 110 110
pmax = 8 bar [m3/min] 13.1 15.7 18.4 19.4 23.3 27.9 34.7 40.7
pmax = 10 bar [m3/min] 11.4 13.7 16.3 17.0 20.8 25.1 30.5 37.1
pmax = 13 bar [m3/min] 9.8 12.0 14.2 14.4 17.8 21.7 24.7 31.7
Drive motor
Rated power [kW] 75 90 110 110 132 160 200 250
Rated speed
50 Hz [min-1] 3000 3000 3000 3000 1500 1500 1500 1500
60 Hz [min-1] 3600 3600 3600 3600 1800 1800 1800 1800
Protection type IP 55/23 55/23 55/23 55/23 55/23 55/23 55/23 55/23
Design IMB 3 3 3 3 3 3 3 3
ISO class F F F F F F F F
Mains voltage 1) [V] 400 400 400 400 400 400 400 400
Frequency 1) [Hz] 50 50 50 50 50 50 50 50
Min. fuse protection 2) 3) [A] 200 250 250 250 315 400 500 630
Recommended fuse protection 2) 3) [A] 200 250 250 250 315 400 500 630
1)
2)
3)
Use fuse gL _ gG or circuit-breaker with C-characteristic only.
Technical data for S 31-2...S 100-2 / SD 40-2...SD 100-2, part 2
S 40-2 S 50-2 S 60-2 S 61-2 S 75-2 S 90-2 S 100-2

Type S 31-2
SD 40-2 SD 50-2 SD 60-2 SD 61-2 SD 75-2 SD 90-2 SD 100-2
Oil filling quantity
Oil receiver volume [l] 46 46 46 46 71 71 71 71
Total oil filling quantity [l] 28 28 28 28 42 42 42 42
Oil topping up quantity
between min. + max. [l] 6 6 6 6 8 8 8 8
Intake air temperature
min. [C] +5 +5 +5 +5 +5 +5 +5 +5
max. [C] + 40 + 40 + 40 + 40 + 40 + 40 + 40 + 40
Cooling air requirement
Air cooling
free-standing installation [m3/h] 9000 11000 13000 13000 13000 16000 17200 18400
with supply and exhaust air duct [m3/h] 4500 5500 6500 6500 6500 8000 8600 9200
free ventilator pressure [Pa] 60 60 60 60 60 60 60 60
free ventilator pressure [mm WC] 6 6 6 6 6 6 6 6
with supply and exhaust [m3/h] 1000 1000 1000 1000 1000 1000 1000 1000
Required cooling water quantity
delta t = 15 K [m3/h] 1.200 1.630 2.010 2.450 2.450 3.000 3.540 4.090
delta t = 30 K [m3/h] 0.600 0.815 1.005 1.225 1.225 1.500 1.770 2.045
Water cooling
Max. cooling water quantity [m3/h] 3.5 3.5 3.5 3.5 4.2 4.2 4.2 4.2
Cooling water inlet temperature
min. [C] +5 +5 +5 +5 +5 +5 +5 +5
max. [C] + 30 + 30 + 30 + 30 + 30 + 30 + 30 + 30
Cooling water outlet temperature
max. [C] + 45 + 45 + 45 + 45 + 45 + 45 + 45 + 45
Cooling water pressure
min. [bar] 2 2 2 2 2 2 2 2
max. [bar] 10 10 10 10 10 10 10 10
)
Operating pressure sensor 1
(factory settings)
pmax = 8 bar: Switch-off press. pmax [bar] 8 8 8 8 8 8 8 8
Switch-on press. pmin [bar] 7 7 7 7 7 7 7 7
Safety valve
Activation pressure at:
pmax = 8 bar [bar] 11 11 11 11 11 11 11 11
pmax = 10 bar [bar] 11 11 11 11 11 11 11 11
pmax = 13 bar [bar] 14 14 14 14 14 14 14 14
1)
Compressors for other operating pressures pmin = pmax 1 bar.
Technical data for S 101...S 341 / SD 101...SD 150, part 2
S 101 S 125 S 150

Type S 151 S 180 S 220 S 271 S 341
SD 101 SD 125 SD 150
Oil receiver volume [l] 120 120 120 188 188 188 230 230
Total oil filling quantity [l] 65 65 65 100 100 100 113 113
between min. + max. [l] 10 10 10 16 16 16 20 20
min. [C] +5 +5 +5 +5 +5 +5 +5 +5
max. [C] + 40 + 40 + 40 + 40 + 40 + 40 + 40 + 40
Air cooling
free ventilator pressure [Pa] 60 60 60 60 60 60 60 60
free ventilator pressure [mm WColumn] 6 6 6 6 6 6 6 6
delta t = 15 K [m3/h] 4.090 4.900 6.000 6.000 7.190 8.720 10.900 13.600
delta t = 30 K [m3/h] 2.045 2.450 3.000 3.000 3.595 4.360 5.450 6.800
Water cooling
Max. cooling water quantity [m3/h] 9.0 9.0 9.0 9.0 12.0 12.0 13.6 13.6
min. [C] +5 +5 +5 +5 +5 +5 +5 +5
max. [C] + 30 + 30 + 30 + 30 + 30 + 30 + 30 + 30
max. [C] + 45 + 45 + 45 + 45 + 45 + 45 + 45 + 45
min. [bar] 2 2 2 2 2 2 2 2
max. [bar] 10 10 10 10 10 10 10 10
)
(factory settings)
Safety valve
pmax = 8 bar [bar] 11 11 11 11 11 11 11 11
pmax = 10 bar [bar] 11 11 11 11 11 11 11 11
pmax = 13 bar [bar] 14 14 14 14 14 14 14 14
1)
Technical data for SF 60-2...SF 150 / SDF 60-2...SDF 150, part 1
SF 60-2 SF100-2 SF 150

Type
SDF 60-2 SDF 100-2 SDF 150
Dimensions
Height (silenced) [mm] 1450 1450 1750
Height (super silenced) [mm] 1950 1950 2250
Width (silenced / super silenced) [mm] 1620 2000 2365
Depth [mm] 960 1065 1335
Weight
silenced [kg] 840 1535 2040
super silenced [kg] 870 1585 2100
accord. to DIN EN ISO 2151:2009 78/73 80/73 79/74
Air cooling
Reference surface measure 15/16 16/17 17/18

Sound power level 93/89 96/90 96/92
accord. to DIN EN ISO 2151:2009 77/72 79/72 73/71
Water cooling

15/16 16/17 17/18
Sound power level
92/88 95/89 90/89
Compressor
max. final compression temperature [C] 110 110 110
pmax = 8 bar [m3/min] 1.75 7.00 3.0 12.10 4.60 18.4
pmax = 10 bar [m3/min] 1.59 6.34 2.6 10.50 4.08 16.3
pmax = 13 bar [m3/min] 1.35 5.36 2.3 9.20 3.55 14.2
Drive motor
Rated power [kW] 45 75 110
Nominal speed
60 Hz [min-1] 3600 3600 3600
Protection type IP 55/23 55/23 55/23
Design IMB 3 3 3
ISO class F F F
Mains voltage 1) 2) [V] 400 400 400
Frequency 1) [Hz] 50 50 50
Min. fuse protection 3) 4) [A] 100 200 250
Recommended fuse protection 3) 4) [A] 125 200 250
1)
2)
3)
4)
Technical data for SF 60-2...SF 150 / SDF 60-2...SDF 150, part 2
SF 60-2 SF 100-2 SF 150

Type
SDF 60-2 SDF 100-2 SDF 150
Oil receiver volume [l] 46 71 120
Total oil filling quantity [l] 28 42 65
between min. + max. [l] 6 8 10
min. [C] +5 +5 +5
max. [C] + 40 + 40 + 40
Air cooling
free-standing installation [m3/h] 13000 18400 32000

with supply and exhaust [m3/h] 6500 9200 16000
free ventilator pressure [Pa] 60 60 60
free ventilator pressure [mm WColumn] 6 6 6
free-standing installation [m3/h] 2000 2000 3400
with supply and exhaust [m3/h] 1000 1000 1700
delta t = 15 K [m3/h] 2.450 4.090 6.000
delta t = 30 K [m3/h] 1.225 2.045 3.000
Water cooling
Max. cooling water quantity [m3/h] 3.5 4.2 9.0

min. [C] +5 +5 +5
max. [C] + 30 + 30 + 30
max. [C] + 45 + 45 + 45
min. [bar] 2 2 2
max. [bar] 10 10 10
1)
Operating pressure transmitter
(factory settings)
pmax = 8 bar: Switch-off press. pmax [bar] 8 8 8
Switch-on press. pmin [bar] 7.5 7.5 7.5
Safety valve
pmax = 8 bar [bar] 11 11 11
pmax = 10 bar [bar] 11 11 11
pmax = 13 bar [bar] 14 14 14
1)
Compressors for other operating pressures pmin = pmax 0.5 bar.
Technical data for S 40-2 BLUEKAT...S 50-2 BLUEKAT, part 1
Type S 40-2 BLUEKAT S 50-2 BLUEKAT

Dimensions
Height (super silenced) [mm] 1950 1950
Width (silenced / super silenced) [mm] 2270 2270
Depth [mm] 960 960
Weight [kg] 1100 1320
accord. to DIN EN ISO 2151:2009 71 72
super silenced [dB(A)]
Air cooling

17.4 17.4
Sound power level
88.4 89.4
accord. to DIN EN ISO 2151:2009 70 71
Water cooling

17.4 17.4
Sound power level
88.4 89.4
Compressor
max. final compression temperature [C] 110 110
pmax = 8 bar [m3/min] 5.01 6.16
pmax = 10 bar [m3/min] 4.49 5.61
pmax = 13 bar [m3/min] 3.71 4.80
Drive motor
Rated power [kW] 30 37
Nominal speed
50 Hz [min-1] 3000 3000
60 Hz [min-1] 3600 3600
Protection type IP 55 55
Design IMB 3 3
ISO class F F
Mains voltage 1) 2) [V] 400 400
Frequency 1) [Hz] 50 50
Min. fuse protection 3) 4) [A] 100 100
Recommended fuse protection 3) 4) [A] 100 125
1)
2)
3)
4)
Product description 2.2 Compressor operation principle
Technical data for S 40-2 BLUEKAT...S 50-2 BLUEKAT, part 2
Type S 40-2 BLUEKAT S 50-2 BLUEKAT

Oil receiver volume [l] 46 46
Total oil filling quantity [l] 28 28
between min. + max. [l] 6 6
min. [C] +5 +5
max. [C] + 40 + 40
Air cooling
free-standing installation [m3/h] 11000 13000

with supply and exhaust [m3/h] 5500 6500
free ventilator pressure [Pa] 60 60
free ventilator pressure [mm WColumn] 6 6
free-standing installation [m3/h] 2000 2000
with supply and exhaust [m3/h] 1000 1000
delta t = 15 K [m3/h] 1.630 2.010
delta t = 30 K [m3/h] 0.815 1.005
Water cooling
Max. cooling water quantity [m3/h] 4.2 4.2

min. [C] +5 +5
max. [C] + 30 + 30
max. [C] + 45 + 45
min. [bar] 2 2
max. [bar] 10 10
)
(factory settings)
pmax = 8 bar: Switch-off press. pmax [bar] 8 8
Switch-on press. pmin [bar] 7 7
Safety valve
pmax = 8 bar [bar] 11 11
1)
2.2 Compressor operation principle
Function principle The air end operates according to the displacement principle. In the housing,
of the air end the main and secondary screws are driven by means of an electric motor and
V-belts.
Both screws have screw-shaped profiles, intermeshing without contact. To-

gether with the housing wall, these screws form chambers which gradually
reduce in size, seen in air flow direction.
Rotation of the rotors causes the air taken in to be compressed to the final
pressure in the chambers.
During compression oil is continuously injected into the air end. This having a
cooling, sealing and lubricating function.
Air circuit
Fig. 2.1: Components of the air circuit
1 Intake filter
The intake filter cleans the air suctioned by the air end.
2 Intake regulator
The intake regulator opens (load operation) or closes (idling operation or
standstill) the suction line depending on the operating condition of the
compressor.
3 Air end
The air end compresses the sucked in air.
4 Compressed air/oil vessel
The compressed air separates from the oil under the force of gravity in the
compressed air/oil vessel.
5 Oil separator
The oil separator separates the residual oil contained in the compressed
air.
6 Minimum pressure check valve
The minimum pressure check valve does not open until the system pres-
sure has increased to 3.5 bar. This causes a rapid build-up of the system
pressure and ensures lubrication in the starting phase. Once the com-
pressor has been switched off, the check valve prevents the compressed
air from flowing back out of the mains line.
7 Compressed air after-cooler (air cooled or water cooled)
The compressed air is cooled in the compressed air after-cooler, causing
the water contained in the air to condensate.
8 Stop valve
The screw compressor may be isolated from the mains by means of the
stop valve.
Oil circuit The oil injected into the air end has the following function:
It dissipates the compression heat (cooling).
It seals the gaps between the screws and between the screws and hous-
ing.
It lubricates the bearings.
Fig. 2.2: Components of the oil circuit
1 Compressed air/oil vessel

The oil separated from the compressed air through the force of gravity col-
lects in the compressed air/oil vessel. The system pressure forces it out
of the vessel into the air end.
2 Thermostatic oil control valve
Depending on the oil temperature, the thermostatic oil control valve either
allows the oil to pass through the oil cooler or through a bypass (e.g. in
the starting phase).
Thus the oil constantly maintains its optimum operating temperature.
3 Oil cooler (air or water cooled)
The oil cooler cools down the hot oil to operating temperature.
4 Oil filter
The oil filter traps impurities in the oil.
5 Air end
The injected oil returns to the compressed air/oil vessel together with the
compressed air.
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.
Product description 2.3 BLUEKAT operation principle
2.3 BLUEKAT operation principle
The screw compressors of the BLUEKAT series (S 40-2 BLUEKAT and

S 50-2 BLUEKAT) are equipped with an integrated converter for catalyctic sep-
aration of oil residues contained in the compressed air. During the oxidation
process, the converter serves to break up residual oil particles from the air com-
pressed by the compressor into carbon dioxide and water. The treated com-
pressed air is classified as oil-free (class 0) according to DIN ISO 8573-1.
Compressor control
Converter control
Compressor Converter
Fig. 2.3: Overview BLUEKAT: compressor (gray section) with integrated con-
verter
As for the screw compressors of the BLUEKAT series, the converter is installed
downstream of the compressor. Prior to the oil separation process the com-
pressed produced by compressor (1) is first heated up in plate heat exchanger
(2) (see figure below).
After escaping from the plate heat exchanger the heated compressed air is fed
into converter (3) which is filled with catalytic material. The catalytic material is
kept at operating temperature (200 C) by means of an electrically powered
heating. At the same time the heating also heats up the incoming compressed
air. Due to the heat build-up the oil particles in the compressed air are able to
react with the catalytic material. When impacting on the catalyst surface the oil
particles (hydrocarbons are completely burnt (oxidized).
The heated oil free compressed air is fed back to plate heat exchanger (2) af-
ter the treatment process. While being in the plate heat exchanger it releases
part of its heat energy to the compressed air (still to be treated) flowing from
the compressor into the plate heat exchanger which is now able to heat up pri-
or to the oxidation process while the already treated compressed air cools off
at the same time. In order to further cool off it is then fed into aftercooler (4).
The compressed air escapes at a temperature of 30 35C and can be fed
into a compressed air receiver for further use. The condensate which is built
up in the compressed air receiver conforms to industrial water quality and may
be discharged accordingly.
Product description 2.4 Compressor control
Compressed air outlet
Fig. 2.4: BLUEKAT functional diagram including compressed air flow direction
2.4 Compressor control
Network pressure For the compressor, the pressure downstream of the check valve is termed
network pressure. The control system switches the compressor on and off dur-
ing operation depending on the network pressure.
Operating states All screw compressor controls are based on three basic operating states:
1. Load operation
The compressor delivers its maximum amount of compressed air.
It consumes its maximum energy.
2. Idling operation
The compressor runs but does not deliver any compressed air.
It consumes approx. 75% less energy than in load operation.
When compressed air is required, it switches to load operation with out
delay.
Idling operation reduces switching frequencies which can damage the
drive motor, and reduces wear of the system.
3. Standstill ready for operation
The compressor is standing still but ready for operation.
When compressed air is required, it switches automatically to load
operation.
Product description 2.4 Compressor control
Operating modes The two most important operating modes are achieved by combining the three
operating states:
1. Intermittent operation
In intermittent operation the energy balance is perfect.
The compressor operates in load operation.
Upon reaching the switch-off pressure pmax the compressor switches
to standstill. It does not consume any energy.
Once the pressure has dropped to the switch-on pressure pmin the
compressor switches back to load operation.
2. Continuous operation
Continuous operation limits the drive motor switching cycles and reduces
wear to the system.
The compressor operates in load operation.
Upon reaching the switch-off pressure pmax the compressor switches
to idling operation.
nce the pressure has dropped to the switch-on pressure pmin the com-
pressor switches from idling operation back to load operation.
Compressed air As for compressors of the BLUEKAT series (S 40-2 BLUEKAT and S 50-2
production control BLUEKAT) the compressed air production depends on the operating state of
the integrated converter.
(BLUEKAT series)
After connection of the compressor to the power supply the integrated convert-
er will start the preheating phase in order to reach its operating temperature
(approx. 200 C).
As long as the converter has not reached its operating temperature, the control
system of the compressor will block compressed air production since the oil
separation process in the converter is unable to start as yet meaning that no
oil free compressed air would be available. The compressor is in the "opera-
tional availability standby mode" (see Operating modes on page 25.).
As soon as the integrated converter has reached its operating temperature
(approx. 200C), it switches from the preheating phase into the "operation"
mode while automatically transmitting this information onto the control system
of the compressor. As soon as the switch-on pressure is achieved, the control
system allows the compressor to switch to load operation. (see Operating
modes on page 25.). The compressor will now start to produce compressed
air while the converter is ready for treatment of the compressed air.
If the integrated converter exceeds its operating temperature ("overtempera-
ture") the heating of the converter switches off automatically. This information
is transmitted to the compressor control system which blocks the compres-
sor's release for compressed air production and puts it back into the "opera-
tional availability standby mode".
Note!
Automatic switching of the compressor availability state when reaching the
switch-off pressure is effected irrespectively of the operating state of the con-
verter (as with compressors without integrated converter).
The compressor either switches into the operational availability standby
mode or back into the idle mode and stops producing compressed air.
Product description 2.5 Control devices
Controlled operation If the pressure has dropped below the switch-on pressure pmin the compressor
(frequency control) starts and operates in load operation.
Once the operation pressure ptarget has been exceeded the control is activated
and reduces the speed.
If the pressure has dropped below the operating pressure ptarget the control is
activated and increases the speed.
Upon reaching the switch-off pressure pmax the compressor switches to idling
operation.
The settings for pmin und pmax are effected by the parameterization of the BASIC/
FOCUS.
For the BASIC control the setting for ptarget is effected at the potentiometer R3
in the compressor switch cabinet.
For the FOCUS control the setting for ptarget is effected via parameterization of
the control.
Short operating times
Attention!
During short operating times, the compressor does not reach its operating
temperature. It operates below the dew point. The generated condensate
mixes with the oil. The lubricating ability of the oil is reduced. This leads to
damage to the air end and to the integrated converter (BLUEKAT series).
It is of utmost importance to consult BOGE, if you operate your system with
short operating times.
2.5 Control devices
Operating pressure The operating pressure transmitter (1) controls the operation of the compres-
transmitter sor within the set switching limits.
Switch-on pressure pmin

If the network pressure drops
to the set switch-on pressure
pmin, the compressor switches
on.
Switch-off pressure pmax
If the network pressure in-
creases to the switch-off
pressure pmax, the compres-
sor either switches off (inter-
mittent operation) or switches
to idling operation (continu-
ous operation).
Fig. 2.5: Operating pressure transmitter
Product description 2.6 Safety and monitoring devices
Proportional controller The proportional controller is an additional control device intervening in the
(option for S series) sequences of the intake regulator.
The intake regulator only opens as far as necessary to supply the current com-
pressed air requirement. Thus the compressor saves compression energy.
A compressor with proportional controller is able to supply its delivered quan-
tity variable between 0% and 100%. However, the energy consumption does
not reduce accordingly. Therefore, a control is only practical between 50% and
100% of the delivered quantity.
The proportional controller is factory set to a delivered quantity between 50%
and 100% of the compressor capacity.
The proportional controller closes when the desired delivered quantity has
dropped below 50% of the compressor capacity. The compressor then oper-
ates in idling operation (continuous operation) or switches off (intermittent
operation).
2.6 Safety and monitoring devices
General The safety devices guarantee a high degree of operational safety, in connec-
tion with the BOGE monitoring system.
When one of the safety devices responds, the control system reacts as fol-
lows:
The compressor is immediately switched off.
A flashing fault number in the left field of the display indicates the cause of
the fault.

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
limiting device the max. permissible final compression temperature has been reached. A
dropping below the minimum temperature prevents the compressor from start-
ing.
Switch off the compressor (OFF button). Fault is acknowledged.
Rectify the fault.
Switch on the compressor (ON-button).
Safety temperature The safety temperature limiter on the integrated converter (S 40-2 BLUEKAT
limiter on the integrated and S 50-2 BLUEKAT) serves to switch off the heating when the temperature
in the converter runs too high (limit value 250C). In such a case, the compres-
converter (BLUEKAT
sor's release for compressed air production is automatically blocked.
series)
The temperature inside the converter starts dropping. Both heating and com-
pressor do not automatically restart operation due to temperature failure.
Use converter temperature control to restart. Also see Converter failures
(BLUEKAT series) on page 53.
Caution!
Restart of compressor station only after consultation with your local BOGE
distribution partner or BOGE service personnel.
It is imperative to determine the cause of the failure prior to restarting the
compressor station.
Additional Monitoring Devices

Additional monitoring devices are located on the switch cabinet of the inte-
grated converter (S 40-2 BLUEKAT and S 50-2 BLUEKAT). These include a
temperature control unit with display serving to retrieve temperature informa-
tion on the converter. In addition, there are three indicator lights on the switch
cabinet serving to indicate the operating state of the converter:
Fig. 2.6: Switch cabinet with monitoring devices
1 Switch cabinet lock

2 Temperature control
3 Indicator lamp Operation (Betrieb), green
4 Indicator lamp Preheating (Aufheizen), yellow
5 Indicator lamp Alarm (Strung), red
The display of the temperature control unit allows you to recall the following
temperature information:
The actual value (top) and the target value (below) of the temperature
(in C) inside the converter are shown in the display as standard.
Pressing the green button once causes the container bed temperature
(in C) to be displayed.
Pressing the green button twice causes the current control mode to be dis-
played.
Pressing the green button three times causes the heating performance
(in %) to be displayed.
Pressing the green button four times causes the state of the self-optimiza-
tion to be displayed.
Pressing the green button five times causes the idle target value (in C) to
be displayed.
Pressing the green button again enables you to return to the standard dis-
play.
Pressing the reset button enables you to immediately return to the stand-
ard display.
Caution!
The settings of the temperature control are completely programmed at the
factory.
Any changes to the presettings for the temperature and other parameters
may only be carried out by BOGE or, after consultation with BOGE, by BOGE
authorized service personnel.
Any unauthorized changes to the parameters may cause damage to the com-
pressor station or result in reduction of the compressed air quality.
Lighting of the indicator lamps serves to indicate:
Indicator lamp Meaning
The temperature inside the converter is below the temperature

Preheating (Aufheizen) which is needed to release compressed air production. The
(yellow) indicator lamp does not indicate whether or not the heating is
properly functioning or in the process of heating.
As soon as the temperature inside the converter is reached for

Operation (Betrieb) release of compressed air production, the yellow indicator lamp
(green) extinguishes before the green lamp lights up. At the same time,
the compressor initializes compressed air production.
The indicator lamp Alarm (Strung) lights up in case of over-

Alarm (Strung) (red)
temperature inside the converter.
Table 2.1: Indicator lamps / Meanings
Safety valve Safety valve (1) on the com-

pressed air/oil vessel pre-
vents the maximum admissi-
ble pressure being exceeded.
Fig. 2.7: Safety valve

When the maximum pressure is exceeded (e.g. incorrect setting of the oper-
ating pressure switch), the entire delivery volume of the compressor is eject-
ed!
Monitoring the drive The drive motor is monitored by PTC resistors.

and fan motor The fan motor is monitored by overcurrent/overload release units.
Rotational direction The pressure switch checks the rotational direction of the drive motor each
monitoring (option) time the system starts up.
System pressure The system pressure build-up unit monitors the system pressure build-up
build-up (option) when the compressor starts up.
Product description 2.7 Water cooling
2.7 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.
Serial connection
Fig. 2.8: Serial connection
Parallel connection
Fig. 2.9: Parallel connection
1 Cooling water solenoid valve

The cooling water solenoid valve closed the cooling water supply when
the compressor switches off.
2 Cooling water stop valve
The compressor may be separated from the cooling water supply by
means of the stop valve (e.g. for maintenance or repair work).
3 Dirt trap (provided by customer)
The dirt trap protects the cooling unit against sedimenting.
Pore size: max. 0.6 mm
4 Oil cooling unit
5 Compressed air after-cooler
The water cooling units are designed for specific standard cooling water
quantities, temperatures and pressures (see "Technical data"). For indi-
vidually fluctuating values, they are designed according to the specified
order data.
Product description 2.8 Cooling water
2.8 Cooling water
Water connection The cooling water must have the following properties:
(for water cooling) Electrical conductivity > 50 S/cm at pH-value 7 9
Carbonate hardness (CaCO3) < 16 dH
Cooling water pressure max. 10.0 bar
min. 2.0 bar
Cooling water inlet temperature max. + 5 C
min. + 30 C
Max. cooling water quantity see "Technical data".
Cooling water quality The cooling units are fitted with nonferrous heat exchangers, as standard. To
avoid damage to these components and to guarantee a long term function, en-
sure that the substances contained in the cooling water used do not exceed
the following values.
Substances Symbol max. admissible concentration [mg/l]

Ammonia HNH3 2
Chloride < 70C Cl 100
Free chlorine Cl 5
Iron Fe 2
Free carbon dioxide CO2 20
Manganese Mn 1
Nitrate NO3 100
Oxygen O2 2
Silicon oxide SiO2 8
Sulphate SO4 60
Totally diluted substances TDS 600
Table 2.2: Maximum admissible concentration of the substances
Note!
If the specified limit values are exceeded, use cooling units made of other
materials.
Please consult BOGE service.
Attention!
If the cooling water data changes, the cooling units may have to be rede-
signed. Incorrectly designed cooling units may cause malfunctions and the
compressor to switch off!
Please consult BOGE.
Installation 3.1 Transport and storage
Part 3: Installation 3.1 Transport and storage
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 improper transport!
Attention!
The transport of the compressor may only be carried out by adequately in-
structed and authorized personnel!
The capacity of the lifting gear (lifting cart or forklift truck) must correspond at
least to that of the compressor / the system (see Technical Data)!
Mind the position of the mass centre prior to lifting the compressor! The posi-
tion of the mass centre is specified both in the attached dimensioned drawing
and on the packing of the compressor.
Any loose or pivoting parts are to be removed prior to lifting the unit.
The compressor is delivered filled with oil. Do not tilt during transport!
Transport possibilities Forklift truck or lifting cart transport
Ensure that the forks are underneath the

base frame of the compressor (see illustra-
tion).
Fig. 3.1: Transport with forklift truck
Installation 3.1 Transport and storage
Crane transport
Attention!
Do not subject the safety cladding to force during transport. Protect the com-
pressor using wooden spacers (see arrows in the following illustrations).
Remove the transport timbers.
Ensure that the forks are underneath the

base frame of the compressor (see illustra-
tion).
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.
Note!
In case of an intermediate storage please observe the specifications and di-
rections as to permissible environmental impacts (see chapter 3.2 Com-
pressor room: Installation conditions and application for compressed air re-
ceivers arranged below or separately).
In case of a careless storage we assume no liability for consequent dam-
ages!
In the event of an extended intermediate storage you should consult BOGE-
Service.
Please observe the directions for commissioning after an extended standstill
(see chapter 3.5 Commissioning).
Installation 3.2 Compressor room
3.2 Compressor room
Installation conditions
and application for
compressed air
receivers arranged
below or separately
Caution!
Protect compressed air receivers against damage through mechanical
effects (e.g. falling objects).
Operate the compressed air receiver and its equipment from a safe loca-
tion.
Adhere to safety areas and safety clearances.
Ensure that the compressed air receiver stands securely. It must not shift
or tilt due to external forces. This also includes the additional weight dur-
ing a pressure test!
The compressed air receiver must not be bolted to the base.
Ensure that the compressed air receiver is easily accessible from all
sides (for recurring tests). For the necessary operating and maintenance
areas have a look at the attached dimensioned drawings.
Ensure that the factory label is clearly visible.
Ensure that compressed air receivers are adequatly protected against
corrosion.
Only use the compressed air receiver for compressors operating with
cut-in and cut-out mode if the pressure fluctuation range amounts to
p 20% of the maximum operating pressure.
Installation surface A level industrial floor without foundation is adequate for the installation of the
compressor. No special fastening elements are required.
Attention!
Make sure that no external vibrations or shock are able to impact on the com-
pressor station (in particular with view to compressors of the BLUEKAT se-
ries with integrated converter).
Fire protection The following applies to rooms in which compressors with oil injection cooling
are to be installed:
Caution!
For compressors with motor ratings exceeding 40 kW and for compres-
sors of the BLUEKAT series, ensure that the compressor room is
equipped with special fire protection.
Install compressors with motor ratings exceeding 100 kW in a separate
fire protected room.
Requirements of fire protected compressor rooms:

Walls, ceilings, floor and doors must be designed in fire protection class
F30 or higher.
Flammable liquids must never be stored in the compressor room.
The floor around the compressor must be made of non-flammable mate-
rial.
Leaking oil must not spread out over the floor.
No inflammable materials must be located within a radius of at least 3 me-
tres around the compressor.
No inflammable machine parts, such as cable ducts, may run overhead of
the compressor.
Sound protection Only install compressors in workrooms if the sound pressure level of their
measuring surfaces does not exceed 85 dB (A).
Admissible ambient The compressor room must be clean, dry, cool and free of dust.
temperatures
Admissible ambient temperatures (see also Technical data).
Maximum ambient temperature (for air cooling): + 40C / + 45C
Maximum ambient temperature (S 40-2 / 50-2 BLUEKAT): + 40C
Minimum ambient temperature: + 5C
Attention!
Nonobservance of the admissible ambient temperature may lead to the fol-
lowing problems:
The compressor will switch off when the admissible final compression
temperature is exceeded or gone below.
Pipe lines and valves will freeze up at low temperatures.
Damage due to reduced lubricating ability of the compressor oil.
Measures to be taken to ensure that admissible ambient temperatures

are observed:
Avoid any pipe lines or units radiating heat in the vicinity of the compres-
sor, or insulate them well.
Never install the compressor in the cooling air flow of other machines.
Provide the supply air openings with adjustable louvres to ensure that the
minimum temperature is not gone below in winter.
Use of anti-freeze function (only in mode: Ready for operation)
Frost protection The compressor must be installed frost-protected. The BOGE anti-freeze de-
vice is a standard feature. It protects the safety devices from freezing up at
ambient temperatures up to 10C.
Ventilation If the following instructions are not observed, the admissible final com-
pression temperature may be exceeded. In this case, the compressor
will switch off automatically.
Caution!
Arrange the compressor intake openings or ducts such, that dangerous ad-
mixtures (e.g. explosive or chemically unstable materials) cannot be drawn
in.
Ventilation openings (free-standing installation)

Arrange supply air openings close to the floor.
Arrange exhaust air openings in the ceiling or at the top of the wall.
The required cross sections for the supply openings (as well as for the
flaps and weather protection grids) are indicated in the table.
Supply and exhaust air ducts

Ensure that the flow rates in the ducts do not exceed 4 m/s.
Never position cooling air ducts directly on the compressor. Always use a
compensator to avoid distortion and the transfer of vibrations.
Ventilators
Ensure that the heated exhaust air is not taken in again. If necessary, the
heated air must be extracted by ventilators.
To ensure perfect cooling even at higher temperatures in the summer, the ven-
tilators must be designed as follows:
The ventilator capacity must be rated approx. 10 15% higher than the
sum of the cooling air quantity required for all machines operated in the
room (VDMA Code of Practice sheet 4363 Ventilation of compressor
rooms).
For free-standing installation, the cooling air requirement specified in the
table corresponds to the required ventilator capacity.
Supply air filter

Equip the compressor with supply air filter mats if the compressor room is
contaminated with dust (option).
Cooling air requirement Please refer to the following table for the cooling air requirement and size of
the supply air openings for your compressor. Ensure that flaps and weather
protection grids have the necessary free cross section. We generally recom-
mend contacting a specialist company for performing the duct construction
work and planning.
Type Drive Air cooling 1)

Water cooling 2)
rating
Cooling air Necessary Cooling air Necessary Cooling air Necessary
require- inlet open- require- free duct require- inlet open-
ment for ing for free ment for cross ment for ing for free
free stand- standing installation section free stand- standing
ing unit unit with ducting ing unit unit
[kW] [m/h] [m] [m/h] [m] [m/h] [m]
S 31-2 22 9.000 1,10 4.500 0,35 2.000 0,25
S 40-2...SD 40-2 30 11.000 1,35 5.500 0,42 2.000 0,25
S 50-2...SD 50-2 37 13.000 1,60 6.500 0,48 2.000 0,25
S 60-2...SD 60-2 45 13.000 1,60 6.500 0,48 2.000 0,25
S 61-2...SD 61-2 45 13.000 1,60 6.500 0,48 2.000 0,25
S 75-2...SD 75-2 55 16.000 2,00 8.000 0,59 2.000 0,25
S 90-2...SD 90-2 65 17.200 2,15 8.600 0,64 2.000 0,25
S 100-2...SD 100-2 75 18.400 2,30 9.200 0,68 2.000 0,25
S 101 75 20.000 2,50 10.000 0,74 3.400 0,45
S 125 90 32.000 4,00 16.000 1,18 3.400 0,45
S 150 / S 151 110 32.000 4,00 16.000 1,18 3.400 0,45
S 180 132 48.800 6,10 24.400 1,74 10.000 1,25
S 220 160 48.800 6,10 24.400 2,11 10.000 1,25
S 271 200 56.000 7,00 28.000 2,50 10.000 1,25
S 341 250 64.000 8,30 33.000 2,50 10.000 1,25
SF 60-2...SDF 60-2 45 13.000 1,60 6.500 0,48 2.000 0,25
SF 100-2...SDF 100-2 75 18.400 2,30 9.200 0,68 2.000 0,25
SF 150...SDF 150 110 32.000 4,00 16.000 1,51 3.400 0,45
S 40-2 BLUEKAT 30 11.000 1,35 5.500 0,42 2.000 0,25
S 50-2 BLUEKAT 37 13.000 1,60 6.500 0,48 2.000 0,25
1)
For the cooling air requirements the basis is a 4C temperature difference between room and outside temperature.
2)
Only with S 31-2 S 341 and SF 60-2 SF 150
Table 3.1: Cooling air requirement, necessary cross sections for openings and ducts.
Ventilation possibilities
Fig. 3.3: Ventilation possibilities
A Supply and exhaust air openings in the outside walls (free-standing

installation)
B Supported by exhaust air ventilator
C Exhaust air duct into the open
D Exhaust air duct with recirculation flap
Hot exhaust air is mixed with the cold ambient air, as required. Thus pre-
venting the plant from freezing up at temperatures below freezing.
E Using the hot exhaust air for heating
In the winter, the hot exhaust air is used for room heating. In summer it is
directed into the open.
Installation 3.3 Installation
Condensate disposal The air taken in contains water in form of vapour, which turns into condensa-
tion during compression.
Attention!
The condensate contains oil. Never lead it into the public sewage system
without prior treatment (Exception: The built-up condensate of compressors
of the BLUEKAT series does not contain any residual oil. The condensate is
to be treated as industrial water).
Strictly observe the effluent disposal laws of your local authorities.
Oil/water separator (not for compressors of the BLUEKAT series)
The BOGE-oil/water separator separates the oil from the condensate. The
cleaned water may be fed directly into the public sewage system.
The oil is collected in a separate container. Dispose of the oil according to
environmental regulations.
If, due to special operating conditions, the oil should emulsify, use an emul-
sion cracking plant.
3.3 Installation
General BOGE compressor units are supplied ready for connection. Only the work de-
scribed in the following paragraphs needs to be carried out during the installa-
tion.
Caution!
Any installation work may only be carried out by appropriately trained per-
sons or specialists (BOGE service personnel).
Lay out all energy supply lines in a trip-proof and barrier-free manner so that
potential accidents can be avoided!
Prior to delivery, each compressor is subjected to a trail run at the factory. It
is carefully tested and set. However, possible transport damage cannot be
excluded.
Please inspect the compressor immediately after delivery and direct dam-
age claims to the last haulier even when the packing is not damaged! To
safeguard claims against the haulier we recommend leaving the machine,
devices and packing material in the same condition as they were in when
the damage was detected.
Prior to commissioning, check the compressor for external damage.
Observe the compressor very closely during commissioning and the fol-
lowing trial run.
If malfunctions occur, switch off the compressor immediately and inform
the BOGE-Service.
Checking the delivery The delivery scope depends on your order.

scope 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:
Keys
Electric circuit diagram (in the compartment of the switch cabinet)
List of electrical equipment (in the compartment of the switch cabinet)
Spare parts list
Installing the Remove the packing material on and in the compressor.

compressor Install compressor and align horizontally. The compressor must stand
firmly on the ground on all feet.
Connecting the Connect the compressor to the compressed air network or a compressed
compressor to the air receiver.
For this, use a BOGE high pressure hose.
compressed air network
Note!
Do not install a check valve in the pressure line.
The compressor is already equipped with a check valve.
Connecting the cooling

water (option)

Risk of injury due to pressurized water when connecting the cooling water
system!
Close external water mains prior to connection!
The connection may only be carried out by authorized qualified personnel!
The pipework for the cooling water circuit in the compressor is completely
installed at the factory.
Only the following work must be performed during installation:

Check, whether the water supply has the required data and whether the
cooling water quality is adequate (see "Cooling water quality").
Connect the cooling water supply and discharge line to the water supply
(cf. dimensioned drawing).
The following component parts must be provided by the customer for cooling
water installation:
Dirt traps
The dirt trap at the cooling water inlet protects the cooling units against
sediment collecting. Pore width: max. 0.6 mm
Expansion vessel and safety valve
Attention!
If the stop valves in the supply and discharge lines are simultaneously closed
in a closed cooling system, an enclosed room will result. If the water heats
up in this room, it will expand and the pressure will increase.
Install an expansion vessel and a safety valve to prevent damage to the
cooling units.
Removing the transport The frame of the drive unit is bolted to the basic frame for transport.
securing bolts
Remove the four red marked
screws (1) and (2) (two of
each on the longitudinal side)
together with the space col-
lars.
Ensure that the forks are un-
derneath the base frame of
the compressor (see illustra-
tion).
Fig. 3.4: Removing the transport securing bolts

(S 60 air-cooled shown on this illustration)
Activating the belt The V-belts are slackened for transport.

tensioning device Activate the GM belt tensioning device prior to commissioning by lowering the
motor plate.
Secure bolt head (1) against

turning by means of a span-
ner (NW 27).
Turn locknut (2) upwards by
turning counterclockwise until
it locks against the bolt head.
The belt tensioning device is
activated. It automatically
sets the correct V-belt tension
in every operating mode.
Fig. 3.5: Activating the belt tension.
Installation 3.4 Electrical connection
Checking the oil level BOGE compressors are supplied with a complete oil filling.
Prior to commissioning/start up, check the oil level as described in chapter
"Maintenance".
3.4 Electrical connection
Caution: High voltage!

Ensure that work on the electrical equipment of the compressor is only car-
ried out by authorized electricians.
When connecting to the power supply, observe the valid VDE, DIN and EVU
regulations or the local safety regulations.
Also observe the regulations of your local power supply company regarding
the load rating of your power supply.
Power disconnecting device

Each compressor plant has to be equipped with a power disconnecting device
according to DIN EN 60204-1:2007.
Rated voltage
The data of your mains (operating voltage, control voltage, type of current, fre-
quency, ...) must coincide with the data on the type plate on the switch cabinet.
In the event of deviations, please contact the BOGE service or your supplier.
Please see "Technical Data" for layout of mains fuse.
Connecting the leads

Check to ensure that all terminals in the switch cabinet are firmly tight-
ened. If necessary, retighten the screw connections.
Guide the lead cable through the PG screw connection.
Connect the leads L1, L2, L3, N, Pe (PEN) firmly to the power supply ter-
minal. A clockwise rotational field must be created.
Retighten the electrical connections after the first 50 operating hours.
Note!
As for the screw compressors S 40-2 BLUEKAT and S 50-2 BLUEKAT the
power supply to the integrated converter is enabled by means of the electri-
cal connection of the compressor.
Installation 3.4 Electrical connection
Drive with frequency converter

According to operational conditions electrical drive systems with frequency
converter may have an earth leakage current above 10 mA.
Therefore the required precautions according to EN 60204-1:2007 and EN
50178:1998 have to be applied as soon as the compressor is electrically con-
nected.
A permanently installed connection is required.
One or several of the following qualifications for the protective-conductor
system have to be fulfilled:
1. The protective conductor must have a minimum cross section of 10 mm2
Cu along its total length.
2. If the protective conductor has a minimum cross section of less than
10 mm2 Cu hat, a second conductor with at least the same cross section
has to be provided up to the point from where the protective conductor
has a minimum cross section of more than 10 mm2.
3. Automatic interruption of the supply if the continuity of the protective con-
ductor is lost.
Please observe any additional national rules and regulations.

Prior to any work on the compressor:
Press Emergency Stop button, open mains disconnection device and
secure against unintentional switch on by means of a padlock.
Check to ensure that all conducting machine parts are voltage free.
Depressurize all areas under pressure.
Allow converter to cool off (only screw compressors S 40-2 BLUEKAT
and S 50-2 BLUEKAT).
Never omit a single safety step! Otherwise, you will risk injuries due to restart-
ing, electric shock or self-releasing parts.
Caution!
With an activated automatic restart (Auto-Restart) the compressor may re-
start automatically after a voltage failure.
Prerequisite: The net pressure is lower than the set switch-on pressure.
Installation 3.5 Commissioning
3.5 Commissioning
Note!
We recommend the drawing up of a commissioning certificate in which the
test results during the commissioning process can be listed up.

The commissioning may only be carried out by experienced and authorized
qualified personnel!
Always wear protective gloves when working on the compressor to avoid
bruising of fingers or hands while opening or closing components!
Check installation
requirements
Attention!
Make sure that the compressor is installed according to the installation re-
quirements!
Prior to starting the compressor for the first time, check if the transport secur-
ing device was duly removed and the GM the belt tensioning device was acti-
vated (see chapter 3.3 Installation)!
List up the test results in the commissioning certificate.
Checking the rotational

direction of drive and
fan motor
Attention!
Always check the rotational direction of the drive and fan motor prior to com-
missioning/initial start up.
Even brief operation in the wrong direction of rotation (more than approx.
5 seconds) may cause total destruction of the air end!
Caution!
Ensure that the rotational direction coincides with the rotational direction ar-
row on the air end.
Close mains disconnecting device.
Switch the compressor on and immediately off again to check the rota-
tional direction.
Changing the rotational direction

Emergency stop switch/button, open mains disconnection device and secure
against unintentional switch on by means of a padlock.
Allow converter to cool off (only screw compressors S 40-2 BLUEKAT and
S 50-2 BLUEKAT).
Interchange two phases (L1, L2 or L3) in the power cable.
Check compressed air

outlet for tightness

Work on the compressed air system may only be carried out by experienced
and authorized qualified personnel!
Always wear protective clothing and goggles!
Immediately after having switched on the machine the connection of the com-
pressed air outlet must be checked for tightness!
Make sure to observe an appropriate safety distance during the inspection!
Close mains disconnecting device.

To conduct the inspection switch on the compressor and check the com-
pressed air outlet for tightness.
Switch off compressor.

Emergency stop switch/button, open mains disconnection device and secure
S 50-2 BLUEKAT).
If required: have any leakages remedied by experienced expert person-
nel.
Opening the stop valve Open ball valve on the compressor delivery.
For water cooling: Open stop valve at the water supply.
Checking for leaks

In case of leakages in the cooling water and/or oil circuit there is a risk of slip-
ping or falling due to cooling water or oil spills!
Have all connections of the oil or water cooling circuit checked for leakages
by authorized qualified personnel!
During the inspection slip-resistant safety shoes and protective clothing are
obligatory!
Undertake the following to prevent leaks:

Check screw connection of the lines and retighten, if necessary.
Check to ensure that the oil filter and oil separator are hand tight seated.
Conduct trail run Close mains disconnecting device.

Use ON button on compressor control to switch on compressor. Compres-
sor starts operating.
When the factory-set switch-off pressure is reached, the compressor cuts
off automatically.
Check network pressure on control display.
If necessary, reset operating pressure (pressure target value).
The compressor is ready for operation.
For control function see control display.
Switch off compressor after several hours of trial operation under max.
work load.
For S 40-2 BLUEKAT and S 50-2 BLUEKAT

Close power disconnecting device.
Use ON button on compressor control to switch on compressor.
The integrated converter starts preheating. The yellow indicator lamp Pre-
heating Aufheizen on the switch cabinet of the converter lights up. The
compressor remains in the "operational availability standby mode".
After approx. 15 to 45 minutes (depending on the residual heat inside the
converter and the ambient temperature) the converter reaches its operat-
ing temperature / release temperature.
The yellow indicator lamps extinguishes and the green indicator lamp ("op-
eration (Betrieb)") lights up. As soon as the switch-on pressure is achieved,
the control system allows the compressor to switch to load operation. The
compressor will now start to produce compressed air while the converter
is ready for treatment of the compressed air.
Switch off compressor after several hours of trial operation under max.
work load.
Note!
When using the compressor control to switch off the compressor, the heating
of the converter remains in operation. This serves to avoid prolonged pre-
heating phases before the next load operation.
Commissioning If an extended stoppage is scheduled, you should contact BOGE-Service be-

following extended forehand.
stoppages Following an extended stoppage of more than 2 months, fill a small amount of
oil in the suction controller prior to starting the compressor!
Attention!
Only fill the suction controller with the grade of oil used to operate the com-
pressor.
Never mix different oil grades and brands.

Press Emergency Stop button, open mains disconnection device and secure
Unscrew plug from the suc-

tion controller (1).
Fig. 3.6: Suction controller
The following compressor oil quantities must be filled into the suction control-
ler:
Model Compressor oil quantity [l]

S 31-2...S 60-2, SF 60-2 + BLUEKAT models approx. 0.5
S 61-2...S 100-2, SF 100-2 approx. 2.5
S 101...S 150, SF 150 approx. 5,0
S 151...S 220 approx. 8.0
S 271...S 341 approx. 10.0
Table 3.2: Compressor oil quantities
Screw in plug again.
Turn compressor stage at the pulley by hand 5- to 10 times to spread the

oil evenly.
Note!
As for screw compressors of the BLUEKAT series please note that, in the
event of prolonged operational shutdowns for several days during which the
compressor station is disconnected from the power supply, restarting the
compressor requires a preheating phase of 15 to 45 minutes since the con-
verter has completely cooled down.
Refrigeration Before commissioning the refrigeration compressed air dryer read attached
compressed air dryer operating instructions.

Observe all safety notes specified in the attached operating instructions when
working with refrigerants!
Installation 3.6 Dismantling
3.6 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!
Make also sure to observe all information in the attached operation instruc-
tions as to a safe dismantling of the refrigeration compressed air dryer and a
secure disposal of the refrigerant!

All work on the electrical installation may only be carried out by authorized
and skilled electricians!
Prior to starting the work the power cable to the switch cabinet must be dis-
connected from the mains and secured against unintentional switching on!
The converter needs to entirely cool down prior to restarting operation (only
screw compressors S 40-2 BLUEKAT and S 50-2 BLUEKAT).
Faults 4.1 General
Part 4: Faults 4.1 General
The tables on the following pages give information on the possible causes of
operating faults and measures for their rectification (please also refer to oper-
ating instructions of the compressor control).
Caution!
Ensure that any work required to rectify faults is only carried out by qualified
personnel or specialists.
Ensure that components which have a safety function be only set, repaired
or exchanged by BOGE service personnel. This applies in particular to any
work carried out on the integrated converter of screw compressors of the
BLUEKAT series.
Please contact BOGE-Service at the following telephone number, if you have
any questions.
Telephone: +49 5206 601-140
4.2 General faults
Fault Possible cause Rectification
No quantity delivered, System components in the com- Check oil and compressed air lines inside the compressor;
no pressure build-up, pressor are leaking tighten and/or reseal screw connections, if necessary
max. pressure 0.5 bar
Minimum pressure valve is Close ball valve and check whether pressure builds up; if so, open
defective ball valve again immediately; replace minimum pressure valve
Electromagnetic venting valve Check solenoid valve and replace, if necessary

does not close
Suction controller does not open Suction controller or solenoid valve is defective; check and replace,
if necessary
V-belts are torn Fit new V-belts
Compressor system does No electric power to compressor Check electrical connection

not start up
Fuses are defective Check the mains and control fuses, replace if necessary
Machine has not vented perfectly Check venting valve and replace, if necessary
Voltage fluctuations in the elec- Ensure constant voltage in accordance with IEC 38
trical mains power
Compressor oil is very viscous Heat up the compressor system (additional heater available as an
due to low ambient temperature option)
Converter failure SeeConverter failures (BLUEKAT series) on page 53.
Faults 4.2 General faults
Oil in suction filter Minimum pressure non-return Check the minimum pressure check valve and replace, if necessary
valve is leaking
Suction controller is leaking Check the suction controller and replace, if necessary
Cut-out performed by emer- Cut-out normally via O-key

gency-off switch
Excessive oil Drain line is blocked Dismantle and clean drain line
consumption
Defective oil separator element Check oil separator and replace, if necessary
Excessive oil filling Drain off oil
Safety valve blows Operating pressure target value Set operating pressure to maximum permissible pressure of the
maladjusted screw compressor
Defective safety valve Replace safety valve
System pressure does Venting valve does not open Check venting valve and replace, if necessary
not decrease when
switching off Check valve is leaking Examine check valve and replace, if necessary
Faults 4.3 Converter failures (BLUEKAT series)
4.3 Converter failures (BLUEKAT series)
Converter failure Incorrect converter temperature Settings of converter temperature control to be checked by BOGE
compressor does not settings service personnel and to be reparametrized if necessary
start
No temperature build-up inside Heating of converter to be checked by BOGE service personnel and
converter to be repaired / replaced if necessary
Converter defect Converter to be checked by BOGE service personnel to be replaced

if necessary
Converter failure com- Temperature inside converter Converter / converter temperature control / heating to be checked by
pressor unexpectedly dis- too high ("overtemperature") BOGE service personnel and to be repaired / replaced if necessary
continues compressed air
production and fails to Temperature drop inside con- Converter / heating to be checked by BOGE service personnel and
automatically restart verter and prolonged undertem- to be repaired / replaced if necessary
perature
Converter failure time Temperature build-up inside Heating of converter to be checked by BOGE service personnel and
period until release for converter insufficient to be repaired / replaced if necessary
compressed air produc-
tion excessively long
Optional features 5.1 BOGE-Duotherm BPT
Part 5: Optional features 5.1 BOGE-Duotherm BPT
Function The heat recovery system BOGE-Duotherm BPT utilizes the heat energy re-
leased during compression to produce warm water free of charge (e.g. for pro-
duction systems or to supply a heater).
The plate heat exchanger is connected in the main stream of the hot oil. It com-
prises of stainless steel plates which are soldered together. These form two
separate duct systems. Compressor oil and water run through these ducts with
opposing flow directions. The hot oil transfers its heat to the colder water via
the plates.
Installation As a rule, the plate heat exchanger is installed into the compressor at the fac-
tory and comes equipped with all necessary pipework. Only the following work
is required during installation:
Connect the supply and discharge water lines to the pipeline mains. Route
the pipelines to prevent transmission of stresses/tension and vibrations to
the heat exchanger.
Provide venting and draining facilities.
The customer must provide the following components for installation:

Stop valves
Stop valves in the water supply and discharge lines enable simple removal
of the heat exchanger.
Expansion vessel and safety valve.
Attention!
If the stop valves in the water supply and discharge lines are closed simul-
taneously, an enclosed space is created. If the water in this space is heated,
it expands and the pressure increases.
Therefore, an expansion vessel and safety valve must be installed to avoid
damage to the plate heat exchanger.
Dirt trap (pore size: max. 0.6 mm)
The dirt trap at the water inlet protects the plate heat exchanger against
dirt deposits in the event of a high degree of water contamination.
Flushing connections
The flushing connections serve to clean the plate heat exchanger.
Separate installation
The plate heat exchanger may also be separately installed or retrofitted by the
customer.
Normally, the plate heat exchanger is held in place by the pipelines. However,
when installing larger types, the customer may have to provide a bracket.
Commissioning Proceed as follows during commissioning:

Check oil level in the oil circuit. If necessary, top up oil.
Slowly open the stop valves in the water supply and discharge line.
Avoid pressure hammers!
Vent the pipelines.
Optional features 5.1 BOGE-Duotherm BPT
Maintenance Lime, oxides as well as grease or oil will deposit in the ducts of the plate heat
exchanger during operation.
Regular cleaning will prevent thick deposits clogging individual ducts of the
plate heat exchanger.
Cleaning intervals
Excessively soiled and limy water: 6 months
Moderately soiled water, surface water: 1 year
Lightly soiled water: 3 years
Recommended cleaning agents

Grease or oil deposits: Paraffin
Oxide or lime deposits: formic acid, acetic acid or citric acid
Attention!
Always observe the instructions of the cleaning agent manufacturer!
Cleaning methods
Flushing:
First close all stop valves in the supply lines.
Close all stop valves in the discharge lines.
Wait until the plate heat exchanger has cooled down.
Open the flushing connections and drain the plate heat exchanger.
Flush the plate heat exchangers.
For this purpose, pump one of the above mentioned cleaning agents
through the plate heat exchangers for an extended period of time.
After flushing, rinse the plate heat exchanger thoroughly with water
(e.g. using a high pressure hose).
Enhance the cleaning action by the following measures:

Use a larger mass flow rate than for standard operation.
Flush the cleaning agent through the plate heat exchanger in opposite
direction to standard operation.
Allow to react (tenacious soiling):

Dismantle plate heat exchanger.
Fill plate heat exchanger with one of the above mentioned cleaning
agents.
Allow the cleaning agent to act for at least six hours. Point the connection
upward to allow gases to escape.
After cleaning, rinse the plate heat exchanger thoroughly with water
(e.g. using a high pressure hose).
Note!
If the cleaning measures specified above are not sufficient, you should have
the exchanger cleaned by a service company. Boge service will recommend
contracting firms on request.
Optional features 5.2 BOGE-Duotherm BSW
5.2 BOGE-Duotherm BSW
Function The safety heat exchanger BOGE Duotherm Plus BSW is approved for drink-
ing water. It is connected in the main stream of the hot compressor oil. The
additional safety feature in comparison to the plate heat exchanger is provided
through the following measures:
Separation of the circuits
For this heat exchanger, the oil and water circuits are completely sepa-
rated by a barrier liquid.
The barrier liquid transmits the heat. In the event of heat exchanger dam-
age it prevents oil and water from mixing. Thus, contamination of the drink-
ing water is excluded.
Pressure monitor
A pressure monitor responds immediately to a pipe rupture within the sys-
tem, emitting a pulse which can be individually processed (e.g. alarm,
switching off the system).
Note!
Set the pressure to a value at least 20% lower than the minimum pressure of
the media used.
Operating conditions
Minimum water pressure: 0.5 bar
Maximum water pressure: 16 bar
Maximum oil pressure: 16 bar
Maximum pressure of the barrier liquid: 10 bar
Maximum temperature (oil and water): 100 C
Note!
Exceeding the maximum temperature will lead to malfunctions. A fault alarm
is triggered.
Commissioning Proceed as follows during commissioning:

Check the oil level in the oil circuit.
Slowly open the valves on the water side.
Prevent pressure hammers!
Vent the pipelines.
Any residual air contained in the heat exchanger will be carried along by
the respective medium and escapes via the system.
Optional features 5.2 BOGE-Duotherm BSW
Maintenance The safety circuit including pressure monitor and compensation vessel forms
an enclosed, maintenance-free system.
Attention!
Do not open the system under any circumstances.
Opening the system will put the operation and safety of the heat exchanger
at risk!
If barrier liquid escapes due to damage, send the heat exchanger to BOGE
for repair.
Maintenance 6.1 Safety instructions
Part 6: Maintenance 6.1 Safety instructions
Caution!
Ensure that maintenance work is only carried out by specialists or appropri-
ately trained person.
Prior to starting any maintenance work, always stop the compressor as
described in these operating instructions before removing any safety
cladding or safety devices. Refit the safety cladding or safety devices
immediately upon completion of the maintenance work.
Heavy components may only be lifted up by various persons in due con-
sideration of the local industrial safety regulations.
Only use original spare parts, compressor oils and operating materials
released by BOGE for the maintenance work.
With an activated automatic restart (Auto-Restart) the compressor may
restart automatically after a voltage failure.
Prerequisite: The net pressure is lower than the set switch-on pressure.
Maintenance 6.1 Safety instructions

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

1. Switch off the compressor using the OFF button.
2. Press Emergency Stop button.
3. Open mains disconnection device and secure against unintentional
switch on by means of a padlock.
4. Fix a warning label to the control and fill in the name of the person re-
sponsible who is authorized to switch on the maschine again.
5. Check to ensure that all machine elements are definitely currentless.
6. Prior to starting work let cool down all hot components of the compressor
to 50C.
7. Allow converter to cool off for several hours (only screw compressors
S 40-2 BLUEKAT and S 50-2 BLUEKAT).
8. Separate the compressor from the compressed air network by closing
the ball valve at the compressed air outlet.
9. Vent the compressor.
To this effect open the safety valve on the combined compressed air-oil
receiver as follows:
Turn the knurled nut counterclockwise until you can feel a resilient
resistance.
Turn the knurled nut a little further.
Any possibly existing air will escape.
The system pressure gauge will indicate a pressure of 0 bar.
Once the residual air has completely escaped from the system, firmly
retighten the knurled nut.
10. Remove all safety cladding necessary to perform the maintenance work.
Once the maintenance work has been concluded:

11. Reattach all removed safety cladding.
12. Open the ball valve at the compressed air outlet.
13. Prior to switching on again, check whether anyone else is working on the
compressor.
14. Remove warning sign not until then and release mains disconnecting
device.
15. Unlock Emergency Stop button.
Maintenance 6.2 General
6.2 General
Maintenance through Have BOGE service check your compressor every 3,000 operating hours or
BOGE customer service annually.
Note!
Maintenance agreement!
Enter into a maintenance agreement with BOGE.
BOGE service will carry out the proper maintenance on your compressor at
regular intervals. This guarantees maximum safety and realiability of your
compressed air supply.
Review of regular S 31-2...S 341

maintenance work
Fig. 6.1: Maintenance works S 31-2...S 341
1 Check/adjust pressure
2 Check suction filter
Clean filter and cartridge
Change filter cartridge
3 Change oil filter
4 Clean compressed air/oil cooler externally
5 Top up oil in the suction controller after an extended down time
6 Change oil separator
7 Check oil level

Top up oil
8 Change oil
9 Check V-belts
10 (Lubricate motor bearings)
11 Change supply air filter (option)
SD 40-2...SD 150
Fig. 6.2: Additional maintenance works SD 40-2...SD 150
1 Replace compressed air filter with differential pressure and filter element
(see separate operating instructions)
2 Compressed air refrigeration dryer (see separate operating instructions)
Maintenance work on compressor: S 40-2 / S 50-2 (BLUEKAT)
Fig. 6.3: Maintenance works S 40-2 BLUEKAT / S 50-2 BLUEKAT
1 Check / adjust pressure

2 Check suction filter
Clean filter and cartridge
Change filter cartridge
3 Clean compressed air/oil cooler externally
4 Change oil filter
5 Top up oil in the suction controller after an extended down time
6 Change oil separator
7 Check oil level
Top up oil
8 Change oil
9 Check V-belt
10 (Lubricate motor bearings)
11 Change supply air filter (option)
Maintenance work on converter: S 40-2 / S 50-2 (BLUEKAT)
Attention!
Maintenance and repair work on integrated converter of the S 40-2 BLUE-
KAT and S 50-2 BLUEKAT series may be carried out by specially trained
BOGE service personnel only.
Non-observance may cause physical injuries and damage to the compressor
station.
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 any maintenance work in the table on the last page. This will facil-
itate trouble shooting for BOGE service.
Attention!
Check monthly if all screw connections on the compressor are fully tight-
ened.
Oil change: Please change oil and replace oil filter and nozzle with dirt catch
after the first 500 operating hours (nozzle with dirt catch only through to
S 100-2 / SD 100-2, SF 100-2 / SDF 100-2 + BLUEKAT series)!
Maintenance work Maintenance intervals in operating hours 1) Page

weeky, 1,000 1,500 3,000 9,000
monthly annually annually annually every
2 years
General maintenance work
Check final compression temperature
w Control
(target value: 70...100C)
Check compressor for leaks X
Check system relief at system pressure display
w Control
(target value 0 1.5 bar)
Check function of emergency stop button m Control
Check and if necessary change supply air filter (option) w 69
Clean oil cooler X 82
Check if electrical connections are tightened X
Air circuit
Check and if necessary clean suction filter m 68
Change suction filter cartridge X 69
Replace suction controller (wearing parts set) X
Check / adjust operating pressure X Control
Replace minimum pressure valve (wearing parts set) X
Replace solenoid valve X
Check safety valve X 84
Oil circuit
Check oil level and top up as required 2) X 74
Replace oil regulator (wearing parts set) 2) X
Replace nozzle with dirt catch
(only through to S 100-2 / SD 100-2, SF 100-2 / SDF 100-2 X
+ BLUEKAT series)
Change oil separator 2) X 77
Change oil filter 2) X 76
Change oil 2)
X 79
Drive
Check / change V-belt X X 72
Lubricate drive motor bearings for details please see nameplate or enclosed operating instructions for drive
motor from 45 kW and up
Replace grease in motor bearings Depending on mains frequency: 50 Hz 10.000 operating hours
60 Hz 8.000 operating hours
1)
If the compressor is not often used, undertake the maintenance according to the specified intervals (weekly/monthly/annually) depending on the
number of operating hours.
2)
The specified intervals only apply when BOGE compressor oil Syprem 8000 S is used! The service life may differ depending on the ambient tempera-
ture. In this case have the oil analyzed by your BOGE service!
Table 6.1: Maintenance intervals
Converter maintenance intervals S 40-2 / S 50-2 (BLUEKAT)
Maintenance interval Maintenance work
Annually (BOGE service personnel) Check electric cable connection for tight fit and connection
Check parameter settings on control
Visual check of converter for damage or corrosion
Complete functional check
Replacement of inserts in VS module and particle filter after inspection and according to
manufacturer specifications (if available)
After 20,000 operating hours, Air quality check

or 3 years at the very latest
(BOGE service personnel)
After 5 years Replacement of electrical component parts (electrical kit)

(BOGE service personnel)
Converter replacement
Note!
In case of converter replacement you are free to either return the old/used
converter to BOGE or to dispose of it as scrap metal.
General information
concerning the
lubricants used

Oil presents a potential danger to health and environment due to their addi-
tives.
Avoid contact with skin and eyes.
Wear protective gloves made of resistant synthetic material.
Wash yourself thoroughly after contact with oils.
Do not inhale the fumes or mist.
Protect your environment.
Ensure that no oil is spilt.
Fire, naked flames and smoking is strictly prohibited when handling oil.
We recommend using only oil according to the following specification:

Viscosity range of 55 mm/s at 40C.
Minimum viscosity at 100C of 8 mm/s.
Maximum viscosity at 0C of 1,000 mm/s.
Comply to FZG test according to DIN 51 354 with failure load stage 10.
(Test Method A/8,3/90 10).
Excellent oxidation stability: Meets requirements of Pneurop oxidation test.
Antifoam additives.
Additives to prevent residue formation.
Compatibility with all used sealing materials like Neoprene, FPM, PTFE,
FKM (Viton) and acrylic and epoxy resin paints.
Flash point > 230C.
Additives for excellent demulsifying properties.
Additives for corrosion protection of metallic surfaces.
Excellent oxidation stability: Rotating bomb oxidation Test
(ASTM D 2272) higher than 2,400 minutes.
Meets VDL requirements DIN 51 506 for lube oils (including Pneurop test).
Or you use BOGE compressor oil Syprem 8000 S.The stated mainte-
nance intervals refer to the use of Syprem 8000 S only.
Syprem 8000 S can be purchased from BOGE retailers.
Never mix different oil types and brands. The additives may be incompat-
ible. It may lead to foam formation, premature aging or loss of lubricating
ability.
Disposal of used
operating material
Attention!
The handling and disposal of mineral oils is subject to legal regulations. It is
an offense not to ensure correct and safe disposal of old oil!
Please instruct one of the known service companies to dispose of used oper-
ating materials or deliver them to an authorized disposal point.
Observe the following points when disposing of old oil:
Never mix the oil with other material or liquids.
Used oil filters and oil separator cartridges require special waste treat-
ment and must be kept separate from normal waste!
Maintenance 6.3 Regular maintenance work
Pressure hoses
Caution!
Risk of injury and damage to compressor due to obsolete pressure hoses!
Never use pressure hoses beyond the prescribed service life!
Check hoses and connections regularly for leakages! Check the service life
of the hoses and replace them in due time!
As replacement only use original spare parts released by BOGE!
Used pressure hoses are not permitted as a replacement!
Spare and wearing parts
Caution!
Only use original spare parts, compressor oils and operating materials re-
leased by BOGE for repair and maintenance work.
BOGE is not liable for any damage resulting from the use of other spare parts
or operating materials.
Attention!
If the nozzle with dirt catch is soiled the oil consumption may increase signif-
icantly (only through to S 100-2 / SD 100-2, SF 100-2 / SDF 100-2 + BLUE-
KAT series)!
6.3 Regular maintenance work
Clean or change Cleaning:

suction filter 1x monthly, however, at least every 500 operating hours.
Correspondingly earlier if the air taken in is heavily soiled.
Change:
In the event of damage.
After the second cleaning.
Switch off the compressor with the OFF button.

S 50-2 BLUEKAT).
Removing the filter car-

tridge
Remove cladding on the
maintenance side.
Remove lid (1) of the filter
housing.
Loosen nut (3) and re-
move filter cartridge (2).
Fig. 6.4: Changing the suction filter
Cleaning the filter

cartridge
Attention!
Do not clean filter cartridges in liquids.
Do not use any hard objects when cleaning to avoid damaging the filter pa-
per.
Refit a new filter cartridge in the event of damage or once it has been cleaned
twice.
Tap on the filter cartridge using the palm of your hand to knock out coarse
dust.
Blow out fine dust from the inside to the outside using dry compressed
air (maximum pressure 5 bar).
Clean the sealing surface of the filter cartridge.
Fitting a filter cartridge

Insert filter cartridge into the filter housing.
Tighten nut.
Attach lid of the filter housing.
Attach cladding on the maintenance side.
Changing the supply air Check:

filter mats (option) 1x weekly,
however, at least every 500 operating hours.
Correspondingly earlier if the air taken in is heavily soiled.
Change:
When a crust of dirt has accumulated on the filter mat.
When the final compression temperature has exceeded its set point value
by 4 to 5C.
The crust of dirt on the filter mat prevents an adequate cooling air supply.

Pull filter mat (1) out of its

holder from above.
Insert new filter mat into the
holder.
Fig. 6.5: Changing the supply air filter
Drive motors with As a rule, the bearings of the drive motors are provided with a maintenance
permanent lubrication free permanent lubrication.
Under normal operating conditions (refrigerant temperature max. 40C, conti-
nous operation) the bearings are maintenance free for the service life.
The service life decreases or increases as thermal stress increases or de-
creases (due to increased or reduced refrigerant temperature).
Attention!
Have BOGE service dismantle the bearings and install new bearings once
the specified service life has expired.
Drive motors with Motors with lubricating devices are easily recognised by the two grease nip-
lubrication device ples on the top of the cover. Additionally stickers on the compressor refer to
the lubricating device. Please check which motor is installed in your compres-
sor and service it according to the respective instructions. Lubricate the bear-
ings of the drive motor at the prescribed intervals so as not to sustain damage
due to lack of lubricant.
On motors with lubricating devices, regular greasing forms part of the scope
of maintenance. The lubrication intervals, quantity and type of grease are
given on the type plate or a separate plate. For lubrication, the required quan-
tity is pressed through the nipple into the bearing with a grease gun while the
compressor is running.
Fig. 6.6: Grease nipples of the lubricating device
Drive motors with Read the attached operating instructions carefully before putting the automatic
automatic lubricating lubrication device into operation.
equipment

Always exercise great caution when lubricating the bearings with the com-
pressor running and observe all safety precautions. Never put your hand in
the area of the V-belt and the fan wheel. Fitted safety devices and cladding
may not be removed.
Attention!
Always use the same type of grease for lubrication. The lubricating ability can
be sharply reduced if different types of greases are mixed.
If you intend to use a different type of grease:
Have the bearings removed and thoroughly cleaned prior to filling with
new grease.
Please always observe the specified lubrication intervals and quantities of
grease.
Over-greasing and an excess of lubricant can also destroy the bearings.
Changing the V-belt Check:

1x per week for damage.
Change:
If damage is visible.

S 50-2 BLUEKAT).
Remove cladding on the maintenance side as well as the belt protection
Slacken the V-belts:

Secure screw head (3) of the
tensioning device with NW 27
spanner to prevent it from
turning.
Turn locknut (4) clockwise.
Raise the motor in arrow
direction (5) until the V-belts
are fully slackened.
Fig. 6.7: The BOGE GM drive system
Changing the V-belts:

Remove the slackened belts from the belt pulleys.
Fit new V-belts on the belt pulleys on the motor and compressor.
Attention!
The new V-belts must be of precisely the same length.
Only change the V-belts as a complete set!
Tensioning the V-belts:

Lower the motor again. For this purpose, secure screw head (3) against
turning, then turn locknut (4) counterclockwise and lock by means of the
screw head. The V-belts are automatically correctly tensioned by the
BOGE GM drive system.
Fit belt protection.
Reattach cladding on the maintenance side.
Settings of the GM-drive blue As to the setting value for tge corresponding motor
systems with standard we refer to the table below.
motors
Settings
sealed
Type Pressure Setting

[bar] [mm]
S 31-2 8 / 10 / 13 84
S 40-2...S 60-2
SD 40-2...SD 60-2 8 / 10 / 13 112
S 40-2 BLUEKAT, S 50-2 BLUEKAT
S 61-2...S 75-2, S 100-2 8 / 10 / 13 112

SD 61-2...SD 75-2, SD 100-2 8 / 10 / 13 112
S 90-2, SD 90-2 10 / 13 103

S 90-2, SD 90-2 8 112
S 101, S 125, S 150, S 151 8 / 10 / 13 84 / 83 / 63
S 180 8 / 10 / 13 92 / 88 / 98
S 220 8 / 10 / 13 76 / 92 / 82
S 271 8 / 10 / 13 102 / 96 / 122
S 341 8 / 10 / 13 90 / 81 / 116
SF 60-2
8 / 10 / 13 112
SDF 60-2
SF 100-2 / SDF 100-2

8 / 10 / 13 112
SF 150 / SDF 150
Table 6.2: Settings with standard motors
The settings shown in the table are fixed by the manufacturer and may not be
changed. Slight deviations are allowed and compensated by the GM drive sys-
tem.
The current settings are also shown on the GM drive system. With special ver-
sions the settings on the sticker may deviate from the standard values.
Checking the oil level, Check:

topping up oil Prior to commissioning/start-up of the compressor.
Then every 1,000 operating hours, however at least once a year.
Topping up:
When the oil level has dropped below the "min" mark (see sketch).
Attention!
Always use the same oil type when topping up. Never mix different oil types
and brands.

Close ball valve at the compressed air outlet.
Open safety sound insulation hood.
Vent the compressor (as described in the beginning of the chapter).
The system pressure gauge must indicate a pressure of 0 bar.
Wait approx. 3 minutes to permit the oil to settle.
Remove cladding on the maintenance side.
Series S 31-2...S 220 / SF 60...SDF 150 / BLUEKAT series

Danger of burning due to hot oil!
Always wear your compulsory personal protective equipment when working
on the compressor!
Remove plug (2) of oil filling socket (1) (see figure below).
Check oil level.
The oil level must not drop below the "min." mark.
If necessary, top up with oil to the lower edge of the thread ("max." mark)
on the oil filling socket.
Screw plug (2) back in.
Close safety sound insulation hood.
Open ball valve at the compressed air outlet.
Fig. 6.8: Checking the oil level, topping up with oil
Series S 271 and S 341

Always wear protective gloves when working on the compressor!
Remove plug (1) with sealing washer (4) from plug (2) (see figure below).
You will find the dip stick (3) in the document pocket of the key ring (when
delivered).
Insert dip stick (3) and measure the oil level. The oil level must neither
drop below the "min." mark nor rise above the "max." mark.
Unscrew plug (2) with sealing washer (5) if necessary and top up with oil.
Screw plug (2) with sealing washer (5) and plug (1) with sealing washer
(4) back in.
Reattach clading on the maintenance side.
Fig. 6.9: Checking the oil level, topping up with oil
Changing the oil filter Change:

After 3,000 operating hours, but no less than once a year.
With each oil change!

Open safety sound insulation hood and take off safety warm air hood.
Wait approx. 3 minutes to permit the oil to settle.

Unscrew soiled oil filter (3) by hand or use a strap wrench, turning counter-
clockwise.
Catch the draining oil and dispose of properly according to environmental
regulations.
Fill the new oil filter (3) with compressor oil.
Lightly oil the sealing ring of the new oil filter.
Screw in new oil filter by hand, turning clockwise.
Attention!
Do not use tools to screw in the new oil filter!
You might damage the oil filter or its sealing ring.
A hand tight seating of the oil filter is sufficient.
Reattach cladding on the maintenance side and close safety sound insula-
tion hood.
Switch on the compressor and heat up to operating temperature.
Subsequently, check the oil filter for leaks once again and tighten by
hand, if necessary (procedure as described above).

Check the oil filter for leaks and tighten by hand, if necessary.
Check oil level. Top up oil losses, if any.
Fig. 6.10: Changing the oil filter
Changing the oil Change:

separator When the difference between network and system pressure exceeds
0.8 bar.
When warning message "8" appears on the control system display (if
option is installed).
After 3,000 operating hours, however, not later than after one year.

If the prescribed maintenance intervals are not observed, the oil separators
might become blocked. In this case, the differential pressure will increase
until the safety valve blows.

Wait for approx. 3 minutes to permit the oil to settle.

Unscrew soiled oil separators (4) by hand or use a strap wrench, turning
counterclockwise.
Catch the draining oil and dispose of properly according to environmental
regulations.
Lightly oil the sealing rings of the new oil separator.
Screw in new oil separators by hand, turning clockwise.
Attention!
Do not use tools to screw in the new oil separators!
You might damage the oil separators or their sealing rings.
A hand tight seating of the oil separators is sufficient.
Switch on the compressor and heat up to operating temperature.
Check the oil separator for leaks once again (procedure as described
above).

Check the oil separators for leaks and tighten by hand, if necessary.
Fig. 6.11: Changing the oil separator
Oil change Change:

After 9,000 operating hours, however, at the latest after two years.
For other types of oil the appropriate oil change intervals must be complied
with.
Note!
The service life of the oil, the oil filter and oil separators is reduced under the
following conditions:
When the compressor is operated at extreme ambient temperatures.
When the intake air is extremely soiled.
Building up a pressure cushion

The combined compressed air / oil receiver is located at the lowest point of the
system. Therefore, a light pressure cushion (approx. 1.5 bar system pressure)
must be applied to drain the oil. This pressure cushion forces the oil through
the drain hose into a suitable collecting vessel.
Attention!
Never use any tools to screw on the cap nut!
They might damage the solenoid valve.
Place oil drain hose into a suitable container (6) as described and take cap
nut (5) out of the switch cabinet.
Press OFF button at the machine during output phase and then shut down
the machine using the emegency stop button after 3 seconds or if a residual
pressure of 2 bar is reached.
Screw cap nut on the bleed aperture of the solenoid valve.
Draining old oil

Place the oil drain hose into a suitable container (6).

Slowly open the stop valve.
The pressure cushion forces the oil into the container.
Once the compressed air/oil receiver has been completely drained, close
the stop valve.
Remove the cap nut from the solenoid valve.
Remove oil filler screw (7) on the compressed air/oil cooler and drain the
residual oil (max. 5 litres) into a suitable container.
Reinsert the oil filler screw together with a new copper sealing ring.
Change oil filter (procedure as described above).
Change oil separators (procedure as described above).
Filling with new oil:

Fill up to the edge of the thread of the filling socket (max.) (procedure as
described above).
Attention!
After each oil change you have to fill a small quantity of oil into the suction
controller before starting the compressor.
For oil quantity and procedure see chapter 3.5 Commissioning: Commis-
sioning following extended stoppages.
Attention!
Always fill with the same oil type as previously used. Never mix different oil
types and brands.
The oil circuit must be flushed prior to changing the oil type.
Conduct trial run.

Check the oil filters and oil separators for leaks and tighten by hand, if
necessary (procedure as described above).
Check oil level (procedure as described above).
Top up oil losses, if any.
Fig. 6.12: Solenoid valve on the suction controller with the cap nut screwed on
Fig. 6.13: Drain off old oil from oil/compressed air receiver
Fig. 6.14: Drain off residual oil from compressed air/oil cooler
Flushing the oil circuit Flushing the oil circuit with clean oil becomes necessary:
When the oil is excessively soiled.
Prior to changing the oil type.
Attention!
Detailed information as to the flushing with BOGE oils you can obtain from
the following service number:
Telephone: +49 5206 601-140
Cleaning the com- Cleaning:

pressed air/oil cooling After 1,500 operating hours, however, not later than after one year.
unit (air cooling)
Note!
The service life of the compressed air/oil cooling unit depends on the degree
of soiling (dust, oil vapour) of the suctioned cooling air. Extreme external soil-
ing of the cooling unit leads to an increased temperature in the oil circuit.

Remove the cladding from the service side.
Unscrew the maintenance flap on the air guidance box.
Remove accumulated soiling with a fibre brush.
Attention!
Do not use any sharp objects for cleaning!
These could damage the cooling unit.
Blow down the dirt with compressed air (1) in the opposite direction to the
normal cooling air flow. Vacuum out the dirt using an industrial vacuum
cleaner (2) (see Fig.).
If the cooling unit is excessively soiled (cleaning is no longer possible with
compressed air), have it disassembled and cleaned by BOGE service.
No cleaning necessary in
case of water cooling.
Fig. 6.15: Cleaning the compressed air/oil cooling unit
As for compressors of the BLUEKAT series, the maintenance flap of the air cir-
culation box is located at the arrow marked in the following illustration:
Fig. 6.16: Cleaning the compressed air/oil cooling unit: S 40-2 / S 50-2
(BLUEKAT)
Cleaning the oil cooling Cleaning:

unit (water cooling) After 1,500 operating hours, however, not later than after one year.
In the event of excessive lime deposits and dirt.
Note!
The service life of the cooling unit depends on the degree of soiling and lime
deposits in the cooling water. In the event of excessive soiling, check the
cooling unit correspondingly earlier.
Carry out the cleaning as described for plate heat exchangers.
Proportional controller Check:

(option for S series) After approx. 3,000 operating hours, however, at least once a year.
1. Setting the operating pressure sensor

Switch-on pressure: pmin = Final compression pressure 1 bar.
Switch-off pressure: pmax = Final compression pressure.
2. Setting the proportional controller

Displace the control range of the propor-
tional controller by turning cap (1).
Increase pressure level: Turn cap
clockwise.
Reduce pressure level: Turn cap coun-
terclockwise.
Fig. 6.17: Setting the proportional controller
Note!
Always set the proportional controller higher than the bottom operating pres-
sure value (pmin)!
3. Pressure switch for infinitely variable capacity control

The low pressure switch for the infinitely variable capacity control limits the
reduction of the delivered quantity and switches the compressor in the event
of less than 50 % delivered quantity into idling operation or off.
Check safety valve Check:

After approx. 3,000 operating hours, however at least once a year.
Check safety valve by opening the screw plug (1).

Danger of scalding due to hot oil!
Take extreme care when checking the safety valve with the compressor
running taking all safety measures into consideration.
A hot air-oil mixture escapes when opening!
Open the threaded plug (1) counterclockwise. The compressed air es-
capes.
Tighten the threaded plug by turning clockwise.
Maintenance 6.4 Spare parts and optional equipment
Fig. 6.18: Check safety valve
6.4 Spare parts and optional equipment
List of spare and

wearing parts Designation
(for maintenance) Filter mat for supply air filter (option)
BOGE Syprem 8000 S special lubricant for screw compressors
Set of V-belts
Lubrication for drive motor bearings
Maintenace package:
oil filter, oil separator, suction filter cartridge, gaskets, nozzle with dirt catch
(nozzle with dirt catch only through to S 100-2 / SD 100-2, SF 100-2 /
SDF 100-2 + BLUEKAT series)
Wearing part kit:

oil regulator, intake regulator, minimum pressure valve
Solenoid valve
Maintenance 6.4 Spare parts and optional equipment
Replacement parts
for converter
(BLUEKAT series)
Note!
Replacement parts management is being permanently updated by BOGE. If
you need any replacement parts for the converter of the BLUEKAT series,
please contact your local BOGE field representative and/or BOGE contract
partner.
Or contact your BOGE replacement parts service:
Telephone: +49 5206 601-120
List of available optional

equipment Designation
Optional equipment for compressed air treatment
Oil/water separator
Frost protection device
Automatic condensate draining unit Bekomat
BOGE-DUOTHERM BPT
Plate heat exchanger
BOGE-DUOTHERM-PLUS BSW
Safety heat exchanger
Attention!
When ordering, please specify the data on the type plate:
Type
Year of manufacture
Machine number
Appendix 7.1 Guidelines and standards complied with
Part 7: Appendix 7.1 Guidelines and standards complied with
The compressor conforms to the following guidelines and standards:
Guidelines and directives

Machinery Directive 2006/42/EC
Pressure Equipment Directive 97/23/EC
EMC Directive 2004/108/EC
Low Voltage Directive 2006/95/EC
Simple Pressure Vessels Directive 2009/105/EC
Applied harmonized standards

DIN EN 1012-1:2011
DIN EN ISO 12100:2011
DIN EN 60204-1 / VDE 0113-1:2007
DIN EN 61000-6-2 / VDE 0839-6-2:2006
DIN EN 61000-6-4 / VDE 0839-6-4:2007
7.2 Flow chart
On the following pages you will find the individual flow charts for the different
machine types and components.
Appendix 7.2 Flow chart
Air cooled version,

standard
101 Intake air INLET

102 Compressed air OUTLET
1 Suction filter
2 Maintenance display (from 30 kW)
3 Vacuum switch (for suction filter monitoring) *
4 Suction controller
5 Ventilation and regulation control valve
7 Drive motor
8 Compressor air end
9 Sensor for final compression temperature
10 Combined compressed air/oil receiver
11 Oil separator
12 Safety valve
17 Oil cooler
18 Oil filter
19 Differential pressure switch (for oil filter monitoring) *
20 Oil throttle
23 Pressure sensor system pressure
24 Pressure sensor network pressure
25 Stop valve, compressed air outlet
27 Stop valve, oil drainage
28 Check valve drainage line (up to 75 kW)
29 Proportional controller *
30 Diff. pressure switch for prop. controller *
31 3/2-way solenoid valve for prop. controller
(with standard control passage here) *
37 Display of F.a.d. for prop. controller *
42 3/2-way solenoid valve for suction control regulation *
43 Double check valve (Pos. 42 + 43 = rapid-start valve) *
44 Double check valve (Monitoring of rotational direction) *
* Option
Water cooled version,

serial connection
parallel connection
Parallel connection * Serial connection

103 Water INLET
104 Water OUTLET
1 Suction filter
2 Maintenance display (from 30 kW)
5 Air relief and regulation control valve
7 Drive motor
8 Air end
9 Sensor for final compression temperature
11 Oil separator
12 Safety valve
17 Oil cooler
18 Oil filter
20 Oil throttle
23 Pressure sensor system pressure
24 Pressure sensor network pressure
30 Diff. pressure switch for prop. controller *
31 3/2-way solenoid valve for prop. controller
(with standard control passage here) *
32 2/2-way solenoid valve
33 Control valve water supply (preadjusted)
34 Control valve water supply (preadjusted)
37 Display of f.a.d. for prop. controller *
42 3/2-way solenoid valve for suction control regulation *
43 Double check valve (Pos. 42 + 43 = rapid-start valve) *
44 Double check valve (Monitoring of rotational direction) *
* Option
To be provided by customer:
35 Dirt trap
36 Stop valve
Air cooled version,

frequency controlled
101
102

1 Suction filter
2 Maintenance display
6 Pressure switch (for rotational direction, system relief and V-belt monitoring)
7 Drive motor
8 Air end
9 Final compression temperature display and switch
11 Oil separator
12 Safety valve
13 Differential pressure switch (for oil separator monitoring) *
14 System pressure switch (for system pressure build-up and monitoring) *
15 Safety pressure switch (for pressure limitation) *
17 Oil cooler
18 Oil filter
20 Oil throttle
23 Pressure sensor for system pressure
24 Network pressure compressor
24.1 Pressure gauge (system pressure)
26 Pressure sensor for network pressure (frequency converter)
27.1 Stop valve, oil drainage (oil cooler, 75 - 250 kW)
28 Rckschlagventil Drainageleitung (up to 75 kW)
* Option

serial connection
frequency controlled
101
104
103
102

103 Water INLET
104 Water OUTLET
1 Suction filter
2 Maintenance display
6 Pressure switch (for rotational direction, system relief and V-belt monitoring) *
7 Drive motor
8 Air end
9 Final compression temperature display and switch
11 Oil separator
12 Safety valve
13 Differential pressure switch (for oil separator monitoring) *
14 System pressure switch (for system pressure build-up and monitoring) *
15 Safety pressure switch (for pressure limitation) *
17 Oil cooler
18 Oil filter
20 Oil throttle
23 Operating pressure switch
24 Pressure gauge
26 Pressure sensor for network pressure (frequency converter)
34.1 Bypass valve *
* Option
To be provided by customer:
35 Dirt trap
36 Stop valve
BLUEKAT series,
air cooled version
31 37 42 5
29 43
11 23
, P
28
30
44
7
4 Rq 12
M 9
21
10
8
3
20 27
2
16
18
1 19
101
17
10 2 25 22
51 50
52
54
59 62
7
24 53
P,
55
60 58 7
3
56
7
61
57
7

1 Suction filter 29 Proportional controller *

2 Maintenance display (from 30 kW) 30 Diff. pressure switch for prop. control-
3 Vacuum switch ler *
(for suction filter monitoring) * 31 3/2-way solenoid valve for prop. con-
4 Suction controller troller (with standard control passage
here) *
37 Display of f.a.d. for prop. controller *
7 Drive motor
42 3/2-way solenoid valve for suction con-
8 Air end
trol regulation *
9 Sensor for final compression tempera-
43 Double check valve
ture
(Pos. 42 + 43 = rapid-start valve) *
11 Oil separator (Monitoring of rotational direction) *
12 Safety valve 50 Filter
16 Thermostatic oil control valve 51 Safety valve
17 Oil cooler 52 Heat exchanger
18 Oil filter 53 Converter
19 Differential pressure switch 54 Heating cartridge with thermocouple
(for oil filter monitoring) *
55 Heating cartridge receiver top
20 Oil throttle
56 Heating cartridge receiver middle
57 Heating cartridge bed temperature
58 Pressure retaining shut-off valve
23 Pressure sensor for system pressure (DHSV)
24 Network pressure compressor 59 DHSV solenoid valve
25 Stop valve, compressed air outlet 60 Gauge
27 Stop valve, oil drainage 61 Relief ball valve
28 Check valve drainage line 62 Condensate discharge valve, auto-
(up to 75 kW) matic
* Option
BLUEKAT series,
water cooled version,
parallel connection
31 37 42 5
29 43
11 23
, P
28
30
44
7
4 Rq 12
M 9
21
10
8
3 20
19 27
2
18
16
1
17
101
104
32
34
35 36
10 2 25
33 103
22
51 50
52
54
59 62
7
24 53
P,
55
60 58 7
3
56
7
61
57
7

103 Water INLET
104 Water OUTLET
1 Suction filter 32 2/2-way solenoid valve

2 Maintenance display (from 30 kW) 33 Regulating valve water supply (preset)
3 Vacuum switch 34 Regulating valve water supply (preset)
(for suction filter monitoring) * 35 Dirt trap
4 Suction controller 36 Stop valve
5 Air relief and regulation control valve 37 Display of f.a.d. for prop. controller *
7 Drive motor 42 3/2-way solenoid valve for suction con-
8 Air end trol regulation *
9 Sensor for final compression tempera- 43 Double check valve
ture (Pos. 42 + 43 = rapid-start valve) *
10 Combined compressed air/oil receiver 44 Double check valve
11 Oil separator (Monitoring of rotational direction) *
12 Safety valve 50 Filter
16 Thermostatic oil control valve 51 Safety valve
17 Oil cooler 52 Heat exchanger
18 Oil filter 53 Converter
19 Differential pressure switch 54 Heating cartridge with thermocouple
(for oil filter monitoring) * 55 Heating cartridge receiver top
20 Oil throttle 56 Heating cartridge receiver middle
21 Minimum pressure check valve 57 Heating cartridge bed temperature
22 Compressed air after-cooler 58 Pressure retaining shut-off valve
23 Pressure sensor for system pressure (DHSV)
24 Network pressure compressor 59 DHSV solenoid valve
25 Stop valve, compressed air outlet 60 Gauge
27 Stop valve, oil drainage 61 Relief ball valve
28 Check valve drainage line 62 Condensate discharge valve, auto-
(up to 75 kW) matic
30 Diff. pressure switch for prop. control- * Option
ler *
31 3/2-way solenoid valve for prop. con-
troller (with standard control passage
here) *
BLUEKAT series,
serial connection
31 37 42 5
29 43
11 23
, P
28
30
44
7
4 Rq 12
M 9
21
10
8
3 20
19 27
2
18
16
1
17
101
104
32
35 36
10 2 25
22 103
51 50
52
54
59 62
7
24 53
P,
55
60 58 7
3
56
7
61
57
7

103 Water INLET
104 Water OUTLET
1 Suction filter 31 3/2-way solenoid valve for prop. con-

2 Maintenance display (from 30 kW) troller (with standard control passage
here) *
3 Vacuum switch
(for suction filter monitoring) * 32 2/2-way solenoid valve
4 Suction controller 35 Dirt trap
5 Air relief and regulation control valve 36 Stop valve
7 Drive motor 37 Display of f.a.d. for prop. controller *
8 Air end 42 3/2-way solenoid valve for suction con-
trol regulation *
9 Sensor for final compression tempera-
ture 43 Double check valve
(Pos. 42 + 43 = rapid-start valve) *
11 Oil separator
(Monitoring of rotational direction) *
12 Safety valve
50 Filter
51 Safety valve
17 Oil cooler
52 Heat exchanger
18 Oil filter
53 Converter
19 Differential pressure switch
54 Heating cartridge with thermocouple
(for oil filter monitoring) *
55 Heating cartridge receiver top
20 Oil throttle
56 Heating cartridge receiver middle
57 Heating cartridge bed temperature
58 Pressure retaining shut-off valve
23 Pressure sensor for system pressure
(DHSV)
24 Network pressure compressor
59 DHSV solenoid valve
60 Gauge
61 Relief ball valve
28 Check valve drainage line
62 Condensate discharge valve, auto-
(up to 75 kW)
matic
30 Diff. pressure switch for prop. control-
* Option
ler *
SD / SDF
1 Screw compressor (see also flow diagram)

2 Cyclone separator
3 Compressed air refrigeration dryer
4 Bypass
5 Drain
9 Condensate
25 Non-return valve compressed air exhaust
BOGE-Duotherm BPT
plate heat exchanger

102 backwards
103 forwards
1 Suction filter
4 Intake regulator
8 Air end
11 Oil separator
17 Oil cooler
18 Oil filter
50 Heat exchanger
BOGE-Duotherm-Plus
BSW safety heat
exchanger
101 Compressed air OFF

102 backwards
103 forwards
1 Suction filter
4 Intake regulator
8 Air end
11 Oil separator
17 Oil cooler
18 Oil filter
51 Safety heat exchanger
52 Pressure monitor for rupture
53 Compensation vessel
Please note the completed maintenance work in the respective columns
Date Operating Network System Tempe- Intake Oil Oil- Oil Cooling Motor C.air dryer Converter- Remarks
hours pressure pressure rature separator service
Appendix
filter filter level unit mainte- Oil-water

* ** cleaning nance separator
Filter
Drain
7.3
BOGE Operating instructions for S 31-2...S 341 series screw compressors

7.3 List of maintenance and service work
List of maintenance and service work
* R = Cleaning ** K = Check
W = Change W = Change
Page 105
Page 106
Appendix

Filter
Drain
7.3

Appendix

Filter
Drain
7.3

Page 107
Page 108
Appendix

Filter
Drain
7.3

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What are the main components of the compressor?

What are the main components of the compressor?

What is the purpose of the oil circuit?

What is the purpose of the oil circuit?

Operating instructions

S 31-2 (22 kW)

SF 60-2 / SDF 60-2 (45 kW)

S 40-2 BLUEKAT (30 kW)

Fon: +49 5206 601-0

Part 1: 1.1 General safety instructions ........................................................... 1

Part 2: 2.1 Technical data............................................................................... 13

2.3 BLUEKAT operation principle ..................................................... 23

2.4 Compressor control ..................................................................... 24

2.5 Control devices ............................................................................. 26

2.6 Safety and monitoring devices.................................................... 27

2.7 Water cooling ................................................................................ 31

2.8 Cooling water ................................................................................ 32

Part 3: 3.1 Transport and storage.................................................................. 33

3.2 Compressor room......................................................................... 35

Activating the belt tensioning device............................................... 42

3.4 Electrical connection.................................................................... 43

3.6 Dismantling ................................................................................... 50

Part 4: 4.1 General .......................................................................................... 51

4.3 Converter failures (BLUEKAT series) ......................................... 53

Part 5: 5.1 BOGE-Duotherm BPT................................................................... 55

5.2 BOGE-Duotherm BSW.................................................................. 57

Part 6: 6.1 Safety instructions ....................................................................... 59

6.3 Regular maintenance work .......................................................... 68

6.4 Spare parts and optional equipment .......................................... 85

Part 7: 7.1 Guidelines and standards complied with ................................... 87

7.3 List of maintenance and service work ...................................... 105

Part 1: General 1.1 General safety instructions

12. Undertake conversions and modifications of the compressor only with

Caution: Risk of injury!

During operation, the compressor generates a high sound pressure level

Obligations of the owner The owner is obliged to,

Personal protective In general for all work on the compressor

For special duties

Safety instructions for

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

3. Prior to maintenance or repair work:

Safety instructions for

Caution: Risk of injury!

Warning of hand injuries!

Only hydrocarbon based oils (synthetic or mineral) may be used as compres-

Fig. 1.1: Data on the type plate

Part 2: Product description 2.1 Technical data

Technical data S 31-2...S 100-2 / SD 40-2...SD 100-2, part 1

S 40-2 S 50-2 S 60-2 S 61-2 S 75-2 S 90-2 S 100-2

Reference surface measure

silenced / super silenced [dB(A)]

Technical data for S 101...S 341 / SD 101...SD 150, part 1

S 101 S 125 S 150

Reference surface measure

silenced / super silenced [dB(A)]

Technical data for S 31-2...S 100-2 / SD 40-2...SD 100-2, part 2

S 40-2 S 50-2 S 60-2 S 61-2 S 75-2 S 90-2 S 100-2

Technical data for S 101...S 341 / SD 101...SD 150, part 2

S 101 S 125 S 150