BOGE K3 K6 K8 K15 Operating Instructions

Operating instructions
Oil-free
piston compressors
Series
K 3...K 15
K Booster
Separate instruction:
Compressor control
www.boge.com
Operating instructions for
oil-free piston compressors
Max. pressure: 10 bar

K 3 ( 2.2 kW) 50 Hz (60 Hz)
K 4 ( 3.0 kW) 50 Hz (60 Hz)
K 6 ( 4.0 kW) 50 Hz (60 Hz)
K 8 ( 5.5 kW) 50 Hz (60 Hz)
K 15 (11.0 kW) 50 Hz (60 Hz)

K 4 – 15 ( 3.0 kW) 50 Hz (60 Hz)
K 6 – 15 ( 4.0 kW) 50 Hz (60 Hz)
K 15 – 15 (11.0 kW) 50 Hz (60 Hz)

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

K 8 Booster ( 5.5 kW) 50 Hz (60 Hz)
K 15 Booster (11.0 kW) 50 Hz (60 Hz)
BOGE KOMPRESSOREN
Postfach 10 07 13
D-33507 Bielefeld
Otto-Boge-Straße 1-7
D-33739 Bielefeld
Phone: +49 5206 601-0

Fax: +49 5206 601-200
Mail: info@boge.com
Net: www.boge.com
Issue: 05 / 2012
No. 596.1028.01
Nominal price: € 5,00
BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page I
Index
Index
Part 1: 1.1 Introduction..................................................................................... 1

General General ............................................................................................. 1
Symbols used ................................................................................... 2
Symbols on the compressor ............................................................. 3
Intended use ..................................................................................... 4
Foreseeable Misuse ......................................................................... 4
Transport damage ............................................................................ 5
Data on the type plate....................................................................... 5
Service.............................................................................................. 5
1.2 General safety instructions ........................................................... 6

Safety instructions for compressor operation ................................... 6
Safety instructions for maintenance and repair of the compressor... 7
Special hazard warnings................................................................... 8
Electrical energy hazards ................................................................. 9
Accident prevention regulations........................................................ 9
Obligations of the owner ................................................................. 10
Personnel requirements.................................................................. 10
Personal protective equipment ....................................................... 10
Part 2: 2.1 Technical data............................................................................... 11

Product description Compressor system: maximum pressure 10 bar, 50 / 60 Hz
(compressor unit)............................................................................... 11
Compressor system: maximum pressure 10 bar, 50 / 60 Hz
(with receiver) .................................................................................... 11
Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz
(compressor unit)............................................................................... 12
Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz
(with receiver) .................................................................................... 12
Booster compressor system: max. booster pressure 10 bar,
max. pressure 40 bar, 50 / 60 Hz (compressor unit) ......................... 13
Booster compressor system: max. booster pressure 10 bar,
max. pressure 40 bar, 50 / 60 Hz (with receiver)............................... 13
Part 3: 3.1 Transport ....................................................................................... 15

Installation General ........................................................................................... 15
Transport possibilities ..................................................................... 15
Intermediate storage or after an extended stoppage...................... 16
BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page III
Index
3.2 The compressor room .................................................................. 17

Installation conditions for compressed air receivers arranged
separately ....................................................................................... 17
Installation surface .......................................................................... 17
Sound protection............................................................................. 17
Admissible environmental influences.............................................. 18
Ventilation ....................................................................................... 18
Cooling air requirement .................................................................. 19
Installation of the compressor ......................................................... 19
Sound insulation hoods .................................................................. 19
Electrical connection ....................................................................... 20
Condensate disposal ...................................................................... 20
3.3 Installation, assembly and commissioning................................ 20

General ........................................................................................... 20
Checking the delivery scope ........................................................... 21
Installing the compressor ................................................................ 21
Assembly ........................................................................................ 22
Assembly in case of booster pressure supply (K Booster) ............. 23
Electrical connection ....................................................................... 25
Compressed air connection ............................................................ 27
Prior to commissioning / start up .................................................... 28
Check installation requirements...................................................... 29
Checking the rotationaldirection ..................................................... 29
Check compressed air outlet for tightness...................................... 30
Checking for leaks (general) ........................................................... 30
Conduct trial run ............................................................................. 30
3.4 Dismantling ................................................................................... 31
Part 4: 4.1 General .......................................................................................... 33

Fault
4.2 Faults and fault rectification ........................................................ 33
Only for 2-stage compressors:........................................................ 34
Part 5: 5.1 Safety instructions ....................................................................... 35

Maintenance
5.2 General .......................................................................................... 36
Maintenance through BOGE service .............................................. 36
Spare and wearing parts................................................................. 37
Overview of regular maintenance work .......................................... 37
Maintenance intervals ..................................................................... 39
5.3 Regular maintenance work .......................................................... 40

Intake filter: Cleaning / changing of filter cartridges ........................ 40
Check pre-filter / Replace filter cartridge ........................................ 41
Lubricate the bearings of the drive motor ....................................... 42
Page IV BOGE Operating instructions for oil-free piston compressors, series K 3...K 15
Index
Drive motors with permanent lubrication ........................................ 42

Cleaning the cooler (air cooling) ..................................................... 43
Checking and setting the operating pressure (with compressor
control)............................................................................................ 44
Check / set operating pressure switch............................................ 44
Checking the safety valve............................................................... 46
5.4 Spare parts and optional extras .................................................. 46

List of spare and wearing parts (for maintenance) ......................... 46
Part 6: 6.1 Guidelines and standards complied with................................... 47

Appendix
6.2 Pneumatic circuit diagrams......................................................... 47
Pneumatic circuit diagram: K 3...K 15
(single stage up to 10 bar with compressor control) ....................... 48
(single stage up to 10 bar with pressure switch ventilation) ........... 49
Pneumatic circuit diagram: K 4 – 15 / K 6 – 15 / K 8 – 40 /
K 15 – 15/40 (two-stage 15...40 bar with compressor control) ....... 50
Pneumatic circuit diagram: K 4 – 15 / K 6 – 15
(two-stage up to 15 bar with pressure switch ventilation) ............... 52
Pneumatic circuit diagram: K 8 Booster and K 15 Booster booster
compressors (single stage up to 40 bar with compressor control) . 54
6.3 List of maintenance and service work ....................................... 56
BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page V
General 1.1 Introduction
Part 1: General 1.1 Introduction
These operating instructions apply to:

– complete machines
(compressor assembly ready for operation, incl. compressed air receiver),
– incomplete machines
(compressor assembly not ready for operation, without compressed air re-
ceiver).
The present operating instructions are based on a complete machine. In case

of an incomplete machine, chapter „3.3 Installation, assembly and commis-
sioning”, page 20 focuses in detail on the particularities of an incomplete ma-
chine (assembly of required components on unit).
General The purpose of these operating instructions is to familiarize the user with the
function and all application possibilities of the compressor.
These operating instructions contain important information on how to operate
the compressor safely, economically and according to its intented use. Ob-
serving these operating instructions will assist in avoiding danger, to reduce
repair costs and down times and to increase the reliability and service life of
the compressor. It contains important information concerning the required
maintenance and repair measures, assists in case of malfunctions and con-
tains data concerning spare and wearing parts.
The operating instructions must be available to the compressor operating per-
sonnel at the place of operation, at all times.
The operating instructions must be carefully read and applied by all persons
engaged to undertake the following work on the compressor:
– Operation, including fault rectification and daily care
– Maintenance (service, inspection, repair)
– Commissioning
– Transport
The compressor and its additional equipment must not be installed and com-
missioned until the operating instructions are understood.
These operating instructions can be supplemented with instructions on the
basis of existing national regulations concerning accident prevention and envi-
ronmental protection.
In the illustrations, the compressor is shown in part without safety cladding or
safety devices for better visualization. However, operation without these com-
ponents is prohibited!
BOGE Operating instructions for oil-free piston compressors, series K 3...K 15 Page 1
Symbols used In these operating instructions, important safety instructions and tips are iden-
tified by the following symbols:
CAUTION: Risk of injury!

This symbol indicates information warning of possible danger to life and limb
of the operator or other persons.
Attention!
This symbol indicates information warning of dangers to life and limb of the
operator or other persons or dangers, which might destroy or damage the
compressor.
Caution: Voltage!
This symbol indicates information warning of life threatening electrical volt-
age levels.
It indicates work which must be exclusively performed by skilled electricians.
Note:
This symbol indicates information and tips concerning the economical and
careful operation of the compressor.
Page 2 BOGE Operating instructions for oil-free piston compressors, series K 3...K 15
Symbols on the
compressor
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!
Intended use
Caution!
BOGE compressors, including their additional equipment, are exclusively
intended for the compression of air for industrial purposes. The air taken in
must not contain any explosive or chemically instable gases or vapours.
Booster compressors of the Booster series are designed to take in the air
from the compressed air network of an existing compressor system. The pre-
compressed air must be available in an adequate amount and the required
pressure. The suction line from the receiver needs possibly be re-dimen-
sioned. The air must not contain any oil, aggressive, abrasive or combustible
admixtures.
As all BOGE compressors, booster compressors do not qualify for compres-
sion of flammable or toxic gases. Certain gases such as nitrogen or carbon
dioxide can, however, be compressed. Please contact BOGE for further de-
tails on such type of applications.
Do not exceed the specified final compression temperature.
BOGE compressors are designed for stationary operation.
Ensure that they are only installed and operated in dry and clean rooms.
The emergency stop device of the compressor (emergency stop switch/but-
ton) is exclusively intended to switch off the compressor in case of emer-
gency.
Operation and control are designed to be executed by trained and authorized
operators.
Foreseeable Misuse
Caution!
Never direct the produced compressed air towards persons. Danger to life!
Only use the produced compressed air for breathing or let it come in contact
with foods, if it was treated beforehand.
This BOGE compressor is not explosion protected.
Do not operate in explosive areas or in a possibly explosive atmosphere!
Do not operate the compressor in rooms in which extreme dust, toxic or flam-
mable vapours and gases may occur.
The emergency stop device of the compressor (emergency stop switch/but-
ton) may not be used for operational tripping of the compressor. Make sure
to actuate the OFF button for operational tripping of the compressor.
The following is not permitted:
– Compression of other media than those mentioned under intended use
or compression of air loaded with contaminants.
– Exceeding the final compression pressure indicated on the type plate.
– Altering the safety devices and safety cladding or placing them out of
operation.
– Removing or painting over signs and symbols on the compressor.
– Operation of the compressor by unauthorized or untrained persons.
Transport damage BOGE does not accept any liability for breakage or transport damage. Please
inspect the compressor immediately after delivery and direct damage claims
to the last haulier – even when the packing is not damaged! To safeguard
claims against the haulier we recommend leaving the machine, devices and
packing material in the same condition as they were in when the damage was
detected.
In the event of any other complaints, please inform us within six days after ar-
rival of the delivery.
Data on the type plate Enter the data of your compressor from the type plate or enclosed data sheet
into fig. 1.1 below.
This will ensure that in the event of enquiries, you will always have the most
important data to hand.

4
min –1

23 4

!" #$ % & '((%() &
*+ ,- +./ . +#+
0
1 #+ +%#( & '((,+% & 2 *+ ,- +./ . +#- ++
34
3
&
54
3

Fig. 1.1: Data on the type plate
Note:
The indication "Max. input pressure" is only appropriate for Booster compres-
sors of the Booster series (K 8 Booster, K 15 Booster).
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
General 1.2 General safety instructions
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!
1.2 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,
– that no persons work on this compressor, whose ability to react is re-
stricted due to misuse of e.g. drugs, alcohol, medication etc.,
– that the operating, maintenance and repair personnel has been made
fully familiar with all safety instructions, and that they are being ob-
served,
– that the compressor is only operated in a safe operating condition.
4. Avoid any operating method which may impair the safety of the compres-
sor.
5. Always wear your compulsory personal protective quipment as a protec-
tion against injuries from sharp corners or edges when working on the
compressor.
6. To avoid dangers from debris or parts lying around, the service area of the
compressor has always to be kept tiedied up and clean.
7. Always squat when working on components mounted at low height, never
stoop. When working on components mounted higher up always stand
upright and erect.
8. It is imperative that the limit values for the max. booster pressure and the
final compression pressure marked on the type plate be not exceeded.
9. Do not operate the compressor without the attendant protection and safety
devices.
Do not dismantle any built-in safety devices or put them out of operation.
Ensure that all safety claddings and doors are closed prior to commission-
ing/starting up the compressor and that they are not opened during oper-
ation.
10. Place the compressor out of operation as described in these operating

instructions, when dismantling the safety claddings or safety devices for
repair or maintenance work. Reattach and close all cladding and safety
devices immediately upon completion of the repair or maintenance work.
11. Only operate the compressor using the additional equipment (options) rec-
ommended or authorized by the manufacturer.
12. Undertake conversions and modifications of the compressor only in agree-
ment with BOGE, taking all relevant safety regulations into consideration.
The manufacturer is not liable for damages resulting from independent
modifications on the compressor.
13. Never start the compressor when one or serveral parts (e.g. cable, plug)
are damaged, when not in perfect working order and when damage is
detected or suspected.
14. Observe all safety and danger signs directly attached on the compressor!
Safety instructions for

maintenance and repair
of the compressor
Caution!
Only use original spare parts, compressor oils and operating materials re-
leased by BOGE during repair or maintenance!
Caution: Voltage!
When working on the electrical system there is a constant danger of getting
into contact with live parts!
To avoid such dangers the mains connection must be equipped with a dis-
connecting device!
The mains disconnecting device has to meet the requirements of DIN EN
60204-1:2007!
Check mains disconnecting device for correct function on a regular basis!
1. Ensure that maintenance work is only carried out by appropriately trained

persons.
2. Ensure that setting work, malfunction rectification and repair is only carried
out by specialists or appropriately trained persons.
3. Prior to maintenance or repair work:
– Press Emergency Stop button.
– Open mains disconnecting device.
– Secure mains disconnecting device against unintentional switching on
by means of a padlock.
– Fix a warning label to the control and fill in the name of the person re-
sponsible who is authorized to switch on the maschine again.
– Check to ensure that all parts are currentless.
– Disconnect the compressor from the compressed air network (relieve
or block pressurized lines).
Additionaly for booster compressors: Vent booster pressure pipe lead-
ing to the booster compressor.
4. Exercise extreme caution during repair or maintenance work requiring the

compressor to be operational.
Ensure that persons keep out of reach of the hazardous area.
5. Ensure that work on the electrical equipment is only executed by qualified
electricians.
6. Work on parts and devices under current is prohibited. Exceptions are gov-
erned by the appropriate regulations, e.g. DIN VDE 0105.
7. Prior to starting work on the electrical system the power supply has to be
switched off and secured against unintentional switching on again. Imme-
diately after having finished the work all dismantled claddings and safety
devices must be refitted.
8. The operator is responsible to check the compressor daily for externally
visible damage and defects, and to immediately report any changes (in-
cluding operational behaviour).
9. When the automatic restart (Auto-Restart) is activated, the compressor will
start automatically following a voltage loss. Prerequisite: The net pressure
is lower than the set switch-on pressure.
Special hazard warnings – Any performance of work on pressurized system components may be car-
ried out by duly qualified and specialized personnel only.
– Always wear your compulsory personal protective equipment when work-
ing on pressure pipes and connections!
– Some of the component parts risk to get extremely hot during compressor
operation! Prior to working on the compressor, allow all hot component
parts cool down to 50°C! Make sure to always wear protective gloves dur-
ing work!
– Reaching into the rotating component parts of the compressor or ejection
of rotating or prestressed component parts is prevented by use of protec-
tive covers. Never operate compressor with protective covers removed!
– A protective grid serves to prevent you from accidentally reaching into the
impeller of the cooling fan.

Never operate compressor with protective grid removed! There is a risk of
putting your hands into the rotating impeller wheel of the cooling fan!
Please note that the cooling fan may run on for a certain time even after the
compressor has been switched off!
– Any pipelines and/or auxiliary equipment on the compressor are designed

such as to resist to any adverse operating conditions and any predictable
external influences. Make sure to operate your compressor within the pa-
rameters specified in the Technical Data Sheet!
– A check valve is used to prevent the admissible operating pressure from
being exceeded.

When the maximum pressure is exceeded (e.g. incorrect setting of the oper-
ating pressure value), the entire delivery volume of the compressor is eject-
ed!
Electrical energy
hazards
Caution: Voltage!
There is danger of life when working on the electrical equipment of the
compressor!
– Disconnect mains connection prior to starting to carry out works on the
compressor and use padlock to secure against switching on again.
– Only duly authorized professional electricians (e.g. plant electricians) are
allowed to carry out works in the electrical area of the machine.
– Make sure to check the electrical equipment of the compressor at regular
intervals for defects such as loose connections or scorched cables and
have any defects repaired immediately.
– Make sure to have all electrical equipment and fixed electrical installa-
tions checked by a professional electrician at least every 4 years.
– Any modifications that may have been carried out after examination must
conform to DIN EN 60204-1:2007.
– Make sure to check all safety installations on the machine for proper func-
tioning at regular intervals.
– Only use original fuses.
Accident prevention The owner of a compressor plant is responsible to ensure that it is properly
regulations installed, operated and maintained.
Prior to commissioning, owners in the Federal Republic of Germany urgently
have to read the currently valid regulations of the Main Association of the In-
dustrial Employers' Liability Insurance. Apart from other regulations particular-
ly the Ordinance on Industrial Safety and Health (BetrSichV) is applicable.
The regulations are available at the following locations:
– Berufsgenossenschaft (Industrial Employers' Liability Insurance)
– Carl-Heymanns-Verlag KG, Luxemburger Straße 449, D-50939 Köln
– Beuth Verlag GmbH, Burggrafenstraße 6, D-10787 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 be-
yond the legal regulations specified in the Federal Republic of Germany or the
data contained in these operating instructions, then it is of utmost importance
that these be carried out prior to commissioning the compressor plant.
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 and/or con-
trol pneumatics)
must be worn.
Before starting work using oils or greases a skin protection cream must be ap-
plied. Having finished the work a skin care product must be applied.
Product description 2.1 Technical data
Part 2: Product description 2.1 Technical data
Compressor system: maximum pressure 10 bar, 50 / 60 Hz (compressor unit)
Max. sound pressure level
silenced / super silenced

Dimensions (W x D x H)
super-silenced approx.
acc. to PN8NTC 2.3

acc. to VDMA 4362
Compressor speed
silenced approx.
silenced approx.
(output rate)
Volume flow
50/60 Hz
at 8 bar
Weight
Weight
Model
[pmax bar] [l/min] [m3/h] [min-1] Motor

[kW] [mm] [mm] [kg] [kg] [dB (A)]
K 3 10 244 14.64 1450/1740 2.2 1012x804x784 1312x804x784 182 189 73/70
K 4 10 328 19.68 1450/1740 3.0 1012x804x784 1312x804x784 182 189 74/71
K 6 10 466 27.96 1450/1740 4.0 1012x804x784 1312x804x784 209 216 75/72
K 8 10 648 38.88 1450/1740 5.5 1012x804x784 1312x804x784 225 232 78/75
K 15 10 1296 77.76 1450/1740 11.0 1497x806x891 2097x806x891 379 391 83/79
Compressor system: maximum pressure 10 bar, 50 / 60 Hz (with receiver)

Model (with receiver size)

acc. to PN8NTC 2.3

acc. to VDMA 4362
Compressor speed
silenced approx.
silenced approx.
(output rate)
Volume flow
50/60 Hz
at 8 bar
Weight
Weight
Motor
[pmax bar] [l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg] [dB (A)]
K 3 – 270 10 244 14.64 1450/1740 2.2 1770x804x1346 290 297 73/70
K 4 – 270 10 328 19.68 1450/1740 3.0 1770x804x1346 290 297 74/71
K 6 – 270 10 466 27.96 1450/1740 4.0 1770x804x1346 320 327 75/72
K 8 – 270 10 648 38.88 1450/1740 5.5 1770x804x1346 330 337 78/75
K 15 – 270 10 1296 77.76 1450/1740 11.0 1770x806x1453 490 502 83/79
Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz (compressor unit)

acc. to PN8NTC 2.3

acc. to VDMA 4362
Compressor speed
silenced approx.
silenced approx.
at 12/32 bar
Volume flow
(output rate)
50/60 Hz
Weight
Weight
Model
Motor
[pmax bar] l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg] [dB (A)]
K 4 15 279 16.74 1450/1740 3.0 1012x804x784 1312x804x784 182 189 71/68
K 6 15 420 25.20 1450/1740 4.0 1012x804x784 1312x804x784 209 216 72/69
K 8 40 390 23.40 1450/1740 5.5 1012x804x784 1312x804x784 232 239 75/72
K 15 15 794 47.64 1450/1740 11.0 1497x806x891 2097x806x891 380 392 83/79
K 15 40 780 46.80 1450/1740 11.0 1497x806x891 2097x806x891 380 392 83/79
Compressor system: maximum pressure 15 and 40 bar, 50 / 60 Hz (with receiver)

Model (with receiver size)

acc. to PN8NTC 2.3

acc. to VDMA 4362
Compressor speed
silenced approx.
silenced approx.
Volume flow
(output rate)
at 12/32 bar
50/60 Hz
Weight
Weight
Motor
[pmax bar] [l/min] [m3/h] [min-1] [kW] [mm] [mm] [kg] [kg [dB (A)]
K 4 – 250 15 279 16.74 1450/1740 3.0 1630x804x1346 1630x804x1346 290 297 71/68
K 6 – 250 15 420 25.20 1450/1740 4.0 1630x804x1346 1630x804x1346 320 327 72/69
K 15 – 250 15 794 47.64 1450/1740 11.0 1520x806x1453 2097x806x1453 490 502 83/79
K 8 – 250 40 390 23.40 1450/1740 5.5 1630x804x1346 1630x804x1346 330 337 75/72
K 15 – 250 40 780 46.80 1450/1740 11.0 1560x806x1453 2097x806x1453 490 502 83/79
Booster compressor system:

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

acc. to PN8NTC 2.3

acc. to VDMA 4362
Compressor speed
silenced approx.
silenced approx.
at 12/32 bar
Volume flow
(output rate)
50/60 Hz
Weight
Model
Motor
[pmax bar] l/min] [m3/h] [min-1] [kW] [mm] [kg] [dB (A)]
K 8 Booster 40 1160 69.60 1450/1740 5.5 1010x930x790 215 75/72
K 15 Booster 40 2320 139.20 1450/1740 11.0 1500x930x885 425 83/79
Installation 3.1 Transport
Part 3: Installation 3.1 Transport
General Please observe the generally accepted safety and accident prevention regu-
lations when transporting the compressor. BOGE accepts no liability for dam-
age caused by incorrect transport!
Attention!
The transport of the compressor may only be carried out by adequately in-
structed and authorized personnel!
The capacity of the lifting gear (lifting cart or forklift truck) must correspond at
least to that of the compressor (see chapter „2.1 Technical data”, page 11)!
Mind the position of the mass centre prior to lifting the compressor! The posi-
tion of the mass centre is specified both in the attached dimensioned drawing
and on the packing of the compressor.
Lifting lugs on certain component parts (e.g. electric motor) are exclusively
intended for lifting the individual parts, however not for lifting the entire com-
pressor!
Do not tilt the compressor during transport!
Move compressor to installation site as described in the following sections.
Transport possibilities Forklift truck or lifting carriage transport
Attention!
Inappropriate transport may lead to compressor damages. Do not subject the
safety cladding to force during transport.
Ensure that the forks are un-

derneath the base frame of
the compressor (see figure).
Fig. 3.1: Transport with forklift truck
Installation 3.1 Transport
Crane transport
Attention!
Inappropriate transport may lead to compressor damages. Do not subject the
safety cladding to force during transport.
– Only lift compressor by using the supplied transport pallet.
– Protect the compressor using wooden spacers (see arrows in the illus-
tration below).
– Remove transport timber.
– Only use suitable transport slings having a minimum length of approx.
5 metres!
Place loops of the transport slings at the

head sides underneath the supplied trans-
port pallet of the compressor.
Neither fasten the transport slings to the
suction filter nor to the eyelet on the motor.
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 The com-
pressor room”, page 17).
In case of a careless storage BOGE does not assume any liability for conse-
quent damages!
In the event of an extended intermediate storage or after an extended stop-
page (6 months) you should consult BOGE-Service.
In case of protracted downtimes and/or temporary storage of more than two
months make sure to also observe the respective measures for commission-
ing (see section „Prior to commissioning / start up”, page 28“).
Installation 3.2 The compressor room
3.2 The compressor room
Installation conditions
for compressed air
receivers arranged
separately
Caution!
– Protect compressed air receivers against damage through mechanical
effects (e.g. falling objects).
– Operate the compressed air receiver and its equipment from a safe loca-
tion.
– Adhere to safety areas and safety clearances.
– Ensure that the compressed air receiver stands securely. It must not shift
or tilt due to external forces. This also includes the additional weight dur-
ing a pressure test!
– The compressed air receiver must not be bolted to the base.
– Ensure that the compressed air receiver is easily accessible from all
sides (for recurring tests).
– Ensure that the type plate is clearly visible.
– Ensure that compressed air receivers are adequatly protected against
corrosion (galvanised receiver).
– Only use the compressed air receiver for compressors operating with
cut-in and cut-out mode if the pressure fluctuation range amounts to
Δp ≤ 20% of the maximum operating pressure.
Installation surface A level industrial floor without foundation is adequate for the installation of the
compressor. No special fastening elements are required.
Note!
If vibrations are detected during commissioning due to an inappropriate foun-
dation the owner has to install a suitable vibration damper between machine
feet and foundation.
Please note that even the use of vibration dampers will not prevent the ma-
chine from causing mechanical residual vibrations. This fact should be drawn
into account when placing sensitive equipment in the immediate neighbor-
hood of the machine.
Sound protection Only install compressors in workrooms if the sound pressure level of their
measuring surfaces does not exceed 85 dB (A).
Admissible The compressor room must be clean, dry, cool and free of dust.
environmental
Admissible ambient temperatures
influences
Maximum ambient temperature (for air cooling): + 40°C
Minimum ambient temperature: + 5°C
Attention!
Non-observance of the admissible ambient temperature may lead to the fol-
lowing problems:
– Pipelines and valves may freeze up at low temperatures.
– The service life of components will fall if temperature limits are exceeded.
Measures to be taken to ensure that admissible ambient temperatures

are observed:
– Avoid having any heat-radiating pipelines or units in the vicinity of the
compressor, or insulate them well.
– Never install the compressor in the cooling air flow of other machinery.
– Provide the supply air openings with adjustable louvres to ensure that the
minimum temperature is not gone below in winter.
Ventilation If the following instructions are not observed, the admissible final com-
pression temperature may be exceeded.
Caution!
Arrange the compressor intake openings or ducts in such a way, that dan-
gerous admixtures (e.g. explosive or chemically unstable materials) cannot
be drawn in.
Ventilation openings (free-standing installation)

– Arrange supply air openings close to the floor.
– Arrange exhaust air openings in the ceiling or at the top of the wall.
– The required cross sections for the supply openings (as well as for the
flaps and weather protection grids) are indicated in the table 3.1.
Ventilators
Ensure that the heated exhaust air is not taken in again.
If necessary, the heated exhaust air must be extracted by ventilators. To en-
sure perfect cooling even at higher temperatures in the summer, the ventila-
tors must be designed as follows:
– The ventilator capacity must be rated approx. 10...15% higher than the
sum of the cooling air quantity required for all machines operated in the
room (VDMA Code of Practice sheet 4363 "Ventilation of compressor
rooms").
– For free-standing installation, the cooling air requirement specified in the
table corresponds to the required ventilator capacity.
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.
Drive rating Required ventilator output for Necessary

room ventilation inlet opening
[kW] [m3/h] [m2]
2.2 1000 0.3
3.0 1400 0.3
4.0 1800 0.3
5.5 2270 0.3
11.0 4750 0.5
Fig. 3.1: Cooling air requirement and necessary size of supply air opening
Installation of the – Set up the compressor in such a way, that

compressor – it can be operated and serviced without disturbances or obstructions
(see layout/space plan).
– there is sufficient space at the front side (min. wall distance: 600 mm)
to suck in air. Otherwise the ventilator efficiency is affected and a prop-
er cooling can no longer be guaranteed!
– The cooling air flow of a compressor must not heat up other machines.
– Ensure that the heated exhaust air is not taken in again.
– Please note that even the use of vibration dampers will not prevent the ma-
chine from causing mechanical residual vibrations. This fact should be
drawn into account when placing sensitive equipment in the immediate
neighborhood of the machine.
– Please observe the admissible surface load of the place of installation (see
layout/space plan).
Sound insulation hoods Only use the original BOGE sound insulation hoods for all BOGE compres-
sors. Other hoods may impair the cooling, causing serious damage!
Attention!
If you fail to observe the instructions on installation, as well as ventilation, the
machine may be damaged and the compressed air quality may be impaired.
Installation 3.3 Installation, assembly and commissioning
Electrical connection
Caution: Voltage!
Make sure to secure the power line to the compressor in conformity with the
technical connection requirements. A power cut-out should also be provided.
The installation must be carried out by a qualified specialist!
Condensate disposal The air taken in contains water in form of vapour, which turns into condensa-
tion during compression.
Attention!
When disposing of the collected condensate, the drainage requirements of
your local water authority are to be adhered to!
Do not hesitate to contact us if you have any questions on this subject.
3.3 Installation, assembly and commissioning
Note!
We recommend the drawing up of an assembly and commissioning certifi-
cate in which the test results during the assembly or commissioning process
can be listed up.

Installation and commissioning are to be carried out by duly authorized and
experienced professional personnel only!
Always wear protective gloves when working on the compressor to avoid
bruising of fingers or hands while opening or closing components!
General Depending on the purchased variant, BOGE compressors will be shipped as

incomplete machines or as ready-for-connection units. Only the work de-
scribed in the following paragraphs needs to be carried out during installation.
As to installation observe the notes in chapter „3.2 The compressor room”,
page 17.
Caution!
Only have the installation work carried out by appropriately trained persons
or specialists.
Lay out all energy supply lines in a trip-proof and barrier-free manner so that
potential accidents can be avoided!
Prior to delivery, each compressor is subjected to a trial run at the factory. It is

carefully tested and set. However, possible transport damage cannot be ex-
cluded.
– It is recommended that the compressor be subject to a visual inspection
immediately after receipt (damage to paintwork, oil stains or other types of
damage) and that any complaints be reported to the last shipping compa-
ny. In order to secure your claims for damages against the shipping com-
pany we would advise you to temporarily leave the machines, equipment
and packaging materials in the condition in which they were received upon
determination of the damage.
– Observe the compressor very closely during commissioning and the fol-
lowing trial run.
– If malfunctions occur, switch off the compressor immediately and inform
the BOGE-Service.
Checking the delivery 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:
– Operating instructions
– Dimensioned drawing
– Keys
– Electric circuit diagram
Installing the
compressor
Attention!
During transportation, do not use intake filter as a means of transportation.
– Remove all packing material in and around the compressor.

– Install compressor and align it horizontally.
– The compressor / compressed air receiver (depending on type) must stand
firmly on the ground on all feet.
Assembly Customized compressor stations (built-in compressors, incomplete ma-

chine)
Customized compressor stations (machines, receivers, fittings and switch de-
vices) are shipped incompletely assembled. receiver fittings, switch devices,
connection piping and control lines are readied at the factory and included with
the shipment.
As a standard, the compressor unit is mounted on the receiver. Depending on
locally available space the unit may also be placed in a different manner. At
any rate, the unit should be in the proximity of the receiver. Prior to installation
of your compressor please contact BOGE for further information or details on
proper positioning and/or connection to existing receivers!
In this conjunction, please observe related references in chapter „3.2 The
compressor room”, page 17“.
Fig. 3.3: View of a customized compressor station
1 Compressor control or compressed air switch (according to type)

2 Electrical connection
3 Air outlet, ball check valve
4 Condensate drain on compressed air receiver
5 Manometer / Safety valve
6 Compressor
7 Elastic bearing
8 Compressed air connection Compressor-Receiver
9 Compressed air receiver
Assembly in case of
booster pressure supply
(K Booster)
Fig. 3.4: Assembly overview: Booster compressor with vertical receiver
1 Inlet pre-compressed compressed air

2 Upstream compressed air receiver
3 Pre-filter
4 High-pressure hose (booster pressure)
5 Booster compressor
6 High-pressure hose (final pressure)
7 Compressed air receiver
8 Outlet finally compressed compressed air
: Compressed air path
Fig. 3.5: Assembly overview: Booster compressor with horizontal receiver
Booster compressors (K 8 Booster, K 15 Booster) are designed to take in pre-

compressed compressed air from the network of an existing compressed air
system, preferably from an upstream compressed air receiver (2) with a min.
250 liter capacity in order to reduce pulsation on the suction side. The sepa-
rately enclosed pre-filter (3) is to be installed in the pre-pressure line upstream
of the flexible connection / hose (4) (see pertaining illustrations 3.4 and 3.5).
Never install the filter directly on the compressor (5). Do not forget to monitor
the differential pressure display of the pre-filter. The filter element has to be
replaced when the differential pressure shows 0.035 bar or at least once a
year. It must be checked that the size of the intake line is correct, otherwise
the quantity of air delivered will be affected.
If the diameter of your compressed air lines is not sufficient, a special connec-
tion line must be laid from the compressed air receiver to your booster com-
pressor.
– Hose and pipeline for booster compressors K 8 Booster and K 15 Booster
at least DN25.
Please consider that the FAD of your compressor must correspond to the
booster pressure supply.
Attention!
The booster pressures specified on the type plate are maximum pressures
and must not be exceeded
With higher network pressure, a reduction valve with safety valve must be
connected upstream from the booster compressor.
Quality of compressed air from the compressd air net
Attention!
The residual oil content of the air taken in may damage the compressor. The
residual oil content must not exceed the value specified below. A pre-treat-
ment of the compressed air is necessary before it is taken in!
The quality of the compressed air taken in must meet certain minimum require-
ments. For BOGE booster compressors the air taken in must not exceed the
following maximum values for impurities:
– Oil content ≤ 0,01 mg/m³ (purity class 1)
– Water content 5,90 g/m3 (Pressure dew point + 3 °C)
– Inlet temperature max. 40 °C
Furthermore thr following amounts of particles (corresponding to particle size)

per cubic meter of compressed air taken in must not be exceeded:
Particle size in μm Particle amount / m³
– 0.1 bis ≤ 0,5 ≤ 20 000
– 0.5 bis ≤ 1,0 ≤ 400
– 1.0 bis ≤ 5,0 ≤ 10
If necessary, the compressed air needs to be pretreated prior to compression
by use of the booster compressor, i.e. cleaned by means of a cyclone separa-
tor, pre-filter and dryer.
Electrical connection
WARNING: Voltage!
Ensure that work on the electrical equipment of the compressor is only car-
ried out by authorized electricians.
Prior to commencement of any works the power supply cable is to be
switched currentless from the power supply system and to be secured
against unintended connection.
When connecting to the power supply, observe the valid VDE, DIN and EVU
regulations or the local safety regulations.
Also observe the regulations of your local power supply company regarding
the load rating of your power supply.
Mains disconnecting device

According to accident prevention regulation VBG 5, § 12, the customer is
responsible to provide the following safety measures:
Compressor plants must be fitted with a power disconnecting device accord-
ing to EN 60204-1:2007
The pressure switch and/or pressure sensor (when using BASIC control) are
not designed as mains disconnecting device!
Fuse protection of compressors at 400 V / 50 – 60 Hz.
Rating Nominal Minimum Minimum Recommended Recom-

current prel. fuse 1) prel. fuse 1) prel. fuse 1) mended
star-delta direct star-delta prel. fuse 1)
direct
[kW] [A] [A] [A] [A] [A]
2.2 4.7...5.2 10 10 10 16
3.0 6.5...7.0 10 16 10 16
4.0 9.7...10.5 16 20 16 20
5.5 13.5 20 25 20 25
11.0 22...23.5 35 35 35 50
1)
Use fuse gL – gG or circuit-breaker with C-characteristic only.
Please see name plate for compressor motor output.

– Use slow fuses only!
– Do not use any circuit breakers!
Rated voltage
The data of your mains (operating voltage, control voltage, type of current, fre-
quency,...) must be identical to the data on the type plate on the switch cabi-
net.
In the event of deviations, please contact the BOGE service or your supplier.
Connect power supply lines

– Check to ensure that all terminals in the switch cabinet are firmly tight-
ened.
If necessary, retighten the screw connections.
Remove screw (1) on either

side.
Use handles to pull cover (2)
upward and carefully put
down the handles.
Pass power supply cable
through cable bushing (PG
gland) (3).
Fig. 3.6: Insert power supply line
Mains Pressure switch with overcurrent

release for direct connection to
three-phase motor (up to 5.5 kW
and max. 15 bar)
Connect the leads L1, L2, L3, N, Pe

(PEN) firmly to the power supply ter-
minal.
A clockwise rotational field must be
created.
Motor
3~
Fig. 3.7: Connection power supply line
– Retighten the electrical connections after the first 50 operating hours.
Compressed air Connect compressed air receiver

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

(1) coming from compressor
to compressed air receiver
(2).
(In case of a customized com-
pressor station the com-
pressed air receiver may be
aligned other than shown in
this illustration.)
Fig. 3.8: Connection compressor unit - compressed air receiver
Compressed air connection for booster compressors (K Booster)
(1) Compressed air inlet

(from pre-filter side)
(2) Compressed air outlet
Fig. 3.9: Compressed air inlet/outlet for booster compressors
Note!
At the booster compressor K 15 Booster the compressed air inlet and com-
pressed air outlet are placed opposite each other on the longitudinal sides of
the housing.
Compressed air inlet and conmpressed air outlet are marked by red arrows
as shown in fig. 3.9.
1 Compressed air inlet (fig. 3.9):

The pre-compressed air was cleaned by means of the pre-filter and is taken
into the booster compressor at this point via a high-pressure hose.
Attention!
Any potential residual oil in the incoming air may cause damage to the com-
pressor. The residual oil content may not exceed the valued specified on
page 24. Make sure to accordingly pre-treat the compressed air before enter-
ing.
2 Compressed air outlet (figure 3.9):

The compressed air is compressed to the final pressure and can now be fed
into a compressed air network or compressed air receiver.
Connection to compressed air pipe network
Connect ball check valve (1)

on compressed air receiver to
compressed air pipe network.
Make sure to use a high pres-
sure hose!
(In case of a customized com-
pressor station the com-
pressed air receiver may be
aligned other than shown in
this illustration).
Fig. 3.10: Connection compressor unit – compressed air receiver
Prior to commissioning /
start up
Note!
We recommend the drawing up of a commissioning certificate in which the
test results during the commissioning process can be listed up.

Prior to any work on the compressor:
– Press Emergency Stop button, open mains disconnection device and
secure against unintentional switch on .
– Check that all electrical components are not under power.
– Depressurize all areas under pressure.
Additionaly for booster compressors: Vent booster pressure pipe leading
to the booster compressor.
Never omit a single safety step! Otherwise, you will risk injuries due to re-
starting, electric shock or self-releasing parts.
Caution!
When the automatic restart (Auto-Restart) is activated, the compressor will
start automatically following a voltage loss.
Prerequisite: The network pressure is lower than the set switch-on pressure.

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

direction
Attention!
Always check the rotational direction of the drive motor prior to commission-
ing/initial start up.
Ensure that the directional rotation coincides with the directional rotation ar-
row on the cooling air hood.
Caution!
Always wear safety gloves!
K 3 – K 8: When watching the flywheel through the grid the compressor must
rotate to the right, in order that the cooling air flow from the ventilator is press-
ing against the compressor.
K 15: When looking at the fan wheel the fan itself must rotate anti-clockwise
so that the fan generated cooling air flow is pushed out upward.
– Close mains disconnecting device.
– Switch the compressor on and immediately off again to check the rota-
tional direction.
Changing the rotational direction

Press Emergency Stop button, open mains disconnection device and secure
against unintentional switch on.
– 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!

– Switch on the compressor and check the compressed air outlet for tight-
ness.
– Switch off compressor.

Open mains disconnection device and secure against unintentional switch
on by means of a padlock.
– If necessary, have leakages repaired by skilled qualified pesonnel.

Checking for leaks Undertake the following to prevent leaks:

(general) – Check screw connection of the lines and retighten, if necessary.
Installation 3.4 Dismantling
Conduct trial run Each compressor is put through a trial run at the factory. It is carefully tested
and set. However, we are unable to guarantee that no damage occurred, e.g.,
during transport. It is therefore necessary to conduct a trial run for a precise
observation of the compressor.
– Switch on the compressor.
The compressor switches off automatically once the switch-off pressure,
has been reached.
– Check pressure at pressure gauge (compressed air net).
If necessary, readjust pressure switch/pressure sensor (see chapter
"Maintenance", section „Checking and setting the operating pressure (with
compressor control)”, page 44).
– Check pressure display on the control.
If necessary, reset the pressure (see separate operating instructions).
The compressor is ready for operation.
Switch off compressor after a 30-minute trial run at max. operating load.
3.4 Dismantling
Note!
To avoid dangers when dismantling the compressor please consult your
BOGE Service:
Telephone: +49 5206 601-140
Caution!
Dismantling of the compressor may only be carried out by experienced and
authorized qualified personnel!
Dispose of collected condensate in accordance with local regulations!
Caution: Voltage!
All work on the electrical installation may only be carried out by authorized
and skilled electricians!
Prior to starting the work the power cable to the switch cabinet must be dis-
connected from the mains and secured against unintentional switching on!
Fault 4.1 General
Part 4: Fault 4.1 General
The tables on this and on the following pages give information on the possible
causes of operating faults and measures for their rectification (please also re-
fer to operating instructions of the compressor control).
Caution!
Ensure that any work required to rectify faults is only carried out by trained
personnel or specialists.
Ensure that components which have a safety function are only set, repaired
or exchanged by BOGE Service!
Please contact BOGE-Service at the following telephone number, if you have
any questions.
Telephone: +49 5206 601-140
Caution: Voltage!
Prior to any work required to rectify faults:
Open mains disconnecting device. Secure mains disconnecting device
against unintentional switching on by means of a padlock.
4.2 Faults and fault rectification
Fault Possible cause Rectification
Receiver safety valve blows Pressure switch set too high Set pressure switch to correct cut-out pressure
off
Safety valve displaced Check seal, if damaged have safety valve read-
justed by BOGE
Air escapes from solenoid Compressor not running:

valve non-return valve leaking Clean ball and seat of non-return valve
Compressor running:
– Solenoid valve soiled Clean solenoid valve, renew seals
– Coil of solenoid valve defective Check coil and replace if necessary
Fault 4.2 Faults and fault rectification
Compressor supplies no Suction filter soiled Clean suction filter

output or output too low
Suction and pressure valves worn or defec- Replace valves
tive
Vent valve not closing Check whether vent valve closes with compressor
running;
Overhaul or replace valve, as necessary
For booster compressors:
Solenoid valve on the intake side does not Replace solenoid valve
open – solenoid valve defective
Booster pressure too low (< 1 bar) Check booster pressure
Only for 2-stage

compressors:
Safety valve of first stage Suction and pressure valves of the second Replace valves
blows off stage defective or worn
Seal between valve and cylinder head Replace seal

defective
Air escapes from solenoid Compressor not running:

valve of first stage non-return valve leaking Clean ball and seat of non-return valve
Compressor running:
– Solenoid valve soiled Clean solenoid valve, renew seals
– Coil of solenoid valve defective Check coil and replace if necessary
The pneumatic vent valve Suction and pressure valves of first stage Replace valves
of the 2nd stage blows with defective or worn
compressor running
Suction filter soiled Clean suction filter
Solenoid valve of first stage defective Check solenoid valve and replace if necessary
Maintenance 5.1 Safety instructions
Part 5: Maintenance 5.1 Safety instructions
Caution!
Ensure that maintenance work is only carried out by specialists or appropri-
ately trained persons.
Any performance of work on pressurized system components may be carried
out by duly qualified and specialized personnel only.
– Prior to starting any maintenance work, always stop the compressor as
described in these operating instructions prior to removing any cladding
or safety devices. Refit the cladding or safety devices immediately upon
completion of the maintenance work.
– Heavy components may only be lifted up by various persons in due con-
sideration of the local industrial safety regulations.
– Only use original spare parts and operating materials released by BOGE
for the maintenance and service work
– When the automatic restart (Auto-Restart) is activated, the compressor
will start automatically following a voltage loss.
Prerequisite:The net pressure is lower than the set switch-on pressure.
Maintenance 5.2 General

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

1. Switch off the compressor using the OFF button.
2. Press Emergency Stop button.
3. Press Emergency Stop button, open mains disconnection device and
secure against unintentional switch on by means of a padlock.
4. Fix a warning label to the control and fill in the name of the person re-
sponsible who is authorized to switch on the machine again.
5. Prior to starting work let cool down all hot components of the compressor
to 50°C.
6. Check to ensure that all machine elements are definitely currentless.
7. Separate the compressor from the compressed air network.
8. Remove all safety cladding necessary to perform the maintenance work.
Once the maintenance work has been concluded:

9. Reattach all removed safety cladding.
10. Prior to switching on again, check whether anyone else is working on the
compressor.
11. Remove warning sign not until then and release mains disconnecting
device.
12. Unlock Emergency Stop button.
13. For booster compressors: Ensure booster pressure supply prior to re-
starting the booster compressor.
5.2 General
Maintenance through Have BOGE service check your compressor completely according to the serv-
BOGE service icing table (see " Maintenance intervals" on page 39).
Maintenance agreement
Enter into a maintenance agreement with BOGE. BOGE service will carry out
the proper maintenance on your compressor at regular intervals. This guar-
antees maximum safety and realiability of your compressed air supply.
Spare and wearing parts
Caution!
Only use original spare parts approved by BOGE for repair or maintenance
work.
BOGE accepts no liability for damage caused by the use of other parts.
Overview of regular
maintenance work
Fig. 5.1: Overview of regular maintenance work
1 Pressure switch with hour counter (not with booster compressors)

2 Check cooler for soiling / clean if necessary
3 Check pressure adjustments / adjust pressure, if necessary
(compressor control)
4 Check/clean both air intake filters (not with booster compressors)
Replace air intake filter cartridge (not with booster compressors)
5 For booster compressors (not illustrated here):
– Check pre-filter
– Replace pre-filter cartridge
1 1
Fig. 5.2: Overview of regular maintenance work K 15
1 Check cooler for soiling / clean if necessary.

2 Check pressure adjustments/adjust pressure, if necessary
3 Check intake filter / clean if necessary (not with booster compressors)
Replace air intake filter cartridge (not with booster compressors)
4 For booster compressors (not illustrated here):
– Check pre-filter
– Replace pre-filter cartridge
Fig. 5.3: Additional service work K 3..K 8
1 Check safety valve
Fig. 5.4: Additional service work K 15
Maintenance intervals The maintenance intervals specified in the table are based on average oper-
ating and ambient conditions.
Extreme conditions may require shorter maintenance intervals.
Note!
Note down all maintenance work in the table on the last pages. This will facil-
itate troubleshooting for BOGE-service.
Retighten the screw connections of the electrical connections after the

first 50 operating hours.
1. Switch off the compressor using the OFF button.
2. Press Emergency Stop button.
3. Open power disconnecting device and secure against unintentional
switch on by means of a padlock.
4. Check to ensure that all machine elements are definitely currentless.
5. Disconnect compressed air network from the compressor.
6. Remove all necessary safety cladding to perform the maintenance work.
7. Retighten the electrical connections in the switch cabinet.
8. Reattach all removed safety cladding.
9. Release power disconnecting device.
10. Unlock Emergency Stop button.
11. For booster compressors: Ensure booster pressure supply prior to re-
starting the booster compressor.
Maintenance work Maintenance intervals in operating hours Page
monthly yearly 3.000

yearly
General maintenance work
Check function of EMERGENCY STOP pushbutton X –
Check / clean intake filter cartridge (not for booster compressors) X 40
Replace intake filter cartridge (not for booster compressors) X 41
Check pre-filter (for booster compressors) X 41
Replace pre-filter cartridge (for booster compressors) X 41
Clean cooler X 43
Check / adjust operating pressure X 44
Check safety valve X 46
Maintenance 5.3 Regular maintenance work
The following servicing tasks must be carried out by expert BOGE servicing personnel:
Operating hrs Operating hrs

at 50 Hz at 60 Hz
Change drive 1) 6.000 5.000
after 2 years at the latest
Replace air intake and pressure valves 6.000 5.000

1)
The specified servicing intervals are mean values that may be shortened or extended according to operating conditions. If installed in areas with ambient temperatures
of 30°C to 40°C the intervals are to be reduced by 1000 operating hours.
Tab. 5.1: Maintenance intervals
5.3 Regular maintenance work
Intake filter:
Cleaning / changing of
filter cartridges
Note!
This servicing is not meant for booster compressors.
Cleaning:
– 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.
Removing the filter cartridge

Press Emergency Stop button, open mains disconnecting device. Secure
mains disconnecting device against unintentional switching on by means of
a padlock.
To clean or replace the filter cartridge proceed as follows:

– Remove cladding on the maintenance side.
– Remove the lid of the filter case.
– Take out the filter cartridge.
– Now the filter cartridge can be cleaned resp. replaced.
Clean filter cartridge
Caution!
Do not clean filter cartridges in liquids.
Do not use hard objects for cleaning in order that the filter paper is not dam-
aged.
Replace the filter cartridge if it is damaged or has been cleaned twice.
– Tap the filter cartridge with your hand to knock out coarse dust.
– Blow out fine dust (max. pressure 5 bar) from the inside to the outside.
– Clean the sealing surfaces of the filter cartridge.
Fitting a filter cartridge

After cleaning and in case of
a replacement insert the
cleaned resp. new filter car-
tridge as follows:
– Insert the filter cartridge
into the filter case.
– Fasten the lid of the filter
case.
– Fit the cladding on the
service side.
Fig. 5.5: Intake filter (1) and filter cartridge (2)
Check pre-filter /
Replace filter cartridge
Note!
This service is only suitable for booster compressors.
Check functionality of pre-filter:

– 1 x per month.
– Pressure display must be in the green area.
Replace filter cartridge:

– after 3.000 operating hours,
however, no later than after one year.

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

– Depressurize pre-filter (cf. filter man-
ual).
– Unscrew and remove bottom part of
housing (1).
– Unscrew filter cartridge (2) and take
out.
– Insert new filter cartridge with O ring.
– Tighten filter cartridge by hand. Make
sure that the O ring is properly seated.
– Check tightness of housing (cf. filter
manual).
– The pre-filter is ready for operation
again.
Lubricate the bearings The bearings of the drive motors usually have a service-free permanent lubri-
of the drive motor cation.
Drive motors with Under normal operating conditions (refrigerant temperature max. 40°C, con-
permanent lubrication tinuous operation) the bearings require no servicing.
Mains frequency Operating hours

50 Hz 18.000
60 Hz 15.000
Tab. 5.2: Service life of bearings
The service lives specified above are extended or shortened in the event of
higher or lower thermal stress (due to the higher or lower temperature of the
coolant).
Attention!
The bearings must be replaced by BOGE-service after their service life has
expired. This is done by BOGE-Service together with the scheduled service
after 6.000/5.000 operating hours by installing an exchange motor. We rec-
ommend the installation of a spare compressor.
Cleaning the cooler Cleaning:

(air cooling) – After 3.000 operating hours,
but no less than once a year.
The service life of the cooler depends on the degree of soiling (dust, oil va-
pour) in the intake cooling air. Heavy external soiling of the cooler leads to
an excessively high temperature in the air circuit.
– Switch off the compressor with the OFF button.

Press Emergency Stop button, open mains disconnecting device. Secure
mains disconnecting device against unintentional switching on by means of
a padlock.
– Remove the cladding from the service side.

– Clean off the collected soiling with a fibre brush (vacuum cleaner).
Attention!
Never use sharp objects to clean the cooler!
You may damage the cooler (vacuum cleaner).
– Blow out any dirt with compressed air (1) against the normal flow of the
cooling air.
If the cooler is very heavily soiled (i.e. a cleaning with compressed air is no
longer possible), it must be dismantled and cleaned by BOGE-Service.
Fig. 5.6: Cleaning the compressed air cooler
Checking and setting Check:

the operating pressure – After approx. 3.000 operating hours,
(with compressor but at least 1x per year.
control) Setting:
– If the switch-on or switch-off pressure no longer matches the set point val-
ues.
Set point values (factory setting):

Switch-on pressure: pmin = final compression pressure – 2 bar at pmax. 10 bar.
– 3 bar at pmax. 15 bar.
– 5 bar at pmax. 40 bar.
Switch-off pressure: pmax = final compression pressure.
The target values (factory setting) can be adjusted individually to the operat-
ing conditions.
Caution!
Never set the operating pressure higher than the admissible final compres-
sion pressure (see type plate).
Check the operating pressure:

– Check the switch-on and switch-off pressure on the net pressure gauge
during operation .
Switch-off pressure =
the pressure at which the compressor switches off.
Switch-on pressure =
the pressure at which the compressor automatically switches on.
Check / set operating Check:

pressure switch – After approx. 2.000 operating hours,
but at least 1x yearly.
Setting:
– If the switch-on or switch-off pressure no longer matches the set point val-
ues.
Set point values (factory setting):
Max. pressure [bar] 8 10 15

Switch-on pressure [bar] 6 8 12
Switch-off pressure [bar] 8 10 15
Attention!
Never set the operating pressure switch above the admissible final com-
pression pressure (see type plate).
Check operating pressure switch:

The operating pressure switch is installed on the compressor unit.
– Check switch-on and switch-off pressure on the pressure gauge during
operation.
Switch-off pressure =
the pressure at which the compressor switches off.
Switch-on pressure =
the pressure at which the compressor automatically switches on.
Set operating pressure switch:
Caution: Voltage!
Ensure that the operating pressure switch is only set by trained electricians.
Live contacts may be exposed on the pressure switch.
Risk of injury resulting from an electrical shock.
Attention!
Ensure that the operating pressure switch is only adjusted while under pres-
sure!
– Loosen fastening screws

(1) and (2) to remove op-
erating pressure switch
housing(3).
– Take out the adjustment
instructions.
– Adjust the pressure
switch according to the
manufacturer's instruc-
tions.
– Put the instructions back
into the casing.
Fig. 5.7: Set pressure switch
– Re-fasten the casing of the operating pressure switch.
Maintenance 5.4 Spare parts and optional extras
Checking the safety Check:

valve – After approx. 3.000 operating hours,
but at least 1x yearly.
Check the safety valve by turning open the lock screw.

Take extreme care when checking the safety valve with the compressor run-
ning, and observe all safety measures.
Hot air escapes during opening!
– Always wear protective goggles and gloves.
– Open the lock screw (1) by turning it anti-clockwise.
The compressed air escapes.
– Tighten the threaded plug by turning clockwise.
– The safety valve is situated on the fitting support of the receiver.
Fig. 5.8: Check safety valve
5.4 Spare parts and optional extras
List of spare and

wearing parts Description
(for maintenance) Intake filter / Cartridge
Pre-filter / cartridge (for booster compressors)
Please always specify the following information from the type plate
when ordering:
– Type
– Year of manufacture
– Machine number
Appendix 6.1 Guidelines and standards complied with
Part 6: Appendix 6.1 Guidelines and standards complied with
The compressor conforms to the following guidelines and standards:
Guidelines and directives

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

– DIN EN 1012-1:2011
– DIN EN ISO 12100:2011
– DIN EN 60204-1 / VDE 0113-1:2007
– DIN EN 61000-6-2 / VDE 0839-6-2:2006
– DIN EN 61000-6-4 / VDE 0839-6-4:2007
6.2 Pneumatic circuit diagrams
On the following pages you will find the individual pneumatic circuit diagrams
for the different machine types.
Appendix 6.2 Pneumatic circuit diagrams

(single stage up to 10 bar with compressor control)
101 Intake air INLET

102 Compressed air OUTLET
1 Intake filter
2 Vacuum switch for intake filter *
3 Service display *
4 Compressor, stage 1
5 Drive motor
6 Safety valve, stage 1 *
7 Cooler, stage 1
8 Pressure sensor, system pressure monitoring *
9 Pressure sensor, net pressure
10 Non-return valve
11 Elastic hose
12 Solenoid valve, stage 1 (ventilation)
13 Silencer, stage 1
* Option

(single stage up to 10 bar with pressure switch ventilation)

1 Intake filter
3 Service display *
5 Drive motor
6 Safety valve, stage 1
7 Cooler, stage 1
8 Pressure switch with ventilation
9 Non-return valve
10 Elastic hose
* Option
Pneumatic circuit diagram: K 4 – 15 / K 6 – 15 / K 8 – 40 / K 15 – 15/40

(two-stage 15...40 bar with compressor control)

1 Intake filter
3 Service display *
5 Drive motor
6 Cooler, stage 1
8 Cooler, stage 2
10 Pressure sensor, system pressure monitoring *
11 Pressure sensor, net pressure
12 Non-return valve
13 Elastic hose
14 Solenoid valve, stage 1 (ventilation)
15 Pneum. vent valve, stage 2 (ventilation)
* Option
Pneumatic circuit diagram: K 4 – 15 / K 6 – 15

(two-stage up to 15 bar with pressure switch ventilation)

1 Intake filter
3 Service display *
5 Drive motor
6 Cooler, stage 1
8 Cooler, stage 2
10 Pressure switch, system pressure monitoring *
11 Pressure switch, net pressure
12 Non-return valve
13 Elastic hose
14 Pneum. vent valve, stage 2 (ventilation)
* Option
Pneumatic circuit diagram: K 8 Booster and K 15 Booster booster compressors

(single stage up to 40 bar with compressor control)
101 Intake air INLET (pre-compressed air)

1 Pre-filter, assembly on site

2 flexible hose
3 Electromagnetic stop valve
4 Booster pressure sensor *
5 Compressor
6 Drive motor
7 Cooler
8 Electromagnetic vent valve
9 Sensor - system pressure build-up *
10 Non-return valve
11 Safety valve
12 Net pressure sensor
13 flexible hose
* Option
Please note the completed maintenance work in the respective columns
Page 56
Date Operating Check Replace Check / clean Replace Check Replace Check / set Check / clean Check
hours automatic drive motor intake filter intake filter pre-filter pre-filter pressure cooler safety valve
Appendix
condensate cartridge cartridge switch

drain
6.3
6.3 List of maintenance and service work

List of maintenance and service work
BOGE Operating instructions for oil-free piston compressors, series K 3...K 15

Appendix
condensate drain cartridge cartridge switch

6.3

Page 57
Page 58
Appendix
condensate drain cartridge cartridge switch

6.3

BOGE K3 K6 K8 K15 Operating Instructions

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BOGE K3 K6 K8 K15 Operating Instructions

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Operating instructions

Max. pressure: 10 bar

Max. pressure: 15 bar

Max. pressure: 40 bar

K Booster: Booster pressure 10 bar, max. pressure 40 bar

Phone: +49 5206 601-0

Part 1: 1.1 Introduction..................................................................................... 1

1.2 General safety instructions ........................................................... 6

Part 2: 2.1 Technical data............................................................................... 11

Part 3: 3.1 Transport ....................................................................................... 15

3.2 The compressor room .................................................................. 17

3.3 Installation, assembly and commissioning................................ 20

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

Part 4: 4.1 General .......................................................................................... 33

Part 5: 5.1 Safety instructions ....................................................................... 35

5.3 Regular maintenance work .......................................................... 40

Drive motors with permanent lubrication ........................................ 42

5.4 Spare parts and optional extras .................................................. 46

Part 6: 6.1 Guidelines and standards complied with................................... 47

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

Part 1: General 1.1 Introduction

These operating instructions apply to:

The present operating instructions are based on a complete machine. In case

CAUTION: Risk of injury!

Fig. 1.1: Data on the type plate

1.2 General safety instructions

10. Place the compressor out of operation as described in these operating

Safety instructions for

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

4. Exercise extreme caution during repair or maintenance work requiring the

CAUTION: Risk of injury!

– Any pipelines and/or auxiliary equipment on the compressor are designed

CAUTION: Risk of injury!

Obligations of the owner The owner is obliged to,

Personal protective In general for all work on the compressor

For special duties

Part 2: Product description 2.1 Technical data

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

Max. sound pressure level

silenced / super silenced

acc. to PN8NTC 2.3

[pmax bar] [l/min] [m3/h] [min-1] Motor

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

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

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

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

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

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

Max. sound pressure level

silenced / super silenced

acc. to PN8NTC 2.3

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

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

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

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

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

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

Max. sound pressure level

silenced / super silenced

acc. to PN8NTC 2.3

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

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

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