Bauer mariner 320 Instruction Manual
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Bauer mariner 320 Instruction Manual

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  • Page 3 The ma­ chine may only be used to produce compressed air as speci­ fied in this manual. Other use is strictly prohibited. Edition January 2010 © 2010 BAUER Kompressoren GmbH, München All rights reserved.

  • Page 4: Table Of Contents

    Instruction Manual w Breathing Air Compressors TABLE OF CONTENTS 1. GENERAL ..................2.
  • Page 5 Mariner 320 420 bar TM320-420-4/3 Dear customer We are happy to give you advice on any questions regarding your BAUER compressor and help as soon as possible with any arising problems. You can contact us Mondays to Thursdays from 08...
  • Page 6 Instruction Manual w Breathing Air Compressors NOTES Model: Serial no.: Date of purchase: Dealer address/phone no.:...
  • Page 7 Instruction Manual w Breathing Air Compressors GENERAL PURPOSE AND SHORT DESCRIPTION The Mariner 320 high pressure compressors are designed to compress air for breathing as required in diving and fire fight­ ing applications. The max. allowable operating pressure (ad­ justed pressure on final pressure safety valve) is 225 bar or 330 bar depending on unit.
  • Page 8 Instruction Manual w Breathing Air Compressors 1 Motor intake filter 2 Motor exhaust 3 Fuel tank 4 Filling valve 5 Oil filler neck 6 Compressor block 7 Compressor intake filter 8 Final pressure safety valve 8 Safety valve 9 Rope starter 10 Hinged motor plate 11 Condensate drain tap 12 Filling manifold...
  • Page 9 Instruction Manual w Breathing Air Compressors 1 Electric control unit 2 Filling valve 3 Oil filler neck 4 Compressor block 5 Intake filter 6 Final pressure safety valve 7 Condensate tank 8 Hinged motor plate 9 Condensate separator 10 Automatic condensate drain unit 11 Filter system P31 Abb.
  • Page 10 Instruction Manual w Breathing Air Compressors 1 Rope starter 2 Engine intake filter 3 Fuel tank 4 Filling valves 5 Compressor intake filter 6 Filter system P41 7 Final pressure safety valve 8 Handle 9 Battery 10 Compressor control 11 Hinged motor plate 12 Condensate separator 13 Automatic condensate drain unit...
  • Page 11 Instruction Manual w Breathing Air Compressors 1 Rope starter 2 Engine intake filter 3 Fuel tank 4 Filling valves 5 Compressor intake filter 6 Final pressure safety valve 7 Filter system P31 8 Handle 9 Condensate tank 10 Hinged motor plate 11 Condensate separator 12 Automatic condensate drain unit...

  • Page 12: Compressor Block

    Compressor block IK12.14 The compressor block IK12.14 is used to compress air in the Smooth running is a particular feature of this BAUER design. high pressure range up to 420 bar (5,000 psi). The balance of masses of the 1st rank is zero. The moving parts of the driving gear are all equally balanced.

  • Page 13: Air Flow Diagram

    Instruction Manual w Breathing Air Compressors Air flow diagram See Abb. 10. The air is drawn in through intake filter -5, com­ filter assembly -12 which is fitted with a Triplex cartridge -17. pressed to final pressure in cylinders -1, -2, -3, and -4, and re­ The interfilters -10 and -11 and filter assembly -12 are drained cooled by inter-coolers -6, -7 and -8, and after-cooler -9.
  • Page 14 Instruction Manual w Breathing Air Compressors TECHNICAL DATA Compressor units without motor Compressor unit Mariner 320- 1 Medium Breathing air Operating pressure PN 200 PN 300 Delivery 320 l/min. 320 l/min. Pressure setting, final pressure safety 225 bar 330 bar...
  • Page 15 Instruction Manual w Breathing Air Compressors TECHNICAL DATA Compressor units with petrol engine Compressor unit Mariner 320-B Medium Breathing air Operating pressure PN 200 PN 300 Delivery 320 l/min. 320 l/min. Operating pressure, final pressure safety 225 bar 330 bar...
  • Page 16 Instruction Manual w Breathing Air Compressors TECHNICAL DATA Compressor unit with three phase motor Compressor unit Mariner 320-E Medium Breathing air Operating pressure PN 200 PN 300 Delivery 320 l/min. 320 l/min. Pressure setting, final pressure safety 225 bar 330 bar...
  • Page 17 Instruction Manual w Breathing Air Compressors SAFETY MEASURES 2.1. NOTES AND WARNING SIGNS This notice is used with maintenance WARNING work and operating procedures and Notes and warning signs displayed on compressors accord­ must be adhered to exactly in order to ing to model, application or equipment.
  • Page 18 Instruction Manual w Breathing Air Compressors • Work on the electrical equipment of the machine / unit underway it is too late. This is particularly relevant for temporary personnel, e.g. maintenance personnel. may only be carried out by a qualified electrician or by an instructed person under the direction and supervision of •...
  • Page 19 Instruction Manual w Breathing Air Compressors • For assembly work above body height, use appropriate • Before carrying out welding, burning or grinding work, safety approved equipment, e.g. ladders and platforms. clean the machine / unit and surrounding area from dust Do not climb on machine parts.
  • Page 20 Instruction Manual w Breathing Air Compressors • Always exchange damaged pressure vessels completely. avoid a drop in pressure, and also the pressure maintain­ Individual parts that are subject to pressure loads cannot ing valves, which should reduce big pressure fluctuations be purchased as spare parts, since the vessels are tested as well, should be checked regularly for internal and ex­...
  • Page 21 Instruction Manual w Breathing Air Compressors permission is according to TRG 730, guidelines for permission to set up and operate filling stations. The test certificates and documents delivered with the compressor are important and may be requested during the procedure for obtaining per­ mission.

  • Page 22: Fuse Table

    Instruction Manual w Breathing Air Compressors INSTALLATION, OPERATION, FILLING PROCEDURE 3.1. INSTALLATION OF THE COMPRESSOR UNIT Indoor location Ensure adequate ventilation. The compressor frame is equipped with anti-vibration mounts and thus a machine base or special means of secur­ Here too, air must be free from exhaust fumes and haz­ ing the compressor are not necessary.

  • Page 23: Operation

    Instruction Manual w Breathing Air Compressors 3.3. OPERATION Prior to each operation check the oil level according to chapter 4.4.1. and determine whether maintenance is necessary in accordance with chapter 4.3. Preparation for operation Every time the unit is started up check all systems for The compressors described in this proper operation.

  • Page 24: Filling Procedure

    Instruction Manual w Breathing Air Compressors Press ON button (2). Filling hoses must be in satisfactory WARNING condition and threads undamaged. Pay particular attention to damage on the interface from hose fitting to hose. If the casing is scored, hose must be discarded. The filling valve connection is of the manual type and permits connection to air tanks without using tools.

  • Page 25: Change-Over Device

    Instruction Manual w Breathing Air Compressors On models of 300 bar rated filling pressure do not attach bottles unless rated for this pressure (note pressure stamped on tank neck). Abb. 17 Filling air bottle Removing the bottles Upon reaching final bottle pressure close bottle valve Abb.

  • Page 26: Shut-Down

    Instruction Manual w Breathing Air Compressors Place main switch (1) to 0. Units with petrol engine: Switch off petrol engine with stop button, close fuel tap Switch off diesel engine with engine switch-off lever, close fuel tap. All units: Vent unit by means of filling valves to approx. 80 bar (1,150 psi) then decompress with drain valves to remove all moisture in filters and oil and water separator.

  • Page 27: B-Timer

    Instruction Manual w Breathing Air Compressors 3.8. B-TIMER Introduction Read operating instructions carefully before operating the unit. The settings in the setup menu are essential for the correct indication of the filter capac­ ity. Without correct settings, the B-Timer can be used as an hourmeter, only! Make sure that the pressure maintaining valve of the compressor is adjusted to 150 bar (factory setting) and is working properly...
  • Page 28 The battery (1, Abb. 25) is merely inserted into the holder. To change the battery remove two bolts and separate housing from base plate. Remove plug (2) and pull out battery. Make sure to use the same type battery (BAUER part no. 82743). Operation Abb.
  • Page 29 Instruction Manual w Breathing Air Compressors Press = key again. Remaining operating hours to service inter­ val A (500 hours or annually) are shown (Abb. 28). Abb. 28 Press = key again. Remaining operating hours to service inter­ val B (1000 hours or annually) are shown (Abb. 29). Abb.
  • Page 30 Instruction Manual w Breathing Air Compressors Setup To enter the setup for the different functions of the B-Timer press the = and o keys on the display simultaneously for more than 5 seconds from the cartridge number display (Abb. 33). Filter symbol starts flashing (Abb.

  • Page 31: Lubrication

    BAUER high performance compressor oils, only, ac­ cording to the oil list. These oils are tested in our compressors and have proved excellent quality under ambient tempera­...

  • Page 32: Changing The Oil Type

    OIL CAPACITY Oil capacity approx. 2.8 liters OIL PACKAGES BAUER compressor oil is available in various quantities, refer to oil list in the annex. OIL CHANGE Run compressor warm. Remove red cap from oil filler neck (1, Abb. 38).
  • Page 33 Instruction Manual w Breathing Air Compressors Fill compressor with the new oil. After approx. 100 operating hours check lubricating oil for degree of contamination, and change oil again if necessary. Perform subsequent oil changes according to chapter OIL CHANGE. Refill compressor with same oil, only. Abb.

  • Page 34: Intake Filter

    Instruction Manual w Breathing Air Compressors 4.5.1. INTAKE FILTER 4.5.2. INTERMEDIATE SEPARATOR DESCRIPTION DESCRIPTION An intermediate separator is mounted on the compressor A dry micronic filter is used to filter intake air, see Abb. 41. after the 2nd and 3rd stage. The separators are designed to remove water and oil accumulating due to cooling the air down after the compression process.
  • Page 35 Instruction Manual w Breathing Air Compressors LIFETIME The filter system is subject to dy­ WARNING namic load. It is designed for a cer­ tain number of load cycles, which originate from an abrupt pressure loss at condensate drain (1 load cycle i.e. condensate drain = 1 depressu­ rization, 1 pressurization).
  • Page 36 To avoid any danger to your health or damage to your unit, saturated and thus be ruined. change used up cartridges in good time. Never fill used up cartridges yourself! The filter material was chosen specifically by BAUER-KOMPRESSOREN for each kind Depressurize filter system by opening condensate drain of application. valves.
  • Page 37 Instruction Manual w Breathing Air Compressors FILLING VALVE MAINTENANCE To protect filling valve against contamination a sintered metal filter is screwed in the filling valve body. Unscrew pressure gauge from filling valve body. Screw off sintered metal filter with a suitable screw driver. To clean filter element, the best method is to use hot soapy water and to blow dry with compressed air.
  • Page 38 Instruction Manual w Breathing Air Compressors 1. Filter cartridge 80100: Filter cartridge lifetime [hours] Filling pressure p = 200 bar Mariner 320 Ambient temperature Temperature of Flow capacity tU [°C] final separator Q [l/min] tAb [°C] 20 - 24 37 - 30...
  • Page 39 Instruction Manual w Breathing Air Compressors 2. Filter cartridge 80114: Filter cartridge lifetime [hours] Filling pressure p = 200 bar Mariner 320 Ambient temperature Temperature of Flow capacity tU [°C] final separator Q [l/min] tAb [°C] 20 - 24 28 - 22...

  • Page 40: Ambient Temperature

    Unlike other filter systems the SECURUS filter system ensures continuous monitoring of the breathing air purification para­ The Mariner 320 compressor units can be fitted with filter meters while the air is still in the regeneration process. The system P41 as an optional extra instead of the standard filter influences of system P31.

  • Page 41: Condensate Drain

    To avoid any danger to your health or damage to your unit, change used up cartridges in good time. Lifetime Never fill used up cartridges yourself! The filter material was chosen specifically by BAUER-KOMPRESSOREN for each kind The oil and water separator is sub­ WARNING of application.
  • Page 42 Instruction Manual w Breathing Air Compressors Change cartridge before reactivating a compressor unit which has been out of service for more than 6 months. Leave cartridge in the filter as long as unit is out of ser­ vice. Keep all condensate drain valves and shut-off valves closed.
  • Page 43 Instruction Manual w Breathing Air Compressors 3. Filter cartridge 062565: Filter cartridge lifetime [hours] Filling pressure p = 200 bar Mariner 320 Ambient temperature Temperature of Flow capacity tU [°C] final separator Q [l/min] tAb [°C] 20 - 24 98 - 78...
  • Page 44 Instruction Manual w Breathing Air Compressors 4. Filter cartridge 067224: Filter cartridge lifetime [hours] Filling pressure p = 200 bar Mariner 320 Ambient temperature Temperature of Flow capacity tU [°C] final separator Q [l/min] tAb [°C] 20 - 24 81 - 65...

  • Page 45: Pressure-Maintaining Valve

    Instruction Manual w Breathing Air Compressors 4.5.5. PRESSURE MAINTAINING VALVE DESCRIPTION A pressure maintaining valve is integrated in the P31 filter base (Abb. 48), or mounted at the outlet of the filter system P41 (Abb. 49). It ensures that pressure is built up in the filter even from the start of delivery, thus achieving a constant, optimum filtra­...

  • Page 46: Pressure Gauge

    Instruction Manual w Breathing Air Compressors This just ensures that the valve is functional and will release dium flows into the cylinders. At the start of the compression pressure in case of a malfunction. To check the blow-off pres­ stroke the intake valve closes and the medium opens the sure value refer to ”Blow-off pressure check”.
  • Page 47 Changing the valves should be performed by trained person­ tors nel, only. Valve change is described in the workshop manual which is available through the BAUER technical service. 4.5.9. CONDENSATE DRAIN DESCRIPTION The intermediate separators and the oil and water separator or filter system are fitted with manual drain taps.
  • Page 48 Instruction Manual w Breathing Air Compressors stage every 15 minutes during operation. In addition, the au­ tomatic condensate drain is designed to drain these filters after shut-down of the compressor unit and to unload the compressor during the starting phase. The automatic condensate drain system (Abb.
  • Page 49 Instruction Manual w Breathing Air Compressors removed and the condensate drain valve (6) drains as de­ Dispose of condensate according to local scribed above. regulations! MAINTENANCE The condensate drain valve for the oil and water separator is fitted with a manual drain tap to check correct operation of the automatic system.

  • Page 50: Electrical System

    Instruction Manual w Breathing Air Compressors Drive engine The compressor unit is driven by an electric motor by means of V-belts. Check the V-belts regularly for tension and wear. See chapter 4.5.12. Except for external cleaning, the drive motor requires no servicing. The motor bearings may need lubricating, depending on the model.

  • Page 51: Cycle Counter

    Instruction Manual w Breathing Air Compressors Cycle counter The cycle counter is mounted in the switch box and labelled P14 (1, Abb. 36) . It counts the electrical control pulses for the automatic condensate drain solenoid valve and hence the accumulated amount of load cycles of the installed oil and water separator after the last compressor stage.
  • Page 52 Instruction Manual w Breathing Air Compressors Place DIP switches 3 and 8 to ON as shown in A, Abb. 66. In this preliminary configuration, the condensate drain in­ terval can be adjusted in seconds. (See also Bürkert in­ structions in the annex). Switch on power.

  • Page 53: Cooling System

    Instruction Manual w Breathing Air Compressors 1 2 3 4 5 6 7 8 After adjustment, run motor for approx. 5 minutes. Stop Preliminary motor, check V-belt tension, and readjust if required. Check setting that after tension adjustment and tightening the motor mounting nuts, both pulleys are in a straight line to avoid ex­...
  • Page 54 Instruction Manual w Breathing Air Compressors 4.6. TROUBLE-SHOOTING Trouble Cause Remedy Drive motor (electric) Motor will not start Electric circuitry faulty Before attempting to make any repairs, check all fuses, terminal connections, wire leads, make sure that motor data complies with mains supply Drive engine (petrol) Engine will not start See engine instructions...
  • Page 55 Instruction Manual w Breathing Air Compressors Trouble Cause Remedy Automatic Condensate Drain (optional) Drain valves do not close No control air Check control air line Drain valves leaking Dismantle drain valve and clean Drain valves do not open Condensate drain valve piston jammed Dismantle drain valve, clean or replace valve Solenoid valve does not close Solenoid valve faulty...

  • Page 56: Preservation

    Instruction Manual w Breathing Air Compressors STORAGE, PRESERVATION GENERAL PREVENTIVE MAINTENANCE DURING STORAGE If the compressor is put out of service for more than six Run the compressor once every 6 months as described in months, the unit should be preserved in accordance with the the following: following instructions: Remove the dust cap from the inlet port and insert the in­...
  • Page 57 Instruction Manual w Breathing Air Compressors REPAIR INSTRUCTIONS GENERAL Preventive maintenance usually involves replacing the valves, gaskets and sealing rings as well as carrying out the mainten­ ance work. Repair work can be carried out on the compressor block to a certain extent but a certain experience and skill is necess­...

  • Page 58: Maintenance Kits

    Instruction Manual w Breathing Air Compressors TABLES MAINTENANCE PARTS Maintenance kits: Designation Part No. Maintenance kit (500 hours) Mariner electric Mariner320-E-MU-a1 Maintenance kit (500 hours) Mariner petrol Mariner320-B-MU-a1 Maintenance kit (1000 hours) Mariner electric Mariner320-E-MU-b1 Maintenance kit (1000 hours) Mariner petrol Mariner320-B-MU-b1 Maintenance kit (2000 hours) Mariner electric Mariner320-E-MU-c1...

  • Page 59: Lubrication Chart

    All valve head filter housing threads part no. N19752 or screws require torque wrench tightening! BAUER special grease part The indicated torque values are valid for no. 072500 bolts in greased condition. Replace self- Sealing rings BAUER special grease part retaining nuts on reassembly.
  • Page 60 Instruction Manual w Breathing Air Compressors...
  • Page 61 Instruction Manual w Breathing Air Compressors ANNEX • Air flow diagram Schematic diagrams Lubricating oil list Parts lists...
  • Page 62 Instruction Manual w Breathing Air Compressors...
  • Page 71 This list is up to date at the time of printing and will be reviewed continuously. Should your list or your instruction manual be older, please request the latest edition from BAUER Customer Services. When using any of the oils listed below, please follow the oil change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit.
  • Page 72 For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recom- mend the BAUER special synthetic compressor oils acc. to the list on the previous page. These have proved excellent quality under ambient temperatures between +5 °C and +45 °C. For lower temperatures a compressor heating device is required which is capable of pre−heating the unit up to +5 °C.

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