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Summary of Contents for Bauer Compact-Line JUNIOR II-B
- Page 1 Operating manual Compressor unit Breathing Air Compact-Line JUNIOR II-B OCEANUS-E JUNIOR II-E OCEANUS-W JUNIOR II-W OCEANUS-B Edition 10-10-2016 A_Compact-Line_002_en...
- Page 2 OPERATING MANUAL A_Compact-Line_002_en 2/106 10-10-2016...
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Page 3: Table Of Contents
Versions and equipment ..................12 1.2.5 Options ......................... 12 1.2.6 Applied standards ....................12 1.2.7 Contact data BAUER KOMPRESSOREN ..............13 For your safety Intended usage ..................... 15 Improper use ......................15 Display and meaning of warnings ................16 2.3.1 Hazard classes ...................... 16 2.3.2... - Page 4 OPERATING MANUAL Safety concept ...................... 26 2.7.1 Structure ....................... 26 2.7.2 Function ........................ 26 Safety regulations ....................27 Product description Structure and function ..................29 3.1.1 Unit overview ......................29 3.1.2 Monitoring units ....................35 Display elements ....................36 3.2.1 B-TIMER display and operating elements .............. 36 Control elements ....................37 3.3.1 Overview of operating elements ................37...
- Page 5 OPERATING MANUAL 5.2.1 Selecting the storage location ................52 5.2.2 Preparing for preservation ..................52 5.2.3 Preservation ......................53 5.2.4 Inspecting the unit during storage ................ 53 Installation Preparing the installation site ................55 Assembling the unit ....................56 6.2.1 Installing the unit ....................56 6.2.2 Installing the B-TIMER ...................
- Page 6 OPERATING MANUAL Evidence of maintenance ..................77 Maintenance table ....................77 Resources for maintenance and repairs ..............78 9.3.1 Bolt torques ......................78 9.3.2 Bolt tightening sequence ..................79 9.3.3 Lubricant .......................79 9.3.4 Lubrication oil ....................... 80 9.3.5 Adhesive and sealants ...................81 9.3.6 Test medium ......................
- Page 7 OPERATING MANUAL Disassembly and disposal 10.1 Decommissioning ....................103 10.2 Disposal ......................103 Appendix 11.1 Declaration of conformity ................... 105 A_Compact-Line_002_en 10-10-2016 7/106...
- Page 8 OPERATING MANUAL A_Compact-Line_002_en 8/106 10-10-2016...
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Page 9: Preface
Chapter 11.1, Page 105 and the following. All the information in this manual is correct at the time of printing. BAUER KOM- PRESSOREN reserves the right to make technical changes that facilitate an im- provement or raise the safety standard. -
Page 10: Symbols And Abbreviations Used
1 | Preface OPERATING MANUAL 1.1.4 Symbols and abbreviations used The following symbols are used in the manual: Symbol Meaning Dangers for persons. For more information, Chapter 2.3 Display and meaning of warn- ings, Page Information for understanding or optimising the work processes. -
Page 11: About This Product
OPERATING MANUAL Preface | 1 1.2 About this product 1.2.1 Identifying the product This manual is applicable for the models and series specified on the title page. • Take the exact model and serial number from the type plate and enter into the figure below. -
Page 12: Versions And Equipment
Chapter 11.1 Declaration of conformity, Page 105. CE mark With the EC mark affixed on the product, BAUER KOMPRESSOREN declares that the product satisfies the application requirements specified in the harmonisation legislation of the European Community provided for its affixing. -
Page 13: Contact Data Bauer Kompressoren
OPERATING MANUAL Preface | 1 1.2.7 Contact data BAUER KOMPRESSOREN BAUER KOMPRESSOREN GmbH Stäblistr. 8 D-81477 Munich Tel.: +49 89 7 80 49-0 Fax: +49 89 7 80 49-167 www.bauer-kompressoren.de info@bauer-kompressoren.de A_Compact-Line_002_en 10-10-2016 13/106... - Page 14 1 | Preface OPERATING MANUAL A_Compact-Line_002_en 14/106 10-10-2016...
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Page 15: For Your Safety
OPERATING MANUAL For your safety | 2 2 For your safety 2.1 Intended usage The machine is intended exclusively for the compression and the storage of the medium specified, under consideration of the conditions specified, see Technical Data. Proper use also includes: •... -
Page 16: Display And Meaning Of Warnings
2 | For your safety OPERATING MANUAL 2.3 Display and meaning of warnings 2.3.1 Hazard classes Important instructions regarding personal protection and safe operation are indica- ted in the manual in distinct hazard classes. The hazard classes explain how states or individual steps of an operation sequence are dangerous and can cause dam- age. -
Page 17: Danger Warnings On The Machine
OPERATING MANUAL For your safety | 2 2.3.3 Danger warnings on the machine Depending on the construction and purpose of use, the following indications are affixed to the machine and included in the manual; these indications point to po- tential dangers: Symbol Meaning Always read the operating instructions before... -
Page 18: Product Safety
2 | For your safety OPERATING MANUAL 2.4 Product safety 2.4.1 Fundamental safety information Fundamental dangers The following safety measures always include: • The machine should only be used in a technically perfect condition and in an intended, safety and danger-aware method, taking into account the operating instructions. -
Page 19: Safety Instructions Regarding Transport And Loading Work
OPERATING MANUAL For your safety | 2 Danger due to gas, dust and smoke Welding, flame-cutting or grinding work can pose a fire or explosion hazard. • Execute welding, flame-cutting and grinding work on the machine only when the work has been specifically approved. •... -
Page 20: Safety Information Regarding Operation
2 | For your safety OPERATING MANUAL 2.4.3 Safety information regarding operation Carry out the following measures to ensure safe operation: • Refrain from any working practices which may compromise safety. • Only operate the machine if all protection equipment and safety-related equip- ment (e.g. -
Page 21: Safety Instructions Regarding Cleaning
OPERATING MANUAL For your safety | 2 2.4.5 Safety instructions regarding cleaning Carry out the following measures to ensure safe cleaning: • Before cleaning the machine with water, a steam jet (high pressure cleaner) or other cleaning agents, cover or seal off all openings that must not be penetra- ted by water/steam/cleaning agents for reasons of safety and/or functionali- ty. -
Page 22: Particular Dangers
2 | For your safety OPERATING MANUAL 2.4.6 Particular dangers Safe handling of pressure vessels There are two types of pressure vessels: • Pressure vessels for static load: The pressure vessels are under virtually con- stant operating pressure, and the pressure fluctuations are very small. Pres- sure vessels for static load are not specially marked and can be operated as long as no safety-relevant faults are found during the regular vessel repeat testing procedures. -
Page 23: Safety And Monitoring Equipment
OPERATING MANUAL For your safety | 2 Instructions regarding handling breathing air Follow the following instructions to ensure the safety of the user: • Adhere to the filter service life. • When changing the cartridge, particular attention must be paid to hygiene and general cleanliness. -
Page 24: Organisational Duties
2 | For your safety OPERATING MANUAL 2.6 Organisational duties 2.6.1 Duties of the operating company The operating company is responsible for the intended use of the machine. • Keep the instruction manual to hand near the machine and must be available to the personnel at all times. -
Page 25: Personnel Selection And Qualification
• Ensure that only trained personnel operate the machine. • Ensure that only the service personnel trained and authorised by BAUER KOM- PRESSOREN carry out the assembly and installation activities. • Ensure that only competent personnel carry out the first commissioning and recurrent tests. -
Page 26: Duties Of The Personnel
2 | For your safety OPERATING MANUAL 2.6.3 Duties of the personnel The personnel must comply with the following safety requirements: • Read and understand the operating instruction manual. • Refrain from any working practices which may compromise safety. • Use personal protection equipment if required. -
Page 27: Safety Regulations
OPERATING MANUAL For your safety | 2 2.8 Safety regulations The following list of safety regulations does not claim to be exhaustive and up-to- date, and is applicable only for the Federal Republic of Germany. • Ensure that the equivalent provisions of the operator’s country are observed. •... - Page 28 2 | For your safety OPERATING MANUAL For further instructions for the licensing process and the testing of filling stations before commissioning, refer to the information sheet (can be obtained from BAUER KOMPRESSOREN). The test certificates and documents supplied with the compressor are important and must be included in the application documents as part of the licensing proc- ess.
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Page 29: Product Description
OPERATING MANUAL Product description | 3 3 Product description 3.1 Structure and function 3.1.1 Unit overview Structure Fig. 3 Structure, version with electric motor Carrying handle Condensate drain cock Carrying handle Motor connection box B-TIMER 10 Safety valve A_Compact-Line_002_en 10-10-2016 29/106... - Page 30 3 | Product description OPERATING MANUAL Fig. 3 Structure, version with electric motor Electric motor Safety valve 11 Suction filter Fan cover Filter system 12 Filling valve with final pressure gauge A_Compact-Line_002_en 30/106 10-10-2016...
- Page 31 OPERATING MANUAL Product description | 3 Fig. 4 Structure, version with electric motor, view from the rear Condensate separator Pressure retention valve Belt guard Final pressure switch Switch-over valve 10 Filling valve with final pressure gauge Condensate drain valve, last Final pressure safety valve, 11 Compressor control system stage...
- Page 32 3 | Product description OPERATING MANUAL Fig. 5 Structure, version with petrol engine Exhaust Pull starter Suction filter Air filter Automatic condensate drain 10 Filling valve with final pressure gauge Tank Carrying handle Choke Safety valve A_Compact-Line_002_en 32/106 10-10-2016...
- Page 33 OPERATING MANUAL Product description | 3 Fig. 6 Structure, version with petrol engine, view from the rear Final pressure safety valve Condensate drain valve, second Filter system stage Condensate separator Pressure retention valve 10 Belt guard Final pressure switch Switch-over valve 11 Filling valve with final pressure gauge Condensate drain valve, last...
- Page 34 3 | Product description OPERATING MANUAL Function Suction The medium or gas mixture to be compressed is directed to the compressor via the suction section. Compression In the compressor block, the medium is compressed up to its final pressure. Paral- lel to the compression process, the medium is pre-cleaned using a separator and cooled using heat exchangers.
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Page 35: Monitoring Units
OPERATING MANUAL Product description | 3 3.1.2 Monitoring units B-TIMER Structure Fig. 7 Structure B-TIMER Function The B-TIMER is a self-activating mini-computer that keeps track of the compres- sor’s operating hours and calculates the filter cartridges’ lifetime with the help of the time, the temperature, the type of cartridge and the delivery volume of the compressor. -
Page 36: Display Elements
3 | Product description OPERATING MANUAL 3.2 Display elements 3.2.1 B-TIMER display and operating elements 654321 Fig. 8 Display and operating elements Display of due maintenance Input key Display of low battery status Display of cartridge saturation Display of operating hours or car- Display of due maintenance type or tridge number the setup menu... -
Page 37: Control Elements
OPERATING MANUAL Product description | 3 3.3 Control elements 3.3.1 Overview of operating elements Fig. 9 Overview of operating elements Filling equipment Changeover device B-TIMER Compressor control system Condensate drain cocks A_Compact-Line_002_en 10-10-2016 37/106... -
Page 38: Filling Equipment
3 | Product description OPERATING MANUAL 3.3.2 Filling equipment Fig. 10 Filling equipment Filling cock International bracket connection, 200 bar Filling connection Filling pressure gauge A_Compact-Line_002_en 38/106 10-10-2016... -
Page 39: Technical Data
OPERATING MANUAL Technical data | 4 4 Technical data 4.1 Technical data about the compressor unit 4.1.1 Technical data, Junior II-B Compressor unit Junior II-B Performance characteristics Medium Suction pressure atmospheric Operating pressure max. [bar] PN200 or PN300 Blow-off pressure, final pressure safety valve 225 / 330 [bar] Setting pressure, pressure retention/non-re-... - Page 40 4 | Technical data OPERATING MANUAL Tab. 7 Technical data, Junior II-B A_Compact-Line_002_en 40/106 10-10-2016...
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Page 41: Technical Data, Junior Ii-E
OPERATING MANUAL Technical data | 4 4.1.2 Technical data, Junior II-E Compressor unit Junior II-E Performance characteristics Medium Suction pressure atmospheric Operating pressure max. [bar] PN200 or PN300 Blow-off pressure, final pressure safety valve 225 / 330 [bar] Setting pressure, pressure retention/non-re- turn valve [bar] Compressor block Junior II, manufacturing status 3... -
Page 42: Technical Data, Junior Ii-W
4 | Technical data OPERATING MANUAL 4.1.3 Technical data, Junior II-W Compressor unit Junior II-W Performance characteristics Medium Suction pressure atmospheric Operating pressure max. [bar] PN200 or PN300 Blow-off pressure, final pressure safety valve 225 / 330 [bar] Setting pressure, pressure retention/non-re- turn valve [bar] Compressor block Junior II, manufacturing status 3... -
Page 43: Technical Data, Oceanus-B
OPERATING MANUAL Technical data | 4 4.1.4 Technical data, OCEANUS-B Compressor unit OCEANUS-B Performance characteristics Medium Suction pressure atmospheric Operating pressure max. [bar] PN200 or PN300 Blow-off pressure, final pressure safety valve 225 / 330 [bar] Setting pressure, pressure retention/non-re- turn valve [bar] Compressor block Oceanus, manufacturing status 1... -
Page 44: Technical Data, Oceanus-E
4 | Technical data OPERATING MANUAL 4.1.5 Technical data, OCEANUS-E Compressor unit OCEANUS-E Performance characteristics Medium Suction pressure atmospheric Operating pressure max. [bar] PN200 or PN300 Blow-off pressure, final pressure safety valve 225 / 330 [bar] Setting pressure, pressure retention/non-re- turn valve [bar] Compressor block Oceanus, manufacturing status 1... -
Page 45: Technical Data, Oceanus-W
OPERATING MANUAL Technical data | 4 4.1.6 Technical data, OCEANUS-W Compressor unit OCEANUS-W Performance characteristics Medium Suction pressure atmospheric Operating pressure max. [bar] PN200 or PN300 Blow-off pressure, final pressure safety valve 225 / 330 [bar] Setting pressure, pressure retention/non-re- turn valve [bar] Compressor block Oceanus, manufacturing status 1... -
Page 46: Technical Data Compressor Block
4 | Technical data OPERATING MANUAL 4.2 Technical data Compressor block 4.2.1 Technical data about the compressor block Compressor block Junior II, manufacturing status 3 Number of stages Number of cylinders Cylinder bore 1st stage [mm] Cylinder bore 2nd stage [mm] Cylinder bore 3rd stage [mm] Piston stroke [mm] Direction of rotation (looking onto the fly-... -
Page 47: Technical Data About The Compressor Block
OPERATING MANUAL Technical data | 4 4.2.2 Technical data about the compressor block Compressor block Oceanus, manufacturing status 1 Number of stages Number of cylinders Cylinder bore 1st stage [mm] Cylinder bore 2nd stage [mm] Cylinder bore 3rd stage [mm] Piston stroke [mm] Direction of rotation (looking onto the fly- left... -
Page 48: Technical Data About The Driving Set
4 | Technical data OPERATING MANUAL 4.4 Technical data about the driving set Driving set 168013 Dimensions (L x W x H) [mm] 987 x 659 x 555 Weight [kg] Max. permissible carrying capacity [kg] Max. permissible inclination in all directions 30°... -
Page 49: Transport And Storage
2. Check the delivered item immediately for transport damage. 3. Check the delivered item immediately against the packing lists for to ensure completeness. 4. Report any irregularities to BAUER KOMPRESSOREN immediately. Complaints made later cannot be considered. 5. Never put the machine into operation if it is damaged. -
Page 50: Transport
5 | Transport and storage OPERATING MANUAL 5.1.3 Transport WARNING Danger of crushing due to falling, tilting or swinging loads! Crushing can result in death or serious injuries. Follow the safety instructions and safety regulations when transporting the machine. Follow the transport instructions. Keep in mind the transport weights and measurements. - Page 51 OPERATING MANUAL Transport and storage | 5 Transport the units using the driving set The compressor unit is switched off, is de-pressurized and is isolated from the power supply and storage bottles. The cables and filling hoses are securely stowed on the compressor unit. ...
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Page 52: Storage And Preservation
5 | Transport and storage OPERATING MANUAL 5.2 Storage and preservation 5.2.1 Selecting the storage location Ensure that the storage space fulfils the following conditions: dry, frost-free, vi- bration-free. Covering with plastic sheets is recommended only if it prevents condensation from being formed. -
Page 53: Preservation
If the unit has to be stored for more than 2 years, request special instructions from BAUER KOMPRESSOREN, see Chapter 1.2.7 Contact data BAUER KOMPRESSO- REN, Page If the unit is put out of operation for more than 6 months, preserve it as follows: 1. - Page 54 5 | Transport and storage OPERATING MANUAL A_Compact-Line_002_en 54/106 10-10-2016...
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Page 55: Installation
OPERATING MANUAL Installation | 6 6 Installation 6.1 Preparing the installation site 1. Ensure necessary environmental conditions, see Technical data. 2. Make sure that the surface is even and clean. 3. Ensure that the machine’s own weight and all operating forces can be accep- ted and that the stability of the machine is guaranteed. -
Page 56: Assembling The Unit
6 | Installation OPERATING MANUAL 6.2 Assembling the unit 6.2.1 Installing the unit DANGER Danger of poisoning! Never use units with a gas engine inside closed rooms. Never use units around open flames. WARNING Danger of injuries due to improper assembling! Improper assembling can result in personal and material damage. - Page 57 OPERATING MANUAL Installation | 6 Erecting the unit outdoors NOTICE Material damage due to seawater and corrosion! In case of operation in salty atmosphere, spray the unit with coating against corrosion. Always use and keep units with an electric motor below deck. Always keep units with a gas engine below deck.
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Page 58: Installing The B-Timer
3mm at each terminal. 6.4 Inspection of the unit At the BAUER KOMPRESSOREN factory, components such as the compressor, storage system and other accompanying components are subjected to a technical partial acceptance inspection by the TÜV. -
Page 59: Commissioning And Operation
4. Perform a visual inspection of all components. If there are any irregularities, switch off the unit immediately and locate and rectify any errors or get in touch with the BAUER customer service department, see Chapter 1.2.7 Con- tact data BAUER KOMPRESSOREN, Page 5. -
Page 60: Starting Up The Unit For The First Time
8. Observe the pressure build-up in the unit properly. If there are any irregulari- ties, switch off the unit immediately and locate and rectify any errors or get in touch with the BAUER customer service department, see Chapter 1.2.7 Con-... -
Page 61: Starting Up The Unit After Longer Downtimes
OPERATING MANUAL Commissioning and operation | 7 7.1.3 Starting up the unit after longer downtimes 1. Follow the instructions on commissioning, see Chapter 7.1.1 Checks before each commissioning, Page 2. Treat the motor in accordance with the instructions provided by the motor manufacturer. -
Page 62: Checking The Direction Of Rotation Of The Motor
7 | Commissioning and operation OPERATING MANUAL 7.1.4 Checking the direction of rotation of the motor DANGER Danger to life due to electric voltages! Contact with live parts can lead to death or serious injuries. Work on the electrical unit may be carried out by an electrician only. Make sure that the unit is tension-free for the necessary work. -
Page 63: Operation
OPERATING MANUAL Commissioning and operation | 7 7.2 Operation CAUTION Danger of injury due to automatic re-start of the unit! The unit can re-start automatically depending on the version. Follow the safety instructions for the unit. Operate the unit only if the safety devices are installed. Ensure that a suddenly restarted unit does not pose dangers to people or the machine. -
Page 64: Switching The Unit On
7 | Commissioning and operation OPERATING MANUAL 7.2.1 Switching the unit on First commissioning has been performed correctly, see Chapter 7.1.2 Starting up the unit for the first time, Page The unit has been prepared correctly for commissioning, see Chapter 7.1.1 ... -
Page 65: Switching The Unit Off
OPERATING MANUAL Commissioning and operation | 7 Fig. 16 Starting units with petrol engine Choke Petrol engine Pull starter Ignition switch Fuel tap 3. Close the condensate drain cocks and run the unit to final pressure. 4. Check the final pressure safety valve and pressure gauge. 5. -
Page 66: Behaviour In Case Of Emergency
7 | Commissioning and operation OPERATING MANUAL 7.2.3 Behaviour in case of emergency Switching the unit off in case of an emergency The unit is equipped with at least one emergency stop switch, see Chapter 2.4.7 Safety and monitoring equipment, Page Press the emergency stop switch. -
Page 67: Operating The B-Timer
OPERATING MANUAL Commissioning and operation | 7 7.2.5 Operating the B-TIMER 654321 Fig. 17 Display and operating elements Display of due maintenance Input key Display of low battery status Display of cartridge saturation Display of operating hours or car- Display of due maintenance type or tridge number the setup menu Selection key... - Page 68 7 | Commissioning and operation OPERATING MANUAL Toggling the display The B-TIMER shows the following information: • Main menu • Remaining filter capacity in percent • Number of operating hours until service interval A (500 hours or yearly) • Number of operating hours until service interval B (1000 hours or every 2 years) •...
- Page 69 OPERATING MANUAL Commissioning and operation | 7 Setting the B-TIMER The following values can be set on the B-TIMER: • Enter the numbers of filter cartridges used • Set the delivery volume • Set the operating pressure • Set the operating hours After changing the set values, the B-TIMER must be reset.
- Page 70 7 | Commissioning and operation OPERATING MANUAL Setting the delivery volume 1. In the setup mode, press the selection key until the corresponding sub-menu is reached. The filter icon blinks and “B" is shown. Ä 2. Refer to the order documents for the delivery volume of the compressor in l/ min.
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Page 71: Filling Operation
OPERATING MANUAL Commissioning and operation | 7 7.2.6 Filling operation DANGER Danger of poisoning due to pollutants in breathing air! Inhaling harmful gases can be dangerous to life. Make sure that the air drawn in is free from toxic gases, exhaust gases or sol- vent vapours. - Page 72 7 | Commissioning and operation OPERATING MANUAL Filling the compressed air cylinders WARNING Danger of injuries due to the use of non-approved or damaged filling equip- ment and compressed air cylinders! Unsuitable or damaged material may explode or rupture under pressure. The use of non-approved intermediate pieces is prohibited.
- Page 73 OPERATING MANUAL Commissioning and operation | 7 6. Remove the compressed air cylinder. During filling, the compressed air cylinder heats up because of the subsequent compression in the compressed air cylinder. Allow the cylinder to cool after remov- ing it: this causes the pressure in the compressed air cylinder to drop. The com- pressed air cylinder can then be reconnected and filled until the relevant nominal filling working pressure is achieved.
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Page 75: Troubleshooting
OPERATING MANUAL Troubleshooting | 8 8 Troubleshooting 8.1 Fault finding and fault correction 8.1.1 Fault finding in drive motor Description Cause Rectification Motor does not start. Fault in the electrical power Check lines and fuses. Com- supply. pare the motor data with the mains supply. -
Page 76: Fault Finding In Electrical Control System
Rectification "Error 1" or "Error 2" is shown Temperature sensor defec- B-TIMER must not be used on the display. tive. any longer. BAUER Contact the Customer Service and get the device repaired. 8.1.5 Fault finding in automatic condensate drain Description... -
Page 77: Maintenance
In the event of warranty claims being made, the service log book will help you to prove that this work has been carried out and that damage cannot be attributed to insufficient maintenance. BAUER KOMPRESSOREN refers to its General Terms and Conditions. -
Page 78: Resources For Maintenance And Repairs
9 | Maintenance OPERATING MANUAL 9.3 Resources for maintenance and repairs 9.3.1 Bolt torques Unless otherwise stated, the following torques must be used. The specified values apply to greased bolts. Valve head screws must be tightened with a torque wrench. Self-locking nuts must not be re-used, replace them. -
Page 79: Bolt Tightening Sequence
Bolt tightening sequence 9.3.3 Lubricant Application range Lubricant Rubber parts, plastic parts, thread of the filter BAUER special grease, order number N19752 housing (container - 350 g) BAUER special grease, order number 072500 (container - 3 g) O-rings BAUER special grease, order number 072500... -
Page 80: Lubrication Oil
Lubrication oil list, Page Lubrication oil list BAUER KOMPRESSOREN units are delivered ex factory with oil filling (order num- ber N28355). Oil type Type of applica-... -
Page 81: Adhesive And Sealants
OPERATING MANUAL Maintenance | 9 9.3.5 Adhesive and sealants Application range Adhesive or sealant Bolt locking, gluing in of threaded studs Order number N25834 Sealing conical threads Order number N28220 Metal-on-metal sealing, high-temperature Temperature-resistant sealant, e.g. order bonds, e.g. valve heads, cylinders number N18247 Paper gaskets Order number N18247... -
Page 82: Maintenance Activities - Lubricating Oil System
9 | Maintenance OPERATING MANUAL 9.5 Maintenance activities - Lubricating oil system MAX. MIN. Fig. 21 Lubrication oil system, view from the rear Oil dipstick Oil drain screw Oil filler spigot 9.5.1 Checking the oil level NOTICE Damage to unit due to incorrect oil level! Ensure that the oil level does not undercut the minimum level or exceed the maximum level, otherwise the compressor gets over-lubricated and the valves carbonise. -
Page 83: Changing The Oil
Dispose of used oil as special waste. Be mindful of the local regulations relating to the disposal of special waste. 4. Dispose of used oil. Filling oil Suitable BAUER compressor oil is available, see lubrication oil list. Refer to technical data for the required quantity. 1. Open oil filler spigot. -
Page 84: Changing The Oil Type
9 | Maintenance OPERATING MANUAL 9.5.3 Changing the oil type Oil is drained NOTICE Damage to unit due to improper change of oil type! Adhere to the following instructions when switching over to another oil type. 1. Check the valves, coolers, separators and lines for deposits. Are deposits present in valves, coolers, separators or lines? Remove deposits, or replace valves, coolers, separators and lines. -
Page 85: Maintenance Activities - Intake Section
OPERATING MANUAL Maintenance | 9 9.6 Maintenance activities - Intake section 9.6.1 Replacing the suction filter The maintenance intervals are dependent on the condition of the air being drawn in. If there is a lot of dust it may be necessary to carry out maintenance monthly or weekly. -
Page 86: Maintenance Activities - Filter System
9 | Maintenance OPERATING MANUAL 9.7 Maintenance activities - Filter system 9.7.1 Determine the service life of the cartridge New filter cartridge is available. The service life card is available; it is included with the filter cartridge. Scales are available. ... -
Page 87: Changing The Cartridge Of The Fine After-Cleaner
OPERATING MANUAL Maintenance | 9 9.7.2 Changing the cartridge of the fine after-cleaner When the system has been used for the maximum permissible number of operating hours, the cartridge must be replaced. Vacuum packing of the cartridge is undamaged. Special filter spanner (part of the scope of supply). - Page 88 9 | Maintenance OPERATING MANUAL Fig. 23 Changing the cartridge of the fine after-cleaner Special tool Filter head Cartridge 4. Wipe out the inside of the filter housing with a clean cloth. Check the filter housing for corrosion and, if necessary, replace the defective parts. 5.
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Page 89: Maintenance Activities - Pressure Maintaining Valve
9.8.2 Adjusting the pressure retention valve The pressure retention valves may only be adjusted by trained personnel. For more information, contact the BAUER customer service department, see Chapter 1.2.7 Contact data BAUER KOMPRESSOREN, Page 1. Disengage locknuts (if they are present). -
Page 90: Maintenance Activities For Filling Equipment
9 | Maintenance OPERATING MANUAL 9.9 Maintenance activities for filling equipment 9.9.1 Maintaining the filling valves A sintered filter in the filling valve body protects the filling valve from contamina- tion. Dismantle and clean the sintered filter of the filling valve as follows; in case of se- vere contamination, replace it if necessary: The compressor unit is switched off. - Page 91 OPERATING MANUAL Maintenance | 9 4. Wash the sintered filter in a grease dissolving hot soap solution and blow out with compressed air; replace it in case of severe contamination or damage. 5. Screw in the sintered filter. 6. Seal the pressure gauge (see Chapter 9.3.5 Adhesive and sealants, Page sealing conical threads) and screw in up to the desired position.
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Page 92: Maintenance Activities For Safety Valves
Switch off the compressor unit immediately and replace the final pressure safe- ty valve. Send the safety valve for repair, see Chapter 1.2.7 Contact data BAUER KOM- PRESSOREN, Page The functional test ensures only the mobility of moving parts. For checking the ac- tual blow-off pressure, see Chapter 9.10.2, Page... -
Page 93: Checking The Blow-Off Pressure
OPERATING MANUAL Maintenance | 9 9.10.2 Checking the blow-off pressure BAUER KOMPRESSOREN recommends that the intermediate pressure safety valves be replaced very carefully. A the blow-off pressure can be tested only with considerable expenditure. 1. The final pressure switch is bypassed. -
Page 94: Maintenance Activities - Intake Valves And Pressure Valves
9.12.2 Replacing the suction valves and pressure valves Only competent personnel may replace the valves of the compressor. For more in- formation, contact the BAUER customer service department, see Chapter 1.2.7 Contact data BAUER KOMPRESSOREN, Page NOTICE Material damage due to dissimilar suction and pressure valves! Replace the suction and pressure valves only in sets. -
Page 95: Maintenance Activities - Automatic Condensate Drain
OPERATING MANUAL Maintenance | 9 9.13 Maintenance activities - Automatic condensate drain 9.13.1 Checking the function of the automatic condensate drain WARNING Danger of injuries due to the gas escaping at high pressure! Wear protective goggles and personal ear defenders. After a water removal operation has been carried out by the automatic conden- sate drain, open the condensate drain cock of the automatic condensate drain. -
Page 96: Adjusting The Timer
9 | Maintenance OPERATING MANUAL 9.13.2 Adjusting the timer Only competent personnel may set the timer. For more information, contact the BAUER customer service department, see Chapter 1.2.7 Contact data BAUER KOMPRESSOREN, Page NOTICE Material damage due to unsuitable condensate drain intervals! Excessively short condensate drain intervals lead to the flooding of the separator and damage the downstream units. - Page 97 OPERATING MANUAL Maintenance | 9 Fig. 26 Adjustment of DIP switch 2. Ensure that all DIP switches are set to OFF. 3. Set DIP switches 3 and 8 to ON, see part A. This switch-over allows determining the drain interval in a setting range Ä...
- Page 98 OPERATING MANUAL Adjusting the timer Only competent personnel may set the timer. For more information, contact the BAUER customer service department, see Chapter 1.2.7 Contact data BAUER KOMPRESSOREN, Page The following timer is fitted to units having an electric motor:...
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Page 99: Maintenance Activities - Electrical System
OPERATING MANUAL Maintenance | 9 9.14 Maintenance activities - Electrical system 9.14.1 Maintaining the electrical control systems DANGER Danger to life due to electric voltages! Contact with live parts can lead to death or serious injuries. Work on the electrical unit may be carried out by an electrician only. Make sure that the unit is tension-free for the necessary work. -
Page 100: Adjusting The Final Pressure Switch
9.14.3 Replace the battery of the B-TIMER The battery (BAUER order number: 82743) is placed in the battery compartment. A battery symbol is used to indicate that the battery is weak and must be replaced. The data is saved and is not lost when the battery is replaced. -
Page 101: Maintenance Activities - Drive System
OPERATING MANUAL Maintenance | 9 9.15 Maintenance activities - Drive system 9.15.1 Servicing the electric motor 1. Clean the exterior of the electric motor on an occasional basis. 2. Be mindful of the instructions on the electric motor that deal with additional maintenance activities. - Page 102 9 | Maintenance OPERATING MANUAL A_Compact-Line_002_en 102/106 10-10-2016...
- Page 103 Disassembly and disposal | 10 10 Disassembly and disposal 10.1 Decommissioning If the unit is to be de-commissioned for more than 6 months, contact the tech- nical customer service department of BAUER KOMPRESSOREN, see Chap- ter 1.2.7 Contact data BAUER KOMPRESSOREN, Page 10.2 Disposal...
- Page 104 10 | Disassembly and disposal OPERATING MANUAL A_Compact-Line_002_en 104/106 10-10-2016...
- Page 105 OPERATING MANUAL Appendix | 11 11 Appendix 11.1 Declaration of conformity The following conformity serves as an example. The original conformity declaration bearing the serial number and signature is delivered along with the machine. Fig. 29 Example of conformity declaration A_Compact-Line_002_en 10-10-2016 105/106...
- Page 106 11 | Appendix OPERATING MANUAL A_Compact-Line_002_en 106/106 10-10-2016...
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