POSEIDON PE 100-T Instruction Manual
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POSEIDON PE 100-T Instruction Manual

High pressure breathing air compressor
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High Pressure Breathing Air Compressors

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  • Page 1: Instruction Manual

    Instruction manual High Pressure Breathing Air Compressors...
  • Page 3 Instruction Manual w PE 100-T INTRODUCTION This manual contains operating instructions and mainten­ ance schedules for the high pressure breathing air com­ pressor unit PE 100-T WARNING ! Pneumatic high pressure system ! The breathing air produced with the compressor units de­...
  • Page 4 Instruction Manual w PE 100-T Dear customer Do you have problems with maintenance or repair work? Technical customer service We are happy to give you advice on any questions regard­ Phone no: (089) 78049-246 or -176 ing your BAUER compressor and help as soon as possible Fax no: (089) 78049-101 with any arising problems.

  • Page 5: Table Of Contents

    Instruction Manual w PE 100-T CONTENTS GENERAL ......SAFETY MEASURES ....
  • Page 6 Instruction Manual w PE 100-T NOTES Model: Serial No..: Date of purchase: Dealer address / phone no.:...

  • Page 7: General

    The compressor unit comprises the following major assem­ blies: PURPOSE compressor block The PE 100-T breathing air compressor is designed to com­ drive motor press air for breathing as required in diving applications. filter system P11 The max. allowable operating pressure (adjusted pressure filling assembly on final pressure safety valve) is 225 bar or 330 bar.
  • Page 8 Instruction Manual w PE 100-T 1 Filling hose 2 Filter system P11 3 Safety valve, final pressure 4 Pressure maintaining valve 5 Oil dipstick 6 Intake filter 7 Filling valve with pressure gauge 8 Handle 10 Mains plug with ON-OFF switch and motor protection circuit breaker (dep.
  • Page 9 Instruction Manual w PE 100-T AIR FLOW DIAGRAM See Fig. 4 . The air is drawn in through telescopic tube (necessary for units with petrol engine) -1, intake filter -2; compressed to final pressure in cylinders -3, -4, -5; recooled by intercoolers -6, -7, and aftercooler -9.
  • Page 10 Instruction Manual w PE 100-T TECHNICAL DATA Compressor unit PE 100-TB-F02 PE 100-TE-F02 PE 100-TW-F02 Medium Delivery 100 l/min. (3,5 Scfm) Operating pressure PN200/PN300 Pressure setting, final pressure safety valve 225/330 bar Sound pressure 87 dB(A) 86 dB(A) Sound (immersion) power...

  • Page 11: Safety Measures

    Instruction Manual w PE 100-T 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 12 Instruction Manual w PE 100-T • As far as necessary or according to regulations, use per­ mediately if anything is not as is should be (including sonal protective equipment. operation). If necessary, shut the machine down im­ mediately and make it safe.
  • Page 13 Instruction Manual w PE 100-T 2.3.5. Particular areas of danger fore putting into use again, reconnect the machine to the mains according to regulations. • Use only original fuses with specified current rating. If • When taking back into operation, proceed according to there is a failure in the electric energy supply, shut the the instruction manual.
  • Page 14 Instruction Manual w PE 100-T examined by means of suitable testing methods, in Burggrafenstr. 4 - 7 order to ensure the operating safety. 10787 Berlin After having reached the total permissible number of The manufacturer has complied with all applicable regula­...

  • Page 15: Location, Operation, Bottle Filling

    Instruction Manual w PE 100-T LOCATION, OPERATION, BOTTLE FILLING 3.1. LOCATION 3.1.3. Electrical installation For installation of electrical equipment observe the follow­ ing: 3.1.1. Outdoor location Comply with regulations of local electricity supply com­ pany. Arrange for the electrics to be connected by an electri­...

  • Page 16: Maintenance

    Instruction Manual w PE 100-T Fit filter cartridge. Refer to chapter. 4.4.4., Fig. 21. Please respect local regulations for WARNING Without cartridge no pressure can be built up. filling hoses. Filling hoses must be satisfactory condition Prior to first operation or operation subsequent to re­...
  • Page 17 Instruction Manual w PE 100-T In case of overstepping the prescriptive limits, see chapter Open condensate drain tap (1, Fig. 5) of interme­ 4.5. Trouble-shooting diate separator (on petrol units additionally the con­ densate drain tap (2, Fig. 5) of final separator) to unload the compressor during the starting phase.
  • Page 18 Instruction Manual w PE 100-T As soon as final speed is reached close condensate drain tap (1, Fig. 5) of intermediate separator (on petrol units additionally the condensate drain tap (2, Fig. 5) of final separator). Open filling valve (Fig. 8), wait until air escapes and flush the compressor unit 1 to 2 minutes, i.e.
  • Page 19 Instruction Manual w PE 100-T petrol units close additionally the condensate drain tap (2, Fig. 12) of final separator). Bottle will be filled. Observe pressure gauge and drain condensate regularly during filling. To avoid needless aperture of the safety valve, the compressor must be switched off manually as soon as the filling pressure is reached.
  • Page 20 Instruction Manual w PE 100-T some pressure in the unit and close all valves again to prevent moisture entering the filter and resulting saturation of the cartridge. Check the oil level in the compressor and top up, if necessary. Also check whether the compressor needs servicing in accordance with maintenance schedule - see service manual.
  • Page 21 Instruction Manual w PE 100-T MAINTENANCE 4.4.1. LUBRICATION TYPE OF OIL 4.1. MAINTENANCE RECORD For proper care and maintenance of the compressor, using the correct oil is of vital importance. Depending on the ap­ We recommend that all maintenance work is recorded in...
  • Page 22 Instruction Manual w PE 100-T OIL PACKAGES 4.4.2. INTAKE FILTER BAUER compressor oil is available in various quantities, DESCRIPTION refer to oil list in chapter 8. A dry micronic filter is used to filter intake air (Fig. 17). OIL CHANGE Run compressor warm.
  • Page 23 Instruction Manual w PE 100-T 4.4.3. INTERMEDIATE SEPARATOR DESCRIPTION An intermediate separator is mounted on the compressor between 2nd and 3rd stage. It is designed to remove water and oil accumulating due to cooling the compressed me­ dium down after the compression process.
  • Page 24 Instruction Manual w PE 100-T though a cartridge is installed, the O-rings are either broken LIFETIME or were damaged on installation. The filter system is subject to dy­ WARNING Remove and check cartridge. If necessary replace cartridge namic load. It is designed for a cer­...
  • Page 25 Instruction Manual w PE 100-T FILTER CARTRIDGES CARTRIDGE CHANGE New filter cartridges are vacuum-packed and can be stored For safety reasons only CO removal for two years (refer to date on the cartridge). A defective WARNING cartridges part no. 059183 should vacuum package cannot protect the cartridge appropri­...
  • Page 26 Instruction Manual w PE 100-T 1. Filter cartridge 057679: lifetime [hours] Filling pressure p = 200 bar PE 100-T Ambient temperature Final separator temperature Delivery tU [°C] tAb [°C] Q [l/min] 20 - 24 26 - 21 25 - 29...
  • Page 27 Instruction Manual w PE 100-T 2. Filter cartridge 059183: lifetime [hours] Filling pressure p = 200 bar PE 100-T Ambient temperature Final separator temperature Delivery tU [°C] tAb [°C] Q [l/min] 20 - 24 22 - 18 25 - 29...
  • Page 28 Instruction Manual w PE 100-T 4.4.5. FILLING VALVE To protect filling valve against contamination a sintered metal filter is screwed in the filling valve body. Unscrew pressure gauge (3, Fig. 22) from filling valve body (1). Screw off sintered metal filter (2) with a suitable screw driver.
  • Page 29 Instruction Manual w PE 100-T Venting 4.4.9. VALVES DESCRIPTION The valve heads of the individual stages form the top part of the cylinders. The intake and pressure valves are fitted in­ side the valve heads. Note that the valves are operated by the flow of the air.
  • Page 30 Instruction Manual w PE 100-T GENERAL INSTRUCTIONS FOR CHANGING THE Remove four valve head screws (5) from valve head (1). VALVES Take off valve head. Remove gasket (2) and plate valve (3). Always replace valves as a complete set. When re-installing the valve, check that mark ”S” is Observe the correct sequence when fitting together facing upwards and towards intake filter side.
  • Page 31 Instruction Manual w PE 100-T 4.4.10. COMPRESSOR DRIVE SYSTEM DESCRIPTION The compressor is driven by the drive motor through a V- belt. The motor is mounted on the base plate and requires adjustment for proper V-belt tension. Improper v-belt tension and adjustment of the pulleys will result in extreme v-belt abrasion and premature wear.
  • Page 32 Instruction Manual w PE 100-T 4.4.11. ELECTRICAL SYSTEM DESCRIPTION This section describes the standard electrical system. For schematic diagram, see annex. The electrical equipment of the compressor unit consists of: drive motor electric control system To start the electric motor and enable the functioning of the...
  • Page 33 Instruction Manual w PE 100-T 4.5. TROUBLE-SHOOTING Trouble Cause Remedy Drive motor (electric) Motor will not start Electric circuitry faulty Check all fuses, terminal connections, wire leads, make sure that motor data complies with mains supply Motor/engine runs eccentrically V-belt worn Replace Wrong adjustment of the motor pro­...
  • Page 34 Instruction Manual w PE 100-T Trouble Cause Remedy Piston rings, Pistons or cylinders worn Replace defective parts, see chapter High oil consumption 4.4.9. Intake filter clogged Replace filter cartridge, see chapter 4.4.2. Compressor too hot Enhance cooling, see chapter 4.4.12.

  • Page 35: Storage, Preservation

    Instruction Manual w PE 100-T STORAGE, PRESERVATION Remove the dust cap from the inlet port and insert the intake filter. Open the filling valves or the outlet valve and let the unit GENERAL run for approx. 10 minutes or until the pressure gauges indicate the correct values.
  • Page 36 Instruction Manual w PE 100-T safety valves are not repaired but always replaced com­ pletely. For many BAUER compressor units, workshop manuals are available through our customer service. For questions on maintenance and repair, please contact our technical service department.
  • Page 37 Instruction Manual w PE 100-T TABLES TIGHTENING TORQUE VALUES Unless otherwise specified in text, the fol­ lowing torque values apply. All valve head screws require torque wrench tight­ ening! The indicated torque values are valid for bolts in greased condition. Re­...
  • Page 38 Instruction Manual w PE 100-T LUBRICATION CHART Usage Lubricants Rubber and plastic parts, filter housing threads WEICON WP 300 WHITE part no. N19752 or BAUER special grease part no. 072500 Sealing rings BAUER special grease part no. 072500 Shaft seal (seal) BAUER special grease part no.
  • Page 39 Instruction Manual w PE 100-T...

  • Page 41: Annex

    Instruction Manual w PE 100-T ANNEX • Schematic diagram Lubricating oil list Parts list...
  • Page 42 Instruction Manual w PE 100-T...
  • Page 43 Instruction Manual w PE 100-T Schematic diagram motor protection switch, three phase current Hauptsicherung bauseits / Main fuse by customer / Fusible principal coté client Ein/Aus On/Off Marche/ Arrêt Schaltplan/Schematic diagram/Schéma électrique Motorschutzschalter Motor protection switch Disjoncteur 76942−S1...
  • Page 44 Instruction Manual w PE 100-T...
  • Page 45 Oil list w Breathing air compressors GENERAL After extensive tests with many different kinds of lubricants, we have decided to authorize the following brands of oil for use in BAUER compressors under the given operating conditions. 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.
  • Page 46 Oil list w Breathing air compressors TYPE OF OIL Due to the thermal load on the compressor only high quality oil should be used. You are recommended to restrict oils to those which have been approved by us and are listed in the instruction manual or in the lubricating list on page 1. Our compressor units are delivered ex works with lubricating oil filled into the crankcase or as consignment, depending on the model, as follows: Breathing air compressor units:...

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