Bauer Kompressoren Profi-Line CAPITANO 140-B User manual

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Table of contents
1Preface
1.1 Manufacturer’s details ............................................................................................ 9
1.1.1 Contact data BAUER KOMPRESSOREN ...................................................................9
1.2 About this manual ................................................................................................. 10
1.2.1 Purpose of this manual ......................................................................................... 10
1.2.2 Contents of this manual ........................................................................................10
1.2.3 Target groups of this manual .................................................................................10
1.2.4 Symbols used ........................................................................................................11
1.3 About this product ................................................................................................ 12
1.3.1 Identifying the product ..........................................................................................12
1.3.2 Application ............................................................................................................ 12
1.3.3 Scope of supply .....................................................................................................12
1.3.4 Variants .................................................................................................................13
1.3.5 Equipment .............................................................................................................13
1.3.6 Options ................................................................................................................. 14
1.3.7 Applied standards ................................................................................................. 14
2 For your safety
2.1 Intended usage ..................................................................................................... 15
2.2 Improper use .........................................................................................................15
2.3 Display and meaning of warnings ..........................................................................16
2.3.1 Hazard classes ...................................................................................................... 16
2.3.2 Structure of the warnings ......................................................................................16
2.3.3 Danger warnings on the machine ..........................................................................17
2.4 Product safety .......................................................................................................18
2.4.1 Fundamental safety information ............................................................................18
2.4.2 Safety instructions regarding transport and loading work .....................................19
2.4.3 Safety information regarding operation .................................................................20
2.4.4 Safety instructions regarding maintenance, service and repairs ...........................21
2.4.5 Safety instructions regarding cleaning .................................................................. 22
2.4.6 Particular dangers .................................................................................................23
2.5 Instructions regarding emergency .........................................................................25
2.5.1 Behaviour in case of faults and emergencies ........................................................ 25
2.5.2 Detecting a critical condition ................................................................................ 25
2.6 Organisational duties ............................................................................................ 26
2.6.1 Duties of the operating company .......................................................................... 26
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2.6.2 Personnel selection and qualification ....................................................................27
2.6.3 Duties of the personnel .........................................................................................28
2.7 Safety regulations ................................................................................................. 29
3 Product description
3.1 Structure and function .......................................................................................... 31
3.1.1 Structure ...............................................................................................................31
3.1.2 Function schematic ...............................................................................................36
3.1.3 Functional principle ...............................................................................................37
3.2 Display elements ...................................................................................................39
3.2.1 Control .................................................................................................................. 39
3.2.2 B-TIMER display and operating elements .............................................................. 40
3.2.3 SECURUS monitoring unit .....................................................................................41
3.3 Control elements ...................................................................................................42
3.3.1 Motor protection switch ........................................................................................42
3.3.2 Motor protection switch ........................................................................................42
3.3.3 Control system ......................................................................................................43
3.3.4 Filling equipment ...................................................................................................44
3.4 Operating modes ...................................................................................................44
3.4.1 Manual .................................................................................................................. 44
3.4.2 Semi-automatic .....................................................................................................44
4 Technical data
4.1 Technical data compressor unit ............................................................................ 45
4.1.1 Technical data CAPITANO140-B ............................................................................45
4.1.2 Technical data CAPITANO140-E ............................................................................46
4.1.3 Technical data MARINER200-B ............................................................................. 47
4.1.4 Technical data MARINER200-E ............................................................................. 48
4.1.5 Technical data MARINER250-B ............................................................................. 49
4.1.6 Technical data MARINER250-E ............................................................................. 50
4.1.7 Technical data MARINER320-B ............................................................................. 51
4.1.8 Technical data MARINER320-E ............................................................................. 52
4.2 Technical data Compressor block ......................................................................... 53
4.2.1 Technical data compressor block IK100 ............................................................... 53
4.2.2 Technical data compressor block IK120 ............................................................... 54
4.2.3 Technical data compressor block IK12.14 ............................................................ 54
4.3 Technical data Filter system ..................................................................................55
4.3.1 Technical data filter system P21 ........................................................................... 55
4.3.2 Technical data filter system P31 ........................................................................... 55
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4.3.3 Technical data filter system P41 ........................................................................... 56
4.4 Technical data Motor ............................................................................................ 56
5 Transport and storage
5.1 Transport ...............................................................................................................57
5.1.1 Checking the cargo ............................................................................................... 57
5.1.2 Preparing for transport ..........................................................................................57
5.1.3 Transport ...............................................................................................................58
5.2 Storage and preservation ......................................................................................59
5.2.1 Selecting the storage location ...............................................................................59
5.2.2 Preparing for preservation .....................................................................................59
5.2.3 Preservation ..........................................................................................................60
5.2.4 Inspecting the unit during storage ........................................................................ 60
6 Installation
6.1 Preparing the installation site ................................................................................61
6.2 Installing the unit .................................................................................................. 62
6.2.1 Installing the unit .................................................................................................. 62
6.3 Electrical connection of the unit ............................................................................65
6.4 Having the unit accepted ...................................................................................... 65
7 Commissioning and operation
7.1 Starting up the unit ............................................................................................... 67
7.1.1 Checks before each commissioning ......................................................................67
7.1.2 Commissioning the unit for the first time ..............................................................68
7.1.3 Commissioning the unit after longer downtimes ...................................................70
7.1.4 Checking the direction of rotation of the motor ....................................................71
7.1.5 Preparing for the operation with B-TIMER ............................................................. 72
7.2 Operation .............................................................................................................. 73
7.2.1 Switching on the unit ............................................................................................ 74
7.2.2 Switching the unit off ............................................................................................ 75
7.2.3 Behaviour in case of emergency ........................................................................... 75
7.2.4 Monitoring operation .............................................................................................76
7.2.5 Operating the B-TIMER ..........................................................................................77
7.2.6 Filling operation .................................................................................................... 81
8 Troubleshooting
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8.1 Fault finding and fault correction .......................................................................... 85
8.1.1 Fault finding in drive motor ................................................................................... 85
8.1.2 Fault finding in compressor block ......................................................................... 85
8.1.3 Fault finding in automatic condensate drain ......................................................... 86
8.1.4 Fault finding in electrical control system ...............................................................87
8.1.5 Error display B-TIMER ............................................................................................87
9 Maintenance
9.1 Evidence of maintenance ...................................................................................... 89
9.2 Maintenance table ................................................................................................ 89
9.3 Resources for maintenance and repairs ................................................................90
9.3.1 Bolt torques .......................................................................................................... 90
9.3.2 Bolt tightening sequence .......................................................................................91
9.3.3 Lubricant ...............................................................................................................91
9.3.4 Lubrication oil ....................................................................................................... 92
9.3.5 Adhesive and sealant ............................................................................................ 94
9.3.6 Test medium ......................................................................................................... 94
9.3.7 Filter cartridges .....................................................................................................95
9.4 Maintenance activities - Lubricating oil system .....................................................96
9.4.1 Checking the oil level ............................................................................................ 96
9.4.2 Oil change ............................................................................................................. 97
9.4.3 Changing the oil type .......................................................................................... 100
9.4.4 Venting the oil pump ...........................................................................................101
9.5 Maintenance activities - Intake section ...............................................................102
9.5.1 Replacing the intake filter ................................................................................... 102
9.6 Maintenance activities filter system ....................................................................103
9.6.1 General maintenance advices ............................................................................. 103
9.6.2 Checking the load cycles .................................................................................... 104
9.6.3 De-pressurising the unit ......................................................................................105
9.6.4 Determine the cartridge service life ....................................................................106
9.6.5 Changing the cartridge of the purifier ................................................................. 109
9.7 Maintenance activities pressure retention valve ................................................. 112
9.7.1 Checking the pressure retention valve ................................................................112
9.7.2 Adjusting the pressure retention valve ................................................................112
9.8 Maintenance activities for filling equipment ........................................................113
9.8.1 Check filling hoses ..............................................................................................113
9.8.2 Maintaining the filling valves ...............................................................................114
9.9 Maintenance activities safety valves ...................................................................116
9.9.1 Checking the function .........................................................................................117
9.9.2 Checking the blow-off pressure .......................................................................... 117
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9.10 Maintenance activities pressure gauge ...............................................................118
9.11 Maintenance activities - Intake valves and pressure valves ................................ 119
9.11.1 Servicing the suction valves and pressure valves ................................................119
9.11.2 Replacing the suction valves and pressure valves ...............................................119
9.12 Maintenance activities - Automatic condensate drain .........................................120
9.12.1 Checking the function of automatic condensate drain ........................................120
9.12.2 Adjusting the timer ............................................................................................. 122
9.12.3 Adjusting the timers ............................................................................................124
9.13 Maintenance activities electrical system ............................................................ 126
9.13.1 Maintaining the electrical control systems ..........................................................126
9.13.2 Adjusting the final pressure switch ..................................................................... 127
9.13.3 Replace the battery of the B-TIMER .................................................................... 127
9.14 Maintenance activities drive system ................................................................... 128
9.14.1 Electric motor maintenance ................................................................................ 128
9.14.2 V-belt maintenance .............................................................................................129
10 Disassembly and disposal
10.1 Decommissioning ................................................................................................131
10.2 Dispose the unit ..................................................................................................131
11 Appendix
11.1 Declaration of conformity ................................................................................... 133
11.2 Connection value table for three-phase motors (230 V) ......................................134
11.3 Connection rating table for three-phase AC motors (400 V / 500 V) ................. 135
11.4 Filter cartridge replacement intervals ................................................................. 136
11.4.1 Filter cartridge 057679 .......................................................................................137
11.4.2 Filter cartridge 059183 .......................................................................................139
11.4.3 Filter cartridge 80100 .........................................................................................141
11.4.4 Filter cartridge 80114 .........................................................................................142
11.4.5 Filter cartridge 062565 .......................................................................................143
11.4.6 Filter cartridge 067224 .......................................................................................145
11.5 Maintenance booklet .......................................................................................... 147
11.5.1 Instruction form for the operator ........................................................................ 147
11.5.2 Maintenance schedule ........................................................................................ 149
11.5.3 Maintenance forms ............................................................................................. 151
11.5.4 Cartridge change .................................................................................................154
Index
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1 Preface
1.1 Manufacturer’s details
1.1.1 Contact data BAUER KOMPRESSOREN
BAUER KOMPRESSOREN GmbH
Stäblistr. 8
D-81477 Munich
Tel.: [phone]
Fax: [phone]
www.bauer-kompressoren.de
[email protected]
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1.2 About this manual
Depending on the version, the unit may look different from the images in this docu-
ment.
1.2.1 Purpose of this manual
This manual will make it easier to become familiar with the product and make use
of its intended application possibilities. The manual contains important information
for operating the product safely, properly and economically. Following the instruc-
tions in this manual will help to avoid dangers, minimise repair costs and down-
times, and increase the reliability and service life of the product.
1.2.2 Contents of this manual
In addition to general safety instructions and a product description, this manual
contains instructions for all life phases of the product ranging from unpacking to
disposal.
Further information like drawings, diagrams, spare parts list or accompanying
booklets as well as manuals of additional devices (if available) are enclosed at the
end of this manual and are a part of this manual, refer to Chapter 11.1, Page 133
and the following.
All the information in this manual is correct at the time of printing.
BAUER KOMPRESSOREN reserves the right to make technical changes that facili-
tate an improvement or raise the safety standard.
1.2.3 Target groups of this manual
The manual is intended for the following target groups:
•Operating company of the machine
•Operating personnel
•Assembly personnel and maintenance personnel
•Testing personnel
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1.2.4 Symbols used
The following symbols are used in the manual:
Symbol Meaning
Dangers for persons. For more information,
see Chapter 2.3 Display and meaning of warn-
ings, Page 16.
Information for understanding or optimising
the work processes.
Information for solving problems or for trou-
bleshooting.
Prerequisite for an operating procedure.
Operating procedure, also measures in a
warning.
1.
2.
...
Step-by-step operating procedure. Follow the
sequence.
End result
Follow the instructions for safe disposal.
Tab. 1 Symbols used and their meaning
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1.3 About this product
1.3.1 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.
•In case of customer service enquiries, always specify the model and serial
number of the product.
1
2
Fig. 1 Type plate
1 Model 2 Serial number
1.3.2 Application
The machine is intended exclusively for the compression and the storage of the
medium specified, under consideration of the conditions specified, see Technical
Data.
1.3.3 Scope of supply
The minimum scope of supply comprises:
•the product
•all necessary consumable material such as oil and filter (except fuel), filled in
an accessory kit already installed
•this manual
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1.3.4 Variants
Type designation Operating pressure
max. [bar]
Delivery rate [l/min] Drive motor
CAPITANO 140-B 350 140 Petrol 4-stroke
CAPITANO 140-E 350 140 3-Phase AC 400V, 50
Hz
MARINER 200-B 350 200 Petrol 4-stroke
MARINER 200-E 350 200 3-Phase AC 400V, 50
Hz
MARINER 250-B 350 250 Petrol 4-stroke
MARINER 250-E 350 250 3-Phase AC 400V, 50
Hz
MARINER 320-B 420 320 Petrol 4-stroke
MARINER 320-E 420 320 3-Phase AC 400V, 50
Hz
Tab. 2 Versions
1.3.5 Equipment
The models contain the following components as standard:
•Carrier frame
•Operating voltage 400 VAC / 50 Hz (only units with electric motor)
•Intake hose (only units with petrol engine)
•Motor protection switch (units with 400V/ 50Hz including plug)
•Filter system:
−CAPITANO 140 and MARINER 200: Filter system P21
−MARINER 250 and MARINER 320: Filter system P31
•TÜV type-tested final pressure safety valve
•Filling device:
−CAPITANO 140: 1 x 200 bar or 1 x 300 bar
−MARINER 200 & 250: 2 x 200 bar or 2 x 300 bar
−MARINER 320: 4 x 200 bar or 4 x 300 bar
•manual condensate drain
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1.3.6 Options
The actual range of options of the unit can be read about in the sales documents.
The following additional equipment is optionally available:
•Trolley
•Special operating voltage (standard operating voltage = 400 V / 50 Hz)
•Automatic condensate drain
•Intake hose (only units with petrol engine)
•Telescopic intake tube (only CAPITANO 140 and MARINER 200)
•Intermediate separator after 1st compressor stage
•Compressor control system with semi-automatic or fully-automatic final pres-
sure switch-off
•Filter system:
−CAPITANO 140 and MARINER 200: Filter system P31
−MARINER 200, MARINER 250 and MARINER 320: Filter system P41
•Filter monitoring:
−B-TIMER Mini-Computer
−SECURUS monitoring unit (only in connection with filter system P41 and
compressor control system)
•Additional filling devices
•Switch-over device for the filling of 200 bar and 300 bar cylinders
1.3.7 Applied standards
Declaration of conformity
The product has been constructed in line with the directives listed in the conformi-
ty declaration or the state of the art and recognised safety-related regulations; see
Chapter 11.1 Declaration of conformity, Page 133.
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.
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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:
•the compliance with this manual and the installation instructions as well as
the fulfilment of the installation requirements.
•the compliance with the maintenance intervals and the fulfilment of the main-
tenance works
•the fulfilment of the applicable regulations
Any use apart from those mentioned above is considered to be not intended.
2.2 Improper use
Any use apart from the intended use mentioned above is considered to be not in-
tended. The manufacturer/supplier can assume no liability for damage resulting
from this type of usage. The user alone bears the risk of this. A claim for guarantee
shall be rendered inapplicable in the following cases:
•In the event of improper use.
•In the event of non-compliance with the performance limits and the authorized
operating conditions of the machine.
•When operating without safety equipment or with incorrect or non-functional
safety equipment.
•If unauthorized or unqualified persons work with or on the machine.
•If unauthorized operating supplies are used.
•If accessories and spare parts that are not made for the machine are used.
Only original spare parts may be used.
•If unauthorised modifications, alterations or program changes are carried out
on the machine.
•If modifications or repairs are carried to pressure vessels that must be accep-
ted, without having obtained consent or another acceptance by an expert
technician or audit authority of the operator’s country.
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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.
Hazard class Description
DANGER Indication of an immediate imminent danger.
If the warning is not observed, this will result
in death or serious injuries.
WARNING Indication of a potentially dangerous situation.
If the warning is not observed, this can result
in death or serious injuries.
CAUTION Indication of a potentially dangerous situation.
If the warning is not observed, this can result
in minor injuries.
NOTICE Indication of a potentially dangerous situation.
If the warning is not observed, this can result
in material damage.
Tab. 3 Hazard classes
2.3.2 Structure of the warnings
The warnings describe the type and source of danger, the consequences of not
heeding these warnings, and measures to be taken to avert the danger. A warning
is always structured according to the following pattern:
WARNING
Type and source of danger.
Consequences of not heeding the warning
Measures for averting the danger.
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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
Caution, automatic control!
Caution, hot surfaces!
Caution, electric shock!
Follow the instructions
Wear hearing protection
Pay attention to the direction of rotation
Tab. 4 Danger warnings on the machine
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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.
•Faults that have a negative effect on safety must be immediately rectified.
•In addition to the manual, follow and advise the generally applicable binding
regulations for accident prevention and for environmental protection.
Danger due to electric current
Work on electrical units or operating equipment may only be carried out by an
electrical technician or other trained persons working under the guidance and su-
pervision of an electrical technician and must be performed in accordance with
electrotechnical regulations.
•Only use original fuses with the current stipulated. In the event of faults in the
electrical power supply, switch off the machine immediately.
•Disconnect machine parts on which inspection, maintenance or repair work is
carried out. Once the components have been isolated from the supply, first
check that they are de-energised and then short-circuit them before also iso-
lating neighbouring energised components.
•Check the electrical equipment of a machine on a regular basis. Defects such
as loose connections or scorched cables must be rectified immediately.
•If work on live parts is required, enlist a second person who can activate the
emergency stop switch in an emergency. Cordon off the working area with a
red-and-white safety chain and a warning sign. Only use insulated tools.
•All persons who handle electrical components and equipment that is fitted in
electrical components must be earthed.
•Measuring instruments and devices must be earthed. Measuring tips on poten-
tial-free measuring instruments must be briefly earthed on suitable earthed
surfaces before being used to take measurements.
Danger due to pneumatics
Work on pneumatic devices must only be carried out by persons having special
skills and experience with pneumatics.
•All lines, hoses and screwed fittings should be checked regularly for leaks and
externally detectable damage. Any damage must be rectified immediately.
Compressed air or gases coming out can cause injuries and fires.
•Before commencing repair work, depressurise any sections of the system and
pressure lines that are going to be opened.
•Lay and fit the pressure lines properly. Do not swap the connections over. The
fittings, length and quality of the pressure lines must comply with require-
ments.
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Danger due to gas, dust and smoke
•When working with smothering gases, you must monitor the oxygen concen-
tration in the room using a mobile gas measuring device.
•When working in confined spaces, ensure adequate ventilation and follow ex-
isting national regulations where applicable.
•Execute welding, flame-cutting and grinding work on and next to the machine
only when the work has been specifically approved.
•Before welding, flame-cutting and grinding, clean the machine and surround-
ings of dust and flammable materials and ensure adequate ventilation to avoid
a danger of explosion.
Danger due to oil, grease and other chemical substances
•When handling oils, grease and other chemical substances, observe the safety
regulations applicable to the product.
Danger due to noise
•The noise protection equipment on the machine must be in the protection po-
sition when the equipment is running.
•Wear the specified personal hearing protection.
2.4.2 Safety instructions regarding transport and loading work
Carry out the following measures to ensure safe transport:
•Machines, individual parts and larger components must be securely fastened
to lifting tackles.
•Do not stand or work under suspended loads.
•Use only experienced persons for slinging the loads and instruct the crane
drivers. The instructor must be in view of the operator or in voice contact with
him.
•Use only suitable lifting tackles, load carrying equipment and transport vehi-
cles with adequate carrying capacity.
•Secure the load in a reliable manner. Use suitable lashing points.
•Fit transport securing devices to the machine for transporting if necessary. Fix
the relevant sign. Remove the transport securing devices before commission-
ing/recommissioning.
•Re-fit and secure the parts removed for transport purposes before recommis-
sioning.
•Isolate the machine from all external energy supplies, even if the location to
be changed is over a small distance. Connect the machine properly to the
mains before recommissioning.
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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. detachable protection equipment, emergency stop equipment and
noise reduction devices) are present and functioning correctly.
•In the event of malfunctions, stop and secure the machine immediately. Any
fault must be rectified or eliminated immediately.
•Switch the machine on and off and manage indicator displays as stipulated in
the operating manual.
•Before switching on / starting up the machine, make sure that there is no risk
of it harming anyone whilst in operation.
•Adhere to the activities and dates for setting, maintenance and inspection as
stipulated in the manual, including specific information on replacing parts/
fitting components. These activities may only be carried out by specialist per-
sonnel.
•Inform the operating personnel about the special tasks and service work be-
fore starting it. Nominate a supervisor.
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