POSEIDON PE300-VE User manual

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Table of contents
1Preface
1.1 Contact data BAUER KOMPRESSOREN ...................................................................9
1.2 About this manual ................................................................................................. 10
1.2.1 Purpose of this manual ......................................................................................... 10
1.2.2 Target groups of this manual .................................................................................10
1.2.3 Storing this manual ............................................................................................... 10
1.2.4 Symbols used ........................................................................................................11
1.2.5 Abbreviations used ................................................................................................11
1.2.6 Disclaimer of liability .............................................................................................11
1.2.7 History .................................................................................................................. 12
1.3 About this product ................................................................................................ 13
1.3.1 Identifying the product ..........................................................................................13
1.3.2 Application ............................................................................................................ 13
1.3.3 Variants and equipment ........................................................................................ 14
1.3.4 Options ................................................................................................................. 14
1.3.5 Scope of supply .....................................................................................................14
1.3.6 Applied standards ................................................................................................. 15
2 For your safety
2.1 Intended usage ..................................................................................................... 17
2.2 Improper use .........................................................................................................17
2.3 Display and meaning of warnings ..........................................................................18
2.3.1 Hazard classes ...................................................................................................... 18
2.3.2 Structure of the warnings ......................................................................................18
2.3.3 Danger warnings on the machine ..........................................................................19
2.4 Product safety .......................................................................................................20
2.4.1 Fundamental safety information ............................................................................20
2.4.2 Safety instructions regarding transport and loading work .....................................21
2.4.3 Safety information regarding operation .................................................................22
2.4.4 Safety instructions regarding maintenance, service and repairs ...........................23
2.4.5 Safety instructions regarding cleaning .................................................................. 24
2.4.6 Particular dangers .................................................................................................25
2.4.7 Safety and monitoring equipment ......................................................................... 26
2.5 Instructions regarding emergency .........................................................................26
2.5.1 Behaviour in case of faults and emergencies ........................................................ 26
2.6 Organisational duties ............................................................................................ 27
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2.6.1 Personnel selection and qualification ....................................................................27
2.6.2 Duties of the operating company .......................................................................... 28
2.6.3 Duties of the personnel .........................................................................................29
2.7 Safety regulations ................................................................................................. 30
3 Product description
3.1 Structure ...............................................................................................................33
3.2 Function ................................................................................................................35
3.2.1 Intake ....................................................................................................................35
3.2.2 Compression .........................................................................................................35
3.2.3 Protection ............................................................................................................. 35
3.2.4 Cooling ..................................................................................................................35
3.2.5 Separation of the condensate ............................................................................... 35
3.2.6 Condensate drain ..................................................................................................36
3.2.7 Collecting the condensate .....................................................................................36
3.2.8 Filtration ................................................................................................................36
3.2.9 Filling .................................................................................................................... 37
3.2.10 Drive ......................................................................................................................37
3.2.11 Control system ......................................................................................................37
3.2.12 Gas measurement (option) ....................................................................................37
3.3 Operating modes ...................................................................................................38
3.3.1 Semi-automatic .....................................................................................................38
3.3.2 Fully automatic ......................................................................................................38
3.3.3 Combined operation ..............................................................................................38
3.4 Connections ..........................................................................................................39
3.4.1 Overview ............................................................................................................... 39
3.5 Control elements ...................................................................................................41
3.5.1 Overview ............................................................................................................... 41
3.5.2 Operating panel .....................................................................................................42
3.6 Display elements ...................................................................................................43
3.6.1 Overview ............................................................................................................... 43
3.6.2 Display elements B-CONTROL MICRO ...................................................................44
4 Technical data
4.1 Technical data compressor unit ............................................................................ 49
4.1.1 Technical data PE300-VE ...................................................................................... 49
4.1.2 Technical data PE320-VE ...................................................................................... 51
4.1.3 Technical data PE400-VE ...................................................................................... 53
4.2 Technical data Compressor block ......................................................................... 55
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4.2.1 Technical data compressor block IK120 ............................................................... 55
4.2.2 Technical data compressor block IK12.14 ............................................................ 56
4.3 Technical data Filter system ..................................................................................56
4.3.1 Technical data filter system P41 ........................................................................... 56
4.4 Technical data B-DETECTION PLUS i .....................................................................57
4.5 Technical data Motor ............................................................................................ 58
5 Transport and storage
5.1 Transport ...............................................................................................................59
5.1.1 Checking the cargo ............................................................................................... 59
5.1.2 Preparing for transport ..........................................................................................59
5.1.3 Transport ...............................................................................................................60
5.2 Storage and preservation ......................................................................................61
5.2.1 Selecting the storage location ...............................................................................61
5.2.2 Preparing for preservation .....................................................................................61
5.2.3 Preservation ..........................................................................................................62
5.2.4 Inspecting the unit during storage ........................................................................ 62
6 Installation
6.1 Preparing the installation site ................................................................................63
6.2 Installing the unit .................................................................................................. 64
6.2.1 Securing the air quality ......................................................................................... 64
6.2.2 Installing the unit .................................................................................................. 65
6.2.3 Ensuring cooling ....................................................................................................66
6.3 Electrical connection of the unit ............................................................................71
6.4 Pneumatic connection of the unit ......................................................................... 72
6.5 Having the unit accepted ...................................................................................... 72
7 Commissioning and operation
7.1 Caution in case of units with gas measurement device .........................................73
7.1.1 Instructions for operation ......................................................................................73
7.2 Starting up the unit ............................................................................................... 75
7.2.1 Checks before each commissioning ......................................................................75
7.2.2 Commissioning the unit for the first time ..............................................................77
7.2.3 Commissioning the unit after longer downtimes ...................................................79
7.2.4 Checking the direction of rotation of the motor ....................................................81
7.3 Operating the electronic control ........................................................................... 82
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7.3.1 Navigating in the control system ...........................................................................82
7.3.2 Modifying the settings ...........................................................................................83
7.3.3 Entering password ................................................................................................ 85
7.3.4 Inserting the memory card ....................................................................................87
7.4 Configuring the electronic control system ............................................................ 89
7.4.1 Setting time and date ............................................................................................89
7.4.2 Setting language and units ....................................................................................90
7.4.3 Setting the display ................................................................................................ 91
7.4.4 Setting the final pressure ......................................................................................92
7.4.5 Setting the valves ..................................................................................................93
7.4.6 Setting the alarm relay ..........................................................................................94
7.4.7 Loading the factory settings ..................................................................................95
7.4.8 Connecting to a local network .............................................................................. 96
7.5 Operation .............................................................................................................. 97
7.5.1 Switching the unit on ............................................................................................ 98
7.5.2 Switching the unit off ............................................................................................ 98
7.5.3 Behaviour in case of emergency ........................................................................... 99
7.5.4 Displaying the operating values ............................................................................ 99
7.5.5 Checking the maintenance intervals ................................................................... 100
7.5.6 Checking the maintenance intervals for gas sensors ..........................................101
7.5.7 Displaying the current messages ........................................................................ 102
7.5.8 Displaying the logbook ........................................................................................103
7.5.9 Resetting the messages ......................................................................................104
7.5.10 Operating the control system with the B-APP ..................................................... 105
7.6 Filling operation .................................................................................................. 108
7.6.1 Flushing the unit manually .................................................................................. 108
7.6.2 Switching over the filling pressure ...................................................................... 109
7.6.3 Analysing the air ................................................................................................. 110
7.6.4 Filling the compressed air cylinders ....................................................................112
7.6.5 Filling the compressed air cylinders ....................................................................115
8 Troubleshooting
8.1 Fault finding and fault correction ........................................................................ 117
8.1.1 Fault finding in drive motor ................................................................................. 117
8.1.2 Fault finding in compressor block ....................................................................... 117
8.1.3 Fault finding in electrical control system .............................................................118
8.1.4 Fault finding in automatic condensate drain ....................................................... 119
8.1.5 Troubleshooting .................................................................................................. 120
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9 Maintenance
9.1 Maintenance table .............................................................................................. 121
9.2 Resources for maintenance and repairs ..............................................................122
9.2.1 Bolt torques ........................................................................................................ 122
9.2.2 Bolt tightening sequence .................................................................................... 123
9.2.3 Adhesive and sealant .......................................................................................... 123
9.2.4 Lubricant .............................................................................................................124
9.2.5 Lubrication oil ..................................................................................................... 125
9.2.6 Test material ....................................................................................................... 127
9.2.7 Filter cartridges ...................................................................................................127
9.3 Checking the unit for leaks ................................................................................. 128
9.4 Depressurising the unit .......................................................................................129
9.4.1 De-pressurising the filter circuit ..........................................................................129
9.5 Maintenance activities - Intake section ...............................................................130
9.5.1 Maintenance work .............................................................................................. 130
9.6 Maintenance activities - Lubricating oil system ...................................................132
9.6.1 Maintenance work .............................................................................................. 133
9.6.2 Changing the oil type .......................................................................................... 137
9.7 Maintenance activities filter system ....................................................................138
9.7.1 General maintenance advices ............................................................................. 138
9.7.2 Checking the load cycles .................................................................................... 138
9.7.3 Determine the cartridge service life ....................................................................139
9.7.4 Changing the cartridge of the filter vessel .......................................................... 143
9.8 Check filling hoses ..............................................................................................144
9.9 Maintenance activities pressure retention valve ................................................. 145
9.9.1 Checking the pressure maintaining valve ............................................................145
9.9.2 Adjusting the pressure retention valve ................................................................146
9.10 Maintenance activities safety valves ...................................................................147
9.10.1 Checking the blow-off pressure of safety valves ................................................. 148
9.11 Maintenance activities pressure gauge ...............................................................150
9.12 Maintenance activities - Intake valves and pressure valves ................................ 150
9.12.1 Replacing the suction valves and pressure valves ...............................................150
9.13 Maintenance activities - Automatic condensate drain .........................................151
9.13.1 Testing the condensate valves ............................................................................ 151
9.13.2 Checking the function of automatic condensate drain ........................................152
9.14 Maintenance activities gas measurement unit ....................................................154
9.14.1 Checking the sensors ..........................................................................................154
9.14.2 Calibrating the sensors ....................................................................................... 156
9.14.3 Replacing the sensors .........................................................................................159
9.14.4 Replacing the filters ............................................................................................ 161
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9.15 Maintenance activities electrical system ............................................................ 162
9.15.1 Maintaining the electrical control systems ..........................................................162
9.16 Maintenance activities drive system ................................................................... 163
9.16.1 V-belt maintenance .............................................................................................163
10 Disassembly and disposal
10.1 Decommissioning and disposal ...........................................................................165
10.1.1 Decommissioning ................................................................................................165
10.1.2 Dispose the unit ..................................................................................................166
11 Appendix
11.1 Sample declaration of conformity ....................................................................... 167
11.2 Filter cartridge replacement intervals ................................................................. 168
11.2.1 Filter cartridge 062565 .......................................................................................169
Index
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1 Preface
1.1 Contact data BAUER KOMPRESSOREN
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BAUER KOMPRESSOREN GmbH
Stäblistr. 8
D-81477 Munich
Germany
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[email protected]
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[phone]
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[phone]
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www.bauer-kompressoren.de
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www.facebook.com/BAUER.KOMPRESSOREN.GmbH
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www.instagram.com/bauer_kompressoren
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www.youtube.com/user/Bauerkompressoren
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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 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
1.2.3 Storing this manual
This manual is a part of the product.
•It must be stored such that it is easily accessible to the personnel at any time.
•No pages may be extracted from the manual.
•If the product is resold, the manual must be handed over along with the prod-
uct.
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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 18.
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
1.2.5 Abbreviations used
The following Abbreviations are used in this manual:
Abbreviations Meaning
Fig. Figure
barg Relative pressure in Bar
bara Absolut pressure in Bar
No. Number
Pos. Position, item
P. Page
Tab. Table
1.2.6 Disclaimer of liability
BAUER KOMPRESSOREN reserves the right to make modifications to the technical
specifications, software described and / or documentation without prior notice.
All the information in this manual is correct at the time of printing.
BAUER KOMPRESSOREN reserves the right to make technical changes that are
made for improvement purposes or increase the safety standard.
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1.2.7 History
The following table shows the most important changes to the documentation com-
pared with the previous version in each case:
Version Edition Remark
001 05/2018 First issue
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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.
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1.3.3 Variants and equipment
Variants PE300-VE PE400-VE PE320-VE
Operating pressure
[bar]
350 350 420
Delivery volume [l/
min]
300 400 320
Cylinder fillings ( 10
l / 0-200 bar) per
hour, approx.
9 12 10
The models contain the following components as standard:
•Automatic condensate drain
•Filter system P41
•Condensate collection vessel (10 l)
•Compressor control system B-CONTROL MICRO
1.3.4 Options
The actual range of options of the unit can be read about in the sales documents.
The following additional equipment is optionally available:
•Completely covered, soundproof frame
•Exhaust chute with or without ventilations flaps
•External intake system via roof
•Condensate collection vessel (60l)
•B-SECURUS filter saturation monitor
•B-LINK Access point for WLAN access
•Extended base frame with storage bottles
•Filling device with up to 4 direct or hose connections and for 1 or 2 filling pres-
sures
1.3.5 Scope of supply
The minimum scope of supply comprises:
•the product
•all necessary consumable material such as oil and filters (excluding fuels such
as petrol or diesel fuel), either provided as accessory kit or already filled in or
installed
•a hose for oil draining and condensate draining
•a funnel for topping up the oil
•a filter wrench for cartridge change (only for units with a filter system)
•a wrench for unlocking the side cladding
•a wrench for opening the control box
•these instructions
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1.3.6 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 .
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. 2 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!
Caution, oxidizing substances!
Follow the instructions
Wear hearing protection
Pay attention to the direction of rotation
Tab. 3 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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