Bauer Junior II-B-F01 Instruction Manual
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Bauer Junior II-B-F01, Oil list 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: BAUER Special Compressor oil, part no. N28355 Nitrox compressor units: BAUER Special Compre
Bauer Junior II-B-F01, Instruction Manual Junior II 8 the critically stressed areas of the vessels are examined by means of suitable testing methods, in order to ensure the operating safety. After having reached the total permissible number of load cycles, the vessel must be exchanged and scrapped. Record the number of load cycles in writing if you do not have an automatic cycle-counter. We recommend that aluminium vessels should be exchanged after 15 years at the latest. Please pay attention to and follow these measures, for your own safety and that
Bauer Junior II-B-F01, WARNING Instruction Manual Junior II 9 3. LOCATION, OPERATION, BOTTLE FILLING LOCATION Outdoor location The compressor unit is not seawater resis tant. At operation in salty air spray com pressor with anticorrosive protection (e. g. Quicksilver Corrosion Guard). Electric driven units should be operated and stored below deck. Units with petrol engine should also be stored below deck after the filling process. Keep unit away from inflammable items. Do not smoke while petrol tank is open and while unit is in operation. - Locate the unit level. - On units with petrol engine it is most important that only clean ai
Bauer Junior II-B-F01, Instruction Manual Junior II 28 MOTOR PROTECTION SWITCH (THREE-PHASE MOTOR) The motor is switched on manually by turning the switch to 1 (Fig. 43). It is switched off manually by turning the switch to 0. For safety of the operating personnel all voltage carrying parts have a protective cover. After the switch has shut off by overcur rent triggering, the motor can be restarted by pressing the start-button not before the bi-metal in the switch has cooled down. This may last a couple of minutes. Protection of the motor is ensured by the thermomagnetic releases integra
Bauer Junior II-B-F01, Instruction Manual Junior II 27 - Remove allen screws (7), take off valve head cover (6). - Put two screwdrivers into the groove of pressure valve body (Fig. 39). If necessary turn valve loose at first using a 13 mm spanner on the flat surfaces. - Lift out pressure valve (3) together with O-ring (2). Reinstall pressure valve (3) in reverse sequence: - Check O-ring for abrasion and replace if necessary. Put O- ring (2) into valve head (5). - Insert pressure valve (3). Install valve head cover (6). - Fasten valve head with allen screws (7) and washers (8). - Screw in torque stud (1) with 20 Nm (2 kpm). Fi
Bauer Junior II-B-F01, WARNING WARNING WARNING Instruction Manual Junior II 10 Units with three phase current motor, additionally: - Immediately after switching on the system for the first time check the direction of rotation of the motor for com pliance with the arrow on the unit. If motor turns in the wrong direction, the phases are not connected properly. Shut down unit immediately and interchange two of the three phase leads in the switch box. Never change leads at the motor terminal board. Units with petrol engine, additionally: - Check engine oil level according to manufacturer's in struction manual. - Check fuel tank. Top up if necessary. - Open fuel
Bauer Junior II-B-F01, Fig. 18 Fig. 19 Fig. 20 Fig. 21 Fi g . 22 Instruction Manual Junior II 15 Operation The B-Timer is activated when starting the compressor. Compressor operation is indi cated by the flashing “h” symbol. To switch on the B-Timer press one of the keys on the display. Main menue will be displayed (Fig. 16). If no key is pressed within 1 minute, the in dication will return to the main menue. After 2 minutes the B-Timer is switched off, if no compressor operation is detected. Function Display To display the desired function, press the se lect key (). Press key. Remaining filter capacity is shown, Fig. 17) Press key again. Remaining operating hours to
Bauer Junior II-B-F01, Fig. 14 Fig. 15 Battery Fig. 16 Fig. 17 1 2 Instruction Manual Junior II 14 A = 500 hours or 1 year B = 1000 hours or 1 year C = 2000 hours or 2 years • Battery symbol indicating that the lithium battery is low and has to be changed. All data are stored and will not be lost when changing battery. The B-Timer is operated using the mode select and the enter keys. Error indication If the temperature sensor in the unit should be defective, an error message “Error 1” or “Error 2” is shown at the display (Fig. 14). In this case the unit should not be used but sent to the factory or the nearest BAUER representative for repair.
Instruction Manual Junior II 11 Scavenging the compressor unit CO 2 is present in the atmosphere with a natural amount of 350 to 400 ppm V . The molecular sieve used in the purifier for drying the breathing air is, as well as other capabilities, able to adsorb CO 2 which is accumulated in the cartridge. After shut-down of the compressor, adsorbed CO 2 ma
Bauer Junior II-B-F01, Instruction Manual Junior II 30 RemedyCauseTrouble High oil consumption Piston rings, Pistons or cylinders worn out Replace defective parts Intake filter clogged Replace filter cartridge Compressor too hot Enhance cooling Air escaping through cartridge safety bore Cartridge missing Insert cartridge Cartridge installed but O-rings defec tive Check/replace O-rings
Bauer Junior II-B-F01, WARNING WARNING Instruction Manual Junior II 17 4. MAINTENANCE 4.1. MAINTENANCE RECORD We recommend that all maintenance work is recorded in the service book, showing the date and details of the work car ried out. This will help to avoid expensive repairwork caused by missed maintenance work. If it is necessary to claim against the warranty, it will help to have proof that regular maintenance work has been carried out and that the dam age has not been caused by insufficient maintenance. Please
Bauer Junior II-B-F01, Instruction Manual Junior II 24 4.4.5. PRESSURE MAINTAINING VALVE DESCRIPTION A pressure maintaining valve is mounted at the outlet of the filter system P21. It ensures that pressure is built up in the filter even from the start of delivery, thus achieving a constant, optimum filtra tion. It will also guarantee proper working conditions for the final stage cylinder. The pressure maintaining valve is adjusted to 150 ±10 bar (2,175 psi). Fig. 31 Pressure maintaining valve 1 2 3 MAINTENANCE Th
Bauer Junior II-B-F01, WARNING Instruction Manual Junior II 20 Fig. 30 Safety bore Venting bore No cartridge Cartridge installed LIFETIME The filter system is subject to dy namic load. It is designed for a cer tain number of load cycles, which originate from an abrupt pressure loss at condensate drain (1 load cycle i.e. condensate drain = 1 depressu rization, 1 pressurization). The filter housing has to be inspected internally by an expert after having reached 1/4 of the determined number of load cycles. The in spection
Bauer Junior II-B-F01, Instruction Manual Junior II 32 6. REPAIR INSTRUCTIONS GENERAL Preventive maintenance usually involves replacing the valves, gaskets and sealing rings as well as carrying out the mainten ance work. Repair work can be carried out on the compressor block to a certain extent but a certain experience and skill is necessary. It should be noted, however, that - no repair should be carried out on the crankdrive nor on the bearings - 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
WARNING Instruction Manual Junior II 21 alent to between 10 and 13 operating hours at a filling pres sure of 200 bar. The longer service life of the cartridge at a filling pressure of 300 bar is annihilated by the larger volume of filled air per bottle, therefore the possible number of bottle fillings stays the same at different pressures. CARTRIDGE CHANGE For safety reasons only CO removal
Bauer Junior II-B-F01, Instruction Manual Junior II i INTRODUCTION This manual contains operating instructions and maintenance schedules for the high pressure breathing air compressor unit WARNING ! Pneumatic high pressure system ! The breathing air produced with the compressor units de scribed in this manual is subject to strict quality standards. Ignoring the operating and maintenance instructions can lead to severe injury or death. This compressor has been built in accordance with the EC ma chine regulations 98/37/EG. Specifications on the noise level in
Bauer Junior II-B-F01, Instruction Manual Junior II 26 CHANGING THE VALVES OF THE 1ST STAGE Intake and pressure valves of the 1st stage are combined in one plate valve under the valve head, see Fig. 36. 1 Valve head 2 Gasket 3 Plate valve 4 O-ring 5 Valve head screw 6 Washer 7 Nut Fi g . 36 Valve head 1st sta g e 5 6 7 2 3 1 4 - Loosen two cap nuts from tube connectors at valve head and safety valve connector and remove inter-cooler. - Remove four valve head screws (5) from valve head (1). Take off valve head. - Remove gasket (2) and plate valve (3). - When re-installing the valve, check that mark ”S�
Bauer Junior II-B-F01, Oil list 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. When using any of the oils listed below, please follow the oil change intervals and the oil filling le
Instruction Manual Junior II 2 1 Filling hose 2 Filling valve with pressure gauge 3 Motor terminal box 4 Three-phase motor 5 Final pressure safety valve 6 Handle 7 Fanwheel cover 8 B-Timer 9 Condensate drain valves 10 Mains plug with ON-OFF switch and motor protection circuit breaker (dep. on country) 6 1 2 4 3 5 7 8 9 10 Fig. 2 Compressor unit with electric motor (three-phase current) 1 F
Bauer Junior II-B-F01, Instruction Manual Junior II 3 1 2 4 3 7 8 5 9 1 Filling hose 2 Filling valve with pressure gauge 3 Final pressure safety valve 4 Filter system P21 5 B-Timer (optional) 6 Pressure maintaining valve 7 Filling connector 8 Intake filter 9 V-belt cover 6 Fig. 4 Compressor unit with electric motor, v-belt cover side 8 11 15 2 1 Telescopic air intake 2 Intake filter 3 Cylinder 1st stage 4 Cylinder 2nd stage 5 Cylinder 3rd stage 6 Inter-cooler 1st/2nd stage 7 Inter-cooler 2nd/3rd stage 8 Intermed. separator 2nd/3rd stage 9 After-cooler 10 Safety valve 1st stage 11 Safety valve 2nd stage 12 Final pressu
Bauer Junior II-B-F01, Instruction Manual Junior II 25 Fi g . 33 Final p ressure g au g e Mark MAINTENANCE We recommend that the final pressure gauge is checked from time to time. For this purpose we have developed a special test pressure gauge with an adaptor which immedi ately recognizes any deviations in readings (see High Pressure Accessories Catalogue 8550/..). Slight deviations during operation are normal and can be ig nored. Excessive inaccuracy will require the pressure gauge to be replaced. 4.4.8. VALVES DESCRIPTION The valve heads of the individual stages form the top part of the cylinders. The intake and pressure valves are fitted inside the valve heads. Note that the valves ar
Bauer Junior II-B-F01, Fig. 13 B-Timer 1 Key symbol (maintenance due) 2 Letter symbol (maintenance type) 3 Low battery symbol 4 Cartridge saturation indicator 5 Operating hours or cartridge number 6 Mode select key 7 Enter key 1 2 3 4 5 6 7 Instruction Manual Junior II 13 B-TIMER (optional) Introduction Read operating instructions carefully before operating the unit. The settings in the setup menu are essential for the correct indication of the filter capac ity. Without correct settings, the B-Timer can be used as an hourmeter, only! Make sure that the pressure maintaining valve of the compressor is adjusted to 150 bar (factory setting, see chapter 4.4.5.) and is working properly to ensure corr
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