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Instruction Manual

Junior II

iii

CONTENTS

GENERAL

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY MEASURES

. . . . . . . . . . . . . . . . . . . .

LOCATION, OPERATION, BOTTLE FILLING

. . .

MAINTENANCE

. . . . . . . . . . . . . . . . . . . . . . .

STORAGE, PRESERVATION

. . . . . . . . . . . . . . .

REPAIR INSTRUCTIONS

. . . . . . . . . . . . . . . . . .

TABLES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANNEX

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX

Adhesive chart, 34
Air flow diagram, 1
Annex, 35

B-Timer, 13

Change-over device, 12
Cooling system, 28

Design, 1
Drive system, 27

V-belt, tension meter, 27
Electrical system, 28

Filling procedure, 10
Filter system, 19

Intake filter, 18
Intermediate separator, 19
Intake air quality, 10

Location, 9
Lubrication, 17
Lubrication chart, 34

Maintenance, 17

Maintenance instructions, 17
Maintenance record, 17
Maintenance schedule, 17
Motor protection switch, 28

Oil change, 18
Oil level check, 17
Oil type, 17
Operation, 9

Preservation, 31
Pressure gauge, 24
Pressure-maintaining valve, 23

Repair instructions, 32

Safety valves, 24
Sealant chart, 34
Shut-down, 12
Storage, 31

Tables, 33
Technical data, 4
Telescopic intake tube, 18
Testing agents, 34
Tightening torque values, 33
Torque sequence, 33
Trouble-shooting, 29

Valves, 25

ANNEX

Schematic diagram motor protection switch, three phase current

76942-S1

Lubricating oil list

70851

Applicable parts list

TJ-4/9

Содержание Junior II-B-F01

Страница 1: ......

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Страница 3: ...05 2004 and the EC machine regulations chapt I section 1 7 4 The machine has been built according to the highest standard of technology and the generally acknowledged safety standards Nevertheless ope...

Страница 4: ...etc Sales department Phone no 089 78049 138 185 154 205 or 202 Fax no 089 78049 103 Are you interested in any training courses Training manager Phone no 089 78049 175 Fax no 089 78049 103 Explanation...

Страница 5: ...air quality 10 L Location 9 Lubrication 17 Lubrication chart 34 M Maintenance 17 Maintenance instructions 17 Maintenance record 17 Maintenance schedule 17 Motor protection switch 28 O Oil change 18 O...

Страница 6: ...Instruction Manual Junior II iv NOTES Model Serial No Date of purchase Dealer address phone no...

Страница 7: ...otected by safety valves 10 11 12 The compressed air is pre cleaned in intermediate separator 8 and purified in filter system P21 13 Intermediate separator and filter system P21 are drained by means o...

Страница 8: ...itch 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 Filling hose 2 Filling valve with pressure gauge 3 Motor t...

Страница 9: ...ntake 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 Safe...

Страница 10: ...ml Oil type see chapter 4 4 1 lubrication Max ambient temperature 5 45 C Max inclination of compressorb 5 Max operating height 0 2000 m above sea level Compressor drive JuniorII B Drive motor Robin S...

Страница 11: ...must be adhered to exactly in order to avoid endangering personnel This notice must be complied with in order to avoid damage to or destruction of the machine or its equipment This notice advises of...

Страница 12: ...quipment emergency shut down devices soundproofing is provided and in good working order At least once every day check the unit externally for dam age and faults Inform the person responsible immedi a...

Страница 13: ...ich need to be dismantled for transport purposes must be carefully replaced and secured before taking into operation Even when moving the unit only slightly the unit must be disconnected from all exte...

Страница 14: ...ssure gases TRG 400 401 402 730 If a high pressure compressor is used for filling pressure vessels or for the supply of pneumatic systems the following regulations apply Accident Prevention Regulation...

Страница 15: ...lt current circuit breaker according to DIN VDE 0664 with a nominal differential current of less than 30 mA up to 16 A in single phase AC circuits For units not connected through a plug but permanentl...

Страница 16: ...limits cannot be guaranteed even with a CO removal filter cartridge resulting in a life threatening CO concentration Also due to chemical re action of CO with hopcalite warming up of the car tridge a...

Страница 17: ...Fig 8 The international connector is not per mitted in the Federal Republic of Germany In other countries it is allowed only for pressures up to 200 bar 2 850 psi Filling the bottles Open filling val...

Страница 18: ...Drain condensate from intermediate separator and Triplex filter by means of the drain taps Vent unit by means of filling valve to approx 80 bar 1 150 psi Close all valves again to prevent moisture ent...

Страница 19: ...deal filter control device for all mobile compressor units especially for portable petrol or diesel driven scuba diving models In addi tion the B Timer can be mounted easily to any unit as an up grade...

Страница 20: ...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 no...

Страница 21: ...ey Remaining filter capacity is shown Fig 17 Press key again Remaining operating hours to service inter val A 500 hours or annually are shown Fig 18 Press key again Remaining operating hours to servic...

Страница 22: ...for the delivery setting Filter symbol starts flashing Fig 24 To change deliv ery in ltrs min press key for 3 seconds the 1st digit starts flashing Press the key to select the correct number press ke...

Страница 23: ...ed on the oil are low deposits no carbonizing effect especially in the valves good anti corrosive properties emulsification of the condensate in the crankcase physiological and toxicological suitabili...

Страница 24: ...icronic filter is used to filter intake air Fig 27 Fig 27 Intake filter 1 Knurled nut 2 Plastic cap 3 Micronic filter cartridge 4 O ring 5 Opening 5 4 3 2 1 INTAKE FILTER MAINTENANCE Filter cartridge...

Страница 25: ...ressurizing in the absence of the filter cartridge A bore provided in the filter bottom is sealed air tight only if the cartridge is in place Fig 30 No pressure build up without cartridge Fig 29 Filte...

Страница 26: ...n age CONDENSATE DRAINAGE Drain condensate from separator and cartridge chamber reg ularly by slowly opening drain taps 2 and 3 Fig 28 before changing cartridge before each filling procedure during fi...

Страница 27: ...t cartridge from packaging prior to actual use otherwise highly sensitive molecular sieve will ab sorb water vapour from surrounding air and cartridge saturated and thus be ruined Prior to changing th...

Страница 28: ...midity saturated X g m3 Processable air volume Va m3 at pressure p bar Number of bottle fillings n acc to bottle size 200 300 7 l 10 l 12 l 10 20 24 17 31 21 80 157 125 236 187 112 89 79 62 65 52 15 2...

Страница 29: ...umidity saturated X g m3 processable air volume Va m3 at pressure p bar Number of bottle fillings n acc to bottle size 200 300 7 l 10 l 12 l 10 20 24 17 31 21 80 134 106 201 160 96 76 67 53 56 44 15 2...

Страница 30: ...ure of the unit see chapter 1 Technical Data 225 bar 3 200 psi for the standard units 330 bar 4 700 psi for models H or HU All safety valves are sealed at the fac tory If one of the intermediate press...

Страница 31: ...HECK After maintenance work on the valves valves should be checked Note that the intake line to the valve heads should be warm and outlet piping should be hot Valves are then op erating properly Fig 3...

Страница 32: ...move plate 3 Remove valves 4 and 7 using two screw drivers as shown in Fig 39 Assemble in reverse sequence Position spring washers with curved side facing upwards Fasten nuts so that plate 3 is parall...

Страница 33: ...V belt tension adjustment Slightly loosen motor mounting nuts Adjust motor until the belt tension is correct see Fig 40 Tighten motor mounting nuts Run motor for approx 5 minutes Stop motor check V b...

Страница 34: ...the motor protection switch The re sponse value of the electromagnetic releases protection against short circuit is preset MAINTENANCE For the electrical system no regular maintenance is required 4 4...

Страница 35: ...t see chapter 4 4 9 Compressor Compressor does not attain final pres sure Condensate drain valve s leaking Tighten and reseal Final pressure safety valve defective blows too soon Replace safety valve...

Страница 36: ...ngs 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...

Страница 37: ...engine according to the instructions of the motor engine manufacturer PREVENTIVE MAINTENANCE DURING STORAGE Run the compressor once every 6 months as described in the following Remove the dust cap fr...

Страница 38: ...e 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 valv...

Страница 39: ...self retaining nuts on reassembly Bolt or screw Thread max torque Hex and allen head M 6 10 Nm 7 ft lbs Hex and allen head M 8 25 Nm 18 ft lbs Hex and allen head M 10 45 Nm 32 ft lbs Hex and allen hea...

Страница 40: ...s threads WEICON ANTI SEIZE AS 040 P part no N19753 or equivalent compound with copper or MoS2 additives For compressor lubricating oils refer to oil list in chapter 8 ADHESIVE AND SEALANT CHART Usage...

Страница 41: ...Instruction Manual Junior II 35 8 ANNEX Schematic diagram Lubricating oil list Parts list...

Страница 42: ...Instruction Manual Junior II 36...

Страница 43: ...principal cot client Ein Aus On Off Marche Arr t Schaltplan Schematic diagram Sch ma lectrique Motorschutzschalter Motor protection switch Disjoncteur 76942 S1 Instruction Manual Junior II 37 Schemati...

Страница 44: ...Instruction Manual Junior II 38...

Страница 45: ...change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit Oil type Use Ambient temperature Brand name Designation Type A Brea...

Страница 46: ...he use of the mineral oil acc to the list on the previous page This oil is suitable for ambient temperatures between 5 C and 45 C Here also a pre heating device will be required if ambient temperature...

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