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Bauer Compressors Oceanus - User Manual
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Instruction Manual and Replacement Parts List
BAUER Compressors, Inc.
Phone: (757) 855-6006
1328 Azalea Garden Road
Fax: (757) 855-6224
Norfolk, V
irginia 23502-1944
www
.bauercomp.com
August 27, 2009
2nd Edition,
Rev
. 0 Chg. 14
MNL-0295
© 2009 Bauer Compressors, Inc.
Oceanus
High Pr
essur
e Br
eathing Air Compr
essor Unit
Oceanus-E1
Oceanus-E3
Oceanus-G
2
Table of Contents
Main Page
default chapter
3
Table of Contents
3
Chapter 1: Introduction
9
How to Use this Manual
9
Manual Safety Notices
9
How to Use the Replacement Parts List
10
Figure 1-1 Compressor Identification Plate
10
How to Use the Appendix
11
Descriptions
12
Compressor Unit Purpose
12
Design
12
Figure 1-2 Oceanus with Gasoline Engine (Typical)
12
Figure 1-3 Oceanus GS; Belt Side
13
Figure 1-4 Oceanus with Three Phase Electric Motor
14
Figure 1-5 Oceanus with Single Phase Electric Motor
14
Figure 1-6 Oceanus, V-Belt Pulley Side
15
Air Flow Diagram
16
Figure 1-7 Internal Air Flow Diagram
16
Compressor Unit Technical Specifications
17
Oceanus-E1
17
Compressor Block Technical Specifications
17
Compressor Drive Technical Specifications
17
Oceanus-E3
18
Free Air Delivery
18
Compressor Block Technical Specifications
18
Compressor Drive Technical Specifications
18
Oceanus-G
19
Compressor Block Technical Specifications
19
Compressor Drive Technical Specifications
19
Chapter 2: Operation
20
Preparation for Operation
20
Units with Three Phase Motor
20
Units with a Gasoline Engine
20
Starting the Unit
20
Units with Electric Drive Motor
20
All Units
20
Filling Procedure
21
General Procedures
21
Intake Air Quality
21
Purging the Compressor Unit
22
Bottle Filling Procedures
22
Connecting the Fill Hose to the Storage Bottle
23
To Fill the Air Storage Bottle
23
Removing the Bottle
23
Figure 2-1 Air Storage Bottle Valve Operating Sequence
23
Shut-Down Procedures
24
Units with Electrical Motor
24
Units with a Gasoline Engine
24
All Units
24
Chapter 3: Oceanus Compressor Block
25
Lubrication
25
Oil Level Check
25
Figure 3-1 Oil Dipstick Markings
25
Type of Oil
25
Oil Change Schedule
25
Oil Change Procedures
26
Intake Filter
26
Description
26
Maintenance
26
Telescopic Intake Tube
26
Figure 3-2 Intake Filter
26
Intermediate Separator
27
Maintenance
27
Compressor Valves
27
Description
27
Figure 3-3 Intermediate Separator
27
Figure 3-4 Valve Function
28
Figure 3-5 1St Stage Plate Valve
28
Initial Operational Check
29
Changing the Valves
29
Changing the 1St Stage Valves
30
Figure 3-6 1St Stage Valve Head
30
Changing the 2Nd Stage Valves
31
Figure 3-7 2Nd Stage Valve Head
31
Changing the 3Rd Stage Valves
32
Figure 3-8 3Rd Stage Valve Head
32
Figure 3-9 Removing the 3Rd Stage Valves
33
Repair and Troubleshooting
34
General Repair Instructions
34
Troubleshooting Tables
35
Compressor Block
35
Electric Motor
36
Gasoline Engine
36
Replacement Parts List
38
Figure 3-10 Crankcase, Driving Gear and Fanwheel
38
Figure 3-11 Pistons and Cylinders
40
Figure 3-12 Valve Heads and Valves
42
Figure 3-13 Cooling System
44
Figure 3-14 Intake Filter and Intermediate Separator
46
Figure 3-15 Frame with Accessories
48
Figure 3-16 Oceanus-G Gasoline Engine
50
Figure 3-17 Oceanus -E1 Electric Motor
51
Figure 3-18 Oceanus -E3 Electric Motor
52
Figure 3-19 Special Tools
53
Manual Condensate Drain System
54
Description
54
Operation
54
Unloaded Start
54
Figure 3-20 Manual Drains
54
Maintenance Record
55
Chapter 4: Oceanus Maintenance Schedule
55
After the First 25 Operating Hours
55
Every 125 Operating Hours
56
Every 1000 Operating Hours or Annually
56
Every 2000 Operating Hours or Biennially
56
Annually or as Required
56
After Repair Work
57
After Storage and Preservation
58
Chapter 5: Purification System
59
General
59
General Purification System Procedures
59
Chamber Safety Bore
59
Figure 5-1 Cartridge Safety Venting
59
Manual Condensate Drainage
59
Model, Serial Number and Part Number Identification
60
Compressor Dataplate
60
Purification System Dataplate
60
Cartridge Installation Dataplate
60
Figure 5-2 Purification Dataplates (Typical)
60
Breathing Air Purification System Configurations
61
Cartridge Operating Life
62
Calculating the Maximum Cartridge Operating Hours
62
Calculating the Adjusted Cartridge Operating Hours
62
Figure 5-3 Correction Factor for Cartridge Operating Hours
63
Figure 5-4 Example Record of Adjusted Operating Hours
63
Air Purification Cartridge Operating Hours Form
64
P0 Purification System
65
Description
65
Figure 5-5 P0 Purification Chamber
65
CO Indicator (Optional)
66
Visual CO & Moisture Indicator
66
Figure 5-6 P0 Purification System Cross Section
66
Figure 5-7 CO & Moisture Indicator
66
Maintenance
67
Replacing the Cartridge
67
Chamber Replacement Interval
67
CO & Moisture Indicator
67
Figure 5-8 Moisture Indicator
68
Replacement Parts List
70
Figure 5-9 P0 Purification System Parts List
70
Figure 5-10 Pressure Maintaining Valve
72
Figure 5-11 CO & Moisture Indicator
73
Chapter 6: Miscellaneous
74
Safety Valves
74
Description
74
Maintenance
74
Checking Function
74
Checking Blow off Pressure
74
Gauges Figure 6-2 Final Pressure Safety Valve
74
Pressure Gauge
74
Cooling System
75
General
75
Compressor Drive System
75
Description
75
Checking the Drive Belt
75
Checking V-Belt Tension Figure 6-4 V-Belt Pulley Alignment
75
V-Belt Tension Adjustment
76
Electric Motor Maintenance
76
Electrical System
76
Description
76
Drive Motor
76
Figure 6-5 Electric Motor Adjustment
76
Electric Drive Replacement Parts
77
Figure 6-6 Oceanus, Drive Assembly
77
Chapter 7: Appendix
78
Safety
78
General Safety Precautions
78
Safety Warning Labels
80
Installation
81
Corrosion Resistance
81
Outdoor Location
81
Indoor Location
81
Electrical Installation
81
Storage and Preservation
82
Storage
82
Figure 7-1 Incoming Power Wiring Label
82
Preservation
83
Preparation for Preservation
83
Preserving the Compressor
83
Preserving the Motor or Engine
83
Reactivating the Compressor Unit
84
Tables and Reference Data
85
Tightening Torque Values
85
Pipe Connections (Swivel Nuts)
85
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Bauer Compressors Oceanus Specifications
General
Brand
Bauer Compressors
Model
Oceanus
Category
Air Compressor
Language
English
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