JuniorII InstructionManual

Instruction Manual w Junior II
INTRODUCTION This manual contains operating instructions and mainten ance schedules for the high pressure breathing air com pressor unit
Junior II
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 machine regulations 2006/42/EG. Specifications on the noise level in accordance with the machine and product safety law as of 01.05.2004 and the EC machine regula tions, 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, operation could still cause danger for the operating per sonnel or third parties, or result in damage to the machine and other values. The machine may only be used to pro duce compressed air as specified in this manual. Other use is strictly prohibited. All instructions should be observed and carried out in the order laid down to prevent damage and premature wear to the equipment. The manufacturer and the supplier void all responsibility for damage or injury resulting from failure to follow these instructions.
Edition January 2010 2010 BAUER Kompressoren GmbH, Mnchen All rights reserved

Dear customer We are happy to give you advice on any questions regard ing your BAUER compressor and help as soon as possible with any arising problems. You can contact us Mondays to Thursdays from 0800 till 1630, Fridays from 0800 till 1400 on phone no. (089) 78049-0. If you call the following extensions directly, it will save you time and continuous dialling. Do you want to order spare parts? . Customer service Phone no: (089) 78049-129 or -149 Fax no: (089) 78049-101 Do you have problems with maintenance or repair work? . Technical customer service Phone no: (089) 78049-246 or -176 Fax no: (089) 78049-101 Do you need further information regarding your unit, ac cessories, prices 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 of the short operating instructions on the unit Read instruction manual before operating unit Position unit level: max. inclination 5
chapter 3.
chapter 3.
Check oil level on compressor and petrol engine before operating unit
Operate unit only at ambient tem peratures between +5 and +45 C
chapter 4.4.1.
chapter 3.
Drain condensate at least every 15 minutes (3 locations)

A
Keep away from hot surfaces on motor and compressor
.
C
chapter 4.4.3. and 4.4.4.
chapter 2.
Position units with petrol engine with exhaust in wind direction to prevent exhaust fumes being sucked in by the compressor
Wear ear protectors when unit is running
chapter 2.
chapter 3.
Petrol driven units must not be op erated indoors.
chapter 3.
ii

CONTENTS 1. 2. 3. 4. 5. 6. 7. 8. INDEX GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . LOCATION, OPERATION, BOTTLE FILLING . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . STORAGE, PRESERVATION . . . . . . . . . . . . . . REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ANNEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5 9 17 31 32 33 35
A
Adhesive chart, 34 Air flow diagram, 1 Annex, 35
Maintenance instructions, 17 Maintenance record, 17 Maintenance schedule, 17 Motor protection switch, 28
B
B-Timer, 13
O
Oil change, 18 Oil level check, 17 Oil type, 17 Operation, 9
C
Change-over device, 12 Cooling system, 28
P
Preservation, 31 Pressure gauge, 24 Pressure-maintaining valve, 23
D
Design, 1 Drive system, 27
E
V-belt, tension meter, 27 Electrical system, 28
R
Repair instructions, 32
S
Safety valves, 24 Sealant chart, 34 Shut-down, 12 Storage, 31
F
Filling procedure, 10 Filter system, 19
I
Intake filter, 18 Intermediate separator, 19 Intake air quality, 10
T
Tables, 33 Technical data, 4 Telescopic intake tube, 18 Testing agents, 34 Tightening torque values, 33 Torque sequence, 33 Trouble-shooting, 29
L
Location, 9 Lubrication, 17 Lubrication chart, 34
V
Valves, 25
M
Maintenance, 17 ANNEX
Schematic diagram motor protection switch, three phase current Lubricating oil list Applicable parts list
76942-S1 70851 TJ-4/9
iii

NOTES
Model: Serial No..: Date of purchase: Dealer address / phone no.:
iv

1. GENERAL
AIR FLOW DIAGRAM See Abb. 5 . The air is drawn in through telescopic tube (necessary for units with petrol engine) -1, intake filter -2; compressed to final pressure in cylinders -3, -4, -5; recooled by intercoolers -6, -7, and aftercooler -9. The pressures of the single stages are protected by safety valves -10, -11, -12. The compressed air is pre-cleaned in intermediate sep arator -8 and purified in filter system P21 -13. Intermediate separator and filter system P21 are drained by means of condensate drain valves -15. Pressure maintaining valve -16 provides a constant pressure within the filter assembly. The compressed, purified air is passed through filling hose -17 and filling valve -18 to the bottles to be filled. Filling pres sure is indicated at pressure gauge -19. With the change over device model it is possible to fill bottles with 200 bar nominal pressure, just by opening valve -21 at filling valve -18. Safety valve -20 is adjusted to a blow off pressure of 225 bar. PURPOSE The JUNIOR II breathing air compressor is designed to compress air for breathing as required in diving applica tions. The max. allowable operating pressure (adjusted pressure on final pressure safety valve) is 225 bar or 330 bar. DESIGN The compressor unit comprises the following major assem blies: - compressor block - drive motor - filter system P21 - filling assembly - base plate and frame The design of the compressor system is shown in Abb. 1 to Abb. 4.
2 3 4 5 6 7 8 9
Abb. 1
1 2 3 4 5 6 7
Compressor unit with petrol engine

8 9 10 11 12 13 14 Starter rope Engine stop switch (ignition) Filling valve with final pressure gauge Safety valve, final pressure Filter system P21 B-Timer Condensate drain taps
Filling hose Exhaust Air filter Tank Throttle lever Choke lever Fuel cock

1 2 3 4 5 6 7 8 9 10 Filling hose Filling valve with pressure gauge Motor terminal box Three-phase motor Final pressure safety valve Handle Fanwheel cover B-Timer Condensate drain valves Mains plug with ON-OFF switch and motor protection circuit breaker (dep. on country) 10 3
1 2
Abb. 2
Compressor unit with electric motor (three-phase current)
1 2 3 4 5 6 7 8 9
Filling hose Filling valve with pressure gauge Motor terminal box with ON-OFF switch Single-phase motor Final pressure safety valve Handle Fanwheel cover Pressure maintaining valve Condensate drain valves
1 2
Abb. 3
Compressor unit with electric motor (alternating current)

1 2 3 4 5 6 7 8 9 Filling hose Filling valve with pressure gauge Final pressure safety valve Filter system P21 B-Timer (optional) Pressure maintaining valve Filling connector Intake filter V-belt cover 7 3 8
4 9 5
Abb. 4
Compressor unit with electric motor, v-belt cover side
11
15
1 2 3 4 5 6 7
Telescopic air intake Intake filter Cylinder 1st stage Cylinder 2nd stage Cylinder 3rd stage Inter-cooler 1st/2nd stage Inter-cooler 2nd/3rd stage
8 9 10 11 12 13 14
Intermed. separator 2nd/3rd stage After-cooler Safety valve 1st stage Safety valve 2nd stage Final pressure safety valve Filter system P21 TRIPLEX longlife cartridge
15 16 17 18 19 20 21
Condensate drain valve Pressure maintaining valve Filling hose Filling valve Final pressure gauge Safety valve, final pressure PN 200 Change over device (optional extra)
Abb. 5
Air flow diagram

TECHNICAL DATA Compressor unit Medium Delivery a) Operating pressure Pressure setting, final pressure safety valve Sound pressure Sound (immersion) power Weight Compressor block Number of stages Number of cylinders Cylinder bore 1st stage Cylinder bore 2nd stage Cylinder bore 3rd stage Piston stroke Speed Intermediate pressure 1st stage Intermediate pressure 2nd stage Compressor block oil capacity Oil volume between min. and max. marks Oil type Max. ambient temperature Max. inclination of compressorb) Max. operating height Compressor drive Drive motor Manual start model (B) Power at nominal speed Compressor drive Drive motor Operating voltage Power Speed Size Type of construction Type of enclosure Compressor drive Drive motor Operating voltage Power Speed Size Type of construction Type of enclosure JuniorII-B-F01 JuniorII-E JuniorII-W air 100 l/min. (3,5 Scfm) PN200/PN300 225/330 bar 86 dB(A) 99 dB(A) 44 kg 47 kg Junior, mod. 3 3 3 60 mm 28 mm 12 mm 24 mm 2,300 min-1 6-7 bar 40-60 bar 360 ml 50 ml see chapter 4.4.1. lubrication +5 ... +45 C 5 0 ... 2000 m above sea level
87 dB(A) 100 dBA) 46 kg
JuniorII-B Robin/Subaru petrol engine EX17 4.2 kW (5.7 PS) 3,600 min-1 JuniorII-E Three phase current 400 V, 50 Hz 2.2 kW (3 PS) 2,850 min-1 90 L B3 IP54 JuniorII-W Alternating current 230 V, 50 Hz 2.2 kW (3 PS) 3,000 min-1 LS 90 PC B3 IP44
a) b)
free air delivered at bottle filling from 0 to 200 bar "5% these values are valid only if the oil of the compressor in normal position corresponds with the upper mark of the oil dipstick and may not be exceeded.

2.
2.1.
SAFETY MEASURES
NOTES AND WARNING SIGNS 2.2. IDENTIFYING THE SAFETY NOTICES Important instructions concerning the endangerment of personnel, technical safety and operating safety will be specially emphasized by placing the following signs before the instructions. This notice is used with maintenance work and operating procedures and must be adhered to exactly in order to avoid endangering personnel.
Notes and warning signs displayed on compressors accord ing to model, application or equipment. WARNING Hot surfaces, do not touch! Danger of burning by touching cylinders, cylinder heads and pressure lines of indi vidual compressor stages. WARNING High voltage! Life threatening danger of electric shock. Maintenance work on electric units or op erating equipment may only be carried out by a qualified electrician or by a per son instructed and supervised by a quali fied electrician according to electrical reg ulations. WARNING Automatic compressor control, unit may start-up without warning! Before carrying out maintenance and re pair work, switch off at the main switch or disconnect from the mains and ensure unit will not restart. MANDATORY Instructions must be read by persons op erating the machinery! The instruction manual supplied and all other applicable instructions, regulations etc. must be read and understood by op erating personnel before using the ma chine. MANDATORY Hearing protectors must be worn! Hearing protectors must be worn when working on a machine which is running. NOTE
MV3A/10/06
WARNING
This notice must be complied with in order to avoid damage to or destruction of the ma chine or its equipment.
This notice advises of technical requirements which the operator must take particular note of. 2.3. FUNDAMENTAL SAFETY NOTICES
2.3.1. Authorized use The machine / unit is built according to state of the art technology and established safety technical regula tions. Nevertheless, its use can cause danger to life and limb of the operator or third parties or damage to the machine and other equipment. Operate the machine / unit only in technically perfect condition in accordance with regulations and safety and danger notices detailed in the instruction manual! In particular, immediately correct faults (or have them cor rected) which can impair safety! The machine / unit is exclusively for the compression of mediums (air/gas) specified in section A, chapter 1.3. Technical data. Any other medium or use outside that specified is not authorized. The manufacturer / supplier is not liable for damage resulting from this. The user alone is responsible for this risk. Authorization for use is also under the condition that the instruction manual is complied with and inspection and maintenance re quirements are enforced. 2.3.2. Organizational measures Keep the instruction manual to hand near the machine / unit at all times in the relevant holder. In addition to the instruction manual, observe and com ply with universally valid legal and other obligatory re gulations regarding accident prevention and environ ment protection. See chapter 2.4. This can involve, for example, contact with hazardous substances or the provision / wearing of personal protective equipment. Personnel engaged to operate the machine must have read the instruction manual before beginning work, es
Ensure correct direction of rotation! When switching on the machine, check the arrow to ensure correct direction of rotation of the drive motor.

pecially the safety notices chapter. When work is al ready underway it is too late. This is particularly relevant for temporary personnel, e.g. maintenance personnel. Personnel may not wear long hair loose, loose clothing or jewellery, including rings. There is a danger of injury through, for example, these getting caught or being pulled into the equipment. As far as necessary or according to regulations, use per sonal protective equipment. Observe all safety and danger notices on the unit. Keep all safety and danger notices on the machine / unit complete and in readable condition. If there are any modifications to the unit or operating conditions which may affect safety, stop the unit im mediately and inform the person responsible of the fault. No modifications may be made to the unit which could impair safety without first obtaining permission from the suppliers. This is also the case with regard to installa tion and adjustment of safety devices and valves as well as welding of piping and reservoirs. Spare parts must always comply with the technical re quirements specified by the manufacturer. This is always guaranteed with original spare parts. Piping must be thoroughly checked (pressure and visual inspection) by the operator at appropriate time inter vals, even if no safety related faults have been noticed. Intervals stipulated or given in the instruction manual for recurring checks / inspections must be adhered to. Make sure location and operation of fire extinguishers is known. Pay attention to fire warning and fire fighting pro cedures. 2.3.3. Qualifications, fundamental duties Work on / with the unit may only be carried out by reli able personnel. Observe the legal minimum age per missible. Ensure that only trained personnel work with the ma chine. Establish the responsibilities of the machine operator and establish a procedure for him to inform a third per son of unfavourable safety conditions. People who are being trained or introduced to the job should only be allowed to work with the unit under con stant supervision of an experienced person. Work on the electrical equipment of the unit may only be carried out by a qualified electrician or by an in structed person under the direction and supervision of a qualified electrician according to electrotechnical re gulations. 2.3.4. Safety notices for operation Do not carry out any work if safety is questionable. Meet all requirements demanding that the unit is only operated in safe and good working order. Only operate the machine if all protective and safety equipment, e.g. all detachable protective equipment, emergency shutdown devices, soundproofing is provided and in good working order. At least once every day, check the unit externally for damage and faults. Inform the person responsible im mediately if anything is not as is should be (including operation). If necessary, shut the machine down im mediately and make it safe. Observe switching on and off processes and monitoring indications according to the instruction manual. Before switching on / starting up the unit, ensure that no one can be put at risk through running the unit. Carry out the setting, maintenance and inspection pro cesses at the intervals specified in the instruction man ual, including replacement of parts / equipment. This work may only be carried out by qualified personnel. Clear and make the maintenance area safe as far as necessary. If the unit is completely switched off for maintenance and repairwork, ensure that it is protected from unex pected start-up. Turn off main control device and re move the key and / or display a warning sign on the main switch. When replacing individual parts and larger assembly groups, they must be carefully fastened to the lifting de vice so that there is no risk of danger. Use only suitable and technically perfect lifting devices and equipment with sufficient lifting power and strength. Do not linger or work under suspended loads. Only entrust an experienced person with the fixing of loads and guiding of crane drivers. The person guiding must remain within sight or in contact with the oper ator. For assembly work above body height, use appropriate safety approved equipment, e.g. ladders and platforms. Do not climb on machine parts. For maintenance work at high levels, wear a safety harness. Clean oil, fuel or care products from the machine, in par ticular the connections and screw joints, before carrying out maintenance / repairwork. Do not use aggressive cleaning fluid. Use a fibre-free cleaning cloth. Before cleaning the machine with water or jet of steam (high pressure cleaner) or detergent, cover / seal all openings which for safety and/or operating reasons no water / steam / detergent may penetrate. Electric motor and switch cabinets are particularly at risk. When cleaning the operating room, ensure that the temperature sensors of the fire alarm and sprinkler sys tem do not come into contact with hot cleaning fluid, in order to avoid triggering the sprinkler system. Completely remove all covers / seals after cleaning. After cleaning, check all pressure lines for leaks, loose connections, wear and damage. Immediately eliminate any faults.

Always retighten any screw connections loosened for maintenance or repairwork. If it is necessary to remove safety devices for mainten ance and repairwork, these must be replaced and checked immediately after completion of the mainten ance or repairwork. Ensure safe and environmentally friendly disposal of consumables and old parts. 2.3.5. Particular areas of danger Use only original fuses with specified current rating. If there is a failure in the electric energy supply, shut the unit down immediately. Work on electric units or operating equipment may only be carried out by a qualified electrician or by a person under the instruction and supervision of a qualified elec trician according to electric technical regulations. Machines and unit parts which must undergo inspec tion, maintenance and repairwork, must be discon nected from the mains supply, if specified. Parts which have been disconnected must first be checked for volt age, then earthed and short-circuited and isolated from live neighbouring parts. The electrical equipment of a unit must be regularly checked. Defects, such as loose screw connections or burnt wires, must be rectified immediately. If work is to be carried out on live parts, work with a sec ond person who can operate the emergency off switch or the main switch in the case of an emergency. Close off the work area with a red and white safety chain and a warning sign. Only use voltage isolated tools. Only personnel with particular knowledge and experi ence with pneumatics may carry out work on pneumatic equipment. Check all pressure lines, hoses and screw connections regularly for leaks and visible damage. Immediately re pair any damage. Escaping air under pressure can cause injury and fire. Depressurize system and pressure lines before com mencing repairwork. Pressurized air lines must be laid and mounted by quali fied personnel. Connections must not be mixed up. Fit tings, length and quality of the piping must correspond to requirements. Soundproofing equipment on the unit must be in place and functional during operation. The stipulated hearing protectors must be worn. With regard to oil, grease and other chemical sub stances, observe the relevant safety regulations for the product. For loading, only use lifting device and equipment with sufficient lifting power and strength. Use only suitable transporters with sufficient carrying power. Secure the load properly. Use suitable fixing points. If necessary, provide unit with transportation brackets. Display the appropriate notice. Remove transportation brackets in the correct manner before taking into oper ation. Parts which need to be dismantled for transport pur poses must be carefully replaced and secured before taking into operation. Even when moving the unit only slightly, the unit must be disconnected from all external energy sources. Be fore putting into use again, reconnect the machine to the mains according to regulations. When taking back into operation, proceed according to the instruction manual. 2.3.6. Notices of danger regarding pressure vessels Never open or loosen pressure vessel lids or pipe con nection parts under pressure; always depressurise the vessel or the unit. Never exceed the permissible operating pressure of the vessels! Never heat the vessels or any of their parts above the stated, maximum operating pressure. Always exchange damaged pressure vessels com pletely. Individual parts that are subject to pressure loads cannot be purchased as spare parts, since the vessels are tested as a complete part and the docu mentation considers them as a whole (see pressure vessel documentation, serial-numbers!). Always pay attention to the permissible operating mode of the pressure vessels. We differentiate: - vessels for static load - vessels for dynamic load Vessels for static load: These pressure vessels are permanently under virtually constant operating pressure; the fluctuations of pres sure are very small. Vessels for this type of load are not marked in a particu lar way and may be used as long as the vessel inspec tions, carried out regularly, do not uncover any safetyrelevant deficiencies. We recommend that aluminium vessels should be exchanged after 15 years at the latest. Vessels for dynamic load: These pressure vessels may also be used under condi tions of changing operating pressure. The pressure may vary between the atmospheric and the maximum ad missible operating pressure. The pressure vessel documentation and the appropriate notes in the operating manual particularly characterise vessels of this type as being adequate for dynamic loads. In the technical information for these vessels you will find specifications concerning their permissible operat ing period. Due to the variation of the operating pressure, these vessels are subject to a so-called dynamic load, which

puts the vessels under great stress. The change between two different pressures is called a load change or cycle. In the technical information for these vessels you will find specifications concerning the permissible number of cycles depending on the fluctuation of the operating pressure. Having reached half the permissible number of cycles, the vessel has to be submitted to an internal check, in which 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 of you employees and cus tomers! In order not to unnecessarily load the pressure vessels additionally, the non-return valves, that are meant to avoid a drop in pressure, and also the pressure maintain ing valves, which should reduce big pressure fluctu ations as well, should be checked regularly for internal and external tightness and functionality. Check the pressure vessels regularly on the inside and outside for damage from corrosion. Be particularly careful with second-hand pressure vessels, when their previous operating mode is not spe cifically clarified. 2.4. SAFETY REGULATIONS (EC; partly Germany, only) A compressor is identified by German law as being a filling system if pressure cylinders are filled by the system, es pecially when these cylinders are made available for third parties. The start-up and operation of compressor systems for use as filling stations is governed by the following re gulations: Pressure vessel directive (Directive 97/23/EC) of 29.05.1997 Operating safety regulations (BetrSichV) of 27.09.2002 Machine safety law (GSG) of 11.05.2001 14th regulation to machine safety law (14. GSGV pressure vessel regulation) of 03.10.2002 Technical regulations for pressure 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 follow ing regulations apply: Accident Prevention Regulations (UVV): BGV A1 of 01. January 2004 Copies of the above regulations are available through the usual outlets, e.g. in Germany from: Carl Heymanns Verlag Luxemburger Str. 449 50939 Kln Beuth-Vertrieb GmbH Burggrafenstr. 4 - 7 10787 Berlin The manufacturer has complied with all applicable regula tions and the unit is prepared accordingly. If desired, we offer at our Munich site a partial acceptance test according to 14 BetrSichV. Please contact our Technical Service De partment with regard to this. They can also supply our leaflet IMPORTANT NOTES FOR CERTIFICATION. According to the operation safety regulations (BetrSichV), all compressor units which will be used as filling stations must undergo an acceptance test by a professional at their location before bringing them into service. If pressure vessels (bottles) are to be filled by the compressor for a third party then the appropriate permission must be obtained from the responsible authority before the acceptance test. As a rule, this is the factory inspectorate. The procedure for obtaining permission is according to TRG 730, guidelines for permission to set up and operate filling stations. The test certificates and documents delivered with the compressor are important and may be requested during the procedure for obtaining permission. In addition, the documents be longing to the unit are important for recurrent inspections and should therefore be carefully kept. Inspections in accordance with the regulations for preven tion of accidents will be carried out by the manufacturer or by a specialist. No guarantees whatsoever are valid for damage caused or favoured by the non-consideration of these directions for use. We strongly emphasize these regulations.

3. LOCATION, OPERATION, BOTTLE FILLING
Ensure correct installation of protective conductor. Check conformity of motor tension and frequency with those of electric network. Operate electric units only on mains sockets equipped with fault 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 perma nently installed, a main switch must be provided which has a contact gap of minimum 3 mm on each pole. Fuse motor correctly; use slow-blow fuses, only. Immediately after start-up check direction of rotation for agreement with arrow on unit. If power supply cable is to be replaced, use cable of same type, only! LOCATION Outdoor location The compressor unit is not seawater re sistant. At operation in salty air spray compressor with anticorrosive protec tion (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 pro cess. Keep unit away from inflammable items. Do not smoke while petrol tank is open and while unit is in op eration. -
WARNING
Locate the unit level. On units with petrol engine it is most important that only clean air be used, position compressor in direction of wind so that exhaust fumes are blown away from the unit. Turn unit as soon as wind direction changes. Take care that no vehicles are in direct vicinity with en gines running. Do not operate unit in the vicinity of open fire (flue gas!).
When using extension leads or cable drums, operate unit with unwound cable, only to avoid overheating and risk of fire. The maximum length for extension cables at normal ambient temperatures (approx. 20 C) is 25 me tres.
OPERATION Preparation for operation All compressor units are tested prior to delivery to the customer, so after correct installation of the unit there should be no problem putting it into operation, observing the fol lowing points: The compressors described in this manual are not suitable for com pression of oxygen. EXPLOSION occurs if an oil lubricated compressor is operated with pure oxygen or gases with an oxygen content of more than 21%!
Indoor location
WARNING
Petrol driven units must not be op erated indoors.
Ensure adequate ventilation. Here too, air must be free from exhaust fumes and haz ardous vapours (e.g. smoke, solvent vapours, etc.). If possible install unit in such a manner that the com pressor fan can get fresh air from outside, for instance through an opening in the wall. Ensure that an adequate exhaust air opening is pro vided. When locating the compressor in small rooms where natural ventilation is not ensured, measures must be taken to provide artificial ventilation (this also applies when other systems having high radiation are operating in the same room).
WARNING
Electrical installation For installation of electrical equipment observe the follow ing: - Comply with regulations of local electricity supply com pany. - Arrange for the electrics to be connected by an electri cian only.
Prior to first operation read Instruction Manual carefully. Make sure that all persons handling the compressor and the filling station are familiar with the function of all con trols and monitors. Particularly observe chapter 2 SAFETY REGULATIONS. After taking unit into operation after a standstill period of 2 years or more change compressor oil. When using a mineral oil change oil after one year. Prior to first operation or operation subsequent to re pair work operate unit for at least 5 minutes with open condensate valves (pressureless) to ensure proper lu brication of all parts before pressure is built up. Prior to each operation check the oil level according to chapter 4.4.1. and determine whether maintenance is necessary in accordance with chapter 4.3.

Every time the unit is started up check all systems for proper operation. If any malfunction is observed stop unit immediately and find the cause of the fault or call the service department. As soon as final pressure is reached and final pressure safety valve blows off, open condensate drain valves and drain condensate - unit is ready for filling operation. Observe regular condensate drain acc. to chapter Maintenance.
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 compliance 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.
FILLING PROCEDURE General Ensure intake air is free from noxious gas (CO), exhaust fumes and solvent vapour. On units em ploying petrol or diesel engine it is most important to use an intake hose and observe that only clean air is drawn in. The intake hose is also recommended for units with electric engine. When operating the unit in areas with possibly high CO contents, the CO removal filter cartridge is recommended for electric driven units, also. Note that for CO contents of more than 25 ppmV in the intake air the allowed limits cannot be guaranteed even with a CO removal filter cartridge, resulting in a life-threatening CO concentration! Also, due to chemical reaction of CO with hopcalite, warm ing up of the cartridge and danger of fire may result.
WARNING
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 shut-off valve.
Starting the unit (electric and petrol) Open condensate drain valves on the filters to release pressure so that motor starts without load.
Units with electric drive motor: Three-phase current: the motor is switched on man ually by turning the switch (1, Abb. 6) to 1.
Filling hoses must be in satisfac tory condition and threads undam aged. Pay particular attention to damage on the interface from hose fitting to hose. If the casing is scored, hose must be discarded.
WARNING
The filling valve connection is of the manual type and per mits connection to air tanks without using tools. An O-ring is provided for self-sealing due to internal overpressure. Compressed air tank filling valves for a pressure in excess of 200 bar are standardized (DIN 477, sheet 5) and connectors for 200 and 300 bar are different and cannot be mixed up. The use of adapters is not allowed! To ensure safe air tank removal after filling, the valve has an integral venting bore. Therefore always close tank valve first before closing filling valve. During filling procedure bottles will warm up due to recompression. After removing, allow to cool down, bottles may then be reconnected and topped up to the respective maximum filling pressure. Motor protection switches (three-phase motor) To meet the CO2 maximum rating value in breathing air bottles, please observe the two following chapters Intake air quality and Scavenging the compressor unit.
Abb. 6 -
WARNING
Alternating current: Set 0-I switch to I.
Units with petrol engine: Set choke to position START. Start engine with recoil starter or crank handle. As soon as motor runs smoothly return choke to normal operating position.
Intake air quality At routine tests, CO2 values beyond the permissible values are noted from time to time. Closer investigations often show that the compressed air is taken from rooms in which one or more persons are working. At insufficient ventila tion, the CO2 value in the surrounding air can increase quite fast because of the exhaling of CO2. CO2 values from 1,000 to 5,000 ppmv in workrooms are not unusual (MAK-value (max. workroom concentration) is 5,000 ppmv). Another
All units (electric and petrol): Close condensate drain valves and run unit to final pres sure. Check final pressure safety valve and pressure gauge.
10

additional increase is caused by cigarette smoking, produc ing approx. 2g CO2 ( 2,000 ppmv) per cigarette. These pollutions add up to the basic pollution of approx. 400 ppmv. The technically caused excessive increase of CO2 during the filling process and the CO2 peak at taking the unit into operation. Because of the reasons stated above and for your own security, the filling of breath ing air bottles is not allowed in rooms used as work rooms. Scavenging the compressor unit CO2 is present in the atmosphere with a natural amount of 350 to 400 ppmV. The molecular sieve used in the purifier for drying the breathing air is, as well as other capabilities, able to adsorb CO2 which is accumulated in the cartridge. After shut-down of the compressor, adsorbed CO2 may be desorbed again due to the partial pressure decrease. The now free CO2 then gets washed out of the cartridge when the compressor is started again. To avoid increased CO2 contents in the compressed breathing air, we recommend to flush the compressor unit 1 to 2 minutes prior to connect ing the bottles, i.e. to let the air escape into the surround ings through the filling valve. Connecting the bottles On models of 300 bar rated filling pres sure do not attach bottles unless rated for this pressure (note pressure stamped on tank neck).
Abb. 7
Connecting air bottle
Abb. 8
International filling connector
2.
Connect air bottle to filling valve (see Abb. 7). Air bottles with international filling connector can be connected with filling adaptor (part no. 79375) to the German filling connector (see Abb. 8).
1.
The international connector is not per mitted in the Federal Republic of Ger many. In other countries it is allowed only for pressures up to 200 bar (2,850 psi). Filling the bottles Open filling valve (1, Abb. 9). Open bottle valve (2) - bottle will be filled. Drain conden sate regularly during filling. On units with automatic condensate drain check that condensate is drained reg ularly. The filling procedure should not be inter rupted for more than 10 minutes to avoid increased CO2-values in the air filled into the bottles.
Abb. 9
Filling air bottle
1.
2.
Abb. 10 Removing air bottle
11

Removing the bottles Upon reaching final bottle pressure close bottle valve first (1, Abb. 10), then filling valve by returning handle to closed position (2). Remove compressed air bottle.
B
CHANGE-OVER DEVICE PN 300/PN 200 (Abb. 11) This device allows bottle filling to 200 bar (3,200 psig) with a 300 bar (4,700 psig) rated unit. Safety valve -B and filling device PN 200 bar are connected by opening change-over valve -A and the connected bottles can be filled with a 200 bar pressure, as described in Filling the bottles. Depressurize unit before opening valve -A to avoid damage to the change-over de vice
Abb. 11 Change-over device
SHUT-DOWN PROCEDURE Close filling valve. Three-phase current: the motor is switched off by turning the switch (1, Abb. 12) to 0. Alternating current: set 0 - I switch to 0. Shut down petrol engine with stop button or stop lever. 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 entering the filter and resulting saturation of the cartridge. Check the oil level in the compressor and top up, if necessary. Also check whether the compressor needs servicing in accordance with maintenance schedule see chapter 4.3. Units with electric motor:
Units with petrol engine: All units:

1
Abb. 12 Motor protection switches (three-phase motor)
12

B-TIMER (optional) Introduction Read operating instructions carefully before operating the unit. The settings in the setup menu are essen tial for the correct indication of the filter capacity. Without correct settings, the BTimer 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 correct in dication of the filter capacity and compressor oper ation recognition. Make sure that all maintenance counter (a+b+c) were reset directly before the delivery. (Otherwise storage times would be taken into account and wrong maintenance in tervals are displayed on the B-Timer.) If no reset of the maintenance counters has been done, you are obliged to reset them. Refer to chapter Reset. The B-Timer (Abb. 13) is a self-activating mini-computer that counts the operating hours of the compressor and calculates the saturation of the filter cartridge from time, temperature, cartridge type, and delivery rate of the com pressor. It displays operating hours, cartridge lifetime, and all maintenance due for the compressor. The B-Timer does neither need external power nor any other connection to the pressure system. It is simply fastened to the filter hous ing which has to be monitored, by means of a clamp, and is therefore the ideal filter control device for all mobile com pressor units, especially for portable petrol or diesel driven scuba diving models. In addition, the B-Timer can be mounted easily to any unit as an upgrade device. Authorized use This unit is to be used exclusively as operating status moni toring device and does not release the user from additional surveillance and testing of the breathing air quality of the filter system according to national standards (e.g. EN 12021). With the B-Timer, this is not possible! The B-Timer may only be used with the filter systems P21, P31 and P41. The respective filter cartridge numbers are stored in the software. Other use is strictly prohibited. The manufacturer and the supplier void all responsibility for risk, damage or injury resulting from failure to follow these instructions. Please observe the operating limits of the unit: Operating temperature range 0 C to +50 C, Storage temperature -20 C bis +70 C Protection class IP65 (Protection against contact with wire, dust, and jet of water Vibration $3g in operation max. 95% humidity, not condensating Description
1 3 5
2 4
Abb. 13 B-Timer
1 2 3 4 5 6 7 Key symbol (maintenance due) Letter symbol (maintenance type) Low battery symbol Cartridge saturation indicator Operating hours or cartridge number Mode select key Enter key
Function
The B-Timer display shows the following functions:
13

Operating hours of the compressor unit Cartridge lifetime in % by means of four segments in the cartridge symbol. Flashing last segment and change from operating hours indication to cartridge part no. if capacity is equal or less than 20% of the original lifetime. Indication of compressor maintenance due by means of letter symbols and operating hours. A = 500 hours or 1 year B = 1000 hours or 2 years C = 2000 hours or 4 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 (Abb. 14). In this case the unit should not be used but sent to the factory or the nearest BAUER representative for re pair. Battery change The battery (1, Abb. 15) is merely inserted into the holder. To change the battery remove two bolts and separate hou sing from base plate. Remove plug (2) and pull out battery. Make sure to use the same type battery (BAUER part no. 82743). Abb. 15 Battery
Abb. 14
Abb. 16
Abb. 17
14

Operation The B-Timer is activated when starting the compressor. Compressor operation is indicated by the flashing h symbol. To switch on the B-Timer press one of the keys on the dis play. Main menue will be displayed (Abb. 16). If no key is pressed within 1 minute, the indication will return to the main menue. After 2 minutes the B-Timer is switched off, if no compressor operation is detected.
Abb. 18
Function Display To display the desired function, press the select key (=). Press = key. Remaining filter capacity is shown, Abb. 17) Abb. 19 Press = key again. Remaining operating hours to service in terval A (500 hours or annually) are shown (Abb. 18).
Press = key again. Remaining operating hours to service in terval B (1000 hours or annually) are shown (Abb. 19). Abb. 20 Press = key again. Remaining operating hours to service in terval C (2000 hours or biennially) are shown (Abb. 20).
Press = key. Filter cartrige number is shown (Filter symbol flashing, Abb. 21). Press = key again. Display returns to the main menue. Abb. 21
Reset The filter capacity must not be reset un less a new filter cartridge has been fitted! To reset the filter capacity or the A, B, and C maintenance intervals, press o key for more than 5 seconds from the re spective maintenance interval display (Abb. 22).
Abb. 22
15

Setup To enter the setup for the different functions of the BTimer press the = and o keys on the display simultaneously for more than 5 seconds from the cartridge number display (Abb. 21). Filter symbol starts flashing (Abb. 23) indicating the setup mode. Under setup A the filter cartridge number is set. To change cartridge type, press o key for 3 seconds, the number starts flashing. Press the = key to select the correct number, press o key to accept the new setting. Numbers beginning with 999 require a special adjustment: Press o key for 3 seconds. Press the = key to select 999000, the last 0 starts flashing. Press the = key to select the correct number, then press o key: the second 0 will start flashing, proceed as above and finally adjust the 3rd 0 accordingly. Pressing the = key, display changes to setup B for the deliv ery setting. Filter symbol starts flashing (Abb. 24). To change delivery (in ltrs./min), press o key for 3 seconds, the 1st digit starts flashing. Press the = key to select the correct number, press o key to accept the new setting. Repeat pro cedure for the other two digits
Abb. 23
Abb. 24
Pressing the = key again, display changes to setup C for the pressure range setting. Filter symbol starts flashing (Abb. 25). To change pressure, press o key for 3 seconds. Press the = key to select the correct pressure (200, 300 or 200/300), press o key to accept the new setting. After finishing setup and fitting a new cartridge, the filter capacity has abso lutely to be reset, see Reset above. Pressing the = key again, display changes to the menue for adjusting the operating hours. Press o key for 2 seconds, the last digit will start flashing. Press the = key to select the correct number, then press o key etc., until all digits are set. Then pressing the = key twice will lead back to the main menue, Pressing the the = key and the o key gives the possi bility to readjust the hours again, if required. Abb. 25
16

4.
4.1.
MAINTENANCE
MAINTENANCE RECORD
4.4.
MAINTENANCE WORK
This chapter contains the maintenance work as well as a short functional description for each component. We recommend that all maintenance work is recorded in the service book, showing the date and details of the work carried 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 damage has not been caused by insufficient mainten ance. Please refer to section 23 of our general terms and conditions. 4.2. MAINTENANCE INSTRUCTIONS Always shut down and decom press the complete system prior to carrying out any work on the com 4.4.1. LUBRICATION TYPE OF OIL For proper care and maintenance of the compressor, using the correct oil is of vital importance. Depending on the ap plication of the compressor the requirements placed 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 suitability. 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 our lubricating oil list. The current oil list is provided in the annex, chapter 8. Order this list regularly through the BAUER Technical Service De partment. Check the complete system for leakage from time to time by brushing all fittings and couplings with soapy water or spray ing with leak test spray. Repair any leak age. For operation under difficult conditions such as continuous running and/or high ambient temperatures we recommend the use of BAUER high performance compressor oils, only, according to the oil list. These oils are tested in our com pressors and have proved excellent quality under ambient temperatures between +5 C (41F) and +45 C (113 F). For lower temperatures, a heating device is required which is capable of pre-heating the crankcase up to +5 C (41 F). For operation under less severe conditions, for intermittent operation, or operation with long idle periods we can also recommend mineral compressor oils which are suitable for operation under ambient temperatures between +5 C (41 F) and +35 C (95 F). Here also, pre-heating is required for lower temperatures. OIL LEVEL CHECK Check oil level daily prior to putting compressor into oper ation. Check using oil dipstick. Take care that dip stick is inserted completely. Note that the oil level must be between minimum and maximum dipstick markings (see Abb. 26). Oil level must not decrease below min. mark but also not exceed max. mark as this will cause excessive lubrication of compressor and result in valves sooting up. OIL CHANGE INTERVALS Mineral oils 4.3. MAINTENANCE SCHEDULE Synthetic oils The maintenance schedule is contained in the service man ual delivered with every compressor unit. every 1,000 operating hours, at least annually every 2,000 operating hours, at least biennially
WARNING
pressor.
WARNING
Never repair pressure lines by sol dering or welding.
Only use original spare parts for mainten ance or repair work.
Change TRIPLEX longlife cartridge ac cording to chapter 4.4.4.!
The used cartridge must be disposed of according to local regulations.
Maintenance of drive motor/engine ac cording to manufacturer's operating in structions.
17

OIL CAPACITY Junior II OIL PACKAGES BAUER compressor oil is available in various quantities, refer to oil list in chapter 8. OIL CHANGE Run compressor warm. Remove oil dipstick. Drain oil while still warm by means of oil drain plug. Re place the sealing, reinstall drain plug and tighten well. Refill with oil through the oil filler neck. Oil level is checked with oil dipstick, oil level is correct if at upper mark.
5 4 3 2 1
approx. 360 ml
Top up compressor and perform subsequent oil changes with same oil, only. 4.4.2. INTAKE FILTER DESCRIPTION A dry micronic filter is used to filter intake air (Abb. 27).
1 2 3 4 5 max. min.
Knurled nut Plastic cap Micronic filter cartridge O-ring Opening
Abb. 27 Intake filter INTAKE FILTER MAINTENANCE Filter cartridge must be changed at regular intervals accord ing to schedule in the service booklet. - Remove knurled nut (1) and take off plastic cap (2). Re move filter cartridge (3). - Clean filter housing inside with a damp cloth. Take care to prevent dust from entering intake pipe. - Replace O-ring (4) if damaged. - Insert a new filter element and fasten with cap and nut. TELESCOPIC INTAKE TUBE The telescopic intake tube has to be inserted in opening 5, Abb. 27. It is necessary to ensure clean air. Petrol driven breathing air compressor units are fitted with a telescopic intake tube supplied with the unit. The use of it is also rec ommended for electric power driven units. 4.4.3. INTERMEDIATE SEPARATOR DESCRIPTION An intermediate separator is mounted on the compressor between 2nd and 3rd stage. It is designed to remove water and oil accumulating due to cooling the compressed me dium down after the compression process. Separation is achieved by means of centrifugal action pro vided by a vortex plate. INTERMEDIATE SEPARATOR MAINTENANCE Proper operation will rely on the intermediate separator being properly serviced.
Abb. 26 Oil dipstick markings
CHANGING THE OIL TYPE To avoid severe damage to the compres sor unit when changing the oil type, the following measures should be strictly ad hered to: Drain oil completely while still warm. Check valves, coolers, separators, purifiers, and all pneumatic tubes and hoses for deposits. If deposits are detected, perform the following: Change or clean valves, coolers, separators, purifiers, and all pneumatic tubes and hoses from deposits. Fill compressor with the new oil. After approx. 100 operating hours check lubricating oil for degree of contamination, and change oil again if necessary.
18

Open drain tap (1, Abb. 28) and drain off condensate every 15 to 30 minutes during operation.
4
3 5
2 6
9 1 2 3 1 10 11
Abb. 28 Condensate drain taps Abb. 29 Filter system P21
4.4.4. FILTER SYSTEM P21 DESCRIPTION The air leaving the final stage is cooled in the after-cooler to approx. 10 - 15 C (18 - 27 F) above ambient tempera ture and then enters filter system P21 with TRIPLEX long life cartridge (Abb. 29). The filter assembly consists of separator and cartridge chamber. In the separator surrounding the cartridge chamber liquid oil and water particles are reliably separated from the compressed medium by a pipe nozzle. Residual oil and water vapors are then removed by the TRIPLEX longlife cartridge. The quality of the breathing air produced conforms to DIN EN 12021. CARTRIDGE SAFETY BORE The filter system P21 is designed to prevent pressurizing 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 (Abb. 30). No pressure build-up without cartridge!
1 2 3 4 5 6 7 8 9 10 11
Filter inlet Jet pipe Filter head Final pressure safety valve Housing Chamber separator Cartridge Filter outlet Pressure maintaining valve Condensate drain tap Condensate outlet
Without cartridge the venting bore is not sealed, the air es capes into the atmosphere, no pressure can be built up and thus it is ensured, that unfiltered air is not supplied to the consuming device. The venting bore is also used to check the O-rings on the cartridge pin. If air is leaking out of the venting bore even though a cartridge is installed, the O-rings are either broken or were damaged on installation. Remove and check cartridge. If necessary replace cartridge or O-rings.
19

Venting bore
1,100 psi) within the system to prevent moisture enter ing the compressor piping and filter system. The nozzle type separator of the TRIPLEX filter system is maintenance-free besides the regular condensate drainage.
CONDENSATE DRAINAGE
No cartridge Cartridge installed
Abb. 30 Safety bore 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 spections have to be arranged by the operator. After reaching the max. number of load cycles the filter as sembly must be replaced, otherwise the housing may burst due to material fatigue.
WARNING
Drain condensate from separator and cartridge chamber regularly by slowly opening drain taps (2 and 3, Abb. 28) - before changing cartridge - before each filling procedure - during filling procedure every 15 minutes. Slowly open left tap first, then right tap approx. 1/3 turn to the left, until condensate is completely drained. The taps close by spring pressure, if necessary tighten by hand to make sure they are completely air-tight. FILTER CARTRIDGES New filter cartridges are vacuum-packed and can be stored for two years (refer to date on the cartridge). A defective vacuum package cannot protect the cartridge appropri ately against environmental influences during storage. Should the package be damaged, do not use the cartridge. To avoid any danger to your health or damage to your unit, change used up cartridges in good time. Never fill used up cartridges yourself! The filter material was chosen specifically by BAUER-KOMPRESSOREN for each kind of application. Pay attention to cleanliness an hygiene when changing the filter. FILTER SERVICE LIFETIME The average weight (without package) of a new cartridge and the increase in weight can be checked with appropriate weighing scales. Due to inevitable production tolerances, there may be small differences compared to the given data. The number of operating hours or the amount of possible bottle fillings per filter cartridge can be determined by the tables on page 22 and 23 taking into consideration the ambient temperature and the cartridge used. These tables contain calculated cartridge lifetime data, that refer to defined and constant operating conditions. Toler ances at bottle fillings and different operating tempera tures can lead to considerable divergences compared to data given, which therefore can only serve as reference va lues for the user. Cartridge 057679 is the normal TRIPLEX-cartridge for electric units. Filling weight: 191 g; Saturation weight 205 g. Example: at an ambient temperature of 20C, 36 to 45 10-ltr-bottles can be filled with a TRIPLEX-cartridge, which is equivalent to 12 to 15 compressor operating hours at a filling pressure of 200 bar. On compressor units with petrol engines only use car tridge, part no. 059183 to dry, de-oil and remove CO. Filling weight: 217 g; Saturation weight 229 g.
The max. number of load cycles for the P21 Central Filter As sembly is 4,000 if operated at the max. allowable pressure difference range of 330 bar (4,700 psi). For a pressure dif ference of 225 bar (3,200 psi) the max. no. of load cycles is 35,000 . To avoid exceeding the max. number of load cycles the op erating hours should be recorded in the service manual. On condition that a max. number of four cycles per hour is not exceeded (condensate is drained every 15 minutes) the max. number of operating hours is 1,000 for 330 bar units, and 8,750 for 225 bar units. GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE Depressurize system before starting any maintenance work. Dry inside of filter housing with a clean cloth before in stalling new cartridge and check for corrosion. Change if necessary. Lubricate threads and O-rings as well as threaded part of cartridge with white petrolatum DAB 9 order no. N19091 or WEICON WP 300 white order no. N19752. Record number of pressure bottles and/or operating hours to ensure exact attention to maintenance inter vals. Change cartridge before reactivating a compressor unit after out-of-service periods of more than 3 months. Leave cartridge in the filter as long as unit is out of ser vice. Keep all condensate drain valves and taps closed. Keep a minimum pressure of approx. 50 to 80 bar (700 to
20

Example: at an ambient temperature of 20C, 31 to 38 10-ltr-bottles can be filled with this cartridge, which is equivalent to between 10 and 13 operating hours at a filling pressure 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 cartridges part no. 059183 should be used on compressor units with petrol engine. On units with electric engine either CO removal cartridge part no. 059183 or TRIPLEX car tridge part no. 057679 can be used. Seal pressure gauge with PTFE tape or Loctite 243 and screw in tight to desired position.
WARNING
Units with petrol engine are delivered with CO removal cartridge part no. 059183 as standard, units with electric engine with TRIPLEX cartridge part no. 057679. When changing from electric engine to a petrol en gine also replace cartridge part no. 057679 with car tridge part no. 059183. Never remove replacement cartridge from packaging prior to actual use other wise highly sensitive molecular sieve will absorb water vapour from surrounding air and car tridge saturated and thus be ruined. Prior to changing the filter cartridge, drain condensate and depressurize filter system completely by opening condensate drain valves. Remove filter head (3, Abb. 29). Extract old cartridge and insert a new one. Screw in filter head to the stop without use of force. The used cartridge must be disposed of according to local regulations.
FILLING VALVE MAINTENANCE To protect filling valve against contamination a sintered metal filter is screwed in the filling valve body. Remove filter insert and clean, if heavily soiled replace, as follows (refer to maintenance schedule, 4.3.): - Unscrew pressure gauge from filling valve body. - Screw off sintered metal filter with a suitable screw driver. - To clean filter element, the best method is to use hot soapy water and to blow dry with compressed air. Re place if heavily soiled. - Screw in filter element,.
21

1. Filter cartridge 057679: lifetime [hours] Filling pressure p = 200 bar
Ambient temperature tU [C] Final separator temperature tAb [C] Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 Ambient temperature tU [C] 20 - 24 25 - 29 30 - 34 35 - 39 40 - 44 45 - 49 50 - 54 26 - 21 20 - 16 15 - 12 11 - 9 9-7 7-6 5-5 Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 20 - 24 25 - 29 30 - 34 35 - 39 40 - 44 45 - 49 50 - 54 39 - 31 29 - 24 22 - 18 17 - 14 13 - 11 10 - 9 8-7
Filling pressure p = 300 bar

Final separator temperature tAb [C]
Filter cartridge 057679: bottle fillings [number] Molecular sieve mass mMS [g] = 68
Ambient temperature tU [C] Final separa tor tempera ture tAb [C] 20 - 24 25 - 29 30 - 34 35 - 39 40 - 44 45 - 49 50 - 54 Air humidity, saturated X [g/m3] Processable air volume Va [m3] at pressure p [bar] 200 17,31 - 21,80 23,07 - 28,79 30,40 - 37,63 39,65 - 48,64 51,21 - 62,41 65,52 - 79,28 83,08 - 99,85 157 - 125 118 - 94 89 - 72 69 - 56 53 - 44 42 - 34 33 - 27 300 236 - 187 177 - 142 134 - 108 103 - 84 80 - 65 62 - 51 49 - 41 7l 112 - 89 84 - 67 64 - 52 49 - 40 38 - 31 30 - 25 23 - 19 Number of bottle fillings n acc. to bottle size 10 l 79 - 62 59 - 47 45 - 36 34 - 28 27 - 22 21 - 17 16 - 14 12 l 65 - 52 49 - 39 37 - 30 29 - 23 22 - 18 17 - 14 14 - 11
10 15 20 25 30 35 40
Bottle volume VF [m3] Bottle size l [ltr.] 7 10 12 at pressure p [bar] 200 1,4 2 2,4 300 2,1 3 3,6
Number of bottle fillings n= processable air volume / bottle volume = Va / VF Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3] Processable air volume: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMS [g] / X [g/m3] Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])
22

2. Filter cartridge 059183: lifetime [hours] Filling pressure p = 200 bar
Ambient temperature tU [C] Final separator temperature tAb [C] Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 Ambient temperature tU [C] 20 - 24 25 - 29 30 - 34 35 - 39 40 - 44 45 - 49 50 - 54 22 - 18 17 - 13 13 - 10 10 - 8 8-6 6-5 5-4 Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 20 - 24 25 - 29 30 - 34 35 - 39 40 - 44 45 - 49 50 - 54 34 - 27 25 - 20 19 - 15 15 - 12 11 - 9 9-7 7-6
Filling pressure p = 300 bar

Final separator temperature tAb [C]
Filter cartridge 059183: bottle fillings [number] molecular sieve mass mMS [g] = 58
Ambient temperature tU [C] Final separa tor tempera ture tAb [C] 20 - 24 25 - 29 30 - 34 35 - 39 40 - 44 45 - 49 50 - 54 Air humidity, saturated X [g/m3] processable air volume Va [m3] at pressure p [bar] 200 17,31 - 21,80 23,07 - 28,79 30,40 - 37,63 39,65 - 48,64 51,21 - 62,41 65,52 - 79,28 83,08 - 99,85 134 - 106 101 - 81 76 - 62 59 - 48 45 - 37 35 - 29 28 - 23 300 201 - 160 151 - 121 114 - 92 88 - 72 68 - 56 53 - 44 42 - 35 7l 96 - 76 72 - 58 55 - 44 42 - 34 32 - 27 25 - 21 20 - 17 Number of bottle fillings n acc. to bottle size 10 l 67 - 53 50 - 40 38 - 31 29 - 24 23 - 19 18 - 15 14 - 12 12 l 56 - 44 42 - 34 32 - 26 24 - 20 19 - 15 15 - 12 12 - 10
10 15 20 25 30 35 40
Bottle volume VF [m3] Bottle size l [ltr.] 7 10 12 at pressure p [bar] 200 1,4 2 2,4 300 2,1 3 3,6
Processable air volume: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMS [g] / X [g/m3] Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])
Number of bottle fillings n= processable air volume / bottle volume = Va / VF Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3]
23

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). 1st stage 2nd stage 9 bar (130 psi) 80 bar (1,160 psi)
The safety valve for protection of the last stage is mounted on top of the filter system P21 and is adjusted to the operat ing pressure 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 pressure safety valves blows off, the valves in the next stage are not closing properly, afford ing valve check. The cause of the trouble is usually the inlet valve of the next stage. See also chapter 4.4.8. MAINTENANCE Checking function The final pressure safety valve has to be checked regularly. For this purpose the safety valve can be vented manually. Turn knurled knob on top of the valve clockwise until valve blows off (Abb. 32). This just ensures that the valve is functional and will release pressure in case of a malfunction. To check the blow-off pressure value refer to Blow-off pressure check. Venting
2 1
Abb. 31 Pressure maintaining valve
MAINTENANCE The pressure maintaining valve (Abb. 31) is adjusted at the factory to the required pressure and normally does not re quire regular maintenance or readjustment. In case of read justment becoming necessary, loosen jam nut (2) and set screw (3). Adjust screw (1) to the required pressure using a suitable screw-driver. Clockwise = increase pressure Counter-clockwise = decrease pressure
Abb. 32 Venting the final pressure safety valve Checking blow-off pressure Check blow-off pressure of the final pressure safety valve regularly, see maintenance schedule chapter 4.3. Pump unit to final pressure with shut-off valve closed until safety valve blows off. Check blow-off pressure of safety valve at pressure gauge. If deviation is 10% or more, replace safety valve. 4.4.7. PRESSURE GAUGE DESCRIPTION The compressor unit is equipped with a final pressure gauge (Abb. 33). The red marking on it shows the max. allowable operating pressure.
4.4.6. SAFETY VALVES DESCRIPTION All three compressor stages are protected by safety valves as follows
24

Mark
Intake
Pressure
Abb. 33 Final pressure gauge
Abb. 34 Valve operation
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 Pres sure Accessories Catalogue 8550/..). Slight deviations during operation are normal and can be ig nored. Excessive inaccuracy will require the pressure gauge to be replaced.
Pressure side Intake side
to 2nd stage
N4860F98
Top view
from intake fil ter
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 in side the valve heads. Note that the valves are operated by the flow of the air. On the suction stroke, the intake valves open and the air flows into the cylinders. At the start of the compression stroke the intake valve closes and the air opens the pressure valve, Abb. 34. Intake and pressure valve of the 1st stage is a plate valve (Abb. 35).
Abb. 35 Valve 1st stage GENERAL VALVES INSTRUCTIONS FOR CHANGING THE
INITIAL OPERATIONAL CHECK 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 operating properly.
Always replace valves as a complete set. Observe the correct sequence when fitting together again. Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the valves. Valve head screws must be tightened with a torque wrench (see tightening torque values chapter 7.). Check the valve space in the valve heads for dirt and clean, if necessary. 30 minutes after restarting the compressor stop unit, let it cool down to ambient temperature and retighten valve studs and cap nuts. Otherwise valves could work loose due to setting of the gaskets. Use only satisfactory gaskets and O-rings on reas sembly. After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed.
25

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 Abb. 36.
7 6 5 1
1 2 3 4 5 6 7
Valve head Gasket Plate valve O-ring Valve head screw Washer Nut
1 2 3 4 5 6 7 8
Nut Spring-washer Plate Pressure valve O-ring Valve head Intake valve Valve head screw
Abb. 37 Valve head 2nd stage CHANGING THE VALVES OF THE 3RD STAGE On this valve head, the valves are arranged on the upper and lower side due to the small diameter of the 3rd stage, see Abb. 38. For removal and installation of the intake valve (4) use special tool which is also part of the tool set delivered with the unit. Pressure valve (3) is merely inserted into valve head (5). It is sealed by O-ring (2) and fixed to the valve head by bolt (1).
Abb. 36 Valve head 1st stage Loosen two cap nuts from tube connectors at valve head and safety valve connector and remove intercooler. 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 is facing upwards and towards intake filter side. The cross bar of gasket (2) seals the intake opening with respect to the two outlet openings of the pressure valve.
CHANGING THE VALVES OF THE 2ND STAGE Both, pressure and intake valves can be serviced from out side, see Abb. 37. - Remove two captive nuts (1) and spring-washers (2). - Remove plate (3). - Remove valves (4) and (7) using two screw-drivers as shown in Abb. 39. - Assemble in reverse sequence. Position spring-washers with curved side facing upwards. Fasten nuts so that plate (3) is parallel to the valve head. Torque with 10 Nm (1 kpm).
1 2 3 4 5 6 7 8
Torque stud O-ring Pressure valve Intake valve Valve head Valve head cover Allen screw Gasket
Abb. 38 Valve head 3rd stage Change intake and pressure valve of 3rd stage together only.
26

Remove of 3rd stage pressure valve (3) according to Abb. 38. - Unwind torque stud (1) a couple of turns. - Remove allen screws (7), take off valve head cover (6). - Put two screwdrivers into the groove of pressure valve body (Abb. 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). Run motor for approx. 5 minutes. Stop motor, check Vbelt tension, and readjust if required. Check that after tension adjustment and tightening the motor mounting nuts, both pulleys are in a straight line to avoid excessive wear of the V-belt. Hold a straight edge against compressor and motor V-belt pulleys as shown in Abb. 41: edge must be parallel to the v-belt.
10 mm
Abb. 40 Checking V-belt tension
Abb. 39 Removal of 3rd stage pressure valve 4.4.9. COMPRESSOR DRIVE SYSTEM DESCRIPTION The compressor is driven by the drive motor through a Vbelt. The motor is mounted on the base plate and requires adjustment for proper V-belt tension. Improper v-belt tension and adjustment of the pulleys will result in extreme v-belt abrasion and premature wear. Abb. 41 V-belt pulley adjustment 4.4.10. ELECTRICAL SYSTEM DESCRIPTION This section describes the standard electrical system. For schematic diagram, see annex.
MAINTENANCE Checking the drive belt tension The best tension for a belt drive is the lowest possible, where the belt under full load does not slip. A rough value for this is when the belt deflects 10 mm when pressed with thumb pressure between the two pulleys (Abb. 40). For best results we recommend our v-belt tension meter, part no. N25238.
The electrical equipment of the compressor unit consists of: - drive motor - electric control system To start the electric motor and enable the functioning of the electric control, the following components are essential: - main switch and main fuse, both to be installed by the customer. DRIVE MOTOR The compressor unit is driven by an alternating or a three phase current motor by means of a V-belt. MOTOR PROTECTION SWITCH (ALTERNATING CUR RENT MOTOR) Protection of the motor is ensured by the thermic releases integrated into the motor protection switch (1, Abb. 42). The response value is preset.The motor is switched on man
V-belt tension adjustment Slightly loosen motor mounting nuts Adjust motor until the belt tension is correct (see Abb. 40). Tighten motor mounting nuts.
27

ually by pressing the 0-I switch to I. For safety of the operat ing personnel all voltage carrying parts have a protective cover. MOTOR MOTOR) PROTECTION SWITCH (THREE-PHASE
1
The motor is switched on manually by turning the switch to 1 (Abb. 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 re started 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 integrated into the motor protection switch. The response value of the electromagnetic releases (protection against short-circuit) is preset. MAINTENANCE For the electrical system no regular maintenance is re quired.
Abb. 42 Motor protection switch (alternating current)
4.4.11. COOLING SYSTEM The cylinders of the compressor block, the intermediate coolers and the after-cooler are air-cooled. For this purpose, the compressor is equipped with a fan wheel connected to the counter-weight at the crankshaft end opposite to the V-belt pulley. It draws the cooling air through the fanwheel cover from the surroundings. Refer to chapter 3. for proper installation and cooling air supply. For maximum ambient temperature, see Technical Data, chapter 1.
1 0
Abb. 43 Motor protection switch (three-phase motor)
28

4.5. TROUBLE-SHOOTING Cause Electric circuitry faulty Remedy Check all fuses, terminal connections, wire leads, make sure that motor data complies with mains supply Replace Set to nominal motor current. Observe temperature compensation (+20 C =1,0) For ambient temperature + 10 C : correction factor 0,94 + 30 C : correction factor 1,05 + 40 C : correction factor 1,12 Switch off other consuming devices Use suitable cable Trouble Drive motor (electric) Motor will not start
Motor/engine runs eccentrically Motor protection switch is switching off the unit
V-belt worn Wrong adjustment of the motor pro tection switch
Motor protection switch is switching off the unit Drive motor (petrol) Motor will not start Motor runs eccentrically Motor stops Drive system Excessive vbelt wear (black deposits on belt guard)
Unsufficient voltage because of weak power supply Power supply cable to long or to thin
See motor instructions V-belt worn Low oil level V-belt tension Pulleys not aligned
See motor instructions Replace Top up oil Re-tighten, see chapter 4.4.9. Re-adjust, see chapter 4.4.9. Tighten and reseal Replace safety valve Replace cartridge
Compressor Compressor does not attain final pres Condensate drain valve(s) leaking sure Final pressure safety valve defective (blows too soon) No cartridge in filter system P21 (air escaping through cartridge safety bore) Vent screw for final pressure safety valve not in operating position Intake filter soiled Pipe coupling leaking Excessive wear of 3rd stage piston Intermediate pressure too high be cause of defective inlet or pressure valve of the following stage Safety valve leaking Insufficient cooling air
Air delivery drops
Intermediate pressure safety valve blows
To vent, unscrew until completely open Clean or replace filter cartridge Retighten couplings Replace piston and sleeve of 3rd stage Check/replace inlet or pressure valve
Compressor overheats
Taste of oil in the air
Replace safety valve Check location; ensure proper cooling air flow Ambient temperature too high Check location; ambient temperature max. +45 C (113 F) Direction of rotation is wrong Correct direction of rotation Inlet and pressure valve of one stage is Check valves, clean/replace if neces leaking sary TRIPLEX cartridge saturated Replace cartridge Unqualified lubricant being used Replace oil with an approved brand
29

Trouble High oil consumption Cause Piston rings, Pistons or cylinders worn out Intake filter clogged Compressor too hot Cartridge missing Cartridge installed but O-rings defec tive Remedy Replace defective parts Replace filter cartridge Enhance cooling Insert cartridge Check/replace O-rings
Air escaping through cartridge safety bore
30

5. STORAGE, PRESERVATION
GENERAL If the compressor is put out of service for more than six months, the unit should be preserved in accordance with the following instructions: Make sure the compressor is kept indoors in a dry, dust free room. Only cover the com pressor with plastic if it is certain that no condensation will form under the sheet. Nevertheless, the sheet should be re moved from time to time and the unit cleaned on the out side. If this procedure cannot be followed and/or the com pressor is going to be taken out of service for more than 2 years, please contact our Technical Service Department for special instructions. The compressor is not resistant to saltwater! If not in use keep unit in a dry place. PREPARATION Before preserving the compressor unit, run it warm and when it reaches the specified service pressure, keep it run ning for approx. 10 minutes. Then carry out the following: - Check all pipes, filters and valves (also safety valves) for leakage. - Tighten all couplings, as required. - After 10 minutes, open the filling valves or the outlet valve and run the compressor at the set minimum pres sure (pressure maintaining valve, see chapter 4.4.5.) for approx. 5 minutes. - After these 5 minutes, shut the system down. Drain con densate from separators. Depressurize unit. Shut filling valves. - Open filters and grease threads. - Ensure that filter cartridge remains in the filter! This will prevent oil entering filling lines as a result of preservation procedures. - Remove intake filter from manifold and all intake lines from valve heads. - Let compressor unit cool down. PRESERVING THE COMPRESSOR - Turn the compressor on and spray a small amount (ap prox. 10 ccm/0.6 cu. in.) of compressor oil into the valve head inlet port while the compressor is running. Do not let the compressor warm up too much, to keep oil sticky. - Shut compressor unit off. - Close all valves. - Place the dust cap onto the inlet port. PRESERVING THE MOTOR/ENGINE Preserve the motor/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 from the inlet port and insert the intake filter. Open the filling valves or the outlet valve and let the unit run for approx. 10 minutes or until the pressure gauges indicate the correct values. Stop the compressor. Open condensate drain valves and release compressed air. Close condensate drain valves again. Carry out preservation procedure according to chapter preserving the compressor
Changing the lube oil for preserving After prolonged storage, the oil will age in the com pressor and engine. It should be drained after 2 years at the latest and replaced with fresh oil. The stated period can only be attained when the crank case is sealed during the preservation period in accord ance with the preservation requirements. After changing the oil, turn the compressor and the en gine or run them for the required period. Check the lubrication of the compressor when putting the unit into operation once every six months or when turning the compressor. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil pressure regulator and if the oil pressure gauge indicates the prescribed pressure.
REACTIVATING THE COMPRESSOR UNIT Remove the dust cap from the inlet port and insert the intake filter. Check the oil level of the compressor. Check the motor/engine according to the manufac turer's instructions. Open the purifier and change all filter cartridges. Run the compressor warm with open filling valves or outlet valve for approx. 10 minutes. Check the oil pressure on the pressure gauge. If there is any fault, check the lubrication of the compressor. After 10 minutes, close the filling valves or the outlet valve and run the unit up to final pressure until the final pressure safety valve blows. Check the inter-pressure safety valves for leakage. Establish cause of any fault from the trouble-shooting table, chapter 4.5., and take corrective action. Stop the system when running properly, the compressor is then ready for operation.
31

6. REPAIR INSTRUCTIONS
GENERAL Preventive maintenance usually involves replacing the valves, gaskets and sealing rings as well as carrying out the maintenance work. Repair work can be carried out on the compressor block to a certain extent but a certain experi ence 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 department.
32

7. TABLES
TIGHTENING TORQUE VALUES Unless otherwise specified in text, the fol lowing torque values apply. All valve head screws require torque wrench tight ening! The indicated torque values are valid for bolts in greased condition. Re place self-retaining nuts on reassembly. Bolt or screw Hex and allen head Hex and allen head Hex and allen head Hex and allen head Hex and allen head Hex and allen head Pipe connections (swivel nuts): TORQUE SEQUENCE Tighten valve head and cylinder bolts/nuts equally in the se quence shown in Abb. 44. Be sure to tighten all parts in cold condition only. Thread M6 M 8* M 10 M 12 M 14 M 16 max. torque 10 Nm (7 ft.lbs) 25 Nm* (18 ft.lbs) 45 Nm (32 ft.lbs) 75 Nm (53 ft.lbs) 120 Nm (85 ft.lbs) 200 Nm (141 ft.lbs) Finger-tight + 1/2 turn
Abb. 44 Torque sequence
Exception: mounting bolts of final pressure safety valve: 10 Nm
33

LUBRICATION CHART Usage Rubber and plastic parts, filter housing threads Sealing rings Shaft seal (seal) Shaft seal (shaft) Screws, bolts, threads Lubricants WEICON WP 300 WHITE part no. N19752 or BAUER special grease part no. 072500 BAUER special grease part no. 072500 BAUER special grease part no. 072500 Klber SK 01-205 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 Screws Seals for conical threads Metal - metal seals High temperature connections, e.g. valve heads, cylin ders Paper gaskets TESTING AGENTS Usage Tube connectors, tubes Testing agents Leakage test spray, part no. FM0089 Adhesives and Sealants Loctite 2701 Loctite 243 Temperature resistant compound, e.g. WACKER E10, part no. N18247 Loctite FAG 2
34

8. ANNEX
Schematic diagram Lubricating oil list Parts list
35
36

Schematic diagram motor protection switch, three phase current
Hauptsicherung bauseits / Main fuse by customer / Fusible principal cot client
Ein/Aus On/Off Marche/ Arrt
Schaltplan/Schematic diagram/Schma lectrique Motorschutzschalter Motor protection switch Disjoncteur 76942-S1
37
38
Oil list w 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 level described for the equivalent BAUER compressor oil in the instruction manual of your unit.
Oil type
Brand name Designation
Special Compressor oil Part no. N28355 Special Compressor oil Part no. N22138
Use
Type
Ambient temperature N
Nitrox +5 ...+45 C
A
Breathing air
b) c) a)
S M
+ +
+ +
Oil type S M synthetic oil mineral oil
Application A N a) b) c) approved for breathing air application with BAUER air purification systems approved for nitrox application (with BAUER membrane unit, only) oil change every 1000 operating hours oil change every 2000 operating hours oil change every 1000 operating hours in case of nitrox application
Suitability + = suitable = not suitable
Oil list w 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: Nitrox compressor units: BAUER Special Compressor oil, part no. N28355 BAUER Special Compressor oil, part no. N28355
For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recommend the BAUER special synthetic compressor oils acc. to the list on the previous page. These have proved excellent quality under ambient temperatures between +5 C and +45 C. For lower temperatures a compressor heating device is required which is capable of preheating the unit up to +5 C. For operation under less severe conditions, and for intermittent operation, i.e. when the compressor is not used for longer periods between the operating periods, we also recommend the 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 preheating device will be required if ambient temperatures should fall below +5 C. Changing the Oil Type To avoid severe damage to the compressor unit when changing to another oil type, the following measures should be strictly adhered to.
Drain mineral oil while still warm. Check valves, coolers, separators, purifiers and all pneumatic tubes and hoses for deposits. If deposits are present, perform the following steps: Remove deposits or change valves, coolers, separators, purifiers and all pneumatic tubes and hoses. Change oil filter, if applicable. Fill compressor with the new oil. After approx. 100 operating hours, replace oil filter again (if applicable). and change oil. Top up with same oil type.
OIL CHANGE Mineral oil Synthetic oil Oil change volume every 1000 operating hours, at least annually every 2000 operating hours, at least every two years see compressor unit operating manual
BAUER compressor oil is available in the following quantities: Oil quantity b type ' 0.5 ltr. bottle 1 ltr. bottle 5 ltr. container 20 ltr. container Oil Synthetic oil N28355 part no. N283550,5 part no. N283551 part no. N283555 part no. N2835520 Mineral oil N22138 part no. N221380,5 part no. N221381 part no. N221385 part no. N2213820

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Instruction Manual w Junior II

Instruction Manual w Junior II

Operate unit only at ambient tem peratures between +5 and +45 C

Drain condensate at least every 15 minutes (3 locations)

Keep away from hot surfaces on motor and compressor

chapter 4.4.3. and 4.4.4.

Wear ear protectors when unit is running

Petrol driven units must not be op erated indoors.

Instruction Manual w Junior II

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

76942-S1 70851 TJ-4/9

Instruction Manual w Junior II

Model: Serial No..: Date of purchase: Dealer address / phone no.:

Instruction Manual w Junior II

Compressor unit with petrol engine

Instruction Manual w Junior II

Compressor unit with electric motor (three-phase current)

Compressor unit with electric motor (alternating current)

Instruction Manual w Junior II

Compressor unit with electric motor, v-belt cover side

Air flow diagram

Instruction Manual w Junior II

87 dB(A) 100 dBA) 46 kg

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Petrol driven units must not be op erated indoors.

Instruction Manual w Junior II

Alternating current: Set 0-I switch to I.

Instruction Manual w Junior II

Connecting air bottle

International filling connector

Filling air bottle

Abb. 10 Removing air bottle

Instruction Manual w Junior II

Abb. 11 Change-over device

Units with petrol engine: All units:

Abb. 12 Motor protection switches (three-phase motor)

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Never repair pressure lines by sol dering or welding.

Change TRIPLEX longlife cartridge ac cording to chapter 4.4.4.!

The used cartridge must be disposed of according to local regulations.

Maintenance of drive motor/engine ac cording to manufacturer's operating in structions.

Instruction Manual w Junior II

Knurled nut Plastic cap Micronic filter cartridge O-ring Opening

Abb. 26 Oil dipstick markings

Instruction Manual w Junior II

Abb. 28 Condensate drain taps Abb. 29 Filter system P21

Instruction Manual w Junior II

Instruction Manual w Junior II

Instruction Manual w Junior II

Filling pressure p = 300 bar