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619395 Junior II instruction manual

1. Top view iS to 2nd stage N4860 F98 from intake fil ter Abb 35 Valve 1st staae GENERAL INSTRUCTIONS FOR CHANGING THE VALVES 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 YANO 35 KOMPRESSOREN 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 om N m mb Valve head Gasket Plate valve O ring Valve head screw Washer Nut Abb 36 Valve head 1st stage NOU bp WN Loosen two cap nuts from tube connectors at valve head and safety valve connector and remove inter cooler Remove four valve head scr
2. Y NE Special Compressor oil Part no N28355 b c BAUER BE KOMPRESSOREN a Oil type synthetic oil S M mineral oil Application 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 BAUER Oil list e Breathing air compressors TYPE OF OIL Due to the thermal load on the compressor only high quality oil should be used You are recommended to restrict oils to those which have been approved by us and are listed in the instruction manual or in the lubricating list on page 1 Our compressor units are delivered ex works with lubricating oil filled into the crankcase or as consignment depending on the model as follows Breathing air compressor units BAUER Special Compressor oil part no N28355 Nitrox compressor units BAUER Special Compressor oil part no N28355 For operation under difficult conditions such as continuous running and or high ambient temperatures we only recom mend 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
3. 44 80 65 65 52 79 28 42 34 62 51 83 08 99 85 332 49 41 Bottle volume VF m3 Number of bottle fillings n processable air volume bottle volume Va VF Bottle size at pressure p bar Itr 200 Bottle volume VF m3 p bar x I I 1000 m 7 14 Processable air volume Va m3 0 2 x mMS g X g m p bar 0 2 x p bar x mMS g X g m Filter cartridge lifetime tp h Va m Q m3 min x 60 min h 10 2 12 2 4 22 g BAUER Instruction Manual Junior II 2 Filter cartridge 059183 lifetime hours Filling pressure p 200 bar Junior Il Ambient temperature Final separator temperature Delivery tU C tAb PC Q l min 100 20 24 22 18 25 29 17 13 30 34 13 10 35 39 10 8 40 44 8 6 45 49 6 5 50 54 5 4 Filling pressure p 300 bar Junior II Ambient temperature Final separator temperature Delivery tU C tAb C Q l min 100 Filter cartridge 059183 bottle fillings number molecular sieve mass mms g 58 Ambient Final separa Air humidity processable air volume Va Number of bottle fillings n temperature tor tempera saturated m3 acc to bottle size A t Pi PC X g m at pressure p bar 200 300 10 17 31 21 80 134 106 201 160 23 07 28 79 101 81 151 121 30 40 37 63 76 62 114 92 39 65 48 64 59 48 88 72 51 21 62 41 45 37 68 56 65 52 79 28 35 29 53 44 83 08 99 85 28 23 42 35 Bottle volume VF m3 Proc
4. 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 at KOMPRESSOREN 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 Instruction Manual e Junior II BALIER Instruction Manual Junior II 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 Thread max torque Hex and allen head 10 Nm 7 ft Ibs Hex and allen head 25 Nm 18 ft lbs Hex and allen head 45 Nm 32 ft lbs Hex and allen head 75 Nm 53 ft lbs Hex and allen head 1
5. 3 tank neck On models of 300 bar rated filling pres sure do not attach bottles unless rated for this pressure note pressure stamped on 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 MEZ mitted in the Federal Republic of Ger many In other countries it is allowed only for pressures up to 200 bar 2 850 psi The international connector is not per 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 CO gt values in the air filled into the bottles 2fAN8 35 KOMPRESSOREN Abb 7 Connecting air bottle Abb 8 International filling connector Abb 9 Filling air bottle Abb 10 Removing air bottle 11 at KOMPRESSOREN 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 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 valv
6. 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 8 Starter rope 9 Engine stop switch ignition 10 Filling valve with final pressure gauge 11 Safety valve final pressure 12 Filter system P21 13 B Timer 14 Condensate drain taps Instruction Manual Junior Il 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 O Mains plug with ON OFF switch and motor protection circuit breaker dep on count
7. N28355 0 5 part no N22138 0 5 1 Itr bottle part no N28355 1 part no N22138 1 5 Itr container part no N28355 5 part no N22138 5 20 Itr container part no N28355 20 part no N22138 20
8. 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 BALER KOMPRESSOREN 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 compre
9. of according to local regulations LVE 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 AN Instruction Manual e Junior II 1 Filter cartridge 057679 lifetime hours Filling pressure p 200 bar Junior Il Ambient temperature Final separator temperature Delivery tU C tAb C Q l min 100 20 24 26 21 25 29 20 16 30 34 15 12 35 39 11 9 40 44 9 7 45 49 7 6 50 54 5 5 Filling pressure p 300 bar Junior II Ambient temperature Final separator temperature Delivery tU C tAb C Q l min 100 Filter cartridge 057679 bottle fillings number Molecular sieve mass mMS g 68 Ambient Final separa Air humidity Processable air volume Va Number of bottle fillings n temperature tor tempera saturated m3 acc to bottle size tU C ture X g m tAb C at pressure p bar 200 300 10 17 31 21 80 157 125 236 187 23 07 28 79 118 94 177 142 30 40 37 63 89 72 134 108 39 65 48 64 69 56 103 84 51 21 62 41 53
10. pre heating 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 pre heating 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 every 1000 operating hours at least annually Synthetic oil every 2000 operating hours at least every two years Oil change volume see compressor unit operating manual BAUER compressor oil is available in the following quantities Oil quantity Oil Synthetic oil N28355 Mineral oil N22138 type 0 5 ltr bottle part no
11. 20 Nm 85 ft Ibs Hex and allen head 200 Nm 141 ft lbs Pipe connections swivel nuts Finger tight 1 2 turn 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 67 4S De 2 2 Abb 44 Torque sequence Exception mounting bolts of final pressure safety valve 10 Nm 33 AN Instruction Manual e Junior II LUBRICATION CHART Rubber and plastic parts filter housing threads WEICON WP 300 WHITE part no N19752 or BAUER special grease part no 072500 Sealing rings BAUER special grease part no 072500 Shaft seal seal BAUER special grease part no 072500 Shaft seal shaft Kluber SK 01 205 Screws bolts threads WEICON ANTI SEIZE AS 040 P part no N19753 or equivalent compound with copper or MoS gt additives For compressor lubricating oils refer to oil list in chapter 8 ADHESIVE AND SEALANT CHART Adhesives and Sealants Screws Loctite 2701 Seals for conical threads Loctite 243 Metal metal seals Temperature resistant compound e g High temperature connections e g valve heads cylin WACKER E10 part no N18247 ders Paper gaskets Loctite FAG 2 TESTING AGENTS Usage Testing agents Tube connectors tubes Leakage test spray part no FM0089 34 Instruction Manual Junior II 8 ANNEX e Schematic diagram Lubricating oil list Parts list BAUER KOMPRESSOREN 35 K
12. 4 MAINTENANCE WORK This chapter contains the maintenance work as well as a short functional description for each component 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 3 partment The current oil list is provided in the annex chapter 8 Order this list regularly through the BAUER Technical Service De 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 41 F 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 lon
13. 5 b 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 MV3 A 10 06 Instruction Manual Junior II 2 SAFETY MEASURES 2 1 NOTES AND WARNING SIGNS 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 IMANDATORY 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 Ensure correct direction of rotation ie O
14. 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 BAUER Instruction Manual Junior II 3 LOCATION OPERATION BOTTLE FILLING 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 zT 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
15. B BB When switching on the machine check the arrow to ensure correct direction of rotation of the drive motor 2fAN8 35 KOMPRESSOREN 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 WARNING aa 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 3 2 3 FUNDAMENTAL SAFETY NOTICES 2 3 1 Authorized use e 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 e 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 e The machine unit is exclusively for the compression of mediums air gas specified in section A chapter 1 3 Technical data An
16. MPRESSOREN 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 unde
17. OMPRESSOREN BAUER Instruction Manual Junior II Schematic diagram motor protection switch three phase current Hauptsicherung bauseits Main fuse by customer Fusible principal cot client Ein Aus On Off Marche F r diese techn Unterlage wird zul Abw Oberflache Masstab Masse jeglicher gesetzlich vorgesehene N Rechtsschutz nach DIN 34 in gt une Werkstoff Anspruch genommen mH 1302 Odoo Eo tum Nme Schaltplan Schematic diagram Schema electrique poof ez 13 06 2002 SCHWARZ a po Ge 13 06 2007 SCHWARZ ein CU E Freig 13 06 2002 Epgcusto Motor protection switch Sm S E ppa sss o sii P ee ae KOMPRESSOREN pita a BEE 37 KOMPRESSOREN BAUER Oil list e 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 Ambient temperature Oil type A N Brand name Designation Type 5 145 C Breathing air Nitrox
18. SAUER Instruction Manual gt JUNIOR II m Zn ha f gt TAPA um 28 l anpa MUR 4 HALA Ann Anaan SNEM 1 a SA u WA www bauer kompressoren de 2 BALIER Instruction Manual e Junior II INTRODUCTION This manual contains operating instructions and mainten ance schedules for the high pressure breathing air com pressor unit Junior Il 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 responsibili
19. VICE 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 20 C 36 to 45 10 Itr 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 BAUER Instruction Manual Junior Il KOMPRESSOREN Example at an ambient temperature of 20 C 31 to 38 Seal pressure gauge with PTFE tape or Loctite 243 and 10 Itr bottles can be filled with this c
20. Valve head cover 7 Allen screw 8 Gasket Abb 38 Valve head 3rd stage Change intake and pressure valve of 3rd stage together only Instruction Manual Junior II 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 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 V belt 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 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 thu
21. 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 e Check the pressure vessels regularly on the inside and outside for damage from corrosion e 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 Opera
22. artridge which is screw in tight to desired position equivalent to between 10 and 13 operating hours at a filling pressure of 200 bar The longer service life of the cartridge at MEZ 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 Units with petrol engine are delivered MEZ 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 gt 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
23. ase current the motor is switched on man ually by turning the switch 1 Abb 6 to 1 GI Abb 6 Motor protection switches three phase motor Alternating current Set 0 switch to 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 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 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 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 chemi
24. bols and operating hours A 500 hours or 1 year B 1000 hours or 2 years C 2000 hours or 4 years e 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 17 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 14 Instruction Manual Junior II Abb 14 Abb 15 Battery Abb 16 Abb 17 Instruction Manual Junior II Operation The B Timer is activated when starting MEZ 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 MEZ indication will return to the main menue After 2 minutes the B Timer is switched Abb 18 off if no compressor operation is detected Function Display To display the desired
25. cal Data chapter 1 28 Instruction Manual e Junior II Abb 42 Motor protection switch alternating current Abb 43 Motor protection switch three phase motor Instruction Manual Junior II 4 5 TROUBLE SHOOTING Trouble Cause BAUER KOMPRESSOREN Remedy Drive motor electric Motor will not start Motor engine runs eccentrically Motor protection switch is switching off the unit Motor protection switch is switching off the unit Drive motor petrol Motor will not start Motor runs eccentrically Motor stops Drive system Excessive v belt wear black depo sits on belt guard Compressor Electric circuitry faulty V belt worn Wrong adjustment of the motor pro tection switch 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 Compressor does not attain final pres Condensate drain valve s leaking sure Air delivery drops Intermediate pressure safety valve blows Compressor overheats Taste of oil in the air 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 def
26. cal reaction of CO with hopcalite warm ing up of the cartridge and danger of fire may result Filling hoses must be in satisfac ens 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 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 To meet the CO maximum rating au value in breathing air bottles please observe the two following chapters Intake air quality and Scavenging the compressor unit Intake air quality At routine tests CO 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 insu
27. cles 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 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 v
28. e 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 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 1096 or more replace safety valve 4 4 7 PRESSURE GAUGE DESCRIPTION The compressor unit is eq
29. e 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 SHUT DOWN PROCEDURE Close filling valve Units with electric motor Three phase current the motor is switched off by turning the switch 1 Abb 12 to 0 Alternating current set O switch to O Units with petrol engine Shut down petrol engine with stop button or stop lever All units 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 12 Instruction Manual e Junior II Abb 11 Change over device Abb 12 Motor protection switches three phase motor Instruction Manual Junior II B TIMER optional Introduction Read operating instructions carefully before operating the unit The settings in the setup menu are essen MEZ tial for the correct indication of the filter capacity Without correct settings the B Timer can be used as an h
30. e 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 khowledge 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 BAUER KO
31. e 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 Key symbol maintenance due Letter symbol maintenance type Low battery symbol Cartridge saturation indicator Operating hours or cartridge number Mode select key Enter key NOU bp WN 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 Function The B Timer display shows the following functions 13 e Operating hours of the compressor unit e Cartridge lifetime in by means of four segments in the cartridge symbol e Flashing last segment and change from operating hours indication to cartridge part no if capacity is equal or less than 2096 of the original lifetime e Indication of compressor maintenance due by means of letter sym
32. ear 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 Wh
33. ective inlet or pressure valve of the following stage Safety valve leaking Insufficient cooling air Ambient temperature too high Direction of rotation is wrong Inlet and pressure valve of one stage is leaking TRIPLEX cartridge saturated Unqualified lubricant being used 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 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 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 Replace safety valve Check location ensure proper cooling air flow Check location ambient temperature max 45 fC 113 F Correct direction of rotation Check valves clean replace if neces sary Replace cartridge Replace oil with an approved brand 29 BAUER Instruction Manual e Junior II Trouble High oil consumption Piston rings Pistons or cylinders worn out Intake filter clogged Compressor too hot Air escap
34. en 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 Instruction Manual Junior II 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 Th
35. essable air volume Va m3 0 2 x mMS g X g m3 Bottle size at pressure p bar p bar 0 2 x p bar x mMS Ig X g m ltr 200 300 Filter cartridge lifetime tp h Va m Q m3 min x 60 min h 7 1 4 2 1 10 2 3 12 2 4 3 6 Number of bottle fillings n processable air volume bottle volume Va VF Bottle volume VF m3 p bar x I 1000 m 23 YANO 35 KOMPRESSOREN 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 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 3 Clockwise increase pressure Counter clockwise decrease pressure 4 4 6 SAFETY VALVES DESCRIPTION All three compressor stages are protected by safety valves as follows 24 Instruction Manual e Junior II 1st stage 2nd stag
36. essor 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 YAN 3 Instruction Manual Junior II KOMPRESSOR Open drain tap 1 Abb 28 and drain off condensate every 15 to 30 minutes during operation ee 4 3 5 2 Er 6 RR 7 8 9 L 10 Abb 28 Condensate drain taps 11 Abb 29 Filter system P21 4 4 4 FILTER SYSTEM P21 DESCRIPTION 1 Filter inlet The air leaving the final stage is cooled in the after cooler pe n 5 3 Filter head to approx 10 15 C 18 27 F above ambient tempera A Final pressure safety valve ture and then enters filter system P21 with TRIPLEX long 5 Housing life cartridge Abb 29 6 Chamber separator The filter assembly consists of separator and cartridge 7 Cartridge chamber In the separator surrounding the cartridge o PUP ae 9 Pressure maintaining valve chamber liquid oil and water particles are reliably separated 10 C
37. ews 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 26 Instruction Manual Junior II 1 Nut 6 2 Spring washer 3 Plate 4 Pressure valve 5 O ring 6 Valve head 7 Intake valve 8 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 1 Torque stud 2 O ring 3 Pressure valve 4 Intake valve 5 Valve head 6
38. fficient ventila tion the CO value in the surrounding air can increase quite fast because of the exhaling of CO CO values from 1 000 to 5 000 ppmv in workrooms are not unusual MAK value max workroom concentration is 5 000 ppmv Another Instruction Manual Junior II additional increase is caused by cigarette smoking produc ing approx 2g CO 2 000 ppmv per cigarette These pollutions add up to the basic pollution of approx 400 ppmv The technically caused excessive increase of CO during the filling process and the CO 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 CO is present in the atmosphere with a natural amount of 350 to 400 ppmy The molecular sieve used in the purifier for drying the breathing air is as well as other capabilities able to adsorb CO which is accumulated in the cartridge After shut down of the compressor adsorbed CO may be desorbed again due to the partial pressure decrease The now free CO then gets washed out of the cartridge when the compressor is started again To avoid increased CO 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
39. function press the MEZ select key 1 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 MEZ less a new filter cartridge has been fitted To reset the filter capacity or the A B and C maintenance intervals press key for more than 5 seconds from the re spective maintenance interval display Abb 22 Abb 22 15 Instruction Manual e Junior II Setup To enter the setup for the different functions of the B Timer press the and 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 key for 3 seconds the number starts flashing Press the key to select the correct number press lt key to accept the new setting Abb 23 Numbers beginning w
40. g 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 every 1 000 operating hours at least annually Synthetic oils every 2 000 operating hours at least biennially 17 YANO 35 KOMPRESSOREN OIL CAPACITY Junior Il approx 360 ml 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 max min Uo me ee ee ee ee ey Abb 26 Oil dipstick markings CHANGING THE OIL TYPE To avoid severe damage to the compres sor unit
41. g 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 Instruction Manual e Junior II 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 shut down 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 Cl
42. ice Keep all condensate drain valves and taps closed Keep a minimum pressure of approx 50 to 80 bar 700 to 20 Instruction Manual e Junior II 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 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 SER
43. ing through cartridge safety Cartridge missing bore Cartridge installed but O rings defec tive 30 Replace defective parts Replace filter cartridge Enhance cooling Insert cartridge Check replace O rings Instruction Manual Junior II 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 gt The compressor is not resistant to salt water If not in use keep unit in a dry PREPARATION place 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
44. ion switch 1 Abb 42 The response value is preset The motor is switched on man 27 ually by pressing the O I switch to For safety of the operat ing personnel all voltage carrying parts have a protective cover MOTOR PROTECTION SWITCH THREE PHASE MOTOR The motor is switched on manually by turning the switch to 1 Abb 43 It is switched off manually by turning the switch to O For safety of the operating personnel all voltage carrying parts have a protective cover 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 gt After the switch has shut off by overcur 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 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 Techni
45. ith 999 require a MEZ special adjustment Press key for 3 seconds Press the key to select 999000 the last O starts flashing Press the key to select the correct number then press key the second O will start flashing proceed as above and finally adjust the 3rd O accordingly Pressing the 1 key display changes to setup B for the deliv ery setting Filter symbol starts flashing Abb 24 To change delivery in Itrs min press l key for 3 seconds the 1st digit starts flashing Press the key to select the correct Abb 24 number press key to accept the new setting Repeat pro cedure for the other two digits Pressing the key again display changes to setup C for the pressure range setting Filter symbol starts flashing Abb 25 To change pressure press key for 3 seconds Press the key to select the correct pressure 200 300 or 200 300 press key to accept the new setting cartridge the filter capacity has abso gt After finishing setup and fitting a new Abb 25 lutely to be reset see Reset above Pressing the key again display changes to the menue for adjusting the operating hours Press key for 2 seconds the last digit will start flashing Press the key to select the correct number then press 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 key gives the possi bility t
46. mb pressure between the two pulleys Abb 40 For best results we recommend our v belt tension meter part no N25238 V belt tension adjustment Slightly loosen motor mounting nuts Adjust motor until the belt tension is correct see Abb 40 Tighten motor mounting nuts BALER KOMPRESSOREN Run motor for approx 5 minutes Stop motor check V belt 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 7 Abb 40 Checking V belt tension Abb 41 V belt pulley adjustment 4 4 10 ELECTRICAL SYSTEM DESCRIPTION This section describes the standard electrical system gt For schematic diagram see annex 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 protect
47. n 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 BAUER Instruction Manual e Junior II 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 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 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 ph
48. o readjust the hours again if required Instruction Manual Junior II 4 MAINTENANCE 4 1 MAINTENANCE RECORD We recommend that all maintenance work is recorded in the service book showing the date and details of the work 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 WARNING i pressor Never repair pressure lines by sol WARNING dering or welding i 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 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 IPR Bb 4 3 MAINTENANCE SCHEDULE The maintenance schedule is contained in the service man ual delivered with every compressor unit BAUER KOMPRESSOREN 4
49. on Manual e Junior II TECHNICAL DATA Jumiori B FO1 Juniore unioriW Medium air Delivery 100 l min 3 5 Scfm Operating pressure PN200 PN300 Pressure setting final pressure safety valve 225 330 bar Sound pressure 87 dB A 86 dB A Sound immersion power 100 dBA 99 dB A Weight 46 kg 44 kg 47 kg Compressor block Junior mod 3 Number of stages 3 Number of cylinders 3 Cylinder bore 1st stage 60 mm Cylinder bore 2nd stage 28 mm Cylinder bore 3rd stage 12 mm Piston stroke 24 mm Speed 2 300 min Intermediate pressure 1st stage 6 7 bar Intermediate pressure 2nd stage 40 60 bar Compressor block oil capacity 360 ml Oil volume between min and max marks 50 ml Oil type see chapter 4 4 1 lubrication Max ambient temperature 5 45 C Max inclination of compressor 5 Max operating height O 2000 m above sea level Compressor drive umiorB S Drive motor Robin Subaru petrol engine Manual start model B EX17 Power 4 2 kW 5 7 PS at nominal speed 3 600 min Compressor drive Drive motor Three phase current Operating voltage 400 V 50 Hz Power 2 2 kW 3 PS Speed 2 850 min Size 90 L Type of construction B3 Compressor drive Drive motor Alternating current Operating voltage 230 V 50 Hz Power 2 2 kW 3 PS Speed 3 000 min Size LS 90 PC Type of construction B3 Type of enclosure IP44 a free air delivered at bottle filling from O to 200 bar
50. ondensate drain ta from the compressed medium by a pipe nozzle j 11 Condensate outlet 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 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 CARTRIDGE SAFETY BORE consuming device The filter system P21 IS designed to prevent pressurizing in The venting bore is also used to check the O rings on the the absence of the filter cartridge A bore provided in the cartridge pin If air is leaking out of the venting bore even filter bottom is sealed air tight only if the cartridge is in though a cartridge is installed the O rings are either broken place Abb 30 or were damaged on installation No pressure build up without cartridge Remove and check cartridge If necessary replace cartridge or O rings 19 YANO 35 KOMPRESSOREN Venting bore No cartridge 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 cy
51. orage 31 T Intake filter 18 Tables 33 Intermediate separator 19 Technical data 4 Intake air quality 10 Telescopic intake tube 18 Testing agents 34 L Tightening torque values 33 Torque sequence 33 Location 9 Lubrication 17 Trouble shooting 29 Lubrication chart 34 V M Valves 25 Maintenance 17 ANNEX Schematic diagram motor protection switch three phase current 76942 51 Lubricating oil list 70851 Applicable parts list TI 4 9 at KOMPRESSOREN NOTES Model Instruction Manual e Junior II Serial No Date of purchase Dealer address phone no Instruction Manual Junior II 1 GENERAL 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 oO N OF OQ Abb 1 Filling hose Exhaust Air filter Tank Throttle lever Choke lever Fuel cock Compressor unit with petrol engine NOU bp WN YAN 3 KOMPRESSOREN AIR FLOW
52. ourmeter only Make sure that the pressure maintaining MEZ 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 MEZ 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 Abb 13 B Timer 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 releas
53. p 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 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 MEZ 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 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 Whe
54. r 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 bein
55. r 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 safety relevant 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 YANO 35 KOMPRESSOREN 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
56. ry alo 00 N ON bi bp WN gt 10 Abb 2 Compressor unit with electric motor three phase current 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 O 60O NO 1 Bp WN Abb 3 Compressor unit with electric motor alternating current Instruction Manual Junior II 2 3 4 5 i u a 6 Co Abb 4 Compressor unit with electric motor v belt cover side eee ee ee ee as Me AG PMc 4 1 gt z i BEE pet A v Mi 15 21 16 15 15 1 Telescopic air intake 8 Intermed separator 2nd 3rd stage 2 Intake filter 9 After cooler 3 Cylinder 1st stage 10 Safety valve 1st stage 4 Cylinder 2nd stage 11 Safety valve 2nd stage 5 Cylinder 3rd stage 12 Final pressure safety valve 6 Inter cooler 1st 2nd stage 13 Filter system P21 7 Inter cooler 2nd 3rd stage 14 TRIPLEX longlife cartridge Abb 5 Air flow diagram 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 O 00 NA 1 bp WN O 15 Condensate drain valve 16 Pressure maintaining valve 17 Filling hose 18 Filling valve 19 Final pressure gauge 20 Safety valve final pressure PN 200 21 Change over device optional extra AN Instructi
57. 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 Indoor location Petrol driven units must not be op eae 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 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 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 u
58. ssor 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
59. ting 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 safety regulations BetrSichV of Instruction Manual Junior II 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 Koln 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
60. tion units with petrol engine with exhaust in wind direction to prevent exhaust fumes being sucked in by the compressor 7 chapter 3 Petrol driven units must not be op erated indoors chapter 3 Position unit level max inclination 5 7 chapter 3 Operate unit only at ambient tem peratures between 5 and 45 C chapter 3 Keep away from hot surfaces on motor and compressor 7 chapter 2 running chapter 2 Wear ear protectors when unit is BAUER Instruction Manual Junior II KOMPRESSOREN CONTENTS 1 GENERAL 0 00 ee eee 1 2 SAFETY MEASURES 0006 5 3 LOCATION OPERATION BOTTLE FILLING 9 4 MAINTENANCE 0 0 0000 17 5 STORAGE PRESERVATION 31 6 REPAIR INSTRUCTIONS 32 7 TABLES jes meaa tases bok AG Bae eos 33 8 ANNEX 0 0 0 0 c eee eee 35 INDEX A Maintenance instructions 17 Maintenance record 17 Adhesive chart 34 Maintenance schedule 17 Air flow diagram 1 Motor protection switch 28 Annex 35 o B Oil change 18 B Timer 13 Oil level check 17 C Oil type 17 Operation 9 Change over device 12 p Cooling system 28 D Preservation 31 Pressure gauge 24 Design 1 Pressure maintaining valve 23 Drive system 27 R E Repair instructions 32 V belt tension meter 27 S Electrical system 28 F Safety valves 24 Sealant chart 34 Filling procedure 10 Shut down 12 Filter system 19 St
61. ty for damage or injury resulting from failure to follow these instructions Edition January 2010 2010 BAUER Kompressoren GmbH Munchen All rights reserved YAN 3 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 080 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 Instruction Manual Junior II Do you have problems with maintenance or repair work 7 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 7 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 chapter 3 Check oil level on compressor and petrol engine before operating unit 7 chapter 4 4 1 Drain condensate at least every 15 minutes 3 locations F7 chapter 4 4 3 and 4 4 4 Posi
62. uipped with a final pressure gauge Abb 33 The red marking on it shows the max allowable Operating pressure Instruction Manual Junior II Abb 33 Final pressure gauge 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 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 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 Pressure Intake Abb 34 Valve operation BS CHA Id sy DO AT IP APAT T 7777 u Pressure side Intake side 6
63. 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 purifi ers and all pneumatic tubes and hoses from depos its 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 Instruction Manual e Junior II 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 Knurled nut Plastic cap Micronic filter cartridge O ring Opening UI BB WUN a 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 compr
64. y 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 e Keep the instruction manual to hand near the machine unit at all times in the relevant holder e 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 e Personnel engaged to operate the machine must have read the instruction manual before beginning work es YANO 35 KOMPRESSOREN 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 dange

619395 Junior II instruction manual

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