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EDP 777965 Instruction Manual

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1. 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 Fig 31 Removal of 3rd stage pressure valve BAUER KOMPRESSOREN 4 4 10 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 thumb pressure between the two pulleys Fig 32 For best results we recommend our v belt ten sion meter part no N25238 V belt tension adjustment Slightly loosen motor mounting nuts Adjust motor until the belt tension is correct see Fig 32 Tighten motor mounting nuts 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
2. MAINTENANCE Checking function The final pressure safety valve has to be checked regularly For this purpose the safety valve can be vented manually Turn knob on top of the valve anticlockwise until valve blows off Fig 24 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 Instruction Manual PE 100 T Venting Fig 24 Venting the final pressure safety valve Checking blow off pressure Check blow off pressure of the final pressure safety valve regularly see service manual 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 devi ation is 10 or more replace safety valve 4 4 8 PRESSURE GAUGE DESCRIPTION The compressor unit is equipped with a final pressure gauge Fig 25 The red marking on it shows the max allowable operating pressure Fig 25 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 BAUER
3. 29 30 BAUER 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 Instruction Manual PE 100 T Instruction Manual PE 100 T 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 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 Fig 35 Be sure to tighten all parts in cold condition only F 3 6 D Q De O 2 Fig 35 Torque sequence Exception mounting bolts of final pressure safety valve 10 Nm BAUER max torque 10 Nm 7 ft lbs 25 Nm 18 ft lbs 45 Nm 32 ft Ibs 75 Nm 53 ft lbs 120 Nm 85 ft lbs 200 Nm 141 ft lbs Finger tight 1 2 turn 31 BAUER Instruction Manual PE 100 T LUBRICATION CHART Usage Lubricants Rubber and plastic parts filter housing threads Sealing rings Shaft seal seal Shaft
4. 4 4 9 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 Fig 26 Intake and pressure valve of the 1st stage is a plate valve Fig 27 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 Intake Pressure Fig 26 Valve operation Sissy SSR ESSLESSSSSS PIAZZA AAP 777777 y Pressure side Intake side le o 0 4m Top view a to 2nd stage N4860 F98 from intake fil ter Fia 27 Valve 1st staae 23 BAUER 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 afte
5. POSEIDON Edition Instruction manual High Pressure Breathing Air Compressors gt PE 100 T 225 bar 330 bar www bauer kompressoren de Instruction Manual PE 100 T BAUER INTRODUCTION This manual contains operating instructions and mainten ance schedules for the high pressure breathing air com pressor unit PE 100 T 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 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 fro
6. 10 15 C 18 27 F above ambient tempera ture and then enters filter system P11 with TRIPLEX long life cartridge Fig 19 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 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 BAUER J CONDENSATE OUT Inlet coupling Filter Pressure maintaining valve Filter head Final pressure safety valve Condensate drain tap Condensate outlet coupling NOU huNn Fig 19 Filter system P11 CARTRIDGE SAFETY BORE The filter system P11 is designed to prevent pressurizing in the absence of the filter cartridge A bore provided in the filter head is sealed air tight only if the cartridge is in place Fig 20 No pressure build up without cartridge 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 BAUER KOMPRESSOREN though a cartridge is installed the O rings are either broken or were damaged on installation Remove and check cartridge If necessar
7. CO concentration Also due to chemical reaction of CO with hopcalite warm ing up of the cartridge and danger of fire may result 10 Instruction Manual PE 100 T Please respect local regulations for filling hoses Filling hoses must be u in satisfactory condition and threads undamaged Pay particular attention to dam age on the interface from hose fitting to hose If the casing is scored or the hose is porose 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 SS value in breathing air bottles please observe the two following chapters Intake air quality and Scavenging the compressor unit 3 3 2 Breathing air quality The breathing air quality is a safety ha MES zard The pres
8. 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 Fig 17 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 Instruction Manual PE 100 T 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 Open drain tap 1 Fig 18 and drain off condensate every 15 to 30 minutes during operation 1 Fig 18 Condensate drain taps 4 4 4 FILTER SYSTEM P11 DESCRIPTION The air leaving the final stage is cooled in the after cooler to approx
9. Maintenance schedule 14 Motor protection switch 25 O Oil change 14 15 Oil level check 14 Oil type 14 change of 15 Operation 9 P Preservation 28 Pressure gauge 22 Pressure maintaining valve 21 R Repair instructions 29 S Safety valves 21 Sealant chart 31 Storage 28 T Tables 30 Technical data 4 Telescopic intake tube 15 Testing agents 31 Tightening torque values 30 Torque sequence 30 Trouble shooting 26 V Valves 22 76942 S1 70851 TPE100 1 0 BALI f Instruction Manual PE 100 T Instruction Manual PE 100 T 1 GENERAL PURPOSE The PE 100 T breathing air compressor is designed to com press air for breathing as required in diving applications The max allowable operating pressure adjusted pressure on final pressure safety valve is 225 bar or 330 bar BAUER DESIGN The compressor unit comprises the following major assem blies compressor block drive motor filter system P11 filling assembly frame The design of the compressor system is shown in Fig 1 to Fig 3 Fig 1 Compressor unit with electric motor three phase current 1 Filling valve with final pressure gauge 2 Drive motor 3 Frame 4 Pressure maintaining valve 5 Filter system P11 6 Safety valve final pressure 7 Condensate drain tap final separator 8 Condensate drain tap intermediate separator Instruction Manual PE 100 T Filling hose Filter system P11 Safety va
10. 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 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 6 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 muc
11. 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 Itr bottle part no 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
12. 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 Operating 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 safety regulations BetrSichV of 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 K ln Beuth Vertrieb GmbH Instruction Manual PE 100 T Burggrafenstr 4 7 10787 Berlin The manufacturer has
13. 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 Ensure correct direction of rotation ie OP PE When switching on the machine check the arrow to ensure correct direction of rotation of the drive motor 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 WARNING BAUER This notice is used with maintenance work and operating procedures and must be adhered to exactly in order to avoid endangering personnel 4 2 3 This notice must be complied with in order to avoid damage to or destruction of the ma chine or its equipment This notice adv
14. 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 1 100 psi within the system to prevent moisture enter ing the compressor piping and filter system CONDENSATE DRAINAGE Drain condensate from separator and cartridge chamber regularly by slowly opening drain taps 6 Fig 19 before changing cartridge before each fill
15. for nitrox application with BAUER membrane unit only a oil change every 1000 operating hours b oil change every 2000 operating hours c 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 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
16. 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 L1 L2 L3 in the motor protection switch Never change leads at the motor ter minal 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 3 3 FILLING PROCEDURE 3 3 1 General Ensure intake air is free from noxious gas CO exhaust fumes j 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
17. l 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 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 Units with petrol engine are delivered Never remove replacement cartridge Prior to changing the filter cartridge drain condensate and depressurize filter system completely by opening condensate drain valves Remove filter head 4 Fig 19 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 BAUER Instruction Manual PE 100 T 1 Filter cartridge 057679 lifetime hours Filling pressure p 200 bar PE 100 T Ambient temperature tU C 10 15 20 25 30 35 40 Final separator temperature tAb C 20 24 25 29 30 34 35 39 40 44 45 49 50 54 Filling pressure p 300 bar Delivery Q l min 100 26 21 20 16 15 12 11 9 9 7 7 6 5 5 PE 100 T Ambient temperature tU C Final separator temperature tAb C Delivery Q l min 100 Filter cartridge 057679 bottle fillings number Molecular sieve mass mMS g 68 20 Ambient temperature
18. motor runs smoothly return choke to normal operating position Fig 13 Motorschutzschalter Petrol engine Fig 14 5 As soon as final speed is reached close condensate drain tap 1 Fig 12 of intermediate separator on BAUER KOMPRESSOREN petrol units close additionally the condensate drain tap 2 Fig 12 of final separator 6 Bottle will be filled Observe pressure gauge and drain condensate regularly during filling To avoid needless aperture of the safety valve the compressor must be switched off manually as soon as the filling pressure is reached Filling pressure safety valve setting pressure 10 bar i e PN200 units must be switched off at 215 bar PN 300 units at 320 bar Eg 7 Switch off the unit e PE 100 TE Shift switch 1 Fig 13 to position O e PE 100 TW Press switch 2 Fig 13 to position 0 e PE 100 TB Shift switch 1 Fig 14 to position 0 Open condensate drain tap 2 Fig 12 and drain shortly the final separator prior to switching off the unit 8 Close bottle valve first 1 Fig 15 then filling valve by returning handle to closed position 2 Remove compressed air bottle Fig 15 Removing air bottle 9 Open condensate drain of the intermediate separa tor Unit is ready for filling Repeat the above described filling procedure to fill further bottles 3 4 SHUT DOWN PROCEDURE 1 Switch off the unit e
19. 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 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
20. 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 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 be
21. tU C Bottle volume VF m3 Bottle size Itr 7 10 12 Final separa tor tempera ture tAb C Air humidity saturated X g m3 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 at pressure p bar 200 1 4 2 2 4 Processable air volume Va m3 at pressure p bar 200 157 12 300 5 236 187 118 94 177 142 89 72 69 56 53 44 42 34 33 27 134 108 103 84 80 65 62 51 49 41 min h Number of bottle fillings n acc to bottle size 10 Number of bottle fillings n processable air volume bottle volume Va VF Bottle volume VF m3 p bar x I 1000 l m3 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 m3 Filter cartridge lifetime tp h Va m3 Q m3 min x 60 Instruction Manual PE 100 T BAUER 2 Filter cartridge 059183 lifetime hours Filling pressure p 200 bar PE 100 T Ambient temperature tu C 10 15 20 25 30 35 40 Final separator temperature tAb C 20 24 25 29 30 34 35 39 40 44 45 49 50 54 Filling pressure p 300 bar Delivery Q l min 100 22 18 17 13 13 10 10 8 8 6 6 5 5 4 PE 100 T Ambient temperature tu C Final separator temperature tAb C Delivery Q l min 100 Filter cartridge 059183 bottle fillings numb
22. 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 Example at an ambient temperature of 20 C 31 to 38 10 Itr 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 MES 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 BAUER CARTRIDGE CHANGE For safety reasons only CO removal cartridges part no 059183 should j 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 with CO removal cartridge part no
23. to desired position Fig 22 Sintered metal filter 4 4 6 PRESSURE MAINTAINING VALVE DESCRIPTION A pressure maintaining valve 1 Fig 23 is mounted on the filter head of the filter system P11 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 22 Instruction Manual PE 100 T Fig 23 Pressure maintaining valve MAINTENANCE The pressure maintaining valve Fig 23 is adjusted at the factory to the required pressure and normally does not re quire regular maintenance 4 4 7 SAFETY VALVES DESCRIPTION All three compressor stages are protected by safety valves as follows 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 9
24. ER 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 Y min Lan oo Fig 16 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 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 Top up compressor and perform subsequent oil changes with same oil only Instruction Manual PE 100 T 4 4 2 INTAKE FILTER DESCRIPTION A dry micronic filter is used to filter intake air Fig 17 Knurled nut Plastic cap Micronic filter cartridge O ring Opening OM Ah UN Fig 17 Intake filter INTAKE FILTER MAINTENANCE
25. H 1302 Datum Name Schaltplan Schematic diagram Sch ma lectrique Gez 73 06 2002 SCHWARZ yi tocchalt Gep 13 06 2007 schwarz MOtorschutzschalter Freig 13 06 2002 EDBCUSTO Motor protection switch Disjoncteur BAUER Zeichnungs Nr 76942 S1 a KOMPRESSOREN Zust Anderung Datum Name 37 BAUER 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 Oil type temperature A N Brand name Designation Type 5 45 C Breathing air Nitrox BAUER Special Compressor oil Part no N28355 S KOMPRESSOREN b c Special Compressor oil P N221 KOMPRESSOREN t no N22138 a M Oil type S synthetic oil M mineral oil Application A approved for breathing air application with BAUER air purification systems N approved
26. N22138 20
27. PE 100 TE Shift switch 1 Fig 13 to position O e PE 100 TW Press switch 2 Fig 13 to position 0 e PE 100 TB Shift switch 1 Fig 14 to position O and close fuel tap 2 Drain condensate from intermediate and final sepa rator by means of drain taps 1 and 2 Fig 12 Let BAUER some pressure in the unit and 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 service manual Instruction Manual PE 100 T Instruction Manual PE 100 T 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 pressor Never repair pressure lines by sol dering or welding WARNING Check the complete system for leakage from time
28. at pressure gauge 19 Fig 4 Air flow diagram 1 Telescopic air intake 2 Intake filter 3 Cylinder 1st stage 4 Cylinder 2nd stage 5 Cylinder 3rd stage 6 Inter cooler 1st 2nd stage 7 Inter cooler 2nd 3rd stage 8 Intermed separator 2nd 3rd stage 9 After cooler 10 Safety valve 1st stage 11 12 13 14 15 16 17 18 19 20 BAUER Safety valve 2nd stage Final pressure safety valve Filter system P11 Condensate drain tap intermediate separator Condensate drain tap final separator Pressure maintaining valve Filling hose Filling valve Filling coupling Final pressure gauge BAUER TECHNICAL DATA Instruction Manual PE 100 T Compressor unit PE 100 TB FO2 PE 100 TE FO2 PE 100 TW FO2 Max operating height 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 42 kg 44 kg 44 kg Compressor block Junior II V001 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 lubric
29. ation Max ambient temperature 5 45 C Max inclination of compressor 5 0 2000 m above sea level Compressor drive PE 100 TB FO2 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 PE 100 TE FO2 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 Type of enclosure IP54 Compressor drive PE 100 TW FO2 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 1P44 a free air delivered at bottle filling from O to 200 bar 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 PE 100 T 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
30. 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 P11 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 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 i
31. 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 Refer to chapter 3 for proper installation and cooling air supply For maximum ambient temperature see Technical Data chapter 1 26 Instruction Manual PE 100 T Fig 34 Motor protection switches 4 4 12 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 Instruction Manual PE 100 T 4 5 TROUBLE SHOOTING Trouble BAUER 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 deposits on belt guard Compressor Electric circuitry faulty V
32. ce 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 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 Fig 16 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 OIL CAPACITY PE 100 T approx 360 ml BAUER OIL PACKAGES BAU
33. 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 8 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 t
34. criptive limits of the minor constituents must be measured regularly see service manual for measure intervals The norm DIN EN 12021 is the actual regulation for natural brea thing air from compressors and air bottles Prescriptive limits for natural breathing air ac cording to DIN EN 12021 Constituents Limits H20 concentration direct from compressor 25 mg m3 from a 200 bar cylinder 50 mg m3 from a 300 bar cylinder 35 mg m3 Oil concentration 0 5 mg m3 CO concentration lt 15 ppm CO concentration lt 500 ppm We recommend the breathing air controller Aerotest from the company Drager see accessories catalog availa ble over the customer service All breathing air control has to be recorded with date and values of the measures Instruction Manual PE 100 T In case of overstepping the prescriptive limits see chapter 4 5 Trouble shooting 3 3 3 Intake air quality 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
35. d 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 BAUER 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
36. e 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 CO2 contents in the compressed breathing air we recommend to flush the compressor unit 1 to 2 minutes prior to con necting the bottles i e to let the air escape into the sur roundings Scavenging procedure 1 Ensure that no bottle is connected to the compres sor BAUER 2 Open condensate drain tap 1 Fig 5 of interme diate separator on petrol units additionally the con densate drain tap 2 Fig 5 of final separator to unload the compressor during the starting phase 1 Fig 5 Condensate drain taps 3 Switch on the unit e PE 100 TE Shift switch 1 Fig 6 to position I e PE 100 TW Press switch 2 Fig 6 to position I e PE 100 TB Shift switch 1 Fig 7 to position Set choke 2 Fig 7 to position START Start engine with recoil starter As soon as motor runs smoothly return choke to normal operating position Fig 6 Motorschutzschalter Fig 7 Petrol engine BAUER 4 Assoon as final speed is reached close condensate drain tap 1 Fig 5 of intermediate separator on petrol units additionally the condensate drain tap 2 Fig 5 of final separator 5 Open filling valve Fig 8 wait until air escapes and flush the compressor unit 1 to 2 minutes i e let the ai
37. er molecular sieve mass mMS g 58 Ambient temperature tU C Bottle volume VF m3 Bottle size tr 7 10 12 Final separa tor tempera ture tAb C Air humidity saturated X g m3 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 at pressure p bar 200 1 4 2 2 4 processable air volume Va m3 at pressure p bar 200 300 134 106 201 160 101 81 151 121 76 62 114 92 59 48 88 72 45 37 68 56 35 29 53 44 28 23 42 35 Number of bottle fillings n acc to bottle size 10 Number of bottle fillings n processable air volume bottle volume Va VF Bottle volume VF m3 p bar x I 1000 l m3 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 m3 Filter cartridge lifetime tp h Va m3 Q m3 min x 60 min h 21 BAUER 4 4 5 FILLING VALVE To protect filling valve against contamination a sintered metal filter is screwed in the filling valve body Unscrew pressure gauge 3 Fig 22 from filling valve body 1 Screw off sintered metal filter 2 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 Replace if heavily soiled Screw in filter element Seal pressure gauge with PTFE tape or Loctite 243 and screw in tight
38. es and old parts Instruction Manual PE 100 T 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 an
39. 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 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 insufficient ventila tion the CO value in the surrounding air can increase quite fast because of the exhaling of CO2 CO values from 1 000 to 5 000 ppmv in workrooms are not unusual MAK value max workroom concentration is 5 000 ppmv Another 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 CO2 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 3 3 4 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 du
40. g 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 consumabl
41. h 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 The compressor is not resistant to salt water If not in use keep unit in a dry BAUER 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
42. hese regulations Instruction Manual PE 100 T 3 LOCATION OPERATION BOTTLE FILLING 3 1 LOCATION 3 1 1 Outdoor location The compressor unit is not seawater re sistant At operation in salty air spray compressor with anticorrosive protec tion see accessories catalog available over the customer service Electric driven units should be operated and stored below deck in dry atmosphere Units with petrol engine should also be stored below deck after the filling process Keep unit away from inflammable ARES items Do not smoke while petrol tank is open and while unit is in op eration 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 3 1 2 Indoor location Petrol driven units must not be op CARS 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 locati
43. ing 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 BAUER 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
44. ing 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 Instruction Manual PE 100 T 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 20 and 21 taking into consideration the ambient temperature and the cartridge used These tables contain calculated cartridge lifetime data that refer
45. 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 shut down devices soundproofing is pr
46. ises of technical requirements which the operator must take particular note of 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 invol
47. le 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 1 Nut 6 2 Spring washer 3 Plate 4 Pressure valve 5 O ring 6 Valve head 7 Intake valve 8 Valve head screw Fig 29 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 Fig 30 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 Instruction Manual PE 100 T 1 Torque stud 2 O ring 3 Pressure valve 4 Intake valve 5 Valve head 6 Valve head cover 7 Allen screw 8 Gasket Fig 30 Valve head 3rd stage Change intake and pressure valve of 3rd stage together only Remove of 3rd stage pressure valve 3 according to Fig 30 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 Fig 31 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
48. lve final pressure Pressure maintaining valve Oil dipstick Intake filter Filling valve with pressure gauge Handle O Mains plug with ON OFF switch and motor protection circuit breaker dep on country OO WwWN Fig 2 Compressor unit with electric motor three phase current 1 Drive engine 2 2 Filling valve with pressure gauge 3 Handle 4 Pressure maintaining valve 5 Filter system P11 6 7 8 w A Fanwheel cover Condensate drain tap intermediate separator Condensate drain tap final separator a Y Se 9 18 mS A i Fig 3 Compressor unit with petrol engine Instruction Manual PE 100 T AIR FLOW DIAGRAM See Fig 4 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 P11 13 Intermediate separator and filter system P11 are drained by means of condensate drain taps 14 and 15 respectively 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 pressure is indicated
49. m failure to follow these instructions Edition January 2010 2010 BAUER Kompressoren GmbH M nchen All rights reserved BAUER 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 Instruction Manual PE 100 T 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 E Training manager Phone no 089 78049 175 Fax no 089 78049 103 Explanation of the short operating instructions on the unit Operate unit only at ambient tem 45 C peratures between 5 and 45 C 115 F A Es 5 C 40 F chapter 3 Keep away from hot surfaces on motor and compressor chapter 2 Wear ear protectors when unit is running chapter 2 Position unit level max inclinatio
50. motor V belt pulleys as shown in Fig 33 edge must be parallel to the v belt 10mm y Fig 32 Checking V belt tension Fig 33 V belt pulley adjustment 25 BAUER KOMPRESSOREN 4 4 11 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 protection switch 2 Fig 34 The response value is preset The motor is switched on manually by pressing the O I switch to I For safety of the operating 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 1 Fig 34 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 lEz rent triggering the motor can be re started
51. n 5 chapter 3 Read instruction manual before operating unit chapter 3 Check oil level on compressor and petrol engine before operating unit IF chapter 4 4 1 Drain condensate at least every 15 minutes 3 locations chapter 4 4 3 and 4 4 4 Change satured filter cartridge IF Kapitel 4 4 4 Petrol driven units must not be op erated indoors chapter 3 Position units with petrol engine with exhaust in wind direction to prevent exhaust fumes being sucked in by the compressor chapter 3 Instruction Manual PE 100 T CONTENTS 1 GENERAL une en e 1 2 SAFETY MEASURES 5 3 LOCATION OPERATION BOTTLE FILLING 9 4 MAINTENANCE 0 0005 14 5 STORAGE PRESERVATION 28 6 REPAIR INSTRUCTIONS 29 7 TABIES votre cabr n q 30 8 ANNEX as ea 33 INDEX A Adhesive chart 31 Air flow diagram 3 Annex 33 C Cooling system 25 D Design 1 Drive system 24 E V belt tension meter 24 Electrical system 25 F Filling procedure 10 Filter system 16 l Intake filter 15 Intermediate separator 16 Intake air quality 10 L Location 9 Lubrication 14 Lubrication chart 31 M Maintenance 14 Maintenance instructions 14 Maintenance record 14 ANNEX Schematic diagram motor protection switch three phase current Lubricating oil list Applicable parts list BAUER
52. ng 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 See Installation manual available over the customer service WARNING BAUER 3 1 3 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 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 safety 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 tempera
53. ng used Piston rings worn out Filter cartridge saturated Unqualified filter cartridge being used High CO concentration in the atmo sphere combustion gas exhaust emis sion High CO concentration in the atmo sphere High CO concentration in the filter system Replace defective parts see chapter 4 4 9 Replace filter cartridge see chapter 4 4 2 Enhance cooling see chapter 4 4 12 Insert cartridge see chapter 4 4 4 Check replace O rings see chapter 4 4 4 Replace cartridge see chapter 4 4 4 Check location ambient temperature max 45 C 113 F Clean separator Replace pressure maintaining valve Replace cartridge see chapter 4 4 4 Replace oil with an approved brand see Lubricating oil list in annex Replace piston rings Replace cartridge see chapter 4 4 4 Replace cartridge with CO removal cartridge see 4 4 4 Change location see chapter 3 1 Connect a CO absorber e g Aero Guard see accessories catalog to the compressor Scavenge the filter system before filling see chapter 3 3 4 Instruction Manual PE 100 T 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
54. nstructions Replace see chapter 4 4 10 Top up oil Re tighten see chapter 4 4 10 Re adjust see chapter 4 4 10 Tighten and reseal Replace safety valve Replace cartridge see chapter 4 4 4 To vent unscrew until completely open see chapter 4 4 7 Clean or replace filter cartridge see chapter 4 4 2 Retighten couplings Replace piston and sleeve of 3rd stage Check replace inlet or pressure valve see chapter 4 4 9 Replace safety valve Check location ensure proper cooling air flow see chapter 3 1 Check location ambient temperature max 45 C 113 F see chapter 3 1 Correct direction of rotation Check valves clean replace if neces sary see chapter 4 4 9 Replace cartridge see chapter 4 4 4 Replace oil with an approved brand see Lubricating oil list in annex 27 BAUER Trouble High oil consumption Instruction Manual PE 100 T Piston rings Pistons or cylinders worn out Intake filter clogged Compressor too hot Air escaping through cartridge safety Cartridge missing bore Breathing air quality Water concentration too high Oil concentration too high CO concentration too high CO concentration too high 28 Cartridge installed but O rings defec tive Filter cartridge saturated Ambient temperature too high Intermediate and oder final separator dirty or clogged Pressure maintaining valve faulty Filter cartridge saturated Unqualified lubricant bei
55. ovided and in good working order At least once every day check the unit externally for damage and faults Inform the person responsible im Instruction Manual PE 100 T 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 guidin
56. r escape into the surroundings Fig 8 Scavenging 6 Close filling valve and start promptly the filling pro cedure See Filling the bottles 3 3 5 Filling the bottles Scavenge the compressor prior to connecting the bottle if the unit has been put out of service for more than several hours See 3 3 4 On models of 300 bar rated filling pres sure do not attach bottles unless rated for this pressure note pressure stamped on tank neck gt 1 Connect air bottle to filling valve See Fig 9 Instruction Manual PE 100 T Fig 9 Connecting air bottle The international connector Fig 10 is not permitted in the Federal Republic of Germany In other countries it is allowed only for pressures up to 200 bar 2 850 psi Fig 10 International filling connector 2 Open filling valve first then bottle valve See Fig 11 Fig 11 Filling air bottle 3 Ensure that condensate drain tap 1 Fig 12 of in termediate separator is open On petrol units open additionally the condensate drain tap 2 Fig 12 of final separator Instruction Manual PE 100 T 1 Fig 12 Condensate drain taps 4 Switch on the unit e PE 100 TE Shift switch 1 Fig 13 to position e PE 100 TW Press switch 2 Fig 13 to position I e PE 100 TB Shift switch 1 Fig 14 to position I Set choke 2 Fig 14 to position START Start engine with recoil starter As soon as
57. r 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 CHANGING THE VALVES OF THE 1ST STAGE Intake and pressure valves of the 1st stage are combined in one plate valve under the valve head see Fig 28 Valve head Gasket Plate valve O ring Valve head screw Washer Nut 28 Valve head 1st stage NOU bh uN Fi O Loosen two cap nuts from tube connectors at valve head and safety valve connector and remove inter cooler 24 Instruction Manual PE 100 T 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 Fig 29 Remove two captive nuts 1 and spring washers 2 Remove plate 3 Remove valves 4 and 7 using two screw drivers as shown in Fig 31 Assemb
58. seal shaft Screws bolts threads 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 Kl ber SK 01 205 WEICON ANTI SEIZE AS 040 P part no N19753 or equivalent compound with copper or MoS additives For compressor lubricating oils refer to oil list in chapter 8 ADHESIVE AND SEALANT CHART Usage Adhesives and Sealants Screws Seals for conical threads Metal metal seals High temperature connections e g valve heads cylin ders Paper gaskets Loctite 2701 Loctite 243 Temperature resistant compound e g WACKER E10 part no N18247 Loctite FAG 2 TESTING AGENTS Usage Testing agents Tube connectors tubes Leakage test spray part no FM0089 32 BAUER KOMPRESSOREN Instruction Manual PE 100 T 8 ANNEX e Schematic diagram Lubricating oil list Parts list BAUER 35 BAUER BAUER Instruction Manual PE 100 T KOMPRESSOREN Schematic diagram motor protection switch three phase current 3 Hauptsicherung bauseits Main fuse by customer Fusible principal cot client A L1 B Ein Aus C On Off Marche 1 D F r diese techn Unterlage wird zul Abw Oberfl che Masstab 1 1 Masse jeglicher gesetzlich vorgesehene DIN ISO Rechtsschutz nach DIN 34 in 30 2168 RECIENTE Anspruch genommen m
59. 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 4 3 MAINTENANCE SCHEDULE The maintenance schedule is contained in the service man ual delivered with every compressor unit 4 4 MAINTENANCE WORK This chapter contains the maintenance work as well as a short functional description for each component BAUER 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 gt partment The current oil list is provided in the annex chapter 8 Order this list regularly through the BAUER Technical Servi
60. tures approx 20 C is 25 me tres 3 2 OPERATION 3 2 1 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 and nitrox gas mixtures EXPLOSION occurs if an oil lubricated com pressor 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 When using a mineral oil change oil after one year BAUER Fit filter cartridge Refer to chapter 4 4 4 Fig 21 Without cartridge no pressure can be built up Prior to first operation or operation subsequent to re pair work operate unit for at least 1 minute 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 the service manual Every time the unit
61. ve 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 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 BAUER 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
62. y replace cartridge or O rings Venting bore A FRR RCR IR RR ISR MS IAN No cartridge Fig 20 Safety bore Filter cartridge installation On filter system P11 the cartridge is fitted to the filter head from below 1 Fig 21 The two o rings at the cartridge neck ensure pressure tightness of the venting hole The lower o ring at the filter head ensures pressure tightness of the filter housing Screw in filter head hand tight only The upper o ring should just touch the housing because it is not used for pressure tightness So do not exert force avoid squeezing the o ring 2 Fig 21 Max 1 Nm Fig 21 Cartridge installation Instruction Manual PE 100 T 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 The max number of load cycles for the P11 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

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