Operator’s Manual
High Pressure Breathing Air Compre ssors
Operator’s Manual
INTRODUCTION
This manual contains general information and instructions to operate
and maintain high pressure breathing air compressor units.
Before taking the compressor intooperation it is essentialto study the
instruction manual of that compressor.
All instructions should be observed and carried out in the order laid
down to prevent damage and premature wear to the equipment and
the units served by it.
While every effort is made to ensure the accuracy of the particulars
contained in this manual, the manufacturing company will not, under
any circumstances, be held liable for any inaccuracies or the consequences thereof.
WARNING
The breathing airproduced with thishigh pressure compressor issubject to strict quality standards.Ignoringtheoperatingand maintenance
instructions can lead to severe injury or in serious cases even death.
We reserve the right to make changes to the technology of our compressors as well as to this accompanying documentation in accordance to technical progress.
Edition January 2005
© 2005 BAUER Kompressoren GmbH, Munich
All rights reserved.
i
Operator’s Manual
TABLE OF CONTENTS
1. GENERAL 1...................................................................................
1.1. PURPOSE AND SHORT DESCRIPTION 1.........................................................
1.2. THEORETICAL PRINCIPLES 2...................................................................
1.3. DESIGN AND MODE OF OPERATION 4...........................................................
2. SAFETY REGULATIONS 8......................................................................
2.1. GENERAL 8...................................................................................
2.2. NOTES AND WARNING SIGNS 9.................................................................
2.3. IDENTIFYING THE SAFETY NOTICES 9...........................................................
2.4. FUNDAMENTAL SAFETY NOTICES 9.............................................................
2.5. SAFETY REGULATIONS (EC; partly Germany, only) 12................................................
3. INSTALLATION, OPERATION 13..................................................................
3.1. INSTALLATION OF THE COMPRESSOR UNIT 13....................................................
3.2. COMPRESSOR ROOM CONDITIONS: 14...........................................................
3.3. NA TURAL VENTILATION 16.......................................................................
3.4. ARTIFICIAL VENTILATION 19.....................................................................
3.5. ELECTRICAL INSTALLATION 22...................................................................
3.6. TAKING INTO OPERATION 23.....................................................................
3.7. FILLING PROCEDURE 25........................................................................
3.8. SHUT--DOWN PROCEDURE 28...................................................................
4. MAINTENANCE 29..............................................................................
4.1. MAINTENANCE RECORD 29......................................................................
4.2. MAINTENANCE INTERVALS 29...................................................................
5. MAINTENANCE SCHEDULE 30...................................................................
5.1. MAINTENANCE INTERVALS 30...................................................................
5.2. MAINTENANCE RECORD 31......................................................................
6. STORAGE, PRESERVATION 32...................................................................
6.1. GENERAL 32...................................................................................
6.2. PREPARATION 32...............................................................................
6.3. PRESERVING THE COMPRESSOR 32.............................................................
6.4. PRESERVING THE MOTOR/ENGINE 32............................................................
6.5. PREVENTIVE MAINTENANCE DURING STORAGE 32...............................................
6.6. REACTIVATING THE COMPRESSOR UNIT 33......................................................
7. REPAIR INSTRUCTIONS 34......................................................................
7.1. GENERAL 34...................................................................................
8. TROUBLE--SHOOTING 35........................................................................
9. FILTER SYSTEM P21 37..........................................................................
9.
1. DESCRIPTION 37...............................................................................
9.2. CARTRIDGE SAFETY BORE 38...................................................................
9.3. LIFETIME 38....................................................................................
9.4. GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE 39..........................................
9.5. CONDENSATE DRAINAGE 39.....................................................................
ii
Operator’s Manual
9.6. FILTER CARTRIDGES 39.........................................................................
9.7. FILTER SERVICE LIFETIME 39....................................................................
9.8. CARTRIDGE CHANGE 40........................................................................
iii
Operator’s Manual
TABLE OF CONTENTS
9.9. FILLING VALVE MAINTENANCE 40................................................................
9.10. REPLACEMENT INTERVALS 41...................................................................
9.11. CONDENSATE DRAINAGE 41.....................................................................
9.12. CARTRIDGE CHANGE 41........................................................................
10. FILTER SYSTEM P41 AND P61 42.................................................................
10.1. APPLICATION AND SUMMARY DESCRIPTION 42...................................................
10.2. FUNCTION 43...................................................................................
10.3. FILTER MAINTENANCE 48.......................................................................
10.4. TECHNICAL DATA 51............................................................................
11. LUBRICATING OIL LIST 52.......................................................................
11.1. GENERAL 52...................................................................................
11.2. TYPE OF OIL 53.................................................................................
11.3. O IL CHANGE 53.................................................................................
12. TRANSPORTING COMPRESSED AIR CYLINDERS 54...............................................
13. FURTHER FILLING POSSIBILITIES 55.............................................................
13.1. OVERFLOW 55..................................................................................
13.2. FILLING FROM STORAGE CYLINDERS 55.........................................................
iv
Operator’s Manual
TABLE OF FIGURES
Fig. 1 Pressure-- and temperature increase 2.............................................................
Fig. 2 P--V Diagram 3.................................................................................
Fig. 3 Saving of work 3................................................................................
Fig. 4 Air flow diagram Purus, Utilus 10 and Junior 5.......................................................
Fig. 5 Air flow diagram Utilus, Capitano und Mariner 6......................................................
Fig. 6 Air flow diagram K14, K15, K150, K180 7..........................................................
Fig. 7 Locating air intake hose 13........................................................................
Fig. 8 Room temperature 14.............................................................................
Fig. 9 Locating the unit 15...............................................................................
Fig. 10 Cooling air flow 15................................................................................
Fig. 11 Installation of the compressor unit (natural ventilation) 16...............................................
Tab. 1 Air intake and outlet openings 17...................................................................
Fig. 12 Installation with natural ventilation, example 1 17......................................................
Fig. 13 Installation with natural ventilation, example 2 18......................................................
Fig. 14 Installation with natural ventilation, example 3 18......................................................
Fig. 15 Installation of the compressor unit (artificial ventilation) 20...............................................
Fig. 16 Installation with artificial ventilation, example 1 21......................................................
Fig. 17 Installation with artificial ventilation, example 2 21......................................................
Fig. 18 Solenoid valve plug 23............................................................................
Fig. 19 Connecting air bottle 26...........................................................................
Fig. 20 International filling connector 26....................................................................
Fig. 21 Connecting air bottle 26...........................................................................
Fig. 22 Opening of filling valve 27.........................................................................
Fig. 23 Opening of filling valve 27.........................................................................
Fig. 24 Removing air bottle 27............................................................................
Fig. 25 Removing air bottle 27............................................................................
Fig. 26 Filter system P21 37..............................................................................
Fig. 27 Safety bore 38...................................................................................
Fig. 28 Filter system P41 left, P61 right with SECURUS--monitoring unit 42......................................
Fig. 29 Oil and water separator 44.........................................................................
Fig. 30 Construction of the filter cartridges 45...............................................................
Fig. 31 Air flow diagram 47...............................................................................
Fig. 32 Cartridge change 49..............................................................................
Fig. 33 Danger label no.2 54..............................................................................
Fig. 34 Automatic switching device 56......................................................................
Fig. 35 Flow chart 56....................................................................................
Fig. 36 Filling from storage cylinders (overflow) 57
ig. 37 Filling with the compressor 57......................................................................
F
Fig. 38 Filling storage cylinders 57.........................................................................
...........................................................
v
Operator’s Manual
ANNEX
Important notices for the TÜV (supervising authorities) inspections of filling stations (German
Pressure Vessels Regulations)
vi
Operator’s Manual
1. GENERAL
1.1. PURPOSE AND SHORT DESCRIPTION
High pressure compressor units are complete units for filling air tanks in the high pressure ranges PN 200 and PN 300 bar. The compressors are mainly used to compress air for breathing as required in diving and fire fighting applications, for instance.
The heart of this unit is formed by a three-- or four stage, air--cooled high pressure compressor block.
The Purus, Utilus 10 and Junior range compressor units are splash--lubricated.
From the Utilus, Capitano and Mariner rangecompressor units onwards, the last stages are lubricated by means of theforced--feed
lubrication system, the other cylinders are splash--lubricated.
All units are equipped witha breathing air -- processing system(P--filter system), that surpassesthe quality requirements of DIN3188.
1
1.2. THEORETICAL PRINCIPLES
Operator’s Manual
Fig. 1 Pressure-- and temperature increase
When the piston movesinto the cylinder,the pressure rises in thecylinder. Atthe same timehowever,the temperatureof the enclosed
gas also rises. This is a basic physical law (Gay--Lussac).
Since with increasing pressure, the occuring temperatures would soon reach inadmissibly high values, the compression has to be
divided into various stages. After every stage the gas is cooled back to approx. 10 -- 15 °C above ambient temperature. This is the
main reason for designing compressors with 3 or 4 stages.
2
Operator’s Manual
By dividing the compression work into various stages it results in a lower power requirment. This is visible in the p-- v diagram.
Fig. 2 shows the power requirement with a theoretical 1 stage compression to 200 bar.
Fig. 3 shows the power requirement witha3stagecompressionandthesavedwork.
200 bar
1 bar
Fig. 2 P--V Diagram
P
200 bar
P
3. Stage
Ideal theoretical
isothermal compression
actual polytropic
compression
V
saving of work
P
200 bar
2. Stage
1. Stage
1 bar
V
Fig. 3 Saving of work
By dividing the compression work it not only saves energy, but it also increases the operating safety due to a lower thermical load.
1 bar
V
3
1.3. DESIGN AND MODE OF OPERATION
1.3.1. Design
The compressor unit comprises the following major assemblies:
• compressor block
• drive motor
• filter set
• base and frame assembly with instrument/filling panel
• electric control system
• electronic monitoring system
• automatic condensate drain
1.3.2. Mode of operation; air flow diagram
The path of the air through the compressor system is shown in the following air flow diagrams.
a)
a)
a)
Operator’s Manual
a) optional extra according to order
4
Operator’s Manual
1.3.3. Air flow diagram 3--stage
Fig. 4 Air flow diagram Purus, Utilus 10 and Junior
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 Intermediate separator 2nd/3rd stage
9 After-- cooler
10 Safety valve 1st stage
11 Safety valve 2nd stage
12 Final pressure safety valve
13 Central filter assembly
14 TRIPLEX longlife cartridge
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 devicea)
a) optional extra
a)
5
Operator’s Manual
Fig. 5 Air flow diagram Utilus, Capitano und Mariner
1 Intake filter
2 Cylinder 1st stage
3 Cylinder 2nd stage
4 Cylinder 3rd stage
5 Inter-- cooler 1st/2nd stage
6 Inter-- cooler 2nd/3rd stage
7 After-- cooler
8 Safety valve 1st stage
9 Safety valve 2nd stage
10 Final pressure safety valve
11 Intermediate separator 2nd/3rd stage
12 Central filter assembly
13 TRIPLEX longlife cartridge
14 Condensate drain valve
15 Pressure maintainig valve
16 Filling hose
17 Filling valve
18 Final pressure gauge
19 Change-- over device
20 Safety valve, final pressure PN 200
a
) optional extra
a
)
a)
6
Operator’s Manual
1.3.4. Air flow diagram 4--stage
Fig. 6 Air flow diagram K14, K15, K150, K180
1 Intake filter
2 Inter-- cooler 1st/2nd stage
3 Inter-- cooler 2nd/3rd stage
4 Inter-- cooler 3rd/4th stage
5 After-- cooler
6 Intermediate separator 2nd/3rd stage
7 Intermediate separator 3rd/4th stage
8 Oil and water separator
9 Purifier
10 Pressure maitaining valve
11 Non--return valve
12 Filling valve
13 Condensate drain valve (manual)
14 Safety valve, intermediate pressure 2nd stage
15 Safety valve, intermediate pressure 3rd stage
16 Safety valve, intermediate pressure 4th stage
17 Safety valve, final pressure
18 Pressure gauge, final pressure
19 Venting valve with pressure gauge
An additional intermediate separator,1./2. stage is available for operation at high temperatures (e.g.: installation in subtropical countries) and high humidity.
The order number can be obtained through our technical customer service, Tel. 089 --78049 175
7
NOTES
Operator’s Manual
8
Operator’s Manual
2. SAFETY REGULATIONS
2.1. GENERAL
WARNING
Never open filling or shut--off valves when under pressure and not connected as highly compressed emerging
air can cause serious accidents.
WARNING
Ensure intake air is free from noxious gas, exhaust fumes and solvent vapour. Use an intake hose and ensure
that it is mounted in such a way as to avoid taking in any noxious substances.
WARNING
Filling hoses must be in satisfactory condition and threads undamaged. Pay particular attention to damage on
the interface from hose fitting to hose. If the rubber is scored, hose must be discarded otherwise water can enter
and attack wire gauze causing it to rust and thus endangering pressure tightness.
CAUTION
Always shut down and decompress the complete system prior to carrying out any work on the compressor.
Working on compressor units requires the necessary expert knowledge!
CAUTION
Check the complete system for leakage from time to time by brushing all fittings and couplings with soapy water
or spraying with leak test spray. Repair any leakage.
CAUTION
Always disconnect the system from mains supply prior to carrying out any work on compressor systems with
electric drive motor.
CAUTION
Never repair pressure lines by soldering or welding.
CAUTION
Do not use any toxic substances like gasoline or acetone or similar to clean the compressor unit or any of its
parts.
9
Operator’s Manual
2.2. NOTES AND WARNING SIGNS
Notes and warning signs displayed on compressors according
to model, application or equipment.
WARNING
Hot surfaces, do not touch!
Danger of burning by touching cylinders, cylinder heads and pressure lines of individual
compressor stages.
WARNING
High voltage!
Life threatening danger of electric shock.
Maintenancework on electric units or operating equipment may only be carried out by a
qualifiedelectrician or by a person instructed
and supervised by a qualified electrician according to electrical regulations.
WARNING
Automatic compressor control, unit may
start--up without warning
Before carrying out maintenance and repair
work, s witch off at the main switch or disconnect from the mains and ensure unit will not
restart.
!
MANDAT ORY
Instructions must be readby personsoperating the machinery
The instruction manual supplied and all other
applicable instructions,regulations etc. must
be read and understood by operating personnel before using the machine.
!
WARNING
This notice is used with maintenance
work and operatingprocedures and must
be adhered to exactly in order to avoid
endangering personnel.
This notice must be complied with in
order to avoid damageto or destructionof
the machine or its equipment.
NOTICE
2.4. FUNDAMENTAL SAFETY NOTICES
Authorized use
• The machine / unit is built according to state of the art technology and established safety technical regulations. Nevertheless,its use can cause danger tolifeand limb of theoperator or third parties or damage to the machine and other
equipment.
• Operate the machine / unit only in technically perfectcondition in accordance with regulations and safety and danger
notices detailed in the instruction manual! In particular, immediately correct faults (or have them corrected) which can
impair safety!
• The machine / unit is exclusively for the compression ofmediums (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. Authorizationfor use is also under the condition
that the instruction manual is complied with and inspection
and maintenance requirements are enforced.
Organizational measures
MANDAT ORY
Hearing protectors must be worn!
Hearing protectors must beworn when working on a machine which is running.
NOTE
Ensure correct direction of rotation!
When switching on the machine, check the
arrowto ensure correct direction of rotationof
the drive motor.
2.3. 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.
• 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 comply
with universally valid legal and other obligatory regulations
regarding accident prevention and environment protection.
This can involve, for example, contact with hazardous substances or the provision / wearing of personal protective
equipment.
• In addition to theinstruction manual, provide supplementary
instructions for supervision and monitoring duties taking
into consideration exceptional factors e.g. with regard to organization of work, production, personnel employed.
• Personnel engaged to operate the machine must have read
the instruction manual before beginning work, especially
the safety notices chapter. When work is already underway
it is too late. This is particularly relevant for temporary personnel, e.g. maintenance personnel.
• At the very least, supervise temporary personnel’s work in
accordance with the instruction manual, taking intoaccount
safety and danger factors.
• Personnel may not wear long hair loose, loose clothing or
jewellery, including rings. There is a danger of injury
10
Operator’s Manual
through, for example, these getting caught or being pulled
into the equipment.
• As far as necessary or according to regulations, use personal protective equipment.
• Observe all safety anddanger notices on the machine / unit.
• Keep all safety and danger notices on the machine / unit
complete and in readable condition.
• If there are any modifications to the machine / unit or operating conditions which may affect safety, stop the machine /
unit immediately and inform the department / person responsible of the fault.
• No modifications may be made to the machine / unit which
could impair safety without first obtaining permission from
the suppliers. This is also thecase withregard to installation
and adjustment of safety devices and valves as well as
welding of piping and reservoirs.
• Spare parts must always comply with the technical requirements specified by the manufacturer. This is always guaranteed with original spare parts.
• Do not carry out programme changes (software) to the programmable control system.
• Piping must be thoroughly checked (pressure and visual inspection) by the operator at appropriate time intervals, 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.
• It is absolutely essential that the workplace is appropriately
equipped for maintenance measures.
• Make sure location and operation of fire extinguishers is
known.
• Pay attention to fire warning and fire fighting procedures.
Qualifications, fundamental duties
• Work on / with the machine / unit may only be c arried out by
reliable personnel. Observe the legal minimum age permissible.
• Only employ trained personnel, clearly establish responsibility of personnel for operation, maintenance and repairwork.
• Ensure that only trained personnel work with the machine.
• Establish the responsibilities of the machine operator and
establish a procedure for him to inform a third person of unfavourable safety conditions.
• People who are being trained or introduced to the job should
only be allowed to work with the machine / unit under constant supervision of an experienced person.
• Work on the electrical equipment of the machine / unit may
only be carried out by a qualified electrician or by an instructed person under the direction and supervision of a
qualified electrician according to electrotechnical regulations.
• Work on gas equipmentmay only be carried out by qualified
personnel.
Safety notices for operation
• Do not carry out any work if safety is questionable.
• Meet all requirements demanding that the machine / 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 machine / unit externally
for damage and faults. Inform the department / person responsible immediately if anything is not as is should be (including operation). If necessary, shut the machine down immediately and make it safe.
• If there are any malfunctions, shut the machine / unit down
immediately and make it safe. Correct faults immediately (or
have them corrected).
• Observe switching on and off processes and monitoring indications according to the instruction manual.
• Before switching on / starting up the machine / unit, ensure
that no one can be put at risk through running the machine
/ unit.
• Carry out the setting, maintenance and inspection processes at the intervals specified in the instruction manual,
including replacement of parts / equipment. This work may
only be carried out by qualified personnel.
• Bef
ore carrying out any exceptional work or repairwork,op-
erating personnel should be informed. Call the supervisor.
• For all work concerning operation, change in production,
conversion or regulating of the machine / unit and its safety
measures such as inspection, maintenance and repairwork, observe the switching on and off processes in the instruction manual and the notices for maintenance work.
• Clear and make the maintenance area safe as far as
necessary.
• If the machine / unit is completely switched off for maintenance and repairwork, ensure that it is protected from unexpected start-- up. Turn off main control device and remove
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 device
so that there is no risk of danger. Use only s uitable 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 operator.
• 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 fromthe machine, in particular 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 system do
not come into contact with hot cleaning fluid, in order to
avoid triggering the sprinkler system.
11
Operator’s Manual
• Completely remove all covers / seals after cleaning.
• After cleaning, check all pressure lines for leaks, loose con-
nections, wear and damage. Immediately eliminate any
faults.
• Always retighten any screw connections loosened formaintenance or repairwork.
• If it is necessary to remove safety devices for maintenance
and repairwork, these must be replaced and checked immediately after completion of the maintenance or repairwork.
• Ensure safe and environmentally friendly disposal of consumables and old parts.
Particular areas of danger
• Use only original fuses with specified current rating. If there
is a failure in the electric energy supply, shut the machine /
unit down immediately.
• Work on electric units or operating equipment may only be
carriedout by a qualifiedelectrician or by a personunder the
instruction and supervision of a qualified electrician according to electric technical regulations.
• Machines and unit parts which must undergo inspection,
maintenance and repairwork, must be disconnected from
the mains supply, if specified. Parts which have been disconnected must first be checked for voltage, then earthed
and short--circuited and isolated from live neighbouring
parts.
• The electrical equipment of a machine / 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 second
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 carry out welding, burning and grinding work on the
machine / unit when specifically approved. There can, for
example, be a risk of fire or explosion.
• Before carrying out welding, burning or grinding work, clean
the machine / unit and surrounding area fromdust and flammable material and ensure there is adequate ventilation
(danger of explosion!).
• When working in smallrooms, observe any national regulations.
• Only personnel with particular knowledge and experience
with pneumatics may carry out work on pneumatic equipment.
• Check all pressure lines,hoses and screw connections regularly for leaks and visible damage. Immediately repair any
damage. Escaping air or gas under pressure can cause injury and fire.
• Depressurize system and pressure lines before commencing repairwork.
• Pressurized air lines must be laid and mounted by qualified
personnel. Connections must not be mixed up. Fittings,
length and quality of the piping must correspond to requirements.
• Soundproofing equipment on the machine / unit must be in
place and functional during operation.
• The stipulated hearing protectors must be worn.
• With regard to oil, grease and other chemical substances,
observe the relevant safety regulations for the product.
• For loading,only use lifting device and equipment with sufficient lifting power and strength.
• Appoint trained guide personnel for lifting operations.
• Machines may only be lifted with a lifting device and by
trainedpersonnelaccording to instructions in theinstruction
manual (fixing points for fixing equipment etc.).
• Use only suitable transporters with sufficient carrying
power.
Secure the load properly. Use suitable fixing points.
• If necessary, provide machine / unit with transportation
brackets. Display the appropriate notice. Remove transportation brackets in the correct manner before taking into
operation.
• Parts which need to be dismantled for transport purposes
must be carefully replaced and secured before taking into
operation.
• Even when moving the machine / unit only slightly, the machine / unit must be disconnected from all external energy
sources. Before putting into use again, reconnect the machi
ne to the mains according to regulations.
• When taking back into operation, proceed according to the
instruction manual.
Notices of danger regarding pressure vessels
• Never open or loosen pressure vessel lids or pipe connection 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 completely.
Individualparts that are subject to pressureloads cannot be
purchased as spare parts, since the vessels are tested as
a complete part and the documentation 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
These pressure vessels are permanently under virtually
constant operating pressure; the fluctuations of pressure
are very small.
Vessels for this type of load are not marked in a particular
way and may be used as long as the vessel inspections,
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:
load:
12
Operator’s Manual
These pressure vessels may also be used under conditions
of changing operating pressure. The pressure may vary between the atmospheric and the maximum admissible operating pressure.
The pressure vessel documentation and the appropriate
notes in the operating manual particularly characterise vessels of this type as being adequate fordynamic loads. In the
technical information for these vessels you will find specifications concerning their permissible operating period.
Due to thevariationofthe operatingpressure,thesevessels
are subject to a so-- called dynamicload, which puts the vessels under great stress. The change between two different
pressures is called a load change or cycle. In the technical
information for these vessels you will find specifications
concerning the permissible number of cycles depending on
the fluctuation of the operating pressure.
Having reached half the permissible number of cycles, the
vessel has to be submitted to an internal check, in which the
critically stressed areas of the vessels are examined by
means of suitable testing methods, in order to ensure the
operating safety.
After having reached the total permissible number of load
cycles, the vessel must be exchanged and scrapped.
Record the number of load cycles in writing if you do not
have an automatic cycle--counter.
We recommend that aluminium vessels should be exchanged after 15 years at the latest.
Please pay attention to and follow these measures, for your
own safety and that of you employees and customers!
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 maintaining valves,
which should reduce big pressure fluctuations as well,
should be checked regularly for internal and external tightness and functionality.
• Check the pressure vessels regularly on the inside and outside for damage from corrosion.
• Be particularly careful with second--hand pressure vessels,
when their previous operating mode is not specifically clarified.
2.5. 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, especially
when these cylinders are made available for third parties. The
start--up and operation of compressorsystems foruse as filling
stations is governed by the following regulations:
a-- Pressure vessel directive (Directive 97/23/EC) of
29.05.1997
b-- Operating safety regulations (BetrSichV) of 27.09.2002
c-- Machine safety law (GSG) as of 11.05.2001
d-- 14th regulation to machine safety law (14. GSGV -- pressure vessel regulation) of 03.10.2002
e-- 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 following regulations apply:
f-- Accident Prevention Regulations (UVV):
• UVV compressors (VBG 16).
Copies of the above regulations are available through the usual
outlets, e.g. in Germany from:
Carl Heymanns Verlag
Luxemburger Str. 449
50939 Köln
Beuth-- Vertrieb GmbH
Burggrafenstr. 4 -- 7
10787 Berlin
The manufacturer has complied with all applicable regulations
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 Department 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 fora third party then the appropriate permission must be obtained from the responsibleauthority
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 testcertificates and documents delivered with the
compressor are important and may be requested during the
procedure for obtaining permission. In addition, the documents
belonging to theunit are important for recurrent inspections and
should therefore be carefully kept.
Inspections in accordance with the regulations for prevention of
accidents will be carried out by the manufacturerorby 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.
13
Operator’s Manual
3. INSTALLATION, OPERATION
3.1. INSTALLATION OF THE COMPRESSOR UNIT
The compressor frame is equipped with anti--vibration mounts and thus a machine base orspecial means ofsecuring thecompressor
are not necessary.
3.1.1. Outdoor location
For installation observe the following:
-- The floor must be capable of taking the load of the system weight.
-- Locate the unit level.
-- On units employing petrol or diesel engine it is mostimportantthat only cleanair be used. Position compressor in direction ofwind
so that exhaust fumes are blown away from the unit. It is good practice to have intake hose of at least 3 m length with pre--filter
and intake filter.Pre-- filterto be located 2 m above ground. See Fig. 7. This arrangement will ensure necessary spacing between
exhaust outlet and air inlet.
-- Turn unit as soon as wind direction changes.
-- On petrol or diesel engines, operation unit must only be located outdoors, never indoors, not even in partially closed rooms however large they may be.
-- Take care that no vehicles with running engines are in direct vicinity.
-- Do notoperate unit in thevicinity ofopen fire (flue gas!). Even cigarette smoke can pollute the breathing air filled in the pressurized
cylinders!
WIND
Fig. 7 Locating air intake hose
EXHAUST
14
Operator’s Manual
3.1.2. Indoor location
WARNING
Petrol and Diesel driven units must not be operated indoors!
-- Ensure adequate ventilation.
-- Here too, air must be free from exhaust fumes and hazardous vapours e.g. smoke, solvent vapours, etc.
-- If possible install unit in such a manner that the compressor fan can get fresh air from outside, for instance through an opening
in the wall.
-- Ensure that an adequate exhaust air opening is provided .
3
-- When locating the compressorin rooms of less than 30m
must be taken to provide artificial ventilation.
This also applies when other systems having high radiation are operating in the same room.
3.2. COMPRESSOR ROOM CONDITIONS:
(39.2 cu yd) space where natural ventilation is not ensured, measures
-- The compressor room must be clean, dust--free, dry and as
cool as possible.
-- Avoid direct exposure to sunlight; if possible, choose north
side of building.
-- Additional heat producing units or line systems should not
be installed in the same room or should be well isolated.
-- The floor must be capable of taking the load of the system
weight.
-- Locate the unit level; refer to technical data for max. allowable inclination.
-- Ensure adequate ventilation. Remember: room temperature = cooling air temperature ! Min. = +5 °C, max. = +45 °C.
Fig. 8.
Fig. 8 Room temperature
15
3.2.1. Locating the unit
-- If possible install unit in such a manner that the compressor
fan can draw fresh air from outside, for instance through an
opening in the wall as low as possible.
-- Ensure that an adequate exhaust air opening is provided,
as high as possible.
-- Locate compressor as close to the air intake opening as
possible. (Minimum distance approx. 50 cm)
-- Locate unit so as to absolutely avoid intake of warm or hot
cooling air.
-- Observe the minimum distances as listed in the table overleaf (Fig. 11).
Operator’s Manual
3.2.2. Cooling air duct installation
On all Verticus 5 units the cooling air outlet can be installed as
standard in two different ways. By simply removingthe air outlet
cover and grid and mounting them in the desired position, the
air outlet can either be on top or on the back of the unit (Fig. 10).
If the outlet on the top is selected, the unit can be positioned
close to a wall, provided a correct airintake according to the following paragraphs is ensured.
3.2.3. Air baffle control (Option)
See drawing 073733 in section F, if applicable. The air circulating baffles ensure optimal temperature in the compressor room
or at least that the temperature stays within the permissible
range of +5 to +45°C when the outside temperature is low.
The recommendedcontrollerthermostatsetting is +15 to 18°C.
Adjustment takes place at 4°C above or below the set value.
A temperature sensor in thecooling air intake channel transmits
to the control unit the temperature of the air taken in. This activates the actuator of the air circulating baffles. According to requirements, one of the two baffles in the cooling air exhaust
channel is opened. One guides the warm cooling air to the outside, the other recirculates the warm cooling air back into the
room. The procedure is continuous and therefore the amount
of warm air being recirculated is continually being adjusted as
necessary.
The cooling air exhaust channel with baffle unit can be connected to the top or the rear of the VERTICUS 5 unit.
Fig. 9 Locating the unit
Front
side
Fig. 10 Cooling air flow
Cooling air outlet
standard
optional
Cooling air inlet
NOTE
For further information on the installation of air
cooled compressors, see our Installation Manual
which can be obtained from BAUER Customer Services, P.O. 710260, D--81452 Munich
16
Operator’s Manual
3.3. NATURAL VENTILATION
Natural ventilation is the most simple and commonly used. It is created by convection and is sufficient if no thermal overload is expected, i.e. for units with small drive motors, for intermittent operation or in moderate climates this is the ideal method of cooling the
compressor unit.
Fig. 11 Installation of the c ompressor unit (natural ventilation)
A Minimum distance from wall, intake side: 0.5 m (may be ignoredif locating the unit in front of an opening).
B Minimum distance from wall, exhaust side: 2 m (may be ignored if locating the unit in front of an opening)
C Intake opening: refer to tab. 1
D Exhaust opening: refer to tab.1
The inlet and outlet air openings are dependent on:
-- the power of the electric motor
-- the height difference between air intake and outlet openings
-- the air volume of the compressor room.
The following table shows some significant values. If the indicated values cannot be obtained, artificial ventilation will be necessary,
seeFig.15toFig.16.
17
Operator’s Manual
Power
(kW)
V=50m
3
Room volume / Height difference
Δh=2m
Intake Outlet Intake Outlet Intake Outlet
2.2 0.12 m
3 0.24 m
4 0.30 m
5.5 0.42 m
7.5 0.90 m
11 1.38 m
15 1.92 m
2
2
2
2
2
2
2
0.10 m
0.20 m
0.25 m
0.35 m
0.75 m
1.15 m
1.60 m
2
2
2
2
2
2
2
-- -- -- -- -- -- -- --
0.12 m
0.12 m
0.24 m
0.60 m
0.90 m
1.45 m
Tab. 1 Air intake and outlet openings
Fig. 12 to Fig. 14 show installation examples with natural ventilation:
V = 100 m
Δh=3m
2
2
2
2
2
2
3
0.10 m
0.10 m
0.20 m
0.50 m
0.75 m
1.20 m
V = 200 m
3
Δh=4m
2
2
2
2
2
2
-- -- -- --
-- -- -- --
2
0.12 m
2
0.24 m
2
0.54 m
2
0.90 m
0.10 m
0.20 m
0.45 m
0.75 m
2
2
2
2
Correct: Air intake low, cooling air flows though
unit
Fig. 12 Installation with natural ventilation, example 1
18
Incorrect: Air intake high, cooling air does not
reach unit
Operator’s Manual
Correct: Air outlet duct upward
Fig. 13 Installation with natural ventilation, example 2
Incorrect: Warm air is not taken away, but circulates and will be taken in again
Correct: Cooling air led directly to unit
Fig. 14 Installation with natural ventilation, example 3
Incorrect: Cooling air does not reach intake opening,
intake air duct too short
19
Operator’s Manual
3.4. ARTIFICIAL VENTILATION
For drive powers above 15 kW natural ventilation is not sufficient. Under certain circumstances this can also apply for smaller power
ratings, e.g.:
-- when locating the compressor in small rooms,
-- if ventilation openings cannot be large enough,
-- when other systems with high heat radiation are operating in the same room or
-- when two or more compressors are operating in the same room.
The principle is: forced ventilation is obligatory if room temperature exceeds the allowed ambient temperature
(45° C)
Cooling air flow
The necessary cooling air flow is calculated to an appoximate value by using the following formula:
3
Required minimum cooling air volume [m
For calculation of the cooling air duct cross section the following formula can be used:
Cooling air duct [m
2
] = cooling air volume [m3/h]
cooling air flow [m/s] x 3600 [s/h]
/h] = 360 x drive power [kW]
The recommended cooling air flow is approx. 3 to 5 m/s, but max. 10 m/s.
Example:
Cooling air volume = 360 x 11 = 3960 m
Cross section =
Verticus III, drive power 11 kW:
3960 m
3
/h
3 m/s x 3600 s/h
=0.36m
3
/h
2
Methods
There are several types of artificial ventilation:
-- free air flow effected by a blower
-- ventilation by means of an air channel with or without additional blower
-- ventilation by means of an air circulating flap with or without additional blower
a)
a)
If installed correctly, the free air flow cooling method should be sufficient for all VERTICUS compressor units.
a) ATTENTION: Ensure that the max. counter--pressure in the intake and outlet channels Δp= 0.5 mbar = 5 mm W.G. (measured at a distance
of 1 m from the compressor unit) is not exceeded.
20
Operator’s Manual
Fig. 15 Installation of the compressor unit (artificial ventilation)
A Minimum distance from wall, intake side: 0.5 m (may be ignored if locating the unit in front of an opening)
B Minimum distance from wall, exhaust side: 1 m
C Intake opening
D Exhaust opening
21
Fig. 16 and Fig. 17 show installation examples with artificial ventilation:
Operator’s Manual
Correct: Air flows along an imaginary streamline
through the compressor
Fig. 16 Installation with artificial ventilation, example 1
Correct: cooling air led directly to unit
Incorrect: Cooling air does not reach unit
Incorrect: cooling air duct does not reach intake
opening, intake duct too short
Fig. 17 Installation with artificial ventilation, example 2
22
Operator’s Manual
3.5. ELECTRICAL INSTALLATION
For installation of electrical equipment observe the following:
-- Observe regulations of local electricity supply company.
-- Arrange for the electrics to be connected by an electrician only.
-- If control devices are delivered by the factory refer to the appropriate wiring diagram.
-- Ensure correct installation of protective conductor.
-- Check conformity of motor and control device tension and frequency with those of electric network.
-- The necessary cables, main fuses and main switch are to be providedby the customer. The fusing should bedone inaccordance
with the regulations of the responsible electricity supply company.
-- Adjust motor protection, thermal overload relay. For start over contactor adjust to motor amperage rating. For start via star--delta
contactor adjust to motor amperage rating x 0.58.
For example: motor amperage rating = 10 Amp.:
Adjust relay to 10 x 0.58 = 5.8 Amp.
-- When connecting the unit to the electrical supply, check direction of rotation for agreement with arrow on unit.
-- Fuse motor correctly (see table below; use slow--blow fuses).
FUSE TABLE
Motor type Voltage V 125 220 240 380 415 440 500 600 660
3--phase, 2.2 kW
(star--delta starting)
3--phase, 2.2 kW
(direct starting)
3--phase, 3 kW
(star--delta starting)
3--phase, 3 kW
(direct starting)
3--phase, 4 kW
(star--delta starting)
3--phase, 4 kW
(direct starting)
3--phase, 5.5 kW
(star--delta starting)
3--phase, 5.5 kW
(direct starting)
3--phase, 7.5 kW
(star--delta starting)
3--phase, 7.5 kW
(direct starting)
3--phase, 11 kW
(star--delta starting)
3--phase, 11 kW
(direct starting)
3--phase, 15 kW
(star--delta starting)
3--phase, 15 kW
(direct starting)
3--phase, 18.5 kW
(star--delta starting)
3--phase, 18.5 kW
(direct starting)
current A 20 10 10 6 6 6 6 4 4
current A 25 16 16 10 10 6 6 6 6
current A 25 16 16 10 10 10 10 6 4
current A 35 20 20 16 16 10 10 6 6
current A 35 20 20 10 -- -- 10 10 10 6
current A 35 25 25 16 -- -- 16 16 10 10
current A 50 25 25 16 16 16 10 10 10
current A 63 35 35 20 20 20 16 16 16
current A 50 35 35 20 16 16 16 16 10
current A 63 35 35 25 25 25 20 16 16
current A -- -- 50 50 25 25 25 20 20 16
current A -- -- 63 50 35 35 35 25 25 25
current A -- -- 63 63 35 35 35 25 25 20
current A -- -- 80 80 50 35 35 35 35 25
current A -- -- 80 63 50 50 35 35 25 25
current A -- -- 100 80 63 50 50 50 35 35
23
Operator’s Manual
3.6. TAKING INTO OPERATION
3.6.1. Preparation for operation
CAUTION
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 following points:
-- Read Instruction Manual carefully. Make sure that all persons handling the compressor and the filling station are familiar with the
function of all controls and monitors. Observe the WARNINGs in the section filling procedure.
-- Depending on the model range, some compressor units are delivered without oil in the crankcase. Check prior to first operation
and if necessary,fillwithoil.Aftertaking unit into operation after a standstill period of 2 years or more changecompressoroil.When
using a mineral oil change oil after one year.
-- Prior to first operation or operation subsequent to maintenance work, turn the compressor manually using the flywheel to ensure
that all parts are turning freely.
-- Immediatelyafterswitchingon the systemfor the first time check thedirectionof rotationof 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.
-- Prior to first operation or operation subsequent to repair
work operate unit for at least 10 minutes with open condensate valves (pressureless) to ensure properlubrication ofall
parts before pressure is built up. For units with automatic
condensate drain, loosen screw (3, Fig. 18) on coil (1) and
pull plug (2) from solenoid valve.
1
2
Fig. 18 Solenoid valve plug
Units with petrol or diesel engines, additionally:
-- Check oil level of petrol or diesel motor according to manufacturer’s instruction manual.
-- Check fuel tank. Top up if necessary.
-- Open fuel shut-- off valve.
NOTE
Charge battery with enclosed battery liquid before taking unit into operation!
Battery is dry and charged !
3
24
Operator’s Manual
3.6.2. Starting the unit
NOTE
Knocking, audible when starting, is due to last stage floating piston. This knocking disappears as soon as there
is pressure between the stages and the piston is running synchronous with the other pistons. Therefore, this
knocking can be ignored.
Units with electric drive motor:
-- Alternating current: Position 0 --1 control switch on engine to 1.
-- Three-- phase current: Master switch must be ON (to be supplied by customer).
-- Depending on model, either set 0 --I switch at switch box to I, or press the I button on the control and monitoring unit.
-- (Units with electronic monitoring unit):
Start--up of the compressor is indicated by the pilot light illuminating on the Electronic Control which must extinguish once the
specified operating conditions have been attained.
-- Observe the pressure switch shut-- off pressure on units with automatic compressor control.
-- If finalpressure is reached and pressure switch shuts off unit properly, open condensate drain valves and drain condensate. Unit
is then ready for filling operation.
Units with petrol or diesel engine
-- Open condensate drain valves on the filters so that motor starts without load.
-- Set choke on petrol engine to position START. Start engine with recoil starter or crank handle. As soon as motor runs smoothly
return choke to normal operating position.
-- Close condensate drain valves and run unit to final pressure. Check final pressure safety valve and pressure gauge.
-- 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.
25
Operator’s Manual
3.7. FILLING PROCEDURE
3.7.1. General
The filling valve connection is of the manual type and permits 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.
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 (max. allowed filling overpressure at 15 °C).
3.7.2. Intake air quality
At routine tests, CO
compressed air is taken from rooms in which one or more persons are working. At insufficient ventilation, the CO
rounding air can increase quite fast because of the exhaling of CO
unusual (MAK--value (max. workroom concentration) is 5,000 ppm
producing approx. 2g CO
technically caused excessive increase of CO
of the reasons stated above and for your own security, the filling of breathing air bottles is not allowed in rooms used as
workrooms.
3.7.3. Scavenging the compressor unit
values beyond the permissible values are noted from time to time. Closer investigations often show that the
2
.CO2values from 1,000 to 5,000 ppmvin workrooms are not
2
). Another additional increase is caused by cigarette smoking,
(¶ 2,000 ppmv) per cigarette. These pollutions add up to the basic pollution of approx. 400 ppmv.The
2
during the filling process and the CO2peak at taking the unit into operation.Because
2
v
value in the sur-
2
is present in the atmosphere with a natural amount of 250 -- 800 ppmV. The molecular sieve used in the purifiers for drying the
CO
2
breathing air is, as well as other capabilities, able to adsorb CO
pressor, adsorbed CO
may be desorbed again due to the partial pressure decrease. The now free CO2then gets washed out of
2
which is accumulated in the cartridge. After shut --down of the com-
2
the cartridge when the compressor is started again.
To avoid increased CO
contents in the compressed breathing air, we recommend scavenging the compressor unit before con-
2
necting and filling the air bottles, i.e. let the compressed air escape into the open air by opening the filling valves for about 1 to 2
minutes. Remove filling hose for this action, or hold the respective filling hose tightly when opening the filling valve, to avoid any uncontrolled whipping of the filling hose. See also chapter filling the bottles.
3.7.4. Switch--over valve
Filling panels for 2 pressure ranges (PN 200 / PN 300) and with a switch--over valve, with which it is possible to s witch between two
pressure ranges, can only be used for one pressure range at a time. The 200 bar side is opened by means of the shut--off valve. The
300 bar filling valves remain pressurized but can only be used up to a pressure of 200 bar. It is impossible to connect 200 bar bottles
to the 300 bar filling connections (right hand side).
CAUTION
Before switching from 300 bar to 200 bar, i.e. to the
lower pressure range, it is essential
venting valve and to reduce the 300 bar line to at
least 200 bar. Otherwise, the pressure gauge could
be damaged or destroyed.
to open the
Open the switch --over valve slowly in order to avoid
a pressure surge! Filling hoses which are not in use
must be hung inthe holderson the bottom of the filling panel, so that should a filling valve be inadvertentlyopened, thepressurized air outstream cannot
WARNING
cause the hose to whip and cause serious injury.
3.7.5. Pressure reducer
Filling panels for 2 pressure ranges (PN 200 / PN 300) and with a pressure reducer, can be used for filling bottles simultaneously
at two pressures, i.e. simultaneous filling of 200 bar and 300 bar bottles is possible!
The pressure reducer used in the filling panel is adjustable to a high precision.
Max. inlet pressure 420 bar
Secondary pressure 0.1 to 280 bar
(range of adjustment)
Temperature range --10 °C to +100 °C
Normal delivery 32 m
3.
A20mm particle filter is installed at the pressure reducer inlet.
26
Operator’s Manual
3.7.6. Connecting the bottles
-- Connect air bottle to filling valve (see Fig. 19 and Fig. 20).
NOTE
On models of 300 bar rated filling pressuredo notattach bottles unless rated for this presssure (note
pressure stamped on tank neck).
-- Air bottles with international filling connector c an be connected with filling adaptor (part no. 08487-- 635) to the German filling connector or with filling adapter (part no.
03147--635) directly to the filling hose (see Fig. 21)
Fig. 19 Connecting air bottle
.
NOTE
The international connector is not permitted in the
Federal Republic ofGermany. Inother countries itis
allowed only for pressures up to 200 bar (2,850 psi).
This filling connector cannot be used on 300 bar
(4,350 psi) models due to constructive measures.
Fig. 20 International filling connector
Fig. 21 Connecting air bottle
27
3.7.7. Filling the bottles
Operator’s Manual
WARNING
Never open filling valve unless bottle is connected
to filling hose.
Hose whipping due topressurizedairoutstreamcan
cause serious injury!
-- First open filling valve. Fig. 22 and Fig. 23
-- Then open bottle valve -- bottle will be filled. Drain condensate regularly during filling. On units with automatic condensate drain check that condensate is drained regularly.
WARNING
The filling procedure should not be interrupted for
more than 10 minutes, to avoid high C0
the bottle air
values in
2
1.
Fig. 22 Opening of filling valve
1.
Fig. 23 Opening of filling valve
2.
2.
3.7.8. Removing the bottles
-- Upon reachingfinalbottlepressureclose bottle valve first,
then filling valve. Fig. 24 and Fig. 25
-- Remove compressed air bottle.
.
WARNING
After removing the air bottle the filling hose should
be secured back into its provided fitting. Never
leave hoses without securing them.
2.
Fig. 24 Removing air bottle
2.
Fig. 25 Removing air bottle
1.
1.
28
Operator’s Manual
3.8. SHUT-- DOWN PROCEDURE
-- Close filling valves.
Units with electric motor:
-- Alternating current: Position 0 --1 control switch on engine to 0.
-- Three-- phase current: Master switch must be OFF (to be supplied by customer).
-- Press control button 0 on the control-- and monitoring unit. Place main switch to position OFF.
-- When servicing the compressor or the electrical control unit switch the master switch (provided by customer) to OFF.
Units with petrol or diesel engines:
-- Shut down petrol engine with stop button, close fuel shut--off valve.
-- Shut down diesel engine with stop lever, close fuel shut --off valve.
-- Open condensate drain valves until no more condensate comes out. Then close all valves again and leave unit with residual
pressure, so that no moisture can penetrate into the unit.
-- Check the oil level in thecompressorand top up,if necessary.Also check whether the compressor needs servicing in accordance
with maintenance schedule -- see next chapter.
29
Operator’s Manual
4. MAINTENANCE
4.1. MAINTENANCE RECORD
We recommend that all maintenance work is recorded in a 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 prove that regular maintenance work has been carried out by BAUER
KOMPRESSOREN GmbH or a specialist agency authorized by BAUER KOMPRESSOREN München, and that the damage has not
been caused by insufficient maintenance. Please refer to section 23 of our general terms and conditions.
For this purpose, the following maintenance control sheet is provided (copy as required). The grey boxes indicate when the maintenance work isdue. The appropriate box(es) will be signed,dated and stamped by the requested specialistagency to show themaintenance work has been carried out in an expert manner.
4.2. MAINTENANCE INTERVALS
CAUTION
For filter cartridge change intervals refer to respective instruction manual !
CAUTION
Saturated filter cartridges as well as any condensate that accumulates are considered to be special
waste! They have to bedisposed of according tothe
valid federal-- and regional waste laws and the local
waste laws (disposal according to DIN safety data
sheet section 5.5)
WARNING
Maintain motors according to the manufacturers
instructions.
30
Operator’s Manual
5. MAINTENANCE SCHEDULE
5.1. MAINTENANCE INTERVALS
CAUTION
For filter cartridge change intervals refer to chap-
ter 5 !
Interval Maintenance work
Daily before taking unit into
operation
1/2 hour after start--up Manual check of valve function 9.
Weekly or as required Check automatic condensate drain; open manual condensate drain
25 operating hours after first
time operation/maintenance
work
250 operating hours Check drive belt(s)
1000 operating hours Dismantle valves, clean, check, and replace if necessary
2000 operating hours Synthetic oil change
Check oil level with dipstick
Operate unit to final pressure and check function of final pressure valve
before opening outlet valve
taps
Tighten drive belt(s), check all accessible screws and nuts are tightly
fitted and if necessary tighten to the stipulated torque.
Service micronic intake filter
Check safety valves
Check all connections for leakage
Mineral oil change
Clean sintered metal filter element(s)
Replace valves
Sec.
2.
7.
10.
12.
12.
3.
7.
-- --
9.
2.
4./5.
2.
9.
3000 operating hours or as required
Annually Mineral oil change, if run for less than 1000 operating hours
Annually or as required Check cycle counter; replace oil and water separator if required 11./5.
Biannually Synthetic oil change, if run for less than 2000 operating hours 2.
Check pistons and piston rings 18.
2.
Check opening pressure of safety valves
7.
31
Operator’s Manual
5.2. MAINTENANCE RECORD
We recommend that all maintenance work is recorded in a 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 maintenance. Please refer again to the explainations made in section 4.1.
For this purpose the following maintenance control sheet is provided (copy as required). The grey boxes indicate the maintenance
work to be carried out. The appropriate box(es) will be signed, dated and stamped by the requested specialist agency to show the
maintenance work has been carried out in an expert manner.
Operating hours
Work to be done
Check drive V--belts
Service micronic intake
filter
Check safety valves
Check connections for
leakage
Dismantle valves, clean,
check
Oil change; mineral oil
Clean sintered metal filter
elements
Oil change; synthetic oil
Replace valves
Check opening pressure
of safety valves
Check pistons and piston
rings
Check cycle counter
a
a
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
Annually
Bi--annually
Date/Signature
Stamp of BAUER
KOMPRESSOREN specialist agency
32
Operator’s Manual
6. STORAGE, PRESERVATION
6.1. GENERAL
If the compressor is put out of service for more than six months, the unit should be preserved inaccordance with the followinginstructions:
Make sure the compressor is kept indoors in a dry, dust free room. Only cover the compressor with plastic, if it is certain that no condensation will form under the sheet.Nevertheless, the sheet should be removed from timeto time and the unit cleanedon theoutside.
If this procedure cannot be followed and/or the compressor is going to be taken out of service for more than 2 years, please contact
our Technical Service Department for special instructions.
6.2. PREPARATION
Before preserving the compressor unit, run it warm and when it reaches the specified service pressure, keep it running for approx.
10 minutes.
Then carry out the following:
-- Check all pipes, filters and valves (also safety v alves) 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 pressure (is approx. 150
bar for 200-- 300 bar units) for approx. 5 minutes.
-- After these 5 minutes,shut the system down.Drain condensate from separators. Depressurizeunit.Shutfillng valves/outlet valve.
-- Remove intake filter from manifold and all intake lines from valve heads.
-- Let compressor unit cool down.
-- Open filters and grease threads, then close them again.
On units equipped with a filter system please observe the following:
-- Ensure that filter cartridges remain in filters!
This will prevent oil entering filling lines as a result of preservation procedures.
6.3. PRESERVING THE COMPRESSOR
-- Turn the compressor on and spray a small amount (approx. 10 ccm/0.6 cu. in.) of compressor oil into the valve heads inlet ports
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.
-- Remount intake lines and close the inlet port with the dust cap.
6.4. PRESERVING THE MOTOR/ENGINE
Preserve the motor/engine according to the instructions of the motor/engine manufacturer.
6.5. PREVENTIVE MAINTENANCE DURING STORAGE
Run the compressor once every 6 months as described in the following:
-- Remove the dust c ap from the inlet port and insert the intake filter.
-- Open the filling valves or the outlet valve.
-- Turn the unit by hand.
-- Let the unit run for approx. 10 minutes or until the air flows out of the filling valves or the outlet valve. With units with pressure oil
lubrication, make sure it’s working properly (oil in sight glass of oil pressure regulator or oil pressure gauges).
-- Repeat preparation work according to para. 6.2.
-- Carry out preservation procedure again according to para. 6.3.
33
Operator’s Manual
6.5.1. Changing the lube oil for preserving
-- After prolonged storage,the oil will age in the compressor and engine. It should be drained after2 yearsat the latestand replaced
with fresh oil.
-- The stated period can only be attained when the crankcase is sealed during the preservation period in accordance with the preservation requirements.
-- After changing the oil, turn the compressor and the engine or run them for the required period. See paras. 6.2. and 6.5
-- 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.
6.6. REACTIVATING THE COMPRESSOR UNIT
-- Remove the dust c ap from the inlet port and insert the intake filter.
-- Check the oil level of the compressor.
-- Check the motor/engine according to the manufacturer’s instructions.
-- Turn the compressor unit a few times by hand.
-- Run the compressor warm with open filling valves or outlet valve for approx. 10 minutes.
-- Check the oil flow through the sight glass or 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. To do so, override the pressure switch, if installed on the unit. On units with a built in compressor control put the S3 service
switch on position ON.
-- Check the intermediate--pressure safety valves for leakage.
-- Establish cause of any fault from the trouble--shooting table and remedy.
-- On units, equipped with a filter system, please note:
open purifier and replace filter cartridge.
-- Stop the system when running properly, the compressor is then ready for operation.
34
Operator’s Manual
7. REPAIR INSTRUCTIONS
7.1. GENERAL
Preventive maintenance usually involves replacing the valves, gaskets and sealing rings as well as carry--ing out the maintenance
work.
Repair work can be carried out on the compressor block to a certain extent but a certain experience and skill is necessary. It should
be noted, however, that
-- no repair should be carried out on the crankdrive nor on the bearings
-- safety valves are not repaired but always replaced completely.
-- suction and pressure valves of each stage are only to be changed together.
NOTE
For all further repair instructions refer to applicable workshop manual.
35
Operator’s Manual
y
pg,
t
i
d
i
l
h
toilt
i
l
8. TROUBLE--SHOOTING
Trouble Cause Remedy
Drive motor (electric)
Motor will not start Electric circuit faulty Before attempting to make any re-
pairs, check all fuses, terminal connections, wire leads, make sure that
motor data complies with mains
supply
Drive motor (petrol or diesel)
Engine will not start
Compressor block
No oil pressure
Sight glass exhibits air bubbles Oil pressure regulator dirty Clean valve and readjust oil pres-
Oil foam in the crankcase Last stage piston worn Operate compressor with final stage
Compressor does not attain final
pressure
See engine instructions See engine instructions
Air trapped in oil pump Vent pump and line
sure
valve head removed. If oil collects
at rim of cylinder, pisston clearance
ok. If oil flows continuously out of
cylinder, replace piston and liner
Last stage outlet valve defective Replace
Oil pressure too low Adjust oil pressure on oil pressure
regulator
Condensate drain valve(s) and/or
fittings leaking (also see trouble
shooting-- automatic condensate
drain)
Premature opening of final safety
valve
Tighten and reseal
Clean valve, if worn replace
Clean final safety valve and get readjusted
Piston rings worn Replace
Excessive piston clearance Replace
Compressor output insufficient Pipes leaking Re--tighten
Safety valves between individual Intermediate pressure too high, val- Check valves
stages releasing pressure
Compressor running too hot Insufficient supply of fresh cooling
Oil residue in delivered air Improper maintenance of filters, fil-
ves not closing properly
Check location. Max. ambient tem-
air
Intake or outlet valves not closing
properly
Wrong direction of rotation Adjust electrical phase sequence
er cartr
type
ge saturated; wrong o
perature + 45 °C(110°F)
Check and clean valves, replace as
necessary
Remedy filters, change filter cartridges, use rig
list). Clean sooted valves
ype(seelatesto
36
Operator’s Manual
f
f
Trouble Cause Remedy
Electric Control System (optional)
Control does not switch on No control voltage Check feed line
Control fuse defective Replace fuse, eliminate cause
Control current line cut off, line or
terminal loose
Thermal overload triggered Clear faults as described in the fol-
Thermal overload relay for drive
motor triggered
Control does not switch off, final
pressure safety valve blows o
Electronic Control (optional)
Electronic Control shuts off unit before 40 seconds have elapsed
Electronic Control indicates fault although all monitored items are ok
Electronic Control indicates fault although operating parameters are ok
Automatic Condensate Drain (optional)
Drain valves do not close No control air Check control air line
Drain valves do not open Condensate drain valve piston jam-
Solenoid valve does not close Solenoid valve faulty Check solenoid valve and replace if
Solenoid valve does not open Solenoid valve faulty Check solenoid valve and replace if
Unsatisfactory drainage (lot of condensate from manual valves)
Current consumption too high Check compressor drive
Overload relay set too low Correct setting, check current con-
Final pressure switch set too high Correct setting
Final pressure safety valve defective
Timing circuit defective Replace Electronic Control
Wire to monitored item broken Repair wiring
Sensor defective Replace sensor
Drain valves leaking due to dirt Dismantle drain valve and clean
med
No electrical signal Check electrical control circuit and
Continuous electrical signal Check electrical control circuit and
Nozzle in 3rd or 4th stage drain
valve clogged
Tighten terminal
lowing
sumption of each phase
Replace safety valve
Dismantle drain valve, clean or replace valve
necessary
timer
necessary
timer
Remove nozzle, clean
37
Operator’s Manual
9. FILTER SYSTEM P21
9.1. DESCRIPTION
The air leaving the final stage is cooled in the after--cooler to approx. 10 -- 15 °C (18 -- 27 °F) above ambient temperature and then
enters filter system P21 with TRIPLEX longlife cartridge (Fig. 26).
The filter assembly consists of separator and cartridge chamber. In the separator surrounding the cartridge chamber liquid oil and
water particles are reliably separated from the compressed medium by a pipe nozzle.
Residual oil and watervapors are then removedby the TRIPLEXlonglifecartridge. The quality of the breathing air produced conforms
to DIN EN 12021.
1 Filter inlet
2 Jet pipe
3 Filter head
4 Final pressure safety valve
4
3
5 Housing
6 Chamber separator
7 Cartridge
8 Filter outlet
9 Pressure maintaining valve
10 Condensate drain tap
11 Condensate outlet
5
2
6
7
8
9
1
10
11
Fig. 26 Filter system P21
9.2. CONDENSATE DRAINAGE
Drain condensate from separator and cartridge chamber regularly by slowly opening drain taps (10, Fig. 26)
-- 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.
38
Operator’s Manual
9.3. CARTRIDGE SAFETY BORE
The filter system P21 is designed to prevent pressurizing in the absence of the filter cartridge. A bore provided in the filter bottom
is sealed air--tight only if the cartridge is in place (Fig. 27).
CAUTION
No pressure build up without cartridge!
Without cartridge the venting bore is not sealed, the air escapes 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. Ifair is leaking out of the ventingbore even though a cartridge
is installed, the O--rings are either broken or were damaged on installation.
Remove and check cartridge. If necessary replace cartridge or O-- rings.
Venting bore
No cartridge
Fig. 27 Safety bore
9.4. LIFETIME
Cartridge installed
WARNING
The filter system is subject to dynamic load. It is designed fora certain number of load cycles, which originate from
an abrupt pressure loss at condensate drain (1 load cycle i.e. condensate drain = 1 depressurization, 1 pressurization). Acc. to no. 15 of the annex II to the German pressure vessel regulations the filter housing has to be inspected
internally by an expert after having reached half of the determined number of load cycles. The inspections have to
be arranged by the operator. After reaching the max. number of load cycles the filter assembly must be replaced,
otherwise the housing may burst due to material fatigue.
The max. number of load cycles for the P21 Central Filter Assembly is 4,500 if operated at the max. allowable pressure difference
range of 330 bar (4,700 psi). For a pressure difference of 225 bar (3,200 psi) the max. no. of load cycles is 63,000.
To avoid exceeding the max. number of load cycles the operating hours should be recorded in the table in the instruction manual
of the compressor unit. 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 1,125 for 330 bar units. It is not necessary to record the operating hours for 225 bar
units as the theoretical filter housing lifetime is 15,750 operating hours.
39
Operator’s Manual
9.5. GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE
-- Depressurize system before starting any maintenance work.
-- Dry inside of filter housing with a clean cloth before installing 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 intervals.
-- 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 service.
-- 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 entering the compressor piping and filter system.
-- The nozzle type separator of the TRIPLEX filter system is maintenance-- free besides the regular condensate drainage.
9.6. FILTER CARTRIDGES
New filtercartridgesare vacuum--packed and can be stored for twoyears (referto date on thecartridge). A defective vacuum package
cannot protect the cartridge appropriately 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.
9.7. 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
41 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. Tolerances at bottle
fillings and different operating temperatures can lead to considerable divergences compared to data given, which therefore can only
serve as reference values 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--ltr--bottles can be filled with a TRIPLEX--cartridge, which is equivalent
to 12 to 15 compressor operating hours at a filling pressure of 200 bar .
On compressor units with petrol engines only use cartridge, 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-- ltr--bottles can be filled with this cartridge, which is equivalent to between
10 and 13 operating hours at a filling pressure of 200 bar.
NOTE
The longer service life of the cartridge at a filling pressure of 300 bar is annihilated by the larger volume of filled air
per bottle, therefore the possible number of bottle fillings stays the same at different pressures.
40
Operator’s Manual
9.8. REPLACEMENT INTERVALS
CAUTION
The indicated change intervalsare valid for 20 °C(68°F) air temperature,of the surroundingair only. Read the correction factor from the table:
Example: Air temperature 30 °C...............
Correction factor 0.58.......................
°C °F
50 122 0.21
40 104 0.34
30 86 0.58
20 68 1.00
10 50 1.81
0 32 3.44
Change cartridge according to the following table:
Filling pressure
Delivery 80 110 140 190 230
PN 200 bar (3,200
psig)
PN 300 bar (4,700
psig)
9.9. CARTRIDGE CHANGE
Airtobeproces-
Correction factor
Correction factor
Ambient temperature in °C
After ... 7--ltr . bottle
sed
Va [Nm
3
]
90 65 45 14 14 11 8 7
135 65 45 20 20 16 12 10
fillings
After ....10--ltr. bottle
fillings
After ...operating hours at ...deli-
very (ltr/min)
WARNING
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 orTRIPLEX cartridge part no. 057679
can be used.
NOTE
Units with petrol engine are delivered with CO removal cartridge part no. 059183 as standard, units with electric engine with TRIPLEXcartridgepart no. 057679. When changing from electric engineto a petrolengine also replacecartridge part no. 057679 with cartridge part no. 059183.
NOTE
Never remove replacement cartridge from packaging prior to actual use otherwise highly sensitive molecular sieve
will absorb water vapour from surrounding air and cartridge 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, Fig. 26).
-- Extract old cartridge and insert a new one.
-- Screw in filter head to the stop without use of force
.
CAUTION
The used cartridge must be disposed of according to local regulations.
41
Operator’s Manual
10. FILTER SYSTEM P41 AND P61
10.1. APPLICATION AND SUMMARY DESCRIPTION
Filter systems P41 or P61 (Fig. 28) consist of:
• Separator with final pressure safety valve
• Non--return valve between separator and purifier
• High pressure purifier
• SECURUS indicator unit
• Venting valve with pressure gauge
• Pressure maintaining/non-- return valve
The system is integrated into the compressor unit, i.e. the filters and other components are mounted on the frame, the pressure
gauges are situated at the filling panel. If the SECURUS monitoring system is provided, the breathing air regeneration process and
the degree of dryness of the air are continuously monitored during the regeneration process by measuring the cartridge saturation
within the filter cartridge.
a)
3
3
5
2
4
1
1
7
6
Fig. 28 Filter system P41 left, P61 right with SECURUS--monitoring unit
1 Oil and water separator
2 Final pressure safety valve
3 Non--return valve
4 Purifier
5 SECURUS indicator unit
6 Bleeding valve with pressure gauge
7 Pressure maintaining/non--return valve
5
4
7
6
a)
a) optional extra
42
Operator’s Manual
10.2. FUNCTION
10.2.1. General
Unlike other filter systems the SECURUS filter system ensures continuous monitoring of the breathing air purification parameters
while the air is still in the regeneration process. The influences of
• ambient temperature
• ambient humidity
• temperatures of the compressor and regeneration system are taken into consideration.
The available exchange SECURUS cartridges are designed for
• drying of air
• adsorption of aromatic components (aerosols)
• partial conversion of CO into CO
• partial adsorption of CO
The quality of the breathing air produced conforms to the national and international
2
2
• DIN 3188
• STANAG 1079 MW
• British Standard 4001
• US CGA Spec. G.7.1
• Canada CSA Standard Z 180.1
• Australian Army Standard 5017
It is impossible to exceed the cartridge utilization time since a preliminary warning signal indicates the approaching saturation of the
cartridge. Depending on the size of compressor used, the prewarning signal will appear between 1 and 7 hours prior to cartridge
saturation.
If the cartridge is not replaced after illumination of the preliminary warning signal, the SECURUS filter system will automatically shut
down the compressor as soon as the cartridge has been exhausted.
The compressor cannot be turned on as long as no cartridge has been inserted.
The SECURUS filter system operates in the FAIL--SAFE mode: the compressor will be shut down if the circuit between the control
unit and the sensor is interrupted.
CAUTION
As soon as the preliminary warning signal appears or, at the latest, after the SECURUS indicator unit has shut
down thesystem, the cartridges ofall filterswithin the systemmustbe changed according tothe instructionmanual.
43
10.2.2. Oil and water separator
The air leaving the final stage is cooled in the after--cooler to
approx.10 to 15°C (18 to 27°F) above ambienttemperature and
then enters the oiland water separator (Fig. 29). The oiland water separator works by means of a sinteredfiltermicro--cartridge
(1), reliably separating liquid oil and water particles from the
compressed air.
CAUTION
The oil and water separator is subject to dynamic
load. It is designed to withstand up to 85,000 load
cycles at a max. allowable pressure fluctuation
range of 350 bar. (1 load cycle = 1 pressurization, 1
depressurization). After reaching the max. number
of load cycles, the oiland waterseparatorshould be
renewed.
The maximum recommended amount of four load cycles per
hour should not be exceeded.
If it is possible to regulate the operation of the unit to such a degree as toachieve approx. four load cycles per hour, in our opinion this would be an optimum between usage of the unit and actual life of the oil and water separator.
Operator’s Manual
Fig. 29 Oil and water separator
10.2.3. Purifier
The filter housing consists of a high--strength anodized aluminium alloy pipe with 100 mm external diameter. Both ends are provided
with fine threads on the inside.
The screw-- in filter bottom contains inlet and outlet. For connector threads see specifications, Technical Data, 10.4.
The upper screw connection contains a pressure resistant bushing for the electrical connections. The co --axial cable which leads
from the sensor to the control unit is connected to the BNC connector located there.
For description of the electrical operation refer to chapter 10.2.5.
44
Operator’s Manual
10.2.4. Filter cartridges
Construction
The cartridge tube is made of aluminium. Cover and bottom consist of pressure diecast aluminium and are sealed with O--rings.The
cartridge cover contains the sensor for the monitoring function and the clip to facilitate changing of the cartridge.
Different cartridges are available depending on the required air quality.
Fig. 30 and the following table show the internal construction of the filter cartridges.
Fig. 30 Construction of the filter cartridges
Pos.
1 Coaxial plug Attachment of the signal cable, connection between cartridge and SECURUS indicator unit
2 Sensor Indication of cartridge saturation to the SECURUS indicator unit
3 Molecular sieve Drying by partial adsorption of CO
4 Foam plastic disc Separation of the filter agents
5 Activated charcoal Adsorption of odour producing substances, oil vapours, and aerosols
6 Hopcalite Catalytic agent with excellent contact time characteristics for converting CO into CO
Designation Purpose
2
2
45
Operator’s Manual
10.2.5. SECURUS indicator unit
Function
The SECURUS indicator unit receives signals concerning theconditionof the drying agent inside the filter cartridge from the attached
sensors and furnishes appropriate control signals whenever the preset threshold values have been reached.
The annular sensor inside the filter cartridge head senses changes in capacitance caused by the saturation within the surrounding
drying agent. The signal path from the sensor leads through a spring pin contact, which forms the connection between cartridge and
filter head, to the pressure resistant bushing in the filter head and continues through the centre conductor of the coaxial cable to the
indicator unit. The signal return is effected through the cable shield to the cartridge housing.
The four operating conditions of the SECURUS system are reported by three relays (normally open contacts). Simultaneously with
the closing of the relay contacts, built--in luminescent diodes illuminate:
1. Continuous green: Unit in operation..........
2. Flashing yellow: Cartridge change pre--warning.............
3. Flashing red: Compressor shut--down because cartridge is used up................
4. Continuous red: Compressor shut -- down because of missing cartridge or cable failure.............
If the yellow diode is flashing, the green diode will continue to illuminate because unit is still operational with the yellow light on. If no
lamp is on, which means thatno relaycontact is closed, the SECURUS indicator unitreceives no operating voltage or the electronics
within the unit have failed.
Afterapplying operatingvoltage to the unititwilltake about 0.5seconds to closethe respectiverelay contactand to light the applicable
diode. During this time the status of the cartridge is being checked.
46
Operator’s Manual
10.2.6. Air flow diagram
Fig. 31 shows the air path through the SECURUS filter system.
The filter assembly with the pressure resistant bushing for the filter cartridge with sensor is installed as the last filter before the pressure maintaining/non-- return valve.
Fig. 31 Air flow diagram
1 Compressor
2 Separator with end non--return valve
3 Venting valve with pressure gauge
4 Purifier with SECURUS c artridge
5 Pressure maintaining/non--return valve
6 SECURUS control unit
7 Indicator lights
8 Final pressure safety valve
9 Compressor control unit
47
Operator’s Manual
10.3. FILTER MAINTENANCE
10.3.1. General instructions
-- Depressurize system before starting any maintenance work. The filter section can be vented manually at venting valve with
gauge. Wait untill the pressure on the gauge has dropped to zero, before opening pressure vessel.
-- Dry inside of filter housing with a clean clothand check for corrosion beforeinstalling new cartridge. Replace any defective parts.
-- Lubricate threads and O--rings as well as threaded part of cartridge with white petrolatum (DAB 9) or Never--Seez White. Apply
sparingly.
-- Observe number of operating hours/no. of bottle fillings to ensure paying exact attention to the maintenace intervals.
-- Leave cartridge in the filter as long as unit is out of service, so that humidity entering the system is absorbed.
-- Change cartridge before reactivating a compressor unit which has been out of service for more than 6 months.
-- Keep all condensate drain valves and shut--off valves closed. Keep a minimum pressure of approx. 50 to 80 bar (700 to 1,100
psig) within the system to prevent moisture entering the compressor piping and filter system.
10.3.2. Oil and water separator maintenance
The sintered filter micro-- cartridge requires periodic cleaning. See maintenance intervals.
Removal of sintered filter element (Fig. 29 ):
-- Remove tube connected to non--return valve (2).
-- Screw off filter head (3) and remove.
-- Unscrew micro--c artridge (1) from filter head (3).
-- Remove centre--screw (4) to remove filter elements.
-- Clean sintered filter elements using hot soapy water and blow dry with clean compressed air.
Condensate drain
The condensate produced by the re--cooling after the compression process has to be drained regularly by means of the condensate
drain valve
• before start-- up of the compressor unit
• during operation every 15 minutes, at high humidity every
10 minutes.
48
Operator’s Manual
10.3.3. Cartridge change
-- On filters with SECURUS monitoring system unlock BNC plug of the coaxial cable by applying light pressure and turning in a
counter--clockwise direction. Pull out BNC plug (see Fig. 32).
-- Unscrew the filter head (1) with the special spanner (2) supplied with the unit. This tool has a recesss to accomodate the BNC
plug.
CAUTION
In order to avoid damaging the BNC coaxial plug, do not use other tools.
-- Pull out used cartridge by means of its clip (3) and replace with a new cartridge.
-- Replace filter head, screw in by hand and tighten with the special spanner. Then turn it back 1/4 turn.
Fig. 32 Cartridge change
49
Operator’s Manual
p
g
10.3.4. SECURUS filter replacement intervals for P41/P61 filter system
NOTE
The entities in the following table are based on estimated filter cartridge life time; on systems equipped with SECURUS monitoring unit, the actual saturation of the cartridge is reported by the electronic monitor.
CAUTION
The indicated change intervalsare valid for 20 °C(68°F) air temperature,of the surroundingair only. Read the correction factor from the tables:
Example: Air temperature 30 °C...............
Correction factor 0.58.......................
°C °F
50 122 0.20
40 104 0.34
30 86 0.57
20 68 1.00
10 50 1.85
5 41 2.60
0 32 3.80
Compressor model Cartridge change after
operating bottle fillings
hours
Filter system P41 ↓ 7l 10 l 7l 10 l
Utilus/V-- U/KAP 11 250/165* 1000/700* 750/500* 700/500* 500/350*
VC--3 220/150* 1000/700* 750/500* 700/500* 500/350*
Capitano/VC--4 180/120* 1000/700* 750/500* 700/500* 500/350*
Mariner/MP3E 130/80* 1000/700* 750/500* 700/500* 500/350*
VM--5,5 130/80* 1000/700* 750/500* 700/500* 500/350*
KAP 14--5,5 120/80* 1000/700* 750/500* 700/500* 500/350*
KAP 14--7,5 100/65* 1000/700* 750/500* 700/500* 500/350*
VM--7,5 100/65* 1000/700* 750/500* 700/500* 500/350*
KAP 14--10 75/50* 1000/700* 750/500* 700/500* 500/350*
V-- 7,5 100/65* 1000/700* 750/500* 700/500* 500/350*
V-- 10 75/50* 1000/700* 750/500* 700/500* 500/350*
KAP 15 60/40* 1000/700* 750/500* 700/500* 500/350*
V-- 15 60/40* 1000/700* 750/500* 700/500* 500/350*
Correction factor
Correction factor
Ambient temperature in °C
200 bar 300 bar
* Cartridge with CO --separator
50
Operator’s Manual
10.4. TECHNICAL DATA
10.4.1.
Filter specifications P41/P61* filter system
a. General
Service pressure, standard
225/330 bar (3,200/4,500 psi)
Service pressure, max. 350 bar (5,000 psi)
Flow rate max. 450 l/min / max. 600 l/min*
Regenerated volume of air, referenced to 1 bar abs,
20°C, flow rate 200 l/min against p = 200 bar
1923 m3; 1732 m3with CO cartridge
3
3139 m
with CO cartridge
Operating temperature range +5 ... +50°C (41 ... 122°F)
Residual water contents <30 mg/m
Residual oil vapour contents <0.1 mg/m
Residual CO contents 5 ppm
Residual CO2contents 400 ... 500 ppm
3
3
V
V
Pressure dew point -- 1 6 °C, equivalvent 1,3 mg/m3at 300 bar
b. Oil and water separator:
External diameter
95 mm
Length 300 mm
Water volume 0.57 l
Weight 4.5 kg
Tube connections (intake and outlet) G1/4”
Max. load cycle number 85,000 at max. allowable pressure range of 330 bar
(4,700 psi)
b. High pressure filter assemblies
External diameter
100 mm
Length 620 mm, 835 mm*
Water volume 2.1l,2,85l*
Weight 8 kg, 10,6 kg*
Tube connections (intake and outlet) G3/8”
51
Operator’s Manual
11. TRANSPORTING COMPRESSED AIR CYLINDERS
Compressed air as a pressurized gas mixture class 2, point 2a is subject to the dangerous goods motor regulations
(GGVS).
For the transportation of all dangerous goods one has to carry a transport sheet according to Rn. 2002 par. 3 of GGVS.
One can do without this, according to exception No. 55 of the dangerous goods regulation exceptions (GGAV), when the max. allowable total gross quantity of each transportation unit according to Rn. 0011 does not exceed, with compressed air, 1000 kg ( equivalent to approx. 70, 10 liter steel compressed air diving bottles).
In this case the compressed air cylinders are to be marked with the designation of the goods, the class, the point, and the letter of
the list of substances --in this case air, class 2 point 2a.
-- In every case the compressed air cylinders must be marked according to Rn. 2224 para. 1 with a danger label No. 2 (gas cylinder
black or white on green* background, small number ”2” in the bottom corner), see Fig. 33.
-- According to Rn 2203 para.1 gas containers -- including pressurized air -- must be closed and tight as to excludeany gas leakage.
-- The shut--off valves must be protected effectively, according to Rn.,2213 para. 2, with protecting caps. The protecting cap can
be done without of, if the compressed air cylinders are packed in protective boxes.
-- Compressed air cylinders must be, according to Rn. 21414, stowed in the vehiclesin such a way that they cannot fall over or drop
off. Cylinders that are stable enough or those transported in the corresponding devices which protect them from falling over, can
be loaded upright. Horizontal bottles must be secured in such a way as to keep them from sliding.
-- According to Rn. 10011 of the enclosure B of the GGVS the regulations (e.g.: driver’s training, equipping of vehicles, caution
boards, accident bulletins) mentioned in Rn. 10011 do not have to be followed when transporting compressed air cylinders up
to a gross mass of 1000 kg per transport unit.
-- In general the following is valid with every transport of dangerous goods: During transportation smoking is forbidden, also during
loading within a parimeter of 10 meters.
-- Empty compressed aircylinders, in otherwords residual pressure below 2 bar are notsubjectto the dangerous goods regulations.
grün*
Fig. 33 Danger label no.2
52
Operator’s Manual
12. FURTHER FILLING POSSIBILITIES
12.1. OVERFLOW
Air from a cylinder with higher pressure can overflow into a cylinder with lower pressure.
In this way an equilization of pressure is reached.
Filling procedure:
-- Connect donating and receiving cylinder to each other (e.g.: with overflow hose)
-- Unscrew donating cylinder, carefully open receiving cylinderas not to damage the sintered metal filterat the water detectorpipe.
-- Equilization of pressure is reached (a complete equilization cannot bereached in thiscase, as the cylinders warm up or cool down
at a different rate).
-- With severalcylinders,couple each donating cylinder with the lowest pressure to the receiving cylinderwiththe highest pressure
(smallest pressure difference ! ).
12.2. FILLING FROM STORAGE CYLINDERS
When using storage cylinders itis recommended to fill them at the max. permissable operating pressureto reach the optimumusage
of the bottle volume.
CAUTION
If the storage bottles are filled at a pressure higherthan 225 bar,then a pressure reducer and an additional final pres sure safety valve are needed to overflow, which avoids a non --permissable highpressure being reached in the cylinders to be filled.
To make the filling procedure easier and faster, an automatic switching device (part no. 062796--635) can be used. This makes
full use of the advantage of storage cylinders.
The automatic switching device functions as follows:
-- With filled storage cylinders (2), first the air compressed to a higher pressure flows from the storage cylinders via the non-- return
valve and filling panel (4) into the compressed air cylinders (see Fig. 36).
-- A pressure reducer in the filling panel ensures that the cylinders to be filled cannot be overfilled.
-- Depending on the volume of the storage cylinders, in this way s everal cylinders can be filled very quickly (overflow principle).
-- If, after filling several cylinders the storage cylinder pressure has dropped to the min. value set on the pressure switch of the automatic switcing device, the compressor automatically switches on and fills the cylinders directly (see Fig. 37).
-- If more cylinders are filled, they will be filled directly from the compressor (1) .
-- As soon as no more cylindersare to be filled or when their final pressure has been reached,the pressure maintaining valve opens
and allows the air to flow from the compressor (1) straight into the storage cylinders (2) until they are full and the max. set value
on the pressure switch of the automatic switching device stops the compressor (1) (see Fig. 38) .
-- The same principle can also be used, when the storage cylinders (2) are filled at ”only” 200 bar .
-- Then not as many cylinders can be filled by overflow, however the total filling time is shorter, as quite a lot of air can be taken out
of the storage cylinders (2) (untilequilization of pressure has been reached)and the the compressor (1)is automaticallyswitched
on and the residual amount is filled up.
53
Operator’s Manual
The automatic device consists of a pressure maintaining valve,
a check valve and an integrated pressure switch for switching
the compressor unit on or off. The use of this automatic device
replaces the cascade filling function.
The two pressure gauges monitor inlet and outlet pressures.
The pressure switch controls the operation of the compressor
unit.
6
4
1
Fig. 34 Automatic switching device
5
2
Fig. 35 Flow chart
54
Operator’s Manual
Filling panel Compressor Storage battery
Fig. 36 Filling from storage cylinders (overflow)
Filling panel Compressor Storage battery
Fig. 37 Filling with the compressor
Filling panel Compressor Storage battery
Fig. 38 Filling storage cylinders
55
NOTES
Operator’s Manual
56
Operator’s Manual
NOTES
57
NOTES
Operator’s Manual
58
Operator’s Manual
NOTES
59
NOTES
Operator’s Manual
60
Lubricating oil list
1. GENERAL
Afterextensive tests with many different kinds of lubricants, we have decided to authorizethe following brands of oil for use in BAUER
compressors under the given operating conditions.
This list is up to date at the time of printing and will be reviewed continuously. Should your list or your instruction manual be older,
please request the latest edition from BAUER Customer Services. When using any of the oils listed below, please follow the oil
change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit.
Oil type Use
Brand name Designation
Special Compressor oil
Part no. N22138
Special Compressor oil
Part no. N26303
Special Compressor oil
Part no. N19745
Special Compressor oil
Part no. N28355
Energol RC 150
LM 750 with corro-
LIQUI MOLY
Anderol
sion protection
755
Rarus 829
Mobil
Shell
Mobil
Corena P150
Pegasus 1
b) c)
a)
b)
b)
a)
b)
b)
a)
b)
b)
Type
M
S
S
S
M
S
S
S
M
S
A
Breathing
air
NitroxNIndustrial
+ -- +
-- -- -- --
+ -- +
+ + + --
air
I
G
Helium,
Argon
--
GI
CNGCNitrogen
-- --
+ -- + +
--
-- -- + +
-- -- + +*
+ -- + -- -- -- +
+ -- +
+ -- +
--
-- + + -- + + +
+ -- +
-- -- --
--
--
--
--
-- -- + +
-- -- + +
-- -- + +
+ -- + +
Ambient
temperature
+5 ...
+35 °C
+5 ...
+45 °C
+ +
z
Oil list /06/06
Oil type
synthetic oil
S
M mineral oil
Application
approved for breathing air application with BAUER air purification systems
A
N approved for nitrox application with BAUER membrane unit
I suitable for industrial air compressor units
G suitable for gas compressor units for dry and highly pure gases
C suitable for compressed natural gas compressors (CNG filling stations)
GI suitable for gas compressor units for nitrogen
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
+
z = partly suitable
-- = not suitable
* Max. ambient temperature: +5 ... +40 °C!!
BAUER KOMPRESSOREN GmbH
Postfach 710260 D--81452 München Tel. 089/78049--0 Fax 089/78049167
Lubricating oil list
2. 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 overleaf.
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, industrial air compressor units:
Nitrox compressor units: BAUER special Compressor oil, part no. N28355
Gas compressor units: Mobil Rarus 829
CNG compressor units BAUER special Compressor oil, part no. N26303
For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recommend the
BAUER specialcompressor oils acc. to the list on the previous page. These have provedexcellent 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
theunitupto+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 mineral oils acc. tothe list on the previouspage. These oils are suitable
for ambient temperaturesbetween +5 °C and +35 °C. Here also,a pre-- heating device will be required if ambient temperatures should
fall below +5 °C.
2.1. Changing the Oil Type
BAUER special Compressor oil, part no. N22138
CAUTION
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.
-- Topupwithsameoiltype.
3. OIL CHANGE
Mineral oil
Synthetic oil Every 2000 operating hours, at least biennially
Oil capacity Refer to compressor unit instruction manual
BAUER compressor oil is available in the following quantities:
Oil quantity b Oil type '
1 l bottle part no. N22138-- 1 part no. N26303 --1 part no. N19745--1 part no. N28355--1
5 l container part no. N22138-- 5 part no. N26303 --5 part no. N19745--5 part no. N28355--5
20 l container part no. N22138-- 20 part no. N26303 --20 part no. N19745--20 part no. N28355-- 20
Mineral oil N22138 Synthetic oil N26303 Synthetic oil N19745 Synthetic oil N28355
Every 1000 operating hours, at least annually
BAUER KOMPRESSOREN GmbH
Postfach 710260 D--81452 München Tel. 089/78049--0 Fax 089/78049167
Loading...