POSEIDON PE 100-T Instruction Manual

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Instruction manual

High Pressure Breathing Air Compressors

Instruction Manual w PE 100-T

INTRODUCTION

This manual contains operating instructions and mainten ance schedules for the high pressure breathing air com pressor unit

PE 100-T

WARNING

! Pneumatic high pressure system !

The breathing air produced with the compressor units de scribed in this manual is subject to strict quality standards. Ignoring the operating and maintenance instructions can lead to severe injury or death.

This compressor has been built in accordance with the EC machine regulations 2006/42/EG. Specifications on the noise level in accordance with the machine and product safety law as of 01.05.2004 and the EC machine regula tions, chapt. I, section 1.7.4. The machine has been built according to the highest standard of technology and the generally acknowledged safety standards. Nevertheless, operation could still cause danger for the operating per sonnel or third parties, or result in damage to the machine and other values. The machine may only be used to pro duce compressed air as specified in this manual. Other use is strictly prohibited.

All instructions should be observed and carried out in the order laid down to prevent damage and premature wear to the equipment.

The manufacturer and the supplier void all responsibility for damage or injury resulting from failure to follow these instructions.

Edition January 2010

Instruction Manual w PE 100-T

Dear customer

We are happy to give you advice on any questions regard ing your BAUER compressor and help as soon as possible with any arising problems.

You can contact us Mondays to Thursdays from 0800 till 1630, Fridays from 0800 till 14 78049-0.

If you call the following extensions directly, it will save you time and continuous dialling.

Do you want to order spare parts?

on phone no. (089)

 Customer service

Phone no: (089) 78049-129 or -149 Fax no: (089) 78049-101

Explanation of the short operating instructions on the unit

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

 chapter 3.

Do you have problems with maintenance or repair work?

 Technical customer service

Phone no: (089) 78049-246 or -176 Fax no: (089) 78049-101

Do you need further information regarding your unit, ac cessories, prices etc.?

 Sales department

Phone no: (089) 78049-138, -185, -154, -205 or -202 Fax no: (089) 78049-103

Are you interested in any training courses?

 Training manager

Phone no: (089) 78049-175 Fax no: (089) 78049-103

Check oil level on compressor and petrol engine before operating unit

 chapter 4.4.1.

Keep away from hot surfaces on motor and compressor

 chapter 2.

Wear ear protectors when unit is running

 chapter 2.

Position unit level: max. inclination 5°

 chapter 3.

Read instruction manual before operating unit

 chapter 3.

Drain condensate at least every 15 minutes (3 locations)

 chapter 4.4.3. and 4.4.4.

Change satured filter cartridge

 Kapitel 4.4.4.

Petrol driven units must not be op erated indoors.

 chapter 3.

Position units with petrol engine with exhaust in wind direction to prevent exhaust fumes being sucked in by the compressor

 chapter 3.

Instruction Manual w PE 100-T

CONTENTS

1. GENERAL 1............................

2. SAFETY MEASURES 5....................

3. LOCATION, OPERATION, BOTTLE FILLING 9..

4. MAINTENANCE 14.......................

5. STORAGE, PRESERVATION 28..............

6. REPAIR INSTRUCTIONS 29.................

7. TABLES 30..............................

8. ANNEX 33..............................

INDEX

Adhesive chart, 31 Air flow diagram, 3 Annex, 33

Cooling system, 25

Design, 1 Drive system, 24

V-belt, tension meter, 24 Electrical system, 25

Filling procedure, 10 Filter system, 16

Intake filter, 15 Intermediate separator, 16 Intake air quality, 10

Location, 9 Lubrication, 14 Lubrication chart, 31

Maintenance, 14 Maintenance instructions, 14 Maintenance record, 14

Maintenance schedule, 14 Motor protection switch, 25

Oil change, 14, 15 Oil level check, 14 Oil type, 14

change of, 15

Operation, 9

Preservation, 28 Pressure gauge, 22 Pressure-maintaining valve, 21

Repair instructions, 29

Safety valves, 21 Sealant chart, 31 Storage, 28

Tables, 30 Technical data, 4 Telescopic intake tube, 15 Testing agents, 31 Tightening torque values, 30 Torque sequence, 30 Trouble-shooting, 26

Valves, 22

ANNEX

Schematic diagram motor protection switch, three phase current 76942-S1 Lubricating oil list 70851 Applicable parts list TPE100-1/0

iii

NOTES

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

Instruction Manual w PE 100-T

1. GENERAL

PURPOSE

The PE 100-T breathing air compressor is designed to com press air for breathing as required in diving applications. The max. allowable operating pressure (adjusted pressure on final pressure safety valve) is 225 bar or 330 bar.

DESIGN

The compressor unit comprises the following major assem blies:

- compressor block

- drive motor

- filter system P11

- filling assembly

- frame The design of the compressor system is shown in Fig. 1 to

Fig. 3.

Fig. 1 Compressor unit with electric motor (three-phase current)

1 Filling valve with final pressure gauge 2 Drive motor 3 Frame 4 Pressure maintaining valve

5 Filter system P11 6 Safety valve, final pressure 7 Condensate drain tap, final separator 8 Condensate drain tap, intermediate separator

Instruction Manual w PE 100-T

1 Filling hose 2 Filter system P11

5 6 87

3 Safety valve, final pressure 4 Pressure maintaining valve 5 Oil dipstick 6 Intake filter 7 Filling valve with pressure gauge 8 Handle 10 Mains plug with ON-OFF switch and moto

protection circuit breaker (dep. on country)

Fig. 2 Compressor unit with electric motor (three-phase current)

1 Drive engine 2 Filling valve with pressure gauge 3 Handle 4 Pressure maintaining valve 5 Filter system P11 6 Fanwheel cover 7 Condensate drain tap, intermediate separator 8 Condensate drain tap, final separator

2 3 4

Fig. 3 Compressor unit with petrol engine

Instruction Manual w PE 100-T

AIR FLOW DIAGRAM

See Fig. 4 . The air is drawn in through telescopic tube (necessary for units with petrol engine) -1, intake filter -2; compressed to final pressure in cylinders -3, -4, -5; recooled by intercoolers -6, -7, and aftercooler -9. The pressures of the single stages are protected by safety valves -10, -11,

-12. The compressed air is pre-cleaned in intermediate sep arator -8 and purified in filter system P11 -13. Intermediate separator and filter system P11 are drained by means of condensate drain taps -14 and -15 respectively. Pressure maintaining valve -16 provides a constant pressure within the filter assembly. The compressed, purified air is passed through filling hose -17 and filling valve -18 to the bottles to be filled. Filling pressure is indicated at pressure gauge

-19.

Fig. 4 Air flow diagram

1 Telescopic air intake 2 Intake filter 3 Cylinder 1st stage 4 Cylinder 2nd stage 5 Cylinder 3rd stage 6 Inter-cooler 1st/2nd stage 7 Inter-cooler 2nd/3rd stage 8 Intermed. separator 2nd/3rd stage 9 After-cooler 10 Safety valve 1st stage

11 Safety valve 2nd stage 12 Final pressure safety valve 13 Filter system P11 14 Condensate drain tap, intermediate separator 15 Condensate drain tap, final separator 16 Pressure maintaining valve 17 Filling hose 18 Filling valve 19 Filling coupling 20 Final pressure gauge

Instruction Manual w PE 100-T

TECHNICAL DATA

Compressor unit PE 100-TB-F02 PE 100-TE-F02 PE 100-TW-F02

Medium air Delivery Operating pressure PN200/PN300 Pressure setting, final pressure safety valve 225/330 bar Sound pressure 87 dB(A) 86 dB(A) Sound (immersion) power 100 dBA) 99 dB(A) Weight 42 kg 44 kg 44 kg

Compressor block Junior II-V001, mod. 3

Number of stages 3 Number of cylinders 3 Cylinder bore 1st stage 60 mm Cylinder bore 2nd stage 28 mm Cylinder bore 3rd stage 12 mm Piston stroke 24 mm Speed 2,300 min Intermediate pressure 1st stage 6-7 bar Intermediate pressure 2nd stage 40-60 bar Compressor block oil capacity 360 ml Oil volume between min. and max. marks 50 ml Oil type see chapter 4.4.1. lubrication Max. ambient temperature +5 ... +45 °C Max. inclination of compressor Max. operating height 0 ... 2000 m above sea level

100 l/min. (3,5 Scfm)

-1

5°

Compressor drive PE 100-TB-F02

Drive motor Robin/Subaru petrol engine Manual start model (B) EX17 Power 4.2 kW (5.7 PS) at nominal speed 3,600 min

-1

Compressor drive PE 100-TE-F02

Drive motor Three phase current Operating voltage 400 V, 50 Hz Power 2.2 kW (3 PS) Speed 2,850 min

-1

Size 90 L Type of construction B3 Type of enclosure IP54

Compressor drive PE 100-TW-F02

Drive motor Alternating current Operating voltage 230 V, 50 Hz Power 2.2 kW (3 PS) Speed 3,000 min

-1

Size LS 90 PC Type of construction B3 Type of enclosure IP44

a) free air delivered at bottle filling from 0 to 200 bar "5% b) these values are valid only if the oil of the compressor in normal position corresponds with the upper mark of the oil dipstick and

may not be exceeded.

Instruction Manual w PE 100-T

2. SAFETY MEASURES

2.1. NOTES AND WARNING SIGNS

Notes and warning signs displayed on compressors accord ing to model, application or equipment.

WARNING

Hot surfaces, do not touch

Danger of burning by touching cylinders, cylinder heads and pressure lines of indi vidual compressor stages.

WARNING

High voltage

Life threatening danger of electric shock. Maintenance work on electric units or op erating equipment may only be carried out by a qualified electrician or by a per son instructed and supervised by a quali fied electrician according to electrical reg ulations.

WARNING

Automatic compressor control, unit may start-up without warning!

Before carrying out maintenance and re pair work, switch off at the main switch or disconnect from the mains and ensure unit will not restart.

MANDATORY

Instructions must be read by persons op erating the machinery!

The instruction manual supplied and all other applicable instructions, regulations etc. must be read and understood by op erating personnel before using the ma chine.

MANDATORY

Hearing protectors must be worn!

Hearing protectors must be worn when working on a machine which is running.

NOTE

Ensure correct direction of rotation!

When switching on the machine, check the arrow to ensure correct direction of rotation of the drive motor.

2.2. IDENTIFYING THE SAFETY NOTICES

Important instructions concerning the endangerment of personnel, technical safety and operating safety will be specially emphasized by placing the following signs before the instructions.

MV3−A/10/06

WARNING

avoid endangering personnel.

2.3. FUNDAMENTAL SAFETY NOTICES

2.3.1. Authorized use

• The machine / unit is built according to state of the art technology and established safety technical regula tions. Nevertheless, its use can cause danger to life and limb of the operator or third parties or damage to the machine and other equipment.

• Operate the machine / unit only in technically perfect condition in accordance with regulations and safety and danger notices detailed in the instruction manual! In particular, immediately correct faults (or have them cor rected) which can impair safety!

• The machine / unit is exclusively for the compression of mediums (air/gas) specified in section A, chapter 1.3. “Technical data”. Any other medium or use outside that specified is not authorized. The manufacturer / supplier is not liable for damage resulting from this. The user alone is responsible for this risk. Authorization for use is also under the condition that the instruction manual is complied with and inspection and maintenance re quirements are enforced.

2.3.2. Organizational measures

• Keep the instruction manual to hand near the machine / unit at all times in the relevant holder.

• In addition to the instruction manual, observe and com ply with universally valid legal and other obligatory re gulations regarding accident prevention and environ ment protection. See chapter 2.4. This can involve, for example, contact with hazardous substances or the provision / wearing of personal protective equipment.

• Personnel engaged to operate the machine must have read the instruction manual before beginning work, es pecially the safety notices chapter. When work is al ready underway it is too late. This is particularly relevant for temporary personnel, e.g. maintenance personnel.

• Personnel may not wear long hair loose, loose clothing or jewellery, including rings. There is a danger of injury through, for example, these getting caught or being pulled into the equipment.

This notice is used with maintenance work and operating procedures and must be adhered to exactly in order to

This notice must be complied with in order to avoid damage to or destruction of the ma chine or its equipment.

This notice advises of technical requirements which the operator must take particular note of.

Instruction Manual w PE 100-T

• As far as necessary or according to regulations, use per sonal protective equipment.

• Observe all safety and danger notices on the unit.

• Keep all safety and danger notices on the machine / unit

complete and in readable condition.

• If there are any modifications to the unit or operating conditions which may affect safety, stop the unit im mediately and inform the person responsible of the fault.

• No modifications may be made to the unit which could impair safety without first obtaining permission from the suppliers. This is also the case with regard to installa tion and adjustment of safety devices and valves as well as welding of piping and reservoirs.

• Spare parts must always comply with the technical re quirements specified by the manufacturer. This is always guaranteed with original spare parts.

• Piping must be thoroughly checked (pressure and visual inspection) by the operator at appropriate time inter vals, even if no safety related faults have been noticed.

• Intervals stipulated or given in the instruction manual for recurring checks / inspections must be adhered to.

• Make sure location and operation of fire extinguishers is known.

• Pay attention to fire warning and fire fighting pro cedures.

2.3.3. Qualifications, fundamental duties

• Work on / with the unit may only be carried out by reli able personnel. Observe the legal minimum age per missible.

• Ensure that only trained personnel work with the ma chine.

• Establish the responsibilities of the machine operator and establish a procedure for him to inform a third per son of unfavourable safety conditions.

• People who are being trained or introduced to the job should only be allowed to work with the unit under con stant supervision of an experienced person.

• Work on the electrical equipment of the unit may only be carried out by a qualified electrician or by an in structed person under the direction and supervision of a qualified electrician according to electrotechnical re gulations.

2.3.4. Safety notices for operation

• Do not carry out any work if safety is questionable.

• Meet all requirements demanding that the unit is only

operated in safe and good working order. Only operate the machine if all protective and safety equipment, e.g. all detachable protective equipment, emergency shutdown devices, soundproofing is provided and in good working order.

• At least once every day, check the unit externally for damage and faults. Inform the person responsible im

mediately if anything is not as is should be (including operation). If necessary, shut the machine down im mediately and make it safe.

• Observe switching on and off processes and monitoring indications according to the instruction manual.

• Before switching on / starting up the unit, ensure that no one can be put at risk through running the unit.

• Carry out the setting, maintenance and inspection pro cesses at the intervals specified in the instruction man ual, including replacement of parts / equipment. This work may only be carried out by qualified personnel.

• Clear and make the maintenance area safe as far as necessary.

• If the unit is completely switched off for maintenance and repairwork, ensure that it is protected from unex pected start-up. Turn off main control device and re move the key and / or display a warning sign on the main switch.

• When replacing individual parts and larger assembly groups, they must be carefully fastened to the lifting de vice so that there is no risk of danger. Use only suitable and technically perfect lifting devices and equipment with sufficient lifting power and strength. Do not linger or work under suspended loads.

• Only entrust an experienced person with the fixing of loads and guiding of crane drivers. The person guiding must remain within sight or in contact with the oper ator.

• For assembly work above body height, use appropriate safety approved equipment, e.g. ladders and platforms. Do not climb on machine parts. For maintenance work at high levels, wear a safety harness.

• Clean oil, fuel or care products from the machine, in par ticular the connections and screw joints, before carrying out maintenance / repairwork. Do not use aggressive cleaning fluid. Use a fibre-free cleaning cloth.

• Before cleaning the machine with water or jet of steam (high pressure cleaner) or detergent, cover / seal all openings which for safety and/or operating reasons no water / steam / detergent may penetrate. Electric motor and switch cabinets are particularly at risk.

• When cleaning the operating room, ensure that the temperature sensors of the fire alarm and sprinkler sys tem do not come into contact with hot cleaning fluid, in order to avoid triggering the sprinkler system.

• Completely remove all covers / seals after cleaning.

• After cleaning, check all pressure lines for leaks, loose

connections, wear and damage. Immediately eliminate any faults.

• Always retighten any screw connections loosened for maintenance or repairwork.

• If it is necessary to remove safety devices for mainten ance and repairwork, these must be replaced and checked immediately after completion of the mainten ance or repairwork.

• Ensure safe and environmentally friendly disposal of consumables and old parts.

Instruction Manual w PE 100-T

2.3.5. Particular areas of danger

• Use only original fuses with specified current rating. If there is a failure in the electric energy supply, shut the unit down immediately.

• Work on electric units or operating equipment may only be carried out by a qualified electrician or by a person under the instruction and supervision of a qualified elec trician according to electric technical regulations.

• Machines and unit parts which must undergo inspec tion, maintenance and repairwork, must be discon nected from the mains supply, if specified. Parts which have been disconnected must first be checked for volt age, then earthed and short-circuited and isolated from live neighbouring parts.

• The electrical equipment of a unit must be regularly checked. Defects, such as loose screw connections or burnt wires, must be rectified immediately.

• If work is to be carried out on live parts, work with a sec ond person who can operate the emergency off switch or the main switch in the case of an emergency. Close off the work area with a red and white safety chain and a warning sign. Only use voltage isolated tools.

• Only personnel with particular knowledge and experi ence with pneumatics may carry out work on pneumatic equipment.

• Check all pressure lines, hoses and screw connections regularly for leaks and visible damage. Immediately re pair any damage. Escaping air under pressure can cause injury and fire.

• Depressurize system and pressure lines before com mencing repairwork.

• Pressurized air lines must be laid and mounted by quali fied personnel. Connections must not be mixed up. Fit tings, length and quality of the piping must correspond to requirements.

• Soundproofing equipment on the unit must be in place and functional during operation.

• The stipulated hearing protectors must be worn.

• With regard to oil, grease and other chemical sub

stances, observe the relevant safety regulations for the product.

• For loading, only use lifting device and equipment with sufficient lifting power and strength.

• Use only suitable transporters with sufficient carrying power. Secure the load properly. Use suitable fixing points.

• If necessary, provide unit with transportation brackets. Display the appropriate notice. Remove transportation brackets in the correct manner before taking into oper ation.

• Parts which need to be dismantled for transport pur poses must be carefully replaced and secured before taking into operation.

• Even when moving the unit only slightly, the unit must be disconnected from all external energy sources. Be

fore putting into use again, reconnect the machine to the mains according to regulations.

• When taking back into operation, proceed according to the instruction manual.

2.3.6. Notices of danger regarding pressure vessels

• Never open or loosen pressure vessel lids or pipe con nection parts under pressure; always depressurise the vessel or the unit.

• Never exceed the permissible operating pressure of the vessels!

• Never heat the vessels or any of their parts above the stated, maximum operating pressure.

• Always exchange damaged pressure vessels com pletely. Individual parts that are subject to pressure loads cannot be purchased as spare parts, since the vessels are tested as a complete part and the docu mentation considers them as a whole (see pressure vessel documentation, serial-numbers!).

• Always pay attention to the permissible operating mode of the pressure vessels.

We differentiate:

- vessels for static load

- vessels for dynamic load Vessels for static load: These pressure vessels are permanently under virtually

constant operating pressure; the fluctuations of pres sure are very small.

Vessels for this type of load are not marked in a particu lar way and may be used as long as the vessel inspec tions, carried out regularly, do not uncover any safetyrelevant deficiencies.

We recommend that aluminium vessels should be exchanged after 15 years at the latest.

Vessels for dynamic load: These pressure vessels may also be used under condi

tions of changing operating pressure. The pressure may vary between the atmospheric and the maximum ad missible operating pressure.

The pressure vessel documentation and the appropriate notes in the operating manual particularly characterise vessels of this type as being adequate for dynamic loads. In the technical information for these vessels you will find specifications concerning their permissible operat ing period.

Due to the variation of the operating pressure, these vessels are subject to a so-called dynamic load, which puts the vessels under great stress. The change between two different pressures is called a load change or cycle. In the technical information for these vessels you will find specifications concerning the permissible number of cycles depending on the fluctuation of the operating pressure.

Having reached half the permissible number of cycles, the vessel has to be submitted to an internal check, in which the critically stressed areas of the vessels are

Instruction Manual w PE 100-T

examined by means of suitable testing methods, in order to ensure the operating safety.

After having reached the total permissible number of load cycles, the vessel must be exchanged and scrapped.

Record the number of load cycles in writing if you do not have an automatic cycle-counter.

We recommend that aluminium vessels should be exchanged after 15 years at the latest.

Please pay attention to and follow these measures, for your own safety and that of you employees and cus tomers!

In order not to unnecessarily load the pressure vessels additionally, the non-return valves, that are meant to avoid a drop in pressure, and also the pressure maintain ing valves, which should reduce big pressure fluctu ations as well, should be checked regularly for internal and external tightness and functionality.

• Check the pressure vessels regularly on the inside and outside for damage from corrosion.

• Be particularly careful with second-hand pressure vessels, when their previous operating mode is not spe cifically clarified.

2.4. SAFETY REGULATIONS (EC; partly Germany,

only)

A compressor is identified by German law as being a filling system if pressure cylinders are filled by the system, es pecially when these cylinders are made available for third parties. The start-up and operation of compressor systems for use as filling stations is governed by the following re gulations:

Pressure vessel directive (Directive 97/23/EC) of

29.05.1997

Operating safety regulations (BetrSichV) of

27.09.2002

Machine safety law (GSG) of 11.05.2001 14th regulation to machine safety law (14. GSGV -

pressure vessel regulation) of 03.10.2002 Technical regulations for pressure gases (TRG 400,

401, 402, 730).

If a high pressure compressor is used for filling pressure vessels or for the supply of pneumatic systems, the follow ing regulations apply:

Accident Prevention Regulations (UVV): BGV A1 of 01. January 2004

Burggrafenstr. 4 - 7

10787 Berlin

The manufacturer has complied with all applicable regula tions and the unit is prepared accordingly. If desired, we offer at our Munich site a partial acceptance test according to § 14 BetrSichV. Please contact our Technical Service De partment with regard to this. They can also supply our leaflet “IMPORTANT NOTES FOR CERTIFICATION”.

According to the operation safety regulations (BetrSichV), all compressor units which will be used as filling stations must undergo an acceptance test by a professional at their location before bringing them into service. If pressure vessels (bottles) are to be filled by the compressor for a third party then the appropriate permission must be obtained from the responsible authority before the acceptance test. As a rule, this is the factory inspectorate. The procedure for obtaining permission is according to TRG 730, guidelines for permission to set up and operate filling stations. The test certificates and documents delivered with the compressor are important and may be requested during the procedure for obtaining permission. In addition, the documents be longing to the unit are important for recurrent inspections and should therefore be carefully kept.

Inspections in accordance with the regulations for preven tion of accidents will be carried out by the manufacturer or by a specialist.

No guarantees whatsoever are valid for damage caused or favoured by the non-consideration of these directions for use.

We strongly emphasize these regulations.

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

Instruction Manual w PE 100-T

3. LOCATION, OPERATION, BOTTLE FILLING

3.1. LOCATION

3.1.1. Outdoor location

The compressor unit is not seawater re sistant. At operation in salty air spray compressor with anticorrosive protec tion (see accessories catalog, available

over the customer service). Electric driven units should be operated and stored below deck in dry atmosphere. Units with petrol engine should also be stored below deck after the filling process.

WARNING

- Locate the unit level.

- On units with petrol engine it is most important that only

clean air be used, position compressor in direction of wind so that exhaust fumes are blown away from the unit.

- Turn unit as soon as wind direction changes.

- Take care that no vehicles are in direct vicinity with en

gines running.

- Do not operate unit in the vicinity of open fire (flue gas!).

Keep unit away from inflammable items. Do not smoke while petrol tank is open and while unit is in op eration.

3.1.3. Electrical installation

For installation of electrical equipment observe the follow ing:

- Comply with regulations of local electricity supply com pany.

- Arrange for the electrics to be connected by an electri cian only.

- Ensure correct installation of protective conductor.

- Check conformity of motor tension and frequency with those of electric network.

- Operate electric units only on mains sockets equipped with fault current circuit breaker according to DIN VDE 0664 with a nominal differential current of less than 30 mA (up to 16 A in single-phase AC circuits).

- For units not connected through a plug, but perma nently installed, a main switch must be provided which has a contact gap of minimum 3 mm on each pole.

- Fuse motor correctly; use safety fuses, only.

- Immediately after start-up check direction of rotation for agreement with arrow on unit.

If power supply cable is to be replaced, use cable of same type, only!

- When using extension leads or cable drums, operate unit with unwound cable, only to avoid overheating and risk of fire. The maximum length for extension cables at normal ambient temperatures (approx. 20 °C) is 25 me tres.

3.2. OPERATION

3.1.2. Indoor location

WARNING

- Ensure adequate ventilation.

- Here too, air must be free from exhaust fumes and haz ardous vapours (e.g. smoke, solvent vapours, etc.).

- If possible install unit in such a manner that the com pressor fan can get fresh air from outside, for instance through an opening in the wall.

- Ensure that an adequate exhaust air opening is pro vided.

- When locating the compressor in small rooms where natural ventilation is not ensured, measures must be taken to provide artificial ventilation (this also applies when other systems having high radiation are operating in the same room). See Installation manual, available over the customer service.

Petrol driven units must not be op erated indoors.

3.2.1. Preparation for operation

All compressor units are tested prior to delivery to the customer, so after correct

installation of the unit there should be no problem putting it into operation, observing the fol lowing points:

WARNING

mixtures. EXPLOSION occurs if an oil lubricated com pressor is operated with pure oxygen or gases with an oxygen content of more than 21%!

- Prior to first operation read Instruction Manual carefully.

Make sure that all persons handling the compressor and the filling station are familiar with the function of all con trols and monitors. Particularly observe chapter 2 SAFETY REGULATIONS.

- After taking unit into operation after a standstill period

of 2 years or more change compressor oil. When using a mineral oil change oil after one year.

The compressors described in this manual are not suitable for com pression of oxygen and nitrox gas

Instruction Manual w PE 100-T

- Fit filter cartridge. Refer to chapter. 4.4.4., Fig. 21. Without cartridge no pressure can be built up.

- Prior to first operation or operation subsequent to re pair work operate unit for at least 1 minute with open condensate valves (pressureless) to ensure proper lu brication of all parts before pressure is built up.

- Prior to each operation check the oil level according to chapter 4.4.1. and determine whether maintenance is necessary in accordance with the service manual.

- Every time the unit is started up check all systems for proper operation. If any malfunction is observed stop unit immediately and find the cause of the fault or call the service department.

Units with three phase current motor, additionally:

- Immediately after switching on the system for the first time check the direction of rotation of the motor for compliance with the arrow on the unit. If motor turns in the wrong direction, the phases are not connected properly. Shut down unit immediately and interchange two of the three phase leads (L1, L2, L3) in the motor protection switch. Never change leads at the motor ter minal board.

Units with petrol engine, additionally:

- Check engine oil level according to manufacturer's in struction manual.

- Check fuel tank. Top up if necessary.

- Open fuel shut-off valve.

3.3. FILLING PROCEDURE

WARNING

threads undamaged. Pay particular attention to dam age on the interface from hose fitting to hose. If the casing is scored or the hose is porose, hose must be discarded.

The filling valve connection is of the manual type and per mits connection to air tanks without using tools. An O-ring is provided for self-sealing due to internal overpressure. Compressed air tank filling valves for a pressure in excess of 200 bar are standardized (DIN 477, sheet 5) and connectors for 200 and 300 bar are different and cannot be mixed up.

The use of adapters is not allowed!

To ensure safe air tank removal after filling, the valve has an integral venting bore. Therefore always close tank valve first before closing filling valve. During filling procedure bottles will warm up due to recompression. After removing, allow to cool down, bottles may then be reconnected and topped up to the respective maximum filling pressure.

WARNING

chapters ”Intake air quality” and ”Scavenging the compressor unit”.

3.3.2. Breathing air quality

(see service manual for measure intervals). The norm DIN EN 12021 is the actual regulation for natural brea thing air from compressors and air bottles:

Please respect local regulations for filling hoses. Filling hoses must be in satisfactory condition and

To meet the CO2 maximum rating value in breathing air bottles, please observe the two following

The breathing air quality is a safety ha zard. The prescriptive limits of the minor constituents must be measured regularly

3.3.1. General

WARNING

ploying petrol or diesel engine it is most important to use an intake hose and observe that only clean air is drawn in. The intake hose is also recommended for units with electric engine. When operating the unit in areas with possibly high CO contents, the CO removal filter cartridge is recommended for electric driven units, also. Note that for CO contents of more than 25 ppmV in the intake air the allowed limits cannot be guaranteed even with a CO removal filter cartridge, resulting in a life-threatening CO concentration! Also, due to chemical reaction of CO with hopcalite, warm ing up of the cartridge and danger of fire may result.

Ensure intake air is free from noxious gas (CO), exhaust fumes and solvent vapour. On units em

Prescriptive limits for natural breathing air ac cording to DIN EN 12021

Constituents Limits

H2O concentration:

- direct from compressor 25 mg/m

- from a 200 bar cylinder 50 mg/m

- from a 300 bar cylinder 35 mg/m

Oil concentration 0,5 mg/m

CO concentration < 15 ppm

CO2 concentration < 500 ppm

We recommend the breathing air controller “Aerotest” from the company Dräger (see accessories catalog, availa ble over the customer service).

All breathing air control has to be recorded with date and values of the measures.

Instruction Manual w PE 100-T

In case of overstepping the prescriptive limits, see chapter

4.5. Trouble-shooting

3.3.3. Intake air quality

WARNING

Ensure intake air is free from noxious gas (CO), exhaust fumes

and solvent vapour. On units em ploying petrol or diesel engine it is most important to use an intake hose and observe that only clean air is drawn in. The intake hose is also recommended for units with electric engine. When operating the unit in areas with possibly high CO contents, the CO removal filter cartridge is recommended for electric driven units, also. Note that for CO contents of more than 25 ppmV in the intake air the allowed limits cannot be guaranteed even with a CO removal filter cartridge, resulting in a life-threatening CO concentration! Also, due to chemical reaction of CO with hopcalite, warm ing up of the cartridge and danger of fire may result.

At routine tests, CO

values beyond the permissible values

are noted from time to time. Closer investigations often show that the compressed air is taken from rooms in which one or more persons are working. At insufficient ventila tion, the CO

value in the surrounding air can increase quite

fast because of the exhaling of CO2. CO2 values from 1,000 to 5,000 ppmv in workrooms are not unusual (MAK-value (max. workroom concentration) is 5,000 ppmv). Another additional increase is caused by cigarette smoking, produc ing approx. 2g CO

( 2,000 ppmv) per cigarette. These

pollutions add up to the basic pollution of approx. 400 ppmv. The technically caused excessive increase of CO during the filling process and the CO2 peak at taking the unit into operation. Because of the reasons stated

above and for your own security, the filling of breath ing air bottles is not allowed in rooms used as work rooms.

2. Open condensate drain tap (1, Fig. 5) of interme

diate separator (on petrol units additionally the con densate drain tap (2, Fig. 5) of final separator) to unload the compressor during the starting phase.

1 2

Fig. 5 Condensate drain taps

3. Switch on the unit:

• PE 100-TE: Shift switch (1, Fig. 6) to position I.

• PE 100-TW: Press switch (2, Fig. 6) to position I.

• PE 100-TB: Shift switch (1, Fig. 7) to position I. Set

choke (2, Fig. 7) to position START. Start engine with recoil starter. As soon as motor runs smoothly return choke to normal operating position.

3.3.4. Scavenging the compressor unit

CO2 is present in the atmosphere with a natural amount of 350 to 400 ppmV. The molecular sieve used in the purifier for drying the breathing air is, as well as other capabilities, able to adsorb CO2 which is accumulated in the cartridge. After shut-down of the compressor, adsorbed CO

may be

desorbed again due to the partial pressure decrease. The now free CO

then gets washed out of the cartridge when

the compressor is started again. To avoid increased CO contents in the compressed breathing air, we recommend to flush the compressor unit 1 to 2 minutes prior to con necting the bottles, i.e. to let the air escape into the sur roundings.

Scavenging procedure

1. Ensure that no bottle is connected to the compres

sor.

Fig. 6 Motorschutzschalter

Fig. 7 Petrol engine

4. As soon as final speed is reached close condensate

drain tap (1, Fig. 5) of intermediate separator (on petrol units additionally the condensate drain tap (2, Fig. 5) of final separator).

5. Open filling valve (Fig. 8), wait until air escapes and

flush the compressor unit 1 to 2 minutes, i.e. let the air escape into the surroundings.

Instruction Manual w PE 100-T

Fig. 9 Connecting air bottle

The international connector (Fig. 10) is not permitted in the Federal Republic of Germany. In other countries it is allowed only for pressures up to 200 bar (2,850 psi).

Fig. 8 Scavenging

6. Close filling valve and start promptly the filling pro

cedure. See Filling the bottles.

3.3.5. Filling the bottles

Scavenge the compressor prior to connecting the bottle if the unit has been put out of service for more than several hours. See 3.3.4.

On models of 300 bar rated filling pres sure do not attach bottles unless rated for this pressure (note pressure stamped on tank neck).

1. Connect air bottle to filling valve. See Fig. 9.

Fig. 10 International filling connector

2. Open filling valve first, then bottle valve. See

Fig. 11.

Fig. 11 Filling air bottle

3. Ensure that condensate drain tap (1, Fig. 12) of in

termediate separator is open. On petrol units open additionally the condensate drain tap (2, Fig. 12) of final separator.

Instruction Manual w PE 100-T

1 2

Fig. 12 Condensate drain taps

4. Switch on the unit:

petrol units close additionally the condensate drain tap (2, Fig. 12) of final separator).

6. Bottle will be filled. Observe pressure gauge and

drain condensate regularly during filling.

To avoid needless aperture of the safety valve, the compressor must be switched off manually as soon as the filling pressure is reached. Filling pressure =

safety valve setting pressure - 10 bar, i.e. PN200 units must be switched off at 215 bar, PN 300 units at 320 bar.

Open condensate drain tap (2, Fig. 12)

and drain shortly the final separator prior

to switching off the unit.

• PE 100-TE: Shift switch (1, Fig. 13) to position I.

• PE 100-TW: Press switch (2, Fig. 13) to position I.

• PE 100-TB: Shift switch (1, Fig. 14) to position I. Set

choke (2, Fig. 14) to position START. Start engine with recoil starter. As soon as motor runs smoothly return choke to normal operating position.

Fig. 13 Motorschutzschalter

7. Switch off the unit:

• PE 100-TE: Shift switch (1, Fig. 13) to position 0

• PE 100-TW: Press switch (2, Fig. 13) to position 0.

• PE 100-TB: Shift switch (1, Fig. 14) to position 0.

8. Close bottle valve first (1, Fig. 15), then filling

valve by returning handle to closed position (2).

Remove compressed air bottle.

Fig. 15 Removing air bottle

Fig. 14 Petrol engine

5. As soon as final speed is reached close condensate

drain tap (1, Fig. 12) of intermediate separator (on

9. Open condensate drain of the intermediate separa

tor. Unit is ready for filling.

Repeat the above described filling procedure to fill further bottles.

3.4. SHUT-DOWN PROCEDURE

1. Switch off the unit:

• PE 100-TE: Shift switch (1, Fig. 13) to position 0

• PE 100-TW: Press switch (2, Fig. 13) to position 0.

• PE 100-TB: Shift switch (1, Fig. 14) to position 0 and

close fuel tap.

2. Drain condensate from intermediate and final sepa

rator by means of drain taps (1 and 2, Fig. 12). Let

some pressure in the unit and close all valves again to prevent moisture entering the filter and resulting saturation of the cartridge.

3. Check the oil level in the compressor and top up, if

necessary. Also check whether the compressor needs servicing in accordance with maintenance schedule - see service manual.

Instruction Manual w PE 100-T

4. MAINTENANCE

4.1. MAINTENANCE RECORD

We recommend that all maintenance work is recorded in the service book, showing the date and details of the work carried out. This will help to avoid expensive repairwork caused by missed maintenance work. If it is necessary to claim against the warranty, it will help to have proof that regular maintenance work has been carried out and that the damage has not been caused by insufficient mainten ance. Please refer to section 23 of our general terms and conditions.

4.2. MAINTENANCE INSTRUCTIONS

WARNING

pressor.

WARNING

Always shut down and decom press the complete system prior to carrying out any work on the com

Never repair pressure lines by sol dering or welding.

Check the complete system for leakage from time to time by brushing all fittings and couplings with soapy water or spray ing with leak test spray. Repair any leak age.

Only use original spare parts for mainten ance or repair work.

4.4.1. LUBRICATION

TYPE OF OIL

For proper care and maintenance of the compressor, using the correct oil is of vital importance. Depending on the ap plication of the compressor the requirements placed on the oil are:

- low deposits

- no carbonizing effect, especially in the valves

- good anti-corrosive properties

- emulsification of the condensate in the crankcase

- physiological and toxicological suitability. Due to the thermal load on the compressor only high quality

oil should be used. You are recommended to restrict oils to those which have been approved by us and are listed in our lubricating oil list.

The current oil list is provided in the

annex, chapter 8. Order this list regularly

through the BAUER Technical Service De partment.

For operation under difficult conditions such as continuous running and/or high ambient temperatures we recommend the use of BAUER high performance compressor oils, only, according to the oil list. These oils are tested in our com pressors and have proved excellent quality under ambient temperatures between +5 °C (41°F) and +45 °C (113 °F). For lower temperatures, a heating device is required which is capable of pre-heating the crankcase up to +5 °C (41 °F).

For operation under less severe conditions, for intermittent operation, or operation with long idle periods we can also recommend mineral compressor oils which are suitable for operation under ambient temperatures between +5 °C (41 °F) and +35 °C (95 °F). Here also, pre-heating is required for lower temperatures.

Change TRIPLEX longlife cartridge ac cording to chapter 4.4.4.!

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

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

4.3. MAINTENANCE SCHEDULE

The maintenance schedule is contained in the service man ual delivered with every compressor unit.

4.4. MAINTENANCE WORK

This chapter contains the maintenance work as well as a short functional description for each component.

OIL LEVEL CHECK

Check oil level daily prior to putting compressor into oper ation. Check using oil dipstick.

Take care that dip stick is inserted completely. Note that the oil level must be between minimum and maximum dipstick markings (see Fig. 16).

Oil level must not decrease below min.

mark but also not exceed max. mark as

this will cause excessive lubrication of

compressor and result in valves sooting

up.

OIL CHANGE INTERVALS

Mineral oils every 1,000 operating hours,

at least annually

Synthetic oils every 2,000 operating hours,

at least biennially

OIL CAPACITY

PE 100-T approx. 360 ml

Instruction Manual w PE 100-T

OIL PACKAGES BAUER compressor oil is available in various quantities,

refer to oil list in chapter 8.

OIL CHANGE

- Run compressor warm.

- Remove oil dipstick.

- Drain oil while still warm by means of oil drain plug. Re place the sealing, reinstall drain plug and tighten well.

- Refill with oil through the oil filler neck.

- Oil level is checked with oil dipstick, oil level is correct if at upper mark.

max.

min.

4.4.2. INTAKE FILTER

DESCRIPTION

A dry micronic filter is used to filter intake air (Fig. 17).

1 Knurled nut 2 Plastic cap 3 Micronic filter cartridge 4 O-ring 5 Opening

Fig. 17 Intake filter

Fig. 16 Oil dipstick markings

CHANGING THE OIL TYPE

To avoid severe damage to the compres sor unit when changing the oil type, the following measures should be strictly ad hered to:

− Drain oil completely while still warm.

− Check valves, coolers, separators, purifiers, and all pneumatic tubes and hoses for deposits.

If deposits are detected, perform the following:

− Change or clean valves, coolers, separators, purifiers, and all pneumatic tubes and hoses from deposits.

− Fill compressor with the new oil.

− After approx. 100 operating hours check lubricating oil for degree of contamination, and change oil again if necessary.

− Top up compressor and perform subsequent oil changes with same oil, only.

INTAKE FILTER MAINTENANCE

Filter cartridge must be changed at regular intervals accord ing to schedule in the service booklet.

- Remove knurled nut (1) and take off plastic cap (2). Re move filter cartridge (3).

- Clean filter housing inside with a damp cloth. Take care to prevent dust from entering intake pipe.

- Replace O-ring (4) if damaged.

- Insert a new filter element and fasten with cap and nut.

TELESCOPIC INTAKE TUBE

The telescopic intake tube has to be inserted in opening 5, Fig. 17. It is necessary to ensure clean air. Petrol driven breathing air compressor units are fitted with a telescopic intake tube supplied with the unit. The use of it is also rec ommended for electric power driven units.

Instruction Manual w PE 100-T

4.4.3. INTERMEDIATE SEPARATOR

DESCRIPTION

An intermediate separator is mounted on the compressor between 2nd and 3rd stage. It is designed to remove water and oil accumulating due to cooling the compressed me dium down after the compression process.

Separation is achieved by means of centrifugal action pro vided by a vortex plate.

INTERMEDIATE SEPARATOR MAINTENANCE

OUT

Proper operation will rely on the intermediate separator being properly serviced.

Open drain tap (1, Fig. 18) and drain off condensate every 15 to 30 minutes during operation.

1 2

Fig. 18 Condensate drain taps

4.4.4. FILTER SYSTEM P11

DESCRIPTION

The air leaving the final stage is cooled in the after-cooler to approx. 10 - 15 °C (18 - 27 °F) above ambient tempera ture and then enters filter system P11 with TRIPLEX long life cartridge (Fig. 19).

The filter assembly consists of separator and cartridge chamber. In the separator surrounding the cartridge chamber liquid oil and water particles are reliably separated from the compressed medium.

Residual oil and water vapors are then removed by the TRIPLEX longlife cartridge. The quality of the breathing air produced conforms to DIN EN 12021.

CONDENSATE OUT

1 Inlet coupling 2 Filter 3 Pressure maintaining valve 4 Filter head 5 Final pressure safety valve 6 Condensate drain tap 7 Condensate outlet coupling

Fig. 19 Filter system P11

CARTRIDGE SAFETY BORE

The filter system P11 is designed to prevent pressurizing in the absence of the filter cartridge. A bore provided in the filter head is sealed air-tight only if the cartridge is in place (Fig. 20).

No pressure build-up without cartridge!

Without cartridge the venting bore is not sealed, the air es capes into the atmosphere, no pressure can be built up and thus it is ensured, that unfiltered air is not supplied to the consuming device.

The venting bore is also used to check the O-rings on the cartridge pin. If air is leaking out of the venting bore even

Instruction Manual w PE 100-T

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. 20 Safety bore

Filter cartridge installation

On filter system P11 the cartridge is fitted to the filter head from below (1, Fig. 21). The two o-rings at the cartridge neck ensure pressure tightness of the venting hole. The lower o-ring at the filter head ensures pressure tightness of the filter housing. Screw in filter head hand-tight, only. The upper o-ring should just touch the housing, because it is not used for pressure tightness. So do not exert force, avoid squeezing the o-ring (2, Fig. 21). Max. 1 Nm.

Cartridge installed

LIFETIME

WARNING

originate from an abrupt pressure loss at condensate drain (1 load cycle i.e. condensate drain = 1 depressu rization, 1 pressurization). The filter housing has to be inspected internally by an expert after having reached 1/4 of the determined number of load cycles. The in spections have to be arranged by the operator. After reaching the max. number of load cycles the filter as sembly must be replaced, otherwise the housing may burst due to material fatigue.

The max. number of load cycles for the P11 Central Filter As sembly is 4,000 if operated at the max. allowable pressure difference range of 330 bar (4,700 psi). For a pressure dif ference of 225 bar (3,200 psi) the max. no. of load cycles is 35,000.

To avoid exceeding the max. number of load cycles the op erating hours should be recorded in the service manual. On condition that a max. number of four cycles per hour is not exceeded (condensate is drained every 15 minutes) the max. number of operating hours is 1,000 for 330 bar units, and 8,750 for 225 bar units.

GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE

- Depressurize system before starting any maintenance work.

- Dry inside of filter housing with a clean cloth before in stalling new cartridge and check for corrosion. Change if necessary.

- Lubricate threads and O-rings as well as threaded part of cartridge with white petrolatum DAB 9 order no. N19091 or WEICON WP 300 white order no. N19752.

- Record number of pressure bottles and/or operating hours to ensure exact attention to maintenance inter vals.

- Change cartridge before reactivating a compressor unit after out-of-service periods of more than 3 months.

- Leave cartridge in the filter as long as unit is out of ser vice.

- Keep all condensate drain valves and taps closed. Keep a minimum pressure of approx. 50 to 80 bar (700 to 1,100 psi) within the system to prevent moisture enter ing the compressor piping and filter system.

The filter system is subject to dy namic load. It is designed for a cer tain number of load cycles, which

1 2

Fig. 21 Cartridge installation

CONDENSATE DRAINAGE

Drain condensate from separator and cartridge chamber regularly by slowly opening drain taps (6, Fig. 19)

- 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.

Instruction Manual w PE 100-T

FILTER CARTRIDGES

New filter cartridges are vacuum-packed and can be stored for two years (refer to date on the cartridge). A defective vacuum package cannot protect the cartridge appropri ately against environmental influences during storage. Should the package be damaged, do not use the cartridge.

To avoid any danger to your health or damage to your unit, change used up cartridges in good time.

Never fill used up cartridges yourself! The filter material was chosen specifically by BAUER-KOMPRESSOREN for each kind of application.

Pay attention to cleanliness an hygiene when changing the filter.

FILTER SERVICE LIFETIME

The average weight (without package) of a new cartridge and the increase in weight can be checked with appropriate weighing scales. Due to inevitable production tolerances, there may be small differences compared to the given data.

The number of operating hours or the amount of possible bottle fillings per filter cartridge can be determined by the tables on page 20 and 21 taking into consideration the ambient temperature and the cartridge used.

These tables contain calculated cartridge lifetime data, that refer to defined and constant operating conditions. Toler ances at bottle fillings and different operating tempera tures can lead to considerable divergences compared to data given, which therefore can only serve as reference va lues for the user.

Cartridge 057679 is the normal TRIPLEX-cartridge for electric units.

Filling weight: 191 g; Saturation weight 205 g. Example: at an ambient temperature of 20°C, 36 to 45

10-ltr-bottles can be filled with a TRIPLEX-cartridge, which is equivalent to 12 to 15 compressor operating hours at a filling pressure of 200 bar.

On compressor units with petrol engines only use car

tridge, part no. 059183 to dry, de-oil and remove CO. Filling weight: 217 g; Saturation weight 229 g. 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.

The longer service life of the cartridge at a filling pressure of 300 bar is annihilated

by the larger volume of filled air per bottle, therefore the possible number of bottle fillings stays the same at different pressures.

CARTRIDGE CHANGE

WARNING

petrol engine. On units with electric engine either CO removal cartridge part no. 059183 or TRIPLEX car tridge part no. 057679 can be used.

engine with TRIPLEX cartridge part no. 057679. When changing from electric engine to a petrol en gine also replace cartridge part no. 057679 with car tridge part no. 059183.

absorb water vapour from surrounding air and car tridge saturated and thus be ruined.

- Prior to changing the filter cartridge, drain condensate and depressurize filter system completely by opening condensate drain valves.

- Remove filter head (4, Fig. 19).

- Extract old cartridge and insert a new one.

- Screw in filter head to the stop without use of force.

For safety reasons only CO removal cartridges part no. 059183 should be used on compressor units with

Units with petrol engine are delivered with CO removal cartridge part no. 059183 as standard, units with electric

Never remove replacement cartridge from packaging prior to actual use other wise highly sensitive molecular sieve will

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

Filling pressure p = 200 bar

Ambient temperature

tU [°C]

10 20 - 24 26 - 21

15 25 - 29 20 - 16

20 30 - 34 15 - 12

25 35 - 39 11 - 9

30 40 - 44 9 - 7

35 45 - 49 7 - 6

40 50 - 54 5 - 5

Filling pressure p = 300 bar

Ambient temperature

tU [°C]

10 20 - 24 39 - 31

15 25 - 29 29 - 24

20 30 - 34 22 - 18

25 35 - 39 17 - 14

30 40 - 44 13 - 11

35 45 - 49 10 - 9

40 50 - 54 8 - 7

Instruction Manual w PE 100-T

1. Filter cartridge 057679: lifetime [hours]

Final separator temperature

tAb [°C]

Final separator temperature

tAb [°C]

PE 100-T

Delivery

Q [l/min]

100

PE 100-T

Delivery

Q [l/min]

100

Filter cartridge 057679: bottle fillings [number] Molecular sieve mass mMS [g] = 68

Ambient

temperature

tU [°C]

10 20 - 24 17,31 - 21,80 157 - 125 236 - 187 112 - 89 79 - 62 65 - 52

15 25 - 29 23,07 - 28,79 118 - 94 177 - 142 84 - 67 59 - 47 49 - 39

20 30 - 34 30,40 - 37,63 89 - 72 134 - 108 64 - 52 45 - 36 37 - 30

25 35 - 39 39,65 - 48,64 69 - 56 103 - 84 49 - 40 34 - 28 29 - 23

30 40 - 44 51,21 - 62,41 53 - 44 80 - 65 38 - 31 27 - 22 22 - 18

35 45 - 49 65,52 - 79,28 42 - 34 62 - 51 30 - 25 21 - 17 17 - 14

40 50 - 54 83,08 - 99,85 33 - 27 49 - 41 23 - 19 16 - 14 14 - 11

Bottle volume VF [m3]

Bottle size at pressure p [bar]

l [ltr.] 200 300

7 1,4 2,1

10 2 3

12 2,4 3,6

Final separa tor tempera

ture

tAb [°C]

Air humidity,

saturated

X [g/m3]

Processable air volume Va

[m3]

at pressure p [bar]

200 300 7 l 10 l 12 l

Number of bottle fillings n= processable air volume / bottle volume = Va / VF

Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3]

Processable air volume: Va [m3] = 0,2 x mMS [g] / (X [g/m / p [bar]) = 0,2 x p [bar] x mMS [g] / X [g/m3]

Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])

Number of bottle fillings n

acc. to bottle size

Instruction Manual w PE 100-T

2. Filter cartridge 059183: lifetime [hours]

Filling pressure p = 200 bar

Ambient temperature

tU [°C]

10 20 - 24 22 - 18

15 25 - 29 17 - 13

20 30 - 34 13 - 10

25 35 - 39 10 - 8

30 40 - 44 8 - 6

35 45 - 49 6 - 5

40 50 - 54 5 - 4

Filling pressure p = 300 bar

Ambient temperature

tU [°C]

10 20 - 24 34 - 27

15 25 - 29 25 - 20

20 30 - 34 19 - 15

25 35 - 39 15 - 12

30 40 - 44 11 - 9

35 45 - 49 9 - 7

40 50 - 54 7 - 6

Final separator temperature

tAb [°C]

PE 100-T

Delivery

Q [l/min]

100

PE 100-T

Delivery

Q [l/min]

100

Filter cartridge 059183: bottle fillings [number] molecular sieve mass mMS [g] = 58

Ambient

temperature

tU [°C]

10 20 - 24 17,31 - 21,80 134 - 106 201 - 160 96 - 76 67 - 53 56 - 44

15 25 - 29 23,07 - 28,79 101 - 81 151 - 121 72 - 58 50 - 40 42 - 34

20 30 - 34 30,40 - 37,63 76 - 62 114 - 92 55 - 44 38 - 31 32 - 26

25 35 - 39 39,65 - 48,64 59 - 48 88 - 72 42 - 34 29 - 24 24 - 20

30 40 - 44 51,21 - 62,41 45 - 37 68 - 56 32 - 27 23 - 19 19 - 15

35 45 - 49 65,52 - 79,28 35 - 29 53 - 44 25 - 21 18 - 15 15 - 12

40 50 - 54 83,08 - 99,85 28 - 23 42 - 35 20 - 17 14 - 12 12 - 10

Bottle volume VF [m3]

Bottle size at pressure p [bar]

l [ltr.] 200 300

7 1,4 2,1

10 2 3

12 2,4 3,6

Final separa tor tempera

ture

tAb [°C]

Air humidity,

saturated

X [g/m3]

processable air volume Va

[m3]

at pressure p [bar]

200 300 7 l 10 l 12 l

Number of bottle fillings n= processable air volume / bottle volume = Va / VF

Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3]

Processable air volume: Va [m3] = 0,2 x mMS [g] / (X [g/m / p [bar]) = 0,2 x p [bar] x mMS [g] / X [g/m3]

Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])

Number of bottle fillings n

acc. to bottle size

4.4.5. FILLING VALVE

Instruction Manual w PE 100-T

To protect filling valve against contamination a sintered metal filter is screwed in the filling valve body.

- Unscrew pressure gauge (3, Fig. 22) from filling valve body (1).

- Screw off sintered metal filter (2) with a suitable screw driver.

- To clean filter element, the best method is to use hot soapy water and to blow dry with compressed air. Replace if heavily soiled.

- Screw in filter element,.

- Seal pressure gauge with PTFE tape or Loctite 243 and screw in tight to desired position.

Fig. 23 Pressure maintaining valve

MAINTENANCE

The pressure maintaining valve (Fig. 23) is adjusted at the factory to the required pressure and normally does not re quire regular maintenance.

4.4.7. SAFETY VALVES

DESCRIPTION

All three compressor stages are protected by safety valves as follows

Fig. 22 Sintered metal filter

4.4.6. PRESSURE MAINTAINING VALVE

DESCRIPTION

A pressure maintaining valve (1, Fig. 23) is mounted on the filter head of the filter system P11.

It ensures that pressure is built up in the filter even from the start of delivery, thus achieving a constant, optimum filtra tion. It will also guarantee proper working conditions for the final stage cylinder.

The pressure maintaining valve is adjusted to 150 ±10 bar

(2,175 psi).

1st stage 9 bar (130 psi) 2nd stage 80 bar (1,160 psi)

The safety valve for protection of the last stage is mounted on top of the filter system P21 and is adjusted to the operat ing pressure of the unit (see chapter 1, Technical Data), 225 bar (3,200 psi) for the standard units, 330 bar (4,700 psi) for models -H or -HU. All safety valves are sealed at the fac tory.

If one of the intermediate pressure safety valves blows off, the valves in the next stage are not closing properly, afford ing valve check. The cause of the trouble is usually the inlet valve of the next stage. See also chapter 4.4.9.

MAINTENANCE

Checking function

The final pressure safety valve has to be checked regularly. For this purpose the safety valve can be vented manually. Turn knob on top of the valve anticlockwise until valve blows off (Fig. 24).

This just ensures that the valve is functional and will release pressure in case of a malfunction. To check the blow-off pressure value refer to ”Blow-off pressure check”.

Instruction Manual w PE 100-T

stage

Venting

Fig. 24 Venting the final pressure safety valve

Checking blow-off pressure

Check blow-off pressure of the final pressure safety valve regularly, see service manual. Pump unit to final pressure with shut-off valve closed until safety valve blows off. Check blow-off pressure of safety valve at pressure gauge. If devi ation is 10% or more, replace safety valve.

4.4.9. VALVES

DESCRIPTION

The valve heads of the individual stages form the top part of the cylinders. The intake and pressure valves are fitted in side the valve heads. Note that the valves are operated by the flow of the air.

On the suction stroke, the intake valves open and the air flows into the cylinders. At the start of the compression stroke the intake valve closes and the air opens the pressure valve, Fig. 26.

Intake and pressure valve of the 1st stage is a plate valve (Fig. 27).

INITIAL OPERATIONAL CHECK

After maintenance work on the valves, valves should be checked. Note that the intake line to the valve heads should be warm and outlet piping should be hot. Valves are then operating properly.

4.4.8. PRESSURE GAUGE

DESCRIPTION

The compressor unit is equipped with a final pressure gauge (Fig. 25). The red marking on it shows the max. allowable operating pressure.

Mark

Fig. 25 Final pressure gauge

MAINTENANCE

Intake Pressure

Fig. 26 Valve operation

Intake sidePressure side

We recommend that the final pressure gauge is checked from time to time. For this purpose we have developed a special test pressure gauge with an adaptor which immedi ately recognizes any deviations in readings (see High Pres sure Accessories Catalogue 8550/..).

Slight deviations during operation are normal and can be ig nored. Excessive inaccuracy will require the pressure gauge to be replaced.

to 2nd stage

Fig. 27 Valve 1st

N4860−F98

Top view

from intake fil ter

Instruction Manual w PE 100-T

GENERAL INSTRUCTIONS FOR CHANGING THE VALVES

- Always replace valves as a complete set.

- Observe the correct sequence when fitting together again.

- Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the valves.

- Valve head screws must be tightened with a torque wrench (see tightening torque values chapter 7.).

- Check the valve space in the valve heads for dirt and clean, if necessary.

- 30 minutes after restarting the compressor stop unit, let it cool down to ambient temperature and retighten valve studs and cap nuts. Otherwise valves could work loose due to setting of the gaskets.

- Use only satisfactory gaskets and O-rings on reas sembly.

- After finishing all maintenance work on the valves, turn the compressor manually using the flywheel and check whether all items have been correctly installed.

CHANGING THE VALVES OF THE 1ST STAGE

Intake and pressure valves of the 1st stage are combined in one plate valve under the valve head, see Fig. 28.

- Remove four valve head screws (5) from valve head (1). Take off valve head.

- Remove gasket (2) and plate valve (3).

- When re-installing the valve, check that mark ”S” is facing upwards and towards intake filter side. The cross bar of gasket (2) seals the intake opening with respect to the two outlet openings of the pressure valve.

CHANGING THE VALVES OF THE 2ND STAGE

Both, pressure and intake valves can be serviced from out side, see Fig. 29.

- Remove two captive nuts (1) and spring-washers (2).

- Remove plate (3).

- Remove valves (4) and (7) using two screw-drivers as shown in Fig. 31.

- Assemble in reverse sequence. Position spring-washers with curved side facing upwards. Fasten nuts so that plate (3) is parallel to the valve head. Torque with 10 Nm (1 kpm).

6 5

1 Valve head 2 Gasket 3 Plate valve 4 O-ring 5 Valve head screw 6 Washer 7 Nut

Fig. 28 Valve head 1st stage

- Loosen two cap nuts from tube connectors at valve head and safety valve connector and remove intercooler.

1 Nut 2 Spring-washer 3 Plate 4 Pressure valve 5 O-ring 6 Valve head 7 Intake valve 8 Valve head screw

Fig. 29 Valve head 2nd stage

CHANGING THE VALVES OF THE 3RD STAGE

On this valve head, the valves are arranged on the upper and lower side due to the small diameter of the 3rd stage, see Fig. 30.

For removal and installation of the intake valve (4) use special tool which is also part of the tool set delivered with the unit.

Pressure valve (3) is merely inserted into valve head (5). It is sealed by O-ring (2) and fixed to the valve head by bolt (1).

Instruction Manual w PE 100-T

1 Torque stud 2 O-ring 3 Pressure valve 4 Intake valve 5 Valve head 6 Valve head cover 7 Allen screw 8 Gasket

Fig. 30 Valve head 3rd stage

Change intake and pressure valve of 3rd stage together only.

Remove of 3rd stage pressure valve (3) according to Fig. 30.

- Unwind torque stud (1) a couple of turns.

- Remove allen screws (7), take off valve head cover (6).

- Put two screwdrivers into the groove of pressure valve body (Fig. 31). If necessary turn valve loose at first using a 13 mm spanner on the flat surfaces.

- Lift out pressure valve (3) together with O-ring (2).

Reinstall pressure valve (3) in reverse sequence:

- Check O-ring for abrasion and replace if necessary. Put O-ring (2) into valve head (5).

- Insert pressure valve (3). Install valve head cover (6).

- Fasten valve head with allen screws (7) and washers (8).

- Screw in torque stud (1) with 20 Nm (2 kpm).

4.4.10. COMPRESSOR DRIVE SYSTEM

DESCRIPTION

The compressor is driven by the drive motor through a Vbelt. The motor is mounted on the base plate and requires adjustment for proper V-belt tension.

Improper v-belt tension and adjustment of the pulleys will result in extreme v-belt abrasion and premature wear.

MAINTENANCE

Checking the drive belt tension

- The best tension for a belt drive is the lowest possible, where the belt under full load does not slip. A rough value for this is when the belt deflects 10 mm when pressed with thumb pressure between the two pulleys (Fig. 32). For best results we recommend our v-belt ten sion meter, part no. N25238.

V-belt tension adjustment

- Slightly loosen motor mounting nuts

- Adjust motor until the belt tension is correct (see Fig. 32).

- Tighten motor mounting nuts.

- Run motor for approx. 5 minutes. Stop motor, check Vbelt tension, and readjust if required.

- Check that after tension adjustment and tightening the motor mounting nuts, both pulleys are in a straight line to avoid excessive wear of the V-belt. Hold a straight edge against compressor and motor V-belt pulleys as shown in Fig. 33: edge must be parallel to the v-belt.

10 mm

Fig. 32 Checking V-belt tension

Fig. 31 Removal of 3rd stage pressure valve

Fig. 33 V-belt pulley adjustment

Instruction Manual w PE 100-T

4.4.11. ELECTRICAL SYSTEM

DESCRIPTION

This section describes the standard electrical system.

For schematic diagram, see annex.

The electrical equipment of the compressor unit consists of:

- drive motor

- electric control system To start the electric motor and enable the functioning of the

electric control, the following components are essential:

- main switch and main fuse, both to be installed by the customer.

DRIVE MOTOR

The compressor unit is driven by an alternating or a three phase current motor by means of a V-belt.

MOTOR PROTECTION SWITCH (ALTERNATING CUR RENT MOTOR)

Protection of the motor is ensured by the thermic releases integrated into the motor protection switch (2, Fig. 34). The response value is preset.The motor is switched on manually by pressing the 0-I switch to I. For safety of the operating personnel all voltage carrying parts have a protective cover.

MOTOR PROTECTION SWITCH (THREE-PHASE MOTOR)

The motor is switched on manually by turning the switch to 1 (1, Fig. 34). It is switched off manually by turning the switch to 0.

For safety of the operating personnel all voltage carrying parts have a protective cover.

After the switch has shut off by overcur rent triggering, the motor can be re

started by pressing the start-button not before the bi-metal in the switch has cooled down. This may last a couple of minutes.

Fig. 34 Motor protection switches

4.4.12. COOLING SYSTEM

The cylinders of the compressor block, the intermediate coolers and the after-cooler are air-cooled.

For this purpose, the compressor is equipped with a fan wheel connected to the counter-weight at the crankshaft end opposite to the V-belt pulley. It draws the cooling air through the fanwheel cover from the surroundings.

Protection of the motor is ensured by the thermomagnetic releases integrated into the motor protection switch. The response value of the electromagnetic releases (protection against short-circuit) is preset.

MAINTENANCE

For the electrical system no regular maintenance is re quired.

Refer to chapter 3. for proper installation and cooling air supply. For maximum ambient temperature, see Technical Data, chapter 1.

Instruction Manual w PE 100-T

4.5. TROUBLE-SHOOTING

Trouble Cause Remedy

Drive motor (electric)

Motor will not start Electric circuitry faulty Check all fuses, terminal connections,

wire leads, make sure that motor data

complies with mains supply Motor/engine runs eccentrically V-belt worn Replace Motor protection switch is switching

off the unit

Motor protection switch is switching off the unit

Drive motor (petrol)

Motor will not start See motor instructions See motor instructions Motor runs eccentrically V-belt worn Replace, see chapter 4.4.10. Motor stops Low oil level Top up oil

Drive system

Excessive v-belt wear (black deposits on belt guard)

Compressor

Compressor does not attain final pres sure

Wrong adjustment of the motor pro tection switch

Unsufficient voltage because of weak power supply

Power supply cable to long or to thin Use suitable cable

V-belt tension Re-tighten, see chapter 4.4.10. Pulleys not aligned Re-adjust, see chapter 4.4.10.

Condensate drain valve(s) leaking Tighten and reseal

Set to nominal motor current. Observe

temperature compensation (+20 °C

=1,0)

For ambient temperature

+ 10 °C : correction factor 0,94

+ 30 °C : correction factor 1,05

+ 40 °C : correction factor 1,12

Switch off other consuming devices

Air delivery drops

Intermediate pressure safety valve blows

Compressor overheats

Taste of oil in the air

Final pressure safety valve defective (blows too soon)

No cartridge in filter system P11 (air escaping through cartridge safety bore)

Vent screw for final pressure safety valve not in operating position

Intake filter soiled Clean or replace filter cartridge, see

Pipe coupling leaking Retighten couplings Excessive wear of 3rd stage piston Replace piston and sleeve of 3rd stage Intermediate pressure too high be

cause of defective inlet or pressure valve of the following stage

Safety valve leaking Replace safety valve Insufficient cooling air Check location; ensure proper cooling

Ambient temperature too high Check location; ambient temperature

Direction of rotation is wrong Correct direction of rotation Inlet and pressure valve of one stage is

leaking TRIPLEX cartridge saturated Replace cartridge, see chapter 4.4.4. Unqualified lubricant being used Replace oil with an approved brand,

Replace safety valve

Replace cartridge, see chapter 4.4.4.

To vent, unscrew until completely

open, see chapter 4.4.7.

chapter 4.4.2.

Check/replace inlet or pressure valve,

see chapter 4.4.9.

air flow, see chapter 3.1.

max. +45 °C (113 °F), see chapter

3.1.

Check valves, clean/replace if neces

sary, see chapter 4.4.9.

see Lubricating oil list in annex.

Instruction Manual w PE 100-T

RemedyCauseTrouble

High oil consumption

Air escaping through cartridge safety bore

Breathing air quality

Water concentration too high

Oil concentration too high

CO concentration too high

CO2 concentration too high

Piston rings, Pistons or cylinders worn out

Intake filter clogged Replace filter cartridge, see chapter

Compressor too hot Enhance cooling, see chapter 4.4.12. Cartridge missing Insert cartridge, see chapter 4.4.4. Cartridge installed but O-rings defec

tive

Filter cartridge saturated Replace cartridge, see chapter 4.4.4. Ambient temperature too high Check location; ambient temperature

Intermediate and/oder final separator dirty or clogged

Pressure maintaining valve faulty Replace pressure maintaining valve Filter cartridge saturated Replace cartridge, see chapter 4.4.4. Unqualified lubricant being used Replace oil with an approved brand,

Piston rings worn out Replace piston rings Filter cartridge saturated Replace cartridge, see chapter 4.4.4. Unqualified filter cartridge being used Replace cartridge with CO removal

High CO concentration in the atmo sphere (combustion gas, exhaust emis sion...)

High CO2 concentration in the atmo sphere

High CO2 concentration in the filter system

Replace defective parts, see chapter

4.4.9.

4.4.2.

Check/replace O-rings, see chapter

4.4.4.

max. +45 °C (113 °F) Clean separator

see Lubricating oil list in annex.

cartridge, see 4.4.4. Change location, see chapter 3.1.

Connect a CO2 absorber (e. g. “AeroGuard”, see accessories catalog) to the compressor

Scavenge the filter system before filling, see chapter 3.3.4.

Instruction Manual w PE 100-T

5. STORAGE, PRESERVATION

GENERAL

If the compressor is put out of service for more than six months, the unit should be preserved in accordance with the following instructions: Make sure the compressor is kept indoors in a dry, dust free room. Only cover the com pressor with plastic if it is certain that no condensation will form under the sheet. Nevertheless, the sheet should be re moved from time to time and the unit cleaned on the out side. If this procedure cannot be followed and/or the com pressor is going to be taken out of service for more than 2 years, please contact our Technical Service Department for special instructions.

The compressor is not resistant to saltwater! If not in use keep unit in a dry place.

PREPARATION

Before preserving the compressor unit, run it warm and when it reaches the specified service pressure, keep it run ning for approx. 10 minutes.

Then carry out the following:

- Check all pipes, filters and valves (also safety valves) for leakage.

- Tighten all couplings, as required.

- After 10 minutes, open the filling valves or the outlet valve and run the compressor at the set minimum pres sure (pressure maintaining valve, see chapter 4.4.6.) for approx. 5 minutes.

- After these 5 minutes, shut the system down. Drain con densate from separators. Depressurize unit. Shut filling valves.

- Open filters and grease threads.

- Ensure that filter cartridge remains in the filter! This will prevent oil entering filling lines as a result of preservation procedures.

- Remove intake filter from manifold and all intake lines from valve heads.

- Let compressor unit cool down.

PRESERVING THE COMPRESSOR

- Turn the compressor on and spray a small amount (ap prox. 10 ccm/0.6 cu. in.) of compressor oil into the valve head inlet port while the compressor is running. Do not let the compressor warm up too much, to keep oil sticky.

- Shut compressor unit off.

- Close all valves.

- Place the dust cap onto the inlet port.

PRESERVING THE MOTOR/ENGINE

Preserve the motor/engine according to the instructions of the motor/engine manufacturer.

PREVENTIVE MAINTENANCE DURING STORAGE

Run the compressor once every 6 months as described in the following:

- Remove the dust cap from the inlet port and insert the intake filter.

- Open the filling valves or the outlet valve and let the unit run for approx. 10 minutes or until the pressure gauges indicate the correct values.

- Stop the compressor.

- Open condensate drain valves and release compressed air. Close condensate drain valves again.

- Carry out preservation procedure according to chapter ”preserving the compressor”

Changing the lube oil for preserving

- After prolonged storage, the oil will age in the com pressor and engine. It should be drained after 2 years at the latest and replaced with fresh oil.

- The stated period can only be attained when the crank case is sealed during the preservation period in accord ance with the preservation requirements.

- After changing the oil, turn the compressor and the en gine or run them for the required period.

- Check the lubrication of the compressor when putting the unit into operation once every six months or when turning the compressor. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil pressure regulator and if the oil pressure gauge indicates the prescribed pressure.

REACTIVATING THE COMPRESSOR UNIT

- Remove the dust cap from the inlet port and insert the intake filter.

- Check the oil level of the compressor.

- Check the motor/engine according to the manufac turer's instructions.

- Open the purifier and change all filter cartridges.

- Run the compressor warm with open filling valves or outlet valve for approx. 10 minutes.

- Check the oil pressure on the pressure gauge. If there is any fault, check the lubrication of the compressor.

- After 10 minutes, close the filling valves or the outlet valve and run the unit up to final pressure until the final pressure safety valve blows.

- Check the inter-pressure safety valves for leakage.

- Establish cause of any fault from the trouble-shooting table, chapter 4.5., and take corrective action.

- Stop the system when running properly, the compressor is then ready for operation.

6. REPAIR INSTRUCTIONS

GENERAL

Preventive maintenance usually involves replacing the valves, gaskets and sealing rings as well as carrying out the maintenance work. Repair work can be carried out on the compressor block to a certain extent but a certain experi ence and skill is necessary. It should be noted, however, that

- no repair should be carried out on the crankdrive nor on the bearings

- safety valves are not repaired but always replaced com pletely.

For many BAUER compressor units, workshop manuals are available through our customer service.

For questions on maintenance and repair, please contact our technical service department.

Instruction Manual w PE 100-T

7. TABLES

TIGHTENING TORQUE VALUES

Unless otherwise specified in text, the fol lowing torque values apply. All valve head screws require torque wrench tight ening! The indicated torque values are valid for bolts in greased condition. Re

place self-retaining nuts on reassembly.

Bolt or screw Thread max. torque

Hex and allen head M 6 10 Nm (7 ft.lbs)

Hex and allen head M 8* 25 Nm* (18 ft.lbs)

Hex and allen head M 10 45 Nm (32 ft.lbs)

Hex and allen head M 12 75 Nm (53 ft.lbs)

Hex and allen head M 14 120 Nm (85 ft.lbs)

Hex and allen head M 16 200 Nm (141 ft.lbs)

Pipe connections (swivel nuts): Finger-tight + 1/2 turn

TORQUE SEQUENCE

Tighten valve head and cylinder bolts/nuts equally in the se quence shown in Fig. 35.

Be sure to tighten all parts in cold condition only.

Fig. 35 Torque sequence

* Exception: mounting bolts of final pressure safety valve: 10 Nm

Instruction Manual w PE 100-T

LUBRICATION CHART

Usage Lubricants

Rubber and plastic parts, filter housing threads WEICON WP 300 WHITE part no. N19752 or

BAUER special grease part no. 072500

Sealing rings BAUER special grease part no. 072500

Shaft seal (seal) Shaft seal (shaft)

Screws, bolts, threads WEICON ANTI-SEIZE AS 040 P part no. N19753 or

For compressor lubricating oils refer to oil list in chapter 8.

ADHESIVE AND SEALANT CHART

Usage Adhesives and Sealants

Screws Loctite 2701

Seals for conical threads Loctite 243

Metal - metal seals High temperature connections, e.g. valve heads, cylin ders

Paper gaskets Loctite FAG 2

BAUER special grease part no. 072500 Klüber SK 01-205

equivalent compound with copper or MoS

Temperature resistant compound, e.g. WACKER E10, part no. N18247

additives

TESTING AGENTS

Usage Testing agents

Tube connectors, tubes Leakage test spray, part no. FM0089

Instruction Manual w PE 100-T

8. ANNEX

• Schematic diagram Lubricating oil list Parts list

Instruction Manual w PE 100-T

Schematic diagram motor protection switch, three phase current

Hauptsicherung bauseits / Main fuse by customer / Fusible principal coté client

Ein/Aus

On/Off

Marche/

Arrêt

Schaltplan/Schematic diagram/Schéma électrique

Motorschutzschalter Motor protection switch Disjoncteur

76942−S1

Instruction Manual w PE 100-T

Oil list w Breathing air compressors

GENERAL

After extensive tests with many different kinds of lubricants, we have decided to authorize the following brands of oil for use in BAUER compressors under the given operating conditions.

This list is up to date at the time of printing and will be reviewed continuously. Should your list or your instruction manual be older, please request the latest edition from BAUER Customer Services. When using any of the oils listed below , please follow the oil change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit.

Oil type Use

Brand name Designation Type

Special Compressor oil Part no. N28355

Special Compressor oil Part no. N22138

Oil type

S synthetic oil M mineral oil

Application

A approved for breathing air application with BAUER air purification systems N approved for nitrox application (with BAUER membrane unit, only) a) oil change every 1000 operating hours b) oil change every 2000 operating hours c) oil change every 1000 operating hours in case of nitrox application

b) c)

Breathing air

+ + + +

Nitrox

−

Ambient

temperature

+5 ...+45 °C

Suitability

+ = suitable

− = not suitable

Oil list w Breathing air compressors

TYPE OF OIL

Due to the thermal load on the compressor only high quality oil should be used. You are recommended to restrict oils to those which have been approved by us and are listed in the instruction manual or in the lubricating list on page 1.

Our compressor units are delivered ex works with lubricating oil filled into the crankcase or as consignment, depending on the model, as follows:

Breathing air compressor units: BAUER Special Compressor oil, part no. N28355

Nitrox compressor units: BAUER Special Compressor oil, part no. N28355

For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recommend the BAUER special synthetic compressor oils acc. to the list on the previous page. These have proved excellent quality under ambient temperatures between +5 °C and +45 °C. For lower temperatures a compressor heating device is required which is capable of pre−heating the unit up to +5 °C.

For operation under less severe conditions, and for intermittent operation, i.e. when the compressor is not used for longer periods between the operating periods, we also recommend the use of the mineral oil acc. to the list on the previous page. This oil is suitable for ambient temperatures between +5 °C and +45 °C. Here also, a pre−heating device will be required if ambient temperatures should fall below +5 °C.

Changing the Oil Type

To avoid severe damage to the compressor unit when changing to another oil type, the following measures should be strictly adhered to.

− Drain mineral oil while still warm.

− Check valves, coolers, separators, purifiers and all pneumatic tubes and hoses for deposits. If deposits are present, perform the following steps:

− Remove deposits or change valves, coolers, separators, purifiers and all pneumatic tubes and hoses.

− Change oil filter, if applicable.

− Fill compressor with the new oil.

− After approx. 100 operating hours, replace oil filter again (if applicable). and change oil.

− Top up with same oil type.

OIL CHANGE

Mineral oil every 1000 operating hours, at least annually Synthetic oil every 2000 operating hours, at least every two years Oil change volume see compressor unit operating manual

BAUER compressor oil is available in the following quantities:

Oil quantity  Oil type 

0.5 ltr. bottle part no. N28355−0,5 part no. N22138−0,5 1 ltr. bottle part no. N28355−1 part no. N22138−1 5 ltr. container part no. N28355−5 part no. N22138−5 20 ltr. container part no. N28355−20 part no. N22138−20

Synthetic oil N28355 Mineral oil N22138

POSEIDON PE 100-T Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. GENERAL

2. SAFETY MEASURES

3. LOCATION, OPERATION, BOTTLE FILLING

4. MAINTENANCE

4.5. TROUBLE-SHOOTING

5. STORAGE, PRESERVATION

6. REPAIR INSTRUCTIONS

7. TABLES

8. ANNEX