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Instruction Manual w Junior II
INTRODUCTION This manual contains operating instructions and mainten­ ance schedules for the high pressure breathing air com­ pressor unit

Junior II

WARNING ! Pneumatic high pressure system ! The breathing air produced with the compressor units de­ scribed in this manual is subject to strict quality standards. Ignoring the operating and maintenance instructions can lead to severe injury or death. This compressor has been built in accordance with the EC machine regulations 2006/42/EG. Specifications on the noise level in accordance with the machine and product safety law as of 01.05.2004 and the EC machine regula­ tions, chapt. I, section 1.7.4. The machine has been built according to the highest standard of technology and the generally acknowledged safety standards. Nevertheless, operation could still cause danger for the operating per­ sonnel or third parties, or result in damage to the machine and other values. The machine may only be used to pro­ duce compressed air as specified in this manual. Other use is strictly prohibited. All instructions should be observed and carried out in the order laid down to prevent damage and premature wear to the equipment. The manufacturer and the supplier void all responsibility for damage or injury resulting from failure to follow these instructions.

Edition January 2010  2010 BAUER Kompressoren GmbH, München All rights reserved

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Instruction Manual w Junior II
Dear customer We are happy to give you advice on any questions regard­ ing your BAUER compressor and help as soon as possible with any arising problems. You can contact us Mondays to Thursdays from 0800 till 1630, Fridays from 0800 till 1400 on phone no. (089) 78049-0. If you call the following extensions directly, it will save you time and continuous dialling. Do you want to order spare parts? . Customer service Phone no: (089) 78049-129 or -149 Fax no: (089) 78049-101 Do you have problems with maintenance or repair work? . Technical customer service Phone no: (089) 78049-246 or -176 Fax no: (089) 78049-101 Do you need further information regarding your unit, ac­ cessories, prices etc.? . Sales department Phone no: (089) 78049-138, -185, -154, -205 or -202 Fax no: (089) 78049-103 Are you interested in any training courses? . Training manager Phone no: (089) 78049-175 Fax no: (089) 78049-103

Explanation of the short operating instructions on the unit Read instruction manual before operating unit Position unit level: max. inclination 5

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chapter 3.

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chapter 3.

Check oil level on compressor and petrol engine before operating unit

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

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chapter 4.4.1.

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chapter 3.

Drain condensate at least every 15 minutes (3 locations)
A

Keep away from hot surfaces on motor and compressor

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C

chapter 4.4.3. and 4.4.4.

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chapter 2.

B

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

Wear ear protectors when unit is running

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chapter 2.

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chapter 3.

Petrol driven units must not be op­ erated indoors.

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chapter 3.

ii

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

Instruction Manual w Junior II NOTES Model: Serial No.: Date of purchase: Dealer address / phone no.: iv ..

Safety valve -20 is adjusted to a blow off pressure of 225 bar. Filling pres­ sure is indicated at pressure gauge -19. final pressure Filter system P21 B-Timer Condensate drain taps Filling hose Exhaust Air filter Tank Throttle lever Choke lever Fuel cock 1 . GENERAL AIR FLOW DIAGRAM See Abb. -4.base plate and frame The design of the compressor system is shown in Abb. The max. 4. and aftercooler -9.filling assembly . 1 1 2 3 4 5 6 7 Compressor unit with petrol engine 8 9 10 11 12 13 14 Starter rope Engine stop switch (ignition) Filling valve with final pressure gauge Safety valve. -7.compressor block .Instruction Manual w Junior II 1. Intermediate separator and filter system P21 are drained by means of condensate drain valves -15. PURPOSE The JUNIOR II breathing air compressor is designed to compress air for breathing as required in diving applica­ tions. -5. compressed to final pressure in cylinders -3. The compressed. The compressed air is pre-cleaned in intermediate sep­ arator -8 and purified in filter system P21 -13.filter system P21 . -11. purified air is passed through filling hose -17 and filling valve -18 to the bottles to be filled. allowable operating pressure (adjusted pressure on final pressure safety valve) is 225 bar or 330 bar. recooled by intercoolers -6. intake filter -2. Pressure maintaining valve -16 provides a constant pressure within the filter assembly.drive motor . The air is drawn in through telescopic tube (necessary for units with petrol engine) -1. 1 2 3 4 5 6 7 8 9 Abb. 5 . With the change over device model it is possible to fill bottles with 200 bar nominal pressure. The pressures of the single stages are protected by safety valves -10. DESIGN The compressor unit comprises the following major assem­ blies: . just by opening valve -21 at filling valve -18. 1 to Abb. -12.

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

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

.1. 4 .5 Scfm) PN200/PN300 225/330 bar 86 dB(A) 99 dB(A) 44 kg 47 kg Junior.2 kW (5.000 min-1 LS 90 PC B3 IP44 a) b) free air delivered at bottle filling from 0 to 200 bar "5% these values are valid only if the oil of the compressor in normal position corresponds with the upper mark of the oil dipstick and may not be exceeded. mod. and max.300 min-1 6-7 bar 40-60 bar 360 ml 50 ml see chapter 4. +45 C 5 0 . final pressure safety valve Sound pressure Sound (immersion) power Weight Compressor block Number of stages Number of cylinders Cylinder bore 1st stage Cylinder bore 2nd stage Cylinder bore 3rd stage Piston stroke Speed Intermediate pressure 1st stage Intermediate pressure 2nd stage Compressor block oil capacity Oil volume between min.2 kW (3 PS) 2. 50 Hz 2.4.850 min-1 90 L B3 IP54 JuniorII-W Alternating current 230 V. 3 3 3 60 mm 28 mm 12 mm 24 mm 2. (3. lubrication +5 . inclination of compressorb) Max.. marks Oil type Max. ambient temperature Max.. operating height Compressor drive Drive motor Manual start model (B) Power at nominal speed Compressor drive Drive motor Operating voltage Power Speed Size Type of construction Type of enclosure Compressor drive Drive motor Operating voltage Power Speed Size Type of construction Type of enclosure JuniorII-B-F01 JuniorII-E JuniorII-W air 100 l/min. 2000 m above sea level 87 dB(A) 100 dBA) 46 kg JuniorII-B Robin/Subaru petrol engine EX17 4.Instruction Manual w Junior II TECHNICAL DATA Compressor unit Medium Delivery a) Operating pressure Pressure setting.. 50 Hz 2.7 PS) 3.2 kW (3 PS) 3.600 min-1 JuniorII-E Three phase current 400 V.

observe and com­ ply with universally valid legal and other obligatory re­ gulations regarding accident prevention and environ­ ment protection. cylinder heads and pressure lines of indi­ vidual compressor stages. Authorized use  The machine / unit is built according to state of the art technology and established safety technical regula­ tions. technical safety and operating safety will be specially emphasized by placing the following signs before the instructions. This can involve. contact with hazardous substances or the provision / wearing of personal protective equipment. 2. do not touch! Danger of burning by touching cylinders. for example. 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. switch off at the main switch or disconnect from the mains and ensure unit will not restart. FUNDAMENTAL SAFETY NOTICES 2. MANDATORY Instructions must be read by persons op­ erating the machinery! The instruction manual supplied and all other applicable instructions.1. The user alone is responsible for this risk.3. es­ Ensure correct direction of rotation! When switching on the machine. Authorization for use is also under the condition that the instruction manual is complied with and inspection and maintenance re­ quirements are enforced. “Technical data”. 2. unit may start-up without warning! Before carrying out maintenance and re­ pair work. Organizational measures  Keep the instruction manual to hand near the machine / unit at all times in the relevant holder. 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.  Personnel engaged to operate the machine must have read the instruction manual before beginning work.3. WARNING Hot surfaces. IDENTIFYING THE SAFETY NOTICES Important instructions concerning the endangerment of personnel. WARNING Automatic compressor control. NOTE MV3−A/10/06 WARNING This notice must be complied with in order to avoid damage to or destruction of the ma­ chine or its equipment. application or equipment.2. Notes and warning signs displayed on compressors accord­ ing to model.3. This notice is used with maintenance work and operating procedures and must be adhered to exactly in order to avoid endangering personnel. SAFETY MEASURES NOTES AND WARNING SIGNS 2.3. WARNING High voltage! Life threatening danger of electric shock. This notice advises of technical requirements which the operator must take particular note of. The manufacturer / supplier is not liable for damage resulting from this.4. MANDATORY Hearing protectors must be worn! Hearing protectors must be worn when working on a machine which is running.  In addition to the instruction manual. chapter 1.1. check the arrow to ensure correct direction of rotation of the drive motor.Instruction Manual w Junior II 2. Any other medium or use outside that specified is not authorized. 5 . must be read and understood by op­ erating personnel before using the ma­ chine. regulations etc. Nevertheless.2.  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. See chapter 2. 2. its use can cause danger to life and limb of the operator or third parties or damage to the machine and other equipment.

 Observe all safety and danger notices on the unit. This is particularly relevant for temporary personnel.  Personnel may not wear long hair loose.  Spare parts must always comply with the technical re­ quirements specified by the manufacturer. Inform the person responsible im­ mediately if anything is not as is should be (including operation).  When cleaning the operating room.3.  If there are any modifications to the unit or operating conditions which may affect safety. they must be carefully fastened to the lifting de­ vice so that there is no risk of danger.  Before switching on / starting up the unit. This work may only be carried out by qualified personnel.  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. ensure that no one can be put at risk through running the unit. 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.  Completely remove all covers / seals after cleaning.Instruction Manual w Junior II pecially the safety notices chapter. maintenance and inspection pro­ cesses at the intervals specified in the instruction man­ ual. wear a safety harness. ensure that the temperature sensors of the fire alarm and sprinkler sys­ tem do not come into contact with hot cleaning fluid. for example.  When replacing individual parts and larger assembly groups. even if no safety related faults have been noticed.  Clear and make the maintenance area safe as far as necessary.  Ensure that only trained personnel work with the ma­ chine. 6 . ensure that it is protected from unex­ pected start-up.3. in par­ ticular the connections and screw joints.  For assembly work above body height. Turn off main control device and re­ move the key and / or display a warning sign on the main switch. 2. e. maintenance personnel. soundproofing is provided and in good working order. loose connections.g.  If the unit is completely switched off for maintenance and repairwork. For maintenance work at high levels. stop the unit im­ mediately and inform the person responsible of the fault. shut the machine down im­ mediately and make it safe. fundamental duties  Work on / with the unit may only be carried out by reli­ able personnel. e. Only operate the machine if all protective and safety equipment. Do not use aggressive cleaning fluid.  Before cleaning the machine with water or jet of steam (high pressure cleaner) or detergent.  No modifications may be made to the unit which could impair safety without first obtaining permission from the suppliers.  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. This is always guaranteed with original spare parts. including replacement of parts / equipment. There is a danger of injury through. Use a fibre-free cleaning cloth. wear and damage. in order to avoid triggering the sprinkler system. The person guiding must remain within sight or in contact with the oper­ ator.  Make sure location and operation of fire extinguishers is known.4.  Carry out the setting. If necessary. before carrying out maintenance / repairwork. Immediately eliminate any faults.  As far as necessary or according to regulations. check all pressure lines for leaks.  Keep all safety and danger notices on the machine / unit complete and in readable condition.  Establish the responsibilities of the machine operator and establish a procedure for him to inform a third per­ son of unfavourable safety conditions.  Piping must be thoroughly checked (pressure and visual inspection) by the operator at appropriate time inter­ vals. ladders and platforms.  Clean oil. Do not climb on machine parts.  After cleaning. loose clothing or jewellery. Use only suitable and technically perfect lifting devices and equipment with sufficient lifting power and strength. cover / seal all openings which for safety and/or operating reasons no water / steam / detergent may penetrate.  Meet all requirements demanding that the unit is only operated in safe and good working order. Do not linger or work under suspended loads. Safety notices for operation  Do not carry out any work if safety is questionable.  Observe switching on and off processes and monitoring indications according to the instruction manual.  At least once every day. use appropriate safety approved equipment. When work is al­ ready underway it is too late. including rings.g. Electric motor and switch cabinets are particularly at risk.  Intervals stipulated or given in the instruction manual for recurring checks / inspections must be adhered to.  Only entrust an experienced person with the fixing of loads and guiding of crane drivers. these getting caught or being pulled into the equipment. e. emergency shutdown devices. Observe the legal minimum age per­ missible. use per­ sonal protective equipment. Qualifications.g.  Pay attention to fire warning and fire fighting pro­ cedures. check the unit externally for damage and faults.3. all detachable protective equipment. fuel or care products from the machine. 2.

 Ensure safe and environmentally friendly disposal of consumables and old parts.  Always pay attention to the permissible operating mode of the pressure vessels.  Machines and unit parts which must undergo inspec­ tion. 2.  When taking back into operation. serial-numbers!).  Even when moving the unit only slightly.  If necessary. Escaping air under pressure can cause injury and fire. We recommend that aluminium vessels should be exchanged after 15 years at the latest. Notices of danger regarding pressure vessels  Never open or loosen pressure vessel lids or pipe con­ nection parts under pressure.  Never exceed the permissible operating pressure of the vessels!  Never heat the vessels or any of their parts above the stated. Individual parts that are subject to pressure loads cannot be purchased as spare parts. Connections must not be mixed up.  If it is necessary to remove safety devices for mainten­ ance and repairwork. Defects. length and quality of the piping must correspond to requirements. 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. Secure the load properly.vessels for static load . such as loose screw connections or burnt wires.  Pressurized air lines must be laid and mounted by quali­ fied personnel. provide unit with transportation brackets. maintenance and repairwork. proceed according to the instruction manual. if specified.Instruction Manual w Junior II  Always retighten any screw connections loosened for maintenance or repairwork.5.6. do not uncover any safetyrelevant deficiencies. these vessels are subject to a so-called dynamic load. the unit must be disconnected from all external energy sources. Parts which have been disconnected must first be checked for volt­ age. which 7 . The pressure vessel documentation and the appropriate notes in the operating manual particularly characterise vessels of this type as being adequate for dynamic loads. Fit­ tings. grease and other chemical sub­ stances.  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. only use lifting device and equipment with sufficient lifting power and strength. work with a sec­ ond person who can operate the emergency off switch or the main switch in the case of an emergency. Remove transportation brackets in the correct manner before taking into oper­ ation. hoses and screw connections regularly for leaks and visible damage.  Check all pressure lines.  If work is to be carried out on live parts. Vessels for dynamic load: These pressure vessels may also be used under condi­ tions of changing operating pressure. Particular areas of danger  Use only original fuses with specified current rating.  Parts which need to be dismantled for transport pur­ poses must be carefully replaced and secured before taking into operation. must be rectified immediately. Use suitable fixing points. since the vessels are tested as a complete part and the docu­ mentation considers them as a whole (see pressure vessel documentation.  For loading. In the technical information for these vessels you will find specifications concerning their permissible operat­ ing period. reconnect the machine to the mains according to regulations. Immediately re­ pair any damage.  Use only suitable transporters with sufficient carrying power.  Only personnel with particular knowledge and experi­ ence with pneumatics may carry out work on pneumatic equipment. always depressurise the vessel or the unit. carried out regularly.  Always exchange damaged pressure vessels com­ pletely. The pressure may vary between the atmospheric and the maximum ad­ missible operating pressure. Display the appropriate notice. maximum operating pressure.  The stipulated hearing protectors must be worn.  Soundproofing equipment on the unit must be in place and functional during operation. 2.  With regard to oil.3. shut the unit down immediately. Only use voltage isolated tools. Due to the variation of the operating pressure. We differentiate: . these must be replaced and checked immediately after completion of the mainten­ ance or repairwork. observe the relevant safety regulations for the product.3. Be­ fore putting into use again. the fluctuations of pres­ sure are very small. If there is a failure in the electric energy supply.  Depressurize system and pressure lines before com­ mencing repairwork.vessels for dynamic load Vessels for static load: These pressure vessels are permanently under virtually constant operating pressure. then earthed and short-circuited and isolated from live neighbouring parts. must be discon­ nected from the mains supply. Close off the work area with a red and white safety chain and a warning sign.  The electrical equipment of a unit must be regularly checked.

2001 14th regulation to machine safety law (14. GSGV pressure vessel regulation) of 03.4. only) A compressor is identified by German law as being a filling system if pressure cylinders are filled by the system. In addition. the documents be­ longing to the unit are important for recurrent inspections and should therefore be carefully kept. Please pay attention to and follow these measures. The change between two different pressures is called a load change or cycle. According to the operation safety regulations (BetrSichV). es­ pecially when these cylinders are made available for third parties. 402. January 2004 Copies of the above regulations are available through the usual outlets. guidelines for permission to set up and operate filling stations.09. this is the factory inspectorate. Inspections in accordance with the regulations for preven­ tion of accidents will be carried out by the manufacturer or by a specialist. e. in order to ensure the operating safety. in Germany from: Carl Heymanns Verlag Luxemburger Str. Having reached half the permissible number of cycles.g. 449 50939 Köln Beuth-Vertrieb GmbH Burggrafenstr. We recommend that aluminium vessels should be exchanged after 15 years at the latest. should be checked regularly for internal and external tightness and functionality. that are meant to avoid a drop in pressure. the non-return valves. 2.2002 Machine safety law (GSG) of 11.Instruction Manual w Junior II puts the vessels under great stress. when their previous operating mode is not spe­ cifically clarified.2002 Technical regulations for pressure gases (TRG 400. 8 . and also the pressure maintain­ ing valves. 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. 4 . If a high pressure compressor is used for filling pressure vessels or for the supply of pneumatic systems. in which the critically stressed areas of the vessels are examined by means of suitable testing methods. The test certificates and documents delivered with the compressor are important and may be requested during the procedure for obtaining permission. 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. After having reached the total permissible number of load cycles. Record the number of load cycles in writing if you do not have an automatic cycle-counter. partly Germany. Please contact our Technical Service De­ partment with regard to this.1997 Operating safety regulations (BetrSichV) of 27. for your own safety and that of you employees and cus­ tomers! In order not to unnecessarily load the pressure vessels additionally.7 10787 Berlin The manufacturer has complied with all applicable regula­ tions and the unit is prepared accordingly. We strongly emphasize these regulations. 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.  Check the pressure vessels regularly on the inside and outside for damage from corrosion.05. The procedure for obtaining permission is according to TRG 730. No guarantees whatsoever are valid for damage caused or favoured by the non-consideration of these directions for use. SAFETY REGULATIONS (EC. They can also supply our leaflet “IMPORTANT NOTES FOR CERTIFICATION”. the vessel has to be submitted to an internal check. the follow­ ing regulations apply: Accident Prevention Regulations (UVV): BGV A1 of 01. As a rule. If desired. we offer at our Munich site a partial acceptance test according to § 14 BetrSichV.10. 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. which should reduce big pressure fluctu­ ations as well.  Be particularly careful with second-hand pressure vessels. 730). the vessel must be exchanged and scrapped. 401.

The maximum length for extension cables at normal ambient temperatures (approx. After taking unit into operation after a standstill period of 2 years or more change compressor oil. Ensure that an adequate exhaust air opening is pro­ vided.1. On units with petrol engine it is most important that only clean air be used.Comply with regulations of local electricity supply com­ pany. position compressor in direction of wind so that exhaust fumes are blown away from the unit. but perma­ nently installed.3. operate unit with unwound cable. Prior to each operation check the oil level according to chapter 4. only. BOTTLE FILLING Ensure correct installation of protective conductor.). and determine whether maintenance is necessary in accordance with chapter 4. only to avoid overheating and risk of fire. air must be free from exhaust fumes and haz­ ardous vapours (e. for instance through an opening in the wall. OPERATION Preparation for operation All compressor units are tested prior to delivery to the customer. Immediately after start-up check direction of rotation for agreement with arrow on unit. use cable of same type.Arrange for the electrics to be connected by an electri­ cian only. Particularly observe chapter 2 SAFETY REGULATIONS. a main switch must be provided which has a contact gap of minimum 3 mm on each pole. 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). Make sure that all persons handling the compressor and the filling station are familiar with the function of all con­ trols and monitors. Fuse motor correctly. If possible install unit in such a manner that the com­ pressor fan can get fresh air from outside. When using a mineral oil change oil after one year. measures must be taken to provide artificial ventilation (this also applies when other systems having high radiation are operating in the same room). When locating the compressor in small rooms where natural ventilation is not ensured. When using extension leads or cable drums.4. 20 C) is 25 me­ tres. use slow-blow fuses. Keep unit away from inflammable items. Electric driven units should be operated and stored below deck. smoke. g. WARNING - - Electrical installation For installation of electrical equipment observe the follow­ ing: .Instruction Manual w Junior II 3. Turn unit as soon as wind direction changes.g. only! LOCATION Outdoor location The compressor unit is not seawater re­ sistant. 9 . Units with petrol engine should also be stored below deck after the filling pro­ cess. Take care that no vehicles are in direct vicinity with en­ gines running. OPERATION. If power supply cable is to be replaced. - - - WARNING - - Locate the unit level. For units not connected through a plug. solvent vapours. so after correct installation of the unit there should be no problem putting it into operation. . Do not operate unit in the vicinity of open fire (flue gas!). Quicksilver Corrosion Guard). Check conformity of motor tension and frequency with those of electric network. etc. Prior to first operation or operation subsequent to re­ pair work operate unit for at least 5 minutes with open condensate valves (pressureless) to ensure proper lu­ brication of all parts before pressure is built up. At operation in salty air spray compressor with anticorrosive protec­ tion (e. - - Ensure adequate ventilation. Do not smoke while petrol tank is open and while unit is in op­ eration. Here too. observing the fol­ lowing points: The compressors described in this manual are not suitable for com­ pression of oxygen. - - Prior to first operation read Instruction Manual carefully. EXPLOSION occurs if an oil lubricated compressor is operated with pure oxygen or gases with an oxygen content of more than 21%! Indoor location WARNING Petrol driven units must not be op­ erated indoors. LOCATION.

An O-ring is provided for self-sealing due to internal overpressure.unit is ready for filling operation. As soon as final pressure is reached and final pressure safety valve blows off. Units with petrol engine: Set choke to position START. Shut down unit immediately and interchange two of the three phase leads in the switch box. CO2 values from 1. Closer investigations often show that the compressed air is taken from rooms in which one or more persons are working. After removing. Therefore always close tank valve first before closing filling valve. If any malfunction is observed stop unit immediately and find the cause of the fault or call the service department. sheet 5) and connectors for 200 and 300 bar are different and cannot be mixed up. CO2 values beyond the permissible values are noted from time to time. Never change leads at the motor terminal board. Pay particular attention to damage on the interface from hose fitting to hose. WARNING Units with petrol engine. additionally: Check engine oil level according to manufacturer's in­ struction manual. Abb. 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.Instruction Manual w Junior II Every time the unit is started up check all systems for proper operation. the CO2 value in the surrounding air can increase quite fast because of the exhaling of CO2. 10 . bottles may then be reconnected and topped up to the respective maximum filling pressure. When operating the unit in areas with possibly high CO contents.000 ppmv in workrooms are not unusual (MAK-value (max. Check final pressure safety valve and pressure gauge. please observe the two following chapters ”Intake air quality” and ”Scavenging the compressor unit”. Compressed air tank filling valves for a pressure in excess of 200 bar are standardized (DIN 477. During filling procedure bottles will warm up due to recompression. WARNING 1 The filling valve connection is of the manual type and per­ mits connection to air tanks without using tools. Abb. the phases are not connected properly. Filling hoses must be in satisfac­ tory condition and threads undam­ aged. 6) to 1. As soon as motor runs smoothly return choke to normal operating position. Start engine with recoil starter or crank handle. allow to cool down. resulting in a life-threatening CO concentration! Also. the CO removal filter cartridge is recommended for electric driven units. due to chemical reaction of CO with hopcalite. 6 - WARNING Alternating current: Set 0-I switch to I. exhaust fumes and solvent vapour. also. workroom concentration) is 5. If motor turns in the wrong direction. Open fuel shut-off valve. Motor protection switches (three-phase motor) To meet the CO2 maximum rating value in breathing air bottles. Intake air quality At routine tests.000 ppmv). 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. Units with three phase current motor. Observe regular condensate drain acc. warm­ ing up of the cartridge and danger of fire may result. Check fuel tank. the valve has an integral venting bore. Starting the unit (electric and petrol) Open condensate drain valves on the filters to release pressure so that motor starts without load. Top up if necessary. The use of adapters is not allowed! To ensure safe air tank removal after filling. If the casing is scored. open condensate drain valves and drain condensate . Another All units (electric and petrol): Close condensate drain valves and run unit to final pres­ sure.000 to 5. Units with electric drive motor: Three-phase current: the motor is switched on man­ ually by turning the switch (1. FILLING PROCEDURE General Ensure intake air is free from noxious gas (CO). 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. The intake hose is also recommended for units with electric engine. to chapter “Maintenance”. At insufficient ventila­ tion. hose must be discarded.

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

Alternating current: set 0 . as described in ”Filling the bottles”. Depressurize unit before opening valve -A to avoid damage to the change-over de­ vice A Abb.200 psig) with a 300 bar (4. Also check whether the compressor needs servicing in accordance with maintenance schedule see chapter 4. Three-phase current: the motor is switched off by turning the switch (1. Units with electric motor: Units with petrol engine: All units: 1 - Abb. 80 bar (1. Vent unit by means of filling valve to approx.3. 12) to 0. Drain condensate from intermediate separator and Triplex filter by means of the drain taps. Shut down petrol engine with stop button or stop lever. then filling valve by returning handle to closed position (2). Check the oil level in the compressor and top up.150 psi).Instruction Manual w Junior II Removing the bottles Upon reaching final bottle pressure close bottle valve first (1. 12 Motor protection switches (three-phase motor) 12 . 10). Close all valves again to prevent moisture entering the filter and resulting saturation of the cartridge. B - CHANGE-OVER DEVICE PN 300/PN 200 (Abb. Safety valve -B and filling device PN 200 bar are connected by opening change-over valve -A and the connected bottles can be filled with a 200 bar pressure. 11 Change-over device SHUT-DOWN PROCEDURE Close filling valve. Remove compressed air bottle. if necessary.700 psig) rated unit. Abb. Abb.I switch to 0. 11) This device allows bottle filling to 200 bar (3.

13) is a self-activating mini-computer that counts the operating hours of the compressor and calculates the saturation of the filter cartridge from time. Make sure that all maintenance counter (a+b+c) were reset directly before the delivery. Other use is strictly prohibited. by means of a clamp. It displays operating hours. The B-Timer (Abb. the BTimer can be used as an hourmeter. EN 12021). 13 B-Timer 1 2 3 4 5 6 7 Key symbol (maintenance due) Letter symbol (maintenance type) Low battery symbol Cartridge saturation indicator Operating hours or cartridge number Mode select key Enter key Function The B-Timer display shows the following functions: 13 .g. cartridge lifetime. The respective filter cartridge numbers are stored in the software.) If no reset of the maintenance counters has been done. temperature. and is therefore the ideal filter control device for all mobile com­ pressor units. see chapter 4.4. Please observe the operating limits of the unit: Operating temperature range 0 C to +50 C. 95% humidity. you are obliged to reset them. With the B-Timer. Authorized use This unit is to be used exclusively as operating status moni­ toring device and does not release the user from additional surveillance and testing of the breathing air quality of the filter system according to national standards (e. (Otherwise storage times would be taken into account and wrong maintenance in­ tervals are displayed on the B-Timer. Without correct settings. and delivery rate of the com­ pressor. It is simply fastened to the filter hous­ ing which has to be monitored. only! Make sure that the pressure maintaining valve of the compressor is adjusted to 150 bar (factory setting. dust.5. In addition.) and is working properly to ensure correct in­ dication of the filter capacity and compressor oper­ ation recognition. damage or injury resulting from failure to follow these instructions. especially for portable petrol or diesel driven scuba diving models. not condensating Description 1 3 5 2 4 6 7 Abb. The manufacturer and the supplier void all responsibility for risk. cartridge type. P31 and P41. and all maintenance due for the compressor. The B-Timer does neither need external power nor any other connection to the pressure system. Refer to chapter Reset. and jet of water Vibration $3g in operation max. the B-Timer can be mounted easily to any unit as an upgrade device. Storage temperature -20 C bis +70 C Protection class IP65 (Protection against contact with wire. this is not possible! The B-Timer may only be used with the filter systems P21.Instruction Manual w Junior II B-TIMER (optional) Introduction Read operating instructions carefully before operating the unit. The settings in the setup menu are essen­ tial for the correct indication of the filter capacity.

17 14 . All data are stored and will not be lost when changing battery. In this case the unit should not be used but sent to the factory or the nearest BAUER representative for re­ pair. 15) is merely inserted into the holder. The B-Timer is operated using the mode select and the enter keys.Instruction Manual w Junior II  Operating hours of the compressor unit  Cartridge lifetime in % by means of four segments in the cartridge symbol. To change the battery remove two bolts and separate hou­ sing from base plate. Abb. 14 2 1 Abb. Make sure to use the same type battery (BAUER part no. 82743). A = 500 hours or 1 year B = 1000 hours or 2 years C = 2000 hours or 4 years  Battery symbol indicating that the lithium battery is low and has to be changed. 16 Abb. 14). Error indication If the temperature sensor in the unit should be defective.  Flashing last segment and change from operating hours indication to cartridge part no. Battery change The battery (1. Abb. Remove plug (2) and pull out battery.  Indication of compressor maintenance due by means of letter symbols and operating hours. if capacity is equal or less than 20% of the original lifetime. 15 Battery Abb. an error message “Error 1” or “Error 2” is shown at the display (Abb.

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

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

chapter 8. Repair any leak­ age. The current oil list is provided in the annex. at least annually every 2. every 1. Oil level must not decrease below min. 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). Maintenance of drive motor/engine ac­ cording to manufacturer's operating in­ structions. MAINTENANCE INSTRUCTIONS Always shut down and decom­ press the complete system prior to carrying out any work on the com­ 4. pre-heating is required for lower temperatures.emulsification of the condensate in the crankcase .4. 17 .4. MAINTENANCE MAINTENANCE RECORD 4. OIL LEVEL CHECK Check oil level daily prior to putting compressor into oper­ ation.1.4. 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. Take care that dip stick is inserted completely.good anti-corrosive properties .3.no carbonizing effect. Due to the thermal load on the compressor only high quality oil should be used. 4. WARNING Never repair pressure lines by sol­ dering or welding. OIL CHANGE INTERVALS Mineral oils 4. according to the oil list.000 operating hours. for intermittent operation. a heating device is required which is capable of pre-heating the crankcase up to +5 C (41 F). only. especially in the valves .Instruction Manual w Junior II 4.low deposits . MAINTENANCE WORK This chapter contains the maintenance work as well as a short functional description for each component. If it is necessary to claim against the warranty. Please refer to section 23 of our general terms and conditions. Order this list regularly through the BAUER Technical Service De­ partment. Check using oil dipstick. Change TRIPLEX longlife cartridge ac­ cording to chapter 4.1. 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). You are recommended to restrict oils to those which have been approved by us and are listed in our lubricating oil list. 26). at least biennially WARNING pressor.4.! The used cartridge must be disposed of according to local regulations. Note that the oil level must be between minimum and maximum dipstick markings (see Abb. For operation under difficult conditions such as continuous running and/or high ambient temperatures we recommend the use of BAUER high performance compressor oils. showing the date and details of the work carried out. MAINTENANCE SCHEDULE Synthetic oils The maintenance schedule is contained in the service man­ ual delivered with every compressor unit.000 operating hours. mark as this will cause excessive lubrication of compressor and result in valves sooting up.2. For lower temperatures. mark but also not exceed max. 4.physiological and toxicological suitability. Depending on the ap­ plication of the compressor the requirements placed on the oil are: . using the correct oil is of vital importance. This will help to avoid expensive repairwork caused by missed maintenance work. Here also. For operation under less severe conditions. Only use original spare parts for mainten­ ance or repair work. We recommend that all maintenance work is recorded in the service book. LUBRICATION TYPE OF OIL For proper care and maintenance of the compressor. 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.

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

In the separator surrounding the cartridge chamber liquid oil and water particles are reliably separated from the compressed medium by a pipe nozzle. the air es­ capes into the atmosphere. If air is leaking out of the venting bore even though a cartridge is installed. 10 . FILTER SYSTEM P21 DESCRIPTION The air leaving the final stage is cooled in the after-cooler to approx. 28 Condensate drain taps Abb. The venting bore is also used to check the O-rings on the cartridge pin. no pressure can be built up and thus it is ensured. the O-rings are either broken or were damaged on installation.4. that unfiltered air is not supplied to the consuming device. The quality of the breathing air produced conforms to DIN EN 12021.27 F) above ambient tempera­ ture and then enters filter system P21 with TRIPLEX long­ life cartridge (Abb. Abb.15 C (18 . 4 3 5 2 6 7 8 9 1 2 3 1 10 11 Abb. If necessary replace cartridge or O-rings.Instruction Manual w Junior II Open drain tap (1. 28) and drain off condensate every 15 to 30 minutes during operation.4. 19 . 29). A bore provided in the filter bottom is sealed air-tight only if the cartridge is in place (Abb. The filter assembly consists of separator and cartridge chamber. No pressure build-up without cartridge! 1 2 3 4 5 6 7 8 9 10 11 Filter inlet Jet pipe Filter head Final pressure safety valve Housing Chamber separator Cartridge Filter outlet Pressure maintaining valve Condensate drain tap Condensate outlet Without cartridge the venting bore is not sealed. Residual oil and water vapors are then removed by the TRIPLEX longlife cartridge. 29 Filter system P21 4. Remove and check cartridge. CARTRIDGE SAFETY BORE The filter system P21 is designed to prevent pressurizing in the absence of the filter cartridge. 30).

To avoid any danger to your health or damage to your unit. Keep a minimum pressure of approx. number of four cycles per hour is not exceeded (condensate is drained every 15 minutes) the max. 30 Safety bore LIFETIME The filter system is subject to dy­ namic load. until condensate is completely drained. 059183 to dry. The max. WARNING Drain condensate from separator and cartridge chamber regularly by slowly opening drain taps (2 and 3.000 if operated at the max.200 psi) the max. which originate from an abrupt pressure loss at condensate drain (1 load cycle i. N19091 or WEICON WP 300 white order no. Abb. The filter housing has to be inspected internally by an expert after having reached 1/4 of the determined number of load cycles. Saturation weight 205 g. number of operating hours is 1. Filling weight: 217 g. allowable pressure difference range of 330 bar (4. which therefore can only serve as reference va­ lues for the user.000 . Change if necessary. On compressor units with petrol engines only use car­ tridge. Should the package be damaged. Never fill used up cartridges yourself! The filter material was chosen specifically by BAUER-KOMPRESSOREN for each kind of application. For a pressure dif­ ference of 225 bar (3. Filling weight: 191 g. CONDENSATE DRAINAGE No cartridge Cartridge installed Abb. 1/3 turn to the left. Due to inevitable production tolerances. 36 to 45 10-ltr-bottles can be filled with a TRIPLEX-cartridge.before changing cartridge . These tables contain calculated cartridge lifetime data.e. de-oil and remove CO. otherwise the housing may burst due to material fatigue. After reaching the max. Slowly open left tap first. Pay attention to cleanliness an hygiene when changing the filter. number of load cycles the op­ erating hours should be recorded in the service manual. Cartridge 057679 is the normal TRIPLEX-cartridge for electric units. Change cartridge before reactivating a compressor unit after out-of-service periods of more than 3 months. 28) . It is designed for a cer­ tain number of load cycles. N19752.100 psi) within the system to prevent moisture enter­ ing the compressor piping and filter system. A defective vacuum package cannot protect the cartridge appropri­ ately against environmental influences during storage. Toler­ ances at bottle fillings and different operating tempera­ tures can lead to considerable divergences compared to data given. Leave cartridge in the filter as long as unit is out of ser­ vice. Saturation weight 229 g.750 for 225 bar units. part no. if necessary tighten by hand to make sure they are completely air-tight. FILTER CARTRIDGES New filter cartridges are vacuum-packed and can be stored for two years (refer to date on the cartridge). do not use the cartridge. To avoid exceeding the max. no. GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE Depressurize system before starting any maintenance work. condensate drain = 1 depressu­ rization. of load cycles is 35. The taps close by spring pressure. The number of operating hours or the amount of possible bottle fillings per filter cartridge can be determined by the tables on page 22 and 23 taking into consideration the ambient temperature and the cartridge used. The nozzle type separator of the TRIPLEX filter system is maintenance-free besides the regular condensate drainage. that refer to defined and constant operating conditions. change used up cartridges in good time. Record number of pressure bottles and/or operating hours to ensure exact attention to maintenance inter­ vals.000 for 330 bar units. FILTER SERVICE LIFETIME The average weight (without package) of a new cartridge and the increase in weight can be checked with appropriate weighing scales. On condition that a max. which is equivalent to 12 to 15 compressor operating hours at a filling pressure of 200 bar.before each filling procedure . Keep all condensate drain valves and taps closed. then right tap approx. 50 to 80 bar (700 to - - - 20 .700 psi). number of load cycles the filter as­ sembly must be replaced.Instruction Manual w Junior II Venting bore - 1. and 8. Example: at an ambient temperature of 20C. there may be small differences compared to the given data.during filling procedure every 15 minutes. The in­ spections have to be arranged by the operator. 1 pressurization). Lubricate threads and O-rings as well as threaded part of cartridge with white petrolatum DAB 9 order no. number of load cycles for the P21 Central Filter As­ sembly is 4. Dry inside of filter housing with a clean cloth before in­ stalling new cartridge and check for corrosion.

059183 should be used on compressor units with petrol engine. The used cartridge must be disposed of according to local regulations.To clean filter element. 21 . 059183 as standard. Extract old cartridge and insert a new one. the best method is to use hot soapy water and to blow dry with compressed air.3. 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. 4. CARTRIDGE CHANGE For safety reasons only CO removal cartridges part no.Screw off sintered metal filter with a suitable screw driver. Screw in filter head to the stop without use of force. Prior to changing the filter cartridge. . Remove filter head (3. 057679 can be used. Remove filter insert and clean.Unscrew pressure gauge from filling valve body.. WARNING Units with petrol engine are delivered with CO removal cartridge part no. - FILLING VALVE MAINTENANCE To protect filling valve against contamination a sintered metal filter is screwed in the filling valve body. which is equivalent to between 10 and 13 operating hours at a filling pressure of 200 bar.Screw in filter element.): . 31 to 38 10-ltr-bottles can be filled with this cartridge. 059183. 057679 with car­ tridge part no. .Instruction Manual w Junior II Example: at an ambient temperature of 20C. When changing from electric engine to a petrol en­ gine also replace cartridge part no. Never remove replacement cartridge from packaging prior to actual use other­ wise highly sensitive molecular sieve will absorb water vapour from surrounding air and car­ tridge saturated and thus be ruined. as follows (refer to maintenance schedule. drain condensate and depressurize filter system completely by opening condensate drain valves. On units with electric engine either CO removal cartridge part no. . Re­ place if heavily soiled. if heavily soiled replace. Abb. 29). 057679. units with electric engine with TRIPLEX cartridge part no. Seal pressure gauge with PTFE tape or Loctite 243 and screw in tight to desired position. 059183 or TRIPLEX car­ tridge part no. therefore the possible number of bottle fillings stays the same at different pressures.

47 45 .39 40 .31 29 .Instruction Manual w Junior II 1.41 7l 112 .2 x mMS [g] / (X [g/m3] / p [bar]) = 0.49 50 .65 62 .44 45 .28 27 .18 17 .24 25 .52 49 .44 42 .08 .85 157 .39 40 .142 134 .29 30 .72 69 .07 .94 89 .30 29 .11 10 15 20 25 30 35 40 Bottle volume VF [m3] Bottle size l [ltr.48.64 51.41 65.14 12 l 65 . saturated X [g/m3] Processable air volume Va [m3] at pressure p [bar] 200 17.14 13 .22 21 .51 49 .9 9-7 7-6 5-5 Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 20 .125 118 . Filter cartridge 057679: lifetime [hours] Filling pressure p = 200 bar Ambient temperature tU [C] Final separator temperature tAb [C] Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 Ambient temperature tU [C] 20 .54 26 .39 40 .21.89 84 .80 23.1 3 3.28 83.24 25 .31 .27 300 236 .44 45 .] 7 10 12 at pressure p [bar] 200 1.99.67 64 .9 8-7 Filling pressure p = 300 bar Final separator temperature tAb [C] Filter cartridge 057679: bottle fillings [number] Molecular sieve mass mMS [g] = 68 Ambient temperature tU [C] Final separa­ tor tempera­ ture tAb [C] 20 .65 .2 x p [bar] x mMS [g] / X [g/m3] Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h]) 22 .25 23 .40 38 .79 30.4 2 2.14 14 .37.18 17 .34 33 .29 30 .34 35 .28.31 30 .62 59 .17 16 .23 22 .39 37 .19 Number of bottle fillings n acc.11 10 .21 .24 25 . to bottle size 10 l 79 .54 39 .24 22 .34 35 .44 45 .16 15 .34 35 .52 .187 177 .12 11 .84 80 .79.49 50 .6 Number of bottle fillings n= processable air volume / bottle volume = Va / VF Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3] Processable air volume: Va [m3] = 0.52 49 .63 39.108 103 .29 30 .54 Air humidity.62.56 53 .4 300 2.36 34 .21 20 .40 .49 50 .

54 Air humidity.44 45 .21. to bottle size 10 l 67 .37 35 . Filter cartridge 059183: lifetime [hours] Filling pressure p = 200 bar Ambient temperature tU [C] Final separator temperature tAb [C] Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 Ambient temperature tU [C] 20 .12 12 .44 42 .85 134 .62 59 .29 30 .81 76 . saturated X [g/m3] processable air volume Va [m3] at pressure p [bar] 200 17.56 53 .1 3 3.34 35 .4 300 2.26 24 .19 18 .21 20 .6 Processable air volume: Va [m3] = 0.31 .28.58 55 .63 39.48 45 .79.20 19 .54 34 .24 25 .40 38 .49 50 .2 x mMS [g] / (X [g/m3] / p [bar]) = 0.48.34 32 .41 65.79 30.15 15 .4 2 2.34 35 .44 42 .160 151 .] 7 10 12 at pressure p [bar] 200 1.52 .17 Number of bottle fillings n acc.62.Instruction Manual w Junior II 2.29 28 .34 35 .34 32 .39 40 .10 10 15 20 25 30 35 40 Bottle volume VF [m3] Bottle size l [ltr.72 68 .31 29 .49 50 .39 40 .08 .18 17 .65 .106 101 .37.54 22 .15 15 .12 11 .76 72 .35 7l 96 .23 300 201 .40 .29 30 .2 x p [bar] x mMS [g] / X [g/m3] Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h]) Number of bottle fillings n= processable air volume / bottle volume = Va / VF Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3] 23 .21 .07 .53 50 .44 45 .13 13 .44 45 .8 8-6 6-5 5-4 Junior II Delivery Q [l/min] 100 10 15 20 25 30 35 40 20 .24 25 .27 25 .20 19 .64 51.9 9-7 7-6 Filling pressure p = 300 bar Final separator temperature tAb [C] Filter cartridge 059183: bottle fillings [number] molecular sieve mass mMS [g] = 58 Ambient temperature tU [C] Final separa­ tor tempera­ ture tAb [C] 20 .29 30 .92 88 .24 25 .49 50 .10 10 .28 83.24 23 .80 23.12 12 l 56 .15 14 .121 114 .99.39 40 .27 25 .44 42 .

allowable operating pressure.7.200 psi) for the standard units. PRESSURE MAINTAINING VALVE DESCRIPTION A pressure maintaining valve is mounted at the outlet of the filter system P21. loosen jam nut (2) and set screw (3). Technical Data). see maintenance schedule chapter 4.4. 32). 225 bar (3. All safety valves are sealed at the fac­ tory. PRESSURE GAUGE DESCRIPTION The compressor unit is equipped with a final pressure gauge (Abb. afford­ ing valve check. SAFETY VALVES DESCRIPTION All three compressor stages are protected by safety valves as follows 24 . Clockwise = increase pressure Counter-clockwise = decrease pressure Abb.3. 4.4.8. thus achieving a constant. The cause of the trouble is usually the inlet valve of the next stage. MAINTENANCE Checking function The final pressure safety valve has to be checked regularly.4.6.4. 33). Turn knurled knob on top of the valve clockwise until valve blows off (Abb. See also chapter 4. Pump unit to final pressure with shut-off valve closed until safety valve blows off. It ensures that pressure is built up in the filter even from the start of delivery.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. If deviation is 10% or more.700 psi) for models -H or -HU.Instruction Manual w Junior II 4. 32 Venting the final pressure safety valve Checking blow-off pressure Check blow-off pressure of the final pressure safety valve regularly. In case of read­ justment becoming necessary. The red marking on it shows the max.175 psi). the valves in the next stage are not closing properly. optimum filtra­ tion. 330 bar (4. It will also guarantee proper working conditions for the final stage cylinder. 31) is adjusted at the factory to the required pressure and normally does not re­ quire regular maintenance or readjustment. Check blow-off pressure of safety valve at pressure gauge. Venting 2 1 3 Abb. 4. This just ensures that the valve is functional and will release pressure in case of a malfunction. The pressure maintaining valve is adjusted to 150 10 bar (2. 1st stage 2nd stage 9 bar (130 psi) 80 bar (1. 31 Pressure maintaining valve MAINTENANCE The pressure maintaining valve (Abb.5. Adjust screw (1) to the required pressure using a suitable screw-driver. For this purpose the safety valve can be vented manually. replace safety valve. If one of the intermediate pressure safety valves blows off. To check the blow-off pressure value refer to ”Blow-off pressure check”.

Excessive inaccuracy will require the pressure gauge to be replaced. the intake valves open and the air flows into the cylinders. 35). Use only satisfactory gaskets and O-rings on reas­ sembly. VALVES DESCRIPTION The valve heads of the individual stages form the top part of the cylinders. Check the valve space in the valve heads for dirt and clean. The intake and pressure valves are fitted in­ side the valve heads. Intake and pressure valve of the 1st stage is a plate valve (Abb. Valve head screws must be tightened with a torque wrench (see tightening torque values chapter 7. replace the valves. Valves are then operating properly.4. Observe the correct sequence when fitting together again. Note that the valves are operated by the flow of the air. 34 Valve operation MAINTENANCE We recommend that the final pressure gauge is checked from time to time.8. valves should be checked. Pressure side Intake side to 2nd stage N4860−F98 Top view from intake fil­ ter 4.). Abb. Slight deviations during operation are normal and can be ig­ nored. If the valve seat and valve disks are dented. Check individual components for excessive wear. 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/. if necessary. After finishing all maintenance work on the valves. - Always replace valves as a complete set. On the suction stroke. At the start of the compression stroke the intake valve closes and the air opens the pressure valve. 25 . 33 Final pressure gauge Abb.. Note that the intake line to the valve heads should be warm and outlet piping should be hot. let it cool down to ambient temperature and retighten valve studs and cap nuts.). 30 minutes after restarting the compressor stop unit. Abb. 34. turn the compressor manually using the flywheel and check whether all items have been correctly installed. Otherwise valves could work loose due to setting of the gaskets. 35 Valve 1st stage GENERAL VALVES INSTRUCTIONS FOR CHANGING THE INITIAL OPERATIONAL CHECK After maintenance work on the valves.Instruction Manual w Junior II Mark Intake Pressure Abb.

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

. 39 Removal of 3rd stage pressure valve 4.Fasten valve head with allen screws (7) and washers (8). part no. .Remove allen screws (7). Tighten motor mounting nuts. DRIVE MOTOR The compressor unit is driven by an alternating or a three phase current motor by means of a V-belt.The motor is switched on man­ V-belt tension adjustment Slightly loosen motor mounting nuts Adjust motor until the belt tension is correct (see Abb. Abb. The response value is preset.Screw in torque stud (1) with 20 Nm (2 kpm).4. Stop motor. both to be installed by the customer. COMPRESSOR DRIVE SYSTEM DESCRIPTION The compressor is driven by the drive motor through a Vbelt. Abb. For schematic diagram. take off valve head cover (6).Lift out pressure valve (3) together with O-ring (2).4. . 27 . 40).9. 39). A rough value for this is when the belt deflects 10 mm when pressed with thumb pressure between the two pulleys (Abb. 5 minutes. 41: edge must be parallel to the v-belt. Reinstall pressure valve (3) in reverse sequence: . both pulleys are in a straight line to avoid excessive wear of the V-belt.Instruction Manual w Junior II Remove of 3rd stage pressure valve (3) according to Abb. . 38.drive motor . see annex. check Vbelt tension.main switch and main fuse. 40). ELECTRICAL SYSTEM DESCRIPTION This section describes the standard electrical system.10. For best results we recommend our v-belt tension meter. Put O-ring (2) into valve head (5). MOTOR PROTECTION SWITCH (ALTERNATING CUR­ RENT MOTOR) Protection of the motor is ensured by the thermic releases integrated into the motor protection switch (1. N25238. . 40 Checking V-belt tension Abb. Run motor for approx.Unwind torque stud (1) a couple of turns. 41 V-belt pulley adjustment 4. 42). The electrical equipment of the compressor unit consists of: .electric control system To start the electric motor and enable the functioning of the electric control. .Insert pressure valve (3). and readjust if required. Improper v-belt tension and adjustment of the pulleys will result in extreme v-belt abrasion and premature wear. where the belt under full load does not slip.Check O-ring for abrasion and replace if necessary. Install valve head cover (6). . Check that after tension adjustment and tightening the motor mounting nuts.Put two screwdrivers into the groove of pressure valve body (Abb. If necessary turn valve loose at first using a 13 mm spanner on the flat surfaces. 10 mm Abb. Hold a straight edge against compressor and motor V-belt pulleys as shown in Abb. MAINTENANCE Checking the drive belt tension The best tension for a belt drive is the lowest possible. the following components are essential: . The motor is mounted on the base plate and requires adjustment for proper V-belt tension.

COOLING SYSTEM The cylinders of the compressor block. MAINTENANCE For the electrical system no regular maintenance is re­ quired. chapter 1. Abb. It is switched off manually by turning the switch to 0. This may last a couple of minutes. MOTOR MOTOR) PROTECTION SWITCH (THREE-PHASE 1 The motor is switched on manually by turning the switch to 1 (Abb. 42 Motor protection switch (alternating current) 4. the motor can be re­ started by pressing the start-button not before the bi-metal in the switch has cooled down. The response value of the electromagnetic releases (protection against short-circuit) is preset. Refer to chapter 3. For this purpose. Protection of the motor is ensured by the thermomagnetic releases integrated into the motor protection switch. for proper installation and cooling air supply. For safety of the operat­ ing personnel all voltage carrying parts have a protective cover. It draws the cooling air through the fanwheel cover from the surroundings. For maximum ambient temperature. 43).Instruction Manual w Junior II ually by pressing the 0-I switch to I. For safety of the operating personnel all voltage carrying parts have a protective cover. the intermediate coolers and the after-cooler are air-cooled. 1 0 Abb. the compressor is equipped with a fan­ wheel connected to the counter-weight at the crankshaft end opposite to the V-belt pulley. After the switch has shut off by overcur­ rent triggering.11.4. 43 Motor protection switch (three-phase motor) 28 . see Technical Data.

+45 C (113 F) Direction of rotation is wrong Correct direction of rotation Inlet and pressure valve of one stage is Check valves. see chapter 4. ensure proper cooling air flow Ambient temperature too high Check location. Re-adjust.05 + 40 C : correction factor 1. Observe temperature compensation (+20 C =1. wire leads.9.4.Instruction Manual w Junior II 4. see chapter 4.5.9. make sure that motor data complies with mains supply Replace Set to nominal motor current.0) For ambient temperature + 10 C : correction factor 0.12 Switch off other consuming devices Use suitable cable Trouble Drive motor (electric) Motor will not start Motor/engine runs eccentrically Motor protection switch is switching off the unit V-belt worn Wrong adjustment of the motor pro­ tection switch Motor protection switch is switching off the unit Drive motor (petrol) Motor will not start Motor runs eccentrically Motor stops Drive system Excessive v−belt wear (black deposits on belt guard) Unsufficient voltage because of weak power supply Power supply cable to long or to thin See motor instructions V-belt worn Low oil level V-belt tension Pulleys not aligned See motor instructions Replace Top up oil Re-tighten. terminal connections. clean/replace if neces­ leaking sary TRIPLEX cartridge saturated Replace cartridge Unqualified lubricant being used Replace oil with an approved brand 29 . TROUBLE-SHOOTING Cause Electric circuitry faulty Remedy Check all fuses. unscrew until completely open Clean or replace filter cartridge Retighten couplings Replace piston and sleeve of 3rd stage Check/replace inlet or pressure valve Compressor overheats Taste of oil in the air Replace safety valve Check location. Tighten and reseal Replace safety valve Replace cartridge Compressor Compressor does not attain final pres­ Condensate drain valve(s) leaking sure Final pressure safety valve defective (blows too soon) No cartridge in filter system P21 (air escaping through cartridge safety bore) Vent screw for final pressure safety valve not in operating position Intake filter soiled Pipe coupling leaking Excessive wear of 3rd stage piston Intermediate pressure too high be­ cause of defective inlet or pressure valve of the following stage Safety valve leaking Insufficient cooling air Air delivery drops Intermediate pressure safety valve blows To vent. ambient temperature max.4.94 + 30 C : correction factor 1.

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

Open condensate drain valves and release compressed air.Shut compressor unit off. Only cover the com­ pressor with plastic if it is certain that no condensation will form under the sheet.Close all valves.Ensure that filter cartridge remains in the filter! This will prevent oil entering filling lines as a result of preservation procedures. 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. Drain con­ densate from separators. . chapter 4.Check all pipes. - 31 . the compressor is then ready for operation. . in. Establish cause of any fault from the trouble-shooting table. 10 minutes or until the pressure gauges indicate the correct values.Tighten all couplings. as required. - - REACTIVATING THE COMPRESSOR UNIT Remove the dust cap from the inlet port and insert the intake filter. the unit should be preserved in accordance with the following instructions: Make sure the compressor is kept indoors in a dry. Open the filling valves or the outlet valve and let the unit run for approx. Close condensate drain valves again.5. . Nevertheless. If there is any fault.Open filters and grease threads. . After 10 minutes. the sheet should be re­ moved from time to time and the unit cleaned on the out­ side. to keep oil sticky. filters and valves (also safety valves) for leakage. Check the lubrication of the compressor when putting the unit into operation once every six months or when turning the compressor. Run the compressor warm with open filling valves or outlet valve for approx. After changing the oil. close the filling valves or the outlet valve and run the unit up to final pressure until the final pressure safety valve blows. please contact our Technical Service Department for special instructions.After these 5 minutes.After 10 minutes.Place the dust cap onto the inlet port. . Check the inter-pressure safety valves for leakage. Open the purifier and change all filter cartridges. shut the system down. If this procedure cannot be followed and/or the com­ pressor is going to be taken out of service for more than 2 years. 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. . 10 ccm/0. STORAGE. Stop the system when running properly. 10 minutes. open the filling valves or the outlet valve and run the compressor at the set minimum pres­ sure (pressure maintaining valve. Carry out preservation procedure according to chapter ”preserving the compressor” - Changing the lube oil for preserving After prolonged storage. It should be drained after 2 years at the latest and replaced with fresh oil. see chapter 4.) of compressor oil into the valve head inlet port while the compressor is running. PREPARATION Before preserving the compressor unit. Then carry out the following: . run it warm and when it reaches the specified service pressure. PRESERVING THE COMPRESSOR . Check the oil pressure on the pressure gauge. Check the motor/engine according to the manufac­ turer's instructions. Shut filling valves. The stated period can only be attained when the crank­ case is sealed during the preservation period in accord­ ance with the preservation requirements. 10 minutes. check the lubrication of the compressor.Remove intake filter from manifold and all intake lines from valve heads. 5 minutes.. turn the compressor and the en­ gine or run them for the required period. Stop the compressor. PRESERVATION GENERAL If the compressor is put out of service for more than six months.5. Do not let the compressor warm up too much. .6 cu. the oil will age in the com­ pressor and engine. dust free room.Turn the compressor on and spray a small amount (ap­ prox. The compressor is not resistant to saltwater! If not in use keep unit in a dry place.Instruction Manual w Junior II 5. . and take corrective action. Check the oil level of the compressor. keep it run­ ning for approx. Depressurize unit.) for approx. PRESERVING THE MOTOR/ENGINE Preserve the motor/engine according to the instructions of the motor/engine manufacturer. . .4.Let compressor unit cool down.

no repair should be carried out on the crankdrive nor on the bearings . gaskets and sealing rings as well as carrying out the maintenance work. workshop manuals are available through our customer service.safety valves are not repaired but always replaced com­ pletely.Instruction Manual w Junior II 6. that . however. For many BAUER compressor units. REPAIR INSTRUCTIONS GENERAL Preventive maintenance usually involves replacing the valves. It should be noted. For questions on maintenance and repair. Repair work can be carried out on the compressor block to a certain extent but a certain experi­ ence and skill is necessary. please contact our technical service department. 32 .

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

N19753 or equivalent compound with copper or MoS2 additives For compressor lubricating oils refer to oil list in chapter 8. bolts. valve heads. FM0089 Adhesives and Sealants Loctite 2701 Loctite 243 Temperature resistant compound. N19752 or BAUER special grease part no. part no.g. ADHESIVE AND SEALANT CHART Usage Screws Seals for conical threads Metal . filter housing threads Sealing rings Shaft seal (seal) Shaft seal (shaft) Screws.metal seals High temperature connections. WACKER E10. part no. tubes Testing agents Leakage test spray. N18247 Loctite FAG 2 34 . 072500 Klüber SK 01-205 WEICON ANTI-SEIZE AS 040 P part no.g. e. e. threads Lubricants WEICON WP 300 WHITE part no. 072500 BAUER special grease part no. cylin­ ders Paper gaskets TESTING AGENTS Usage Tube connectors.Instruction Manual w Junior II LUBRICATION CHART Usage Rubber and plastic parts. 072500 BAUER special grease part no.

ANNEX  Schematic diagram Lubricating oil list Parts list 35 .Instruction Manual w Junior II 8.

Instruction Manual w Junior II 36 .

Instruction Manual w Junior II 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 37 .

Instruction Manual w Junior II 38 .

Should your list or your instruction manual be older.. N22138 Use Type Ambient temperature N Nitrox +5 . Oil type Brand name Designation Special Compressor oil Part no. 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. only) oil change every 1000 operating hours oil change every 2000 operating hours oil change every 1000 operating hours in case of nitrox application Suitability + − = suitable = not suitable .+45 C A Breathing air b) c) a) S M + + + − + + Oil type S M synthetic oil mineral oil Application A N a) b) c) approved for breathing air application with BAUER air purification systems approved for nitrox application (with BAUER membrane unit. When using any of the oils listed below. This list is up to date at the time of printing and will be reviewed continuously. we have decided to authorize the following brands of oil for use in BAUER compressors under the given operating conditions..Oil list w Breathing air compressors GENERAL After extensive tests with many different kinds of lubricants. please request the latest edition from BAUER Customer Services. N28355 Special Compressor oil Part no.

For lower temperatures a compressor heating device is required which is capable of pre−heating the unit up to +5 C. Change oil filter. separators. N28355 For operation under difficult conditions. OIL CHANGE Mineral oil Synthetic oil Oil change volume every 1000 operating hours. part no. we also recommend the use of the mineral oil acc. N22138−20 . bottle 5 ltr. Fill compressor with the new oil. These have proved excellent quality under ambient temperatures between +5 C and +45 C. After approx. at least annually every 2000 operating hours. N28355−1 part no. i. N28355−0. to the list on the previous page.5 part no. perform the following steps: − − − − − Remove deposits or change valves. For operation under less severe conditions. the following measures should be strictly adhered to. Top up with same oil type.5 part no. at least every two years see compressor unit operating manual BAUER compressor oil is available in the following quantities: Oil quantity b type ' 0. N22138−1 part no.Oil list w Breathing air compressors TYPE OF OIL Due to the thermal load on the compressor only high quality oil should be used. N22138−0.e. to the list on the previous page. N22138−5 part no. purifiers and all pneumatic tubes and hoses. 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 1.5 ltr. N28355−20 Mineral oil N22138 part no. such as continuous running and/or high ambient temperatures. replace oil filter again (if applicable). Changing the Oil Type To avoid severe damage to the compressor unit when changing to another oil type. This oil is suitable for ambient temperatures between +5 C and +45 C. N28355 BAUER Special Compressor oil. − Check valves. − Drain mineral oil while still warm. 100 operating hours. container Oil Synthetic oil N28355 part no. coolers. as follows: Breathing air compressor units: Nitrox compressor units: BAUER Special Compressor oil. a pre−heating device will be required if ambient temperatures should fall below +5 C. we only recommend the BAUER special synthetic compressor oils acc. and change oil. coolers. separators. depending on the model. if applicable. when the compressor is not used for longer periods between the operating periods. and for intermittent operation. Our compressor units are delivered ex works with lubricating oil filled into the crankcase or as consignment. If deposits are present. part no. container 20 ltr. purifiers and all pneumatic tubes and hoses for deposits. Here also. N28355−5 part no. bottle 1 ltr.