Operator’s Manual - BAUER KOMPRESSOREN

1 operator s ManualHigh Pressure Breathing Air CompressorsOperator s ManualiINTRODUCTIONThis Manual containsgeneralinformation and instructions tooperateand maintain high pressure breathing air compressor intooperation itisessentialto study theinstruction Manual of that instructions should be observed and carried out in the order laiddown to prevent damage and premature wear to the equipment andthe units served by every effort is made to ensure the accuracy of the particularscontained in this Manual , the manufacturing company will not, underany circumstances, be held liable for any inaccuracies or the conse-quences breathing air producedwith thishigh pressurecompressor can lead to severe injury or in serious cases even reserve the right to make changes to the technology of our com-pressors as well as to this accompanying documentation in accor-dance to technical January 2005 2005 BAUER KOMPRESSOREN GmbH, MunichAll rights s ManualiiTABLE OF AND SHORT AND MODE OF AND WARNING THE SAFETY SAFETY REGULATIONS (EC; partly Germany, only) , OF THE compressor ROOM INTO , THE THE MAINTENANCE DURING THE compressor SYSTEM SAFETY INSTRUCTIONS FOR FILTER s SERVICE s ManualivTABLE OF VALVE SYSTEM P41 AND AND SUMMARY OIL OF COMPRESSED AIR FILLING FROM STORAGE s ManualvTABLE OF FIGURESFig.

2 1 Pressure-- and temperature 2P--V 3 Saving of 4 Air flow diagram Purus, Utilus 10 and 5 Air flow diagram Utilus, Capitano und 6 Air flow diagram K14, K15, K150, 7 Locating air intake 8 Room 9 Locating the 10 Cooling air 11 Installation of the compressor unit (natural ventilation) 1 Air intake and outlet 12 Installation with natural ventilation, example 13 Installation with natural ventilation, example 14 Installation with natural ventilation, example 15 Installation of the compressor unit (artificial ventilation) 16 Installation with artificial ventilation, example 17 Installation with artificial ventilation, example 18 Solenoid valve 19 Connecting air 20 International filling 21 Connecting air 22 Opening of filling 23 Opening of filling 24 Removing air 25 Removing air 26 Filter system 27 Safety 28 Filter system P41 left, P61 right with SECURUS--monitoring 29 Oil and water 30 Construction of the filter 31 Air flow 32 Cartridge 33 Danger label 34 Automatic switching 35 Flow 36 Filling from storage cylinders (overflow) 37 Filling with the 38 Filling storage s ManualviANNEXI mportant notices for the T V (supervising authorities) inspections of filling stations (GermanPressure Vessels Regulations) operator s AND SHORT DESCRIPTIONHigh pressure compressor units are complete units for filling air tanks in the high pressure ranges PN 200 and PN 300 bar.

3 The com-pressors are mainly used to compress air for breathing as required in diving and fire fighting applications, for heart of this unit is formed by a three-- or four stage, air--cooledhigh pressure compressor , Utilus 10andJuniorrange compressor units are ,CapitanoandMarinerrangecompressor unitsonwards, thelast stagesare lubricatedby meansof theforced--feedlubrication system, the other cylinders are -- processingsystem(P--filtersystem),thatsu rpassesthequality requirementsof s PRINCIPLESFig. 1 Pressure-- and temperature increaseWhenthepistonmovesintothecylinde r, however,the temperatureof theenclosedgas also rises. This is a basic physical law (Gay--Lussac).Since with increasing pressure, the occuring temperatures would soon reach inadmissibly high values, the compression has to bedivided into various stages. After every stage the gas is cooled back to approx. 10 -- 15 C above ambient temperature.

4 This is themain reason for designing compressors with 3 or 4 s Manual3By dividing the compression work into various stages it results in a lower power requirment. This is visible in the p--v 2 shows the power requirement with a theoretical 1 stage compression to 200 3 shows the power requirement bar1 barIdeal theoreticalisothermal compressionactual polytropiccompressionFig. 2P--V DiagramP200 bar1 barVP200 bar1 barV1. Stage2. Stage3. Stagesaving of workFig. 3 Saving of workBy dividing the compression work it not only saves energy, but it also increases theoperating safetydue to a lower thermical s AND MODE OF DesignThe compressor unit comprises the following major assemblies: compressor block drive motor filter set base and frame assembly with instrument/filling panel electric control systema) electronic monitoring systema) automatic condensate draina) Mode of operation; air flow diagramThe path of the air through the compressor system is shown in the following air flow ) optional extra according to orderOperator s Air flow diagram 3--stageFig.

5 4 Air flow diagram Purus, Utilus 10 and Junior1 Telescopic air intake2 Intake filter3 Cylinder 1st stage4 Cylinder 2nd stage5 Cylinder 3rd stage6 Inter--cooler 1st/2nd stage7 Inter--cooler 2nd/3rd stage8 Intermediate separator 2nd/3rd stage9 After--cooler10 Safety valve 1st stage11 Safety valve 2nd stage12 Final pressure safety valve13 Central filter assembly14 TRIPLEX longlife cartridge15 Condensate drain valve16 Pressure maintaining valve17 Filling hose18 Filling valve19 Final pressure gauge20 Safety valve, final pressure PN 200a)21 Change--over devicea)a) optional extraOperator s Manual6 Fig. 5 Air flow diagram Utilus, Capitano und Mariner1 Intake filter2 Cylinder 1st stage3 Cylinder 2nd stage4 Cylinder 3rd stage5 Inter--cooler 1st/2nd stage6 Inter--cooler 2nd/3rd stage7 After--cooler8 Safety valve 1st stage9 Safety valve 2nd stage10 Final pressure safety valve11 Intermediate separator 2nd/3rd stage12 Central filter assembly13 TRIPLEX longlife cartridge14 Condensate drain valve15 Pressure maintainig valve16 Filling hose17 Filling valve18 Final pressure gauge19 Change--over devicea)20 Safety valve, final pressure PN 200a)a) optional extraOperator s Air flow diagram 4--stageFig.

6 6 Air flow diagram K14, K15, K150, K1801 Intake filter2 Inter--cooler 1st/2nd stage3 Inter--cooler 2nd/3rd stage4 Inter--cooler 3rd/4th stage5 After--cooler6 Intermediate separator 2nd/3rd stage7 Intermediate separator 3rd/4th stage8 Oil and water separator9 Purifier10 Pressure maitaining valve11 Non--return valve12 Filling valve13 Condensate drain valve ( Manual )14 Safety valve, intermediate pressure 2nd stage15 Safety valve, intermediate pressure 3rd stage16 Safety valve, intermediate pressure 4th stage17 Safety valve, final pressure18 Pressure gauge, final pressure19 Venting valve with pressure gaugeAn additional intermediate separator, stage is available for operation at high temperatures ( : installation in subtropical coun-tries) and high order number can be obtained through our technical customer service, Tel. 089--78049 175 operator s Manual8 NOTESO perator s open filling or shut--off valves whenunder pressure and not connected as highly compressed emergingair can cause serious intake air is free from noxious gas, exhaust fumes and solvent vapour.

7 Use an intake hose and ensurethat it is mounted in such a way as to avoid taking in any noxious hoses must be in satisfactory condition and threads undamaged. Pay particular attention to damage onthe interface from hose fitting to hose. If the rubber is scored, hose must be discarded otherwise water can enterand attack wire gauze causing it to rust and thus endangering pressure shut down and decompress the complete system prior to carrying out any work on the on compressor units requires the necessary expert knowledge!CAUTIONC heck the complete system for leakage from time to time by brushing all fittings and couplings with soapy wateror spraying with leak test spray. Repair any disconnect the system from mains supply prior to carrying out any work on compressor systems withelectric drive repair pressure lines by soldering or not use any toxic substances like gasoline or acetone or similar to clean the compressor unit or any of s AND WARNING SIGNSN otes and warning signs displayed on compressors accordingto model, application or surfaces, do not touch!

8 Danger of burning by touching cylinders, cyl-inder heads and pressure lines of individualcompressor voltage!Life threatening danger of electric oroperat-ing equipment may only be carried out by aqualified electrician or by a person instructedand supervised by a qualified electrician ac-cording to electrical compressor control, unitmaystart--up without warning!Before carrying out maintenance and repairwork, switch off at the main switch or discon-nect from the mains and ensure unit will must be readby personsoperat-ing the machinery!Theinstructionmanual suppliedand allotherapplicable instructions, regulations etc. mustbe read and understood by operating per-sonnel before using the protectors must be worn!Hearing protectorsmust beworn whenwork-ing on a machine which is correct direction of rotation!When switching on the machine, check thearrowtoensurecorrectdirectionofrotati onofthe drive THE SAFETY NOTICESI mportant instructions concerning the endangerment of per-sonnel, technical safety and operating safety will be speciallyemphasized by placing the following signs before the notice is used with maintenanceworkand operatingprocedures andmustbe adhered to exactly in order to avoidendangering notice must be complied with inordertoavoiddamagetoordestructionofthe machine or its SAFETY NOTICESA uthorized use The machine / unit is built according to state of the art tech-nology and established safetytechnical ,itsusecancausedangertolifeandlimboftheo per-ator or third parties or damage to the machine and otherequipment.

9 Operate the machine / unit only in technically perfect condi-tion in accordance with regulations and safety and dangernotices detailed in the instruction Manual ! In particular, im-mediately correct faults (or have them corrected) which canimpair safety! The machine / unit is exclusively for thecompression ofme-diums (air/gas) specified in section A, chapter Techni-cal data . Any other medium or use outside that specified isnot authorized. The manufacturer / supplier is not liable fordamage resulting from this. The user alone is responsiblefor this risk. Authorizationfor useis alsounder theconditionthat the instruction Manual is complied with and inspectionand maintenance requirements are measures Keep the instruction Manual to hand near the machine / unitat all times in the relevant holder. In addition to the instruction Manual , observe and complywith universally valid legal and other obligatory regulationsregarding accident prevention and environment can involve, for example, contact with hazardous sub-stances or the provision / wearing of personal protectiveequipment.

10 Inadditiontotheinstructionmanual,provide supplementaryinstructions for supervision and monitoring duties takinginto consideration exceptional factors with regard to or-ganization of work, production, personnel employed. Personnelengagedto operatethe machinemust havereadthe instruction Manual before beginning work, especiallythe safety notices chapter. When work is already underwayit is too late. This is particularly relevant for temporary per-sonnel, maintenance personnel. At the very least, supervise temporary personnel s work inaccordance with the instruction Manual , taking into accountsafety and danger factors. Personnel may not wear long hair loose, loose clothing orjewellery, including rings. There is a danger of injuryOperator s Manual11through, for example, these getting caught or being pulledinto the equipment. As far as necessary or according to regulations, use per-sonal protective equipment.