Bauer Junior II-B-F01 Instruction Manual
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Bauer Junior II-B-F01 Instruction Manual

Junior ii series
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Summary of Contents for Bauer Junior II-B-F01

  • Page 3: General

    The manufacturer and the supplier void all responsibility for damage or injury resulting from failure to follow these instruc­ tions. Edition January 2009 © 2009 BAUER Kompressoren GmbH, München All rights reserved...
  • Page 4 Technical customer service We are happy to give you advice on any questions regarding Phone no: (089) 78049-246 or -176 your BAUER compressor and help as soon as possible with Fax no: (089) 78049-101 any arising problems. Do you need further information regarding your unit, ac­...

  • Page 5: Table Of Contents

    Instruction Manual w Junior II CONTENTS GENERAL ......SAFETY MEASURES ....LOCATION, OPERATION, BOTTLE FILLING .
  • Page 6 Instruction Manual w Junior II NOTES Model: Serial No..: Date of purchase: Dealer address / phone no.:...
  • Page 7 Instruction Manual w Junior II GENERAL AIR FLOW DIAGRAM See Fig. 5 . The air is drawn in through telescopic tube PURPOSE (necessary for units with petrol engine) -1, intake filter -2; The JUNIOR II breathing air compressor is designed to com­ compressed to final pressure in cylinders -3, -4, -5;...
  • Page 8 Instruction Manual w Junior II 1 Filling hose 2 Filling valve with pressure gauge 3 Motor terminal box 4 Three-phase motor 5 Final pressure safety valve 6 Handle 7 Fanwheel cover 8 B-Timer 9 Condensate drain valves 10 Mains plug with ON-OFF switch and motor protection circuit breaker (dep.
  • Page 9 Instruction Manual w Junior II 1 Filling hose 2 Filling valve with pressure gauge 3 Final pressure safety valve 4 Filter system P21 5 B-Timer (optional) 6 Pressure maintaining valve 7 Filling connector 8 Intake filter 9 V-belt cover Fig. 4 Compressor unit with electric motor, v-belt cover side 1 Telescopic air intake 8 Intermed.
  • Page 10 Instruction Manual w Junior II TECHNICAL DATA Compressor unit JuniorII-B-F01 JuniorII-E JuniorII-W Medium Delivery 100 l/min. (3,5 Scfm) Operating pressure PN200/PN300 Pressure setting, final pressure safety valve 225/330 bar Sound pressure 87 dB(A) 86 dB(A) Sound (immersion) power 100 dBA) 99 dB(A) Weight 46 kg...
  • Page 11 Instruction Manual w Junior II SAFETY MEASURES 2.1. NOTES AND WARNING SIGNS 2.2. IDENTIFYING THE SAFETY NOTICES Important instructions concerning the endangerment of per­ Notes and warning signs displayed on compressors accord­ sonnel, technical safety and operating safety will be specially ing to model, application or equipment.
  • Page 12 Instruction Manual w Junior II pecially the safety notices chapter. When work is already devices, soundproofing is provided and in good working underway it is too late. This is particularly relevant for order. temporary personnel, e.g. maintenance personnel. • At least once every day, check the unit externally for dam­ •...
  • Page 13 Instruction Manual w Junior II • Ensure safe and environmentally friendly disposal of con­ • Even when moving the unit only slightly, the unit must be sumables and old parts. disconnected from all external energy sources. Before putting into use again, reconnect the machine to the mains according to regulations.
  • Page 14 Instruction Manual w Junior II the critically stressed areas of the vessels are examined by The manufacturer has complied with all applicable regula­ means of suitable testing methods, in order to ensure the tions and the unit is prepared accordingly. If desired, we offer operating safety.

  • Page 15: Location, Operation, Bottle Filling

    Instruction Manual w Junior II LOCATION, OPERATION, BOTTLE FILLING LOCATION Check conformity of motor tension and frequency with those of electric network. Outdoor location Operate electric units only on mains sockets equipped with fault current circuit breaker according to DIN VDE The compressor unit is not seawater resis­...
  • Page 16 Instruction Manual w Junior II Units with three phase current motor, additionally: FILLING PROCEDURE Immediately after switching on the system for the first General time check the direction of rotation of the motor for com­ Ensure intake air is free from pliance with the arrow on the unit.
  • Page 17 Instruction Manual w Junior II Scavenging the compressor unit is present in the atmosphere with a natural amount of 350 to 400 ppm . The molecular sieve used in the purifier for drying the breathing air is, as well as other capabilities, able to adsorb CO which is accumulated in the cartridge.

  • Page 18: Maintenance

    Instruction Manual w Junior II SHUT-DOWN PROCEDURE Close filling valve. Units with electric motor: Three-phase current: the motor is switched off by turn­ ing the switch (1, Fig. 12) to 0. Alternating current: set 0 - I switch to 0. Units with petrol engine: Shut down petrol engine with stop button or stop lever.

  • Page 19: Tables

    Instruction Manual w Junior II B-TIMER (optional) Introduction Read operating instructions carefully before operating the unit. The settings in the setup menu are essential for the correct indication of the filter capac­ ity. Without correct settings, the B-Timer can be used as an hourmeter, only! Make sure that the pressure maintaining valve of the compressor is adjusted to 150 bar (factory setting, see chapter 4.4.5.) and...
  • Page 20 The battery (1, Fig. 15) is merely inserted into the holder. To change the battery remove two bolts and separate housing from base plate. Remove plug (2) and pull out battery. Make sure to use the same type battery (BAUER part no. 82743). Fig. 15 Battery Fig.
  • Page 21 Instruction Manual w Junior II Operation The B-Timer is activated when starting the compressor. Compressor operation is indi­ cated by the flashing “h” symbol. To switch on the B-Timer press one of the keys on the display. Main menue will be displayed (Fig. 16). If no key is pressed within 1 minute, the in­...
  • Page 22 Instruction Manual w Junior II Setup To enter the setup for the different functions of the B-Timer press the = and o keys on the display simultaneously for more than 5 seconds from the cartridge number display (Fig. 21). Filter symbol starts flashing (Fig. 23) indicating the setup mode.

  • Page 23: Annex

    BAUER high performance compressor oils, only, ing with leak test spray. Repair any leak­ according to the oil list. These oils are tested in our com­...

  • Page 24: Oil Change

    360 ml DESCRIPTION A dry micronic filter is used to filter intake air (Fig. 27). OIL PACKAGES BAUER compressor oil is available in various quantities, refer to oil list in chapter 8. OIL CHANGE Run compressor warm. Remove oil dipstick.
  • Page 25 Instruction Manual w Junior II Fig. 28 Condensate drain taps 4.4.4. FILTER SYSTEM P21 Fig. 29 Filter system P21 DESCRIPTION 1 Filter inlet The air leaving the final stage is cooled in the after-cooler to approx. 10 - 15 °C (18 - 27 °F) above ambient temperature 2 Jet pipe 3 Filter head and then enters filter system P21 with TRIPLEX longlife car­...
  • Page 26 Never fill used up cartridges yourself! The filter material was chosen specifically by BAUER-KOMPRESSOREN for each kind of application. The max. number of load cycles for the P21 Central Filter As­...
  • Page 27 Instruction Manual w Junior II alent to between 10 and 13 operating hours at a filling pres­ sure of 200 bar. The longer service life of the cartridge at a filling pressure of 300 bar is annihilated by the larger volume of filled air per bottle, therefore the possible number of bottle fillings stays the same at different pressures.
  • Page 28 Instruction Manual w Junior II 1. Filter cartridge 057679: lifetime [hours] Filling pressure p = 200 bar Junior II Ambient temperature Final separator temperature Delivery tU [°C] tAb [°C] Q [l/min] 20 - 24 26 - 21 25 - 29 20 - 16 30 - 34 15 - 12...
  • Page 29 Instruction Manual w Junior II 2. Filter cartridge 059183: lifetime [hours] Filling pressure p = 200 bar Junior II Ambient temperature Final separator temperature Delivery tU [°C] tAb [°C] Q [l/min] 20 - 24 22 - 18 25 - 29 17 - 13 30 - 34 13 - 10...
  • Page 30 Instruction Manual w Junior II 4.4.5. PRESSURE MAINTAINING VALVE 1st stage 9 bar (130 psi) 2nd stage 80 bar (1,160 psi) DESCRIPTION The safety valve for protection of the last stage is mounted on top of the filter system P21 and is adjusted to the operat­ A pressure maintaining valve is mounted at the outlet of the ing pressure of the unit (see chapter 1, Technical Data), 225 filter system P21.
  • Page 31 Instruction Manual w Junior II Mark Intake Pressure Fig. 33 Final pressure gauge Fig. 34 Valve operation MAINTENANCE We recommend that the final pressure gauge is checked Pressure side Intake side from time to time. For this purpose we have developed a special test pressure gauge with an adaptor which immedi­...
  • Page 32 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, see Fig. 36. 1 Nut 2 Spring-washer 3 Plate 4 Pressure valve 5 O-ring 6 Valve head 7 Intake valve...
  • Page 33 Instruction Manual w Junior II Remove allen screws (7), take off valve head cover (6). Check that after tension adjustment and tightening the motor mounting nuts, both pulleys are in a straight line to Put two screwdrivers into the groove of pressure valve avoid excessive wear of the V-belt.
  • Page 34 Instruction Manual w Junior II MOTOR PROTECTION SWITCH (THREE-PHASE MOTOR) The motor is switched on manually by turning the switch to 1 (Fig. 43). It is switched off manually by turning the switch to 0. For safety of the operating personnel all voltage carrying parts have a protective cover.
  • Page 35 Instruction Manual w Junior II 4.5. TROUBLE-SHOOTING Trouble Cause Remedy Drive motor (electric) Motor will not start Electric circuitry faulty Check all fuses, terminal connections, wire leads, make sure that motor data complies with mains supply Motor/engine runs eccentrically V-belt worn Replace Motor protection switch is switching Wrong adjustment of the motor pro­...
  • Page 36 Instruction Manual w Junior II Trouble Cause Remedy Piston rings, Pistons or cylinders worn Replace defective parts High oil consumption Intake filter clogged Replace filter cartridge Compressor too hot Enhance cooling Cartridge missing Insert cartridge Air escaping through cartridge safety bore Cartridge installed but O-rings defec­...
  • Page 37 Instruction Manual w Junior II STORAGE, PRESERVATION Remove the dust cap from the inlet port and insert the in­ take filter. GENERAL Open the filling valves or the outlet valve and let the unit run for approx. 10 minutes or until the pressure gauges If the compressor is put out of service for more than six indicate the correct values.
  • Page 38 For many BAUER compressor units, workshop manuals are available through our customer service. For questions on maintenance and repair, please contact our technical service department.
  • Page 39 Instruction Manual w Junior II TABLES TIGHTENING TORQUE VALUES Unless otherwise specified in text, the fol­ lowing torque values apply. All valve head screws require torque wrench tightening! The indicated torque values are valid for bolts in greased condition. Replace self-retaining nuts on reassembly.

  • Page 40: Lubrication Chart

    Usage Lubricants Rubber and plastic parts, filter housing threads WEICON WP 300 WHITE part no. N19752 or BAUER special grease part no. 072500 Sealing rings BAUER special grease part no. 072500 Shaft seal (seal) BAUER special grease part no. 072500 Shaft seal (shaft) Klüber SK 01-205...
  • Page 41 Instruction Manual w Junior II ANNEX • Schematic diagram Lubricating oil list Parts list...
  • Page 42 Instruction Manual w Junior II...
  • Page 43 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...
  • Page 44 Instruction Manual w Junior II...
  • Page 45 This list is up to date at the time of printing and will be reviewed continuously. Should your list or your instruction manual be older, please request the latest edition from BAUER Customer Services. When using any of the oils listed below, please follow the oil change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit.
  • Page 46 For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recom- mend the BAUER special synthetic compressor oils acc. to the list on the previous page. These have proved excellent quality under ambient temperatures between +5 °C and +45 °C. For lower temperatures a compressor heating device is required which is capable of pre−heating the unit up to +5 °C.

This manual is also suitable for:

Junior ii-eJunior ii-w

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