Page 2 OPERATING MANUAL A_K12,P41_001_en 2/174 02.12.2019...
Page 3: Table Of Contents
OPERATING MANUAL Table of contents Preface Contact data BAUER KOMPRESSOREN ..............9 About this manual ....................10 1.2.1 Purpose of this manual ..................10 1.2.2 Target groups of this manual .................10 1.2.3 Storing this manual ....................10 1.2.4 Symbols used ......................11 1.2.5 Abbreviations used ....................11 1.2.6...
Page 4 Overview ....................... 43 3.6.2 Display elements B-CONTROL MICRO ..............44 Technical data Technical data compressor unit ................49 4.1.1 Technical data PE300-VE ..................49 4.1.2 Technical data PE320-VE ..................51 4.1.3 Technical data PE400-VE ..................53 Technical data Compressor block ................. 55...
Page 5 OPERATING MANUAL 4.2.1 Technical data compressor block IK120 ............... 55 4.2.2 Technical data compressor block IK12.14 ............56 Technical data Filter system ..................56 4.3.1 Technical data filter system P41 ................56 Technical data B-DETECTION PLUS i ..............57 Technical data Motor .................... 58 Transport and storage Transport .......................59 5.1.1...
Page 6 OPERATING MANUAL 7.3.1 Navigating in the control system ................82 7.3.2 Modifying the settings ...................83 7.3.3 Entering password ....................85 7.3.4 Inserting the memory card ..................87 Configuring the electronic control system ............89 7.4.1 Setting time and date ....................89 7.4.2 Setting language and units ..................90 7.4.3 Setting the display ....................
Page 7 OPERATING MANUAL Maintenance Maintenance table ....................121 Resources for maintenance and repairs ..............122 9.2.1 Bolt torques ......................122 9.2.2 Bolt tightening sequence ..................123 9.2.3 Adhesive and sealant ..................123 9.2.4 Lubricant ......................124 9.2.5 Lubrication oil ..................... 125 9.2.6 Test material ....................... 127 9.2.7 Filter cartridges ....................127 Checking the unit for leaks .................
Page 8 OPERATING MANUAL 9.15 Maintenance activities electrical system ............162 9.15.1 Maintaining the electrical control systems ............162 9.16 Maintenance activities drive system ..............163 9.16.1 V-belt maintenance ..................... 163 Disassembly and disposal 10.1 Decommissioning and disposal ................165 10.1.1 Decommissioning ....................165 10.1.2 Dispose the unit ....................
Page 9: Preface
OPERATING MANUAL Preface | 1 1 Preface 1.1 Contact data BAUER KOMPRESSOREN ------------------------------------------------------------------------------------------ BAUER KOMPRESSOREN GmbH Stäblistr. 8 D-81477 Munich Germany ------------------------------------------------------------------------------------------ info@bauer-kompressoren.de ------------------------------------------------------------------------------------------ +49 89 7 80 49-0 ------------------------------------------------------------------------------------------ +49 89 7 80 49-167 ------------------------------------------------------------------------------------------ www.bauer-kompressoren.de ------------------------------------------------------------------------------------------ www.facebook.com/BAUER.KOMPRESSOREN.GmbH ------------------------------------------------------------------------------------------ www.instagram.com/bauer_kompressoren ------------------------------------------------------------------------------------------ www.youtube.com/user/Bauerkompressoren...
Page 10: About This Manual
1 | Preface OPERATING MANUAL 1.2 About this manual Depending on the version, the unit may look different from the images in this docu- ment. 1.2.1 Purpose of this manual This manual will make it easier to become familiar with the product and make use of its intended application possibilities.
Page 11: Symbols Used
OPERATING MANUAL Preface | 1 1.2.4 Symbols used The following symbols are used in the manual: Symbol Meaning Dangers for persons. For more information, Chapter 2.3 Display and meaning of warn- ings, Page Information for understanding or optimising the work processes. Information for solving problems or for trou- bleshooting.
Page 12: History
1 | Preface OPERATING MANUAL 1.2.7 History The following table shows the most important changes to the documentation com- pared with the previous version in each case: Version Edition Remark 05/2018 First issue A_K12,P41_001_en 12/174 02.12.2019...
Page 13: About This Product
OPERATING MANUAL Preface | 1 1.3 About this product 1.3.1 Identifying the product This manual is applicable for the models and series specified on the title page. • Take the exact model and serial number from the type plate and enter into the figure below.
Page 14: Variants And Equipment
1 | Preface OPERATING MANUAL 1.3.3 Variants and equipment Variants PE300-VE PE400-VE PE320-VE Operating pressure [bar] Delivery volume [l/ min] Cylinder fillings ( 10 l / 0-200 bar) per hour, approx. The models contain the following components as standard: •...
Page 15: Applied Standards
OPERATING MANUAL Preface | 1 1.3.6 Applied standards Declaration of conformity The product has been constructed in line with the directives listed in the conformi- ty declaration or the state of the art and recognised safety-related regulations; see . CE mark With the EC mark affixed on the product, BAUER KOMPRESSOREN declares that the product satisfies the application requirements specified in the harmonisation legislation of the European Community provided for its affixing.
Page 16 1 | Preface OPERATING MANUAL A_K12,P41_001_en 16/174 02.12.2019...
Page 17: For Your Safety
OPERATING MANUAL For your safety | 2 2 For your safety 2.1 Intended usage The machine is intended exclusively for the compression and the storage of the medium specified, under consideration of the conditions specified, see Technical Data. Proper use also includes: •...
Page 18: Display And Meaning Of Warnings
2 | For your safety OPERATING MANUAL 2.3 Display and meaning of warnings 2.3.1 Hazard classes Important instructions regarding personal protection and safe operation are indica- ted in the manual in distinct hazard classes. The hazard classes explain how states or individual steps of an operation sequence are dangerous and can cause dam- age.
Page 19: Danger Warnings On The Machine
OPERATING MANUAL For your safety | 2 2.3.3 Danger warnings on the machine Depending on the construction and purpose of use, the following indications are affixed to the machine and included in the manual; these indications point to po- tential dangers: Symbol Meaning Caution, automatic control!
Page 20: Product Safety
2 | For your safety OPERATING MANUAL 2.4 Product safety 2.4.1 Fundamental safety information Fundamental dangers The following safety measures always include: • The machine should only be used in a technically perfect condition and in an intended, safety and danger-aware method, taking into account the operating instructions.
Page 21: Safety Instructions Regarding Transport And Loading Work
OPERATING MANUAL For your safety | 2 Danger due to gas, dust and smoke • When working with smothering gases, you must monitor the oxygen concen- tration in the room using a mobile gas measuring device. • When working in confined spaces, ensure adequate ventilation and follow ex- isting national regulations where applicable.
Page 22: Safety Information Regarding Operation
2 | For your safety OPERATING MANUAL 2.4.3 Safety information regarding operation Carry out the following measures to ensure safe operation: • Refrain from any working practices which may compromise safety. • Only operate the machine if all protection equipment and safety-related equip- ment (e.g.
Page 23: Safety Instructions Regarding Maintenance, Service And Repairs
OPERATING MANUAL For your safety | 2 2.4.4 Safety instructions regarding maintenance, service and repairs Carry out the following measures for ensuring safe maintenance, service and repair work: • For all work that affects the operation, adjustment of production capacities, changeover or setting of the machine and its safety-relevant equipment and inspection, maintenance and repair, observe the switching on and switching off procedures in accordance with the operating instructions and instructions...
Page 24: Safety Instructions Regarding Cleaning
2 | For your safety OPERATING MANUAL 2.4.5 Safety instructions regarding cleaning Carry out the following measures to ensure safe cleaning: • Before cleaning the machine with water, a steam jet (high pressure cleaner) or other cleaning agents, cover or seal off all openings that must not be penetra- ted by water/steam/cleaning agents for reasons of safety and/or functionali- ty.
Page 25: Particular Dangers
OPERATING MANUAL For your safety | 2 2.4.6 Particular dangers Safe handling of pressure vessels There are two types of pressure vessels: • Pressure vessels for static load: The pressure vessels are under virtually con- stant operating pressure, and the pressure fluctuations are very small. Pres- sure vessels for static load are not specially marked and can be operated as long as no safety-relevant faults are found during the regular vessel repeat testing procedures.
Page 26: Safety And Monitoring Equipment
2 | For your safety OPERATING MANUAL Instructions regarding handling breathing air Follow the following instructions to ensure the safety of the user: • Adhere to the filter service life. • When changing the cartridge, particular attention must be paid to hygiene and general cleanliness.
Page 27: Organisational Duties
OPERATING MANUAL For your safety | 2 2.6 Organisational duties 2.6.1 Personnel selection and qualification Pay attention to the following points when selecting the personnel: • Ensure that statutory minimum age limits are observed. • Ensure that only entrusted personnel work on the assigned tasks. •...
Page 28: Duties Of The Operating Company
2 | For your safety OPERATING MANUAL Personnel Qualification Trained personnel (e.g. operators and This manual was read and understood. employees) Instruction by the manufacturer or a person authorised by the manufacturer for this purpose. Trained personnel and/or experts (e.g. An expert is a person who has the required expert knowledge for the servicing the expert electricians and maintenance per- products described in these operating instructions.
Page 29: Duties Of The Personnel
OPERATING MANUAL For your safety | 2 2.6.3 Duties of the personnel The personnel must comply with the following safety requirements: • Read and understand the operating instruction manual. • Refrain from any working practices which may compromise safety. • Use personal protection equipment if required.
Page 30: Safety Regulations
2 | For your safety OPERATING MANUAL 2.7 Safety regulations The following list of safety regulations does not claim to be exhaustive and up-to- date, and is applicable only for the Federal Republic of Germany. • Ensure that the equivalent provisions of the operator’s country are observed. •...
Page 31 OPERATING MANUAL For your safety | 2 For further instructions for the licensing process and the testing of filling stations before commissioning, refer to the information sheet (can be obtained from BAUER KOMPRESSOREN). The test certificates and documents supplied with the compressor are important and must be included in the application documents as part of the licensing proc- ess.
Page 32 2 | For your safety OPERATING MANUAL A_K12,P41_001_en 32/174 02.12.2019...
Page 33: Product Description
OPERATING MANUAL Product description | 3 3 Product description 3.1 Structure The machine may vary slightly from the following illustrations, depending on the scope of delivery and equipment level. Fig. 2 Compressor unit Main switch Removable cover Storage bottles (option) Operating panel Cooling air inlet opening Condensate collection vessel...
Page 34 3 | Product description OPERATING MANUAL Fig. 3 Compressor unit with hidden cladding Compressor block Final pressure safety valve Condensate collection vessel Filter (option) Non-return valve with pressure Main switch gauge and venting valve Particle filter (option, not availa- Final separator Operating panel ble for Nitrox applications) A_K12,P41_001_en...
Page 35: Function
OPERATING MANUAL Product description | 3 3.2 Function The method of operation, i.e. the route of the medium through the unit is shown in the piping layout in the appendix. 3.2.1 Intake The compressor unit draws the medium to be compressed via the intake filter. The replaceable filter element removes the solid particles from the medium taken in and protects the compressor and the downstream fittings.
Page 36: Condensate Drain
3 | Product description OPERATING MANUAL 3.2.6 Condensate drain Electro-pneumatic drain valves drain away the condensate that gathers in the sep- arators at regular intervals. In addition, the automatic condensate drain is designed so that it removes the water from the separators when the unit is switched off and unloads the compressor when the unit is started.
Page 37: Filling
OPERATING MANUAL Product description | 3 3.2.9 Filling Filling fittings are used to distribute the compressed medium. The consumers are connected using special valves and filling couplings. 3.2.10 Drive The compressor is driven by the drive motor via one or more V-belts. Depending on the compressor unit, the motor is either mounted on clamping rails or on a hinged platform.
Page 38: Operating Modes
3 | Product description OPERATING MANUAL 3.3 Operating modes 3.3.1 Semi-automatic After the compressor is switched on manually, it switches off automatically on reaching the switch-off pressure. It needs to be restarted manually. It can be switched off manually at all times. 3.3.2 Fully automatic After the compressor is switched on manually, its further operation takes place de-...
Page 39: Connections
OPERATING MANUAL Product description | 3 3.4 Connections 3.4.1 Overview Fig. 4 Connections Intake system via roof (option) Filling connection (option) Pressure outlet Filling panel (option) Condensate outlet B-Link for W-LAN connection (option) A_K12,P41_001_en 02.12.2019 39/174...
Page 40 3 | Product description OPERATING MANUAL Fig. 5 Connections, rear Exhaust chute (option) Pressure outlet Electrical connection A_K12,P41_001_en 40/174 02.12.2019...
Page 41: Control Elements
OPERATING MANUAL Product description | 3 3.5 Control elements 3.5.1 Overview Fig. 6 Control elements Main switch Operating panel A_K12,P41_001_en 02.12.2019 41/174...
Page 42: Operating Panel
3 | Product description OPERATING MANUAL 3.5.2 Operating panel Operating panel B-CONTROL MICRO Fig. 7 Operating keys B-CONTROL MICRO Move selection frame upwards or in- Move selection frame or cursor right crease the value Confirm selection or input Stop unit Move selection frame or cursor left Start unit Move selection frame down or reduce...
Page 43: Display Elements
OPERATING MANUAL Product description | 3 3.6 Display elements 3.6.1 Overview Fig. 8 Display elements Pressure gauge, filter pressure Operating panel A_K12,P41_001_en 02.12.2019 43/174...
Page 44: Display Elements B-Control Micro
3 | Product description OPERATING MANUAL 3.6.2 Display elements B-CONTROL MICRO Fig. 9 Display elements B-CONTROL MICRO Display Warning LED Operating parameters and configura- Optical signalisation of a warning tion parameters, display of alarm messages and warning messages Alarm-LED Optical signalisation of an alarm A_K12,P41_001_en 44/174 02.12.2019...
Page 45 OPERATING MANUAL Product description | 3 Start page The start page appears when the unit is turned on and includes all the important information concerning the unit. Fig. 10 Start page B-Control micro Main menu Footer: Red for fault, yellow for warn- Measured values menu Digital final pressure display Compressor setup menu...
Page 46 3 | Product description OPERATING MANUAL Meaning of the symbols displayed The following symbols can be displayed on the control system: Symbol Where? Meaning Footer There is a warning message. Warning LED flashing. Footer There is a fault message. Alarm LED flashing. Header Unit is running Header...
Page 47 OPERATING MANUAL Product description | 3 Programme overview Level 0 Level 1 Level 2 Level 3 Level 4 Authorisa- tion Main menu Measured values Compressor Final pressure Setup Intake pressure Gas balloon level Unit / com- Operating mode pressor setup Control logic Valves Condensate...
Page 48 3 | Product description OPERATING MANUAL Level 0 Level 1 Level 2 Level 3 Level 4 Authorisa- tion Maintenance Maintenance Calibration in- air analysis intervals air tervals air analysis analysis Calibration gas sensors Messages Current mes- Historical list Logbook ex- sage list of messages port...
Page 49: Technical Data
OPERATING MANUAL Technical data | 4 4 Technical data 4.1 Technical data compressor unit 4.1.1 Technical data PE300-VE Category and unit Value Performance characteristics Medium Breathing air, air Intake pressure atmospheric Operating pressure max. [bar] Setting pressure, pressure maintaining/non- return valve [bar]...
Page 50 4 | Technical data OPERATING MANUAL Category and unit Value Noise output level [dB(A)] in accordance with ISO 2151 at 1 m distance Electricity Standard operating voltage [V] Standard frequency [Hz] Motor power [kW] Power consumption [kW] A_K12,P41_001_en 50/174 02.12.2019...
Page 51: Technical Data Pe320-Ve
OPERATING MANUAL Technical data | 4 4.1.2 Technical data PE320-VE Category and unit Value Performance characteristics Medium Breathing air, air Intake pressure atmospheric Operating pressure max. [bar] Setting pressure, pressure maintaining/non- return valve [bar] Compressor block IK12.14 Delivery volume [l/min] measured using cylin- der filling (10 l) from 0 to 200 bar, ±...
Page 52 4 | Technical data OPERATING MANUAL Category and unit Value Standard frequency [Hz] Motor power [kW] Power consumption [kW] A_K12,P41_001_en 52/174 02.12.2019...
Page 53: Technical Data Pe400-Ve
OPERATING MANUAL Technical data | 4 4.1.3 Technical data PE400-VE Category and unit Value Performance characteristics Medium Breathing air, air Intake pressure atmospheric Operating pressure max. [bar] Setting pressure, pressure maintaining/non- return valve [bar] Compressor block IK12.14 Delivery volume [l/min] measured using cylin- der filling (10 l) from 0 to 200 bar, ±...
Page 54 4 | Technical data OPERATING MANUAL Category and unit Value Standard frequency [Hz] Motor power [kW] Power consumption [kW] 9.35 A_K12,P41_001_en 54/174 02.12.2019...
Page 55: Technical Data Compressor Block
OPERATING MANUAL Technical data | 4 4.2 Technical data Compressor block 4.2.1 Technical data compressor block IK120 Category and unit Value Number of stages Number of cylinders Cylinder bore 1st stage [mm] Cylinder bore 2nd stage [mm] Cylinder bore 3rd stage [mm] Piston stroke [mm] Direction of rotation (looking onto the fly- left...
Page 56: Technical Data Compressor Block Ik12.14
4 | Technical data OPERATING MANUAL 4.2.2 Technical data compressor block IK12.14 Category and unit Value Number of stages Number of cylinders Cylinder bore 1st stage [mm] 105 /88 Cylinder bore 2nd stage [mm] Cylinder bore 3rd stage [mm] Piston stroke [mm] Direction of rotation (looking onto the fly- left wheel)
Page 57: Technical Data B-Detection Plus I
OPERATING MANUAL Technical data | 4 4.4 Technical data B-DETECTION PLUS i Category and unit B-DETECTION PLUS i Medium Natural air, Nitrox (max. 40% O Minimum air quality: • Particle class in accordance with ISO 8573: 5 • Humidity class in continuous running mode: 3 (≤-20°C) •...
Page 58: Technical Data Motor
4 | Technical data OPERATING MANUAL Category and unit B-DETECTION PLUS i • ±1.0 % (calibration temperature) • ±2.0 % (at 10°C deviation from calibra- tion temperature) • ±3.5 % (over entire temperature range) ±1% measured value Dewpoint at 20°C ±2 °C Absolute humidity •...
Page 59: Transport And Storage
OPERATING MANUAL Transport and storage | 5 5 Transport and storage 5.1 Transport 5.1.1 Checking the cargo The shipping agent shall be liable for damage that can be traced back without a doubt to improper transport. The passage of risk is contractually regulated. 1.
Page 60: Transport
5 | Transport and storage OPERATING MANUAL 5.1.3 Transport WARNING Danger of crushing due to falling, tilting or swinging loads! Crushing can result in death or serious injuries. Follow the safety instructions and safety regulations when transporting the machine. Follow the transport instructions. Keep in mind the transport weights and measurements.
Page 61: Storage And Preservation
OPERATING MANUAL Transport and storage | 5 5.2 Storage and preservation 5.2.1 Selecting the storage location Ensure that the storage space fulfils the following conditions: dry, frost-free, vi- bration-free. Covering with plastic sheets is recommended only if it prevents condensation from being formed.
Page 62: Preservation
5 | Transport and storage OPERATING MANUAL 5.2.3 Preservation If the unit has to be stored for more than 2 years, request special instructions from BAUER KOMPRESSOREN, see Chapter 1.1 Contact data BAUER KOMPRESSOREN, Page If the unit is put out of operation for more than 6 months, preserve it as follows: 1.
Page 63: Installation
OPERATING MANUAL Installation | 6 6 Installation 6.1 Preparing the installation site 1. Make sure that the installation site complies with the required ambient condi- tions, see technical data. 2. Make sure that the surface is flat and clean. 3. Make sure that the surface can support the weight of the machine and that the machine is stable.
Page 64: Installing The Unit
6 | Installation OPERATING MANUAL 6.2 Installing the unit 6.2.1 Securing the air quality You must always ensure that the compressor unit draws in fresh air, i.e. free from toxic gases, exhaust gases or solvent vapours. Note the following: • Operating rooms where persons are housed will exhibit high levels of CO as a result of the breathing, and will be unsuitable for filling breathing air cylinders.
Page 65: Installing The Unit
OPERATING MANUAL Installation | 6 6. Structure the wall bushing in such a way that the compressor does not suck in dirt or water. 6.2.2 Installing the unit WARNING Danger of injuries due to improper assembling! Improper assembling can result in personal and material damage. Install and connect the unit properly and in accordance with the relevant guidelines.
Page 66: Ensuring Cooling
6 | Installation OPERATING MANUAL 6.2.3 Ensuring cooling For the unit to operate, sufficient cooling air must be ensured. The cooling temper- ature here is the same as room temperature. Observe the operating conditions for correct room temperature and cooling temperature, see Technical Data. A_K12,P41_001_en 66/174 02.12.2019...
Page 67 OPERATING MANUAL Installation | 6 Ensuring natural ventilation A supply of natural cooling air is possible under the following circumstances: • No thermal overloads are expected • The unit has a low drive power rating • The unit is operated only intermittently •...
Page 68 6 | Installation OPERATING MANUAL Fig. 13 Ensuring natural ventilation Correct: Air inlet low, cooling air Correct: Air outlet directed up- Correct: Cooling air is directed di- flows through the unit wards, cooling circuit possible rectly into the unit Incorrect: Air inlet too high, cool- Incorrect: Hot air is not dissipa- Incorrect: Cooling air does not ing air does not reach the unit...
Page 69 OPERATING MANUAL Installation | 6 Installing artificial ventilation Artificial ventilation is required if natural ventilation does not prevent the room temperature from rising above the permissible maximum ambient temperature, see technical data. The natural ventilation cannot be sufficient in the following cases: •...
Page 70 6 | Installation OPERATING MANUAL Fig. 14 Installing artificial ventilation Correct: The air flows along an in- Correct: The cooling air is direc- tended flow line through the com- ted downwards through a venti- pressor lation duct Incorrect: The cooling air draws Incorrect: Length of the ventila- through tion duct inadequate...
Page 71: Electrical Connection Of The Unit
OPERATING MANUAL Installation | 6 6.3 Electrical connection of the unit DANGER Danger to life due to electric voltages! Contact with live parts leads to death or serious injuries. Work on the electrical unit may be carried out by an electrician only. Make sure that the unit is tension-free for the necessary work.
Page 72: Pneumatic Connection Of The Unit
6 | Installation OPERATING MANUAL 6.4 Pneumatic connection of the unit WARNING Danger of injury from improper connection! Pressure lines improperly laid out and installed can burst or tear under pressure! Trained expert personnel must establish the pneumatic connection. Lay out and install the pressure lines properly. Do not swap the connections over.
Page 73: Commissioning And Operation
OPERATING MANUAL Commissioning and operation | 7 7 Commissioning and operation 7.1 Caution in case of units with gas measurement device 7.1.1 Instructions for operation WARNING Danger on account of incorrect measurement results! Make sure that all persons who operate the device at least meet the require- ments for trained personnel.
Page 74 7 | Commissioning and operation OPERATING MANUAL Keep the following in mind for measuring devices with the VOC* sensor: In case of unforeseeable deviations in the operating characteristic due to an early warning and/or shutdown of the compressor, the optional VOC sensor* helps pre- vent an excessively high percentage of specific volatile hydrocarbons in the breath- ing air.
Page 75: Starting Up The Unit
OPERATING MANUAL Commissioning and operation | 7 7.2 Starting up the unit 7.2.1 Checks before each commissioning WARNING High noise level! Remaining next to open units can lead to hearing loss. Wear ear defenders. The unit is correctly installed and connected. ü...
Page 76 7 | Commissioning and operation OPERATING MANUAL Further caution must be exercised in case of units with gas measure- ment device 1. Check the gas sensors. See or check the measurements using an independent measurement device. 2. Apply the gas to be analysed to the measurement device or start the compres- sor unit.
Page 77: Commissioning The Unit For The First Time
OPERATING MANUAL Commissioning and operation | 7 7.2.2 Commissioning the unit for the first time All compressor units are checked before delivery in the factory so that commis- sioning can be carried out after proper erection, installation and successful accept- ance tests.
Page 78 7 | Commissioning and operation OPERATING MANUAL Further caution must be exercised in case of units with gas measure- ment device Starting up the measurement device for the first time, or after long standstill times Until the measured value of the moisture sensor is within the permissible range, a significantly longer purging time than the pre-set alarm block may be required on first commissioning.
Page 79: Commissioning The Unit After Longer Downtimes
OPERATING MANUAL Commissioning and operation | 7 7.2.3 Commissioning the unit after longer downtimes 1. Please see chapter “Checks before each commissioning”. 2. Treat the motor in accordance with the instructions provided by the motor manufacturer. 3. After an extended period of storage, or after a standstill time of more than 2 years: the oil should be drained off and replaced with fresh oil, see Chap- ter 9.6 Maintenance activities - Lubricating oil system , Page...
Page 80 7 | Commissioning and operation OPERATING MANUAL Further caution must be exercised in case of units with gas measure- ment device Starting up the measurement device for the first time, or after long standstill times Until the measured value of the moisture sensor is within the permissible range, a significantly longer purging time than the pre-set alarm block may be required on first commissioning.
Page 81: Checking The Direction Of Rotation Of The Motor
OPERATING MANUAL Commissioning and operation | 7 7.2.4 Checking the direction of rotation of the motor DANGER Danger to life due to electric voltages! Contact with live parts leads to death or serious injuries. Work on the electrical unit may be carried out by an electrician only. Make sure that the unit is tension-free for the necessary work.
Page 82: Operating The Electronic Control
7 | Commissioning and operation OPERATING MANUAL 7.3 Operating the electronic control This chapter describes only the settings editable by the operator e.g. within the au- thorization level "0". All other settings require special knowledge and must be car- ried out by qualified personnel within the relevant login level. 7.3.1 Navigating in the control system If no action is taken after 10 minutes the display goes back to the homepage.
Page 83: Modifying The Settings
OPERATING MANUAL Commissioning and operation | 7 7.3.2 Modifying the settings Grey input fields are protected and can be edited only with the appropriate authori- sation, see Chapter 7.3.3 Entering password, Page Fig. 17 Selecting field 1. Place the red selection frame on the desired field using the navigation keys 2.
Page 84 7 | Commissioning and operation OPERATING MANUAL The display returns to the menu or sub-menu and displays the new value. Ä The wrong menu was selected or was no change made? Press reset button to cancel the input. A_K12,P41_001_en 84/174 02.12.2019...
Page 85: Entering Password
OPERATING MANUAL Commissioning and operation | 7 7.3.3 Entering password Certain parameters are password-protected to provide protection for personnel and machine. When an attempt is made to change a password-protected value or setting, the message “Authorisation required” appears on the screen. Access to the input of the password is located in the following menu: Start page →...
Page 86 7 | Commissioning and operation OPERATING MANUAL Authorisations The type and number of adjustable parameters depends on the level of authorisa- tion. For an overview of the setting parameters and the corresponding required au- thorisations, see Chapter 3.6, Page Keep password secure and give them only to instructed personnel. The responsibil- ity of passing on the password falls to the operating company.
Page 87: Inserting The Memory Card
OPERATING MANUAL Commissioning and operation | 7 7.3.4 Inserting the memory card DANGER Danger of electrocution! Danger to life due to contact with live parts. Allow work be carried out on and in the control system only by qualified per- sonnel with professional training as electricians.
Page 88 7 | Commissioning and operation OPERATING MANUAL Insert the memory card of the unit control system The unit is switched off. ü 1. Open the cover of the compressor control system. Fig. 21 Insert the memory card in the compressor control system 2.
Page 89: Configuring The Electronic Control System
OPERATING MANUAL Commissioning and operation | 7 7.4 Configuring the electronic control system 7.4.1 Setting time and date Access to the setting of the time and date is located in the following menu: Start page → B-Control Setup → Time/Date Fig.
Page 90: Setting Language And Units
7 | Commissioning and operation OPERATING MANUAL 7.4.2 Setting language and units Access to the setting of the language and units is located in the following menu: Start page → B-Control Setup → Language/Units Fig. 23 Setting language and units 1.
Page 91: Setting The Display
OPERATING MANUAL Commissioning and operation | 7 7.4.3 Setting the display The Display page allows the user to set the display of the lighting conditions and determine the duration of the background lighting following the last action. Access to the setting of the display is located in the following menu: Start page →...
Page 92: Setting The Final Pressure
7 | Commissioning and operation OPERATING MANUAL 7.4.4 Setting the final pressure The final pressure measured controls the switching on and off of the compressor unit. A second final pressure sensor is optional. The set values of the second final pres- sure sensor are displayed only if the sensor is registered.
Page 93: Setting The Valves
OPERATING MANUAL Commissioning and operation | 7 7.4.5 Setting the valves The individual settings pages help in setting the valve type and the response times of the valves. The number and type of valves depend on the compressor type. Access to the setting of the valves is located in the following menu: Start page →...
Page 94: Setting The Alarm Relay
7 | Commissioning and operation OPERATING MANUAL 7.4.6 Setting the alarm relay The alarm relay determines the behaviour of the unit when a warning message or a fault message is received. Three operating modes are available for selection: Errors only: The unit stops automatically when an error occurs. •...
Page 95: Loading The Factory Settings
OPERATING MANUAL Commissioning and operation | 7 7.4.7 Loading the factory settings Loading the factory settings allows the original settings that were available when the unit was delivered to be restored. The current settings are overwritten and lost once the configuration is loaded. The factory settings are protected and can be reloaded at any time.
Page 96: Connecting To A Local Network
7 | Commissioning and operation OPERATING MANUAL 7.4.8 Connecting to a local network The units are equipped, as standard for connection to a local network using a LAN bush. The LAN connection serves primarily for the connection to a local WLAN router, in order to operate the unit using a smartphone via a WLAN, see Chap- ter 7.5.10 Operating the control system with the B-APP, Page 105...
Page 97: Operation
OPERATING MANUAL Commissioning and operation | 7 7.5 Operation CAUTION Danger of injury due to automatic re-start of the unit! The unit can re-start automatically depending on the version. Follow the safety instructions for the unit. Operate the unit only if the safety devices are installed. Ensure that a suddenly restarted unit does not pose dangers to people or the machine.
Page 98: Switching The Unit On
7 | Commissioning and operation OPERATING MANUAL 7.5.1 Switching the unit on Initial start-up has been performed correctly. ü All covers are kept closed. ü WARNING Danger of injury due to unit in operation. Do not perform any work on the unit when it is in operation. For all assembly and maintenance work, disconnect the motor and secure it against turning on again.
Page 99: Behaviour In Case Of Emergency
OPERATING MANUAL Commissioning and operation | 7 7.5.3 Behaviour in case of emergency Switching the unit off in case of an emergency The unit is equipped with at least one emergency stop switch, see Chapter 2.4.7 Safety and monitoring equipment, Page Press the emergency stop switch.
Page 100: Checking The Maintenance Intervals
7 | Commissioning and operation OPERATING MANUAL 7.5.5 Checking the maintenance intervals For planning purposes, the upcoming maintenance activities can be displayed at any time in the "Maintenance" menu. Access Maintenance > Maintenance intervals Proceed as follows to display the maintenance intervals: 1.
Page 101: Checking The Maintenance Intervals For Gas Sensors
OPERATING MANUAL Commissioning and operation | 7 7.5.6 Checking the maintenance intervals for gas sensors For planning purposes, the upcoming maintenance activities for the gas sensors can be displayed at any time in the "Maintenance" menu. Access Maintenance > Maintenance air analysis Proceed as follows to display the maintenance intervals: Fig.
Page 102: Displaying The Current Messages
7 | Commissioning and operation OPERATING MANUAL 7.5.7 Displaying the current messages Current warning and fault messages are listed in the Messages menu and can be called up at any time. Each message contains a time stamp with the date and time, message number and the message text.
Page 103: Displaying The Logbook
OPERATING MANUAL Commissioning and operation | 7 7.5.8 Displaying the logbook The control system stores every warning and fault message received in the "log- book". Access Start page → Messages → Logbook Proceed as follows to display the logbook: The display shows the Messages page, see Chapter 7.5.7 Displaying the cur- ü...
Page 104: Resetting The Messages
7 | Commissioning and operation OPERATING MANUAL 7.5.9 Resetting the messages A message can be acknowledged before or after the fault rectification. However, the unit will only be ready for operation after the fault has been rectified or after the message has disappeared from the alarm list. Access Start page →...
Page 105: Operating The Control System With The B-App
OPERATING MANUAL Commissioning and operation | 7 7.5.10 Operating the control system with the B-APP The electronic control system B-CONTROL MICRO can be operated via WLAN using a smartphone. You can download the B-APP free of charge from the AppStore and from Google Play.
Page 106 7 | Commissioning and operation OPERATING MANUAL Fig. 36 Connecting the B-APP with the compressor control system 4. Click on the "Remote" symbol in the footer on the B-APP start page. The router or the device "B-LINK (192.168.0.100)" appears in the list of Ä...
Page 107 OPERATING MANUAL Commissioning and operation | 7 6. Enter the B-APP password in the relevant box and click on the "Connect" box. The start page of the control system appears on the Smartphone. Remote Ä only allows control of start , stop and "message acknowledge".
Page 108: Filling Operation
7 | Commissioning and operation OPERATING MANUAL 7.6 Filling operation DANGER Danger of poisoning due to pollutants in breathing air! Inhaling harmful gases can be dangerous to life. Make sure that the air drawn in is free from toxic gases, exhaust gases or sol- vent vapours.
Page 109: Switching Over The Filling Pressure
OPERATING MANUAL Commissioning and operation | 7 7.6.2 Switching over the filling pressure Filling panels for 2 pressure ranges (PN200 / PN300) and with switch-over valve can only be used for one pressure range at a time. NOTICE Damage to the pressure gauge by too high a pressure Before switching over from 300 bar to 200 bar you must always open the purge valve and vent the 300 bar section to at least 200 bar.
Page 110: Analysing The Air
7 | Commissioning and operation OPERATING MANUAL 7.6.3 Analysing the air The unit is switched on, and it was either started up properly or calibrated cor- ü rectly. The function of the sensors was tested. ü WARNING Danger on account of incorrect measurement results! Check the measured values using a second measurement device.
Page 111 OPERATING MANUAL Commissioning and operation | 7 Instruction for measuring the oil content Keep the following in mind for measuring devices with the VOC* sensor: In case of unforeseeable deviations in the operating characteristic due to an early warning and/or shutdown of the compressor, the optional VOC sensor helps pre- vent an excessively high percentage of specific volatile hydrocarbons in the breath- ing air.
Page 112: Filling The Compressed Air Cylinders
7 | Commissioning and operation OPERATING MANUAL 7.6.4 Filling the compressed air cylinders WARNING Danger of injury from unconnected filling connections! The filling hose can be set in uncontrolled motion by the flow of air coming out, and can cause severe injuries! Never open the filling valve without a connected compressed air cylinder! WARNING Danger of injuries due to the use of non-approved or damaged filling equip-...
Page 113 OPERATING MANUAL Commissioning and operation | 7 Fig. 39 Filling the compressed air cylinder Filling valve Cylinder cock 2. Open filling valve (Fig. 39-1). 3. Open cylinder cock (Fig. 39-2). 4. Switch on unit. - Or - On units with automatic starting, check that the unit starts automatically. The compressed air cylinder is filled.
Page 114 7 | Commissioning and operation OPERATING MANUAL Fig. 40 Removing the compressed air cylinder Cylinder cock Filling valve 7. Close cylinder cock (Fig. 40-1). 8. Close filling valve (Fig. 40-2). 9. Remove compressed air cylinder. During filling, the compressed air cylinder heats up because of the subsequent compression in the compressed air cylinder.
Page 115: Filling The Compressed Air Cylinders
OPERATING MANUAL Commissioning and operation | 7 7.6.5 Filling the compressed air cylinders WARNING Danger of injuries due to the use of non-approved or damaged filling equip- ment and compressed air cylinders! Unsuitable or damaged material may burst or tear under pressure. Use only approved filling devices and compressed air cylinders.
Page 116 7 | Commissioning and operation OPERATING MANUAL 4. Switch on unit. - Or - On units with automatic starting, check that the unit starts automatically. The compressed air cylinder is filled. The unit switches off automatically Ä when the filling pressure has been reached. 5.
Page 117: Troubleshooting
OPERATING MANUAL Troubleshooting | 8 8 Troubleshooting 8.1 Fault finding and fault correction 8.1.1 Fault finding in drive motor Description Cause Rectification Motor does not start. Fault in the electrical power Check lines and fuses. Com- supply. pare the motor data with the mains supply.
Page 118: Fault Finding In Electrical Control System
8 | Troubleshooting OPERATING MANUAL 8.1.3 Fault finding in electrical control system Description Cause Rectification Control system does not No control voltage present. Check the supply line. switch on. Control fuse defective. Replace fuse and rectify the Control voltage circuit inter- cause.
Page 119: Fault Finding In Automatic Condensate Drain
OPERATING MANUAL Troubleshooting | 8 8.1.4 Fault finding in automatic condensate drain Description Cause Rectification Inadequate water removal or Opening time or cycle time of Check the set opening time or much condensate coming out solenoid valve set incorrectly cycle time at the timer and (>40 ml at function check) Solenoid valve does not open have it adjusted if necessary...
Page 120: Troubleshooting
8 | Troubleshooting OPERATING MANUAL 8.1.5 Troubleshooting Description Cause Rectification Differential pressure too high - Flow rate too high - Check installation of nozzle - Secondary pressure at pres- in AIRBOX, re-install if neces- sure reducer too high sary - Measure secondary pres- sure, replace pressure reduc- er if too high Differential pressure too low...
Page 121: Maintenance
OPERATING MANUAL Maintenance | 9 9 Maintenance 9.1 Maintenance table The following chapters describe the maintenance activities that are listed in the maintenance table, and which are necessary for optimal and fault-free operations. If the regularly scheduled checks reveal an enhanced degree of wear and tear, the required maintenance intervals must be shortened in accordance with the ob- served wear and tear.
Page 122: Resources For Maintenance And Repairs
9 | Maintenance OPERATING MANUAL 9.2 Resources for maintenance and repairs 9.2.1 Bolt torques Unless otherwise stated, the following torques must be used. The specified values apply to greased bolts. Valve head screws must be tightened with a torque wrench. Self-locking nuts must not be re-used, replace them.
Page 123: Bolt Tightening Sequence
OPERATING MANUAL Maintenance | 9 9.2.2 Bolt tightening sequence All the valve head screws, cylinder fixing screws and the corresponding nuts must be tightened evenly in a cold condition, and this must be done in the following or- der. Fig. 44 Bolt tightening sequence 9.2.3 Adhesive and sealant...
Page 124: Lubricant
9 | Maintenance OPERATING MANUAL 9.2.4 Lubricant Application range Lubricant Rubber parts, plastic parts, thread of the filter BAUER special grease, order number N19752 housing (container - 350 g) BAUER special grease, order number 072500 (container - 3 g) O-rings BAUER special grease, order number 072500 (container - 3 g) Shaft seal rings: Ring and shaft...
Page 125: Lubrication Oil
OPERATING MANUAL Maintenance | 9 9.2.5 Lubrication oil Depending on the type of application of the unit, the following is demanded of the lubrication oil that is used: • low residue formation • no carbon deposits in the valves • good corrosion protection •...
Page 126 9 | Maintenance OPERATING MANUAL Lubrication oil list The exclusive use of high-quality branded oils is essential because of the thermal loads encountered in the compressor. In order to ensure perfect operation, we rec- ommend using only those oils listed below from BAUER in the quoted operating conditions tested and approved by us.
Page 127: Test Material
OPERATING MANUAL Maintenance | 9 N28355 Volume Order number 5-l can N28355-5 20-l can N28355-20 9.2.6 Test material Application range Test medium Screwed fittings, lines Leak detection spray, order number N25833 Tab. 12 Test medium table 9.2.7 Filter cartridges Replacement cartridges Replacement cartridges for filter system P41 Order number Application...
Page 128: Checking The Unit For Leaks
9 | Maintenance OPERATING MANUAL 9.3 Checking the unit for leaks In “Tightness test” mode, the compressor is started manually and then switches off automatically after the final pressure has been reached. Venting of the condensate valves is blocked for entire running time, the compressor comes to a standstill at the prevailing excess pressure after switching off automatically.
Page 129: Depressurising The Unit
OPERATING MANUAL Maintenance | 9 9.4 Depressurising the unit 9.4.1 De-pressurising the filter circuit De-pressurise the filter circuit as follows before any work is carried out: Fig. 46 De-pressurising the filter The unit is switched off. ü 1. Open the left-hand side cladding. 2.
Page 130: Maintenance Activities - Intake Section
9 | Maintenance OPERATING MANUAL 9.5 Maintenance activities - Intake section 9.5.1 Maintenance work CAUTION Danger of burns! Even after switching off the unit, pressure lines, heat exchangers, compressors, condensate valves, oil and possibly cooling water can be at high temperatures. There is a danger of burns if they are touched! Wear appropriate personal protection equipment or gloves.
Page 131 OPERATING MANUAL Maintenance | 9 Replacing the intake filter Maintain the filter insert of the intake filter regularly and/or as per the mainte- nance plan. The maintenance intervals are dependent on the condition of the air being drawn in. If there is a lot of dust it may be necessary to carry out maintenance monthly or weekly.
Page 132: Maintenance Activities - Lubricating Oil System
9 | Maintenance OPERATING MANUAL 9.6 Maintenance activities - Lubricating oil system CAUTION Danger of burns! Even after switching off the unit, pressure lines, heat exchangers, compressors, condensate valves, oil and possibly cooling water can be at high temperatures. There is a danger of burns if they are touched! Wear appropriate personal protection equipment or gloves.
Page 133: Maintenance Work
OPERATING MANUAL Maintenance | 9 9.6.1 Maintenance work Checking the oil level NOTICE Damage to unit due to incorrect oil level! Make sure that the oil level is between the minimum mark and the maximum mark. Fig. 48 Oil level gauge Use the oil level gauge to check the oil level.
Page 134 9 | Maintenance OPERATING MANUAL Oil change CAUTION Danger of burns! Even after switching off the unit, pressure lines, heat exchangers, compressors, condensate valves, oil and possibly cooling water can be at high temperatures. There is a danger of burns if they are touched! Wear appropriate personal protection equipment or gloves.
Page 135 OPERATING MANUAL Maintenance | 9 Draining the oil Unit is at operating temperature. ü Suitable container is available for collecting the oil. ü Fig. 49 Draining the oil Oil filler spigot Oil drain cock 1. Open oil filler spigot. 2. Open the oil drain cock and collect the oil in a suitable container. If the red plastic handle of the oil drain cock is damaged or lost, the cock can be opened using the cover cap.
Page 136 9 | Maintenance OPERATING MANUAL NOTICE Environmental damage caused by improper disposal of waste oil! Dispose of used oil as special waste. Be mindful of the local regulations relating to the disposal of special waste. 8. Dispose of used oil. Changing the oil filter The required replacement parts are available.
Page 137: Changing The Oil Type
OPERATING MANUAL Maintenance | 9 Filling oil NOTICE Risk of damage when changing the oil type! Observe chapter “Changing the oil type” before changing the oil type. Suitable BAUER compressor oil is available, see Chapter 9.2.5 Lubrication oil, ü Page 125.
Page 138: Maintenance Activities Filter System
9 | Maintenance OPERATING MANUAL 9.7 Maintenance activities filter system 9.7.1 General maintenance advices WARNING Risk of damages and injuries during maintenance! When disregarding the maintenance instructions, injuries and/or damages may occur. Observe following advices: Depressurise system before starting any maintenance work. Replace tilter cartridges in time.
Page 139: Determine The Cartridge Service Life
OPERATING MANUAL Maintenance | 9 9.7.3 Determine the cartridge service life In case of units without filter monitoring, BAUER recommends the use of the BAUER KOMPRESSOREN APP (B-APP) and of the contained calculation tool for the determination of the cartridge service life. The calculation tool takes into account a variety of parameters and thus enables a precise determination of the service life.
Page 140 9 | Maintenance OPERATING MANUAL Determine cartridge service life on the basis of tables The number of operating hours or the number of possible cylinder fillings per filter cartridge can be determined using the tables in the appendix, with due regard to the ambient temperature and the cartridge being used.
Page 141 OPERATING MANUAL Maintenance | 9 Determining the cartridge service life in hours The cartridge service life values and the maximum number of operating hours per filter cartridge or cartridge combination is to be determined as follows: Cartridge Life time [hours] Filling pressure p = Delivery [l/min] 200 bar...
Page 142 9 | Maintenance OPERATING MANUAL Determining the cartridge service life in cylinder fillings The cartridge service life values and the maximum number of cylinder fillings per filter cartridge or cartridge combination is to be determined as follows: Number of bottle fillings n and bottle size [l] 10 l Ambient Temperature in...
Page 143: Changing The Cartridge Of The Filter Vessel
OPERATING MANUAL Maintenance | 9 9.7.4 Changing the cartridge of the filter vessel Vacuum packing of the cartridge is undamaged. ü Special filter wrench (part of the scope of supply) is available ü A clean cloth is provided. ü A suitable lubricant is available, see Chapter 9.2 Resources for maintenance ü...
Page 144: Check Filling Hoses
9 | Maintenance OPERATING MANUAL NOTICE Environmental damage caused by improper disposal of filter cartridges! Dispose of saturated filter cartridges as special waste. Be mindful of the local regulations relating to the disposal of special waste. 10. Dispose of saturated cartridge. 11.
Page 145: Maintenance Activities Pressure Retention Valve
OPERATING MANUAL Maintenance | 9 9.9 Maintenance activities pressure retention valve 9.9.1 Checking the pressure maintaining valve In order not additionally to load the pressure vessel unnecessarily, the pressure maintaining valve must be checked regularly or in accordance with the mainte- nance schedule.
Page 146: Adjusting The Pressure Retention Valve
9 | Maintenance OPERATING MANUAL 9.9.2 Adjusting the pressure retention valve The pressure retention valves may only be adjusted by trained personnel. For more information, contact the BAUER customer service department, see Chapter 1.1 Contact data BAUER KOMPRESSOREN, Page 1. Disengage locknuts (if they are present). 2.
Page 147: Maintenance Activities Safety Valves
OPERATING MANUAL Maintenance | 9 9.10 Maintenance activities safety valves WARNING Danger of injury for compressed gas escaping! The resultant noise can damage hearing. Ejected particles may cause eye inju- ries. Wear protective goggles and personal ear defenders. Check the safety valves with utmost care when the compressor is running. Do not repair safety valves;...
Page 148: Checking The Blow-Off Pressure Of Safety Valves
9 | Maintenance OPERATING MANUAL 9.10.1 Checking the blow-off pressure of safety valves BAUER KOMPRESSOREN recommends that the intermediate pressure safety valves be replaced as a precautionary measure. The blow-off pressure can be checked only with considerable expenditure. The blow-off pressure of the final pressure safety valve can be checked using the Safety valve test mode.
Page 149 OPERATING MANUAL Maintenance | 9 Fig. 54 Checking the safety valve 1. Safety Valve Select Test and confirm. The warning LED flashes. Ä 2. Press start button I to start the test. The compressor starts to build up pressure. Ä 3.
Page 150: Maintenance Activities Pressure Gauge
9 | Maintenance OPERATING MANUAL 9.11 Maintenance activities pressure gauge Pressure gauges must be checked in accordance with the maintenance schedule. Using a special testing pressure gauge is recommended for checking the pressure gauges, see BAUER KOMPRESSOREN catalogue of high-pressure accessories. Allowances should be made for minor deviations during operation.
Page 151: Maintenance Activities - Automatic Condensate Drain
OPERATING MANUAL Maintenance | 9 9.13 Maintenance activities - Automatic condensate drain 9.13.1 Testing the condensate valves The sub-menu Valve test displays the current status of the valves (open / closed) and enables the function of the individual valves to be checked. Access to the valve test is located in the following menu: Start page →...
Page 152: Checking The Function Of Automatic Condensate Drain
9 | Maintenance OPERATING MANUAL 9.13.2 Checking the function of automatic condensate drain WARNING Danger of injury for compressed gas escaping! Wear protective goggles and personal ear defenders. CAUTION Danger of poisoning! Condensate is toxic. Condensate must not be swallowed. Do not breathe condensate in.
Page 153 OPERATING MANUAL Maintenance | 9 2. Clean the float switch in the condensate collection vessel, if fitted, in order to prevent it from sticking on account of oil residues. A_K12,P41_001_en 02.12.2019 153/174...
Page 154: Maintenance Activities Gas Measurement Unit
9 | Maintenance OPERATING MANUAL 9.14 Maintenance activities gas measurement unit 9.14.1 Checking the sensors The sensors must be checked before each commissioning and once every 3 months, with the help of certified gas samples of known concentrations. We rec- ommend using the BAUER test gas kit for testing the sensors.
Page 155 OPERATING MANUAL Maintenance | 9 Fig. 59 Inserting and removing the hose 2. Use the hose to connect the flow meter to the pressure reducer. Insert the in- take hose into the plug connection up to the stop (at least to a depth of 15 mm).
Page 156: Calibrating The Sensors
9 | Maintenance OPERATING MANUAL 9.14.2 Calibrating the sensors We recommend using the BAUER calibration gas kit for calibration. Two different gas samples are required for calibrating the individual sensors: Low calibration gas and High calibration gas. See the spare parts list provided for reference and application purposes of the gas samples.
Page 157 OPERATING MANUAL Maintenance | 9 Fig. 60 Calibration page 1. Select the sensor on the calibration page. The calibration page shows the date and the values of the last calibration Ä carried out. 2. Press the "Calibration" box. 3. Select "Two-point calibration". 4.
Page 158 9 | Maintenance OPERATING MANUAL 15. Repeat the calibration as described above for all sensors (excluding the dew- point sensor). A_K12,P41_001_en 158/174 02.12.2019...
Page 159: Replacing The Sensors
OPERATING MANUAL Maintenance | 9 9.14.3 Replacing the sensors The CO and O sensors must be replaced with new ones after a specified service life. The residual service life of the specific sensor is quoted on the "Maintenance intervals" page: Start page →...
Page 160 9 | Maintenance OPERATING MANUAL Fig. 61 Removing the sensors 4. Unscrew the fixing screws on the sensor board with a suitable screwdriver. 5. Insert the new board and fix in place. 6. Reinstall the plug and hoses. 7. Replace all filters, see Chapter 9.14.4 Replacing the filters, Page 161.
Page 161: Replacing The Filters
OPERATING MANUAL Maintenance | 9 9.14.4 Replacing the filters The filters must be replaced at least once every 12 months, and whenever the sen- sor is replaced. The personnel executing the work must fulfil the minimum requirements for ü trained personnel. ü...
Page 162: Maintenance Activities Electrical System
9 | Maintenance OPERATING MANUAL 9.15 Maintenance activities electrical system 9.15.1 Maintaining the electrical control systems DANGER Danger to life due to electric voltages! Contact with live parts leads to death or serious injuries. Work on the electrical unit may be carried out by an electrician only. Make sure that the unit is tension-free for the necessary work.
Page 163: Maintenance Activities Drive System
OPERATING MANUAL Maintenance | 9 9.16 Maintenance activities drive system 9.16.1 V-belt maintenance WARNING Danger of injury due to unit in operation! Do not perform any work on the unit when it is in operation. For all assembly and maintenance work, disconnect the motor and secure it against re-start pressure.
Page 164 9 | Maintenance OPERATING MANUAL Replacing the V-belt Replace damaged and worn V-belts as follows. In case the situation involves multiple V-belts, always replace them in sets. The unit is switched off and secured against being switched on again. ü 1.
Page 165: Disassembly And Disposal
OPERATING MANUAL Disassembly and disposal | 10 10 Disassembly and disposal 10.1 Decommissioning and disposal 10.1.1 Decommissioning Shut off the unit as follows: 1. Disconnect the unit from the power supply or any energy supply. 2. Depressurize the unit. 3. Disconnect pneumatic connections. 4.
Page 166: Dispose The Unit
10 | Disassembly and disposal OPERATING MANUAL 10.1.2 Dispose the unit To exclude health and enviromental damage when disposing the unit, assemblies and equipment, observe the following instructions. NOTICE Environmental damage in case of improper disposal! Electrical waste, electronic components, lubricants and other auxiliary materials are subject to the provisions regarding the treatment of special waste.
Page 167: Appendix
This sample declaration of conformity serves as an example. The signed declara- tion of conformity is supplied separately. Declaration of conformity according to Machinery Directive 2006/42/EC The manufacturer, BAUER KOMPRESSOREN GmbH, Stäblistr. 8, D-81477 Munich hereby declares that the following products PE300-VE PE320-VE PE400-VE PE500-VE PE550-VE PE600-VE PE700-VE...
Page 168: Filter Cartridge Replacement Intervals
11 | Appendix OPERATING MANUAL 11.2 Filter cartridge replacement intervals The determination of the number of operating hours or the number of possible cyl- inder fillings per filter cartridge is carried out using the following information, with due regard to the ambient temperature and the cartridge being used. The tables contain calculated cartridge service life figures, which refer to defined and constant operating conditions.
Page 169: Filter Cartridge 062565
OPERATING MANUAL Appendix | 11 11.2.1 Filter cartridge 062565 Cartridge service life [hours] Filling pressure p = Delivery volume [l/min] 200 bar Ambient Tempera- tempera- ture in fi- ture tU nal sepa- [°C] rator tAb [°C] 20 - 24 394 - 313 197 - 157 129 - 102 91 - 72 67 - 53 45 - 35...
Page 170 11 | Appendix OPERATING MANUAL 30 - 34 449 - 363 224 - 181 147 - 119 103 - 83 76 - 62 51 - 41 35 - 39 344 - 281 172 - 140 113 - 92 79 - 64 59 - 48 39 - 32 40 - 44...
Page 171 OPERATING MANUAL Index Compressed air cylinders Filling........... 112, 115 Abbreviations............11 Compression............35 Acceptance............72 Condensate Acknowledge............ 104 Collection............36 Adhesive............123 Separation............. 35 Alarm LED............44 Condensate drain..........36 Alarm relay Condensate drain cock........152 setting............94 Condensate valves Analysing the air..........
Page 172 OPERATING MANUAL Electrical connection ......... 71 History..............12 Electrical system Maintenance..........162 Installation............64 Emergency............99 Intake filter Equipment............14 Maintenance..........131 Erection.............. 64 Keys..............42 Factory settings load............... 95 Fault finding............117 Language Filling..............37 setting............90 Direct connection........115 Leakage test.............
Page 173 OPERATING MANUAL Measuring............110 Memory card............87 Remote control..........105 Menu Resetting messages......... 104 Overview............47 Revision index............. 12 Messages............102 Safety valve Navigation............82 Checking the blow-off pressure....148 Network Maintenance..........148 Connection............ 96 Safety valves Maintenance..........147 Scope of supply..........14 Lubrication oil list........
Page 174 OPERATING MANUAL P41..............56 PE300-VE............49 PE320-VE............51 PE400-VE............53 Temperature............66 Test material............. 127 Tightness test........... 128 Time setting............89 Torques............122 Training............... 86 Transport............59, 59 Troubleshooting........120, 120 Units setting............90 V-belt maintenance.......... 163 Valves setting............93 Variants..............

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