Instruction Manual  Junior II

INTRODUCTION

This manual contains operating instructions and maintenance

schedules for the high pressure breathing air compressor 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 ma­
chine regulations 98/37/EG. Specifications on the noise level
in accordance with the machine and product safety law as of
01.05.2004 and the EC machine regulations, 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 personnel or third parties, or result
in damage to the machine and other values. The machine
may only be used to produce compressed air as specified in
this manual. Other use is strictly prohibited.
All instructions should be observed and carried out in the or­
der 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 instruc­
tions.

Edition January 2009

© 2009 BAUER Kompressoren GmbH, München
All rights reserved

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

Explanation of the short operating instructions on the unit

Read instruction manual before op­ Position unit level: max. inclination
erating unit 5°

 chapter 3.
 chapter 3.

Check oil level on compressor and

Operate unit only at ambient tem­
petrol engine before operating unit
peratures between +5 and +45 °C
 chapter 4.4.1.
 chapter 3.

Drain condensate at least every 15

minutes (3 locations) Keep away from hot surfaces on
motor and compressor
A
 chapter 4.4.3. and 4.4.4.
 chapter 2.

B
C

Position units with petrol engine

with exhaust in wind direction to Wear ear protectors when unit is
prevent exhaust fumes being sucked running
in by the compressor
 chapter 2.
 chapter 3.

Petrol driven units must not be oper­

ated indoors.

 chapter 3.

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Instruction Manual  Junior II
CONTENTS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2. SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . 5
3. LOCATION, OPERATION, BOTTLE FILLING . . 9
4. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 17
5. STORAGE, PRESERVATION . . . . . . . . . . . . . . 31
6. REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . 32
7. TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8. ANNEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

INDEX

A Maintenance instructions, 17
Maintenance record, 17
Adhesive chart, 34 Maintenance schedule, 17
Air flow diagram, 1 Motor protection switch, 28
Annex, 35
O
B
Oil change, 18
B-Timer, 13 Oil level check, 17
Oil type, 17
C Operation, 9
Change-over device, 12
Cooling system, 28 P
Preservation, 31
D Pressure gauge, 24
Design, 1 Pressure-maintaining valve, 23
Drive system, 27
R
E Repair instructions, 32
V-belt, tension meter, 27
Electrical system, 28 S
Safety valves, 24
F Sealant chart, 34
Filling procedure, 10 Shut-down, 12
Filter system, 19 Storage, 31

I T
Intake filter, 18 Tables, 33
Intermediate separator, 19 Technical data, 4
Intake air quality, 10 Telescopic intake tube, 18
Testing agents, 34
L Tightening torque values, 33
Location, 9 Torque sequence, 33
Lubrication, 17 Trouble-shooting, 29
Lubrication chart, 34 V
M Valves, 25
Maintenance, 17

ANNEX

Schematic diagram motor protection switch, three phase current 76942-S1

Lubricating oil list 70851
Applicable parts list TJ-4/9

iii
 Instruction Manual  Junior II
NOTES

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

iv
Instruction Manual  Junior II
1. GENERAL AIR FLOW DIAGRAM

PURPOSE See Abb. 5 . The air is drawn in through telescopic tube

(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; recooled
press air for breathing as required in diving applications. The
by intercoolers -6, -7, and aftercooler -9. The pressures of the
max. allowable operating pressure (adjusted pressure on
single stages are protected by safety valves -10, -11, -12. The
final pressure safety valve) is 225 bar or 330 bar.
compressed air is pre-cleaned in intermediate separator -8
DESIGN and purified in filter system P21 -13. Intermediate separator
The compressor unit comprises the following major assem­ and filter system P21 are drained by means of condensate
blies: drain valves -15. Pressure maintaining valve -16 provides a
- compressor block constant pressure within the filter assembly. The com­
- drive motor pressed, purified air is passed through filling hose -17 and fill­
- filter system P21 ing valve -18 to the bottles to be filled. Filling pressure is indi­
cated at pressure gauge -19. With the change over device
- filling assembly
model it is possible to fill bottles with 200 bar nominal pres­
- base plate and frame sure, just by opening valve -21 at filling valve -18. Safety valve
The design of the compressor system is shown in Abb. 1 to -20 is adjusted to a blow off pressure of 225 bar.
Abb. 4.

10

3 11

4
5
6 12
7
8
13
9

14

Abb. 1 Compressor unit with petrol engine

1 Filling hose 8 Starter rope
2 Exhaust 9 Engine stop switch (ignition)
3 Air filter 10 Filling valve with final pressure gauge
4 Tank 11 Safety valve, final pressure
5 Throttle lever 12 Filter system P21
6 Choke lever 13 B-Timer
7 Fuel cock 14 Condensate drain taps

1
 Instruction Manual  Junior II

1 Filling hose
2 Filling valve with pressure gauge
3 Motor terminal box
4 Three-phase motor
5 Final pressure safety valve 1
6 Handle
7 Fanwheel cover
2
8 B-Timer
9 Condensate drain valves
10 Mains plug with ON-OFF switch and motor
protection circuit breaker (dep. on country)
5
10
6
3

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

1 Filling hose
2 Filling valve with pressure gauge
3 Motor terminal box with ON-OFF switch
4 Single-phase motor 1
5 Final pressure safety valve
6 Handle
7 Fanwheel cover 2
8 Pressure maintaining valve
9 Condensate drain valves
5

7
4

8
9

Abb. 3 Compressor unit with electric motor (alternating current)

2
Instruction Manual  Junior II

1 Filling hose
2 Filling valve with pressure gauge
3 Final pressure safety valve
4 Filter system P21
1 5 B-Timer (optional)
6 Pressure maintaining valve
7 Filling connector
8 Intake filter
2
9 V-belt cover
7

4
9

Abb. 4 Compressor unit with electric motor, v-belt cover side

11

15

1 Telescopic air intake 8 Intermed. separator 2nd/3rd stage 15 Condensate drain valve
2 Intake filter 9 After-cooler 16 Pressure maintaining valve
3 Cylinder 1st stage 10 Safety valve 1st stage 17 Filling hose
4 Cylinder 2nd stage 11 Safety valve 2nd stage 18 Filling valve
5 Cylinder 3rd stage 12 Final pressure safety valve 19 Final pressure gauge
6 Inter-cooler 1st/2nd stage 13 Filter system P21 20 Safety valve, final pressure PN 200
7 Inter-cooler 2nd/3rd stage 14 TRIPLEX longlife cartridge 21 Change over device (optional extra)
Abb. 5 Air flow diagram

3
 Instruction Manual  Junior II
TECHNICAL DATA
Compressor unit JuniorII-B-F01 JuniorII-E JuniorII-W
Medium air
Delivery a) 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 44 kg 47 kg
Compressor block Junior, mod. 3
Number of stages 3
Number of cylinders 3
Cylinder bore 1st stage 60 mm
Cylinder bore 2nd stage 28 mm
Cylinder bore 3rd stage 12 mm
Piston stroke 24 mm
Speed 2,300 min-1
Intermediate pressure 1st stage 6-7 bar
Intermediate pressure 2nd stage 40-60 bar
Compressor block oil capacity 360 ml
Oil volume between min. and max. marks 50 ml
Oil type see chapter 4.4.1. lubrication
Max. ambient temperature +5 ... +45 °C
Max. inclination of compressorb) 5°
Max. operating height 0 ... 2000 m above sea level
Compressor drive JuniorII-B
Drive motor Robin/Subaru petrol engine
Manual start model (B) EX17
Power 4.2 kW (5.7 PS)
at nominal speed 3,600 min-1
Compressor drive JuniorII-E
Drive motor Three phase current
Operating voltage 400 V, 50 Hz
Power 2.2 kW (3 PS)
Speed 2,850 min-1
Size 90 L
Type of construction B3
Type of enclosure IP54
Compressor drive JuniorII-W
Drive motor Alternating current
Operating voltage 230 V, 50 Hz
Power 2.2 kW (3 PS)
Speed 3,000 min-1
Size LS 90 PC
Type of construction B3
Type of enclosure IP44

a) free air delivered at bottle filling from 0 to 200 bar "5%

b) these values are valid only if the oil of the compressor in normal position corresponds with the upper mark of the oil dipstick and may
not be exceeded.

4
 Instruction Manual  Junior II
2. SAFETY MEASURES
2.1. NOTES AND WARNING SIGNS 2.2. IDENTIFYING THE SAFETY NOTICES

Notes and warning signs displayed on compressors accord­ Important instructions concerning the endangerment of per­
ing to model, application or equipment. sonnel, technical safety and operating safety will be specially
emphasized by placing the following signs before the in­
WARNING structions.
This notice is used with maintenance
Hot surfaces, do not touch! WARNING
work and operating procedures and
must be adhered to exactly in order to
Danger of burning by touching cylinders,
avoid endangering personnel.
cylinder heads and pressure lines of individ­
ual compressor stages.
This notice must be complied with in order to
WARNING avoid damage to or destruction of the machine
or its equipment.
High voltage!

Life threatening danger of electric shock.

Maintenance work on electric units or op­ This notice advises of technical requirements
erating equipment may only be carried out which the operator must take particular note
by a qualified electrician or by a person of.
instructed and supervised by a qualified
electrician according to electrical regula­
tions. 2.3. FUNDAMENTAL SAFETY NOTICES

WARNING 2.3.1. Authorized use

• The machine / unit is built according to state of the art
Automatic compressor control, unit may technology and established safety technical regulations.
start-up without warning! Nevertheless, its use can cause danger to life and limb of
the operator or third parties or damage to the machine
Before carrying out maintenance and re­
and other equipment.
pair work, switch off at the main switch or
disconnect from the mains and ensure unit • Operate the machine / unit only in technically perfect
will not restart. condition in accordance with regulations and safety and
danger notices detailed in the instruction manual! In par­
ticular, immediately correct faults (or have them cor­
MANDATORY
rected) which can impair safety!
Instructions must be read by persons oper­ • The machine / unit is exclusively for the compression of
ating the machinery! mediums (air/gas) specified in section A, chapter 1.3.
“Technical data”. Any other medium or use outside that
The instruction manual supplied and all specified is not authorized. The manufacturer / supplier is
other applicable instructions, regulations not liable for damage resulting from this. The user alone
etc. must be read and understood by oper­ is responsible for this risk. Authorization for use is also
ating personnel before using the machine. under the condition that the instruction manual is com­
plied with and inspection and maintenance requirements
MANDATORY are enforced.

Hearing protectors must be worn! 2.3.2. Organizational measures

• Keep the instruction manual to hand near the machine /
Hearing protectors must be worn when
working on a machine which is running. unit at all times in the relevant holder.
• In addition to the instruction manual, observe and com­
ply with universally valid legal and other obligatory re­
NOTE
gulations regarding accident prevention and environ­
Ensure correct direction of rotation! ment protection. See chapter 2.4. This can involve, for
MV3−A/10/06

example, contact with hazardous substances or the

When switching on the machine, check the provision / wearing of personal protective equipment.
arrow to ensure correct direction of rota­ • Personnel engaged to operate the machine must have
tion of the drive motor. read the instruction manual before beginning work, es­

5
 Instruction Manual  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
• Personnel may not wear long hair loose, loose clothing or age and faults. Inform the person responsible immedi­
jewellery, including rings. There is a danger of injury ately if anything is not as is should be (including oper­
through, for example, these getting caught or being ation). If necessary, shut the machine down immediately
pulled into the equipment. and make it safe.
• As far as necessary or according to regulations, use per­ • Observe switching on and off processes and monitoring
sonal protective equipment. indications according to the instruction manual.
• Observe all safety and danger notices on the unit. • Before switching on / starting up the unit, ensure that no
one can be put at risk through running the unit.
• Keep all safety and danger notices on the machine / unit
complete and in readable condition. • Carry out the setting, maintenance and inspection pro­
cesses at the intervals specified in the instruction manual,
• If there are any modifications to the unit or operating
including replacement of parts / equipment. This work
conditions which may affect safety, stop the unit immedi­
may only be carried out by qualified personnel.
ately and inform the person responsible of the fault.
• Clear and make the maintenance area safe as far as
• No modifications may be made to the unit which could necessary.
impair safety without first obtaining permission from the
suppliers. This is also the case with regard to installation • If the unit is completely switched off for maintenance and
and adjustment of safety devices and valves as well as repairwork, ensure that it is protected from unexpected
welding of piping and reservoirs. start-up. Turn off main control device and remove the key
and / or display a warning sign on the main switch.
• Spare parts must always comply with the technical re­
quirements specified by the manufacturer. This is always • When replacing individual parts and larger assembly
guaranteed with original spare parts. groups, they must be carefully fastened to the lifting de­
vice so that there is no risk of danger. Use only suitable
• Piping must be thoroughly checked (pressure and visual and technically perfect lifting devices and equipment
inspection) by the operator at appropriate time intervals, with sufficient lifting power and strength. Do not linger
even if no safety related faults have been noticed. or work under suspended loads.
• Intervals stipulated or given in the instruction manual for • Only entrust an experienced person with the fixing of
recurring checks / inspections must be adhered to. loads and guiding of crane drivers. The person guiding
• Make sure location and operation of fire extinguishers is must remain within sight or in contact with the operator.
known. • For assembly work above body height, use appropriate
• Pay attention to fire warning and fire fighting procedures. safety approved equipment, e.g. ladders and platforms.
Do not climb on machine parts. For maintenance work at
high levels, wear a safety harness.
2.3.3. Qualifications, fundamental duties
• Clean oil, fuel or care products from the machine, in par­
• Work on / with the unit may only be carried out by reliable ticular the connections and screw joints, before carrying
personnel. Observe the legal minimum age permissible. out maintenance / repairwork. Do not use aggressive
• Ensure that only trained personnel work with the ma­ cleaning fluid. Use a fibre-free cleaning cloth.
chine. • Before cleaning the machine with water or jet of steam
• Establish the responsibilities of the machine operator and (high pressure cleaner) or detergent, cover / seal all open­
establish a procedure for him to inform a third person of ings which for safety and/or operating reasons no water
unfavourable safety conditions. / steam / detergent may penetrate. Electric motor and
switch cabinets are particularly at risk.
• People who are being trained or introduced to the job
should only be allowed to work with the unit under con­ • When cleaning the operating room, ensure that the tem­
stant supervision of an experienced person. perature sensors of the fire alarm and sprinkler system do
not come into contact with hot cleaning fluid, in order to
• Work on the electrical equipment of the unit may only be avoid triggering the sprinkler system.
carried out by a qualified electrician or by an instructed
person under the direction and supervision of a qualified • Completely remove all covers / seals after cleaning.
electrician according to electrotechnical regulations. • After cleaning, check all pressure lines for leaks, loose
connections, wear and damage. Immediately eliminate
any faults.
2.3.4. Safety notices for operation
• Always retighten any screw connections loosened for
• Do not carry out any work if safety is questionable. maintenance or repairwork.
• Meet all requirements demanding that the unit is only op­ • If it is necessary to remove safety devices for maintenance
erated in safe and good working order. Only operate the and repairwork, these must be replaced and checked im­
machine if all protective and safety equipment, e.g. all de­ mediately after completion of the maintenance or repair­
tachable protective equipment, emergency shut-down work.

6
Instruction Manual  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.
2.3.5. Particular areas of danger
• When taking back into operation, proceed according to
• Use only original fuses with specified current rating. If the instruction manual.
there is a failure in the electric energy supply, shut the unit
down immediately. 2.3.6. Notices of danger regarding pressure vessels
• Work on electric units or operating equipment may only • Never open or loosen pressure vessel lids or pipe connec­
be carried out by a qualified electrician or by a person tion parts under pressure; always depressurise the vessel
under the instruction and supervision of a qualified elec­ or the unit.
trician according to electric technical regulations. • Never exceed the permissible operating pressure of the
• Machines and unit parts which must undergo inspection, vessels!
maintenance and repairwork, must be disconnected • Never heat the vessels or any of their parts above the
from the mains supply, if specified. Parts which have been stated, maximum operating pressure.
disconnected must first be checked for voltage, then • Always exchange damaged pressure vessels completely.
earthed and short-circuited and isolated from live neigh­ Individual parts that are subject to pressure loads cannot
bouring parts. be purchased as spare parts, since the vessels are tested
• The electrical equipment of a unit must be regularly as a complete part and the documentation considers
checked. Defects, such as loose screw connections or them as a whole (see pressure vessel documentation,
burnt wires, must be rectified immediately. serial-numbers!).
• If work is to be carried out on live parts, work with a sec­ • Always pay attention to the permissible operating mode
ond person who can operate the emergency off switch of the pressure vessels.
or the main switch in the case of an emergency. Close off We differentiate:
the work area with a red and white safety chain and a - vessels for static load
warning sign. Only use voltage isolated tools.
- vessels for dynamic load
• Only personnel with particular knowledge and experi­
Vessels for static load:
ence with pneumatics may carry out work on pneumatic
equipment. These pressure vessels are permanently under virtually
constant operating pressure; the fluctuations of pressure
• Check all pressure lines, hoses and screw connections are very small.
regularly for leaks and visible damage. Immediately repair
Vessels for this type of load are not marked in a particular
any damage. Escaping air under pressure can cause injury
way and may be used as long as the vessel inspections,
and fire.
carried out regularly, do not uncover any safety-relevant
• Depressurize system and pressure lines before commenc­ deficiencies.
ing repairwork.
We recommend that aluminium vessels should be
• Pressurized air lines must be laid and mounted by quali­ exchanged after 15 years at the latest.
fied personnel. Connections must not be mixed up. Fit­ Vessels for dynamic load:
tings, length and quality of the piping must correspond
These pressure vessels may also be used under conditions
to requirements.
of changing operating pressure. The pressure may vary
• Soundproofing equipment on the unit must be in place between the atmospheric and the maximum admissible
and functional during operation. operating pressure.
• The stipulated hearing protectors must be worn. The pressure vessel documentation and the appropriate
• With regard to oil, grease and other chemical substances, notes in the operating manual particularly characterise
observe the relevant safety regulations for the product. vessels of this type as being adequate for dynamic loads.
In the technical information for these vessels you will find
• For loading, only use lifting device and equipment with
specifications concerning their permissible operating
sufficient lifting power and strength.
period.
• Use only suitable transporters with sufficient carrying Due to the variation of the operating pressure, these
power. Secure the load properly. Use suitable fixing vessels are subject to a so-called dynamic load, which
points. puts the vessels under great stress. The change between
• If necessary, provide unit with transportation brackets. two different pressures is called a load change or cycle.
Display the appropriate notice. Remove transportation In the technical information for these vessels you will find
brackets in the correct manner before taking into oper­ specifications concerning the permissible number of
ation. cycles depending on the fluctuation of the operating
• Parts which need to be dismantled for transport purposes pressure.
must be carefully replaced and secured before taking into Having reached half the permissible number of cycles, the
operation. vessel has to be submitted to an internal check, in which

7
 Instruction Manual  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. at our Munich site a partial acceptance test according to §
After having reached the total permissible number of 14 BetrSichV. Please contact our Technical Service Depart­
load cycles, the vessel must be exchanged and scrapped. ment with regard to this. They can also supply our leaflet
Record the number of load cycles in writing if you do not “IMPORTANT NOTES FOR CERTIFICATION”.
have an automatic cycle-counter. According to the operation safety regulations (BetrSichV), all
We recommend that aluminium vessels should be compressor units which will be used as filling stations must
exchanged after 15 years at the latest. undergo an acceptance test by a professional at their loca­
Please pay attention to and follow these measures, for tion before bringing them into service. If pressure vessels
your own safety and that of you employees and cus­ (bottles) are to be filled by the compressor for a third party
tomers! then the appropriate permission must be obtained from the
In order not to unnecessarily load the pressure vessels responsible authority before the acceptance test. As a rule,
additionally, the non-return valves, that are meant to this is the factory inspectorate. The procedure for obtaining
avoid a drop in pressure, and also the pressure maintain­ permission is according to TRG 730, guidelines for per­
ing valves, which should reduce big pressure fluctuations mission to set up and operate filling stations. The test certifi­
as well, should be checked regularly for internal and ex­ cates and documents delivered with the compressor are im­
ternal tightness and functionality. portant and may be requested during the procedure for ob­
taining permission. In addition, the documents belonging to
• Check the pressure vessels regularly on the inside and
the unit are important for recurrent inspections and should
outside for damage from corrosion.
therefore be carefully kept.
• Be particularly careful with second-hand pressure vessels,
when their previous operating mode is not specifically Inspections in accordance with the regulations for preven­
clarified. tion of accidents will be carried out by the manufacturer or
by a specialist.
2.4. SAFETY REGULATIONS (EC; partly Germany, No guarantees whatsoever are valid for damage caused or
only) favoured by the non-consideration of these directions for
A compressor is identified by German law as being a filling use.
system if pressure cylinders are filled by the system, especially We strongly emphasize these regulations.
when these cylinders are made available for third parties. The
start-up and operation of compressor systems for use as fill­
ing stations is governed by the following regulations:
Pressure vessel directive (Directive 97/23/EC) of
29.05.1997
Operating safety regulations (BetrSichV) of 27.09.2002
Machine safety law (GSG) of 11.05.2001
14th regulation to machine safety law (14. GSGV - pres­
sure vessel regulation) of 03.10.2002
Technical regulations for pressure gases (TRG 400, 401,
402, 730).
If a high pressure compressor is used for filling pressure
vessels or for the supply of pneumatic systems, the following
regulations apply:
Accident Prevention Regulations (UVV):
BGV A1 of 01. January 2004
Copies of the above regulations are available through the
usual outlets, e.g. in Germany from:
Carl Heymanns Verlag
Luxemburger Str. 449
50939 Köln

Beuth-Vertrieb GmbH
Burggrafenstr. 4 - 7
10787 Berlin

8
Instruction Manual  Junior II
3. 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
The compressor unit is not seawater resis­ with fault current circuit breaker according to DIN VDE
tant. At operation in salty air spray com­ 0664 with a nominal differential current of less than 30
pressor with anticorrosive protection (e. g. mA (up to 16 A in single-phase AC circuits).
Quicksilver Corrosion Guard). Electric - For units not connected through a plug, but permanently
driven units should be operated and stored below deck. installed, a main switch must be provided which has a
Units with petrol engine should also be stored below contact gap of minimum 3 mm on each pole.
deck after the filling process. - Fuse motor correctly; use slow-blow fuses, only.
- Immediately after start-up check direction of rotation for
agreement with arrow on unit.
Keep unit away from inflammable items.
Do not smoke while petrol tank is open If power supply cable is to be replaced, use
and while unit is in operation. cable of same type, only!

- Locate the unit level.

- When using extension leads or cable drums, operate unit
- On units with petrol engine it is most important that only with unwound cable, only to avoid overheating and risk
clean air be used, position compressor in direction of of fire. The maximum length for extension cables at nor­
wind so that exhaust fumes are blown away from the mal ambient temperatures (approx. 20 °C) is 25 metres.
unit.
OPERATION
- Turn unit as soon as wind direction changes.
- Take care that no vehicles are in direct vicinity with en­ Preparation for operation
gines running.
All compressor units are tested prior to de­
- Do not operate unit in the vicinity of open fire (flue gas!). livery to the customer, so after correct in­
Indoor location stallation of the unit there should be no
problem putting it into operation, observing the fol­
Petrol driven units must not be operated lowing points:
indoors.
The compressors described in this
CAUTION manual are not suitable for com­
pression of oxygen. EXPLOSION oc­
curs if an oil lubricated compressor is operated with
- Ensure adequate ventilation. pure oxygen or gases with an oxygen content of more
than 21%!
- Here too, air must be free from exhaust fumes and haz­
ardous vapours (e.g. smoke, solvent vapours, etc.).
- Prior to first operation read Instruction Manual carefully.
- If possible install unit in such a manner that the com­
Make sure that all persons handling the compressor and
pressor fan can get fresh air from outside, for instance
the filling station are familiar with the function of all con­
through an opening in the wall.
trols and monitors. Particularly observe chapter 2
- Ensure that an adequate exhaust air opening is provided. SAFETY REGULATIONS.
- When locating the compressor in small rooms where - After taking unit into operation after a standstill period of
natural ventilation is not ensured, measures must be 2 years or more change compressor oil. When using a
taken to provide artificial ventilation (this also applies mineral oil change oil after one year.
when other systems having high radiation are operating - Prior to first operation or operation subsequent to repair
in the same room). work operate unit for at least 5 minutes with open con­
Electrical installation densate valves (pressureless) to ensure proper lubrication
of all parts before pressure is built up.
For installation of electrical equipment observe the follow­
- Prior to each operation check the oil level according to
ing:
chapter 4.4.1. and determine whether maintenance is
- Comply with regulations of local electricity supply com­ necessary in accordance with chapter 4.3.
pany.
- Every time the unit is started up check all systems for
- Arrange for the electrics to be connected by an electri­ proper operation. If any malfunction is observed stop unit
cian only. immediately and find the cause of the fault or call the ser­
- Ensure correct installation of protective conductor. vice department.

9
 Instruction Manual  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. If motor turns in the CAUTION noxious gas (CO), exhaust fumes and
wrong direction, the phases are not connected properly.
solvent vapour. On units employing
Shut down unit immediately and interchange two of the
petrol or diesel engine it is most important to use an
three phase leads in the switch box. Never change leads
intake hose and observe that only clean air is drawn in.
at the motor terminal board.
The intake hose is also recommended for units with
Units with petrol engine, additionally: electric engine. When operating the unit in areas with
possibly high CO contents, the CO removal filter car­
- Check engine oil level according to manufacturer's in­
tridge is recommended for electric driven units, also.
struction manual.
Note that for CO contents of more than 25 ppmV in the
- Check fuel tank. Top up if necessary. intake air the allowed limits cannot be guaranteed even
- Open fuel shut-off valve. with a CO removal filter cartridge, resulting in a life-
threatening CO concentration! Also, due to chemical re­
Starting the unit
action of CO with hopcalite, warming up of the car­
- Open condensate drain valves on the filters to release tridge and danger of fire may result.
pressure so that motor starts without load.
Filling hoses must be in satisfactory
Units with electric drive motor: CAUTION condition and threads undamaged.
- Three-phase current: the motor is switched on man­ Pay particular attention to damage
ually by turning the switch (1, Abb. 6) to 1. on the interface from hose fitting to hose. If the casing
is scored, hose must be discarded.
The filling valve connection is of the manual type and permits
connection to air tanks without using tools. An O-ring is pro­
vided for self-sealing due to internal overpressure. Com­
pressed air tank filling valves for a pressure in excess of 200
bar are standardized (DIN 477, sheet 5) and connectors for
200 and 300 bar are different and cannot be mixed up. The
use of adapters is not allowed!
To ensure safe air tank removal after filling, the valve has an
integral venting bore. Therefore always close tank valve first
1 before closing filling valve. During filling procedure bottles
will warm up due to recompression. After removing, allow to
cool down, bottles may then be reconnected and topped up
to the respective maximum filling pressure.
To meet the CO2 maximum rating
CAUTION value in breathing air bottles, please
observe the two following chapters
”Intake air quality” and ”Scavenging the compressor
Abb. 6 Motor protection switches
(three-phase motor) unit”.
Intake air quality
- Alternating current: Set 0-I switch to I.
At routine tests, CO2 values beyond the permissible values
Units with petrol engine: are noted from time to time. Closer investigations often
show that the compressed air is taken from rooms in which
- Set choke to position START. Start engine with recoil one or more persons are working. At insufficient ventilation,
starter or crank handle. As soon as motor runs smoothly the CO2 value in the surrounding air can increase quite fast
return choke to normal operating position. because of the exhaling of CO2. CO2 values from 1,000 to
All units: 5,000 ppmv in workrooms are not unusual (MAK-value (max.
workroom concentration) is 5,000 ppmv). Another addi­
- Close condensate drain valves and run unit to final pres­ tional increase is caused by cigarette smoking, producing ap­
sure. Check final pressure safety valve and pressure prox. 2g CO2 ( 2,000 ppmv) per cigarette. These pollutions
gauge. add up to the basic pollution of approx. 400 ppmv. The
- As soon as final pressure is reached and final pressure technically caused excessive increase of CO2 during the filling
safety valve blows off, open condensate drain valves and process and the CO2 peak at taking the unit into operation.
drain condensate - unit is ready for filling operation. Ob­ Because of the reasons stated above and for your own
serve regular condensate drain acc. to chapter “Mainten­ security, the filling of breathing air bottles is not al­
ance”. lowed in rooms used as workrooms.

10
Instruction Manual  Junior II
Scavenging the compressor unit

CO2 is present in the atmosphere with a natural amount of

350 to 400 ppmV. The molecular sieve used in the purifier for
drying the breathing air is, as well as other capabilities, able
to adsorb CO2 which is accumulated in the cartridge. After
shut-down of the compressor, adsorbed CO2 may be de­
sorbed again due to the partial pressure decrease. The now
free CO2 then gets washed out of the cartridge when the
compressor is started again. To avoid increased CO2 con­ Abb. 8 International filling connector
tents in the compressed breathing air, we recommend to
flush the compressor unit 1 to 2 minutes prior to connecting
the bottles, i.e. to let the air escape into the surroundings.
2.
Connecting the bottles

On models of 300 bar rated filling pressure

do not attach bottles unless rated for this
pressure (note pressure stamped on tank
neck).
1.

- Connect air bottle to filling valve (see Abb. 7).

- Air bottles with international filling connector can be
connected with filling adaptor (part no. 79375) to the
Abb. 9 Filling air bottle
German filling connector (see Abb. 8).

The international connector is not per­

mitted in the Federal Republic of Germany. 1.
In other countries it is allowed only for
pressures up to 200 bar (2,850 psi).

Filling the bottles

- Open filling valve (1, Abb. 9).

2.
- Open bottle valve (2) - bottle will be filled. Drain conden­
sate regularly during filling. On units with automatic con­
densate drain check that condensate is drained regularly.

The filling procedure should not be inter­

rupted for more than 10 minutes to avoid Abb. 10 Removing air bottle
increased CO2-values in the air filled into
the bottles. Removing the bottles
- Upon reaching final bottle pressure close bottle valve
first (1, Abb. 10), then filling valve by returning handle
to closed position (2).
- Remove compressed air bottle.

CHANGE-OVER DEVICE PN 300/PN 200

(Abb. 11) This device allows bottle filling to 200 bar
(3,200 psig) with a 300 bar (4,700 psig) rated unit. Safety
valve -B and filling device PN 200 bar are connected by open­
ing change-over valve -A and the connected bottles can be
filled with a 200 bar pressure, as described in ”Filling the
bottles”.
Depressurize unit before opening valve -A
to avoid damage to the change-over de­
Abb. 7 Connecting air bottle vice

11
 Instruction Manual  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, Abb. 12) to 0.
- Alternating current: set 0 - I switch to 0. B
Units with petrol engine:
- Shut down petrol engine with stop button or stop lever.
All units:
A
- Drain condensate from intermediate separator and
Triplex filter by means of the drain taps. Vent unit by
means of filling valve to approx. 80 bar (1,150 psi). Close Abb. 11 Change-over device
all valves again to prevent moisture entering the filter and
resulting saturation of the cartridge.
- Check the oil level in the compressor and top up, if
necessary. Also check whether the compressor needs
servicing in accordance with maintenance schedule - see
chapter 4.3.

Abb. 12 Motor protection switches

(three-phase motor)

12
Instruction Manual  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
is working properly to ensure correct indication of the
filter capacity and compressor operation recognition.
Description
The B-Timer (Abb. 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, temperature,
cartridge type, and delivery rate of the compressor. It displays
operating hours, cartridge lifetime, and all maintenance due
for the compressor. The B-Timer does neither need external
power nor any other connection to the pressure system. It is
simply fastened to the filter housing which has to be moni­ 1 2
tored, by means of a clamp, and is therefore the ideal filter
control device for all mobile compressor units, especially for 3 4
portable petrol or diesel driven scuba diving models. In addi­
tion, the B-Timer can be mounted easily to any unit as an up­ 5
grade device.
Authorized use
This unit is to be used exclusively as operating status monito­ 6 7
ring device and does not release the user from additional sur­
veillance and testing of the breathing air quality of the filter
system according to national standards (e.g. EN 12021). With
the B-Timer, this is not possible! Abb. 13 B-Timer
The B-Timer may only be used with the filter systems P21, P31
and P41. The respective filter cartridge numbers are stored in 1 Key symbol (maintenance due)
the software. Other use is strictly prohibited. The manufac­ 2 Letter symbol (maintenance type)
turer and the supplier void all responsibility for risk, damage or 3 Low battery symbol
4 Cartridge saturation indicator
injury resulting from failure to follow these instructions.
5 Operating hours or cartridge number
Please observe the operating limits of the unit: 6 Mode select key
Operating temperature range 0° C to +50 °C, 7 Enter key
Storage temperature -20° C bis +70 °C
Protection class IP65 (Protection against contact with wire,
dust, and jet of water
Vibration $3g in operation
max. 95% humidity, not condensating
Function
The B-Timer display shows the following functions:
• Operating hours of the compressor unit
• Cartridge lifetime in % by means of four segments in the
cartridge symbol.
• Flashing last segment and change from operating hours in­
dication to cartridge part no. if capacity is equal or less than
20% of the original lifetime.
• Indication of compressor maintenance due by means of
letter symbols and operating hours.

13
 Instruction Manual  Junior II
A = 500 hours or 1 year
B = 1000 hours or 1 year
C = 2000 hours or 2 years
• Battery symbol indicating that the lithium battery is low
and has to be changed. All data are stored and will not
be lost when changing battery.
The B-Timer is operated using the mode select and the enter
keys.

Error indication Abb. 14

If the temperature sensor in the unit should be defective, an
error message “Error 1” or “Error 2” is shown at the display
(Abb. 14). In this case the unit should not be used but sent to
the factory or the nearest BAUER representative for repair.

Battery change
The battery (1, Abb. 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. 2

Make sure to use the same type battery (BAUER part no.
82743).
1

Abb. 15 Battery

Abb. 16

Abb. 17

14
Instruction Manual  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 (Abb. 16).

If no key is pressed within 1 minute, the in­

dication will return to the main menue.
After 2 minutes the B-Timer is switched off, Abb. 18
if no compressor operation is detected.

Function Display
To display the desired function, press the
select key ().

Press  key. Remaining filter capacity is shown, Abb. 17)

Abb. 19

Press  key again. Remaining operating hours to service inter­

val A (500 hours or annually) are shown (Abb. 18).

Press  key again. Remaining operating hours to service inter­

val B (1000 hours or annually) are shown (Abb. 19).

Abb. 20

Press  key again. Remaining operating hours to service inter­

val C (2000 hours or biennially) are shown (Abb. 20).

Press  key. Filter cartrige number is shown (Filter symbol

flashing, Abb. 21).
Press  key again. Display returns to the main menue.
Abb. 21

Reset
The filter capacity must not be reset unless
a new filter cartridge has been fitted!

To reset the filter capacity or the A, B, and C maintenance in­

tervals, press  key for more than 5 seconds from the respect­
ive maintenance interval display (Abb. 22). Abb. 22

15
 Instruction Manual  Junior II
Setup
To enter the setup for the different functions of the B-Timer
press the  and  keys on the display simultaneously for more
than 5 seconds from the cartridge number display (Abb. 21).
Filter symbol starts flashing (Abb. 23) indicating the setup
mode.
Under setup A the filter cartridge number is set. To change
cartridge type, press  key for 3 seconds, the number starts
flashing. Press the  key to select the correct number, press 
key to accept the new setting.
Abb. 23
Numbers beginning with 999 require a
special adjustment:

Press  key for 3 seconds. Press the  key to select 999000, the
last 0 starts flashing. Press the  key to select the correct
number, then press  key: the second 0 will start flashing, pro­
ceed as above and finally adjust the 3rd 0 accordingly.
Pressing the  key, display changes to setup B for the delivery
setting. Filter symbol starts flashing (Abb. 24). To change de­
livery (in ltrs./min), press  key for 3 seconds, the 1st digit starts
flashing. Press the  key to select the correct number, press  Abb. 24
key to accept the new setting. Repeat procedure for the other
two digits

Pressing the  key again, display changes to setup C for the

pressure range setting. Filter symbol starts flashing (Abb. 25).
To change pressure, press  key for 3 seconds. Press the  key
to select the correct pressure (200, 300 or 200/300), press 
key to accept the new setting.

After finishing setup and fitting a new car­ Abb. 25

tridge, the filter capacity has absolutely to
be reset, see “Reset” above.

Pressing the  key again, display changes to the menue for

adjusting the operating hours. Press  key for 2 seconds,
the last digit will start flashing. Press the  key to select the
correct number, then press  key etc., until all digits are set.
Then pressing the  key twice will lead back to the main
menue, Pressing the the  key and the  key gives the possi­
bility to readjust the hours again, if required.

16
Instruction Manual  Junior II
4. MAINTENANCE 4.4. MAINTENANCE WORK
This chapter contains the maintenance work as well as a
short functional description for each component.
4.1. MAINTENANCE RECORD
We recommend that all maintenance work is recorded in the 4.4.1. LUBRICATION
service book, showing the date and details of the work car­
ried out. This will help to avoid expensive repairwork caused TYPE OF OIL
by missed maintenance work. If it is necessary to claim For proper care and maintenance of the compressor, using
against the warranty, it will help to have proof that regular the correct oil is of vital importance. Depending on the ap­
maintenance work has been carried out and that the dam­ plication of the compressor the requirements placed on the
age has not been caused by insufficient maintenance. Please oil are:
refer to section 23 of our general terms and conditions.
- low deposits
4.2. MAINTENANCE INSTRUCTIONS - no carbonizing effect, especially in the valves
- good anti-corrosive properties
Always shut down and decompress - emulsification of the condensate in the crankcase
CAUTION the complete system prior to carry­ - physiological and toxicological suitability.
ing out any work on the compres­
Due to the thermal load on the compressor only high quality
sor.
oil should be used. You are recommended to restrict oils to
those which have been approved by us and are listed in our
lubricating oil list.
Never repair pressure lines by sol­
CAUTION dering or welding. The current oil list is provided in the annex,
chapter 8. Order this list regularly through
the BAUER Technical Service Department.

Check the complete system for leakage For operation under difficult conditions such as continuous
from time to time by brushing all fittings running and/or high ambient temperatures we recommend
and couplings with soapy water or spray­ the use of 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
age. pressors and have proved excellent quality under ambient
temperatures between +5 °C (41°F) and +45 °C (113 °F). For
lower temperatures, a heating device is required which is ca­
pable of pre-heating the crankcase up to +5 °C (41 °F).
Only use original spare parts for mainten­
ance or repair work. For operation under less severe conditions, for intermittent
operation, or operation with long idle periods we can also
recommend mineral compressor oils which are suitable for
operation under ambient temperatures between +5 °C (41
°F) and +35 °C (95 °F). Here also, pre-heating is required for
Change TRIPLEX longlife cartridge accord­ lower temperatures.
ing to chapter 4.4.4.!
OIL LEVEL CHECK
Check oil level daily prior to putting compressor into oper­
ation. Check using oil dipstick.
The used cartridge must be disposed of ac­ Take care that dip stick is inserted completely. Note that the
cording to local regulations. oil level must be between minimum and maximum dipstick
markings (see Abb. 26).
Oil level must not decrease below min.
mark but also not exceed max. mark as this
Maintenance of drive motor/engine ac­
will cause excessive lubrication of com­
cording to manufacturer's operating in­
pressor and result in valves sooting up.
structions.
OIL CHANGE INTERVALS
Mineral oils every 1,000 operating hours,
4.3. MAINTENANCE SCHEDULE at least annually
The maintenance schedule is contained in the service manual Synthetic oils every 2,000 operating hours,
delivered with every compressor unit. at least biennially

17
 Instruction Manual  Junior II
OIL CAPACITY 4.4.2. INTAKE FILTER
Junior II approx. 360 ml DESCRIPTION
A dry micronic filter is used to filter intake air (Abb. 27).
OIL PACKAGES
BAUER compressor oil is available in various quantities, refer
to oil list in chapter 8.

OIL CHANGE 5

- Run compressor warm. 4

- Remove oil dipstick. 3
- Drain oil while still warm by means of oil drain plug. Re­
place the sealing, reinstall drain plug and tighten well. 2

- Refill with oil through the oil filler neck.

1
- Oil level is checked with oil dipstick, oil level is correct if
at upper mark.

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

Abb. 27 Intake filter

max.
INTAKE FILTER MAINTENANCE
min.
Filter cartridge must be changed at regular intervals accord­
ing to schedule in the service booklet.
- Remove knurled nut (1) and take off plastic cap (2). Re­
move filter cartridge (3).
- Clean filter housing inside with a damp cloth. Take care
to prevent dust from entering intake pipe.
- Replace O-ring (4) if damaged.
Abb. 26 Oil dipstick markings - Insert a new filter element and fasten with cap and nut.

TELESCOPIC INTAKE TUBE

CHANGING THE OIL TYPE
The telescopic intake tube has to be inserted in opening 5,
To avoid severe damage to the compressor Abb. 27. It is necessary to ensure clean air. Petrol driven
unit when changing the oil type, the fol­ breathing air compressor units are fitted with a telescopic in­
lowing measures should be strictly ad­ take tube supplied with the unit. The use of it is also recom­
hered to: mended for electric power driven units.

4.4.3. INTERMEDIATE SEPARATOR

− Drain oil completely while still warm.
DESCRIPTION
− Check valves, coolers, separators, purifiers, and all
pneumatic tubes and hoses for deposits. An intermediate separator is mounted on the compressor
between 2nd and 3rd stage. It is designed to remove water
If deposits are detected, perform the following: and oil accumulating due to cooling the compressed medium
− Change or clean valves, coolers, separators, purifiers, down after the compression process.
and all pneumatic tubes and hoses from deposits. Separation is achieved by means of centrifugal action pro­
− Fill compressor with the new oil. vided by a vortex plate.

− After approx. 100 operating hours check lubricating oil INTERMEDIATE SEPARATOR MAINTENANCE
for degree of contamination, and change oil again if Proper operation will rely on the intermediate separator
necessary. being properly serviced.
− Top up compressor and perform subsequent oil Open drain tap (1, Abb. 28) and drain off condensate every
changes with same oil, only. 15 to 30 minutes during operation.

18
Instruction Manual  Junior II

3
5

8
1 2 3
9
Abb. 28 Condensate drain taps
1
10

11
4.4.4. FILTER SYSTEM P21

DESCRIPTION Abb. 29 Filter system P21

The air leaving the final stage is cooled in the after-cooler to 1 Filter inlet
approx. 10 - 15 °C (18 - 27 °F) above ambient temperature 2 Jet pipe
and then enters filter system P21 with TRIPLEX longlife car­ 3 Filter head
4 Final pressure safety valve
tridge (Abb. 29).
5 Housing
The filter assembly consists of separator and cartridge 6 Chamber separator
chamber. In the separator surrounding the cartridge 7 Cartridge
chamber liquid oil and water particles are reliably separated 8 Filter outlet
from the compressed medium by a pipe nozzle. 9 Pressure maintaining valve
10 Condensate drain tap
Residual oil and water vapors are then removed by the 11 Condensate outlet
TRIPLEX longlife cartridge. The quality of the breathing air
produced conforms to DIN EN 12021.
Without cartridge the venting bore is not sealed, the air es­
capes into the atmosphere, no pressure can be built up and
CARTRIDGE SAFETY BORE thus it is ensured, that unfiltered air is not supplied to the con­
suming device.
The filter system P21 is designed to prevent pressurizing in
The venting bore is also used to check the O-rings on the car­
the absence of the filter cartridge. A bore provided in the
tridge pin. If air is leaking out of the venting bore even
filter bottom is sealed air-tight only if the cartridge is in place
though a cartridge is installed, the O-rings are either broken
(Abb. 30).
or were damaged on installation.
No pressure build-up without cartridge! Remove and check cartridge. If necessary replace cartridge
or O-rings.

19
 Instruction Manual  Junior II
Venting bore - The nozzle type separator of the TRIPLEX filter system is
maintenance-free besides the regular condensate drain­
age.

CONDENSATE DRAINAGE
Drain condensate from separator and cartridge chamber
regularly by slowly opening drain taps (2 and 3, Abb. 28)
No cartridge Cartridge installed - before changing cartridge
- before each filling procedure
Abb. 30 Safety bore
- during filling procedure every 15 minutes.
LIFETIME Slowly open left tap first, then right tap approx. 1/3 turn to
the left, until condensate is completely drained. The taps
The filter system is subject to dy­ close by spring pressure, if necessary tighten by hand to
CAUTION namic load. It is designed for a cer­ make sure they are completely air-tight.
tain number of load cycles, which FILTER CARTRIDGES
originate from an abrupt pressure loss at condensate
drain (1 load cycle i.e. condensate drain = 1 depressu­ New filter cartridges are vacuum-packed and can be stored
rization, 1 pressurization). The filter housing has to be for two years (refer to date on the cartridge). A defective vac­
inspected internally by an expert after having reached uum package cannot protect the cartridge appropriately
1/4 of the determined number of load cycles. The in­ against environmental influences during storage. Should the
spections have to be arranged by the operator. After package be damaged, do not use the cartridge.
reaching the max. number of load cycles the filter as­ To avoid any danger to your health or damage to your unit,
sembly must be replaced, otherwise the housing may change used up cartridges in good time.
burst due to material fatigue. Never fill used up cartridges yourself! The filter material was
chosen specifically by BAUER-KOMPRESSOREN for each kind
The max. number of load cycles for the P21 Central Filter As­ of application.
sembly is 4,000 if operated at the max. allowable pressure Pay attention to cleanliness an hygiene when changing the
difference range of 330 bar (4,700 psi). For a pressure differ­ filter.
ence of 225 bar (3,200 psi) the max. no. of load cycles is
FILTER SERVICE LIFETIME
35,000.
To avoid exceeding the max. number of load cycles the oper­ The average weight (without package) of a new cartridge
ating hours should be recorded in the service manual. On and the increase in weight can be checked with appropriate
condition that a max. number of four cycles per hour is not weighing scales. Due to inevitable production tolerances,
exceeded (condensate is drained every 15 minutes) the max. there may be small differences compared to the given data.
number of operating hours is 1,000 for 330 bar units, and The number of operating hours or the amount of possible
8,750 for 225 bar units. bottle fillings per filter cartridge can be determined by the
tables on page 22 and 23 taking into consideration the ambi­
GENERAL INSTRUCTIONS FOR FILTER MAINTENANCE
ent temperature and the cartridge used.
- Depressurize system before starting any maintenance These tables contain calculated cartridge lifetime data, that
work. refer to defined and constant operating conditions. Toler­
- Dry inside of filter housing with a clean cloth before in­ ances at bottle fillings and different operating temperatures
stalling new cartridge and check for corrosion. Change if can lead to considerable divergences compared to data
necessary. given, which therefore can only serve as reference values for
- Lubricate threads and O-rings as well as threaded part the user.
of cartridge with white petrolatum DAB 9 order no. Cartridge 057679 is the normal TRIPLEX-cartridge for elec­
N19091 or WEICON WP 300 white order no. N19752. tric units.
- Record number of pressure bottles and/or operating Filling weight: 191 g; Saturation weight 205 g.
hours to ensure exact attention to maintenance intervals. Example: at an ambient temperature of 20°C, 36 to 45
- Change cartridge before reactivating a compressor unit 10-ltr-bottles can be filled with a TRIPLEX-cartridge, which is
after out-of-service periods of more than 3 months. equivalent to 12 to 15 compressor operating hours at a filling
pressure of 200 bar.
- Leave cartridge in the filter as long as unit is out of ser­
vice. On compressor units with petrol engines only use cartridge,
part no. 059183 to dry, de-oil and remove CO.
- Keep all condensate drain valves and taps closed. Keep
a minimum pressure of approx. 50 to 80 bar (700 to 1,100 Filling weight: 217 g; Saturation weight 229 g.
psi) within the system to prevent moisture entering the Example: at an ambient temperature of 20°C, 31 to 38
compressor piping and filter system. 10-ltr-bottles can be filled with this cartridge, which is equiv­

20
Instruction Manual  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.

CARTRIDGE CHANGE
For safety reasons only CO removal
CAUTION cartridges part no. 059183 should
be used on compressor units with
petrol engine. On units with electric engine either CO
removal cartridge part no. 059183 or TRIPLEX car­
tridge part no. 057679 can be used.

Units with petrol engine are delivered with

CO removal cartridge part no. 059183 as
standard, units with electric engine with
TRIPLEX cartridge part no. 057679. When changing
from electric engine to a petrol engine also replace car­
tridge part no. 057679 with cartridge part no. 059183.

Never remove replacement cartridge from

packaging prior to actual use otherwise
highly sensitive molecular sieve will ab­
sorb water vapour from surrounding air and cartridge
saturated and thus be ruined.

- Prior to changing the filter cartridge, drain condensate

and depressurize filter system completely by opening
condensate drain valves.
- Remove filter head (3, Abb. 29).
- Extract old cartridge and insert a new one.
- Screw in filter head to the stop without use of force.
The used cartridge must be disposed of ac­
cording to local regulations.

FILLING VALVE MAINTENANCE

To protect filling valve against contamination a sintered
metal filter is screwed in the filling valve body.
Remove filter insert and clean, if heavily soiled replace, as fol­
lows (refer to maintenance schedule, 4.3.):
- Unscrew pressure gauge from filling valve body.
- Screw off sintered metal filter with a suitable screw driver.
- To clean filter element, the best method is to use hot
soapy water and to blow dry with compressed air. Re­
place if heavily soiled.
- Screw in filter element,.
- Seal pressure gauge with PTFE tape or Loctite 243 and
screw in tight to desired position.

21
 Instruction Manual  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]
100
10 20 - 24 26 - 21
15 25 - 29 20 - 16
20 30 - 34 15 - 12
25 35 - 39 11 - 9
30 40 - 44 9-7
35 45 - 49 7-6
40 50 - 54 5-5
Filling pressure p = 300 bar Junior II
Ambient temperature Final separator temperature Delivery
tU [°C] tAb [°C] Q [l/min]
100
10 20 - 24 39 - 31
15 25 - 29 29 - 24
20 30 - 34 22 - 18
25 35 - 39 17 - 14
30 40 - 44 13 - 11
35 45 - 49 10 - 9
40 50 - 54 8-7

Filter cartridge 057679: bottle fillings [number] Molecular sieve mass mMS [g] = 68
Ambient Final separa­ Air humidity, Processable air volume Va Number of bottle fillings n
temperature tor tempera­ saturated [m3] acc. to bottle size
tU [°C] ture X [g/m3] at pressure p [bar]
tAb [°C]
200 300 7l 10 l 12 l
10 20 - 24 17,31 - 21,80 157 - 125 236 - 187 112 - 89 79 - 62 65 - 52
15 25 - 29 23,07 - 28,79 118 - 94 177 - 142 84 - 67 59 - 47 49 - 39
20 30 - 34 30,40 - 37,63 89 - 72 134 - 108 64 - 52 45 - 36 37 - 30
25 35 - 39 39,65 - 48,64 69 - 56 103 - 84 49 - 40 34 - 28 29 - 23
30 40 - 44 51,21 - 62,41 53 - 44 80 - 65 38 - 31 27 - 22 22 - 18
35 45 - 49 65,52 - 79,28 42 - 34 62 - 51 30 - 25 21 - 17 17 - 14
40 50 - 54 83,08 - 99,85 33 - 27 49 - 41 23 - 19 16 - 14 14 - 11

Bottle volume VF [m3] Number of bottle fillings n=

processable air volume / bottle volume = Va / VF
Bottle size at pressure p [bar]
Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3]
l [ltr.] 200 300
Processable air volume: Va [m3] = 0,2 x mMS [g] / (X [g/m3] /
7 1,4 2,1
p [bar]) = 0,2 x p [bar] x mMS [g] / X [g/m3]
10 2 3
Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60
12 2,4 3,6 [min/h])

22
Instruction Manual  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]
100
10 20 - 24 22 - 18
15 25 - 29 17 - 13
20 30 - 34 13 - 10
25 35 - 39 10 - 8
30 40 - 44 8-6
35 45 - 49 6-5
40 50 - 54 5-4
Filling pressure p = 300 bar Junior II
Ambient temperature Final separator temperature Delivery
tU [°C] tAb [°C] Q [l/min]
100
10 20 - 24 34 - 27
15 25 - 29 25 - 20
20 30 - 34 19 - 15
25 35 - 39 15 - 12
30 40 - 44 11 - 9
35 45 - 49 9-7
40 50 - 54 7-6

Filter cartridge 059183: bottle fillings [number] molecular sieve mass mMS [g] = 58
Ambient Final separa­ Air humidity, processable air volume Va Number of bottle fillings n
temperature tor tempera­ saturated [m3] acc. to bottle size
tU [°C] ture X [g/m3] at pressure p [bar]
tAb [°C]
200 300 7l 10 l 12 l
10 20 - 24 17,31 - 21,80 134 - 106 201 - 160 96 - 76 67 - 53 56 - 44
15 25 - 29 23,07 - 28,79 101 - 81 151 - 121 72 - 58 50 - 40 42 - 34
20 30 - 34 30,40 - 37,63 76 - 62 114 - 92 55 - 44 38 - 31 32 - 26
25 35 - 39 39,65 - 48,64 59 - 48 88 - 72 42 - 34 29 - 24 24 - 20
30 40 - 44 51,21 - 62,41 45 - 37 68 - 56 32 - 27 23 - 19 19 - 15
35 45 - 49 65,52 - 79,28 35 - 29 53 - 44 25 - 21 18 - 15 15 - 12
40 50 - 54 83,08 - 99,85 28 - 23 42 - 35 20 - 17 14 - 12 12 - 10

Bottle volume VF [m3] Processable air volume: Va [m3] = 0,2 x mMS [g] / (X [g/m3] /
p [bar]) = 0,2 x p [bar] x mMS [g] / X [g/m3]
Bottle size at pressure p [bar]
l [ltr.] 200 300 Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60
[min/h])
7 1,4 2,1
10 2 3
12 2,4 3,6
Number of bottle fillings n=
processable air volume / bottle volume = Va / VF
Bottle volume: VF [m3] = p [bar] x l [l] / 1000 [l/m3]

23
 Instruction Manual  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
A pressure maintaining valve is mounted at the outlet of the on top of the filter system P21 and is adjusted to the operat­
filter system P21. ing pressure of the unit (see chapter 1, Technical Data), 225
bar (3,200 psi) for the standard units, 330 bar (4,700 psi)
It ensures that pressure is built up in the filter even from the for models -H or -HU. All safety valves are sealed at the fac­
start of delivery, thus achieving a constant, optimum filtra­ tory.
tion. It will also guarantee proper working conditions for the
final stage cylinder. If one of the intermediate pressure safety valves blows off,
the valves in the next stage are not closing properly, afford­
The pressure maintaining valve is adjusted to 150 ±10 bar ing valve check. The cause of the trouble is usually the inlet
(2,175 psi). valve of the next stage. See also chapter 4.4.8.
MAINTENANCE
Checking function
The final pressure safety valve has to be checked regularly.
For this purpose the safety valve can be vented manually.
3 Turn knurled knob on top of the valve clockwise until valve
2
blows off (Abb. 32).
1 This just ensures that the valve is functional and will release
pressure in case of a malfunction. To check the blow-off pres­
sure value refer to ”Blow-off pressure check”.
Venting

Abb. 31 Pressure maintaining valve

MAINTENANCE
The pressure maintaining valve (Abb. 31) is adjusted at the
factory to the required pressure and normally does not re­
quire regular maintenance or readjustment. In case of read­ Abb. 32 Venting the final pressure safety valve
justment becoming necessary, loosen jam nut (2) and set
screw (3). Adjust screw (1) to the required pressure using a Checking blow-off pressure
suitable screw-driver.
Check blow-off pressure of the final pressure safety valve
Clockwise = increase pressure regularly, see maintenance schedule chapter 4.3. Pump unit
Counter-clockwise = decrease pressure to final pressure with shut-off valve closed until safety valve
blows off. Check blow-off pressure of safety valve at pressure
gauge. If deviation is 10% or more, replace safety valve.

4.4.6. SAFETY VALVES 4.4.7. PRESSURE GAUGE

DESCRIPTION
DESCRIPTION
The compressor unit is equipped with a final pressure gauge
All three compressor stages are protected by safety valves as (Abb. 33). The red marking on it shows the max. allowable
follows operating pressure.

24
Instruction Manual  Junior II

Mark

Intake Pressure

Abb. 33 Final pressure gauge Abb. 34 Valve operation

MAINTENANCE

We recommend that the final pressure gauge is checked

from time to time. For this purpose we have developed a Pressure side Intake side
special test pressure gauge with an adaptor which immedi­
ately recognizes any deviations in readings (see High Pres­
sure Accessories Catalogue 8550/..).
N4860−F98

Slight deviations during operation are normal and can be ig­

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

25
 Instruction Manual  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 Abb. 36.

7
6
5 1

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

Abb. 38 Valve head 3rd stage

Change intake and pressure valve of 3rd

stage together only.

Remove of 3rd stage pressure valve (3) according to Abb. 38.

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

26
Instruction Manual  Junior II
- Remove allen screws (7), take off valve head cover (6). - Check that after tension adjustment and tightening the
- Put two screwdrivers into the groove of pressure valve motor mounting nuts, both pulleys are in a straight line
body (Abb. 39). If necessary turn valve loose at first using to avoid excessive wear of the V-belt. Hold a straight edge
a 13 mm spanner on the flat surfaces. against compressor and motor V-belt pulleys as shown in
Abb. 41: edge must be parallel to the v-belt.
- Lift out pressure valve (3) together with O-ring (2).
Reinstall pressure valve (3) in reverse sequence:
- Check O-ring for abrasion and replace if necessary. Put 10 mm
O-ring (2) into valve head (5).
- Insert pressure valve (3). Install valve head cover (6).
- Fasten valve head with allen screws (7) and washers (8).
- Screw in torque stud (1) with 20 Nm (2 kpm).

Abb. 40 Checking V-belt tension

Abb. 39 Removal of 3rd stage pressure valve

4.4.9. COMPRESSOR DRIVE SYSTEM Abb. 41 V-belt pulley adjustment

DESCRIPTION
4.4.10. ELECTRICAL SYSTEM
The compressor is driven by the drive motor through a V-belt.
The motor is mounted on the base plate and requires adjust­ DESCRIPTION
ment for proper V-belt tension.
This section describes the standard electrical system.
Improper v-belt tension and adjustment of For schematic diagram, see annex.
the pulleys will result in extreme v-belt ab­
rasion and premature wear.
The electrical equipment of the compressor unit consists of:
- drive motor
MAINTENANCE - electric control system
Checking the drive belt tension To start the electric motor and enable the functioning of the
electric control, the following components are essential:
- The best tension for a belt drive is the lowest possible, - main switch and main fuse, both to be installed by the
where the belt under full load does not slip. A rough value customer.
for this is when the belt deflects 10 mm when pressed
with thumb pressure between the two pulleys (Abb. 40). DRIVE MOTOR
For best results we recommend our v-belt tension meter, The compressor unit is driven by an alternating or a three
part no. N25238. phase current motor by means of a V-belt.
V-belt tension adjustment
MOTOR PROTECTION SWITCH (ALTERNATING CUR­
- Slightly loosen motor mounting nuts RENT MOTOR)
- Adjust motor until the belt tension is correct (see
Protection of the motor is ensured by the thermic releases
Abb. 40).
integrated into the motor protection switch (1, Abb. 42). The
- Tighten motor mounting nuts. response value is preset.The motor is switched on manually
- Run motor for approx. 5 minutes. Stop motor, check V- by pressing the 0-I switch to I. For safety of the operating per­
belt tension, and readjust if required. sonnel all voltage carrying parts have a protective cover.

27
 Instruction Manual  Junior II
MOTOR PROTECTION SWITCH (THREE-PHASE MOTOR)
The motor is switched on manually by turning the switch to
1 (Abb. 43). It is switched off manually by turning the switch
to 0.
For safety of the operating personnel all voltage carrying 1
parts have a protective cover.
After the switch has shut off by overcur­
rent triggering, the motor can be restarted
by pressing the start-button not before the
bi-metal in the switch has cooled down. This may last
a couple of minutes.

Protection of the motor is ensured by the thermomagnetic

releases integrated into the motor protection switch. The re­
sponse value of the electromagnetic releases (protection
against short-circuit) is preset.
MAINTENANCE
For the electrical system no regular maintenance is required. Abb. 42 Motor protection switch (alternating current)

4.4.11. COOLING SYSTEM

The cylinders of the compressor block, the intermediate
coolers and the after-cooler are air-cooled.
For this purpose, the compressor is equipped with a fan­
wheel connected to the counter-weight at the crankshaft
end opposite to the V-belt pulley. It draws the cooling air
through the fanwheel cover from the surroundings.
Refer to chapter 3. for proper installation and cooling air sup­
ply. For maximum ambient temperature, see Technical Data,
chapter 1. 0
1

Abb. 43 Motor protection switch (three-phase motor)

28
Instruction Manual  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 Set to nominal motor current. Observe
off the unit tection switch temperature compensation (+20 °C
=1,0)
For ambient temperature
+ 10 °C : correction factor 0,94
+ 30 °C : correction factor 1,05
+ 40 °C : correction factor 1,12
Unsufficient voltage because of weak Switch off other consuming devices
power supply
Motor protection switch is switching Power supply cable to long or to thin Use suitable cable
off the unit
Drive motor (petrol)
Motor will not start See motor instructions See motor instructions
Motor runs eccentrically V-belt worn Replace
Motor stops Low oil level Top up oil
Drive system
Excessive v−belt wear (black depo- V-belt tension Re-tighten, see chapter 4.4.9.
sits on belt guard) Pulleys not aligned Re-adjust, see chapter 4.4.9.
Compressor
Compressor does not attain final pres­ Condensate drain valve(s) leaking Tighten and reseal
sure
Final pressure safety valve defective Replace safety valve
(blows too soon)
No cartridge in filter system P21 (air Replace cartridge
escaping through cartridge safety bore)
Vent screw for final pressure safety To vent, unscrew until completely open
valve not in operating position
Air delivery drops Intake filter soiled Clean or replace filter cartridge
Pipe coupling leaking Retighten couplings
Excessive wear of 3rd stage piston Replace piston and sleeve of 3rd stage
Intermediate pressure safety valve Intermediate pressure too high be­ Check/replace inlet or pressure valve
blows cause of defective inlet or pressure
valve of the following stage
Safety valve leaking Replace safety valve
Compressor overheats Insufficient cooling air Check location; ensure proper cooling
air flow
Ambient temperature too high Check location; ambient temperature
max. +45 °C (113 °F)
Direction of rotation is wrong Correct direction of rotation
Inlet and pressure valve of one stage is Check valves, clean/replace if necessary
leaking
Taste of oil in the air TRIPLEX cartridge saturated Replace cartridge
Unqualified lubricant being used Replace oil with an approved brand

29
 Instruction Manual  Junior II

Trouble Cause Remedy

High oil consumption Piston rings, Pistons or cylinders worn Replace defective parts
out
Intake filter clogged Replace filter cartridge
Compressor too hot Enhance cooling
Air escaping through cartridge safety Cartridge missing Insert cartridge
bore Cartridge installed but O-rings defec­ Check/replace O-rings
tive

30
Instruction Manual  Junior II
5. 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
If the compressor is put out of service for more than six run for approx. 10 minutes or until the pressure gauges
months, the unit should be preserved in accordance with the indicate the correct values.
following instructions: Make sure the compressor is kept in­ - Stop the compressor.
doors in a dry, dust free room. Only cover the compressor - Open condensate drain valves and release compressed
with plastic if it is certain that no condensation will form air. Close condensate drain valves again.
under the sheet. Nevertheless, the sheet should be removed - Carry out preservation procedure according to chapter
from time to time and the unit cleaned on the outside. If this ”preserving the compressor”
procedure cannot be followed and/or the compressor is
Changing the lube oil for preserving
going to be taken out of service for more than 2 years, please
contact our Technical Service Department for special instruc­ - After prolonged storage, the oil will age in the com­
tions. pressor and engine. It should be drained after 2 years at
The compressor is not resistant to salt- the latest and replaced with fresh oil.
water! If not in use keep unit in a dry place. - The stated period can only be attained when the crank­
case is sealed during the preservation period in accord­
PREPARATION ance with the preservation requirements.
Before preserving the compressor unit, run it warm and - After changing the oil, turn the compressor and the en­
when it reaches the specified service pressure, keep it run­ gine or run them for the required period.
ning for approx. 10 minutes. - Check the lubrication of the compressor when putting
the unit into operation once every six months or when
Then carry out the following:
turning the compressor. The oil pump is functioning
- Check all pipes, filters and valves (also safety valves) for properly when oil can be seen flowing through the sight
leakage. glass of the oil pressure regulator and if the oil pressure
- Tighten all couplings, as required. gauge indicates the prescribed pressure.
- After 10 minutes, open the filling valves or the outlet
valve and run the compressor at the set minimum pres­ REACTIVATING THE COMPRESSOR UNIT
sure (pressure maintaining valve, see chapter 4.4.5.) for - Remove the dust cap from the inlet port and insert the in­
approx. 5 minutes. take filter.
- After these 5 minutes, shut the system down. Drain con­ - Check the oil level of the compressor.
densate from separators. Depressurize unit. Shut filling - Check the motor/engine according to the manufacturer's
valves. instructions.
- Open filters and grease threads. - Open the purifier and change all filter cartridges.
- Ensure that filter cartridge remains in the filter! - Run the compressor warm with open filling valves or
This will prevent oil entering filling lines as a result of pres­ outlet valve for approx. 10 minutes.
ervation procedures. - Check the oil pressure on the pressure gauge. If there is
- Remove intake filter from manifold and all intake lines any fault, check the lubrication of the compressor.
from valve heads. - After 10 minutes, close the filling valves or the outlet valve
- Let compressor unit cool down. and run the unit up to final pressure until the final pres­
PRESERVING THE COMPRESSOR sure safety valve blows.
- Turn the compressor on and spray a small amount (ap­ - Check the inter-pressure safety valves for leakage.
prox. 10 ccm/0.6 cu. in.) of compressor oil into the valve - Establish cause of any fault from the trouble-shooting
head inlet port while the compressor is running. Do not table, chapter 4.5., and take corrective action.
let the compressor warm up too much, to keep oil sticky. - Stop the system when running properly, the compressor
- Shut compressor unit off. is then ready for operation.
- Close all valves.
- Place the dust cap onto the inlet port.
PRESERVING THE MOTOR/ENGINE
Preserve the motor/engine according to the instructions of
the motor/engine manufacturer.
PREVENTIVE MAINTENANCE DURING STORAGE
Run the compressor once every 6 months as described in
the following:

31
 Instruction Manual  Junior II
6. REPAIR INSTRUCTIONS

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

32
Instruction Manual  Junior II
7. 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.

Bolt or screw Thread max. torque

Hex and allen head M6 10 Nm (7 ft.lbs)
Hex and allen head M 8* 25 Nm* (18 ft.lbs)
Hex and allen head M 10 45 Nm (32 ft.lbs)
Hex and allen head M 12 75 Nm (53 ft.lbs)
Hex and allen head M 14 120 Nm (85 ft.lbs)
Hex and allen head M 16 200 Nm (141 ft.lbs)
Pipe connections (swivel nuts): Finger-tight + 1/2 turn

TORQUE SEQUENCE
Tighten valve head and cylinder bolts/nuts equally in the se­
quence shown in Abb. 44.
Be sure to tighten all parts in cold condition only.

Abb. 44 Torque sequence

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

33
 Instruction Manual  Junior II
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
Screws, bolts, threads WEICON ANTI-SEIZE AS 040 P part no. N19753 or
equivalent compound with copper or MoS2 additives

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

ADHESIVE AND SEALANT CHART

Usage Adhesives and Sealants

Screws Loctite 2701
Seals for conical threads Loctite 243
Metal - metal seals Temperature resistant compound, e.g.
High temperature connections, e.g. valve heads, cylin­ WACKER E10, part no. N18247
ders
Paper gaskets Loctite FAG 2

TESTING AGENTS

Usage Testing agents

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

34
Instruction Manual  Junior II
8. ANNEX

• Schematic diagram
Lubricating oil list
Parts list

35
 Instruction Manual  Junior II

36
Instruction Manual  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  Junior II

38
Oil list  Breathing air compressors
GENERAL

After extensive tests with many different kinds of lubricants, we have decided to authorize the following brands of oil for
use in BAUER compressors under the given operating conditions.
This list is up to date at the time of printing and will be reviewed continuously. Should your list or your instruction manual
be older, please request the latest edition from BAUER Customer Services. When using any of the oils listed below, please
follow the oil change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction
manual of your unit.

Ambient
Oil type Use temperature
A N
Brand name Designation Type +5 ...+45 °C
Breathing air Nitrox
Special Compressor oil
Part no. N28355
b) c)
S + + +
+ − +
Special Compressor oil
Part no. N22138
a) M

Oil type

S synthetic oil
M mineral oil

Application

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

Suitability

+ = suitable
− = not suitable
 Oil list  Breathing air compressors
TYPE OF OIL

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

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

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

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

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

Changing the Oil Type

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

− Drain mineral oil while still warm.

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

If deposits are present, perform the following steps:

− Remove deposits or change valves, coolers, separators, purifiers and all pneumatic tubes and hoses.
− Change oil filter, if applicable.
− Fill compressor with the new oil.
− After approx. 100 operating hours, replace oil filter again (if applicable). and change oil.
− Top up with same oil type.

OIL CHANGE

Mineral oil every 1000 operating hours, at least annually

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

BAUER compressor oil is available in the following quantities:

Oil quantity  Oil Synthetic oil N28355 Mineral oil N22138

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