HIGH PRESSURE INDUSTRIAL COMPRESSOR UNITS

225 bar
330 bar
Model range MINI-VERTICUS 3
A
DESCRIPTION

B
INSTALLATION, TAKING INTO OPERATION

C
OPERATION

D
MAINTENANCE, REPAIR

E
STORAGE, PRESERVATION

F
DIAGRAMS, DRAWINGS

G
SPARE PARTS CATALOGUE
 Instruction Manual • Industrial Compressor Units
INTRODUCTION

This manual contains operating instructions and maintenance

schedules for the industrial compressor units of the model
range

MV 3 ”Mini--Verticus”

Model: ____________________________

Serial no.: ____________________________

WARNING
! Pneumatic high pressure system !
The air produced with this unit must not be used for breathing
air supply.
Ignoring the operating and maintenance instructions can lead
to severe injury or death.
The machine 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.
MV-- I/02/07

Edition February 2007

© 2007 BAUER Kompressoren GmbH, München
All rights reserved
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 Instruction Manual • Industrial Compressor Units
INTRODUCTION

NOTICE

Layout and use of instruction manuals

Working with pneumatic high pressure systems cannot always be considered safe and one should possess a mini-
mum knowledge of how to operate them. For this reason, please read this instruction manual before operating your
unit, to get to know the components and processes.

This instruction manual is made up according to the building block principle. It is divided into 7 sections, whose content
varies according to the type of unit, standard or special and of course the accustomized extras, which are available
for all our units in large numbers. With this kind of subdivision system, all sections should be in existence, in order to
give a complete picture. In other words: even if one particular component is not part of the unit, the relative section will
still be kept, although only a notice may be printed there. On the other hand, other sections could be represented more
than once if certain units require this. In such a case one only has to refer to the applicable section, all superfluous
ones can be removed. This is quite simple due to the ring binding system.

Please note that the circuit diagrams in section F, unless otherwise stated, are the standard circuit diagrams for your
specific unit. So please always refer to the circuit diagram enclosed in the compressor unit control box, in which any
possible changes are registered.

The same thing applies for the spare parts lists in section G. To avoid misunderstanding when ordering spare parts,
we advise you to remove the parts that are not applicable. The spare parts lists that apply to the relative unit are listed
in the section Index.

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Instruction Manual • Industrial Compressor Units

TABLE OF CONTENTS

A. DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--3

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 3

1.1. PURPOSE AND SHORT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--3

1.2. DESIGN AND MODE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--7
1.3. TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--10

2. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 17

2.1. FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--17

2.2. TYPE OF OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--17
2.3. OIL PRESSURE MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--17

3. INTAKE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 18

3.2. COMPRESSOR UNITS FOR GAS APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--18

4. INTERMEDIATE SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 19

4.1. INTERMEDIATE SEPARATOR AFTER 1ST. STAGE (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--19

5. FINAL SEPARATOR / FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 19

5.1. PURPOSE AND SHORT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--19

5.2. FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--19

6. PRESSURE MAINTAINING / NON-- RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 22

7. SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 22

8. PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 23

8.1. INTERMEDIATE PRESSURE GAUGE (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--23

8.2. OIL PRESSURE GAUGE (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--23
8.3. FINAL PRESSURE GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--23

9. VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 23

10. AUTOMATIC CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 24

10.1. CONDENSATE COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--24

10.2. ELECTRICAL CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--24

11. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 25

11.1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--25

11.2. DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--25
11.3. ELECTRICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--25
11.4. ELECTRONIC FILTER MONITORING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--27

12. COMPRESSOR DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 27

13. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-- 27

B. INSTALLATION, OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--3

1. INSTALLATION OF THE COMPRESSOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-- 3

1.1. COMPRESSOR ROOM CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--3

1.2. LOCATING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--3
1.3. NATURAL VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--3

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 Instruction Manual • Industrial Compressor Units

TABLE OF CONTENTS

2. ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-- 3

3. TAKING INTO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-- 4

3.1. PREPARATION FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--4

C. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--3

1. SAFETY MEASURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-- 3

1.1. NOTES AND WARNING SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--3

1.2. IDENTIFYING THE SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--3
1.3. FUNDAMENTAL SAFETY NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--3
1.4. SAFETY REGULATIONS (EC; partly Germany, only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--6

2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-- 7

2.1. PREPARATION FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--7

2.2. STARTING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--8
2.3. SHUTDOWN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C--8

D. MAINTENANCE, REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 3

1.1. MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3

1.2. MAINTENANCE WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3
1.3. MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3

2. LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 3

2.1. OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3

2.2. OIL CHANGE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3
2.3. OIL CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3
2.4. OIL PACKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3
2.5. CHANGING THE OIL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3
2.6. OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--4
2.7. VENTING OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--4

3. INTAKE FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 5

3.1. COMPRESSOR UNIT FOR AIR APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--5

3.2. COMPRESSOR UNIT FOR GAS APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--5

4. INTERMEDIATE SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 5

4.1. CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--5

5. FINAL SEPARATOR / FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 6

5.1. OIL AND WATER SEPARATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--6

5.2. FILTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--6

6. PRESSURE MAINTAINING / NON-- RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 7

7. SAFETY VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 8

7.1. OPERATING CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--8

7.2. BLOW--OFF PRESSURE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--8

8. PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 13

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9. VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 13

9.1. GENERAL INSTRUCTIONS FOR CHANGING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--13

9.2. VALVE CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--13

10. AUTOMATIC CONDENSATE DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 14

10.1. CHECKING THE AUTOMATIC DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--14

11. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 14

11.1. CHECKING THE TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--14

11.2. ADJUSTMENT OF FINAL PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--14

12. COMPRESSOR DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 15

12.1. ELECTRIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--15

12.2. V--BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--15

13. REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 15

14. TROUBLE-- SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 16

15. TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-- 17

15.1. TIGHTENING TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--17

15.2. TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--17
15.3. LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--18
15.4. ADHESIVE AND SEALANT CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--18
15.5. TESTING AGENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--18

E. STORAGE, PRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E--3

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-- 3

2. PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-- 3

3. PRESERVING THE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-- 3

4. PRESERVING THE MOTOR/ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-- 3

5. PREVENTIVE MAINTENANCE DURING STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-- 3

5.1. CHANGING THE LUBE OIL FOR PRESERVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E--3

6. REACTIVATING THE COMPRESSOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-- 3

F. DIAGRAMS, DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F--3

1. FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-- 3

2. SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-- 3

3. DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-- 3

4. LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-- 3

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G. PARTS LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G--3

1. COMPRESSOR UNIT MV-- I100-- 3-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 3

2. COMPRESSOR UNIT MV-- I100-- 4-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 3

3. COMPRESSOR UNIT MV-- I120-- 4-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 3

4. COMPRESSOR UNIT MV-- I120-- 5.5-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 4

5. COMPRESSOR UNIT MV-- GI100-- 3-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 4

6. COMPRESSOR UNIT MV-- GI100-- 4-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 4

7. COMPRESSOR UNIT MV-- GI120-- 4-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 5

8. COMPRESSOR UNIT MV-- GI120-- 5.5-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 5

9. COMPRESSOR UNIT MV-- GIB12.2-- 5.5-- 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-- 5

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TABLE OF FIGURES
Fig. 1 High Pressure Compressor Unit, Model range MV 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--3
Fig. 2 High Pressure Compressor Unit MV 3--I with storage bottle B50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--4
Fig. 3 High pressure compressor unit, model range MV--GIB12.2 with gas intake system and filter system P61* . . . . . . . . . . . . . . . . . . A--5
Fig. 4 High pressure compressor unit MV--GIB12.2--5.5--3 with storage bottles, model range MV 3* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--6
Fig. 5 Instrumental Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--7
Fig. 6 Compressor block IK120, front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--8
Fig. 7 Compressor block BK12.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--9
Fig. 8 Dimensions (in mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--16
Fig. 9 Lube oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--17
Fig. 10 Oil pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--17
Fig. 11 Intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--18
Fig. 12 Intakesystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--18
Fig. 13 Intake pressure reducing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--18
Fig. 14 Filtersystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--19
Fig. 15 Securus indicator unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--21
Fig. 16 Pressure Maintaining / Non--return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--22
Fig. 17 Final pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--23
Fig. 18 Valve operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--23
Fig. 19 Condensate drain, 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--24
Fig. 20 Condensate drain, 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--24
Fig. 21 Compressor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--25
Fig. 22 Final pressure switch for semi--automatic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--26
Fig. 23 Final pressure switch for automatic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--26
Fig. 24 Monitoring instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A--26
Fig. 28 Lift magnet connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B--4
Fig. 29 Oil sight gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--3
Fig. 30 Oil filler neck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--4
Fig. 31 Removing the cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--4
Fig. 32 Replacing the oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--4
Fig. 33 Intake filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--5
Fig. 34 Removing the filter head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--6
Fig. 35 Extracting the cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--6
Fig. 36 Pressure Maintaining / Non--Return Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--7
Fig. 37 Venting the final pressure safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--8
Fig. 38 Final pressure switch, semi--automatic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--14
Fig. 39 Final pressure switch for fully automatic operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--14
Fig. 40 Torque sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D--17

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INDEX
A I
Ambient temperature, A--20, A--27 Industrial compressor unit, A--3
Automatic condensate drain, A--24, D--14 Installation, B--3
Intake filter, A--18, D--5
Intermediate separators, A--19, D--5
B
Bedientafel, elektr. Steuerung, A--5
BK12.2, A--9 L
Load cycle, A--20
Lubrication, D--3
C Lubrication system, A--17
Changing the oil type, A--17, D--3
Compressor block, A--8
Compressor drive system, A--27 M
Condensate drain, D--5, D--6 Maintenance record, D--3
Cooling system, A--27 Maintenance work, Maintenance intervals, D--3
Customer Services, x Mini--Verticus, A--3
Cycle counter, A--26 Motor protection overload relay, Thermal, B--3
Motor protection relay, B--3

D
Description, A--3 N
Design, A--7 Noise level, A--3
Diagrams, drawings, F--3
Drive system, D--15
O
Oil change, D--3, D--4

E Oil pressure monitoring, A--27

Electric control, Installation, B--3 Oil pump, Venting, D--4
Electrical system, A--25, D--14 Operation, C--7

F P
Filter system, A--19, D--6 Parts Lists, G--3
Final pressure Preservation, E--3
adjustment, D--14 Presssure switch, A--26
hysteresis, D--14
Pressure dew point, A--15
Final separator, A--19, A--20, D--6
Pressure gauge
Flow diagram, A--7
Final pressure, A--23
Fuse table, B--4 Intermediate pressure guage, A--23
Oil pressure, A--23
Pressure gauges, A--23, D--13
G Pressure maintaining / Non--return valve, D--7
Gas compressor unit, A--3

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Instruction Manual • Industrial Compressor Units

INDEX
R
Repair instructions, D--15
Residual CO contents, A--15
Residual CO2 contents, A--15
Residual oil vapour contents, A--15
Residual water contents, A--15

S
Safety valves, A--22, D--8
Final pressure, D--8
Operating check, D--8
Sales Department, x
Semi--automatic compressor control, A--26
Service switch, A--26
Starting the unit, C--8
Storage, E--3

T
Tables, Testing agents, D--18
Taking into operation, B--4
Technical Customer Services, x
Technical data, Compressor units, A--10
Telephone numbers, x
TERMINALS, CHECKING, D--14
Training Courses, x
Trouble--shooting, D--16

V
V--belts, Drive system, A--27
Valves, A--23, D--13
Ventilation, Natural, B--3

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 Instruction Manual • Industrial Compressor Units
Change notice

Changes which differ from the previous edition are marked with a vertical line.

Change no. Change date and changes

0 First Edition October 2006
1 February 2007; Service manual

Dear Customer

We are happy to give you advice on any questions regarding your BAUER compressor and help as soon as possible with any arising
problems.
You can contacts us Mondays to Thursdays from 0800 to 1630, Fridays from 0800 to 1500 on phone no. (089) 78049--0.
If you call the following extensions directly, it will save you time.
Do you want to order spare parts?
. Customer Services Tel: (089) 78049--129 or --149
Fax: (089) 78049--101
Do you have problems with maintenance or repair work?
. Technical Customer Services Tel: (089) 78049--176 or --246
Fax: (089) 78049--101
Do you need further information regarding your unit, accessories, prices etc.?
. Sales Department Tel: (089) 78049--138, --154, --185 or --202
Fax: (089) 78049--103
Are you interested in training courses?
. Training Manager Tel: (089) 78049--175
Fax: (089) 78049--101
Meet us in the internet at: [Link]

x
Instruction Manual • Industrial Compressor Units

A--1
 Instruction Manual • Industrial Compressor Units

A--2
 Instruction Manual • Industrial Compressor Units

A. DESCRIPTION
1. GENERAL The gas compressor units (GI, and GIB models) are designed
for compression nitrogen in the high pressure range. The maxi-
mum operating pressure of the compressors in the GI and GIB
1.1. PURPOSE AND SHORT DESCRIPTION series is 350 bar (5,000 psi).

This instruction manual describes the industrial compressor

units of the Mini--Verticus 3 model range. This model range The industrial compressor units of the MV 3 series are mounted
comprises air as well as gas compressor units. in the Super--Silent fully enclosed, sound--proof ”Mini--Ver-
ticus” housing.
The air compressor units (I models) are designed for compres-
sion of industrial air in the high pressure range. The maximum
operating pressure of the compressor is 350 bar (5,000 psi). The noise level is less than 70 dB(A).

1
2

Fig. 1 High Pressure Compressor Unit, Model range MV 3

1 Main switch 3 Final pressure gauge

2 Instrument panel, electric control 4 Condensate collecting tank
MV-- I/02/07

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 Instruction Manual • Industrial Compressor Units

Fig. 2 High Pressure Compressor Unit MV 3--I with storage bottle B50

1 Safety valve and pressure gauge 3 Intermediate pressure gauges

2 Storage bottle B50 4 Condensate collecting tank

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Instruction Manual • Industrial Compressor Units

2
3

9
4

10

Fig. 3 High pressure compressor unit, model range MV--GIB12.2 with gas intake system and filter system P61*
1 Instrument panel, electric control 6 Oil and Water separator
2 Final pressure switch 7 Condensate drain valve
3 Non--return valve 8 Gas inlet connection
4 Filter key 9 Intake pressure switch
5 Venting valve with pressure gauge 10 Fine filter

* Front and side panels removed

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 Instruction Manual • Industrial Compressor Units

8
3

9
6
10

Fig. 4 High pressure compressor unit MV--GIB12.2--5.5--3 with storage bottles, model range MV 3*

1 Pressure gauge, storage 6 Fine filter

2 Storage bottels 7 Drive motor
3 Compressor control 8 Gas inlet connection
4 Final pressure switch 9 Solenoid valve
5 Compressor block 10 Intake filter

* Front and side panels removed

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Instruction Manual • Industrial Compressor Units
1.2. DESIGN AND MODE OF OPERATION • Automatic condensate drain unit and condensate collector
tank
1.2.1. Design • Instrument panel with final pressure gauge and hourmeter.

The compressor unit comprises the following major assem- • Oil pressure control
blies:
Optionally, the units can be delivered with:
• compressor block
• Filter system P41 / P61 for longer cartridge lifetime
• drive motor
• SECURUS monitoring unit for the filter system
• frame and housing assembly with instrument panel
• Oil pressure gauge
• automatic condensate drain
• connection for external warning lamp (with SECURUS mo-
• filter set nitoring unit, only)
• electric control system
1.2.2. Mode of operation; flow diagram
All units are equipped as standard as follows:
The path of the medium through the compressor system is
• TÜV approved final pressure safety valve shown in the flow diagram in section F.

1 2 3 4 5 6 7 8 9 10

Fig. 5 Instrumental Panel

1 Main switch
2 Oil pressure warning light
3 OFF button
4 ON button
5 Hourmeter
6 Short instruction
7 Short instruction SECURUS monitoring unit for the filter system
8 SECURUS indicating light green
9 SECURUS warning light yellow
10 SECURUS warning light red

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 Instruction Manual • Industrial Compressor Units
1.2.3. Compressor block The compressor blocks used in the Mini--Verticus compressor
units are particularly suitable for continuous operation because
The assembly of the compressor block is shown in Fig. 6 of their rugged design and the corrosion resistant intermediate
The compressor blocs IK100 and IK120 are designed to com- filter and cooler assemblies. Smooth running is a particular fea-
press air in a high pressure [Link] maximum workingpres- ture of this BAUER design. The balance of masses of the 1st
sure is 350 bar. rank is zero. The moving parts of the driving gear are all equally
balanced. This results in a vibration--free running.
The compressor blocks IK100--GI and IK120--GI are designed
to compress nitrogen in a high pressure level. The maximum The driving gear is fitted with three bearings. It is here that the
workingpressure is 350 bar. energy saving cylinder roller bearings are put to use. The upper
and lower connecting rod bearings are also roller bearings. This
The compressor blocks are of a three stage, three cylinder de- allows for an even longer life which lasts at least 30,000 operat-
sign (Fig. 6). The cylinders are arranged in a W form, 1st stage ing hours. All valves have free access for time saving mainte-
in the centre, 2nd stage on the right, and 3rd stage on the left nance. There is no need for dismantling of pipes or pressure
side looking from the filter side. gauges.

1
2
10
3
4

5 11

12

13
8

14

1 Cylinder 1st stage

2 Intake filter
15 3 Oil filler neck
4 Cylinder, 3rd stage
9
5 Safety valve, 2nd stage
6 Oil filter housing
7 Intermediate separator, 2nd stage
8 Inter--cooler 2nd stage
9 Condensate drain connector
10 Safety valve, 1st stage
11 After--cooler
12 Cylinder, 2nd stage
13 Inter--cooler 1st stage
14 Oil drain tap
15 Air outlet connector

Fig. 6 Compressor block IK120, front view

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Instruction Manual • Industrial Compressor Units
BK12.2 The cylinders are lubricated by the lubricating system.
The compressor block BK12.2 are designed to repressing of ni- The assembly of the compressor block is shown in Fig. 7
trogen in a high pressure level. The maximum workingpressure
is 350 bar. The mode of operation is showen by the flow diagram in chapter
F.
The compressor blocks are of a two stage, three cylinder design
(Fig. 7). The cylinders are arranged in a W form, 1st stage on
the right and in center and 2nd stage on the left, looking from the
filter side.

2
10
3

4 11
5 12

13
7

8
14

15
9

Fig. 7 Compressor block BK12.2

1 Intake connection
2 Cylinder 1st. stage, center
3 Oil filling pipe
4 Safety valve, 2nd. stage
5 Cylinder, 2nd. stage
6 Oilfilter housing
7 Intermediate separator, 2nd. stage
8 Intermediate cooler, 2nd. stage
9 Condensate drain connection
10 Safety valve, 1st. stage
11 Cylinder, 1st. stage, right
12 Crankcase venting
13 Intermediate cooler, 1st. stage
14 Oil sight gauge
15 Pressure outlet

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 Instruction Manual • Industrial Compressor Units

1.3. TECHNICAL DATA

To minimize multiple quotations, the com-

mon features are listed under General, all
compressor block and motor data are listed
in 1.3.4. and 1.3.5., respectively.

1.3.1. Industrial compressor units for air up to 350 bar

General:

Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air
Intake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . atmospheric
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 -- 350 bar
Adjustment, final pressure safety valve . . . . . . . . . . . . . . . . . . . . max. 365 bar
Adjustment, final pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . max. 350 bar
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +5 to +45 °C
Allowable altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ... 2000 m above sea level
Max. inclination of compressora) . . . . . . . . . . . . . . . . . . . . . . . . . . 10°
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to oil list
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380--440 V, 50--60 Hz
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V, 50--60 Hz
Type of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 phase squirrel cage motor
Type of construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
Protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP54

Compressor unit . . . . . . . . . . . . . . . . . . . . MV--I100--3--3 . . . . MV--I100--4--3 . . . . . MV--I120--4--3 . . . . . MV--I120--5.5--3

Compressor block . . . . . . . . . . . . . . . . . . . . IK100--F07 . . . . . . . IK100--F07 . . . . . . . IK120--F07 . . . . . . . . IK120--F07

Deliveryb) . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 l/min . . . . . . . . . 125 l/min . . . . . . . . . 170 l/min . . . . . . . . . 215 l/min
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 cfm . . . . . . . . . . . . 4.4 cfm . . . . . . . . . . . 6 cfm . . . . . . . . . . . . . 7,6 cfm
Pressure setting, pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . according to order . . . . . . . . . . . . . . . . . . . .
Pressure setting, final pressure safety valve . . . . . . . . . . . . . . . . according to order . . . . . . . . . . . . . . . . . . . .
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . 70 dB(A) . . . . . . . . . 70 dB(A) . . . . . . . . . 70 dB(A) . . . . . . . . . . 70 dB(A)
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 min --1 . . . . . . . . 1270 min --1 . . . . . . . 1200 min --1 . . . . . . . . 1470 min --1
Drive input . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,2 kW . . . . . . . . . . . 3,3 kW . . . . . . . . . . . 3,7 kW . . . . . . . . . . . 4,7 kW
Drive motor power . . . . . . . . . . . . . . . . . . . . 3 kW . . . . . . . . . . . . 4 kW . . . . . . . . . . . . . 4 kW . . . . . . . . . . . . . 5,5 kW
Weight, approx. . . . . . . . . . . . . . . . . . . . . . . 255 kg . . . . . . . . . . . 255 kg . . . . . . . . . . . 260 kg . . . . . . . . . . . . 260 kg

Subject to change without prior notice

a) These values are valid only if the oil level of the compressor in normal position corresponds to the upper mark of the oil sight glass and may
not be exceeded.
b) Free air delivered at tank filling from 0 to 200 bar ± 5% or 300 bar ± 5% for 420 bar units.

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Instruction Manual • Industrial Compressor Units
TECHNICAL DATA (Cont.)

1.3.2. Industrial compressor units for nitrogen up to 350 bar

General:

Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nitrogen
Intake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . atmospheric
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 -- 350 bar
Adjustment, final pressure safety valve . . . . . . . . . . . . . . . . . . . . max. 365 bar
Adjustment, final pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . max. 350 bar
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +5 to +45 °C
Allowable altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 ... 2000 m above sea level
Max. inclination of compressora) . . . . . . . . . . . . . . . . . . . . . . . . . . 10°
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to oil list
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380--440 V, 50--60 Hz
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V, 50--60 Hz
Type of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 phase squirrel cage motor
Type of construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
Protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP54

Compressor unit . . . . . . . . . . . . . . . . . . . . MV--GI100--3--3 . . . MV--GI100--4--3 . . . MV--GI120--4--3 . . . . MV--GI120--5.5--3

Compressor block . . . . . . . . . . . . . . . . . . . . IK100--GI--F06 . . . . IK100--GI--F06 . . . . IK120--GI--F06 . . . . . IK120--GI--F06

Deliveryb) . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 l/min . . . . . . . . . 125 l/min . . . . . . . . . 170 l/min . . . . . . . . . 215 l/min
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 cfm . . . . . . . . . . . . 4.4 cfm . . . . . . . . . . . 6 cfm . . . . . . . . . . . . . 7,6 cfm
Pressure setting, pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . according to order . . . . . . . . . . . . . . . . . . . .
Pressure setting, final pressure safety valve . . . . . . . . . . . . . . . . according to order . . . . . . . . . . . . . . . . . . . .
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . 70dB(A) . . . . . . . . . . 70dB(A) . . . . . . . . . . 70dB(A) . . . . . . . . . . 70dB(A)
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900 min --1 . . . . . . . . 1270 min --1 . . . . . . . 1200 min --1 . . . . . . . . 1470 min --1
Drive input . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,2 kW . . . . . . . . . . . 3,3 kW . . . . . . . . . . . 3,7 kW . . . . . . . . . . . 4,7 kW
Drive motor power . . . . . . . . . . . . . . . . . . . . 3 kW . . . . . . . . . . . . 4 kW . . . . . . . . . . . . . 4 kW . . . . . . . . . . . . . 5,5 kW
Weight, approx. . . . . . . . . . . . . . . . . . . . . . . 255 kg . . . . . . . . . . . 255 kg . . . . . . . . . . . 260 kg . . . . . . . . . . . . 260 kg

1.3.3. Booster compressor units for nitrogen up to 350 bar

Compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GIB 12.2--5,5--3

Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BK12.2--F07

Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nitrogen
Intake pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 to 11 barü
Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 -- 350 bar
Delivery with 5 bar intake pressure . . . . . . . . . . . . . . . . . . . . . . . . 200 l/min
....................................................... 7cfm
Delivery with 11 bar intake pressure . . . . . . . . . . . . . . . . . . . . . . . 475 l/min
....................................................... 17 cfm
Adjustment, final pressure safety valve . . . . . . . . . . . . . . . . . . . . max. 365 bar
Adjustment, final pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . bar
Sound level, lesser than . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 dB(A)
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250 min --1
Drive input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,5 kW
Drive motor power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5,5 kW
Weight, approx. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260 kg

Subject to change without prior notice

a) These values are valid only if the oil level of the compressor in normal position corresponds to the upper mark of the oil sight glass and may
not be exceeded.
b) Free air delivered at tank filling from 0 to 200 bar ± 5% or 300 bar ± 5% for 420 bar units.

A--11
 Instruction Manual • Industrial Compressor Units
TECHNICAL DATA (Cont.)

1.3.4. Compressor blocks

Compressor blocks, air

Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IK100--F07, mod.7

No. of stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
No. of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder bore 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 mm
Cylinder bore 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 mm
Cylinder bore 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Direction of rotation (viewing at flywheel) . . . . . . . . . . . . . . . . . . . counter--clockwise
Intermediate pressure 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . 3,5 ... 4 bar
Adjustment, Safety valve 1st. stage . . . . . . . . . . . . . . . . . . . . . . . 8 bar
Intermediate pressure 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ... 40 bar
Adjustment, Safety valve 2nd. stage . . . . . . . . . . . . . . . . . . . . . . . 60 bar
Compressor block oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 l
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to chapter 2. lubrication
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar

Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IK120--F07, mod.7

No. of stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
No. of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder bore 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 mm
Cylinder bore 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 mm
Cylinder bore 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Direction of rotation (viewing at flywheel) . . . . . . . . . . . . . . . . . . . counter--clockwise
Intermediate pressure 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ... 6,5 bar
Adjustment, Safety valve 1st. stage . . . . . . . . . . . . . . . . . . . . . . . 8 bar
Intermediate pressure 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ... 45 bar
Adjustment, Safety valve 2nd. stage . . . . . . . . . . . . . . . . . . . . . . . 60 bar
Compressor block oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 l
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to chapter 2. lubrication
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar

Compressor blocks, nitrogen

Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IK100--GI--F06, mod.6

No. of stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
No. of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder bore 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 mm
Cylinder bore 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 mm
Cylinder bore 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Direction of rotation (viewing at flywheel) . . . . . . . . . . . . . . . . . . . counter--clockwise
Intermediate pressure 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . 3,5 ...4 bar
Adjustment, Safety valve 1st. stage . . . . . . . . . . . . . . . . . . . . . . . 8 bar
Intermediate pressure 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ... 40 bar
Adjustment, Safety valve 2nd. stage . . . . . . . . . . . . . . . . . . . . . . . 60 bar
Compressor block oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 l
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to chapter 2. lubrication
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar

Subject to change without prior notice

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Instruction Manual • Industrial Compressor Units
Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IK120--GI--F06, mod.6
No. of stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
No. of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder bore 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 mm
Cylinder bore 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 mm
Cylinder bore 3rd stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Direction of rotation (viewing at flywheel) . . . . . . . . . . . . . . . . . . . counter--clockwise
Intermediate pressure 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ...6,5 bar
Adjustment, Safety valve 1st. stage . . . . . . . . . . . . . . . . . . . . . . . 8 bar
Intermediate pressure 2nd stage . . . . . . . . . . . . . . . . . . . . . . . . . . 38 ... 45 bar
Adjustment, Safety valve 2nd. stage . . . . . . . . . . . . . . . . . . . . . . . 60 bar
Compressor block oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 l
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to chapter 2. lubrication
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 bar

Compressor blocks, booster

Compressor block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BK12.2--F07, mod.7

No. of stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
No. of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cylinder bore 1st stage (left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/60 mm
Cylinder bore 1st stage (center) . . . . . . . . . . . . . . . . . . . . . . . . . . . 32/60 mm
Cylinder bore 2nd stage (right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15/60 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 mm
Drive input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max. 5,5 kW
Intermediate pressure 1st stage . . . . . . . . . . . . . . . . . . . . . . . . . . 40 ...78 bar
Adjustment, Safety valve 1st. stage . . . . . . . . . . . . . . . . . . . . . . . 80 bar
Direction of rotation (viewing at flywheel) . . . . . . . . . . . . . . . . . . . counter--clockwise
Compressor block oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 l
Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5 bar ± 1,5 bar
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . refer to chapter 2. lubrication

Subject to change without prior notice

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 Instruction Manual • Industrial Compressor Units

TECHNICAL DATA (Cont.)

1.3.5. Drivemotors

All motors:
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 phase squirrel cage motor
Type of construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
Protection class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IP55
Operating voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380--440 V, 50--60 Hz
Control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 V, 50--60 Hz

Drive motor 3 kW
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 kW
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,850 min --1
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 L
Drive motor 4 kW
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 kW
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,850 min --1
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 M
Drive motor 5.5 kW
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 kW
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,850 min --1
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 M

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Instruction Manual • Industrial Compressor Units

TECHNICAL DATA (Cont.)

1.3.6. High pressure filter assemblies

General
Service pressure, standard 225/330 bar
Service pressure, max. 350 bar
Flow rate P41 max. 450 l/min
P61 max. 600 l/min
Regenerated volume of air, referenced to 1 bar abs, 20°C, P41 1,500 m3; with CO cartridge 1100 m3
flow rate 200 l/min against p = 200 bar (2,900 psi) P61 2,200 m3; with CO cartridge 1,700 m3
Operating temperature range +5 ... +50°C
Residual water contents < 10 mg/m3
Residual oil vapour contents < 0.1 mg/m3
Residual CO contents < 5 ppmV
Residual CO2 contents < 500 ppmV
Pressure dew point --20 °C, 3 mg/m3 at 300 bar

Oil and water separator:

External diameter 95 mm
Length 306 mm
Water volume 0.54 l
Weight 9 kg
Tube connections (intake and outlet) G 1/4”
Max. no. of load cycles see pressure vessel documentation in chapter F

Purifier:
External diameter 100 mm
Length P41: 620 mm; P61: 835 mm
Water volume P41: 2.1 l; P61: 2.85 l
Weight P41: 8 kg; P61: 10.6 kg
Tube connections (intake and outlet) G 3/8”

Electrical specifications
Assemblies used 1 SECURUS indicator
1 Filter housing with pressure resistant conductor bushing
1 Sensor inside the SECURUS cartridge
Operating voltages of the SECURUS indicator unit 190 ... 250 V, 50 ... 60 Hz or
110 ... 127 V, 50 ... 60 Hz or
12 ... 24 V DC
Power consumption of the SECURUS indicator unit AC version 3 VA
DC version 2 W
Contact components 3 N/O contacts for preliminary warning and for compressor
shut--off
Contacts switching current 6 Amps/250 Volts
Protection class for SECURUS indicator unit IP65
Dimensions of the SECURUS indicator unit 120 x 120 x 55 mm (L x W x H)
Mains connections and switching outputs via terminals

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 Instruction Manual • Industrial Compressor Units

Cooling air exit

Cooling
air input

Fig. 8 Dimensions (in mm)

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 Instruction Manual • Industrial Compressor Units

2. LUBRICATION SYSTEM

2.1. FUNCTIONAL DESCRIPTION

3
The compressor is provided with a forced--feed lubrication
2
(Fig. 9). The oil pressure is produced by a low reving gear pump
(1, Fig. 9). The oil pressure is approximately 5 bar. 4
1
This oil pump will operate in the correct
sense of rotation, only. Otherwise, no oil
pressure will be built up resulting in damage
of the compressor block. 5

The oil pump (1, Fig. 9) is coupled to and driven by the crank-
shaft. It pumps oil from the oil sump (5, Fig. 9) through the oil fine
filter (Fig.8, Pos.2) and a minimum pressure valve (3, Fig. 9) to
the 3rd stage cylinder. The oil is then distributed by the guide 1 Oil pump
2 Oil filter
piston (4, Fig. 9) of the 3rd stage and lubricates all moving parts 3 Min. pressure valve
of the compressor block. 4 Guide piston
The minimum pressure valve allows for oil pressure indication Fig. 9 Lube oil system
at a pressure gauge and electronic oil pressure monitoring.
(Optional)

2.2. TYPE OF OIL

2.2.1. Changing the oil type
For proper care and maintenance of the compressor, using the
correct oil is of vital importance. Depending on the application
To avoid severe damage to the compressor
of the compressor the requirements placed on the oil are: unit when changing the oil type, follow the
• low deposits measures given in section D 2.

• no carbonizing effect, especially in the valves

• good anti--corrosive properties
• emulsification of the condensate in the crankcase
2.3. OIL PRESSURE MONITORING
• for breathing air application, also physiological and toxico-
logical suitability.
Oil pressure monitoring is performed by means of a pressure
Due to the thermal load on the compressor only high quality oil switch (1, Fig. 10). See chapter A 11.3.7.
should be used. You are recommended to restrict oils to those
which have been approved by us and are listed in our lubricat-
ing oil list.
1
The current oil list is provided in section F .
Order this list regularly through the BAUER
Technical Service Department.

For operation under difficult conditions such as continuous run-

ning and/or high ambient temperatures we recommend the use
of BAUER high performance compressor oils, only, according
to the oil list. These oils are tested in our compressors 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 capable of pre--heating the
crankcase up to +5 °C (41 °F).

All our compressor units are delivered ex--

works with lubricating oil N28355.
MV-- I/02/07

For operation under less severe conditions we can also recom-

mend 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 lower tempera- Fig. 10 Oil pressure switch
tures.
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 Instruction Manual • Industrial Compressor Units

3. INTAKE FILTER
1
8
3.1. Compressor units for air applications
A dry micronic filter is used to filter intake air, see Fig. 11. It is
fitted with a replaceable filter cartridge (1, Fig. 11).

1
6
5

3
4
Fig. 11 Intake filter

3.2. Compressor units for gas applications

3.2.1. Gas intake system Fig. 12 Intakesystem

The gas compressor draws the medium to be compressed from
a line system, a gas balloon, or from gas bottles.
In order for the compressor to work satisfactorily, it is essential
to supply the medium at a constant pressure. Therefore, a pres- 7
sure reducer in the intake line is necessary if the supply pres-
sure is above atmospheric pressure or fluctuating (e.g. when
6
emptying gas bottles). For the maximum allowable intake pres-
sure refer to the Technical Data section, 1.3. An intake expan-
sion tank between pressure reducer and compressor is also
necessary. It compensates for the pressure surges caused by
the piston of the 1st stage.
5
For the designations in the following description refer to this flow
diagram in section F. 1
2
[Link]. Intake system
3
The medium flows through the gas inlet connection A (8,
Fig. 10), through the in--line filter A7 (3, Fig. 10) and through the 4
solenoid--non return valve Y5 (5, Fig. 10) into the intake expan-
sion tank (2, Fig. 10).
Pneumatic monitoring of the intake pressure is carried out by Fig. 13 Intake pressure reducing
means of a safety valve U6 (4, Fig. 10). In addition, the intake
pressure is monitored by pressure sensors F12.1 F12.2 (6, 7,
3.2.2. Intake shut--off valve
Fig. 10) and by pressure gauge P19 (1, Fig. 10) as well.
An electromagnetic shut--off valve (Y5) is provided in the gas in-
[Link]. Intake pressure reducing take line before the intake filter. It is open during operation and
is closed when the compressor is shut down, preventing gas
The medium flows through gas inlet connection A, over the in-- loss from the pipe system.
line filter A7 (1, Fig. 13) to pressure reducer J1 (4) and sole-
noid--non return valve Y5 (5) into the compressor block. The 3.2.3. Venting the intake line
MV-- I/02/07

pressure reducer reduces the supply pressure to the correct in-

take pressure. For the max. allowable intake pressure refer to Compressor shuts off automatically when the intake pressure
the Technical Data section, 1.3. exceeds the adjusted values on the intake pressure switches.
If the max. allowable intake pressure has been exceeded, it is
Supply pressure is secured by safety valve U12 (2) and is indi- necessary to vent the intake line before restarting the compres-
cated at pressure gauge P23 (3).The intake pressure is moni- sor. Vent the intake line with the help of the venting valve (6,
tored by the pressure sensors F11.1 and F12.2 (7) and is indi- Fig. 13) and readjust the intake pressure with the help of the
cated by pressure gauge P19. pressure reducer (4).
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 Instruction Manual • Industrial Compressor Units

4. INTERMEDIATE SEPARATOR • DIN EN 12021

• STANAG 1079 MW
An intermediate separator is mounted on the 2nd stage. This
separator is designed to remove water and oil accumulating • British Standard 4001
due to cooling the medium down after the compression pro- • US CGA Spec. G.7.1
cess. Separation is achieved by means of centrifugal action
• Canada CSA Standard Z 180.1
provided by a vortex plate.
• Australian Army Standard 5017
It is impossible to exceed the cartridge utilization time since a
4.1. INTERMEDIATE SEPARATOR AFTER 1ST. preliminary warning message indicates the approaching satu-
STAGE (OPTIONAL) ration of the cartridge. Depending on the size of compressor
used, the prewarning message will appear between 1 and 7
For severe environmental conditions, especially high tempera-
hours prior to cartridge saturation. If the cartridge is not replaced
tures and humidity, an additional separator after the 1st stage
after indication of the preliminary warning message, the
can be provided. Refer to flow diagram in chapter F. This sepa-
SECURUS filter system will automatically shut down the com-
rator is similar to the separators as described above.
pressor as soon as the cartridge has been exhausted. The
compressor cannot be turned on as long as no cartridge has
5. FINAL SEPARATOR / FILTER SYSTEM been inserted.
The SECURUS filter system operates in the FAIL--SAFE mode:
5.1. PURPOSE AND SHORT DESCRIPTION the compressor will be shut down if the circuit between the con-
trol unit and the sensor is interrupted.
All Mini--Verticus compressor units can be fitted with filter sys-
tem P41 or with filter system P61. By both filter systems is the As soon as the preliminary warning mes-
mode of operation the same. The difference is a higher filter car- sage appears or, at the latest, after the SE-
tridge life time of the P61 system. CURUS monitoring unit has shut down the
system, the cartridges of all filters within the
Filter system P41/P61 (Fig. 14) consists of: systems must be changed according to
• Separator with final pressure safety valve D--5.2.2.
• Non--return valve between separator and purifier
• High pressure purifier
• SECURUS sensor heada)
• Venting valve with pressure gauge
• Pressure maintaining/non--return valve
The system is integrated into the compressor unit, i.e. the filters
and other components are mounted on the frame, the pressure
maintaining valve is situated at the filling panel. If the
SECURUS monitoring system is provided, the compressed air
4
regeneration process and the degree of dryness of the air are 2
continuously monitored during the regeneration process by
measuring the cartridge saturation within the filter cartridge.
5.2. FUNCTION 3
5
5.2.1. Securus monitoring unit 6
Unlike other filter systems the SECURUS filter system ensures
continuous monitoring of the compressed air purification pa- 1
rameters while the air is still in the regeneration process. The in-
fluences of
• ambient temperature
• ambient humidity
• temperatures of the compressor and regeneration system
are taken into consideration.
The exchangeable SECURUS cartridges are designed for
1 Separator
• drying of air 2 Final pressure Safety valve
• adsorption of aromatic components (aerosols) 3 Non--return valve and pressure gauge
MV-- I/02/07

• partial conversion of CO into CO2 4 Purifier

5 Filter cartridge
• partial adsorption of CO2 6 Non--return valve
The quality of the breathing air produced conforms to the na-
tional and international Fig. 14 Filtersystem

a) Optional

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 Instruction Manual • Industrial Compressor Units
5.2.2. Final Separator If it is possible to regulate the operation of the unit to such a de-
gree as to achieve four load cycles per hour, in our opinion this
The air leaving the final stage is cooled in the after--cooler to would be an optimum between usage and actual life.
approx.10 to 15 °C (18--27 °F) above ambient temperature and
then enters the oil and water separator (Fig. 14). The oil and 5.2.3. Purifier
water separator is part of the breathing air purification system.
The oil and water separator is filtering liquid oil and water par- The filter housing (4, Fig. 14) consists of an anodized alumin-
ticles from the compressed air. ium alloy pipe with 100 mm external diameter. Both ends are
provided with fine threads on the inside.
The oil and water separator is subject to dy-
namic load. It is designed to withstand a cer- The screw--in filter bottom contains inlet and outlet. For connec-
tain no. of load cycles. (1 load cycle = 1 pres- tor threads see specifications, chapter 1.
surization, 1 depressurization.) at the speci- The upper screw connection contains a pressure resistant
fied pressure range. The oil and water sepa- bushing for the electrical connections. The coaxial cable which
rator must be replaced when the maximum permissible no.
leads from the sensor to the control unit is connected to the BNC
of load cycles has been reached. Refer to the pressure ves-
connector located there.
sel operating manual delivered with the unit.
For description of the electrical operation refer to para. 5.2.5.

5.2.4. Filter cartridges

The maximum recommended amount of four load cycles per
hour should not be exceeded. If it is possible to regulate the op- Different cartridges are available depending on the required air
eration of the unit to such a degree as to achieve four load quality. See specifications, and parts list. (5, Fig. 14) and the fol-
cycles per hour, in our opinion this would be an optimum be- lowing table show the internal construction of the filter car-
tween usage and actual life. tridges.

Filter cartridges

Part no. Filter Cartridge contents a) SECURUS Length Elimination

system sensor mm
062565 P41 MS/MS/AC/MS ------ 503 H2O/Oil
061686 P41 MS/MS/AC/MS F 513 H2O/Oil
061687 P41 MS/MS/AC/MS/HP F 513 H2O/Oil/CO
058826 P61 MS/MS/AC/MS ------ 705 H2O/Oil
060036 P61 MS/MS/AC/MS F 705 H2O/Oil
060037 P61 MS/MS/AC/MS/HP F 705 H2O/Oil/CO

a) MS = Molecular Sieve, AC = Activated Charcoal, HP = Hopcalite

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Instruction Manual • Industrial Compressor Units
5.2.5. SECURUS indicator unit

Function
The SECURUS indicator unit (Fig. 10) receives signals con- The four operating conditions of the SECURUS system are re-
cerning the condition of the drying agent inside the filter car- ported by three relays (normally open contacts). Simulta-
tridge from the attached sensors and furnishes appropriate neously with the closing of the relay contacts, built--in lumines-
control signals whenever the preset threshold values have cent diodes illuminate: (Refer to Fig. 10)
been reached.

Conditions of Cartridge conditions and Plant conditions

Securus--System
1. Continuous green Unit in operation
2. Flashing yellow Cartridge change pre--warining
3. Flashing red Compressor shut--down because cartridge is used up
4. Continuous red Compressor shut--down because of missing cartridge or cable failure

If yellow diode is flashing, the green diode will continue to illumi-

nate because unit is still operational with the yellow light on. If
no lamp is on, which means that no relay contact is closed, the
SECURUS indicator unit is receiving no operating voltage or the
electronics within the unit have failed.
After applying operating voltage to the unit it will take about 0.5
seconds to close the respective relay contact and to light the ap-
plicable diode. During this time the status of the cartridge is be-
ing checked.

1
2
3

Fig. 15 Securus indicator unit

1 Green indicating light

2 Yellow warning light
3 Red warning light

5.2.6. Electrical connection

See diagram in chapter F.

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 Instruction Manual • Industrial Compressor Units

6. PRESSURE MAINTAINING / NON--RETURN 7. SAFETY VALVES

VALVE
All compressor stages are protected by safety valves. The ad-
A pressure maintaining and a non--return valve (1, Fig. 10) are
justment of the safety valves is as follows:
provided downstream of the filter system. Refer to flow diagram
in section F. The combined pressure maintaining/non--return
Compressor 1st stage 2nd stage 3rd stage
valve is mounted at the manifold block (2, Fig. 10) on the rear
block
side of the instrument panel.
IK100 9 bar 60 bar 365 bar
IK120 9 bar 60 bar 365 bar
BK12.2 80 bar 365 bar ------

The safety valve for protection of the last stage is adjusted ac-
1 cording to order, see 1.3., Technical Data, but maximally to the
values given above.

Fig. 16 Pressure Maintaining / Non--return valve

The pressure maintaining valve ensures that pressure is built

up in the filters even from the start of delivery, thus achieving a
constant, optimum filtration. It will also guarantee proper work-
ing conditions for the final stage cylinder.
The adjustment of the pressure maintaining valve is
approx. 150 bar.
An additional non--return valve is mounted after the oil and wa-
ter separator -- flanged directly to the filter head. It prevents al-
ready filtered medium from flowing back from the downstream
filters when draining condensate from the oil and water separa-
tor.
MV-- I/02/07

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 Instruction Manual • Industrial Compressor Units

8. PRESSURE GAUGES 9. VALVES

The intermediate pressure, the operating pressure and the oil

pressure of the compressor can be monitored by means of
pressure gauges in the instrument panel. The valve heads of the individual stages form the top part of the
cylinders. The intake and pressure valves are fitted inside the
The pressure in the final compressor stage can be monitored valve heads.
by the final pressure gauge. For indicating the intermediate
pressure and the oil pressure can be attached additional pres-
sure gauges in the instrument panel. They are optional extras Note that the valves are operated by the flow of the medium. On
for all MV3--I units. the suction stroke, the intake valves open and the medium flows
into the cylinders. At the start of the compression stroke the in-
take valve closes and the medium opens the pressure valve,
8.1. INTERMEDIATE PRESSURE GAUGE (Optional)
Fig. 18.
The correct values are given in chapter A--1.3., Technical Data.

8.2. OIL PRESSURE GAUGE (Optional)

Correct oil pressure indication should read 5 bar.

If not, check the lube oil circuit or adjust the oil pressure. See
chapter D--2.

8.3. FINAL PRESSURE GAUGE

The final pressure gauge shows a mark indicating the maxi-

mum operating pressure.

final pressure mark

Intake Pressure

Fig. 18 Valve operation

Fig. 17 Final pressure gauge

MV-- I/02/07

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 Instruction Manual • Industrial Compressor Units

10. AUTOMATIC CONDENSATE DRAIN

The automatic condensate drain unit (Fig. 10 and Fig. 20) 5

4
drains the intermediate separator and the oil and water separa-
tor after the last stage every 15 minutes during operation. In
addition, the automatic condensate drain is designed to drain
these filters after shut--down of the compressor unit, and to un-
load the compressor during the starting phase.
The automatic condensate drain system operates electrically 3
and comprises the following main items:
• Two condensate drain valves (1, Fig. 10 and Fig. 20), one
for the intermediate separator(5, Fig. 10) after the 2nd stage
and one for the oil and water separator(5, Fig. 20) after the 2
last stage. The condensate drain valves are open current-
less.
• Two solenoid valve (2, Fig. 10 and 3, Fig. 20) mounted on
top of the condensate drain valve. 1 6
• A condensate collecting tank.
• Two electrical timers. The timers are mounted in the com-
Fig. 19 Condensate drain, 2nd stage
pressor control box.
1 Condensate drain
2 Lift magnet
10.1. CONDENSATE COLLECTOR 3 Connector
4 Condensate output
The condensate drain valves are connected to a collecting tank 5 Intermediate separator
at the front of the unit. A filter/silencer is mounted on top of the 6 Drain tap
tank. It separates the oil particles from the air escaping together
with the condensate from the filters. The condensate collecting
tank should be emptied at regular intervals. For this purpose the
tank is connected to the collecting hoses (4, Fig. 10 and Fig. 20)
with a quick fitting and can be removed easily.

10.2. ELECTRICAL CONNECTION 5

For electrical connection of the automatic condensate drain
system refer to the schematic diagrams in section F. 4

Fig. 20 Condensate drain, 3rd stage

1 Condensate drain
2 Connector
3 Lift magnet
4 Condensat output
5 Final separator
MV-- I/02/07

6 Drain tap

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 Instruction Manual • Industrial Compressor Units

11. ELECTRICAL SYSTEM

11.1. GENERAL • ON/OFF-- button (S1/S2) with operation signal lamp

(H1)
This section describes the standard electric control and elec- • main switch S0
tronic monitoring system of the compressor unit. The amount of
built--in components varies depending on order. • hour meter P1
• oil pressure switch F13
For schematic diagrams, see section F.
• oil pressure-- warning light H2
To start the electric motor and enable the functioning of the con-
trols as well as the monitors, the following components are es-
The electrical equipment of the compressor unit consists of: sential:

• drive motor M1 • main switch Q1 and

• electric control system, containing: • main fuse, both to be installed by the customer.

• final pressure switch F16

11.2. DRIVE MOTOR
• switch box containing air break contactor K1 or star--
delta contactor K1--K3 with time relay K4 for drive motor The compressor unit is driven by an electric motor by means of
V--belts.
• timer K10 for automatic condensate drain
Except for external cleaning, the drive motor requires no servic-
• service switch S3
ing. The motor bearings may need lubricating, depending on
• oil pressure monitoring relay K20 the model. Please observe the instructions written on the motor.
• cycle counter P14 11.3. ELECTRICAL CONTROL

1 2 3 4 5
MV-- I/02/07

Fig. 21 Compressor control

1 Main switch S0
2 Oil pressure-- warning light H2
3 OFF-- button S1
4 ON-- buton S2
5 Hour meter P1
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 Instruction Manual • Industrial Compressor Units
11.3.1. Semi--automatic compressor control 11.3.4. Cycle counter
Unit switches off automatically when the final pressure is The cycle counter is mounted in the switch box and labelled
reached in the pressure system connected to the compressor. P14 (1, Fig. 10). It counts the electrical control pulses for the au-
Restart the unit manually by pressing oparation button S2 on tomatic condensate drain unit and hence the accumulated
the control and monitrong unit. amount of load cycles of the installed oil and water separator af-
11.3.2. Fully automatic compressor control ter the last compressor stage.
Refer to chapter 5.
Unit switches off automatically when the final pressure is
reached in the pressure system connected to the compressor.
Restart of the unit is performed automatically if pressure drops
to the lower set value. Operation switch S2 and main switch S0
must be switched on.
11.3.3. Final pressure switch
Switching on and/or off of the compressor unit is controlled by
pressure switch F16.
With the semi--automatic compressor con-
trol, only the upper switching point is adju-
stable.

The upper threshold value is adjustable as follows:

OFF max. = 400 bara) OFF min. = 100 bar

1 1 2 3 3 4 5 5
Fig. 24 Monitoring instruments
1 Cycle counter P14
2 Service switch S3
2 3 Time relay for oil pressure monitoring K20
4 Auxiliary relays K17, K18
5 Timer for automatic condensate drain unit K10

11.3.5. Service switch

1 Adjustment screw, switch--off
pressure The switch is labelled S3 (2, Fig. 10). In position “0” the com-
2 Electric connector pressor operates normally, i.e. the unit is switched OFF auto-
Fig. 22 Final pressure switch for semi--automatic opera- matically by the pressure switch. In position “1” the pressure
tion switch F16 is overridden.

With the fully automatic compressor control, upper and lower- Use this switch position for servicing purpo-
threshold values are adjustable as follows: ses only, e.g. checking the blow--off pressure
of the safety valves. The unit will not shut off
OFF max. = 500 bar OFF min. = 30 bar
automatically when switch is in this position.
Max. hystereses in upper range = 300 bar
Min. hysteresis in lower range = 23 bar
Min. hystereseis in upper range = 52,6 bar

1
2

1 Adjust. screw, switch--off pres-

sure
2 Adjust. screw, hysteresis
3 Switch--off pressure indicator
4 Hysteresis indicator
Fig. 23 Final pressure switch for automatic operation

a) = Maximum possible operating pressure; for maximum allowable operating pressure, refer to Technical Data,A1. 3.
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Instruction Manual • Industrial Compressor Units
11.3.6. Timer for automatic condensate drain unit 12. COMPRESSOR DRIVE SYSTEM
Timer K10 (5, Fig. 10) controls the automatic condensate drain
unit. For description refer to chapter A.10. As standard, the compressor is driven by the drive motor
K10 is an industrial time relay with one change--over contact. through V--belts. Direction of rotation is left, looking at the cool-
The plus-- and intervaltime for the control unit of the automatic ing fan, i.e. clockwise standing in front of the unit. Observe ar-
condensate drain will adjusted with the two adjuster t1 and t2. row on compressor.
The sliding switch is adjusted to give a puls first. At factory the V--belt tension is adjusted automatically by the weight of the
adjuster t1 is set of 15 min. and t2 is set of 6 sec. to drain the motor. The motor is mounted on a hinged motor plate.
condensate.
13. COOLING SYSTEM
11.3.7. Oil pressure monitoring
The oil pressure monitoring ensures that the compressor is op- The cylinders of the compressor block, the intermediate coolers
erated with the correct oil pressure. Missing or low oil pressure and the after--cooler are air--cooled. For this purpose, the com-
causes the compressor to be switched off and the red warning pressor is equipped with a fanwheel which draws the cooling air
lamp (3, Fig. 21) at the instrument panel to be illuminated. At through the fanwheel cover from the surroundings. The fan-
start, the missing oil pressure is overriden for 40 seconds. wheel is driven by the drive motor V--belt and is also used as the
flywheel.
11.3.8. Control voltage, transformer
The cooling air outlet can be selected by removing and re--
The complete control system including all the unit’s contactors
mounting the cover plate as required.
and solenoid valves are operated with a control voltage of 24 V
AC. This control voltage is generated by a transformer. For installation of the unit ensure sufficient cooling air supply.
The primary voltage is taken from 2 phases of a three--phase Refer to section B.
network. The transformer has a terminal strip on the primary For maximum ambient temperature, see Technical Data, chap-
side with connection possibilities for different supply voltages. ter 1.3.
The control system can therefore be adjusted quickly to the
above--mentioned voltages. Only the power unit (contactor and
overload relay) has to be individually adjusted to the motor cur-
rent.

Technical data
Power 50 VA
Primary voltage: 200, 208, 220 V 50/60 Hz
400, 415, 440 V 50/60 Hz
Secondary voltage: 24 V ± 10%

11.4. ELECTRONIC FILTER MONITORING UNIT

Refer to chapter A.5.

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 Instruction Manual • Industrial Compressor Units

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Instruction Manual • Industrial Compressor Units

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 Instruction Manual • Industrial Compressor Units

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 Instruction Manual • Industrial Compressor Units

B. INSTALLATION, OPERATION
1. INSTALLATION OF THE COMPRESSOR Air intake and outlet openings
UNIT Power Room volume / Height difference
(kW)
V = 50 m3
The compressor frame is isolated with regard to the base frame ∆h = 2 m
of the compressor unit by anti--vibration mounts and thus a ma-
chine base or special means of securing the compressor are Intake Outlet
not necessary. 2.2 -- 3 0.24 m2 0.20 m2

For installation observe the following: 4 0.30 m2 0.25 m2

5.5 0.42 m2 0.35 m2
Power Room volume / Height difference
1.1. COMPRESSOR ROOM CONDITIONS
(kW)
V = 100 m3
-- The compressor room must be clean, dust--free, dry and as ∆h = 3 m
cool as possible. Intake Outlet
-- Avoid direct exposure to sunlight; if possible, choose north 2.2 -- 3 0.12 m2 0.10 m2
side of building. 4 0.12 m2 0.10 m2
-- Additional heat producing units or line systems should not 5.5 0.24 m2 0.20 m2
be installed in the same room or should be well isolated. Power Room volume / Height difference
(kW)
-- The floor must be capable of taking the load of the system V = 200 m3
weight. ∆h = 4 m
Intake Outlet
-- Locate the unit as level as possible; For the max. allowable
inclination refer to Technical Data in section A. 2.2 -- 3 ---- ----
4 ---- ----
-- Ensure adequate ventilation. Remember: room tempera-
ture = cooling air temperature ! Min. = +5 °C, max. = +45 °C. 5.5 0.12 m2 0.10 m2

For further information on the installation of

1.2. LOCATING THE UNIT air cooled compressors, see our Installation
Manual which can be obtained from BAUER
-- If possible install unit in such a manner that the compressor Customer Services, P.O. 710260, D--81452
fan can draw fresh air from outside, for instance through an Munich
opening in the wall as low as possible.

-- Ensure that an adequate exhaust air opening is provided,

2. ELECTRICAL INSTALLATION
as high as possible.

-- Locate compressor as close to the air intake opening as For installation of electrical equipment observe the following:
possible. -- In section F. you will find the standard schematic diagrams
-- Locate unit so as to absolutely avoid intake of warm or hot valid for the respective compressor unit. To connect the
cooling air. compressor control system, use only the diagram contained
in the control box of the unit, because any deviations from
-- Observe the minimum distances as listed below. the standard diagrams according to order are marked there.

Minimum distance from wall,rear side: 0.1 m -- Observe regulations of local electricity supply company.
-- Connection should be carried out by an expert only.
Minimum distance from wall, intake side: 0.5 m
-- Ensure correct installation of protective conductor.
See also unit drawing in section F.
-- Check conformity of motor and control device tension and
frequency with those of electric network.
1.3. NATURAL VENTILATION
-- The necessary cabling, main fuse and a main switch (load--
break switch) are to be provided by the customer. Ensure
Natural ventilation is the most simple and commonly used. It is that the main switch is for one unit only and is clearly and im-
created by convection and is sufficient if no thermal overload is mediately recognizable. Fusing must be according to the
expected, i.e. for units with small drive motors, for intermittent electricity supply company’s regulations. For units not con-
operation or in moderate climates this is the ideal method of nected through a plug, but permanently installed, a main
cooling the compressor unit.
MV-- I/02/07

switch must be provided which has a contact gap of 3 mm

The inlet and outlet air openings are dependent on: minimum on each pole.
-- Adjust motor protection, thermal overload relay. For start
-- the power of the electric motor
over contactor adjust to motor amperage rating. For start via
-- the height difference between air intake and outlet openings star--delta contactor adjust to motor amperage rating x 0.58.
For example: motor amperage rating = 10 Amp.:
-- the air volume of the compressor room. Adjust relay to 10 x 0.58 = 5.8 Amp.
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 Instruction Manual • Industrial Compressor Units
-- Fuse motor correctly (see following table; use slow--blow -- Prior to first operation or operation subsequent to mainte-
fuses, only). nance or repairwork, turn the compressor manually using
the flywheel to ensure that all parts are turning free. Check
FUSE TABLE that all fastening bolts and threaded pipes are secure and
sealed, if necessary tighten them to the correct torque
Motor type V 125 220 240 400 415 440 500 600 660
value.
3--phase, 3 kW A 25 16 16 10 10 10 10 6 4
(star--delta)
3--phase, 3 kW A 35 20 20 16 16 10 10 6 6 -- Open the outlet valve, this must be open during operation.
(direct starting) Close only for servicing the compressor to avoid gas escap-
3--phase, 4 kW A 35 20 20 10 ---- 10 10 10 6 ing from connected receivers.
(star--delta)
3--phase, 4 kW A 35 25 25 16 ---- 16 16 10 10
(direct starting) -- Every time the unit is started up check all systems for
3--phase, 5.5 A 50 25 25 16 16 16 10 10 10 proper operation. If any malfunction is observed stop unit
kW immediately and find the cause of the fault or call the ser-
(star--delta)
vice department.
3--phase, 5.5 A 63 35 35 20 20 20 16 16 16
kW
(direct starting) -- Prior to first operation or operation subsequent to repair
work operate unit for at least 10 minutes with open conden-
sate valves (pressureless) to ensure proper lubrication of all
3. TAKING INTO OPERATION parts before pressure is built up. To keep drain valves open,
loosen screw (1, Fig. 28) and pull plug (2, Fig. 25) from sole-
3.1. PREPARATION FOR OPERATION noid valve (3, Fig. 26) of all condensate drain valves (4,
All compressor units are tested prior to deliv- Fig. 27).
ery to the customer, so after correct installa-
tion of the unit there should be no problem
putting it into operation, observing the fol-
lowing points:

-- Prior to first operation read Instruction Manual carefully.

Make sure that all persons handling the compressor and the
filling station are familiar with the function of all controls and
monitors. Observe the WARNINGs in chapter C--1.1.
-- Depending on the model range, some compressor units are
delivered without oil in the crankcase. In this case, the first
1
filling quantity is delivered separately in the consignment.
Prior to first operation fill with oil according to chapter D--2.
After taking unit into operation after a standstill period of 2
2
years or more change compressor oil. When using a min-
eral oil change oil after one year.
-- Prior to each operation check the oil level according to
chapter D--2. and determine whether maintenance is nec-
essary in accordance with chapter D--1.2.

The oil pump will operate in the correct sense

3
of rotation, only. Otherwise, no oil pressure
will be built up resulting in damage of the
compressor block.

-- Immediately after switching on the system for the first time

check the direction of rotation of the motor for compliance 4
with the arrow on the unit. If motor turns in the wrong direc-
tion, the phases are not connected properly. Shut down unit Fig. 28 Lift magnet connector
immediately and interchange two of the three phase leads
in the switch box. Never change leads at the motor terminal
board.

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Instruction Manual • Industrial Compressor Units

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 Instruction Manual • Industrial Compressor Units

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 Instruction Manual • Industrial Compressor Units

C. OPERATION 1.2. IDENTIFYING THE SAFETY NOTICES

Important instructions concerning the endangerment of per-

sonnel, technical safety and operating safety will be specially
1. SAFETY MEASURES emphasized by placing the following signs before the instruc-
tions.

1.1. NOTES AND WARNING SIGNS This notice is used with maintenance
WARNING work and operating procedures and must
Notes and warning signs displayed on compressors according be adhered to exactly in order to avoid
to model, application or equipment. endangering personnel.

WARNING This notice must be complied with in order to

avoid damage to or destruction of the machine or
Hot surfaces, do not touch! its equipment.

Danger of burning by touching cylinders, cyl-

inder heads and pressure lines of individual
compressor stages. This notice advises of technical requirements
which the operator must take particular note of.
WARNING

High voltage! 1.3. FUNDAMENTAL SAFETY NOTICES

Life threatening danger of electric shock. 1.3.1. Authorized use

Maintenance work on electric units or operat- • The machine / unit is built according to state of the art
ing equipment may only be carried out by a technology and established safety technical regulations.
qualified electrician or by a person instructed Nevertheless, its use can cause danger to life and limb of
and supervised by a qualified electrician ac- the operator or third parties or damage to the machine and
cording to electrical regulations. other equipment.
• Operate the machine / unit only in technically perfect condi-
WARNING tion in accordance with regulations and safety and danger
notices detailed in the instruction manual! In particular, im-
Automatic compressor control, unit may mediately correct faults (or have them corrected) which can
start--up without warning! impair safety!
• The machine / unit is exclusively for the compression of me-
Before carrying out maintenance and repair diums (air/gas) specified in section A., chapter 1.3. “Techni-
work, switch off at the main switch or discon- cal data”. Any other medium or use outside that specified is
nect from the mains and ensure unit will not not authorized. The manufacturer / supplier is not liable for
restart. damage resulting from this. The user alone is responsible
for this risk. Authorization for use is also under the condition
that the instruction manual is complied with and inspection
MANDATORY and maintenance requirements are enforced.
Instructions must be read by persons operat- 1.3.2. Organizational measures
ing the machinery!
• Keep the instruction manual to hand near the machine / unit
The instruction manual supplied and all other at all times in the relevant holder.
applicable instructions, regulations etc. must • In addition to the instruction manual, observe and comply
be read and understood by operating per- with universally valid legal and other obligatory regulations
sonnel before using the machine. regarding accident prevention and environment protection.
See chapter 1.4. This can involve, for example, contact with
hazardous substances or the provision / wearing of per-
MANDATORY
sonal protective equipment.
Hearing protectors must be worn! • In addition to the instruction manual, provide supplementary
instructions for supervision and monitoring duties taking
Hearing protectors must be worn when work- into consideration exceptional factors e.g. with regard to or-
ing on a machine which is running. ganization of work, production, personnel employed.
• Personnel engaged to operate the machine must have read
MV-- I/02/07

NOTE the instruction manual before beginning work, especially

the safety notices chapter. When work is already underway
Ensure correct direction of rotation! it is too late. This is particularly relevant for temporary per-
sonnel, e.g. maintenance personnel.
When switching on the machine, check the • At the very least, supervise temporary personnel’s work in
arrow to ensure correct direction of rotation of accordance with the instruction manual, taking into account
the drive motor. safety and danger factors.
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 Instruction Manual • Industrial Compressor Units
• Personnel may not wear long hair loose, loose clothing or • Meet all requirements demanding that the machine / unit is
jewellery, including rings. There is a danger of injury only operated in safe and good working order. Only operate
through, for example, these getting caught or being pulled the machine if all protective and safety equipment, e.g. all
into the equipment. detachable protective equipment, emergency shut--down
devices, soundproofing is provided and in good working or-
• As far as necessary or according to regulations, use per-
der.
sonal protective equipment.
• At least once every day, check the machine / unit externally
• Observe all safety and danger notices on the machine / unit.
for damage and faults. Inform the department / person re-
• Keep all safety and danger notices on the machine / unit sponsible immediately if anything is not as is should be (in-
complete and in readable condition. cluding operation). If necessary, shut the machine down im-
mediately and make it safe.
• If there are any modifications to the machine / unit or operat-
ing conditions which may affect safety, stop the machine / • If there are any malfunctions, shut the machine / unit down
unit immediately and inform the department / person re- immediately and make it safe. Correct faults immediately (or
sponsible of the fault. have them corrected).
• No modifications may be made to the machine / unit which • Observe switching on and off processes and monitoring in-
could impair safety without first obtaining permission from dications according to the instruction manual.
the suppliers. This is also the case with regard to installation • Before switching on / starting up the machine / unit, ensure
and adjustment of safety devices and valves as well as that no one can be put at risk through running the machine
welding of piping and reservoirs. / unit.
• Spare parts must always comply with the technical require- • Carry out the setting, maintenance and inspection pro-
ments specified by the manufacturer. This is always guar- cesses at the intervals specified in the instruction manual,
anteed with original spare parts. including replacement of parts / equipment. This work may
• Do not carry out programme changes (software) to the pro- only be carried out by qualified personnel.
grammable control system. • Before carrying out any exceptional work or repairwork, op-
• Piping must be thoroughly checked (pressure and visual in- erating personnel should be informed. Call the supervisor.
spection) by the operator at appropriate time intervals, even • For all work concerning operation, change in production,
if no safety related faults have been noticed. conversion or regulating of the machine / unit and its safety
• Intervals stipulated or given in the instruction manual for re- measures such as inspection, maintenance and repair-
curring checks / inspections must be adhered to. work, observe the switching on and off processes in the
instruction manual and the notices for maintenance work.
• It is absolutely essential that the workplace is appropriately
equipped for maintenance measures. • Clear and make the maintenance area safe as far as neces-
sary.
• Make sure location and operation of fire extinguishers is
• If the machine / unit is completely switched off for mainte-
known.
nance and repairwork, ensure that it is protected from unex-
• Pay attention to fire warning and fire fighting procedures. pected start--up. Turn off main control device and remove
the key and / or display a warning sign on the main switch.
1.3.3. Qualifications, fundamental duties • When replacing individual parts and larger assembly
• Work on / with the machine / unit may only be carried out by groups, they must be carefully fastened to the lifting device
reliable personnel. Observe the legal minimum age permis- so that there is no risk of danger. Use only suitable and tech-
sible. nically perfect lifting devices and equipment with sufficient
lifting power and strength. Do not linger or work under sus-
• Only employ trained personnel, clearly establish responsi- pended loads.
bility of personnel for operation, maintenance and repair-
• Only entrust an experienced person with the fixing of loads
work.
and guiding of crane drivers. The person guiding must re-
• Ensure that only trained personnel work with the machine. main within sight or in contact with the operator.
• Establish the responsibilities of the machine operator and • For assembly work above body height, use appropriate
establish a procedure for him to inform a third person of un- safety approved equipment, e.g. ladders and platforms. Do
favourable safety conditions. not climb on machine parts. For maintenance work at high
levels, wear a safety harness.
• People who are being trained or introduced to the job should
only be allowed to work with the machine / unit under • Clean oil, fuel or care products from the machine, in particu-
constant supervision of an experienced person. lar the connections and screw joints, before carrying out
maintenance / repairwork. Do not use aggressive cleaning
• Work on the electrical equipment of the machine / unit may
fluid. Use a fibre--free cleaning cloth.
only be carried out by a qualified electrician or by an
instructed person under the direction and supervision of a • Before cleaning the machine with water or jet of steam (high
qualified electrician according to electrotechnical regula- pressure cleaner) or detergent, cover / seal all openings
tions. which for safety and/or operating reasons no water / steam
/ detergent may penetrate. Electric motor and switch cabi-
• Work on gas equipment may only be carried out by qualified nets are particularly at risk.
personnel.
• When cleaning the operating room, ensure that the temper-
1.3.4. Safety notices for operation ature sensors of the fire alarm and sprinkler system do not
come into contact with hot cleaning fluid, in order to avoid
• Do not carry out any work if safety is questionable. triggering the sprinkler system.
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Instruction Manual • Industrial Compressor Units
• Completely remove all covers / seals after cleaning. • With regard to oil, grease and other chemical substances,
observe the relevant safety regulations for the product.
• After cleaning, check all pressure lines for leaks, loose con-
nections, wear and damage. Immediately eliminate any • For loading, only use lifting device and equipment with suffi-
faults. cient lifting power and strength.
• Always retighten any screw connections loosened for main- • Appoint trained guide personnel for lifting operations.
tenance or repairwork. • Machines may only be lifted with a lifting device and by
• If it is necessary to remove safety devices for maintenance trained personnel according to instructions in the instruction
and repairwork, these must be replaced and checked im- manual (fixing points for fixing equipment etc.).
mediately after completion of the maintenance or repair- • Use only suitable transporters with sufficient carrying
work. power.
• Ensure safe and environmentally friendly disposal of con- Secure the load properly. Use suitable fixing points.
sumables and old parts.
• If necessary, provide machine / unit with transportation
brackets. Display the appropriate notice. Remove trans-
1.3.5. Particular areas of danger portation brackets in the correct manner before taking into
• Use only original fuses with specified current rating. If there operation.
is a failure in the electric energy supply, shut the machine / • Parts which need to be dismantled for transport purposes
unit down immediately. must be carefully replaced and secured before taking into
• Work on electric units or operating equipment may only be operation.
carried out by a qualified electrician or by a person under the • Even when moving the machine / unit only slightly, the ma-
instruction and supervision of a qualified electrician accord- chine / unit must be disconnected from all external energy
ing to electric technical regulations. sources. Before putting into use again, reconnect the ma-
chine to the mains according to regulations.
• Machines and unit parts which must undergo inspection,
maintenance and repairwork, must be disconnected from • When taking back into operation, proceed according to the
the mains supply, if specified. Parts which have been dis- instruction manual.
connected must first be checked for voltage, then earthed
and short--circuited and isolated from live neighbouring 1.3.6. Notices of danger regarding pressure vessels
parts. • Never open or loosen pressure vessel lids or pipe connec-
• The electrical equipment of a machine / unit must be regu- tion parts under pressure; always depressurise the vessel
larly checked. Defects, such as loose screw connections or or the unit.
burnt wires, must be rectified immediately. • Never exceed the permissible operating pressure of the
• If work is to be carried out on live parts, work with a second vessels!
person who can operate the emergency off switch or the • Never heat the vessels or any of their parts above the
main switch in the case of an emergency. Close off the work stated, maximum operating pressure.
area with a red and white safety chain and a warning sign.
• Always exchange damaged pressure vessels completely.
Only use voltage isolated tools.
Individual parts that are subject to pressure loads cannot be
• Only carry out welding, burning and grinding work on the purchased as spare parts, since the vessels are tested as
machine / unit when specifically approved. There can, for a complete part and the documentation considers them as
example, be a risk of fire or explosion. a whole (see pressure vessel documentation, serial--num-
bers!).
• Before carrying out welding, burning or grinding work, clean
the machine / unit and surrounding area from dust and flam- • Always pay attention to the permissible operating mode of
mable material and ensure there is adequate ventilation the pressure vessels.
(danger of explosion!). We differentiate:
• When working in small rooms, observe any national regula- -- vessels for static load
tions.
-- vessels for dynamic load
• Only personnel with particular knowledge and experience
with pneumatics may carry out work on pneumatic equip- Vessels for static load:
ment. These pressure vessels are permanently under virtually
• Check all pressure lines, hoses and screw connections reg- constant operating pressure; the fluctuations of pressure
ularly for leaks and visible damage. Immediately repair any are very small.
damage. Escaping air or gas under pressure can cause in- Vessels for this type of load are not marked in a particular
jury and fire. way and may be used as long as the vessel inspections,
• Depressurize system and pressure lines before commenc- carried out regularly, do not uncover any safety--relevant
ing repairwork. deficiencies.
• Pressurized air lines must be laid and mounted by qualified We recommend that aluminium vessels should be ex-
personnel. Connections must not be mixed up. Fittings, changed after 15 years at the latest.
length and quality of the piping must correspond to require-
Vessels for dynamic load:
ments.
These pressure vessels may also be used under conditions
• Soundproofing equipment on the machine / unit must be in
of changing operating pressure. The pressure may vary be-
place and functional during operation.
tween the atmospheric and the maximum admissible oper-
• The stipulated hearing protectors must be worn. ating pressure.
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 Instruction Manual • Industrial Compressor Units
The pressure vessel documentation and the appropriate f-- Accident Prevention Regulations (UVV):
notes in the operating manual particularly characterise ves-
sels of this type as being adequate for dynamic loads. In the • BGV A1 of 01. January 2004
technical information for these vessels you will find specifi-
cations concerning their permissible operating period. Copies of the above regulations are available through the usual
outlets, e.g. in Germany from:
Due to the variation of the operating pressure, these vessels
are subject to a so--called dynamic load, which puts the ves- Carl Heymanns Verlag
sels under great stress. The change between two different Luxemburger Str. 449
pressures is called a load change or cycle. In the technical 50939 Köln
information for these vessels you will find specifications
concerning the permissible number of cycles depending on Beuth--Vertrieb GmbH
the fluctuation of the operating pressure. Burggrafenstr. 4 -- 7
Having reached half the permissible number of cycles, the 10787 Berlin
vessel has to be submitted to an internal check, in which the The manufacturer has complied with all applicable regulations
critically stressed areas of the vessels are examined by and the unit is prepared accordingly. If desired, we offer at our
means of suitable testing methods, in order to ensure the Munich site a partial acceptance test according to § 14 Betr-
operating safety. SichV. Please contact our Technical Service Department with
After having reached the total permissible number of load regard to this. They can also supply our leaflet “IMPORTANT
cycles, the vessel must be exchanged and scrapped. NOTES FOR CERTIFICATION”.
Record the number of load cycles in writing if you do not According to the operation safety regulations (BetrSichV), all
have an automatic cycle--counter. compressor units which will be used as filling stations must un-
We recommend that aluminium vessels should be ex- dergo an acceptance test by a professional at their location be-
changed after 15 years at the latest. fore bringing them into service. If pressure vessels (bottles) are
Please pay attention to and follow these measures, for your to be filled by the compressor for a third party then the appropri-
own safety and that of you employees and customers! ate permission must be obtained from the responsible authority
before the acceptance test. As a rule, this is the factory inspec-
In order not to unnecessarily load the pressure vessels ad-
torate. The procedure for obtaining permission is according to
ditionally, the non--return valves, that are meant to avoid a
TRG 730, guidelines for permission to set up and operate filling
drop in pressure, and also the pressure maintaining valves,
stations. The test certificates and documents delivered with the
which should reduce big pressure fluctuations as well,
compressor are important and may be requested during the
should be checked regularly for internal and external tight-
procedure for obtaining permission. In addition, the documents
ness and functionality.
belonging to the unit are important for recurrent inspections and
• Check the pressure vessels regularly on the inside and out- should therefore be carefully kept.
side for damage from corrosion.
• Be particularly careful with second--hand pressure vessels, Inspections in accordance with the regulations for prevention of
accidents will be carried out by the manufacturer or by a special-
when their previous operating mode is not specifically clari-
ist.
fied.
No guarantees whatsoever are valid for damage caused or fa-
1.4. SAFETY REGULATIONS (EC; partly Germany,
voured by the non--consideration of these directions for use.
only)
A compressor is identified by German law as being a filling sys- We strongly emphasize these regulations.
tem if pressure cylinders are filled by the system, especially
when these cylinders are made available for third parties. The
start--up and operation of compressor systems for use as filling
stations is governed by the following regulations:
a-- Pressure vessel directive (Directive 97/23/EC) of
29.05.1997
b-- Operating safety regulations (BetrSichV) of 27.09.2002
c-- Machine safety law (GSG) of 11.05.2001
d-- 14th regulation to machine safety law (14. GSGV -- pres-
sure vessel regulation) of 03.10.2002
e-- Technical regulations for pressure gases (TRG 400, 401,
402, 730).
If a high pressure compressor is used for filling pressure ves-
sels or for the supply of pneumatic systems, the following regu-
lations apply:

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Instruction Manual • Industrial Compressor Units

2. OPERATION

2.1. PREPARATION FOR OPERATION

The compressors described in this

WARNING manual are not suitable for compres-
sion of oxygen. EXPLOSION occurs if
an oil lubricated compressor is operated with pure oxygen
or gases with an oxygen content of more than 21%!

1 Make sure that all persons handling the compressor and the
filling station are familiar with the function of all controls and
monitors. In particular, observe the safety warnings in
chapter C--1.

2 Make sure, that all covers are closed.

3 Prior to each operation check the oil level according to

chapter D--2. and determine whether additional maintenance
is necessary in accordance with section D.

4 Ensure proper ventilation. Note that room

temperature = cooling air temperature !
Min. = +5 °C, max. = +45 °C.

5 Install unit level. Max. allowable inclination = 5°.

6 Make sure that the compressor unit is depressurized

by means of the venting valve, befor you open the filter.

7 Every time the unit is started up check all systems for

proper operation. If any malfunction is observed stop unit
immediately and find the cause of the fault or call the service
department.

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 Instruction Manual • Industrial Compressor Units
2.2. STARTING THE UNIT 2.3. SHUTDOWN PROCEDURE
-- Main switch must be set to 1 (ON). -- Push red OFF button -- unit will stop.
Knocking, audible when starting, is due to
-- Set main switch to 0 (OFF).
the last stage floating piston. This knocking
disappears as soon as there is pressure be- Always set the main switch to 0 (OFF)
tween the stages, and the piston is running WARNING when servicing the compressor unit.
synchronous with the other pistons. There-
fore, this knocking can be ignored.

The automatic condensate drain unit drains

the filters during two minutes after shut--
down of the compressor unit. The compres-
sor unit should not be started before the de-
pressurization is finished!

-- Push green ON button -- unit will start.

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Instruction Manual • Industrial Compressor Units

D--1
 Instruction Manual • Industrial Compressor Units

D--2
 Instruction Manual • Industrial Compressor Units

D. MAINTENANCE, REPAIR The maintenance schedule is contained in the service manual

delivered with every compressor unit.

1. GENERAL 2. LUBRICATION SYSTEM

1.1. MAINTENANCE RECORD 2.1. OIL LEVEL CHECK

We recommend that all maintenance work is recorded in the Check oil level at sight gauge on either side of compressor
service booklet delivered with every compressor unit, showing block every day prior to putting compressor into operation. Oil
the date and details of the work carried out. This will help to level must be between minimum and maximum notches, see
avoid expensive repairwork caused by missed maintenance Fig. 29. Oil level must never be below minimum mark as this will
work. If it is necessary to claim against the warranty, it will help cause severe damages due to lack of lubrication. Oil level must
to have proof that regular maintenance work has been carried also not exceed maximum as this will cause excessive lubrica-
out and that the damage has not been caused by insufficient tion of compressor and result in valves sooting up.
maintenance. Please refer to section 23 of our general terms
and conditions. At each oil change unscrew and remove the
oil sight glass and clean the prism inside.
Check gasket and screw in the oil sight glass
1.2. MAINTENANCE WORK again.
(Torque approx. 10 Nm)
Always shut down and decompress
WARNING the complete system prior to carrying
out any work on the compressor.

Always disconnect the system from

WARNING mains supply prior to carrying out any
work on compressor systems with
electric drive motor.

Never repair pressure lines by solder- Maximum

WARNING ing or welding.
Minimum

Check the complete system for leakage from

time to time by brushing all fittings and cou-
plings with soapy water or spraying with leak
test spray. Repair any leakage.

Only use original spare parts for mainten-

ance or repair work. Fig. 29 Oil sight gauge

2.2. OIL CHANGE INTERVALS

For filter cartridge change intervals refer to Mineral oils every 1,000 operating hours,
chapter D--5 ! at least annually
Synthetic oils every 2,000 operating hours,
at least biennially
The used cartridge must be disposed of ac-
cording to local regulations. 2.3. OIL CAPACITY

Oil capacity approx. 2.8 liters

2.4. OIL PACKAGES

1.3. MAINTENANCE INTERVALS BAUER compressor oil is available in various quantities, refer
MV-- I/02/07

to oil list in section F.

All maintenance intervals refer to normal op-
erating conditions. Operating the compres- 2.5. CHANGING THE OIL TYPE
sor under extreme conditions like high tem-
peratures, humidity, continuous operation To avoid severe damage to the compressor
may shorten the intervals significantly. If in unit when changing the oil type, the following
doubt, please contact our service dept. measures should be strictly adhered to:
D--3
 Instruction Manual • Industrial Compressor Units
-- Drain oil completely while still warm.

-- Check valves, coolers, separators, purifiers, and all pneu-

matic tubes and hoses for deposits.

If deposits are detected, perform the following:

-- Change or clean valves, coolers, separators, purifiers, and

all pneumatic tubes and hoses from deposits. 1
-- Replace oilfilter, if it’s available.

-- Fill compressor with the new oil.

-- After approx. 100 operating hours check lubricating oil for

degree of contamination, and change oil again if necessary.

-- Refill compressor with same oil, only.

2.6. OIL CHANGE

Replace oil filter with every oil change, other- Fig. 30 Oil filler neck
wise the bypass valve would open if filter is
clogged, and the oil would circulate without
being filtered!

-- Run compressor warm.

1
-- Remove red cap from oil filler neck (1, Fig. 30).
1
-- Drain oil while still warm by means of oil drain plug. On units
equipped with oil drain hose remove hose union nut from
coupling at hose bracket. Collect oil in a suitable container.
Exchange gasket and reinstall plug.

-- Remove two screws (1, Fig. 31) with a 13 mm spanner. Re- 2

move cover (2).

-- Remove oil filter (1, Fig. 32) from rubber gasket at cover.
3
-- Mount a new filter element (P/N N25326) and replace and
fasten cover.

-- Fill new oil through filler neck to Max.-- mark at sight gauge.
Fig. 31 Removing the cover
-- Pour oil in slowly, wait a few minutes, then put unit into op-
eration.

2.7. VENTING OIL PUMP

To avoid severe damage to the compressor

unit observe this notice.

If no or low oil pressure builds up after starting the unit-- espe- 1

cially after maintenance or repair work, or if the unit should have
been running in the wrong direction due to a wrong phase se-
quence -- venting of the oil pump may be necessary. Proceed
as follows:

-- With the compressor running and all condensate drain

valves open to avoid pressure being built up during this pro-
cedure, unscrew screw cap and plug (3, Fig. 31) three turns
and wait until oil pours out free of air bubbles. Retighten plug
and cap nut. Fig. 32 Replacing the oil filter
D--4
 Instruction Manual • Industrial Compressor Units

3. INTAKE FILTER 4. INTERMEDIATE SEPARATOR

3.1. COMPRESSOR UNIT FOR AIR APPLICATIONS Proper operation of the individual compression stages will rely
The filter cartridge must be cleaned or changed at regular inter- on the intermediate separator being properly serviced.
vals. The intervals depend on the air taken in by the compres-
sor. In heavy dust conditions monthly or even weekly servicing
can be necessary. In all conditions, observe the minimum inter- 4.1. CONDENSATE DRAIN
vals according to maintenance schedule in chapter D--1.2.
Drain condensate every 15 to 30 minutes from these separators
or ensure that the automatic condensate drain unit drains regu-
larly. See chapter 10.

Fig. 33 Intake filter

To clean, remove cover and spring (1, Fig. 33), take out mi-
cronic filter cartridge (1) and clean with brush or by blowing air
inside out. Turn cartridge through 90° when replacing. Replace
dirty cartridge once it has been turned three times and thus
used on all sides.
Clean filter housing inside with a damp cloth. Take care to pre-
vent dust from entering intake pipe.

3.2. COMPRESSOR UNIT FOR GAS APPLICATIONS

The intervals for cleaning the particular filters in the gas intake--
line is depending on the constitution of the medium. The filter
must be cleaned according chapter D.1. or minimum annually.
MV-- I/02/07

D--5
 Instruction Manual • Industrial Compressor Units

5. FINAL SEPARATOR / FILTER SYSTEM 5.2.2. Cartridge change

-- On filter systems with SECURUS monitoring, unscrew nut
5.1. OIL AND WATER SEPARATOR and pull off cable plug.
-- Unscrew the filter head (1, Fig. 34) with the special spanner
5.1.1. Lifetime (2, Fig. 34) supplied with the unit.

The oil and water separator is subject to dy- -- Pull out used cartridge by means of its clip (3, Fig. 35).
namic load. It is designed to withstand a cer-
-- Remove new cartridge from packing and protective caps
tain no. of load cycles. (1 load cycle = 1 pres- from both ends of cartridge.
surization, 1 depressurization) at the speci-
fied pressure range. The oil and water sepa- -- Insert new cartridge into housing and push down firmly.
rator must be replaced when the maximum permissible no.
of load cycles has been reached. Refer to the pressure ves- -- Replace filter head, screw in by hand and tighten with the
sel operating manual delivered with the unit. special spanner.

The cycles are counted by the cycle counter of the compressor

control unit. Refer to chapter A--11. After the max. number of
load cycles have been reached, the separator must be ex-
changed.

5.1.2. Condensate drain

The condensate produced by the re--cooling after the compres-
sion process has to be drained regularly by means of the 2
manual condensate drain valves
• before start--up of the compressor unit
• during operation every 30 minutes, at high humidity every 1
15 minutes.
For automatic condensate drain system refer to chapter D--10.

5.2. FILTER SYSTEM

Fig. 34 Removing the filter head
5.2.1. General instructions
-- Depressurize system before starting any maintenance
work. The filter line can be vented manually with the venting
valve, wait until the pressure gauge reads zero.
-- Dry inside of filter housing with a clean cloth before installing
new cartridge and check for corrosion.
-- Lubricate threads and O--rings as well as end of cartridge
with both o--rings with white petrolatum. Apply sparingly.
See chapter 15.
-- Observe number of operating hours as indicated on hour
meter to ensure exact attention to the maintenance inter-
vals.
-- Change cartridge before reactivating a compressor unit
which has been out of service for more than 6 months.
-- Leave cartridge in the filter as long as unit is out of service.
-- Keep all condensate drain valves and shut--off valves
closed. Keep a minimum pressure of approx. 50 to 80 bar
(700 to 1,100 psig) within the system to prevent moisture en-
tering the compressor piping and filter system. Fig. 35 Extracting the cartridge
MV-- I/02/07

D--6
 Instruction Manual • Industrial Compressor Units
5.2.3. Filter replacement intervals 6. PRESSURE MAINTAINING / NON--RETURN
VALVE
On filter systems with SECURUS monitoring
system the saturation of the cartridge is indi- For pressure adjustment see chapter A--6.
cated by LED’s at the monitor display.

The number of operating hours or the amount of possible bottle

fillings per filter cartridge can be determined by the tables of
pages D--11 to D--15 taking into consideration the ambient tem- 1
perature and the cartridge used. 2
3
These tables contain calculated cartridge lifetime data, that
refer to defined and constant operating conditions. Tolerances
at bottle fillings and different operating temperatures can lead
to considerable divergences compared to data given, which
therefore can only serve as reference values for the user.

The used cartridge must be disposed of ac-

cording to local regulations.

Fig. 36 Pressure Maintaining / Non--Return Valve

The pressure maintaining valve is adjusted at the factory to the

required pressure and normally does not require regular main-
tenance or readjustment. In case of readjustment becoming
necessary, loosen jam nut (2, Fig. 36) and set screw (3,
Fig. 36). Adjust screw (1, Fig. 36) to the required pressure using
a suitable screwdriver.
How to determine the opening pressure of the pressure main-
taining valve:
As long as the pressure built up by the compressor is below the
adjusted opening pressure of the pressure maintaining valve,
the final pressure indication remains at zero. But, the pressure
building up in front of the pressure maintaining valve can be
read from the pressure gauge mounted at the final separator.
At this moment, read the opening pressure from the pressure
gauge at the separator.
Clockwise = increase pressure
Counter--clockwise = decrease pressure
MV-- I/02/07

D--7
 Instruction Manual • Industrial Compressor Units

7. SAFETY VALVES

7.1. OPERATING CHECK

The final pressure safety valve has to be checked regularly be-

fore starting each filling process. See chapter D--1.2.
For this purpose the safety valve can be vented manually. We
recommend that a final pressure setting of 80 % should not be
exceeded, to avoid damaging the safety valve. This just en-
sures that the valve works and will release pressure in case of
a malfunction. To check the blow--off pressure value refer to
D 7.2.
The safety valve is mounted on top of the final separator. Turn
knurled knob on top of the valve clockwise until valve blows off
(Fig. 37).

VENTING

Fig. 37 Venting the final pressure safety valve

7.2. BLOW--OFF PRESSURE CHECK

Check blow--off pressure of the final pressure safety valve regu-

larly, see maintenance schedule chapter D--1.2. Pump unit to
final pressure with shut--off valve closed until safety valve blows
off. Check blow--off pressure of safety valve at pressure gauge.

Set service switch S3 to “ON” to disable the

final pressure switch.

D--8
Instruction Manual • Industrial Compressor Units

1. Filter system P41; Filter cartridge 62504: Filter cartridge lifetime [hours]
Filling pressure p = 200 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 414 -- 328 281 -- 223 207 -- 164 164 -- 130
15 25 -- 29 310 -- 249 211 -- 169 155 -- 124 123 -- 98
20 30 -- 34 236 -- 190 160 -- 129 118 -- 95 93 -- 75
25 35 -- 39 181 -- 147 123 -- 100 90 -- 74 71 -- 58
30 40 -- 44 140 -- 115 95 -- 78 70 -- 57 55 -- 45
35 45 -- 49 109 -- 90 74 -- 61 55 -- 45 43 -- 36
40 50 -- 54 86 -- 72 59 -- 49 43 -- 36 34 -- 28
Filling pressure p = 300 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 621 -- 493 422 -- 335 310 -- 246 245 -- 195
15 25 -- 29 466 -- 373 317 -- 254 233 -- 187 184 -- 147
20 30 -- 34 353 -- 285 240 -- 194 177 -- 143 140 -- 113
25 35 -- 39 271 -- 221 184 -- 150 135 -- 110 107 -- 87
30 40 -- 44 210 -- 172 143 -- 117 105 -- 86 83 -- 68
35 45 -- 49 164 -- 135 111 -- 92 82 -- 68 65 -- 54
40 50 -- 54 129 -- 108 88 -- 73 65 -- 54 51 -- 43

Filter cartridge 062504: Bottle fillings [number] mass of molecular sieve mMS [g] = 913
Ambient tem- Temperature in Moisture content of Volume of processed air Va [m3]
perature final separator air 100% satured at pressure p [bar]
tU [°C] tAb [°C] X [g/m3]
200 300
10 20 -- 24 17,31 -- 21,8 2110 -- 1675 3165 -- 2513
15 25 -- 29 23,07 -- 28,79 1583 -- 1268 2375 -- 1903
20 30 -- 34 30,4 -- 37,63 1201 -- 971 1802 -- 1456
25 35 -- 39 39,65 -- 48,64 921 -- 751 1382 -- 1126
30 40 -- 44 51,21 -- 62,41 713 -- 585 1070 -- 878
35 45 -- 49 65,52 -- 79,28 557 -- 461 836 -- 691
40 50 -- 54 83,08 -- 99,85 440 -- 366 659 -- 549

Volume of processed air: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMs [g] / X [g/m3]
Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])

D--9
 Instruction Manual • Industrial Compressor Units

2. Filter system P41; Filter cartridge 062565: Filter cartridge--lifetime [hours]

Filling pressure p = 200 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 552 -- 438 375 -- 298 276 -- 219 218 -- 173
15 25 -- 29 414 -- 332 282 -- 226 207 -- 166 164 -- 131
20 30 -- 34 314 -- 254 214 -- 173 157 -- 127 124 -- 100
25 35 -- 39 241 -- 196 164 -- 134 120 -- 98 95 -- 78
30 40 -- 44 187 -- 153 127 -- 104 93 -- 77 74 -- 61
35 45 -- 49 146 -- 120 99 -- 82 73 -- 60 58 -- 48
40 50 -- 54 115 -- 96 78 -- 65 57 -- 48 45 -- 38
Fülldruck p = 300 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 552 -- 438 375 -- 298 276 -- 219 218 -- 173
15 25 -- 29 414 -- 332 282 -- 226 207 -- 166 164 -- 131
20 30 -- 34 314 -- 254 214 -- 173 157 -- 127 124 -- 100
25 35 -- 39 241 -- 196 164 -- 134 120 -- 98 95 -- 78
30 40 -- 44 187 -- 153 127 -- 104 93 -- 77 74 -- 61
35 45 -- 49 146 -- 120 99 -- 82 73 -- 60 58 -- 48
40 50 -- 54 115 -- 96 78 -- 65 57 -- 48 45 -- 38

Filter cartridge 062565:Bottle fillings [number] mass of molecular sieve mMS [g] = 812
Ambient temperature Temperature of final se- Moisture con- Volume of processed air Va [m3]
tU [°C] parator tent of air 100% at pressure p [bar]
tAb [°C] satured
X [g/m3] 200 300
10 20 -- 24 17,31 -- 21,80 1876 -- 1490 2815 -- 2235
15 25 -- 29 23,07 -- 28,79 1408 -- 1128 2112 -- 1692
20 30 -- 34 30,40 -- 37,63 1068 -- 863 1603 -- 1295
25 35 -- 39 39,65 -- 48,64 819 -- 668 1229 -- 1002
30 40 -- 44 51,21 -- 62,41 634 -- 520 951 -- 781
35 45 -- 49 65,52 -- 79,28 496 -- 410 744 -- 615
40 50 -- 54 83,08 -- 99,85 391 -- 325 586 -- 488

Volume of processed air: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMs [g] / X [g/m3]
Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])

D--10
Instruction Manual • Industrial Compressor Units

3. Filter system P61; Filter cartridge 058825: Filter cartridge--lifetime [hours]

Filling pressure p = 200 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 655 -- 520 445 -- 354 327 -- 260 259 -- 206
15 25 -- 29 491 -- 394 334 -- 268 246 -- 197 194 -- 156
20 30 -- 34 373 -- 301 254 -- 205 186 -- 151 147 -- 119
25 35 -- 39 286 -- 233 194 -- 158 143 -- 117 113 -- 92
30 40 -- 44 221 -- 182 150 -- 123 111 -- 91 87 -- 72
35 45 -- 49 173 -- 143 118 -- 97 86 -- 71 68 -- 57
40 50 -- 54 136 -- 114 93 -- 77 68 -- 57 54 -- 45
Filling pressure p = 300 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 982 -- 780 668 -- 530 491 -- 390 388 -- 308
15 25 -- 29 737 -- 590 501 -- 402 368 -- 295 291 -- 233
20 30 -- 34 559 -- 452 380 -- 307 280 -- 226 221 -- 179
25 35 -- 39 429 -- 350 292 -- 238 214 -- 175 170 -- 138
30 40 -- 44 332 -- 272 226 -- 185 166 -- 136 131 -- 108
35 45 -- 49 259 -- 214 176 -- 146 130 -- 107 103 -- 85
40 50 -- 54 205 -- 170 139 -- 116 102 -- 85 81 -- 67

Filter cartridge 062504: Bottle fillings [number] mass of molecular sieve mMS [g] = 1445
Ambient tem- Temperature of Moisture content of air Volume of processed air Va [m3]
perature final separator 100% satured at pressure p [bar]
tU [°C] tAb [°C] X [g/m3]
200 300
10 20 -- 24 17,31 -- 21,8 3339 -- 2651 5009 -- 3977
15 25 -- 29 23,07 -- 28,79 2505 -- 2008 3758 -- 3011
20 30 -- 34 30,4 -- 37,63 1901 -- 1536 2852 -- 2304
25 35 -- 39 39,65 -- 48,64 1458 -- 1188 2187 -- 1782
30 40 -- 44 51,21 -- 62,41 1129 -- 926 1693 -- 1389
35 45 -- 49 65,52 -- 79,28 882 -- 729 1323 -- 1094
40 50 -- 54 83,08 -- 99,85 696 -- 579 1044 -- 868

Volume of processed air: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMs [g] / X [g/m3]
Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])

D--11
 Instruction Manual • Industrial Compressor Units

4. Filter system P61; Filter cartridge 058826: Filter cartridge--lifetime [hours]

Filling pressure p = 200 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 577 -- 458 393 -- 312 289 -- 229 228 -- 181
15 25 -- 29 433 -- 347 295 -- 236 217 -- 174 171 -- 137
20 30 -- 34 329 -- 266 224 -- 181 164 -- 133 130 -- 105
25 35 -- 39 252 -- 205 171 -- 140 126 -- 103 100 -- 81
30 40 -- 44 195 -- 160 133 -- 109 98 -- 80 77 -- 63
35 45 -- 49 153 -- 126 104 -- 86 76 -- 63 60 -- 50
40 50 -- 54 120 -- 100 82 -- 68 60 -- 50 48 -- 40
Filling pressure p = 300 bar MV--I100--3--3 MV--I100--4--3 MV--I120--4--3 MV--I120--5.5--3
Delivery Q [l/min]
Ambient tem- Temperature 85 125 170 215
perature of final sepa-
tU [°C] rator
tAb [°C]
10 20 -- 24 866 -- 688 589 -- 468 433 -- 344 342 -- 272
15 25 -- 29 650 -- 521 442 -- 354 325 -- 260 257 -- 206
20 30 -- 34 493 -- 398 335 -- 271 247 -- 199 195 -- 157
25 35 -- 39 378 -- 308 257 -- 210 189 -- 154 149 -- 122
30 40 -- 44 293 -- 240 199 -- 163 146 -- 120 116 -- 95
35 45 -- 49 229 -- 189 156 -- 129 114 -- 95 90 -- 75
40 50 -- 54 180 -- 150 123 -- 102 90 -- 75 71 -- 59

Filter cartridge 062504: Bottle fillings [numbers] mass of molecular sieve mMS [g] = 1274
Ambient tem- Temperature of Moisture content of air Volume of processed air Va [m3]
perature final separator 100% satured at pressure p [bar]
tU [°C] tAb [°C] X [g/m3]
200 300
10 20 -- 24 17,31 -- 21,8 2944 -- 2338 4416 -- 3506
15 25 -- 29 23,07 -- 28,79 2209 -- 1770 3313 -- 2655
20 30 -- 34 30,4 -- 37,63 1676 -- 1354 2514 -- 2031
25 35 -- 39 39,65 -- 48,64 1285 -- 1048 1928 -- 1572
30 40 -- 44 51,21 -- 62,41 995 -- 817 1493 -- 1225
35 45 -- 49 65,52 -- 79,28 778 -- 643 1167 -- 964
40 50 -- 54 83,08 -- 99,85 613 -- 510 920 -- 766

Volume of processed air: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMs [g] / X [g/m3]
Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])

5. Filter system P61; Filter cartridge 068622: Filter cartridge--lifetime [hours] Activated charcoal--Masse mAC [g] = 648
Delivery Q [l/min]
85 125 170 215 260 320 370 450
1270 864 635 502 415 338 292 240

Volume of processed air: Va [m3] = 0,2 x mMS [g] / (X [g/m3] / p [bar]) = 0,2 x p [bar] x mMs [g] / X [g/m3]
Filter cartridge lifetime: tp [h] = Va [m3] / (Q [m3/min] x 60 [min/h])
D--12
 Instruction Manual • Industrial Compressor Units

8. PRESSURE GAUGES 9. VALVES

If the values listed in section A are exceeded and the safety 9.1. GENERAL INSTRUCTIONS FOR CHANGING THE
valve of the corresponding stage blows off, this is an indication VALVES
that the downstream compressor stage is not working properly. • Always replace valves as a complete set.
See section A--9.
• Carefully clean dirty valves. Never use a sharp tool for this
We recommend that pressure gauges are checked from time to purpose. Soak the valves in diesel oil or petroleum and
time. For this purpose we have developed a special test pres- clean with soft brush.
sure gauge with an adaptor which immediately recognizes any • Lubricate valves before installing with Weicon AS 040, or-
deviations in readings. der no. N19753, or equivalent.
See High Pressure Accessories Catalogue no. 8550/7.92. • Check individual components for excessive wear. If the
valve seat and valve disks are dented, replace the valves.
Slight deviations during operation are normal and can be ig-
• Valve head screws must be tightened with a torque wrench
nored. Excessive inaccuracy will require the pressure gauge to
(see tightening torque values chapter D--15.
be readjusted or sent back for repair.
• Check the valve space in the valve heads for dirt and clean,
if necessary.
• Use only satisfactory gaskets and O--rings on reassembly.
• Observe the correct sequence when fitting together again.
• After finishing all maintenance work on the valves, turn the
compressor manually using the flywheel and check
whether all items have been correctly installed.
• 30 minutes after restarting the compressor unit stop unit,
let it cool down to ambient temperature and retighten valve
studs and cap nuts. Otherwise valves could work loose due
to setting of the gaskets.
• Remove and check the valves every 1000 operating
hours.
• Replace the valves every 2000 operating hours to avoid
fatigue failure.
9.2. VALVE CHANGE
Changing the valves should be performed by trained person-
nel, only.
Valve change is described in the workshop manual which is
available through the BAUER technical service.
MV-- I/02/07

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 Instruction Manual • Industrial Compressor Units

10. AUTOMATIC CONDENSATE DRAIN 11. ELECTRICAL SYSTEM

Due care must be taken to ensure that any oil which may be 11.1. CHECKING THE TERMINALS
drained with the condensate will not pollute the environment. On compressor units with factory--installed electric compressor
For example, the drain pipe can be directed into a collecting control system, check all screw--type teminals regularly, at least
vessel or into drain facilities incorporating oil separators. annually, especially the power relay terminals.
All spring--loaded terminals are maintenance--free.
Dispose of the condensate according to local
Besides that, the operator is responsible to ensure that all re-
regulations!
quired safety checks acc. to BGV and DIN VDE are carried out.

11.2. ADJUSTMENT OF FINAL PRESSURE SWITCH

10.1. CHECKING THE AUTOMATIC DRAIN 11.2.1. Semi--automatic compressor control

The pressure switch is adjusted to the required pressure acc.
The condensate drain valves for the intermediate separators
to order. If readjustment is necessary, open cover (2, Fig. 38)
and for the oil and water separator are provided with manual
and adjust screw (1) with a 6 mm allen key to the required pres-
drain valves to check correct operation of the automatic system.
sure.
The automatic condensate drain system must be serviced as
follows:
-- Open all manual drain valves on the separators one after
the other, once a week.

This must be carried out immediately after the automatic sys-

tem has drained the condensate. Observe the drainage of con-
densate when opening the manual drain valves. If the system
drains a lot of condensate this is a sign that the system or the
corresponding condensate drain valves are not working prop-
erly. Find the fault and remedy accordingly. If hardly any con-
densate emerges, the automatic system is operating properly.
For fault correction, see section D--14. “Trouble--shooting”.

Fig. 38 Final pressure switch, semi--automatic

control unit

11.2.2. Fully automatic compressor control

Both, upper (switch off) and lower (switch on) pressure can be
adjusted with this type of pressure switch (Fig. 39).
The required maximum pressure is always
adjusted first, using the red screw (1) follo-
wed by the adjustment of the minimum pres-
sure with the green screw (2).

1
2

1 Adjustment screw, switch--off

pressure
MV-- I/02/07

2 Adjustment screw, hysteresis

3 Switch--off pressure indicator
4 Hysteresis indicator

Fig. 39 Final pressure switch for fully automatic operation

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 Instruction Manual • Industrial Compressor Units

12. COMPRESSOR DRIVE SYSTEM 13. REPAIR INSTRUCTIONS

12.1. ELECTRIC DRIVE MOTOR Preventive maintenance usually involves replacing the valves,
gaskets and sealing rings as well as carrying out the mainte-
The drive motor normally needs no servicing except outer nance work.
cleaning from time to time. Depending on manufacturer and
model, greasing of the bearings may be necessary. Observe re- Repair work can be carried out on the compressor block to a
spective notes on the motor. certain extent but a certain experience and skill is necessary. It
should be noted, however, that
12.2. V--BELTS
-- no repair should be carried out on the crankdrive nor on the
V--belt tension is adjusted automatically by the weight of the bearings
motor. The motor is mounted on a hinged motor plate.
-- safety valves are not repaired but always replaced com-
Check the V--belt regularly for damage and wear (see section pletely.
D--1.2.)
Replace if necessary. If more than one V--belt is installed, al- For all further repair instructions refer to ap-
ways replace the complete set. plicable workshop manual.
MV-- I/02/07

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 Instruction Manual • Industrial Compressor Units

14. TROUBLE--SHOOTING

Trouble Cause Remedy

Compressor unit
Compressor unit doesn’t start (gas com- Intake pressure too low Control intake pressure and readjust as
pressors) necessary -- see A.3.2.3.
Intake pressure too high Control intake pressure and readjust as
necessary -- see A.3.2.3.
Drive Motor
Motor will not start Electric circuitry faulty Before attempting to make any repairs,
check all fuses, terminal connections,
wire leads, make sure that motor data
complies with mains supply
Wrong phase sequence; control relay Correct phase sequence acc. to chapter
triggered. B.3.1.
Compressor Block
Compressor does not attain final pres- Condensate drain valve(s) and/or fittings Tighten and reseal
sure leaking

Premature opening of final safety valve Clean final safety valve and readjust

Piston rings worn Replace

Excessive piston clearance Replace

Compressor output insufficient Pipes leaking Re--tighten
Safety valves between individual stages Intermediate pressure too high Check valves -- see D--9.
releasing pressure
Valves not closing properly
Compressor running too hot Insufficient supply of fresh cooling air Check location max. ambient tempera-
ture + 45 °C (110 °F)
Intake or outlet valves not closing prop- Check and clean valves, replace as nec-
erly essary
Wrong direction of rotation See arrow on compressor and remedy
accordingly
Automatic Condensate Drain
Drain valves do not close No control air Check control air line
Drain valves leaking Dismantle drain valve and clean
Drain valves do not open Condensate drain valve piston jammed Dismantle drain valve, clean or replace
valve
Solenoid valve does not close Solenoid valve faulty Check solenoid valve and replace if nec-
essary
No electrical signal Check for voltage from timer
Solenoid valve does not open Solenoid valve faulty Check solenoid valve and replace if nec-
essary
Continuous electrical signal Check electrical control circuit and timer
Unsatisfactory drainage (lot of conden- Drain valves clogged Dismantle drain valves, clean
sate from manual valves)
MV-- I/02/07

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 Instruction Manual • Industrial Compressor Units

15. TABLES

15.1. TIGHTENING TORQUE VALUES

Unless otherwise specified in text, the follow-

ing 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 [Link])

Hex and allen head M 8* 25 Nm* (18 [Link])

Hex and allen head M 10 45 Nm (32 [Link])

Hex and allen head M 12 75 Nm (53 [Link])

Hex and allen head M 14 120 Nm (85 [Link])

Hex and allen head M 16 200 Nm (141 [Link])

Pipe connections (swivel nuts): Finger--tight + 1/2 turn

15.2. TORQUE SEQUENCE

Tighten valve head and cylinder bolts/nuts equally in the se-
quence shown in Fig. 40.
Be sure to tighten all parts in cold condition only.
MV-- I/02/07

Fig. 40 Torque sequence

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

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 Instruction Manual • Industrial Compressor Units
15.3. LUBRICATION CHART

Usage Lubricants

Rubber and plastic parts, filter housing threads WEICON WP 300 WHITE part no. N19752
or
BAUER special lubricant P/N 072500

Sealing rings BAUER special lubricant P/N 072500

Shaft seal (seal) BAUER special lubricant P/N 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 all lubricating oils refer to chapter 2 or lubricating oil list available through BAUER Service Department.

15.4. ADHESIVE AND SEALANT CHART

Usage Adhesives and Sealants

Screws, Studs Loctite 2701

Seal for conical threads Loctite 243

Metal -- metal seals Temperature resistant compound, e.g.

High temperature connections, e.g. valve heads, cylinders WACKER E10, part no. N18247

Paper gaskets Loctite FAG 2

15.5. TESTING AGENTS

Usage Testing agents

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

D--18
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E. STORAGE, PRESERVATION

1. GENERAL 5. PREVENTIVE MAINTENANCE DURING

STORAGE
If the compressor is put out of service for more than six months,
the unit should be preserved in accordance with the following
instructions: Run the compressor once every 6 months as described in the
following:
Make sure the compressor is kept indoors in a dry, dust free
room. Only cover the compressor with plastic if it is certain that
-- Remove the dust cap from the inlet port and insert the intake
no condensation will form under the sheet. Nevertheless, the
filter.
sheet should be removed from time to time and the unit cleaned
on the outside.
-- Open the filling valves or the outlet valve and let the unit run
If this procedure cannot be followed and/or the compressor is for approx. 10 minutes or until the pressure gauges indicate
going to be taken out of service for more than 2 years, please the correct values.
contact our Technical Service Department for special instruc-
tions. -- Stop the compressor.

2. PREPARATION -- Open condensate drain valves and release compressed air.

Close condensate drain valves again.
Before preserving the compressor unit, run it warm and when
it reaches the specified service pressure, keep it running for -- Carry out preservation procedure according to para.3.
approx. 10 minutes.
Then carry out the following:
5.1. CHANGING THE LUBE OIL FOR PRESERVING
-- Check all pipes, filters and valves (also safety valves) for
leakage.
-- After prolonged storage, the oil will age in the compressor
-- Tighten all couplings, as required. and engine. It should be drained after 2 years at the latest
and replaced with fresh oil.
-- After 10 minutes, open the filling valves or the outlet valve
and run the compressor at the set minimum pressure (pres-
-- The stated period can only be attained when the crankcase
sure maintaining valve, (see chapter A--6.) for approx. 5
is sealed during the preservation period in accordance with
minutes.
the preservation requirements.
-- After these 5 minutes, shut the system down. Drain conden-
sate from separators. Depressurize unit. Shut filling valves/ -- After changing the oil, turn the compressor and the engine
outlet valve. or run them for the required period. See paras. 3. and 4.
-- Open filters and grease threads.
-- Check the lubrication of the compressor when putting the
On units equipped with a filter system please observe the fol- unit into operation once every six months or when turning
lowing: the compressor.

-- Ensure that filter cartridges remain in filters! The oil pump is functioning properly when oil can be seen flow-
This will prevent oil entering filling lines as a result of pres- ing through the sight glass of the oil pressure regulator and if the
ervation procedures. oil pressure gauge indicates the prescribed pressure.
-- Remove intake filter from manifold and all intake lines from
valve heads.
6. REACTIVATING THE COMPRESSOR UNIT
-- Let compressor unit cool down.

3. PRESERVING THE COMPRESSOR -- Remove the dust cap from the inlet port and insert the intake
filter.
-- Turn the compressor on and spray a small amount (approx.
10 cm3 of compressor oil into the valve head inlet port (com- -- Check the oil level of the compressor.
pressors with dual 1st stage: each of the inlet ports) while
the compressor is running. Do not let the compressor warm -- Check the motor/engine according to the manufacturer’s
up too much, to keep oil sticky. instructions.
-- Shut compressor unit off.
-- Only applicable for units equipped with a filter system:
-- Close all valves. open the purifier and change all filter cartridges.
MV-- I/02/07

-- Place the dust cap onto the inlet port. -- Run the compressor warm with open filling valves or outlet
valve for approx. 10 minutes.
4. PRESERVING THE MOTOR/ENGINE
-- Check the oil pressure on the pressure gauge or the oil flow
Preserve the motor/engine according to the instructions of the in the sight glass. If there is any fault, check the lubrication
motor/engine manufacturer. of the compressor.
E--3
 Instruction Manual • Industrial Compressor Units
-- After 10 minutes, close the filling valves or the outlet valve
and run the unit up to final pressure until the final pressure
safety valve blows. To do so, override the pressure switch,
if installed on the unit (refer to chapter A--11.).
-- Check the inter--pressure safety valves for leakage.
-- Establish cause of any fault from the trouble--shooting table,
section D--14., and remedy.
-- Stop the system when running properly, the compressor is
then ready for operation.

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 Instruction Manual • Industrial Compressor Units

F. DIAGRAMS, DRAWINGS
1. FLOW DIAGRAMS
Flow diagrams No.
Flow diagram MV3--I according to order

2. SCHEMATIC DIAGRAMS

Drawing No.
Schematic diagram according to order
Electric part list 76360

3. DRAWINGS
List No.
Drawing of compressor unit MV3--I

4. LISTS
Schematic diagram Dwg.--No.
Lubrication oil list, english 70851
MV-- I/02/07

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G. PARTS LISTS
1. COMPRESSOR UNIT MV--I100--3--3
Applicable spare parts lists: Code
Compressor block IK100--F07 A1.7
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

2. COMPRESSOR UNIT MV--I100--4--3

Applicable spare parts lists: Code
Compressor block IK100--F07 A1.7
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

3. COMPRESSOR UNIT MV--I120--4--3

Applicable spare parts lists: Code
Compressor block IK120--F07 A1.7
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

a) optional extras according to order

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 Instruction Manual • Industrial Compressor Units

4. COMPRESSOR UNIT MV--I120--5.5--3

Applicable spare parts lists: Code
Compressor block IK120--F07 A1.7
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

5. COMPRESSOR UNIT MV--GI100--3--3

Applicable spare parts lists: Code
Compressor block IK100--GI--F06 A41.6
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

6. COMPRESSOR UNIT MV--GI100--4--3

Applicable spare parts lists: Code
Compressor block IK100--GI--F06 A41.6
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

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Instruction Manual • Industrial Compressor Units

7. COMPRESSOR UNIT MV--GI120--4--3

Applicable spare parts lists: Code
Compressor block IK120--GI--F06 A41.6
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

8. COMPRESSOR UNIT MV--GI120--5.5--3

Applicable spare parts lists: Code
Compressor block IK120--GI--F06 A41.6
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

9. COMPRESSOR UNIT MV--GIB12.2--5.5--3

Applicable spare parts lists: Code
Compressor block BK12.2--F07 A92.7
Filter system B64
Automatic condensate drain unit C75
Instrument panel D17--I
Frame and panelling E28--I
Drive system F16--I
Compressor control system G68
Accessoriesa) :
Storage batteries G7
Air--Kool G64
Intake system G70

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 Instruction Manual • Industrial Compressor Units

G--6
 Lubricating oil list
1. 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
Brand Designation Type A N I G C GI
name Breathing Industrial Helium, +5 ...+45 °C
air Nitrox CNG Nitrogen
air Argon

+ + + + -- + +
Special Compressor oil
Part no. N28355
b) c)
S
Special Compressor oil
Part no. N22138
a) M + -- + -- -- -- +
Special Compressor oil
Part no. N26303
b) S -- -- -- -- + -- +
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
I suitable for industrial air compressor units
G suitable for gas compressor units for dry and highly pure gases
C suitable for compressed natural gas compressors (CNG filling stations)
GI suitable for gas compressor units for nitrogen
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
z = partly suitable
-- = not suitable
Oil list /06/06

BAUER KOMPRESSOREN GmbH

Postfach 710260 D--81452 München Tel. 089/78049--0 Fax 089/78049167
 Lubricating oil list
2. 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

Industrial air and gas compressor units: BAUER Special Compressor oil, part no. N28355

CNG compressor units: BAUER Special Compressor oil, part no. N26303

For operation under difficult conditions, such as continuous running and/or high ambient temperatures, we only recommend 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.

2.1. Changing the Oil Type

CAUTION
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.

3. 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 b Oil type ' Synthetic oil N28355 Synthetic oil N26303 Mineral oil N22138
0.5 ltr. bottle Best.--Nr. N28355--0,5 not available Best.--Nr. N22138--0,5
1 ltr. bottle part no. N28355--1 part no. N26303--1 part no. N22138--1
5 ltr. container part no. N28355--5 part no. N26303--5 part no. N22138--5
20 ltr. container part no. N28355--20 part no. N26303 --20 part no. N22138--20

BAUER KOMPRESSOREN GmbH

Postfach 710260 D--81452 München Tel. 089/78049--0 Fax 089/78049167