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Instruction Manual

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PE 100-T

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Summary of Contents for PE 100-T

Page 1: ...High Pressure Breathing Air Compressors Instruction manual...

Page 2: ......

Page 3: ...1 05 2004 and the EC machine regula tions 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...

Page 4: ...ne no 089 78049 138 185 154 205 or 202 Fax no 089 78049 103 Are you interested in any training courses Training manager Phone no 089 78049 175 Fax no 089 78049 103 Explanation of the short operating i...

Page 5: ...ation 9 Lubrication 14 Lubrication chart 31 M Maintenance 14 Maintenance instructions 14 Maintenance record 14 Maintenance schedule 14 Motor protection switch 25 O Oil change 14 15 Oil level check 14...

Page 6: ...Instruction Manual w PE 100 T iv NOTES Model Serial No Date of purchase Dealer address phone no...

Page 7: ...The compressor unit comprises the following major assem blies compressor block drive motor filter system P11 filling assembly frame The design of the compressor system is shown in Fig 1 to Fig 3 Fig...

Page 8: ...andle 10 Mains plug with ON OFF switch and motor protection circuit breaker dep on country Fig 2 Compressor unit with electric motor three phase current 1 2 3 4 1 Drive engine 2 Filling valve with pre...

Page 9: ...nstant pressure within the filter assembly The compressed purified air is passed through filling hose 17 and filling valve 18 to the bottles to be filled Filling pressure is indicated at pressure gaug...

Page 10: ...50 ml Oil type see chapter 4 4 1 lubrication Max ambient temperature 5 45 C Max inclination of compressorb 5 Max operating height 0 2000 m above sea level Compressor drive PE 100 TB F02 Drive motor R...

Page 11: ...ent This notice advises of technical requirements which the operator must take particular note of 2 3 FUNDAMENTAL SAFETY NOTICES 2 3 1 Authorized use The machine unit is built according to state of th...

Page 12: ...hing is not as is should be including operation If necessary shut the machine down im mediately and make it safe Observe switching on and off processes and monitoring indications according to the inst...

Page 13: ...replaced and secured before taking into operation Even when moving the unit only slightly the unit must be disconnected from all external energy sources Be fore putting into use again reconnect the ma...

Page 14: ...402 730 If a high pressure compressor is used for filling pressure vessels or for the supply of pneumatic systems the follow ing regulations apply Accident Prevention Regulations UVV BGV A1 of 01 Janu...

Page 15: ...the follow ing Comply with regulations of local electricity supply com pany Arrange for the electrics to be connected by an electri cian only Ensure correct installation of protective conductor Check...

Page 16: ...ulting in a life threatening CO concentration Also due to chemical reaction of CO with hopcalite warm ing up of the cartridge and danger of fire may result Please respect local regulations for filling...

Page 17: ...p to the basic pollution of approx 400 ppmv The technically caused excessive increase of CO2 during the filling process and the CO2 peak at taking the unit into operation Because of the reasons stated...

Page 18: ...f the unit has been put out of service for more than several hours See 3 3 4 On models of 300 bar rated filling pres sure do not attach bottles unless rated for this pressure note pressure stamped on...

Page 19: ...ressure is reached Filling pressure safety valve setting pressure 10 bar i e PN200 units must be switched off at 215 bar PN 300 units at 320 bar Open condensate drain tap 2 Fig 12 and drain shortly th...

Page 20: ...ll valves again to prevent moisture entering the filter and resulting saturation of the cartridge 3 Check the oil level in the compressor and top up if necessary Also check whether the compressor need...

Page 21: ...low deposits no carbonizing effect especially in the valves good anti corrosive properties emulsification of the condensate in the crankcase physiological and toxicological suitability Due to the the...

Page 22: ...essor with the new oil After approx 100 operating hours check lubricating oil for degree of contamination and change oil again if necessary Top up compressor and perform subsequent oil changes with sa...

Page 23: ...ridge chamber In the separator surrounding the cartridge chamber liquid oil and water particles are reliably separated from the compressed medium Residual oil and water vapors are then removed by the...

Page 24: ...700 psi For a pressure dif ference of 225 bar 3 200 psi the max no of load cycles is 35 000 To avoid exceeding the max number of load cycles the op erating hours should be recorded in the service manu...

Page 25: ...ltr bottles can be filled with a TRIPLEX cartridge which is equivalent to 12 to 15 compressor operating hours at a filling pressure of 200 bar On compressor units with petrol engines only use car tri...

Page 26: ...midity saturated X g m3 Processable air volume Va m3 at pressure p bar Number of bottle fillings n acc to bottle size 200 300 7 l 10 l 12 l 10 20 24 17 31 21 80 157 125 236 187 112 89 79 62 65 52 15 2...

Page 27: ...midity saturated X g m3 processable air volume Va m3 at pressure p bar Number of bottle fillings n acc to bottle size 200 300 7 l 10 l 12 l 10 20 24 17 31 21 80 134 106 201 160 96 76 67 53 56 44 15 25...

Page 28: ...CE The pressure maintaining valve Fig 23 is adjusted at the factory to the required pressure and normally does not re quire regular maintenance 4 4 7 SAFETY VALVES DESCRIPTION All three compressor sta...

Page 29: ...see High Pres sure Accessories Catalogue 8550 Slight deviations during operation are normal and can be ig nored Excessive inaccuracy will require the pressure gauge to be replaced 4 4 9 VALVES DESCRIP...

Page 30: ...nuts from tube connectors at valve head and safety valve connector and remove inter cooler Remove four valve head screws 5 from valve head 1 Take off valve head Remove gasket 2 and plate valve 3 When...

Page 31: ...iven by the drive motor through a V belt The motor is mounted on the base plate and requires adjustment for proper V belt tension Improper v belt tension and adjustment of the pulleys will result in e...

Page 32: ...y by turning the switch to 1 1 Fig 34 It is switched off manually by turning the switch to 0 For safety of the operating personnel all voltage carrying parts have a protective cover After the switch h...

Page 33: ...ensate drain valve s leaking Tighten and reseal Final pressure safety valve defective blows too soon Replace safety valve No cartridge in filter system P11 air escaping through cartridge safety bore R...

Page 34: ...ator dirty or clogged Clean separator Pressure maintaining valve faulty Replace pressure maintaining valve Oil concentration too high Filter cartridge saturated Replace cartridge see chapter 4 4 4 Unq...

Page 35: ...t cap from the inlet port and insert the intake filter Open the filling valves or the outlet valve and let the unit run for approx 10 minutes or until the pressure gauges indicate the correct values S...

Page 36: ...y valves are not repaired but always replaced com pletely For many BAUER compressor units workshop manuals are available through our customer service For questions on maintenance and repair please con...

Page 37: ...self retaining nuts on reassembly Bolt or screw Thread max torque Hex and allen head M 6 10 Nm 7 ft lbs Hex and allen head M 8 25 Nm 18 ft lbs Hex and allen head M 10 45 Nm 32 ft lbs Hex and allen he...

Page 38: ...s threads WEICON ANTI SEIZE AS 040 P part no N19753 or equivalent compound with copper or MoS2 additives For compressor lubricating oils refer to oil list in chapter 8 ADHESIVE AND SEALANT CHART Usage...

Page 39: ...Instruction Manual w PE 100 T 33...

Page 40: ......

Page 41: ...Instruction Manual w PE 100 T 35 8 ANNEX Schematic diagram Lubricating oil list Parts list...

Page 42: ...Instruction Manual w PE 100 T 36...

Page 43: ...principal cot client Ein Aus On Off Marche Arr t Schaltplan Schematic diagram Sch ma lectrique Motorschutzschalter Motor protection switch Disjoncteur 76942 S1 Instruction Manual w PE 100 T 37 Schemat...

Page 44: ...Instruction Manual w PE 100 T 38...

Page 45: ...l change intervals and the oil filling level described for the equivalent BAUER compressor oil in the instruction manual of your unit Oil type Use Ambient temperature Brand name Designation Type A Bre...

Page 46: ...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 temperatur...

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