Bauer Junior II-B-F01 User manual

Instruction Manual Junior II
i
INTRODUCTION
This manual contains operating instructions and maintenance
schedules for the high pressure breathing air compressor unit
WARNING
! Pneumatic high pressure system !
The breathing air produced with the compressor units de
scribed in this manual is subject to strict quality standards.
Ignoring the operating and maintenance instructions can
lead to severe injury or death.
This compressor has been built in accordance with the EC ma
chine regulations 98/37/EG. Specifications on the noise level
in accordance with the machine and product safety law as of
01.05.2004 and the EC machine regulations, chapt. I, section
1.7.4. The machine has been built according to the highest
standard of technology and the generally acknowledged
safety standards. Nevertheless, operation could still cause
danger for the operating personnel or third parties, or result
in damage to the machine and other values. The machine
may only be used to produce compressed air as specified in
this manual. Other use is strictly prohibited.
All instructions should be observed and carried out in the or
der laid down to prevent damage and premature wear to the
equipment.
The manufacturer and the supplier void all responsibility for
damage or injury resulting from failure to follow these instruc
tions.
Edition January 2009
©2009 BAUER Kompressoren GmbH, München
All rights reserved
Junior II

A
BC
Instruction Manual Junior II
ii
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 contact us Mondays to Thursdays from 0800 till 1630,
Fridays from 0800 till 1400 on phone no. (089) 78049-0.
If you call the following extensions directly, it will save you
time and continuous dialling.
Do you want to order spare parts?
 Customer service
Phone no: (089) 78049-129 or -149
Fax no: (089) 78049-101
Do you have problems with maintenance or repair work?
 Technical customer service
Phone no: (089) 78049-246 or -176
Fax no: (089) 78049-101
Do you need further information regarding your unit, ac
cessories, prices etc.?
 Sales department
Phone 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 instructions on the unit
Read instruction manual before op
erating unit
 chapter 3.
Check oil level on compressor and
petrol engine before operating unit
 chapter 4.4.1.
Drain condensate at least every 15
minutes (3 locations)
 chapter 4.4.3. and 4.4.4.
Position units with petrol engine
with exhaust in wind direction to
prevent exhaust fumes being sucked
in by the compressor
 chapter 3.
Petrol driven units must not be oper
ated indoors.
 chapter 3.
Position unit level: max. inclination
5°
 chapter 3.
Operate unit only at ambient tem
peratures between +5 and +45 °C
 chapter 3.
Keep away from hot surfaces on
motor and compressor
 chapter 2.
Wear ear protectors when unit is
running
 chapter 2.

Instruction Manual Junior II
iii
CONTENTS
1. GENERAL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. SAFETY MEASURES 5. . . . . . . . . . . . . . . . . . . .
3. LOCATION, OPERATION, BOTTLE FILLING 9. . .
4. MAINTENANCE 17. . . . . . . . . . . . . . . . . . . . . . .
5. STORAGE, PRESERVATION 31. . . . . . . . . . . . . . .
6. REPAIR INSTRUCTIONS 32. . . . . . . . . . . . . . . . . .
7. TABLES 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. ANNEX 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INDEX
A
Adhesive chart, 34
Air flow diagram, 1
Annex, 35
B
B-Timer, 13
C
Change-over device, 12
Cooling system, 28
D
Design, 1
Drive system, 27
E
V-belt, tension meter, 27
Electrical system, 28
F
Filling procedure, 10
Filter system, 19
I
Intake filter, 18
Intermediate separator, 19
Intake air quality, 10
L
Location, 9
Lubrication, 17
Lubrication chart, 34
M
Maintenance, 17
Maintenance instructions, 17
Maintenance record, 17
Maintenance schedule, 17
Motor protection switch, 28
O
Oil change, 18
Oil level check, 17
Oil type, 17
Operation, 9
P
Preservation, 31
Pressure gauge, 24
Pressure-maintaining valve, 23
R
Repair instructions, 32
S
Safety valves, 24
Sealant chart, 34
Shut-down, 12
Storage, 31
T
Tables, 33
Technical data, 4
Telescopic intake tube, 18
Testing agents, 34
Tightening torque values, 33
Torque sequence, 33
Trouble-shooting, 29
V
Valves, 25
ANNEX
Schematic diagram motor protection switch, three phase current 76942-S1
Lubricating oil list 70851
Applicable parts list TJ-4/9

Instruction Manual Junior II
iv
NOTES
Model:
Serial No..:
Date of purchase:
Dealer address / phone no.:

11
12
13
14
1
3
8
4
10
6
5
7
2
9
Instruction Manual Junior II
1
1. GENERAL
PURPOSE
The JUNIOR II breathing air compressor is designed to com
press air for breathing as required in diving applications. The
max. allowable operating pressure (adjusted pressure on final
pressure safety valve) is 225 bar or 330 bar.
DESIGN
The compressor unit comprises the following major assem
blies:
- compressor block
- drive motor
- filter system P21
- filling assembly
- base plate and frame
The design of the compressor system is shown in Fig. 1 to
Fig. 4.
AIR FLOW DIAGRAM
See Fig. 5 . The air is drawn in through telescopic tube
(necessary for units with petrol engine) -1, intake filter -2;
compressed to final pressure in cylinders -3, -4, -5; recooled
by intercoolers -6, -7, and aftercooler -9. The pressures of the
single stages are protected by safety valves -10, -11, -12. The
compressed air is pre-cleaned in intermediate separator -8
and purified in filter system P21 -13. Intermediate separator
and filter system P21 are drained by means of condensate
drain valves -15. Pressure maintaining valve -16 provides a
constant pressure within the filter assembly. The com
pressed, purified air is passed through filling hose -17 and fill
ing valve -18 to the bottles to be filled. Filling pressure is indi
cated at pressure gauge -19. With the change over device
model it is possible to fill bottles with 200 bar nominal pres
sure, just by opening valve -21 at filling valve -18. Safety valve
-20 is adjusted to a blow off pressure of 225 bar.
Fig. 1 Compressor unit with petrol engine
1 Filling hose
2 Exhaust
3 Air filter
4 Tank
5 Throttle lever
6 Choke lever
7 Fuel cock
8 Starter rope
9 Engine stop switch (ignition)
10 Filling valve with final pressure gauge
11 Safety valve, final pressure
12 Filter system P21
13 B-Timer
14 Condensate drain taps

Instruction Manual Junior II
2
1 Filling hose
2 Filling valve with pressure gauge
3 Motor terminal box
4 Three-phase motor
5 Final pressure safety valve
6 Handle
7 Fanwheel cover
8 B-Timer
9 Condensate drain valves
10 Mains plug with ON-OFF switch and motor
protection circuit breaker (dep. on country)
6
1
2
4
3
5
7
8
9
10
Fig. 2 Compressor unit with electric motor (three-phase current)
1 Filling hose
2 Filling valve with pressure gauge
3 Motor terminal box with ON-OFF switch
4 Single-phase motor
5 Final pressure safety valve
6 Handle
7 Fanwheel cover
8 Pressure maintaining valve
9 Condensate drain valves
6
1
2
4
3
5
7
8
9
Fig. 3 Compressor unit with electric motor (alternating current)

Instruction Manual Junior II
3
1
2
4
3
7
8
5
9
1 Filling hose
2 Filling valve with pressure gauge
3 Final pressure safety valve
4 Filter system P21
5 B-Timer (optional)
6 Pressure maintaining valve
7 Filling connector
8 Intake filter
9 V-belt cover
6
Fig. 4 Compressor unit with electric motor, v-belt cover side
8
11
15
2
1 Telescopic air intake
2 Intake filter
3 Cylinder 1st stage
4 Cylinder 2nd stage
5 Cylinder 3rd stage
6 Inter-cooler 1st/2nd stage
7 Inter-cooler 2nd/3rd stage
8 Intermed. separator 2nd/3rd stage
9 After-cooler
10 Safety valve 1st stage
11 Safety valve 2nd stage
12 Final pressure safety valve
13 Filter system P21
14 TRIPLEX longlife cartridge
15 Condensate drain valve
16 Pressure maintaining valve
17 Filling hose
18 Filling valve
19 Final pressure gauge
20 Safety valve, final pressure PN 200
21 Change over device (optional extra)
Fig. 5 Air flow diagram

Instruction Manual Junior II
4
TECHNICAL DATA
Compressor unit JuniorII-B-F01 JuniorII-E JuniorII-W
Medium air
Deliverya) 100 l/min. (3,5 Scfm)
Operating pressure PN200/PN300
Pressure setting, final pressure safety valve 225/330 bar
Sound pressure 87 dB(A) 86 dB(A)
Sound (immersion) power 100 dBA) 99 dB(A)
Weight 46 kg 44 kg 47 kg
Compressor block Junior, mod. 3
Number of stages 3
Number of cylinders 3
Cylinder bore 1st stage 60 mm
Cylinder bore 2nd stage 28 mm
Cylinder bore 3rd stage 12 mm
Piston stroke 24 mm
Speed 2,300 min-1
Intermediate pressure 1st stage 6-7 bar
Intermediate pressure 2nd stage 40-60 bar
Compressor block oil capacity 360 ml
Oil volume between min. and max. marks 50 ml
Oil type see chapter 4.4.1. lubrication
Max. ambient temperature +5 ... +45 °C
Max. inclination of compressorb) 5°
Max. operating height 0 ... 2000 m above sea level
Compressor drive JuniorII-B
Drive motor Robin/Subaru petrol engine
Manual start model (B) EX17
Power 4.2 kW (5.7 PS)
at nominal speed 3,600 min-1
Compressor drive JuniorII-E
Drive motor Three phase current
Operating voltage 400 V, 50 Hz
Power 2.2 kW (3 PS)
Speed 2,850 min-1
Size 90 L
Type of construction B3
Type of enclosure IP54
Compressor drive JuniorII-W
Drive motor Alternating current
Operating voltage 230 V, 50 Hz
Power 2.2 kW (3 PS)
Speed 3,000 min-1
Size LS 90 PC
Type of construction B3
Type of enclosure IP44
a) free air delivered at bottle filling from 0 to 200 bar "5%
b) these values are valid only if the oil of the compressor in normal position corresponds with the upper mark of the oil dipstick and may
not be exceeded.

MV3−A/10/06
WARNING
Instruction Manual Junior II
5
2. SAFETY MEASURES
2.1. NOTES AND WARNING SIGNS
Notes and warning signs displayed on compressors accord
ing to model, application or equipment.
WARNING
Hot surfaces, do not touch!
Danger of burning by touching cylinders,
cylinder heads and pressure lines of individ
ual compressor stages.
WARNING
High voltage!
Life threatening danger of electric shock.
Maintenance work on electric units or op
erating equipment may only be carried out
by a qualified electrician or by a person
instructed and supervised by a qualified
electrician according to electrical regula
tions.
WARNING
Automatic compressor control, unit may
start-up without warning!
Before carrying out maintenance and repair
work, switch off at the main switch or dis
connect from the mains and ensure unit will
not restart.
MANDATORY
Instructions must be read by persons oper
ating the machinery!
The instruction manual supplied and all
other applicable instructions, regulations
etc. must be read and understood by oper
ating personnel before using the machine.
MANDATORY
Hearing protectors must be worn!
Hearing protectors must be worn when
working on a machine which is running.
NOTE
Ensure correct direction of rotation!
When switching on the machine, check the
arrow to ensure correct direction of rota
tion of the drive motor.
2.2. IDENTIFYING THE SAFETY NOTICES
Important instructions concerning the endangerment of per
sonnel, technical safety and operating safety will be specially
emphasized by placing the following signs before the instruc
tions.
This notice is used with maintenance
work and operating procedures and
must be adhered to exactly in order to
avoid endangering personnel.
This notice must be complied with in order to
avoid damage to or destruction of the machine
or its equipment.
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 the art
technology and established safety technical regulations.
Nevertheless, its use can cause danger to life and limb of
the operator or third parties or damage to the machine
and other equipment.
•Operate the machine / unit only in technically perfect
condition in accordance with regulations and safety and
danger notices detailed in the instruction manual! In par
ticular, immediately correct faults (or have them cor
rected) which can impair safety!
•The machine / unit is exclusively for the compression of
mediums (air/gas) specified in section A, chapter 1.3.
“Technical data”. Any other medium or use outside that
specified is not authorized. The manufacturer / supplier is
not liable for 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 com
plied with and inspection and maintenance requirements
are enforced.
2.3.2. Organizational measures
•Keep the instruction manual to hand near the machine /
unit at all times in the relevant holder.
•In addition to the instruction manual, observe and com
ply with universally valid legal and other obligatory re
gulations regarding accident prevention and environ
ment protection. See chapter 2.4. This can involve, for
example, contact with hazardous substances or the provi
sion / wearing of personal protective equipment.
•Personnel engaged to operate the machine must have
read the instruction manual before beginning work, es

Instruction Manual Junior II
6
pecially the safety notices chapter. When work is already
underway it is too late. This is particularly relevant for
temporary personnel, e.g. maintenance personnel.
•Personnel may not wear long hair loose, loose clothing or
jewellery, including rings. There is a danger of injury
through, for example, these getting caught or being
pulled into the equipment.
•As far as necessary or according to regulations, use per
sonal protective equipment.
•Observe all safety and danger notices on the unit.
•Keep all safety and danger notices on the machine / unit
complete and in readable condition.
•If there are any modifications to the unit or operating
conditions which may affect safety, stop the unit immedi
ately and inform the person responsible of the fault.
•No modifications may be made to the unit which could
impair safety without first obtaining permission from the
suppliers. This is also the case with regard to installation
and adjustment of safety devices and valves as well as
welding of piping and reservoirs.
•Spare parts must always comply with the technical re
quirements specified by the manufacturer. This is always
guaranteed with original spare parts.
•Piping must be thoroughly checked (pressure and visual
inspection) by the operator at appropriate time intervals,
even if no safety related faults have been noticed.
•Intervals stipulated or given in the instruction manual for
recurring checks / inspections must be adhered to.
•Make sure location and operation of fire extinguishers is
known.
•Pay attention to fire warning and fire fighting procedures.
2.3.3. Qualifications, fundamental duties
•Work on / with the unit may only be carried out by reliable
personnel. Observe the legal minimum age permissible.
•Ensure that only trained personnel work with the ma
chine.
•Establish the responsibilities of the machine operator and
establish a procedure for him to inform a third person of
unfavourable safety conditions.
•People who are being trained or introduced to the job
should only be allowed to work with the unit under con
stant supervision of an experienced person.
•Work on the electrical equipment of the unit may only be
carried out by a qualified electrician or by an instructed
person under the direction and supervision of a qualified
electrician according to electrotechnical regulations.
2.3.4. Safety notices for operation
•Do not carry out any work if safety is questionable.
•Meet all requirements demanding that the unit is only op
erated in safe and good working order. Only operate the
machine if all protective and safety equipment, e.g. all de
tachable protective equipment, emergency shut-down
devices, soundproofing is provided and in good working
order.
•At least once every day, check the unit externally for dam
age and faults. Inform the person responsible immedi
ately if anything is not as is should be (including oper
ation). If necessary, shut the machine down immediately
and make it safe.
•Observe switching on and off processes and monitoring
indications according to the instruction manual.
•Before switching on / starting up the unit, ensure that no
one can be put at risk through running the unit.
•Carry out the setting, maintenance and inspection pro
cesses at the intervals specified in the instruction manual,
including replacement of parts / equipment. This work
may only be carried out by qualified personnel.
•Clear and make the maintenance area safe as far as
necessary.
•If the unit is completely switched off for maintenance and
repairwork, ensure that it is protected from unexpected
start-up. Turn off main control device and remove the key
and / or display a warning sign on the main switch.
•When replacing individual parts and larger assembly
groups, they must be carefully fastened to the lifting de
vice so that there is no risk of danger. Use only suitable
and technically perfect lifting devices and equipment
with sufficient lifting power and strength. Do not linger
or work under suspended loads.
•Only entrust an experienced person with the fixing of
loads and guiding of crane drivers. The person guiding
must remain within sight or in contact with the operator.
•For assembly work above body height, use appropriate
safety approved equipment, e.g. ladders and platforms.
Do not climb on machine parts. For maintenance work at
high levels, wear a safety harness.
•Clean oil, fuel or care products from the machine, in par
ticular the connections and screw joints, before carrying
out maintenance / repairwork. Do not use aggressive
cleaning fluid. Use a fibre-free cleaning cloth.
•Before cleaning the machine with water or jet of steam
(high pressure cleaner) or detergent, cover / seal all open
ings which for safety and/or operating reasons no water
/ steam / detergent may penetrate. Electric motor and
switch cabinets are particularly at risk.
•When cleaning the operating room, ensure that the tem
perature sensors of the fire alarm and sprinkler system do
not come into contact with hot cleaning fluid, in order to
avoid triggering the sprinkler system.
•Completely remove all covers / seals after cleaning.
•After cleaning, check all pressure lines for leaks, loose
connections, wear and damage. Immediately eliminate
any faults.
•Always retighten any screw connections loosened for
maintenance or repairwork.
•If it is necessary to remove safety devices for maintenance
and repairwork, these must be replaced and checked im
mediately after completion of the maintenance or repair
work.

Instruction Manual Junior II
7
•Ensure safe and environmentally friendly disposal of con
sumables and old parts.
2.3.5. Particular areas of danger
•Use only original fuses with specified current rating. If
there is a failure in the electric energy supply, shut the unit
down immediately.
•Work on electric units or operating equipment may only
be carried out by a qualified electrician or by a person
under the instruction and supervision of a qualified elec
trician according to electric technical regulations.
•Machines and unit parts which must undergo inspection,
maintenance and repairwork, must be disconnected
from the mains supply, if specified. Parts which have been
disconnected must first be checked for voltage, then
earthed and short-circuited and isolated from live neigh
bouring parts.
•The electrical equipment of a unit must be regularly
checked. Defects, such as loose screw connections or
burnt wires, must be rectified immediately.
•If work is to be carried out on live parts, work with a sec
ond person who can operate the emergency off switch or
the main switch in the case of an emergency. Close off the
work area with a red and white safety chain and a warn
ing sign. Only use voltage isolated tools.
•Only personnel with particular knowledge and experi
ence with pneumatics may carry out work on pneumatic
equipment.
•Check all pressure lines, hoses and screw connections
regularly for leaks and visible damage. Immediately repair
any damage. Escaping air under pressure can cause injury
and fire.
•Depressurize system and pressure lines before commenc
ing repairwork.
•Pressurized air lines must be laid and mounted by quali
fied personnel. Connections must not be mixed up. Fit
tings, length and quality of the piping must correspond to
requirements.
•Soundproofing equipment on the unit must be in place
and functional during operation.
•The stipulated hearing protectors must be worn.
•With regard to oil, grease and other chemical substances,
observe the relevant safety regulations for the product.
•For loading, only use lifting device and equipment with
sufficient lifting power and strength.
•Use only suitable transporters with sufficient carrying
power. Secure the load properly. Use suitable fixing
points.
•If necessary, provide unit with transportation brackets.
Display the appropriate notice. Remove transportation
brackets in the correct manner before taking into oper
ation.
•Parts which need to be dismantled for transport purposes
must be carefully replaced and secured before taking into
operation.
•Even when moving the unit only slightly, the unit must be
disconnected from all external energy sources. Before
putting into use again, reconnect the machine to the
mains according to regulations.
•When taking back into operation, proceed according to
the instruction manual.
2.3.6. Notices of danger regarding pressure vessels
•Never open or loosen pressure vessel lids or pipe connec
tion parts under pressure; always depressurise the vessel
or the unit.
•Never exceed the permissible operating pressure of the
vessels!
•Never heat the vessels or any of their parts above the
stated, maximum operating pressure.
•Always exchange damaged pressure vessels completely.
Individual parts that are subject to pressure loads cannot
be purchased as spare parts, since the vessels are tested
as a complete part and the documentation considers
them as a whole (see pressure vessel documentation,
serial-numbers!).
•Always pay attention to the permissible operating mode
of the pressure vessels.
We differentiate:
- vessels for static load
- vessels for dynamic load
Vessels for static load:
These pressure vessels are permanently under virtually
constant operating pressure; the fluctuations of pressure
are very small.
Vessels for this type of load are not marked in a particular
way and may be used as long as the vessel inspections,
carried out regularly, do not uncover any safety-relevant
deficiencies.
We recommend that aluminium vessels should be
exchanged after 15 years at the latest.
Vessels for dynamic load:
These pressure vessels may also be used under conditions
of changing operating pressure. The pressure may vary
between the atmospheric and the maximum admissible
operating pressure.
The pressure vessel documentation and the appropriate
notes in the operating manual particularly characterise
vessels of this type as being adequate for dynamic loads.
In the technical information for these vessels you will find
specifications concerning their permissible operating
period.
Due to the variation of the operating pressure, these
vessels are subject to a so-called dynamic load, which
puts the vessels under great stress. The change between
two different pressures is called a load change or cycle. In
the technical information for these vessels you will find
specifications concerning the permissible number of
cycles depending on the fluctuation of the operating
pressure.
Having reached half the permissible number of cycles, the
vessel has to be submitted to an internal check, in which

Instruction Manual Junior II
8
the critically stressed areas of the vessels are examined by
means of suitable testing methods, in order to ensure the
operating safety.
After having reached the total permissible number of
load cycles, the vessel must be exchanged and scrapped.
Record the number of load cycles in writing if you do not
have an automatic cycle-counter.
We recommend that aluminium vessels should be
exchanged after 15 years at the latest.
Please pay attention to and follow these measures, for
your own safety and that of you employees and cus
tomers!
In order not to unnecessarily load the pressure vessels
additionally, the non-return valves, that are meant to
avoid a drop in pressure, and also the pressure maintain
ing valves, which should reduce big pressure fluctuations
as well, should be checked regularly for internal and ex
ternal tightness and functionality.
•Check the pressure vessels regularly on the inside and out
side for damage from corrosion.
•Be particularly careful with second-hand pressure vessels,
when their previous operating mode is not specifically
clarified.
2.4. SAFETY REGULATIONS (EC; partly Germany,
only)
A compressor is identified by German law as being a filling
system 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 fill
ing stations is governed by the following regulations:
Pressure vessel directive (Directive 97/23/EC) of
29.05.1997
Operating safety regulations (BetrSichV) of 27.09.2002
Machine safety law (GSG) of 11.05.2001
14th regulation to machine safety law (14. GSGV - pres
sure vessel regulation) of 03.10.2002
Technical regulations for pressure gases (TRG 400, 401,
402, 730).
If a high pressure compressor is used for filling pressure
vessels or for the supply of pneumatic systems, the following
regulations apply:
Accident Prevention Regulations (UVV):
BGV A1 of 01. January 2004
Copies of the above regulations are available through the
usual outlets, e.g. in Germany from:
Carl Heymanns Verlag
Luxemburger Str. 449
50939 Köln
Beuth-Vertrieb GmbH
Burggrafenstr. 4 - 7
10787 Berlin
The manufacturer has complied with all applicable regula
tions and the unit is prepared accordingly. If desired, we offer
at our Munich site a partial acceptance test according to §
14 BetrSichV. Please contact our Technical Service Depart
ment with regard to this. They can also supply our leaflet
“IMPORTANT NOTES FOR CERTIFICATION”.
According to the operation safety regulations (BetrSichV), all
compressor units which will be used as filling stations must
undergo an acceptance test by a professional at their loca
tion before bringing them into service. If pressure vessels
(bottles) are to be filled by the compressor for a third party
then the appropriate permission must be obtained from the
responsible authority before the acceptance test. As a rule,
this is the factory inspectorate. The procedure for obtaining
permission is according to TRG 730, guidelines for permission
to set up and operate filling stations. The test certificates and
documents delivered with the compressor are important and
may be requested during the procedure for obtaining per
mission. In addition, the documents belonging to the unit are
important for recurrent inspections and should therefore be
carefully kept.
Inspections in accordance with the regulations for preven
tion of accidents will be carried out by the manufacturer or
by a specialist.
No guarantees whatsoever are valid for damage caused or
favoured by the non-consideration of these directions for
use.
We strongly emphasize these regulations.

WARNING
Instruction Manual Junior II
9
3. LOCATION, OPERATION, BOTTLE FILLING
LOCATION
Outdoor location
The compressor unit is not seawater resis
tant. At operation in salty air spray com
pressor with anticorrosive protection (e. g.
Quicksilver Corrosion Guard). Electric
driven units should be operated and stored below deck.
Units with petrol engine should also be stored below
deck after the filling process.
Keep unit away from inflammable items.
Do not smoke while petrol tank is open
and while unit is in operation.
- Locate the unit level.
- On units with petrol engine it is most important that only
clean air be used, position compressor in direction of
wind so that exhaust fumes are blown away from the unit.
- Turn unit as soon as wind direction changes.
- Take care that no vehicles are in direct vicinity with en
gines running.
- Do not operate unit in the vicinity of open fire (flue gas!).
Indoor location
Petrol driven units must not be operated
indoors.
- Ensure adequate ventilation.
- Here too, air must be free from exhaust fumes and haz
ardous vapours (e.g. smoke, solvent vapours, etc.).
- If possible install unit in such a manner that the com
pressor fan can get fresh air from outside, for instance
through an opening in the wall.
- Ensure that an adequate exhaust air opening is provided.
- When locating the compressor in small rooms where
natural ventilation is not ensured, measures must be
taken to provide artificial ventilation (this also applies
when other systems having high radiation are operating
in the same room).
Electrical installation
For installation of electrical equipment observe the follow
ing:
- Comply with regulations of local electricity supply com
pany.
- Arrange for the electrics to be connected by an electrician
only.
- Ensure correct installation of protective conductor.
- Check conformity of motor tension and frequency with
those of electric network.
- Operate electric units only on mains sockets equipped
with fault current circuit breaker according to DIN VDE
0664 with a nominal differential current of less than 30
mA (up to 16 A in single-phase AC circuits).
- For units not connected through a plug, but permanently
installed, a main switch must be provided which has a
contact gap of minimum 3 mm on each pole.
- Fuse motor correctly; use slow-blow fuses, only.
- Immediately after start-up check direction of rotation for
agreement with arrow on unit.
If power supply cable is to be replaced, use
cable of same type, only!
- When using extension leads or cable drums, operate unit
with unwound cable, only to avoid overheating and risk
of fire. The maximum length for extension cables at nor
mal ambient temperatures (approx. 20 °C) is 25 metres.
OPERATION
Preparation for operation
All compressor units are tested prior to de
livery to the customer, so after correct in
stallation of the unit there should be no
problem putting it into operation, observing the fol
lowing points:
The compressors described in this
manual are not suitable for com
pression of oxygen. EXPLOSION oc
curs if an oil lubricated compressor is operated with
pure oxygen or gases with an oxygen content of more
than 21%!
- 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 con
trols and monitors. Particularly observe chapter 2
SAFETY REGULATIONS.
- After taking unit into operation after a standstill period of
2 years or more change compressor oil. When using a
mineral oil change oil after one year.
- Prior to first operation or operation subsequent to repair
work operate unit for at least 5 minutes with open con
densate valves (pressureless) to ensure proper lubrication
of all parts before pressure is built up.
- Prior to each operation check the oil level according to
chapter 4.4.1. and determine whether maintenance is
necessary in accordance with chapter 4.3.
- 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 ser
vice department.

WARNING
WARNING
WARNING
Instruction Manual Junior II
10
Units with three phase current motor, additionally:
- Immediately after switching on the system for the first
time check the direction of rotation of the motor for com
pliance with the arrow on the unit. If motor turns in the
wrong direction, the phases are not connected properly.
Shut down unit immediately and interchange two of the
three phase leads in the switch box. Never change leads
at the motor terminal board.
Units with petrol engine, additionally:
- Check engine oil level according to manufacturer's in
struction manual.
- Check fuel tank. Top up if necessary.
- Open fuel shut-off valve.
Starting the unit
- Open condensate drain valves on the filters to release
pressure so that motor starts without load.
Units with electric drive motor:
-Three-phase current: the motor is switched on man
ually by turning the switch (1, Fig. 6) to 1.
Fig. 6 Motor protection switches
(three-phase motor)
1
-Alternating current: Set 0-I switch to I.
Units with petrol engine:
- Set choke to position START. Start engine with recoil
starter or crank handle. As soon as motor runs smoothly
return choke to normal operating position.
All units:
- Close condensate drain valves and run unit to final pres
sure. Check final pressure safety valve and pressure
gauge.
- As soon as final pressure is reached and final pressure
safety valve blows off, open condensate drain valves and
drain condensate - unit is ready for filling operation. Ob
serve regular condensate drain acc. to chapter “Mainten
ance”.
FILLING PROCEDURE
General
Ensure intake air is free from
noxious gas (CO), exhaust fumes and
solvent vapour. On units employing
petrol or diesel engine it is most important to use an
intake hose and observe that only clean air is drawn in.
The intake hose is also recommended for units with
electric engine. When operating the unit in areas with
possibly high CO contents, the CO removal filter car
tridge is recommended for electric driven units, also.
Note that for CO contents of more than 25 ppmV in the
intake air the allowed limits cannot be guaranteed even
with a CO removal filter cartridge, resulting in a life-
threatening CO concentration! Also, due to chemical re
action of CO with hopcalite, warming up of the car
tridge and danger of fire may result.
Filling hoses must be in satisfactory
condition and threads undamaged.
Pay particular attention to damage
on the interface from hose fitting to hose. If the casing
is scored, hose must be discarded.
The filling valve connection is of the manual type and permits
connection to air tanks without using tools. An O-ring is pro
vided for self-sealing due to internal overpressure. Com
pressed air tank filling valves for a pressure in excess of 200
bar are standardized (DIN 477, sheet 5) and connectors for
200 and 300 bar are different and cannot be mixed up. The
use of adapters is not allowed!
To ensure safe air tank removal after filling, the valve has an
integral venting bore. Therefore always close tank valve first
before closing filling valve. During filling procedure bottles
will warm up due to recompression. After removing, allow to
cool down, bottles may then be reconnected and topped up
to the respective maximum filling pressure.
To meet the CO2maximum rating
value in breathing air bottles, please
observe the two following chapters
”Intake air quality” and ”Scavenging the compressor
unit”.
Intake air quality
At routine tests, CO2values beyond the permissible values are
noted from time to time. Closer investigations often show
that the compressed air is taken from rooms in which one or
more persons are working. At insufficient ventilation, the
CO2value in the surrounding air can increase quite fast be
cause of the exhaling of CO2. CO2values from 1,000 to 5,000
ppmv in workrooms are not unusual (MAK-value (max. work
room concentration) is 5,000 ppmv). Another additional in
crease is caused by cigarette smoking, producing approx. 2g
CO2(2,000 ppmv) per cigarette. These pollutions add up
to the basic pollution of approx. 400 ppmv. The technically
caused excessive increase of CO2during the filling process
and the CO2peak at taking the unit into operation. Because
of the reasons stated above and for your own security,
the filling of breathing air bottles is not allowed in
rooms used as workrooms.

Instruction Manual Junior II
11
Scavenging the compressor unit
CO2is present in the atmosphere with a natural amount of
350 to 400 ppmV
. The molecular sieve used in the purifier for
drying the breathing air is, as well as other capabilities, able
to adsorb CO2which is accumulated in the cartridge. After
shut-down of the compressor, adsorbed CO2may be de
sorbed again due to the partial pressure decrease. The now
free CO2then gets washed out of the cartridge when the
compressor is started again. To avoid increased CO2contents
in the compressed breathing air, we recommend to flush the
compressor unit 1 to 2 minutes prior to connecting the
bottles, i.e. to let the air escape into the surroundings.
Connecting the bottles
On models of 300 bar rated filling pressure
do not attach bottles unless rated for this
pressure (note pressure stamped on tank
neck).
- Connect air bottle to filling valve (see Fig. 7).
- Air bottles with international filling connector can be
connected with filling adaptor (part no. 79375) to the
German filling connector (see Fig. 8).
The international connector is not per
mitted in the Federal Republic of Germany.
In other countries it is allowed only for
pressures up to 200 bar (2,850 psi).
Filling the bottles
- Open filling valve (1, Fig. 9).
- Open bottle valve (2) - bottle will be filled. Drain conden
sate regularly during filling. On units with automatic con
densate drain check that condensate is drained regularly.
The filling procedure should not be inter
rupted for more than 10 minutes to avoid
increased CO2-values in the air filled into
the bottles.
Fig. 7 Connecting air bottle
Fig. 8 International filling connector
2.
1.
Fig. 9 Filling air bottle
Fig. 10 Removing air bottle
2.
1.
Removing the bottles
- Upon reaching final bottle pressure close bottle valve
first (1, Fig. 10), then filling valve by returning handle
to closed position (2).
- Remove compressed air bottle.
CHANGE-OVER DEVICE PN 300/PN 200
(Fig. 11) This device allows bottle filling to 200 bar
(3,200 psig) with a 300 bar (4,700 psig) rated unit. Safety
valve -B and filling device PN 200 bar are connected by open
ing change-over valve -A and the connected bottles can be
filled with a 200 bar pressure, as described in ”Filling the
bottles”.
Depressurize unit before opening valve -A
to avoid damage to the change-over de
vice

Instruction Manual Junior II
12
SHUT-DOWN PROCEDURE
- Close filling valve.
Units with electric motor:
-Three-phase current: the motor is switched off by turn
ing the switch (1, Fig. 12) to 0.
-Alternating current: set 0 - I switch to 0.
Units with petrol engine:
- Shut down petrol engine with stop button or stop lever.
All units:
- Drain condensate from intermediate separator and
Triplex filter by means of the drain taps. Vent unit by
means of filling valve to approx. 80 bar (1,150 psi). Close
all valves again to prevent moisture entering the filter and
resulting saturation of the cartridge.
- Check the oil level in the compressor and top up, if necess
ary. Also check whether the compressor needs servicing
in accordance with maintenance schedule - see chapter
4.3.
Fig. 11 Change-over device
B
A
Fig. 12 Motor protection switches
(three-phase motor)
1

Fig. 13 B-Timer
1 Key symbol (maintenance due)
2 Letter symbol (maintenance type)
3 Low battery symbol
4 Cartridge saturation indicator
5 Operating hours or cartridge number
6 Mode select key
7 Enter key
12
34
5
6 7
Instruction Manual Junior II
13
B-TIMER (optional)
Introduction
Read operating instructions carefully before operating the
unit.
The settings in the setup menu are essential
for the correct indication of the filter capac
ity. Without correct settings, the B-Timer
can be used as an hourmeter, only!
Make sure that the pressure maintaining
valve of the compressor is adjusted to 150
bar (factory setting, see chapter 4.4.5.) and
is working properly to ensure correct indication of the
filter capacity and compressor operation recognition.
Description
The B-Timer (Fig. 13) is a self-activating mini-computer that
counts the operating hours of the compressor and calculates
the saturation of the filter cartridge from time, temperature,
cartridge type, and delivery rate of the compressor. It displays
operating hours, cartridge lifetime, and all maintenance due
for the compressor. The B-Timer does neither need external
power nor any other connection to the pressure system. It is
simply fastened to the filter housing which has to be moni
tored, by means of a clamp, and is therefore the ideal filter
control device for all mobile compressor units, especially for
portable petrol or diesel driven scuba diving models. In addi
tion, the B-Timer can be mounted easily to any unit as an up
grade device.
Authorized use
This unit is to be used exclusively as operating status monito
ring device and does not release the user from additional sur
veillance and testing of the breathing air quality of the filter
system according to national standards (e.g. EN 12021). With
the B-Timer, this is not possible!
The B-Timer may only be used with the filter systems P21, P31
and P41. The respective filter cartridge numbers are stored in
the software. Other use is strictly prohibited. The manufac
turer and the supplier void all responsibility for risk, damage or
injury resulting from failure to follow these instructions.
Please observe the operating limits of the unit:
Operating temperature range 0°C to +50 °C,
Storage temperature -20°C bis +70 °C
Protection class IP65 (Protection against contact with wire,
dust, and jet of water
Vibration $3g in operation
max. 95% humidity, not condensating
Function
The B-Timer display shows the following functions:
•Operating hours of the compressor unit
•Cartridge lifetime in % by means of four segments in the
cartridge symbol.
•Flashing last segment and change from operating hours in
dication to cartridge part no. if capacity is equal or less than
20% of the original lifetime.
•Indication of compressor maintenance due by means of
letter symbols and operating hours.

Fig. 14
Fig. 15 Battery
Fig. 16
Fig. 17
1
2
Instruction Manual Junior II
14
A = 500 hours or 1 year
B = 1000 hours or 1 year
C = 2000 hours or 2 years
•Battery symbol indicating that the lithium battery is low
and has to be changed. All data are stored and will not
be lost when changing battery.
The B-Timer is operated using the mode select and the enter
keys.
Error indication
If the temperature sensor in the unit should be defective, an
error message “Error 1” or “Error 2” is shown at the display
(Fig. 14). In this case the unit should not be used but sent to
the factory or the nearest BAUER representative for repair.
Battery change
The battery (1, Fig. 15) is merely inserted into the holder.
To change the battery remove two bolts and separate housing
from base plate. Remove plug (2) and pull out battery.
Make sure to use the same type battery (BAUER part no.
82743).