POSEIDON PE 250-HE User manual

PE 250-HE
PE 300-HE
High Pressure
Breathing Air Compressors
Instruction Manual
Copyright 2013 BAUER Kompressoren GmbH München

PE 320-HE
Instruction Manual Breathing Air Compressors
i
INTRODUCTION
This manual contains operating instructions and mainte
nance schedules for the high pressure breathing air compres
sors
WARNING
! Pneumatic high pressure system !
The breathing air produced with the compressor units de
scribed in this manual is subject to strict quality standards. Ig
noring 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 2006/42/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 acknowl
edged 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 ma
chine may only be used to produce compressed air as speci
fied in this manual. Other use is strictly prohibited.
Edition January 2014
©2014 BAUER Kompressoren GmbH, München
All rights reserved.

Instruction Manual Breathing Air Compressors
ii
TABLE OF CONTENTS
1. GENERAL 1......................................................................................
2. SAFETY MEASURES 9..............................................................................
3. INSTALLATION, OPERATION, FILLING PROCEDURE 13....................................................
4. MAINTENANCE 20.................................................................................
5. STORAGE, PRESERVATION 40........................................................................
6. REPAIR INSTRUCTIONS 41...........................................................................
7. TABLES 42.......................................................................................
8. ANNEX 43........................................................................................
INDEX
A
Adhesive chart, 42
Air flow diagram, 5
Ambient temperature, 27
B
B-Timer, 16
C
Changing the oil type, 21
Compressor block, 4
Condensate drain, 28
timer adjustment, 35
Control unit, 16
Cooling system, 37
D
Drive system, 36
E
Electrical system, 35
F
Filling procedure, 14
Filling valve maintenance, 30
Filter system, 23
Final separator, 27
Fuse table, 13
I
Installation, 13
Intake air quality, 14
Intake filter, 22
Intermediate separator, 22
L
Lubrication, 20
Lubrication chart, 42
M
Maintenance instructions, 20
Maintenance record, 20
Maintenance schedule, 20
O
Oil change, 21
Oil pump, Venting, 22
Operation, 13
P
Preservation, 40
Pressure gauge, 32
Pressure switch, 35
Pressure-maintaining valve, 31
S
Safety valves, 31
Sealant chart, 42
Shut-down, 15
Starting the unit, 14
Storage, 40
T
Tables, 42
Technical data, 6
Testing agents, 42
Tightening torque values, 42
Torque sequence, 42
V
Valves, 32

Instruction Manual Breathing Air Compressors
iii
ANNEX
Air flow diagram See Chapter 8, Annex
Schematic diagram See Chapter 8, Annex
Components parts list See Chapter 8, Annex
Lubricating oil list on CD
Applicable parts list
PE 250-HE, PE 300-HE TPEH-2/0 (on CD)
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 repeated 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, accessories, 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) 78049-101
Meet us in the internet at: www.bauer-kompressoren.de

Instruction Manual Breathing Air Compressors
iv
NOTES
Model:
Serial no.:
Date of purchase:
Dealer address/phone no.:

Instruction Manual Breathing Air Compressors
1
1. GENERAL
PURPOSE AND SHORT DESCRIPTION
The PE 250-HE and PE 300-HE high pressure compressors
are designed to compress air for breathing as required in div
ing and fire fighting applications. The max. allowable operat
ing pressure (adjusted pressure on final pressure safety valve)
is 225 bar or 330 bar depending on the model.
2 2
3
4
1
1 Final pressure gauge
2 Filling valve, 300 bar
3 Control unit
4 Condensate tank
5 Cover
,
v-belt turnbuckle
5
Fig. 1 Compressor unit PE 300-HE

Instruction Manual Breathing Air Compressors
2
DESIGN AND MODE OF OPERATION
Design
The compressor unit comprises the following major assem
blies:
•drive motor
•filter assembly
•filling assembly
•protection and anti-vibration frame
•automatic condensate drain
•electric control system
Standard equipment:
•Filter system P31
•TÜV-approved final pressure safety valve
•Instrument panel with final pressure gauge
•electric control system with automatic switch-off
Optional equipment:
•Filter system P42 with or without SECURUS monitoring
device
•filling device with 2 filling valves
•filling panel with 4 filling valves (with direct or hose
connectors) for filling of 200 and 300 bar bottles
•Air-Kool for increased filter cartridge life time
•B-Timer for monitoring of cartridge saturation.
The compressor units are available with electric motor, only.
Function
The operating principle, i.e. the way of the air through the
compressor, is shown in Fig. 6.
3
12 11 10
1
9 8 7
4 5
6
2
1 Automatic condensate drain
2 Compressor block
3 SECURUS mionitering device
4 Filter P42
5 Final pressure switch
6 Pressure maintaining valve
7 Venting valve w. pressure gauge
8 Timer
9 Condensate drain tap
10 Condensate separator
11 Electric motor
12 Condensate tank
Fig. 2 Compressor unit PE 300-HE, rear view

Instruction Manual Breathing Air Compressors
3
1 Filling connector PN300
2 Filling pressure gauge
3 Phase-sequence warning light
4 Condensate tank
5 Stop button
6 Start button
7 Hour meter
8 Main switch
6
1
2
3
4
5
8 7
Fig. 3 Compressor unit PE 300-HE, right side view
1 2 2 4 43 5
1 Filling pressure gauge 300 bar
2 Filling valve 300 bar
3 Safety valve 200 bar
4 Filling valve 200 bar
5 Filling pressure gauge 300 bar
Fig. 4 Filling panel with two pressure ranges

Instruction Manual Breathing Air Compressors
4
Compressor block IK120
The design of the compressor block is shown in Fig. 5. For the
mode of operation refer to the flow diagram, Fig. 6.
The compressor block is used to compress air in the high
pressuare range. The max. allowable operating pressure is
350 bar.
The compressor block is of a three stage, three cylinder
design. The cylinders are arranged in a W form, 1st stage in
the centre, 2nd stage on the right, and 3rd stage on the left
side looking from the filter side.
These compressor blocks are particularly suitable for
continuous operation because of their rugged design and
the corrosion resistant intermediate filter and cooler
assemblies. Smooth running is a particular feature of this
BAUER design. The balance of masses of the 1st rank is zero.
The moving parts of the driving gear are all equally balanced.
This results in a vibration-free running.
The driving gear is fitted with energy saving cylinder roller
bearings. The upper and lower connecting rod bearings are
also roller bearings. This allows for an even longer life which
lasts at least 30,000 operating hours.
3
2
13
5
4
6
8
7
9
10
12
15
11
1
14
1 Cylinder 1st stage
2 Intake filter
3 Oil filler neck
4 Cylinder, 3rd stage
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. 5 Compressor block

Instruction Manual Breathing Air Compressors
5
Air flow diagram
See Fig. 6. The air is drawn in through intake filter -5, com
pressed to final pressure in cylinders -1, -2, -3, and -4, and re
cooled by inter-coolers -6, -7 and -8, and after-cooler -9. The
safety valves -13, -14, -15 and -16 protect the pressure of the
single stages.
The compressed air is purified by interfilters -10 and -11 and
filter assembly -12 which is fitted with a Triplex cartridge -17.
The interfilters -10 and -11 and filter assembly -12 are
drained by condensate drain valves -18. Pressure maintain
ing valve -19 keeps the pressure constant within filter assem
bly -12. Through filling hose -20 and filling valves -21 the
compressed and purified air is conducted to the bottles to be
filled. Filling pressure can be read from pressure gauge -22.
300 bar compressor units are available with a change-over
device -23 to fill 200 bar bottles. In this case, safety valve -24
(225 bar) takes over the function of the final safety valve -16
(330 bar).
5
6
7
8
9
10
11
12
13
1415
16
18 19
17
20
21
21
22
22
23
24
18
18
Fig. 6 Air flow diagram with filter system P31
1 Cylinder 1st stage
2 Cylinder 2nd stage
3 Cylinder 3rd stage
4 Cylinder 4th stage
5 Intake filter
6 Cooler 1st stage
7 Cooler 2nd stage
8 Cooler 3rd stage
9 After-cooler
10 Intermediate separator 2nd stage
11 Intermediate separator 3rd stage
12 Filter system P31 (Central filter assembly)
13 Safety valve 1st stage
14 Safety valve 2nd stage
15 Safety valve 3rd stage
16 Final pressure safety valve
17 Triplex filter cartridge
18 Manual condensate drain taps
19 Pressure maintaining valve
20 Filling hose
21 Filling connector
22 Filling pressure gauge
23 Change-over device 300 bar - 200 bar
24 Safety valve 225 bar

Instruction Manual Breathing Air Compressors
6
TECHNICAL DATA
Compressor unit PE 250-HE
Compressor unit PE 250-HE-F02
Medium Breathing air
Operating pressure PN 200 PN 300
Deliverya) 250 l/min. 250 l/min.
Pressure setting, final pressure safety valve 225 bar 330 bar
Sound pressure level 87 dB(A) 87 dB(A)
Sound power level 101 dB(A) 101 dB(A)
Weight 220 kg 200 kg
Compressor block IK120-F07
Number of stages 3
Number 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
Speed 1,470 min-1
Intermediate pressure 1st stage 6 bar 6.5 bar
Intermediate pressure 2nd stage 45 bar 47 bar
Compressor block oil capacity 2.8 ltrs.
Oil pressure 5 bar (3 to 6 bar)
Type of oil see lubricating oil list
Max. ambient temperature +5 ... +45 °C (+43 ... +113 °F)
Max. permissible inclination b) 15°
Max. permissible operating height 0 ... 2000 m above sea level
Drive motor Three phase squirrel cage
Operating voltage 380 - 415 V, 50 Hz; 380 - 480 V, 60 Hz
Power 5,5 kW (7,5 PS)
Speed (at 50 Hz) 2,910 min-1
Size 112 M
Type of construction B 3
Type of enclosure IP 55
a) free air delivered at tank filling from 0 to 200 bar 5%
b) these values are valid only if the oil level of the compressor in normal position corresponds with the upper mark of the sight gauge and
may not be exceeded

Instruction Manual Breathing Air Compressors
7
Compressor unit PE 300-HE
Compressor unit PE 300-HE-F02
Medium Breathing air
Operating pressure PN 200 PN 300
Deliverya) 300 l/min. 300 l/min.
Pressure setting, final pressure safety valve 225 bar 330 bar
Sound pressure level 87 dB(A) 87 dB(A)
Sound power level 106 dB(A) 106 dB(A)
Weight 230 kg 230 kg
Compressor block IK120-F07
Number of stages 3
Number 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
Speed 1,800 min-1
Intermediate pressure 1st stage 6 bar 6.5 bar
Intermediate pressure 2nd stage 45 bar 47 bar
Compressor block oil capacity 2.8 l
Oil pressure 3 to 6 bar
Oil type see lubricating oil list
Max. permissible ambient temperature +5 ... +45 °C (+43 ... +113 °F)
Max. permissible inclination of compressorb) 15°
Max. permissible operating height 0 ... 2000 m above sea level
Drive motor Three phase squirrel cage
Operating voltage 380 - 415 V, 50 Hz; 380 - 480 V, 60 Hz
Power 7.5 kW (= 10 HP)
Speed (at 50 Hz) 2,910 min-1
Size 132 S
Type of construction B 3
Type of enclosure IP 55
a) free air delivered at tank filling from 0 to 200 bar 5%
b) these values are valid only if the oil level of the compressor in normal position corresponds with the upper mark of the sight gauge and
may not be exceeded

MV3
−
A/10/06
WARNING
Instruction Manual Breathing Air Compressors
9
2. SAFETY MEASURES
2.1. NOTES AND WARNING SIGNS
Notes and warning signs displayed on compressors
according to model, application or equipment.
WARNING
Hot surfaces, do not touch!
Danger of burning by touching cylinders,
cylinder heads and pressure lines of
individual compressor stages.
WARNING
High voltage!
Life threatening danger of electric shock.
Maintenance work on electric units or
operating equipment may only be carried
out by a qualified electrician or by a person
instructed and supervised by a qualified
electrician according to electrical
regulations.
WARNING
Automatic compressor control, unit may
start-up without warning!
Before carrying out maintenance and
repair work, switch off at the main switch
or disconnect from the mains and ensure
unit will not restart.
MANDATORY
Instructions must be read by persons
operating the machinery!
The instruction manual supplied and all
other applicable instructions, regulations
etc. must be read and understood by
operating 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
rotation of the drive motor.
2.2. IDENTIFYING THE SAFETY NOTICES
Important instructions concerning the endangerment of
personnel, technical safety and operating safety will be
specially emphasized by placing the following signs before
the instructions.
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
particular, immediately correct faults (or have them
corrected) which can impair safety!
•The machine / unit is exclusively for the compression of
mediums (air/gas) specified in section A, chapter 1.3.
Technicaldata". 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
complied 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
comply with universally valid legal and other obligatory
regulations regarding accident prevention and
environment protection. See chapter 2.4. This can
involve, for example, contact with hazardous substances
or the provision / wearing of personal protective
equipment.
•Personnel engaged to operate the machine must have
read the instruction manual before beginning work,
especially the safety notices chapter. When work is
already underway it is too late. This is particularly relevant
for temporary personnel, e.g. maintenance personnel.

Instruction Manual Breathing Air Compressors
10
•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
personal 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
immediately 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
requirements 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
machine.
•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
constant 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
operated in safe and good working order. Only operate
the machine if all protective and safety equipment, e.g.
all detachable protective equipment, emergency shut-
down devices, soundproofing is provided and in good
working order.
•At least once every day, check the unit externally for
damage and faults. Inform the person responsible
immediately if anything is not as is should be (including
operation). 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
processes 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
device 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
particular 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
openings 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
temperature 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
immediately after completion of the maintenance or
repairwork.
•Ensure safe and environmentally friendly disposal of
consumables 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

Instruction Manual Breathing Air Compressors
11
under the instruction and supervision of a qualified
electrician 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
neighbouring 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
second 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 warning sign. Only use voltage isolated tools.
•Only personnel with particular knowledge and
experience 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
commencing repairwork.
•Pressurized air lines must be laid and mounted by
qualified personnel. Connections must not be mixed up.
Fittings, 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
operation.
•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
connection 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
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.

Instruction Manual Breathing Air Compressors
12
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
customers!
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
maintaining valves, which should reduce big pressure
fluctuations as well, should be checked regularly for
internal and external tightness and functionality.
•Check the pressure vessels regularly on the inside and
outside 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
filling 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 -
pressure 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
regulations 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 Department 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
location 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 permission. 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
prevention 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 Breathing Air Compressors
13
3. INSTALLATION, OPERATION, FILLING PROCEDURE
3.1. INSTALLATION OF THE COMPRESSOR UNIT
The compressor frame is equipped with anti-vibration
mounts and thus a machine base or special means of secur
ing the compressor are not necessary.
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 en
gine should also be stored below deck
after the filling process.
- Ensure adequate ventilation.
- Air must be free from exhaust fumes and hazardous va
pours (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. Distance from wall
should be at least 0.5 meters.
3.2. ELECTRICAL INSTALLATION
For installation of electrical equipment observe the follow
ing:
- In the annex of this instruction manual you will find the
standard schematic diagrams valid for the respective
compressor unit. To connect the compressor control sys
tem, use only the diagram contained in the control box
of the unit, because any deviations from the standard dia
grams according to order are marked there.
- Observe regulations of local electricity supply company.
- Connection must be carried out by an expert only. Units
which are operated with 380/400 V are delivered with an
electric plug. All other units are delivered without a plug
and have to be equipped with a suitable plug depending
on the country.
- Ensure correct installation of protective conductor.
- Check conformity of motor and control device tension
and frequency with those of electric network.
- Adjust motor protection, thermal overload relay. For start
over contactor adjust to motor amperage rating. For start
via star-delta contactor adjust to motor amperage rating
x 0.58.
For example: motor amperage rating = 10 Amp.:
adjust relay to 10 x 0.58 = 5.8 Amp.
- Fuse motor correctly (see table below; use slow-blow
fuses, only).
Fuse table
PE 250 V 127 230 240 400 415 440 500 600 660
3-phase, 5.5 kW (star-delta starting) A 50 25 25 16 16 16 10 10 10
3-phase, 5.5 kW (direct starting) A 63 35 35 20 20 20 16 16 16
PE300
3-phase, 7.5 kW (star-delta starting) A 50 35 35 20 16 16 16 16 10
3-phase, 7.5 kW (direct starting) A 63 35 35 25 25 25 20 16 16
3.3. OPERATION
Preparation for operation
The compressors described in this man
ual are not suitable for compression of
oxygen. EXPLOSION occurs if an oil lubri
cated compressor is operated with pure oxygen or gases with
an oxygen content of more than 21%!
All compressor units are tested prior to delivery
to the customer, so after correct installation of
the unit there should be no problem putting it
into operation, observing the following points:
-Prior to first operation read Instruction Manual care
fully. Make sure that all persons handling the compressor
and the filling station are familiar with the function of all
controls and monitors. Particularly observe chapter 2.
SAFETY REGULATIONS.
-Before 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.
-Immediately after switching on the system for the
first time check the direction of rotation of the motor for
compliance 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.
-Prior to first operation or operation subsequent to re
pair work operate unit for at least 10 minutes with open
condensate valves (pressureless) to ensure proper lu
brication of all parts before pressure is built up. To keep

WARNING
WARNING
WARNING
Instruction Manual Breathing Air Compressors
14
drain valves open, loosen screw (3, Fig. 7) on coil (1) and
pull timer (2) from solenoid valve.
Fig. 7 Solenoid valve with timer
3
1
2
- Prior to each operation check the oil level according to
chapter 4.4.1. and determine whether maintenance is
necessary in accordance with Service manual
- 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.
3.4. STARTING THE UNIT
- Place main switch (2, Fig. 8) to 1.
- Press ON button (4).
1 Warning light, phase sequence alarm
2 Main switch
3 Hour meter
4 ON button
5 OFF button
1 2 3 4 5
Fig. 8 Compressor control unit
- 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.
3.5. FILLING PROCEDURE
General
Ensure intake air is free from
noxious gas (CO), exhaust fumes
and solvent vapour. On units em
ploying 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 cartridge 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, re
sulting 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.
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
provided for self-sealing due to internal overpressure.
Compressed 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
because of the exhaling of CO2. CO2values from 1,000 to
5,000 ppmvin workrooms are not unusual (MAK-value (max.
workroom concentration) is 5,000 ppmv). Another addi
tional increase is caused by cigarette smoking, producing ap
prox. 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