POSEIDON PE320-VE User manual

PE 320-VE
PE 500-VE
PE 680-VE
High Pressure Breathing Air Compressors
Instruction Manual
Copyright 2010 BAUER Kompressoren GmbH München

3
A
B
C
D
E
F
G
DESCRIPTION
INSTALLATION, TAKING INTO OPERATION
OPERATION
MAINTENANCE, REPAIR
STORAGE, PRESERVATION
DIAGRAMS, DRAWINGS
SPARE PARTS CATALOGUE

4

PE−VE/10/09
Instruction Manual •Breathing Air Compressors
i
INTRODUCTION
This manual contains operating instructions and maintenance sched
ules for the breathing air compressor units of the model range
Model: ____________________________
Serial no.: ____________________________
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.
The machine has been built in accordance with the EC machine regula
tions 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 ma
chine regulations, chapt. I, section 1.7.4. The machine has been built
according to the highest standard of technology and the generally ac
knowledged 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 pro
duce compressed air as specified in this manual. Other use is strictly
prohibited.
Edition January 2010
©2010 BAUER Kompressoren GmbH, München
All rights reserved
PE-VE Verticus 5

Instruction Manual •Breathing Air Compressors
ii
INTRODUCTION
NOTICE
Layout and use of instruction manuals
Working with pneumatic high pressure systems cannot always be considered safe and one should possess a minimum
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 spe-
cific 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.

Instruction Manual •Breathing Air Compressors
iii
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-3. . . . . .
1.3. TECHNICAL DATA A-11. . . . . . . . . . . . . . . . . . . . .
2. LUBRICATION SYSTEM A-15. . . . . . . . . . . . . . .
2.1. FUNCTIONAL DESCRIPTION A-15. . . . . . . . . . . . .
2.2. TYPE OF OIL A-15. . . . . . . . . . . . . . . . . . . . . . . . .
3. INTAKE FILTER A-16. . . . . . . . . . . . . . . . . . . . . .
3.1. FUNCTIONAL DESCRIPTION A-16. . . . . . . . . . . . .
4. INTERMEDIATE SEPARATORS A-16. . . . . . . . .
4.1. FUNCTIONAL DESCRIPTION A-16. . . . . . . . . . . . .
4.2. 1ST STAGE SEPARATOR (OPTION) A-16. . . . . . . .
5. FINAL SEPARATOR / FILTER SYSTEM A-16. . .
5.1. GENERAL A-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2. FUNCTION A-17. . . . . . . . . . . . . . . . . . . . . . . . . . .
6. PRESSURE MAINTAINING / NON-RETURN
VALVE A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1. COMPRESSOR UNITS UP TO 350 BAR A-19. . . . .
6.2. COMPRESSOR UNITS UP TO 420 BAR A-19. . . . .
7. SAFETY VALVES A-19. . . . . . . . . . . . . . . . . . . . .
8. PRESSURE GAUGES A-19. . . . . . . . . . . . . . . . . .
8.1. INTERMEDIATE PRESSURE GAUGES A-19. . . . . . .
8.2. FINAL PRESSURE GAUGE A-19. . . . . . . . . . . . . . .
8.3. OIL PRESSURE GAUGE A-19. . . . . . . . . . . . . . . . .
9. VALVES A-20. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. AUTOMATIC CONDENSATE DRAIN A-20. . . .
10.1. COMPRESSOR BLOCKS IK12.14, IK150, IK180 . . . .
A-20
10.2. COMPRESSOR BLOCK IK18.1 A-21. . . . . . . . . . . .
10.3. START UNLOADING A-23. . . . . . . . . . . . . . . . . . .
10.4. STANDSTILL DRAINAGE A-23. . . . . . . . . . . . . . . .
10.5. CONDENSATE COLLECTOR 10 ltrs. A-23. . . . . . .
10.6. CONDENSATE COLLECTOR 40 ltrs. (OPTIONAL) . . . .
A-23
10.7. Condensate disposal A-25. . . . . . . . . . . . . . . . . .
11. ELECTRICAL SYSTEM A-25. . . . . . . . . . . . . . . .
11.1. GENERAL A-25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2. EMERGENCY SHUTDOWN A-25. . . . . . . . . . . . . .
11.3. COMPRESSOR CONTROL UNIT
B-CONTROL HW A-25. . . . . . . . . . . . . . . . . . . . . .
12. COMPRESSOR DRIVE SYSTEM A-26. . . . . . . .
13. COOLING SYSTEM A-26. . . . . . . . . . . . . . . . . . .
B. INSTALLATION, OPERATION B-3. . . . . . . . . .
1. INSTALLATION B-3. . . . . . . . . . . . . . . . . . . . . .
1.1. COMPRESSOR ROOM CONDITIONS B-3. . . . . .
1.2. LOCATING THE UNIT B-3. . . . . . . . . . . . . . . . . .
1.3. NATURAL VENTILATION B-3. . . . . . . . . . . . . . . .
1.4. ARTIFICIAL VENTILATION B-5. . . . . . . . . . . . . . .
2. ELECTRICAL INSTALLATION B-7. . . . . . . . . .
3. CONNECTING EXTERNAL FILLING
PANELS (OPTIONAL) B-8. . . . . . . . . . . . . . . . .
4. CONNECTING STORAGE BOTTLES
(OPTIONAL) B-8. . . . . . . . . . . . . . . . . . . . . . . .
5. TAKING INTO OPERATION B-9. . . . . . . . . . .
5.1. PREPARATION FOR OPERATION B-9. . . . . . . . .
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-8. . . . . . . . . . . . . . . . . . . . . . . .
2.1. PREPARATION FOR OPERATION C-8. . . . . . . . .
2.2. STARTING THE UNIT C-8. . . . . . . . . . . . . . . . . . .
2.3. FILLING 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-4. . . . . . . . . . . . . . .
2.3. OIL CAPACITY D-4. . . . . . . . . . . . . . . . . . . . . . . .
2.4. OIL PACKAGES D-4. . . . . . . . . . . . . . . . . . . . . . .
2.5. OIL CHANGE D-4. . . . . . . . . . . . . . . . . . . . . . . . .
2.6. CHANGING THE OIL TYPE D-4. . . . . . . . . . . . . .
2.7. VENTING OIL PUMP D-5. . . . . . . . . . . . . . . . . . .
3. INTAKE FILTER D-6. . . . . . . . . . . . . . . . . . . . . .
3.1. MAINTENANCE D-6. . . . . . . . . . . . . . . . . . . . . . .

Instruction Manual •Breathing Air Compressors
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TABLE OF CONTENTS
4. INTERMEDIATE SEPARATORS D-6. . . . . . . . .
4.1. MAINTENANCE D-6. . . . . . . . . . . . . . . . . . . . . . .
5. FINAL SEPARATOR / FILTER SYSTEM D-7. . .
5.1. OIL AND WATER SEPARATOR D-7. . . . . . . . . . .
5.2. PURIFIER D-7. . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. PRESSURE MAINTAINING / NON-RETURN
VALVE D-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1. COMPRESSORS UP TO 330 BAR D-13. . . . . . . . .
6.2. COMPRESSORS UP TO 420 BAR D-13. . . . . . . . .
7. SAFETY VALVES D-13. . . . . . . . . . . . . . . . . . . . .
7.1. OPERATING CHECK D-13. . . . . . . . . . . . . . . . . . .
7.2. BLOW-OFF PRESSURE CHECK D-14. . . . . . . . . . .
8. PRESSURE GAUGES D-14. . . . . . . . . . . . . . . . . .
9. VALVES D-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1. GENERAL INSTRUCTIONS FOR CHANGING THE
VALVES D-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2. Changing the valves D-14. . . . . . . . . . . . . . . . . .
9.3. VALVE CHANGE D-14. . . . . . . . . . . . . . . . . . . . . .
10. AUTOMATIC CONDENSATE DRAIN D-14. . . .
10.1. GENERAL D-14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2. MAINTENANCE D-14. . . . . . . . . . . . . . . . . . . . . . .
10.3. ACTIVATED CHARCOAL ELEMENT MAINTENANCE .
D-14
10.4. ACTIVATED CHARCOAL MAINTENANCE D-15. . .
10.5. FLOAT SWITCH MAINTENANCE D-15. . . . . . . . .
11. ELECTRICAL SYSTEM D-15. . . . . . . . . . . . . . . .
11.1. DRIVE MOTOR D-15. . . . . . . . . . . . . . . . . . . . . . .
11.2. ELECTRIC CONTROL D-15. . . . . . . . . . . . . . . . . . .
11.3. ADJUSTMENT OF FINAL PRESSURE SWITCH D-15
12. COMPRESSOR DRIVE SYSTEM D-15. . . . . . . .
12.1. ELECTRIC DRIVE MOTOR D-15. . . . . . . . . . . . . . .
12.2. V-BELTS D-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13. MAINTENANCE ON FILLING VALVES D-15. .
13.2. REPLACING DAMAGED COMPONENTS D-16. . . .
14. MAINTENANCE OF STORAGE BOTTLES D-16
14.1. LIFETIME D-16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
14.2. INSPECTIONS D-16. . . . . . . . . . . . . . . . . . . . . . . .
14.3. CONDENSATE DRAIN D-16. . . . . . . . . . . . . . . . . .
15. REPAIR INSTRUCTIONS D-16. . . . . . . . . . . . . .
16. TROUBLE-SHOOTING D-17. . . . . . . . . . . . . . . .
17. TABLES D-19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
17.1. TIGHTENING TORQUE VALUES D-19. . . . . . . . . .
17.2. TORQUE SEQUENCE D-19. . . . . . . . . . . . . . . . . . .
17.3. LUBRICATION CHART D-20. . . . . . . . . . . . . . . . . .
17.4. ADHESIVE AND SEALANT CHART D-20. . . . . . . .
17.5. TESTING AGENTS D-20. . . . . . . . . . . . . . . . . . . . .
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
7. TRANSPORTATION E-4. . . . . . . . . . . . . . . . . .
F. DIAGRAMS, DRAWINGS F-3. . . . . . . . . . . . . .
1. FLOW DIAGRAMS F-3. . . . . . . . . . . . . . . . . . .
2. SCHEMATIC DIAGRAMS F-3. . . . . . . . . . . . . .
3. DRAWINGS F-3. . . . . . . . . . . . . . . . . . . . . . . . .
4. LISTS F-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
G. PARTS LISTS G-3. . . . . . . . . . . . . . . . . . . . . . . .
1. COMPRESSOR UNITS UP TO 330 BAR G-3.
1.1. COMPRESSOR UNITS PE 320-VE G-3. . . . . . . . .
1.2. COMPRESSOR UNITS PE 500-VE G-3. . . . . . . . .
1.3. COMPRESSOR UNITS PE 680-VE G-4. . . . . . . . .
2. COMPRESSOR UNITS UP TO 420 BAR G-4.
2.1. COMPRESSOR UNITS PE 320-VE-420 G-4. . . . .
2.2. COMPRESSOR UNITS PE 500-VE-420 G-5. . . . .
2.3. COMPRESSOR UNITS PE 600-VE-420 G-5. . . . .

Instruction Manual •Breathing Air Compressors
v
TABLE OF FIGURES
Fig. 1 Compressor unit, PE-VE series; with open
housing A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 2 Compressor unit, PE-VE series with
super-silent housing A-5. . . . . . . . . . . . . . . . . . .
Fig. 3 Compressor block IK12.14 A-6. . . . . . . . . . . . .
Fig. 4 Compressor block IK150, front view A-8. . . . .
Fig. 5 Compressor block IK180, front view A-9. . . . .
Fig. 6 Compressor block IK18.1, front view A-10. . . . .
Fig. 7 Lube oil circuit, IK12.14 A-15. . . . . . . . . . . . . . . .
Fig. 8 Lube oil system IK150 to IK18.1 A-15. . . . . . . . .
Fig. 9 Intake filter, IK12.14 A-16. . . . . . . . . . . . . . . . . .
Fig. 10 Intake filter, IK150, IK180, IK18.1 A-16. . . . . . .
Fig. 11 Filtersystem A-17. . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 12 Pressure maintaining/non-return valve,
350 bar A-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 13 Final pressure gauge A-19. . . . . . . . . . . . . . . . . .
Fig. 14 Valve operation A-20. . . . . . . . . . . . . . . . . . . . . .
Fig. 15 Valve head 1st stage A-20. . . . . . . . . . . . . . . . . .
Fig. 16 Automatic condensate drain unit A-20. . . . . . . .
Fig. 17 Normal operation A-21. . . . . . . . . . . . . . . . . . . .
Fig. 18 Condensate drain A-21. . . . . . . . . . . . . . . . . . . .
Fig. 19 Automatic condensate drain unit A-22. . . . . . . .
Fig. 20 Drain valve 2nd stage separator A-22. . . . . . . . .
Fig. 21 Normal operation A-23. . . . . . . . . . . . . . . . . . . .
Fig. 22 Condensate drain A-23. . . . . . . . . . . . . . . . . . . .
Fig. 23 Condensate collector, 40 ltrs. A-24. . . . . . . . . . .
Fig. 24 Float switch orientation A-24. . . . . . . . . . . . . . .
Fig. 25 Condensate collector, function A-24. . . . . . . . . .
Fig. 26 Service switch A-26. . . . . . . . . . . . . . . . . . . . . . .
Fig. 27 Cycle counter A-26. . . . . . . . . . . . . . . . . . . . . . . .
Fig. 28 Cooling air flow A-26. . . . . . . . . . . . . . . . . . . . . .
Fig. 29 Room temperature B-3. . . . . . . . . . . . . . . . . . .
Fig. 30 Locating the unit B-3. . . . . . . . . . . . . . . . . . . . .
Fig. 31 Installation (natural ventilation) B-3. . . . . . . . .
Tab. 1 Air intake and outlet openings B-4. . . . . . . . . .
Fig. 32 Installation with natural ventilation,
example 1 B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 33 Installation with natural ventilation,
example 2 B-4. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 34 Installation with natural ventilation,
example 3 B-5. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 35 Installation (artificial ventilation) B-5. . . . . . . . .
Fig. 36 Installation with artificial ventilation,
example 1 B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 37 Installation with artificial ventilation,
example 2 B-6. . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 38 B-CONTROLr-HW Control unit B-8. . . . . . . . . .
Fig. 39 Solenoid valve B-9. . . . . . . . . . . . . . . . . . . . . . .
Fig. 40 Scavenging valve C-9. . . . . . . . . . . . . . . . . . . . .
Fig. 41 Connecting air bottle C-9. . . . . . . . . . . . . . . . .
Fig. 42 International filling connector C-9. . . . . . . . . .
Fig. 43 Filling air bottle C-10. . . . . . . . . . . . . . . . . . . . . .
Fig. 44 Removing air bottle C-10. . . . . . . . . . . . . . . . . . .
Fig. 45 Oil sight gauge IK12.14 D-3. . . . . . . . . . . . . . . .
Fig. 46 Oil sight gauge IK150, IK180, IK18.1 D-4. . . . .
Fig. 47 Oil filler, IK12.14 D-4. . . . . . . . . . . . . . . . . . . . .
Fig. 48 Oil filler, IK150, IK180, IK18.1 D-5. . . . . . . . . . .
Fig. 49 Removing the cover D-5. . . . . . . . . . . . . . . . . . .
Fig. 50 Replacing the oil filter D-5. . . . . . . . . . . . . . . . .
Fig. 51 Intake filter, IK12.14 D-6. . . . . . . . . . . . . . . . . .
Fig. 52 Intake filter, IK150, IK180, IK18.1 D-6. . . . . . .
Fig. 53 Oil and water separator, 420 bar D-7. . . . . . . .
Fig. 54 Removing the filter head D-8. . . . . . . . . . . . . . .
Fig. 55 Extracting the cartridge D-8. . . . . . . . . . . . . . . .
Fig. 56 Pressure maintaining/non-return valve
350 bar D-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 57 Pressure maintaining/non-return valve
420 bar D-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 58 Final pressure safety valve, 225 and 330 bar D-13
Fig. 59 Safety valve, 420 bar D-13. . . . . . . . . . . . . . . . . .
Fig. 60 Final pressure switch D-15. . . . . . . . . . . . . . . . . .
Fig. 61 Filling valve on external filling panel D-16. . . . .
Fig. 62 Torque sequence D-19. . . . . . . . . . . . . . . . . . . . .

Instruction Manual •Breathing Air Compressors
vi
INDEX
A
Ambient temperature, A-17, A-26, B-5
Automatic condensate drain, A-20, D-14
C
Changing the oil type, A-16, D-4
Compressor control unit, B-Control Compact, A-25
Compressor drive system, A-26
Condensate disposal, D-14
Condensate drain, D-6, D-7
Cooling air flow, B-5
Cooling methods, B-5
Cooling system, A-26
Customer Services, viii
Cycle counter, A-26
D
Diagrams, drawings, F-3
Drive system, D-15
E
Electric control, Installation, B-7
Electrical system, A-25, D-15
Emergency shutdown, A-25
F
Filter system, A-16, D-7
Final separator, A-16, A-17, D-7
Flow diagram, A-3
Fuse table, B-7
I
IK14.12, A-6
IK150 II, A-7
IK18.1, A-7
IK180 II, A-7
Installation, B-3
Intake air quality, C-8
Intake filter, A-16, D-6
Intermediate separators, A-16, D-6
L
Load cycle, A-17, D-16
Lubrication, D-3
Lubrication system, A-15
M
Maintenance record, D-3
Maintenance work, Maintenance intervals, D-3
Motor protection overload relay, Thermal, B-7
Motor protection relay, B-7
N
Noise level, A-3
O
Oil change, D-4
Oil level check, D-3
Oil pump, Venting, D-5
Operation, C-8
P
Parts Lists, G-3
Preservation, E-3
Presssure switch, A-25
Pressure dew point, A-14
Pressure gauge
Final pressure, A-19
Intermediate pressure, A-19
Oil pressure, A-19
Pressure gauges, A-19, D-14
Pressure maintaining / non-return valve, D-13
R
Repair instructions, D-16
Residual CO contents, A-14
Residual CO2 contents, A-14
Residual oil vapour contents, A-14
Residual water contents, A-14

Instruction Manual •Breathing Air Compressors
vii
INDEX
S
Safety valves, A-19, D-13
Final pressure, D-13, D-14
Operating check, D-13
Sales Department, viii
Service switch, A-25
Starting the unit, C-8
Storage, E-3
T
Tables, Testing agents, D-20
Taking into operation, B-9
Technical Customer Services, viii
Technical data, Compressor units, A-11
Telephone numbers, viii
Training Courses, viii
Trouble-shooting, D-17
V
V-belts, Drive system, A-26
Valves, A-20, D-14
Ventilation, B-5
Artificial, B-5
Natural, B-3

Instruction Manual •Breathing Air Compressors
viii
Change notice
Change no. Change date and changes
0January 2010, units version no. 2
1
2
3
4
5
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.
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Fax: [phone]
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Technical Customer Services Tel: [phone] or 246
Fax: [phone]
Do you need further information regarding your unit, accessories, prices etc.?
Sales Department:
Breathing air compressors Tel: [phone], -154, -185 or -202
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Fax: [phone]
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Training Manager Tel: [phone]
Fax: [phone]
Meet us in the internet at: www.bauer-kompressoren.de

Instruction Manual •Breathing Air Compressors
A−1

Instruction Manual •Breathing Air Compressors
A−2

PE−VE/10/09
Instruction Manual •Breathing Air Compressors
A−3
A. DESCRIPTION
1. GENERAL
1.1. PURPOSE AND SHORT DESCRIPTION
This instruction manual describes the breathing air com
pressor units of the PE-VE VERTICUS 5 model range.
The compressor units are complete units for filling tanks in
the pressure range 225 bar (3,200 psi) and/or 330 bar (4,700
psi), or 420 bar (6,000 psi), respectively. They are used mainly
to compress air for breathing as required in diving and fire
fighting applications.
The breathing air compressor units are available in two hous
ing types:
The PE series mounted in the open housing
The PE series mounted in the Super-Silent housing
PE 320-VE
PE 500-VE
PE 680-VE
PE 320-VE-420
PE 500-VE-420
PE 600-VE-420
The open units can be upgraded to a Super-Silent version at
any time.
The noise level of the Super-Silent units is 69 dB(A) ±2 dB(A)
in 1 m distance (according to DIN 45635).
All units are equipped as standard with TÜV approved final
pressure safety valve and automatic condensate drain
unit with 10 l. condensate collector.
PE 320 and PE 500 units are equipped as standard with filter
system P41, PE 600 and PE 680 with filter system P61.
All units are equipped as standard with filter system P41
(except KAP and V 600 F-420), SECURUS monitoring system
for the filter system, TÜV approved final pressure safety
valve and automatic condensate drain unit with 10 l. con
densate collector.
Optionally, as described in the following chapters, the units
can be delivered with external filling panels for one or two
pressure ranges, with SECURUS monitoring system for the
filter system,, and with 40 l. condensate collector.
1.2. DESIGN AND MODE OF OPERATION
Design
The compressor unit comprises the following major assem
blies:
•Compressor block
•Drive motor
•Frame and housing assembly with instrument panel
•Filter set
•Automatic condensate drain
•Filling panela)
•Electric control and electronic monitoring system
The design of the compressors is shown in Fig. 1 and Fig. 2.
For special equipment according to order see figures and
parts lists in the annex.
Mode of operation; flow diagram
The path of the air through the compressor system is shown
in the flow diagram. For flow diagram refer to section F of this
manual.
a) optional extra according to order

Instruction Manual •Breathing Air Compressors
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5
2
1
4
3
Fig. 1 Compressor unit, PE-VE series; with open housing
1 Hourmeter
2 Oil pressure warning lamp
3 Condensate collector, 10 ltrs.
4 Operation switch ON-OFF
5 Main switch

Instruction Manual •Breathing Air Compressors
A−5
5
2
1
4
3
Fig. 2 Compressor unit, PE-VE series with super-silent housing
1 Hourmeter
2 Oil pressure warning lamp
3 Condensate collector, 10 ltrs.
4 Operation switch ON-OFF
5 Main switch

Instruction Manual •Breathing Air Compressors
A−6
Compressor block
General
The compressor blocks are particularly suitable for continu
ous operation because of their rugged design and the corro
sion 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.
Compressor block IK12.14
The compressor block IK12.14 is used to compress air in the
high pressure range up to 420 bar (6,100 psi).
The compressor block is of a four stage, three cylinder design.
The cylinders are arranged in a W form, the 1st/2nd stage
vertical stepped cylinder in the centre, 3rd stage on the right,
and 4th stage on the left side looking from the filter side.
The design of the compressor block is shown in Fig. 3. For the
mode of operation refer to the flow diagram in sec. F.
2
1
12
15
5
4
6
8
7
9
10
11
13
16
18
3
14
17
Fig. 3 Compressor block IK12.14
1 Valve head, 1st stage
2 Safety valve, 1st stage
3 Intake manifold, 2nd stage
4 Oil filler neck
5 Cylinder, 4th stage
6 Safety valve, 3rd stage
7 Intermediate separator, 3rd stage
8 Inter-cooler, 3rd stage
9 Condensate drain connector
10 Intake filter
11 Outlet manifold, 2nd stage
12 Cylinder, 3rd stage
13 Safety valve, 2nd stage
14 Oil filter housing
15 Intermediate separator, 2nd stage
16 Inter-cooler, 2nd stage
17 Oil drain tap
18 After-cooler, 4th stage

Instruction Manual •Breathing Air Compressors
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Compressor blocks IK150, IK180 and IK18.1
The compressor blocks IK150 and IK180 are used to com
press air in the high pressure ranges PN200 and PN300 for
breathing air application, for industrial application up to 350
bar (5,000 psi). The max. allowable operating pressure (ad
justment of final pressure safety valve) is 225 bar (3,200 psi)
or 330 bar (4,700 psi).
Compressor block IK18.1 is used to compress air in the high
pressure range PN420 (6,100 psi). The max. allowable oper
ating pressure (adjustment of final pressure safety valve) is
435 bar (6,300 psi).
All compressor blocks except the IK18.1 are of a four stage,
four cylinder design. The four cylinders are arranged at an
angle of 90°to each other, 1st and 2nd stage, and 3rd and
4th stage opposite to each other. The 4th stage cylinder is
lubricated by means of the force-feed lubrication system, the
other cylinders are splash-lubricated.
These compressor blocks are particularly suitable for continu
ous operation because of their rugged design and the corro
sion 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 three bearings. It is here that
the energy saving cylinder roller bearings are put to use. The
upper and lower connecting rod bearings are also roller bear
ings. This allows for an even longer life which lasts at least
30,000 operating hours. All valves have free access for time
saving maintenance. There is no need for dismantling of
pipes or pressure gauges.
The design of the compressor block is shown in Fig. 4.to
Fig. 6. For the mode of operation refer to the flow diagram
in sec. F.

Instruction Manual •Breathing Air Compressors
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15
22
12
21
3
1
2
4
7
10
8
9
6
5
16
11
20
18
17
13
19
14
Fig. 4 Compressor block IK150, front view
1 Service indicator
2 Intake filter
3 Crankcase vent feedback line
4 Cylinder, 1st stage
5 Intermediate pressure safety valve, 2nd/3rd stage
6 Intermediate separator, 2nd stage
7 Inter-cooler, 2nd stage
8 Oil pump housing
9 Cylinder 3rd stage
10 Compressed air outlet
11 Lifting eyebolt
12 Inter-cooler 1st stage
13 Cylinder, 4th stage
14 After-cooler 4th stage
15 Oil pressure regulating valve
16 Intermediate pressure safety valve,
17 Intermediate separator, 3rd stage
18 Intermediate pressure safety valve 1st/2nd stage
19 Inter-cooler 3rd stage
20 Cylinder 2nd stage
21 Oil filler with sight glass
22 Condensate outlet