Bauer VERTICUS 5 PE 320-VE / PE 500-VE / PE 680-VE Breathing Air Compressor Instruction Manual

Description

File Details

• Manual type: Instruction manual for high pressure breathing air compressor units
• Brand: BAUER KOMPRESSOREN
• Model range: PE-VE VERTICUS 5
• Compressor blocks covered: IK12.14, IK150, IK180, IK18.1
• Language: English
• Length: 103 pages
• Format: PDF
• Document revision shown: change no. 0, January 2010 (units version no. 21)

Chapters Covered

• A. Description – general, purpose and short description, design and mode of operation, technical data, lubrication system, intake filter, intermediate separators, final separator/filter system, pressure maintaining/non-return valve, safety valves, pressure gauges, valves, automatic condensate drain, electrical system, compressor drive system, cooling system
• B. Installation, Taking into Operation – compressor room conditions, locating the unit, natural ventilation, artificial ventilation, electrical installation, connecting external filling panels, connecting storage bottles, preparation for operation
• C. Operation – safety measures, notes and warning signs, fundamental safety notices, safety regulations, preparation for operation, starting the unit, filling procedure, intake air quality, scavenging, switch-over valve, pressure reducer, connecting and removing bottles
• D. Maintenance, Repair – maintenance record, maintenance work, maintenance intervals, oil level check, oil change intervals, oil capacity, changing the oil type, venting the oil pump, intake filter, intermediate separators, oil and water separator, purifier, filter cartridge change, pressure maintaining/non-return valve, safety valves, pressure gauges, valves, automatic condensate drain, electrical system, final pressure switch, V-belts, filling valves, storage bottles, repair instructions, trouble-shooting, tightening torque values, torque sequence, lubrication chart, adhesive and sealant chart, testing agents
• E. Storage, Preservation – preparation, preserving the compressor, preserving the motor, preventive maintenance during storage, changing the lube oil for preserving, reactivating the compressor unit, transportation
• F. Diagrams, Drawings – flow diagrams, schematic diagrams, drawings, lists
• G. Spare Parts Catalogue – spare parts lists by compressor unit and assembly group

What This PE-VE VERTICUS 5 Manual Covers in Practice

This is the full instruction manual written for the BAUER PE-VE VERTICUS 5 range of breathing air compressor units, the complete units used to fill tanks in the 225 bar, 330 bar and 420 bar pressure ranges. It is not a generic compressor booklet: the text is broken down by compressor block, so the information you read is matched to the IK12.14, IK150, IK180 or IK18.1 block actually fitted to your unit.

The document opens with the description section, walking through the major assemblies of the unit – compressor block, drive motor, frame and housing with instrument panel, filter set, automatic condensate drain, filling panel and the electric control and electronic monitoring system. From there it moves into each subsystem in turn: the lubrication circuit with its gear pump and minimum pressure valve, the intake filter, the intermediate separators after the second and third stages, the final separator and purifier with the SECURUS monitoring system, the pressure maintaining and non-return valve, the safety valves, the pressure gauges and the automatic condensate drain with its 10 litre collector.

The technical data section gives the compressor unit and compressor block figures side by side, including delivery rates, speed, drive input, motor power, weight, cylinder bores, piston stroke, intermediate pressures and oil pressure. Filter system data is listed separately for P41 and P61, covering service pressure, flow rate, regenerated air volume, operating temperature range and the residual water, oil vapour, CO and CO2 limits the purification system is built to hold.

Installation and Commissioning

Section B deals with everything that has to be right before the unit is switched on for the first time. Compressor room conditions, minimum and maximum room temperature, locating the unit, and the air intake and outlet opening sizes needed for natural ventilation at each drive power are all laid out, together with the artificial ventilation calculations used when natural ventilation is not enough. The electrical installation chapter covers the standard schematic diagrams, the fuse table for the 7.5 kW, 11 kW and 15 kW motors in both direct and star-delta starting, motor protection relay adjustment, and the connection of external filling panels and storage bottles.

Preparation for operation is where most first-time problems are avoided, and the manual is explicit about it: checking oil level, turning the compressor over by hand, checking the direction of rotation against the arrow on the unit and swapping two phase leads in the switch box if it runs backwards, and running the unit pressureless with the condensate valves open for at least ten minutes so every part is lubricated before pressure builds.

Filling Procedure and Safety

The operation section covers the filling procedure step by step with illustrations for connecting a bottle, filling and removing it, plus the two pressure range arrangements – switch-over valve and pressure reducer – and the rules for each. It also explains why intake air quality matters, how CO2 accumulates in a purifier cartridge and why the compressor should be scavenged before bottles are connected, along with the warning that these oil lubricated compressors must never be run on oxygen.

Safety content runs through the whole document rather than sitting in one block, covering hot surfaces, high voltage, automatic restart, hearing protection, pressure vessel load cycles and the disposal of condensate.

Maintenance, Troubleshooting and Torque Data

The maintenance section is the working heart of the manual for anyone keeping a PE 320-VE, PE 500-VE or PE 680-VE in service. It sets out oil level checks, oil change intervals for mineral and synthetic oil, oil capacities for each block, oil filter replacement, venting the oil pump after repair work or a wrong phase sequence, intake filter servicing, cleaning the sintered metal element in the oil and water separator, purifier cartridge change with the special spanner, safety valve operating and blow-off pressure checks, valve change practice, and V-belt inspection.

Cartridge lifetime is supported by detailed tables that give filter cartridge hours and expected bottle fillings for the P41 and P61 systems against ambient temperature, final separator temperature, filling pressure and delivery rate, so replacement can be planned from actual operating conditions rather than guesswork. The trouble-shooting table then maps symptoms to causes and remedies across the drive motor, compressor block, electric control system and automatic condensate drain. A tightening torque table, a torque sequence diagram for valve head and cylinder bolts, a lubrication chart, an adhesive and sealant chart and a list of testing agents close out the reference material.

Why This Manual Matters for Your Unit

Breathing air compressors are unforgiving of improvised maintenance. The manual states plainly that ignoring the operating and maintenance instructions can lead to severe injury or death, and that the compressed air produced is subject to strict quality standards. Working from the correct figures – the 4.5 bar oil pressure, the pressure maintaining valve setting, the safety valve blow-off pressures per stage, the specified torque values, the load cycle limits on pressure vessels – is what keeps a unit producing air that meets the standards it was built for.

With this instruction manual for the BAUER PE-VE VERTICUS 5 breathing air compressor units you can install the unit correctly, run the filling procedure properly, service the lubrication, filtration and condensate systems on schedule, adjust and test the safety valves, replace purifier cartridges at the right time, and diagnose faults before they turn into compressor damage. It covers the PE 320-VE, PE 500-VE, PE 680-VE and the 420 bar variants PE 320-VE-420, PE 500-VE-420 and PE 600-VE-420.

IMAGES PREVIEW

Delivery is instant. The PDF is available for download immediately after payment, with no shipping and no waiting. Read it on a laptop, tablet or phone in the workshop or at the filling station, and print the pages you need – the torque tables, the trouble-shooting chart or the maintenance schedule – so they are at hand when the tools come out.