BAUER

COMPRESSORS
Instruction Manual and Replacement Parts List

BF Series
Bottle Fill Panels
BFP2/BULK BFP2/4CSCD
BFP4/BULK BFP4/4CSCD
BF450-FCP

Febuary 3, 2006 1st Ed. Rev. 2 Chg. 1 MNL-0022

© 1995 Bauer Compressors, Inc.
BAUER Compressors, Inc. Phone: (757) 855-6006
1328 Azalea Garden Road Fax: (757) 855-6224
Norfolk, Virginia 23502-1944 www.bauercomp.com
BAUER BF Series
COMPRESSORS

This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication,
but Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information
set forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use
of this information. All information supplied is in connection with sales of Bauer’s products, and is thus
subject to Bauer’s standard terms and conditions of sale. Bauer reserves the right to change this infor-
mation and has no obligation to update these materials. This information is © 1995 Bauer Compressors,
Inc., and Bauer reserves to itself all rights to this publication. Bauer’s customers have no right to repro-
duce, rewrite, modify, license or permit anyone else’s use of this information, without the express writ-
ten permission of Bauer Compressors, Inc.

^ WARNING ^
This Instruction Manual and Replacement Parts List contains safety information and instructions for the
BF Series Bottle Fill Panels.
You must read, understand and follow all safety precautions and instructions.

1st Edition September 1995

Rev Chg Date Notes Auth

0 0 9/95

1 0 5/00 All. Removal of RPL JH

2 0 12/16/05 All. JD

2 1 02/03/06 Part number changes and theory update JD

Page i 1st Ed. Rev. 2 Chg. 1

MNL-0022 BAUER
COMPRESSORS

TABLE OF CONTENTS

CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
1.1 HOW TO USE THIS MANUAL ........................................................................................................................................ 1
1.1.1 Manual Safety Notices ....................................................................................................................................................... 1
1.2 HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2
1.3 HOW TO USE THE APPENDIX....................................................................................................................................... 3

CHAPTER 2: - - - - - - - - - - - BF SERIES UNIT SPECIFICATION

2.1 UNIT DESCRIPTION......................................................................................................................................................... 4
2.2 SPECIFICATIONS - BF SERIES...................................................................................................................................... 6
2.2.1 Technical Specifications .................................................................................................................................................... 6

CHAPTER 3: - - - - - - - - - - - - - - - - - BF SERIES OPERATION

3.1 BF SERIES THEORY OF OPERATION ......................................................................................................................... 7
3.1.1 BF450-FCP Dual Function Valve Theory of Operation .................................................................................................... 9
3.1.2 The Safety Valve.............................................................................................................................................................. 10
3.1.3 The Check Valve.............................................................................................................................................................. 10
3.2 FILLING PROCEDURE PRECAUTIONS .................................................................................................................... 11
3.3 BFP TO BOTTLE ATTACHMENTS ............................................................................................................................. 12
3.3.1 Bottle Fill Hose Attachments ........................................................................................................................................... 12
3.3.2 Attaching the Fill Yoke to the SCUBA Storage Bottle.................................................................................................... 13
3.4 FILLING PROCEDURES ................................................................................................................................................ 14
3.4.1 BFP/BULK Series Filling Procedure ............................................................................................................................... 14
3.4.2 BFP/BULK Series Closing Procedure ............................................................................................................................. 15
3.4.3 BF Series with Cascade Panel Filling Procedure ............................................................................................................. 17
3.4.4 BF Series with Cascade Panel Closing Procedure ........................................................................................................... 19
3.5 REPLACEMENT AND SPARE PARTS LIST .............................................................................................................. 20

CHAPTER 4: - - - - - - - - - - - - - - - - - - - - - MAINTENANCE
4.1 PRESSURE GAUGES....................................................................................................................................................... 26
4.2 SAFETY VALVE............................................................................................................................................................... 26
4.3 TUBE CONNECTIONS.................................................................................................................................................... 26
4.4 PRESSURE HOSES .......................................................................................................................................................... 26
4.5 STORAGE BOTTLES ...................................................................................................................................................... 26

CHAPTER 5: - - - - - - - - - - - - - - - - - - BF SERIES APPENDIX

5.1 SAFETY.............................................................................................................................................................................. 27
5.1.1 General Safety Precautions .............................................................................................................................................. 27
5.1.2 Safety Warning Labels ..................................................................................................................................................... 28
5.2 REFERENCE DATA ........................................................................................................................................................ 29
5.2.1 Conversion Formulas ....................................................................................................................................................... 29

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BAUER BF SERIES
COMPRESSORS
5.2.2 Approved Lubricants Chart ..............................................................................................................................................29
5.2.3 Glossary of Abbreviations and Acronyms .......................................................................................................................29
5.3 ADDITIONAL DOCUMENTS.........................................................................................................................................30
5.3.1 Diagrams and Drawings ...................................................................................................................................................30
5.3.2 Other Documents..............................................................................................................................................................30

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MNL-0022 BAUER
COMPRESSORS

LIST OF FIGURES

Chapter 1: - - - - - - - - - - - - - - - - - - - - - - - - - Introduction
There are no Figures in this Chapter

Chapter 2: - - - - - - - - - - - - - - - - - BF Series Unit Specification

Figure 2-1 BFP2/BULK ............................................................................................................................................................ 4
Figure 2-2 BFP2/4CSCD .......................................................................................................................................................... 4
Figure 2-3 BFP4/BULK ............................................................................................................................................................ 4
Figure 2-4 BFP4/4CSCD .......................................................................................................................................................... 4
Figure 2-5 BFP2/BULK mounted on a Bottle Rack ................................................................................................................. 5
Figure 2-6 BF450-FCP.............................................................................................................................................................. 5

Chapter 3: - - - - - - - - - - - - - - - - - - - - - BF Series Operation

Figure 3-1 BFP2/BULK Air Flow Paths................................................................................................................................... 7
Figure 3-3 BFP2/4CSCD Air Flow Paths ................................................................................................................................. 8
Figure 3-2 Plugs on the BFP2/BULK ....................................................................................................................................... 8
Figure 3-4 BF450-FCP Dual Function Valve ........................................................................................................................... 9
Figure 3-5 Safety Valve .......................................................................................................................................................... 10
Figure 3-6 Check Valve .......................................................................................................................................................... 10
Figure 3-7 Bottle Fill Attachments Options............................................................................................................................ 12
Figure 3-8 Air Storage Bottle Valve Operating Sequence...................................................................................................... 13
Figure 3-9 Air Storage Bottle Filling Sequence for a BFP2/BULK ....................................................................................... 14
Figure 3-10 Air Storage Bottle Closing Sequence for a BFP2/BULK ..................................................................................... 15
Figure 3-11 Air Storage Bottle Filling Sequence for a BFP2/4CSCD...................................................................................... 18
Figure 3-12 Air Storage Bottle Closing Sequence for a BFP2/4CSCD.................................................................................... 19
Figure 3-13 BFP-2/4CSCD ....................................................................................................................................................... 20
Figure 3-14 BFP-2/4CSCD Detail ............................................................................................................................................ 21
Figure 3-15 BFP-2/4CSCD (Back View).................................................................................................................................. 22
Figure 3-16 PLU-0004 on the BFP2/BULK ............................................................................................................................. 23
Figure 3-17 BF450-FP .............................................................................................................................................................. 24
Figure 3-18 Fill Hose Assemblies............................................................................................................................................. 25

Chapter 4: - - - - - - - - - - - - - - - - - - - - - - - - - Maintenance
Figure 4-1 Safety Valve .......................................................................................................................................................... 26

Chapter 5: - - - - - - - - - - - - - - - - - - - - - BF Series Appendix

There are no Figures in this Chapter

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BAUER BF Series
COMPRESSORS
CHAPTER 1:INTRODUCTION
1.1 How To Use This Manual
This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-
uct(s) listed on the front cover.
All instructions in this manual should be observed and carried out as written to prevent damage or pre-
mature wear to the product or the equipment served by it.
If your unit is equipped with nonstandard accessories and/or options, supplemental information is nor-
mally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.
While every effort is made to ensure the accuracy of the information contained in this manual, Bauer
Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the
consequences thereof.
1.1.1 Manual Safety Notices
Important instructions concerning the endangerment of personnel, technical safety or operator safety
will be specially emphasized in this manual by placing the information in the following types of safety
notices.

^ DANGER ^
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This is limited to the most extreme situations.

^ WARNING ^
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death
or injury.

^ CAUTION ^
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices.

^ NOTE ^
NOTE advise of technical requirements that require particular attention by the operator or the
maintenance technician for proper maintenance and utilization of the equipment.

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MNL-0022 BAUER
COMPRESSORS
1.2 How to Use the Replacement Parts List
• A lozenge ◊ in the Item Number column indicates the part number for a complete assembly.
• a dagger (†) in the Qty column with or without an ellipis (…) in the Part Number column means the
part is illustrated for assembly purposes only and is not available for sale as an individual component.
This part can be obtained by ordering the complete assembly.
• AR in the Qty column means that the item is cut or manufactured to the size which the customer spec-
ifies.
• A dash (—) in the Item Number column indicates that there is more than one part number applicable
to the preceding Item Number.
• The letter(s) in the columns labeled Kit indicate the number of operating hours when the part is to be
replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000
hours.
• NS in the Item Number column indicates the part is not illustrated but is available.
When placing an order for spare parts, please provide the following information to ensure delivery of
the correct parts. The model number, date of manufacture and serial number can be found of the com-
pressor unit identification plate on the compressor unit’s frame.

Information Example

Model Number TCOM25

Serial Number 32165

Date of Manufacture 02/2005

Quantity required 2

Part Number N04860

Part Description Valve

^ WARNING ^
The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-
threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, BAUER
Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.

Febuary 3, 2006 Page 2

BAUER BF Series
COMPRESSORS
1.3 How to Use the Appendix
Information contained in the Appendix to this manual includes the following.
• The safety instructions applicable to this product. They must be read, understood and complied with
prior to operating the product.
• The instructions for installing this product. They must be read, understood and complied with prior to
operating the product.
• The instructions for long term storage (over 90 days) of this product.

Page 3 1st Ed. Rev. 2 Chg. 1

MNL-0022 BAUER
COMPRESSORS
CHAPTER 2:BF SERIES UNIT SPECIFICATION
2.1 Unit Description
The BAUER BF Series fill panels are used in conjunction with an air storage system and/or an Air
Compressor to recharge air bottles. The BF Series is available with a variety of fill hose and bank con-
nection combinations. For specific model information refer to Chapter 3. For design and layout of the
various models, refer to the following illustrations.

Figure 2-1 BFP2/BULK Figure 2-2 BFP2/4CSCD

Figure 2-3 BFP4/BULK Figure 2-4 BFP4/4CSCD

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BAUER BF Series
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Figure 2-5 BFP2/BULK mounted on a Bottle Racka

a.Bottle rack sold separately.

Figure 2-6 BF450-FCP

Page 5 1st Ed. Rev. 2 Chg. 1

MNL-0022 BAUER
COMPRESSORS
2.2 Specifications - BF Series
Medium air
Operating pressure, max. 6,000 psig (414 bar)
Ambient temperature range 32 - 105° F (0 - 40° C)
Inlet pressure gauge 0-7500 psig
Adjustable pressure regulator (6000 psig in, 0-5000 Out)
BFP Dimensions 28 1/2" L x 8" W x 7 1/2" H
BF450-FCP Dimensions 18" L x 12" W x 32" H
2.2.1 Technical Specifications

Table 2-1: Technical Specifications

Model Designation Fill Positions Description

BFP2 (or BFP2/BULK) 2 Wall Mounted Fill Panel

BFP2/2CSCD 2 Wall Mounted Fill Panel with 2 bank cascade
BFP2/3CSCD 2 Wall Mounted Fill Panel with 3 bank cascade
BFP2/4CSCD 2 Wall Mounted Fill Panel with 4 bank cascade
BFP4 (or BFP4/BULK) 4 Wall Mounted Fill Panel
BFP4/2CSCD 4 Wall Mounted Fill Panel with 2 bank cascade
BFP4/3CSCD 4 Wall Mounted Fill Panel with 3 bank cascade
BFP4/4CSCD 4 Wall Mounted Fill Panel with 4 bank cascade
BF450-FCP 2 Wall mounted, Dual Function 4 bank cascade fill con-
trol panel with Air Direction Valve

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BAUER BF Series
COMPRESSORS
CHAPTER 3:BF SERIES OPERATION
3.1 BF Series Theory of Operation
(See Figure 3-1)
All units in the BF Series of Bottle Fill Panels control the process of filling SCBA/SCUBA bottles from
the Fill Bank and/or Air Compressor. A Fill Bank consists of one or more High Pressure Storage Bot-
tles connected in series. In Bulk Fill BFP’s the Fill Bank is connected in series to the BFP, in Cascade
Fill BFP’s two or more Fill Banks are connected to the BFP in parallel.
Air follows the path of least resistance along the Fill Line. This means that the fill destination is filled
by the higher air pressure of the Fill Bank. As illustrated in Figure 3-1 with a BFP2/BULK, the Fill
Bank’s air pressure is higher than the fill destination; so the air flows towards the SCBA/SCUBA bot-
tle. In this example, the air source consists of a Fill Bank of two storage bottles and an Air Compressor.
The Fill Bank is connected to the BFP2/BULK’s Inlet Connector and the two bottles work together to
fill the SCBA/SCUBA bottle. The collective air pressure from the Fill Bank is the average air pressure
of the two storage bottles; and this is the air pressure shown on the Fill Bank’s Fill Valve Gauge.
Within the BFP2/BULK the air pressure is carried across the Fill Line in different directions, halted in
various places by closed valves, and Plugs in the top ports (See Figure 3-2).
When the air pressure in the Fill Bank goes below a preset air pressure level, the Air Compressor starts
to fill the Fill Bank until the two storage bottles are full again. Meanwhile, the Fill Bank is still filling
the SCBA/SCUBA bottle. The preset air pressure level is set by the user or the type of Air Compressor
used.

Figure 3-1 BFP2/BULK Air Flow Paths

Flow direction (With the BULK assembly, all top ports are plugged.)

Flow halted

Adjustable Regulator

Check Valve
Fill
Bank’s Safety Valve
Gauge
SCBA /
SCUBA
Air Compressor
Bottle
outputs to
Fill Bank Closed Opened
Fill Valve Fill Valve
Fill
Bank

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MNL-0022 BAUER
COMPRESSORS

Figure 3-2 Plugs on the BFP2/BULK

Plug

(See Figure 3-3) The BFP with a Cascade Panel also follows the theory of least resistance. When Fill
Bank 1's air pressure is more than SCBA/SCUBA storage bottle's air pressure, the direction of air flow
is towards the SCBA/SCUBA storage bottle. When SCBA/SCUBA storage bottle's air pressure is the
same as Fill Bank 1's air pressure, the air flow is static across the Fill Line and the filling process halts.
Moreover, if storage bottle's air pressure is more than Fill Bank 1's air pressure then the air flow will
improperly be towards Fill Bank 1. But before the air reaches the Fill Bank 1, it is halted by one of the
Check Valves, or Bank Values.

Figure 3-3 BFP2/4CSCD Air Flow Paths

Fill Bank 1
Fill Fill Fill
Bank 2 Bank 3 Bank 4

Flow direction
Gauges show the
Flow halted input pressure of
Adjustable each bank.
Regulator

Opened
Bank Valve

Check Valve
SCBA /
SCUBA
Inlet Bottle
Safety Valve
Connector

Air Compressor
outputs to the
Inlet Connector
of the BFP. Closed Opened
Fill Valve Fill Valve

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BAUER BF Series
COMPRESSORS
3.1.1 BF450-FCP Dual Function Valve Theory of Operation
The BF450-FCP relies on the air flow’s path of least resistance, with check valves throughout the unit
to direct the air flow. However, the BF450-FCP also uses the Dual Function Cascade Panel with an Air
Direction Valve. This Air Direction Valve is a three way valve with two settings, which are “From
Storage” and “From Compressor”. “From Storage” switches to the air input from any of the four top
ports of the Cascade Panel Bank Connections, drawing from the high pressure storage bottles. “From
Compressor” switches to the Air Compressor’s air input from the Inlet Connector.

Figure 3-4 BF450-FCP Dual Function Valve

Cascade Panel Inlet

Bank Connections Connector

Dual
Function
Valve
Inlet Pressure
Gauge

Adjustable
Bank Cascade Regulator
Fill Controls
Fill Pressure
Gauge

Fill Hoses
Controls

Fill Hose Connection Values

Page 9 1st Ed. Rev. 2 Chg. 1

MNL-0022 BAUER
COMPRESSORS

3.1.2 The Safety Valve

The Safety Valve is a key internal component of the BF Series, which guards against excess air pres-
sure; so it protects the BFP unit, the high pressure bottle, and the operator. When the output pressure is
greater than the Safety Value’s setting, the Safety Value activates and excess air is vented. Each Safety
Valve is set at the factory to the customer’s air pressure requirement. If the customer wants to change
the Safety Valve’s setting, the customer must acquire a new Safety Valve from the factory or seek a
high pressure system distributor’s assistance to recalibrate it. See Paragraph 4.2 for further maintenance
details.

Figure 3-5 Safety Valve

^ WARNING ^
The customer should never try to recalibrate the Safety Valve themselves.

^ WARNING ^
The Safety Valve is only used for safety and protection for the unit in the case of excessive air pressure,
therefore avoiding excessive popping of the Safety Valve during operation is highly recommended.

3.1.3 The Check Valve

The Check Valve is a key internal component of the BF Series, which is between the BFP Input Con-
nector for the air source and the rest of the BFP. The Check Valve is a one-way directional valve and
it’s purpose is to prevent air from going back to the Air Compressor and damaging it.

Figure 3-6 Check Valve

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BAUER BF Series
COMPRESSORS

3.2 Filling Procedure Precautions

^ CAUTION ^
Before opening any high pressure bottle, the operator must ensure all valves and the Adjustable Regulator
are closed; and that all attachments are made.

^ WARNING ^
Do not attach bottles to 4350 psi (300 bar) units unless the bottle is rated for this pressure. (Note pressure
stamped on the tank neck)

^ WARNING ^
Never open the fill valve unless the bottle is connected to the fill hose. Whipping of an unrestrained hose
caused by high pressure air discharge can cause serious injury!

^ CAUTION ^
The filling procedure should not be interrupted for more than 10 minutes to avoid increased CO2 levels in
the air filling the bottle.

^ CAUTION ^
Never leave pressure in the fill hose while the BFP is not in use, because the fill hose will weaken and
burst.

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MNL-0022 BAUER
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3.3 BFP to Bottle Attachments
3.3.1 Bottle Fill Hose Attachments
There are various Fill Hose Attachments available for the customer’s specific needs. All Fill Hose
Attachments include a Vent Valve for line pressure relief and operator safety. See Figure 3-7 for an
overview of the various Fill Hose Options, See Figure 3-18 for parts details, and See Paragraph 3.3.2
for the Fill Yoke, SCUBA option bottle attachment instructions.

^ NOTE ^
The operator must be sure to use the proper CGA Connector as supplied with the BFP Unit.

Figure 3-7 Bottle Fill Attachments Options

1 2 3

5 4
5
4
5

1. Fill Yoke, SCUBA 4. Vent Valve

2. Fill Assembly, Female 5. Vent Hole
3. Fill Assembly, Male

Febuary 3, 2006 Page 12

BAUER BF Series
COMPRESSORS
3.3.2 Attaching the Fill Yoke to the SCUBA Storage Bottle
1. Ensure that the Vent Valve, fill valve and bottle valve are closed.
2. Connect the air bottle to the compressor fill hose utilizing the SCUBA Fill Yoke.
3. The operator must open the Vent Value to relieve any residual air pressure on the Fill Line before
disconnecting SCUBA Fill Yoke.

Figure 3-8 Air Storage Bottle Valve Operating Sequence

2 3

Attaching the Fill Yoke Tightening Fill Adaptor Loosening Fill Adaptor

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MNL-0022 BAUER
COMPRESSORS
3.4 Filling Procedures
3.4.1 BFP/BULK Series Filling Procedure
(See Figure 3-9)

^ WARNING ^
The Safety Valve is only used for safety and protection for the unit in the case of excessive air pressure,
therefore avoiding excessive popping of the Safety Valve during operation is highly recommended.

^ NOTE ^
Adjustable valves open clockwise and close counter-clockwise. The Adjustable Regulator opens counter-
clockwise and closes clockwise.

1. Ensure that both BFP Fill Valves (8) and the Adjustable Regulator (4) are closed, and that all fill
adaptor’s hoses are fastened securely with Vent Values (6) closed (See Paragraph 3.3.2 for the Fill
Yoke hose).
2. If the Air Compressor is not on, ensure that the Air Compressor is fastened securely to Inlet Con-
nector (9) and energize it by using the start-up procedures in the compressor’s operating instruc-
tions.
3. Open the Fill Bank’s storage bottle(s) (1). The Fill Bank’s Gauge (2) and BFP’s Inlet Pressure
Gauge (3) now show the pressure of the storage bottle(s) and Air Compressor.

Figure 3-9 Air Storage Bottle Filling Sequence for a BFP2/BULK

3 4 5

1 2

7
Air Compressor
outputs to
Fill Bank

9 8

1. Fill Bank 4. Adjustable Regulator 7. SCBA/SCUBA bottle

2. Fill Bank’s Gauge 5. Fill Pressure 8. Fill Valve
3. Inlet Pressure Gauge 6. Vent Value 9. Inlet Connector

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BAUER BF Series
COMPRESSORS
4. Increase the Adjustable Regulator counter-clockwise slowly, until the working pressure of the
SCBA/SCUBA bottle (7) is reached on the Fill Pressure Gauge (5). The Fill Pressure must not
exceed the maximum working pressure of the SCBA/SCUBA bottle.
5. With the fill adaptor attached to the SCBA/SCUBA bottle, open the SCBA/SCUBA bottle valve.
Follow the operating sequence for the Fill Yoke adaptor, if used (See Paragraph 3.3.2).
6. Open the Fill Valve that has the fill hose attached to the SCBA/SCUBA bottle.
a. The SCBA/SCUBA bottle will begin filling. When filling begins, the BFP’s Inlet Pressure Gauge
drops to about zero and gradually raises.
b. During the filling process, monitor the bottle pressure on Fill Bank’s Gauge.
c. Monitor compressor operation and drain condensate at the Air Compressor, if used.
d. When the BFP’s Inlet Pressure gauge and Fill Pressure gauge equalize and desired SCBA/
SCUBA bottle pressure is reached, then the fill procedure is complete.

3.4.2 BFP/BULK Series Closing Procedure

(See Figure 3-10)
1. Close the Fill Bank’s storage bottle(s) (1).
2. Shut down the Air Compressor, if used.
3. Close the filled SCBA/SCUBA bottle (4) tightly.
4. Open the Vent Valve (3) on the fill adaptor clockwise to bleed off any residual line pressure.

^ CAUTION ^
Before disconnecting any lines, the operator must open the Vent Valve to bleed off any residual line pres-
sure, to avoid injury. Check the Fill Valve Gauge of the Fill Bank to verify that the hose is fully bled.

Figure 3-10 Air Storage Bottle Closing Sequence for a BFP2/BULK

2
1

4
Air Compressor
outputs to
Fill Bank

5
1. Fill Bank 4. SCBA/SCUBA bottle
2. Adjustable Regulator 5. Fill Valve
3. Vent Value

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MNL-0022 BAUER
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5. Close the Adjustable Regulator (2), clockwise.
6. Close all opened Fill Valves (5), counter-clockwise.
7. Close the Vent Valve on the fill adaptor. Remove fill adaptor from the SCBA/SCUBA bottle and
store compressed air bottle. Follow the closing Sequence for the Fill Yoke adaptor (See Paragraph
3.3.2), if used.

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BAUER BF Series
COMPRESSORS
3.4.3 BF Series with Cascade Panel Filling Procedure
(See Figure 3-11)

^ WARNING ^
The Safety Valve is only used for safety and protection for the unit in the case of excessive air pressure,
therefore avoiding excessive popping of the Safety Valve during operation is highly recommended.

^ NOTE ^
Adjustable valves open clockwise and close counter-clockwise. While, the Adjustable Regulator opens
counter-clockwise and closes clockwise.

1. Ensure that BFP Fill Valves (8), all Bank Valves (3), and the Adjustable Regulator (6) are closed,
and that all fill adaptor’s hoses are fastened securely with Vent Values (9) closed (See Paragraph
3.3.2 for the Fill Yoke hose).
2. Open Fill Bank 1’s storage bottle (1). Increase Fill Bank 1’s input pressure until it’s PSI level
matches the target PSI level of the SCBA/SCUBA (10).
3. The Fill Bank 1’s Gauge (2) now shows the pressure of Fill Bank 1.
4. If the Air Compressor is not on, energize it by using the start-up procedures in the compressor’s
operating instructions and ensure that the Air Compressor is fastened securely to Inlet Connector
(4).
5. Open the Bank Valve 1 (3) gradually until the PSI measurement on the BFP’s front panel Inlet Pres-
sure Gauge (5) matches the PSI of Bank Valve 1’s gauge.
6. Increase the Adjustable Regulator counter-clockwise slowly, until the PSI storage capacity of the
SCBA/SCUBA bottle is reached on the Fill Pressure Gauge (7). The Adjustable Regulator setting
must not exceed the maximum working pressure of the SCBA/SCUBA bottle. At this time, the
operator notes that the total pressure on the Fill Line is from the Fill Bank to the Fill Valves (8) on
the bottom of the Basic Fill Panel.
7. With the fill adaptor attached to the SCBA/SCUBA bottle, open the SCBA/SCUBA bottle valve.
Follow the operating sequence for the Fill Yoke adaptor, if used (See Paragraph 3.3.2).
8. Open the Fill Valve that has the fill hose attached to the SCBA/SCUBA bottle.
a. The SCBA/SCUBA bottle will begin filling. When filling begins, the BFP’s Inlet Pressure Gauge
drops to about zero and gradually raises.
b. During the filling process, monitor the bottle pressure on Fill Bank 1’s Gauge, and the drain con-
densate at the Air Compressor, if used.
c. When the BFP’s front panel Inlet Pressure gauge and Fill Pressure gauge equalize and desired
SCBA/SCUBA bottle PSI level is reached, then the fill procedure is complete.

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MNL-0022 BAUER
COMPRESSORS
If the storage bottle has completed filling without the BFP’s front gauges equalizing, then this means
that there wasn’t enough air pressure in the Bank 1’s storage bottle.
• (Cascade Option) To complete the filling of the SCBA/SCUBA bottle, just close the Bank Valve
1’s and open a second Bank Valve.
• (BF450-FCP Dual Function Valve Option) If filling is still not complete, rotate Dual Function
Valve from “From Storage” to “From Compressor”. The Air Compressor completely fills the
SCBA/SCUBA bottle. When finished, rotate the valve back to “From Storage”.

Figure 3-11 Air Storage Bottle Filling Sequence for a BFP2/4CSCD

5 6 7 10
4
8

1. Fill Bank 1 5. Inlet Pressure Gauge 8. Fill Valve

2. Fill Bank 1’s Gauge 6. Adjustable Regulator 9. Vent Value
3. Bank Valve 7. Fill Pressure Gauge 10. SCBA/SCUBA bottle
4. Inlet Connector

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BAUER BF Series
COMPRESSORS

3.4.4 BF Series with Cascade Panel Closing Procedure

(See Figure 3-12)
1. Close the Fill Bank 1’s storage bottle (1), and shut down the Air Compressor, if used.
2. Close the filled SCBA/SCUBA bottle (6).
3. Open the Vent Valve (5) to bleed off any residual line pressure.

^ CAUTION ^
Before disconnecting any lines, the operator must open the Vent Valve to bleed off any residual line pres-
sure, to avoid injury. Check the Fill Valve Gauge of the Fill Bank to verify that the hose is fully bled.

4. Close the Adjustable Regulator (3), clockwise.

5. Close all opened Fill Valves (4) and Bank Values (2), counter-clockwise.
6. Close the Vent Valve on the fill adaptor. Remove fill adaptor from the SCBA/SCUBA bottle and
store compressed air bottle. Follow the closing Sequence for the Fill Yoke adaptor (See Paragraph
3.3.2), if used.

Figure 3-12 Air Storage Bottle Closing Sequence for a BFP2/4CSCD

3
4

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3.5 Replacement and Spare Parts List
Figure 3-13 BFP-2/4CSCD

1 2

3 3

Item Qty Part No. Description Notes

1 6 GAG-0009W Gauge, Bottle Cascade 7500 PSI, PSI/BAR, 1/4CBM
2 6 VAL-0006 Valve, Needle 6000 PSI, 1/4” NPT, Line
3 2 YOK-0001 Yoke, Scuba Fill w/Bleeder, Plated
4 1 REG-0003 Regulator, Adjustable, 1/4”NPT 6000PSI-in and 0-5000PSI-out
5 2 HOS-0123 Hose Assembly

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Figure 3-14 BFP-2/4CSCD Detail

2
3
4

5 5
6
7

Item Qty Part No. Description Notes

1 4 GAG-0009W Gauge 7500PSI/BAR, 1/4CBM
2 4 ELL-0018 Elbow 1/4”NPT
3 4 TEE-0012 Tee, Male Run 1/4” NPT
4 4 VAL-0006 Valve, Needle 6000PSI, 1/4NPT, Line
5 7 CON-0033 Connector, Bulk Head 1/4” Tube X 1/4” NPTF
6 1 CON-0017 Connector, Hex Nipple; Fill 2 1/4” NPTM
N.S. 1 CON-0017 Connector, Hex Nipple; Fill 1 1/4” NPTM
7 1 CON-0039 Connector, Inlet Connector 1/4” NPTM

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Figure 3-15 BFP-2/4CSCD (Back View)

1
3 2

Item Qty Part No. Description Notes

1 1 CON-0039 Connector, Inlet Connector 1/4” NPTM
2 1 VAL-0007 Valve, Check 1/4” NPTF in X 1/4” NPTM
3 1 VAL-0169 Valve, Safety 1000-6500, 1/4” NPTM

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Figure 3-16 PLU-0004 on the BFP2/BULK

Plug

Item Qty Part No. Description Notes

1 4 PLU-0004 Plug;1/4" NPTM
2

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Figure 3-17 BF450-FP

6 3

5
4
4

1, 2

Item Qty Part No. Description Notes

1 8 CON-0033 Connector, Bulk Head
2 8 CON-0039 Connector, 1/4"
3 1 VAL-0067 Valve, 3-Way Control Ball
4 8 GAG-0009W Gauge, Bottle Cascade
5 1 REG-0003 Regulator,1/4”NPT
6 6 VAL-0076 Valve, Needle

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Figure 3-18 Fill Hose Assemblies

1 2 3

Item Qty Part No. Description Notes

1 1 YOK-0001 Fill Adapter, SCUBA High PSI
2 1 ADP-0113 Fill Adapter, Female Silver Plated; High PSI
— 1 ADP-0112 Fill Adapter, Female Gold Plated; Low PSI
3 1 ADP-0207 Fill Adapter, Male DIN Silver Plated; High PSI
4 1 HOS-0123 Hose Assembly

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CHAPTER 4:MAINTENANCE
4.1 Pressure Gauges
Observe the pressure gauges daily. If the readings of any of the gauges seem to be incorrect, bleed off
all system pressure. Then, remove the gauge and check for wear and tear, accuracy and proper function-
ing by comparing it to a precision test gauge or a dead weight tester. Replace all broken or damaged
gauges immediately.
4.2 Safety Valve
Develop a regular program of visual inspection, looking for clogged drains and discharge pipe, dirt
buildup in and around the valve seat, and broken or missing parts.
Avoid excessive operation of the safety valve, as even one opening can provide a means for leakage.
Safety valves should be operated only often enough to assure that they are in good working order.
Do not paint, oil or otherwise cover any interior or working parts of any safety valve. They do not
require any lubrication or protective coating to work properly.

Figure 4-1 Safety Valve

4.3 Tube Connections

Pipe connections (swivel nuts): Tighten just firmly enough so that leakage is stopped (finger tight plus
up to an additional 1/2 turn as necessary). Please note that the compression type coupling fittings are
capable of exerting extreme force on the tubing and should not be tightened more than is required to
seal the joint. To improve the sealing of the pipe connections and to facilitate installation, the following
should be observed:
• Apply a thin layer of Never-Seez NSWT or equivalent on the outside of the ferrule during assembly.
• Lubricate the threads of the connector with Never-Seez NSWT or a similar PFTE base lubricant to
facilitate future disassembly.
4.4 Pressure Hoses
The hoses should be inspected periodically for wear and damage. If a hose is worn or damaged, remove
and replace it.
4.5 Storage Bottles

^ NOTE ^
All storage bottles must be inspected or tested according to national and local regulation.

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CHAPTER 5:BF SERIES APPENDIX
5.1 Safety
5.1.1 General Safety Precautions
• Read this BF Series operating manual before installing or operating this BF Series unit. Follow appro-
priate handling, operation and maintenance procedures from the very beginning. Maintenance is
simple, but must be executed regularly to achieve safe operation, maximum efficiency and long
service life.
• The BF Series unit must be installed, operated, maintained and repaired only by authorized, trained
and qualified personnel.
• Consult and follow all OSHA, NEMA, ASME, DOT, and local regulations, laws and codes covering
the installation and operation of the compressor and accessories before operating the unit.
• Do not operate this unit in excess of it’s rated capacity, speed, pressure, temperature, or otherwise
than in accordance with the instructions contained in this manual. Operation of this unit in excess of
the conditions set forth in this manual will subject the unit to limits which it may not be designed to
withstand.
• Keep safety guards in place.
• Do not modify the BF Series unit or its systems.
• Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, brace-
lets, hand rags, etc. are potential hazards.
• Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes
of escape and post such routes.
• Make sure you are equipped with all required safety equipment; hearing protection, safety glasses,
hard hats, safety shoes and fire extinguisher.
• Visually inspect the unit before starting. Remove and /or replace any loose or broken components,
tools, valves, missing equipment, etc.
• Do not tamper with, modify, or bypass safety and shutdown equipment.
• Do not tighten or adjust fitting or connections under pressure.
• The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to
insure system compatibility of flex joints and flexible hose can result in mechanical failure, property
damage, and serious injury or death.
• Incorrect placement of the inlet and pressure valves in a BF Series unit can cause an extremely
dangerous condition. Refer to the appropriate section of this manual before installing or replacing
valves.
• Do not use gasoline, diesel fuel or other flammable products as a cleaning solution.
• The use of repair parts other than those listed in this manual or purchased from BAUER Compressors,
Inc. may create unsafe conditions over which BAUER has no control. Such unsafe conditions can
lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage
to the equipment. Therefore, BAUER Compressors, Inc. can bear no responsibility for equipment in
which non-approved repair parts are installed

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5.1.2 Safety Warning Labels

Notes, labels and warning signs are displayed on the compressor unit according to model, application or
equipment and may include any of the following.

HOT SURFACES DO NOT TOUCH!

Danger of burning if cylinders, cylinder heads, or pressure lines of individual

compressor stages are touched.
HIGH VOLTAGE!

Life threatening danger of electrical shock. Maintenance work on electric units

or operating equipment should be carried out by a qualified electrician or by a
person supervised by a qualified electrician according to electrical regulations.
AUTOMATIC COMPRESSOR CONTROL
UNIT MAY START WITHOUT WARNING!

Before carrying out maintenance and repair work, switch off at the main switch
and ensure the unit will not restart.
THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT!

The instruction manual and all other applicable instructions, regulations, etc.
must be read and understood by the operating personnel before using the
machine.
HEARING PROTECTION MUST BE WORN!

Hearing protectors must be worn when working on a machine which is running.

DIRECTION OF ROTATION!

When switching on the machine, check the arrow to ensure correct direction of
rotation by the drive motor.

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5.2 Reference Data
5.2.1 Conversion Formulas
°F = 9/5°C + 32 °C = 5/9 x (°F-32)
PSI = BAR x 14.5 BAR =PSI x 0.0689
5.2.2 Approved Lubricants Chart
Unless otherwise specified in text, use the lubricants in Table 2.

Table 5-1: Lubricant Chart

Usage Lubricants

O-rings, rubber and plastic parts; filter housing

Parker Super “O” Lube
threads, sealing rings

Bolts, nuts, studs, valve parts, copper gaskets and

tube connection parts (threads, cap nut and com- Never-Seez® NSWT, Pipe Dope or teflon tape
pression rings)

DOW Corning 732 or equivalent silicon compound

Paper gaskets
applied on both sides before assembly,

DOW Corning 732 or equivalent temperature resis-

High temperature connections
tant compound,

Tube connection ferrules, Never-Seez® NSWT

5.2.3 Glossary of Abbreviations and Acronyms

† Available Only as Part of a Complete Assembly
AC Activated Charcoal, removes odor and taste
ACD automatic condensate drain
ASME American Society of Mechanical Engineers
CW clockwise
CCW counterclockwise
CGA Compressed Gas Association
DIN Deutsches Institut für Normung
DOT Department of Transportation
E1 single phase electrical supply
E3 three phase electrical supply
HP Chemical Catalyst, converts carbon monoxide to carbon dioxide
IAW In Accordance With
MS Molecular Sieve, removes moisture
NEC National Electrical Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
OSHA Occupational Safety & Health Administration
ODP open drip-proof (motor)

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MNL-0022 BAUER
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OEM Original Equipment Manufacturer
PCB printed circuit board
PLC Programable Logic Controller
PMV pressure maintaining valve
SC Securus® Moisture Sensing Device
5.3 Additional Documents
5.3.1 Diagrams and Drawings
Any included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound next to the back
cover in a hardcopy manual or included as a separate file on a CD.
5.3.2 Other Documents
OEM Manuals and other BAUER manuals may be included in the documentation shipping package.

Febuary 3, 2006 Page 30