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MNL-0096

April 17, 2013

Page 88

6.1.2

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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Summary of Contents for IP10S

Page 1: ...ion Rev 0 Chg 6 MNL 0096 Bauer Compressors Inc Breathing Air Purification Systems and Industrial Air Purification Systems Breathing Air Purification Models P0 P1 P2 P4 P5 P10 P31 P41 P42 P43 with Securus Electronic Moisture Monitor System P2S P5S P10S P14S P42S P43S P12 P14 Industrial Air Purification Models IP41 IP42 IP43 with Securus Moisture Monitoring System IP2S IP5S IP10S IP41S IP42S IP43S ...

Page 2: ...se s use of this information without the express written permission of Bauer Compressors Inc EDITIONS REVISIONS AND CHANGES An Edition is the original or a complete rewriting of the entire Manual A Revision occurs whenever a complete Section or Appendix is rewritten or added A Change occurs when individual pages drawings or tables are changed WARNING This Instruction Manual and Replacement Parts L...

Page 3: ...ge Operating Life 7 2 1 7 1 Calculating the Maximum Cartridge Operating Hours 8 2 1 7 2 Calculating the Adjusted Cartridge Operating Hours 8 2 1 7 3 Air Purification Cartridge Operating Hours Form 10 CHAPTER 3 SINGLE CHAMBER PURIFICATION SYSTEMS 3 1 APPLICABILITY 11 3 2 P0 PURIFICATION SYSTEM DESCRIPTION 11 3 2 1 Maintenance 12 3 2 1 1 Replacing the Cartridge 12 3 2 1 2 Chamber Replacement Interva...

Page 4: ...6 12 P42 and IP42 Purification System 42 4 6 13 P42S and IP42S Purification System 43 4 6 14 P43 and IP43 Purification System 44 4 6 15 P43S and IP43S Purification System 45 4 7 PURIFICATION COMPONENTS REPLACEMENT PARTS LIST 46 4 7 1 Oil and Water Separator P N 079416 46 4 7 2 10 Chamber P N 080143 47 4 7 3 20 Chamber P N 082135 48 4 7 4 20 Securus Chamber P N 082136 49 4 7 5 20 Securus II Chamber...

Page 5: ...t Parts List 77 CHAPTER 6 APPENDIX 6 1 SAFETY 86 6 1 1 General Safety Precautions 86 6 1 2 Safety Warning Labels 88 6 2 UNPACKING HANDLING AND INSTALLATION 89 6 2 1 Unpacking and Handling 89 6 2 2 Installation of the Unit 89 6 2 2 1 General 89 6 2 2 2 Electrical Installation 89 6 3 LONG TERM STORAGE 90 6 3 1 General 90 6 3 2 Preparations 90 6 3 2 1 Units Equipped with a Filter System 90 6 3 3 Pres...

Page 6: ...Figure 3 8 P31 Purification System Check Valve 22 CHAPTER 4 MULTI CHAMBER PURIFICATION SYSTEMS Figure 4 1 Typical Bauer Purification System 23 Figure 4 2 Oil and Water Separator 24 Figure 4 3 OIl and Water Separator Labels 25 Figure 4 4 Oil and Water Separator 27 Figure 4 5 Sintered Metal Filter Assembly 27 Figure 4 6 Cartridge Replacement 28 Figure 4 7 Purification Chamber Position 29 Figure 4 8 ...

Page 7: ...S Figure 5 1 P12 Purification System 59 Figure 5 2 Oil and Water Separator 62 Figure 5 3 Cartridge Replacement 63 Figure 5 4 P12 Purification System 64 Figure 5 5 Oil and Water Separator 65 Figure 5 6 27 High Flow Chamber Assembly 67 Figure 5 7 Securus Chamber Assembly 69 Figure 5 8 CO Removal Chamber 71 Figure 5 9 P14 Purification System 72 Figure 5 10 Oil and Water Separator 75 Figure 5 11 Cartr...

Page 8: ...countable for any inaccuracies or the con sequences 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 ...

Page 9: ... letters 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...

Page 10: ...g the product Reproducible Forms Reference Data Torque Values Torque Sequence Conversion Formulas Approved Lubricants Glossary of Abbreviations Acronyms Additional Documents 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 threaten...

Page 11: ...rate record of operating hours to ensure exact attention to maintenance intervals 2 Change all cartridges before reactivating a compressor unit that has been out of service more than three months Leave cartridges in the unit as long as it is out of service 3 While out of service keep all condensate drain valves closed Maintain a pressure of 700 1 100 psi 50 to 80 bar within the system to prevent m...

Page 12: ...2 1 4 Model Serial Number and Part Number Identification 2 1 4 1 Compressor Dataplate The model number date of manufacture and serial number can be found on the compressor unit identifi cation plate in the main electrical enclosure and frame Figure 2 1 Cartridge Safety Venting Figure 2 2 P0 P31 Safety Venting Figure 2 3 Purification System Dataplates typical Purification System Cartridge Installat...

Page 13: ...of the cartridge installed in that chamber Figure 2 3 2 1 5 Breathing Air Purification System Configurations Purification System Number and Type of Cartridges Processing Capacity Dryer Purification Securus cubic ft ft 3 P0 Combined 3 200 P1 1 15 000 P2 1 40 000 P2 with Securus 1 67 000 P4 1 1 60 000 P5 1 1 90 000 P5 with Securus 1 1 150 000 P10 2 1 140 000 P10 with Securus 2 1 230 000 P12a a P12 a...

Page 14: ...ient air temperature and its ability to cool the compressor will effect the operating life of the car tridge See Paragraph 2 1 7 2 for the method of calculating this adjustment factor The optimum place to measure the temperature is at the inlet to the final separator as this best reflects the temperature of the air as it enters the chambers Experience has shown that this temperature is approxi mat...

Page 15: ... by the Charging Rate to obtain the Maximum Operating Time in minutes 4 Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours 5 Record the answer on the Air Purification Cartridge Operating Hours form 2 1 7 2 Calculating the Adjusted Cartridge Operating Hours 1 Using the Air Purification Cartridge Operating Hours form record the Date Operating Hours and Ambient A...

Page 16: ...or 50 122 0 21 40 104 0 34 30 86 0 58 20 68 1 00 10 50 1 81 0 32 3 44 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 0 C 10 C 20 C 30 C 40 C 50 C Conversion Factor 32 F 50 F 68 F 86 F 104 F 122 F Date Operating Hours Ambient Temp during Compression 18 F Correction Factor Adjusted Cartridge Hours Today Total 10 19 04 8 92 F 33 C 0 5 16 00 16 00 11 01 04 4 45 F 7 2 C 2 25 1 78 17 78 Op hrs Corr factor Total hrs To...

Page 17: ...MNL 0096 April 17 2013 Page 10 2 1 7 3 Air Purification Cartridge Operating Hours Form Date Operating hours Ambient temp 18 F during compression Correction factor Adjusted cartridge hours Today Total ...

Page 18: ... separator surround ing the cartridge chamber liquid oil and water particles are separated from the compressed air by a pipe nozzle Residual oil and water particles are then removed by the filter cartridge and the air leaving the P0 Purification System is free of water oil taste and smell Figure 3 1 P0 Purification Chamber 1 Inlet Connection 2 Condensate Drain Connection 3 Condensate Drain Valve 4...

Page 19: ...e of the housing 4 with a clean cloth Check for corrosion Replace if necessary 5 Lubricate all threads and O rings on both the Plug 5 and the Cartridge 2 with petroleum jelly 6 Insert new cartridge and secure in place with plug 5 Figure 3 2 P0 Purification System Cross Section 1 Inlet 2 Cartridge 3 Jet Pipe 4 Housing 5 Plug 6 Final Pressure Safety Valve 7 Adjustment Knob 8 Separator Chamber 9 Outl...

Page 20: ...P0 Purification System must be replaced is 11 125 hours at 5 000 psi 300 bar To avoid exceeding the maximum number of load cycles the operating hours should always be recorded NOTICE The used filter cartridge must be disposed of in accordance with local regulations WARNING The P0 Purification System is subject to dynamic loading It is designed for a certain number of load cycles A load cycle equat...

Page 21: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing ...

Page 22: ...2 O ring 4 Housing Available only with 077159 D V001 5 Bottom Available only with 077159 D V001 6 1 073793 Condensate Drain Tap Assembly 7 1 059183A Cartridge Assembly Includes Items 9 and 10 8 1 N4566 O ring 9 1 N3824 O ring 10 1 059410 Safety Valve 11 1 077235 Pressure Maintaining Valve 12 4 SCR 0177 Socket Head Cap Screw Figure 3 3 P0 Purification System 20 19 18 17 6 11 16 12 15 14 13 23 5 2 2...

Page 23: ... Description Notes 13 1 57937 Cover 14 2 N16591 O ring 15 1 57904 Connection Pipe 16 1 N24788 O ring 17 2 N19547 Allen Screw 18 2 WAS 0021 Washer 19 1 N24910 Male Connector 20 1 N20287 Male Connector 21 4 SCR 0139 Allen Screw 22 1 N4882 O ring 23 1 073093 Rubber Wrap 24 1 CMP 0075 Clamp ...

Page 24: ...tridge chamber In the separator liquid oil and water particles are separated from the compressed air by a pipe nozzle Residual oil and water particles are then removed by the filter cartridge and the air leaving the filter assembly is free of oil taste and smell Figure 3 4 P31 Purification System 1 Final Safety Valve 2 Plug 3 Housing 4 System Check Valve 5 Bottom 1 2 3 4 5 ...

Page 25: ...ified at the time of purchase as a factory installed option and may not be installed on your unit Figure 3 5 P31 Purification System Cross Section 1 Inlet 2 Jet Pipe 3 Plug 4 Final Pressure Safety Valve 5 Housing 6 Cartridge 7 Bottom 8 Pressure Maintaining Valve 9 Safety Bore 1 2 3 4 5 4 6 7 8 9 Cartridge Removal ...

Page 26: ... psi 300 bar or 20 000 if operated at 3 200 psi 225 bar If the number of load cycles of four per hour i e the condensate is drained every fifteen minutes is not exceeded then the maximum number of operating hours before the filter must be replaced is 11 625 hours at 5 000 psi 300 bar To avoid exceeding the maximum number of load cycles the operating hours should always be recorded NOTICE The used ...

Page 27: ...ble only with 082374 2 1 N4784 O ring 3 2 N4736 Backup Ring 4 2 N4735 O ring 5 1 080100A Filter Cartridge MS AC or 1 080114A Filter Cartridge MS AC HP 6 1 80066 Filter Housing Available only with 082374 7 1 80593 Filter Base Assembly See Figure 3 7 8 1 011430 Condensate Drain Tap Assembly Figure 3 6 P31 Purification System 1 2 3 4 5 6 4 3 7 8 ...

Page 28: ...h 082374 5 1 79199 Seat Spring Available only with 082374 6 1 2623 Spring 7 1 57935 Adjusting Screw Available only with 082374 8 1 N27297 Set Screw 9 1 N3837 Hex Nut 10 1 78106 Cylindric Pin 11 1 78688 Valve Piston 12 1 N23166 O ring 13 1 4602 Backup Ring 14 1 91038 Valve Seat 15 1 80603 Nozzle Available only with 082374 16 1 N24788 O ring Figure 3 7 P31 Purification System Base Assembly 1 2 3 4 5...

Page 29: ...ge 22 Item Qty Part No Description Notes 1 80555 Check Valve 1 1 80716 Valve Seat 2 1 N29166 O ring 3 1 73767 Valve Piston 4 1 80552 Valve Housing 5 4 N19539 Allen Screw Figure 3 8 P31 Purification System Check Valve 1 2 3 4 5 ...

Page 30: ...ification Chamber Different models add one or more Dryer Chambers and replace the Purification Chamber with a Securus Electronic Moisture Monitor System Purification Chamber Additional compo nents generally include a Condensate Drain Valve Check Valves a Bleed Valve a Pressure Maintaining Valve and a Safety Valve Figure 4 1 shows the typical interconnection of these components Figure 4 1 Typical B...

Page 31: ... Separator WARNING The rapid depressurizing and repressurizing of the oil and water separator during condensate draining subjects it to metallurgical stresses To prevent catastrophic failure with the possibility of damage injury or death the oil and water separator P N 079416 must be replaced after a predetermined number of cycles One load cycle equals one pressurization plus one depressurization ...

Page 32: ...l and water 2 Activated carbon which absorbs oil vapors effecting taste and odor 3 A catalyst to convert carbon monoxide to carbon dioxide 4 A sensor for the Securus Electronic Moisture Monitor System 4 3 3 1 Cartridge Handling 1 Never open the protective packaging a cartridge comes in prior to its actual use The highly sensitive filter materials will absorb moisture from the atmosphere becoming s...

Page 33: ...ater Separator To remove the sintered metal filter proceed as follows See Figure 4 4 1 Disconnect the power and shut off the inlet supply line if applicable 2 Depressurize the system by means of the bleed valve 3 Remove the tubes connected to the side of the filter head 1 4 Unscrew and remove the filter head 5 Unscrew the sintered metal filter assembly 2 from the filter head 6 Remove the center sc...

Page 34: ...f the inlet supply line if applicable 1 Depressurize the system by means of the bleed valve 2 Unscrew the chamber head using the special wrench supplied 3 Pull out the cartridge using the lifting ring on top of the cartridge Figure 4 4 Oil and Water Separator Figure 4 5 Sintered Metal Filter Assembly 1 Filter Head 2 Sintered Metal Filter 3 Center Screw 4 O rings 1 2 3 4 ...

Page 35: ...e bleed valve restore the power and reconnect the inlet supply line if applicable 4 4 2 1 Leaking at the Safety Bore 1 Remove the cartridge following steps to 3 in Paragraph 4 4 2 2 Install cartridge if missing 3 Remove cartridge and inspect O rings 4 Replace O rings if necessary 5 Ensure protective caps and devices have all been removed 6 Replace cartridge following steps 7 to 10 in Paragraph 4 4...

Page 36: ...gh Table 4 4 the Cartridge Part Numbers are cross indexed to the Purification System Model Number and the highlighted Chamber Part Number The Cartridge Part Numbers are used with Figure 4 24 through Figure 4 30 for determining the correct part numbers for maintenance and repair Figure 4 7 Purification Chamber Position Table 4 1 Cartridge Applications for Purification Systems P1 to P4 P N Descripti...

Page 37: ...plications for Purification Systems P41 to P43 P N Description P41 P41S P42 P42S P43 P43S 082135 20 Chamber A A A B A A B C A B 082136 20 Securus Chamber B C 062504 20 Dryer Cartridge B B B C B C 067224 20 Purification Cartridge Breathing A A A 061687 20 Securus Cartridge Breathing A A A Table 4 4 Cartridge Applications for Purification Systems IP41 to IP43S Industrial Applications Only P N Descri...

Page 38: ...y Part No Description Notes 1 1 079416 Oil and Water Separator See Figure 4 23 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 1 080143 10 Purification Chamber See Figure 4 24 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 VAL 0169 Safety Valve Figure 4 8 P1 Purification System OUT IN 1 2 3 4 5 6 3 7 ...

Page 39: ...9416 Oil and Water Separator See Figure 4 23 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 1 VAL 0377 Bleed Valve 5 1 VAL 0053 Pressure Maintaining Valve 6 1 080144 27 Purification Chamber See Figure 4 28 7 1 VAL 0169 Safety Valve Figure 4 9 P2 Purification System OUT IN 1 2 3 4 3 5 6 7 ...

Page 40: ...lve 3 2 VAL 0007 Check Valves 4 1 VAL 0377 Bleed Valve 5 1 VAL 0053 Pressure Maintaining Valve 6 1 080145 27 Securus Purification Chamber See Figure 4 30 7 1 VAL 0169 Safety Valve 8 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC 1 MNR 0042 Securus II Monitor Figure 4 10 P2S and IP2S Purification System OUT IN 1 2 3 4 3 5 8 6 7 Securus OUT IN 1 2 3 4 3 5 8 6 7 S...

Page 41: ...ator See Figure 4 23 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 1 080144 27 Dryer Chamber See Figure 4 28 5 1 080143 10 Purification Chamber See Figure 4 24 6 1 VAL 0377 Bleed Valve 7 1 VAL 0053 Pressure Maintaining Valve 8 1 VAL 0169 Safety Valve Figure 4 11 P4 Purification System IN OUT 1 2 3 4 5 6 3 7 8 ...

Page 42: ...Water Separator See Figure 4 23 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 1 080144 27 Dryer Chamber See Figure 4 28 5 1 080144 27 Purification Chamber See Figure 4 28 6 1 VAL 0377 Bleed Valve 7 1 VAL 0053 Pressure Maintaining Valve 8 1 VAL 0169 Safety Valve Figure 4 12 P5 Purification System OUT IN 7 3 8 1 2 3 4 5 6 ...

Page 43: ...es 4 1 080144 27 Dryer Chamber See Figure 4 28 5 1 080145 27 Securus Chamber See Figure 4 30 6 1 VAL 0377 Bleed Valve 7 1 VAL 0053 Pressure Maintaining Valve 8 1 VAL 0169 Safety Valve 9 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC 1 MNR 0042 Securus Monitor Figure 4 13 P5S and IP5S Purification System OUT IN 7 3 8 1 2 3 4 5 6 9 Securus OUT IN 7 3 8 1 2 3 4 5 ...

Page 44: ...Water Separator See Figure 4 23 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 2 080144 27 Dryer Chamber See Figure 4 28 5 1 080144 27 Purification Chamber See Figure 4 28 6 1 VAL 0377 Bleed Valve 7 1 VAL 0053 Pressure Maintaining Valve 8 1 VAL 0169 Safety Valve Figure 4 14 P10 Purification System OUT IN 1 2 3 4 5 6 3 7 8 ...

Page 45: ...e Drain Valve 3 2 VAL 0007 Check Valves 4 2 080144 27 Dryer Chamber See Figure 4 28 5 1 080145 27 Securus Chamber See Figure 4 30 6 1 VAL 0377 Bleed Valve 7 1 VAL 0053 Pressure Maintaining Valve 8 1 VAL 0169 Safety Valve 9 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC Figure 4 15 P10S and IP10S Purification System OUT IN 1 2 3 4 5 6 3 7 9 8 ...

Page 46: ...r See Figure 4 23 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 2 080144 27 Dryer Chamber See Figure 4 28 5 1 080145 27 Securus Chamber See Figure 4 30 6 1 VAL 0377 Bleed Valve 7 1 VAL 0053 Pressure Maintaining Valve 8 1 VAL 0169 Safety Valve 9 1 MNR 0042 Securus II Monitor Figure 4 16 P10S II Purification System OUT IN 1 2 3 4 5 6 3 7 8 9 ...

Page 47: ... Gauge 2 1 011430 Condensate Drain Valve 3 1 079416 Oil and Water Separator See Figure 4 23 4 1 VAL 0007 Check Valves 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 082135 20 Purification Chamber See Figure 4 25 8 1 VAL 0169 Safety Valve Figure 4 17 P41 and IP41 Purification System 8 4 5 6 7 2 1 3 4 IN OUT ...

Page 48: ...lve 3 1 079416 Oil and Water Separator See Figure 4 23 4 1 VAL 0007 Check Valves 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 VAL 0169 Safety Valve 8 1 082136 20 Securus Purification Chamber See Figure 4 26 9 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC Figure 4 18 P41S and IP41S Purification System IN 7 8 2 1 3 4 4 5 6 OUT 9 ...

Page 49: ...nsate Drain Valve 3 1 079416 Oil and Water Separator See Figure 4 23 4 1 VAL 0007 Check Valves 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 VAL 0169 Safety Valve 8 1 082135 20 Dryer Chamber See Figure 4 25 9 1 082135 20 Purification Chamber See Figure 4 25 Figure 4 19 P42 and IP42 Purification System 8 9 7 2 1 3 4 IN 4 5 6 OUT ...

Page 50: ...ater Separator See Figure 4 23 4 1 VAL 0007 Check Valves 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 VAL 0169 Safety Valve 8 1 082135 20 Dryer Chamber See Figure 4 25 9 1 082136 20 Securus Purification Chamber See Figure 4 26 10 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC Figure 4 20 P42S and IP42S Purification System 8 7 2 1 3 4 IN ...

Page 51: ...nsate Drain Valve 3 1 079416 Oil and Water Separator See Figure 4 23 4 1 VAL 0007 Check Valves 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 VAL 0169 Safety Valve 8 2 082135 20 Dryer Chamber See Figure 4 25 9 1 082135 20 Purification Chamber See Figure 4 25 Figure 4 21 P43 and IP43 Purification System 7 8 2 1 3 4 IN 4 5 6 OUT 9 ...

Page 52: ...ater Separator See Figure 4 23 4 1 VAL 0007 Check Valves 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maintaining Valve 7 1 VAL 0169 Safety Valve 8 2 082135 20 Dryer Chamber See Figure 4 25 9 1 082136 20 Securus Purification Chamber See Figure 4 26 10 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC Figure 4 22 P43S and IP43S Purification System 7 8 2 1 3 4 IN ...

Page 53: ...d Available only with 079416 2 2 N04586 O Ring 3 1 061860 Sintered Metal Filter 3a 1 N15133 O Ring 3b 2 N04496 O Ring small 3c 2 N04385 O Ring large 3d 1 061858 Sleeve Element large 3e 1 061859 Sleeve Element small 3f 1 N07091 O Ring 3g 1 061857 Screw 4 Separator Housing Available only with 079416 5 Bottom Plug Available only with 079416 Figure 4 23 Oil and Water Separator P N 079416 1 2 3 4 5 2 a...

Page 54: ...sembly 10 1 2 012293 Tool Post Screw 2 1 061237 Cover Plate 3 Filter Head Available only with 080143 4 2 N04736 Back up Ring 5 2 N04735 O ring 6 Filter Housing Available only with 080143 7 Filter Bottom Available only with 080143 8 1 10 Purification Cartridge Refer to Paragraph 4 5 Figure 4 24 10 Chamber P N 080143 1 2 3 4 4 5 5 7 6 8 ...

Page 55: ... 1 2 012293 Tool Post Screw 2 1 061237 Cover Plate 3 Filter Head Available only with 082135 4 2 N04736 Back up Ring 5 2 N04735 O ring 6 82137 Filter Housing Available only with 082135 7 80148 Filter Bottom Available only with 082135 8 1 Cartridge Refer to Paragraph 4 5 Figure 4 25 20 Chamber P N 082135 1 2 3 4 4 5 5 6 7 8 ...

Page 56: ...only with 082136 2 2 N04736 Backup Ring 3 2 N04735 O ring 4 1 Securus Cartridge Refer to Paragraph 4 5 5 Filter Body Available only with 082136 6 1 ADP 0204 Adapter Right Angle 7 1 059850 Socket RF type 8 2 012293 Tool Post Screw 9 1 06135 Cover Plate 10 Filter Head Available only with 082136 Figure 4 26 20 Securus Chamber P N 082136 1 2 3 3 2 9 6 7 8 10 11 12 13 14 15 16 17 18 4 5 ...

Page 57: ... Qty Part No Description Notes 11 1 059855 Nut 12 1 059852 Drawback Screw 13 1 059854 Loose Pin 14 1 060062 Compression Spring 15 1 059853 Fixed Pin 16 1 059851 Bolt 17 1 002181 Compression Spring 18 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC ...

Page 58: ...tom Plug Available only with 082136 2 2 N04736 Backup Ring 3 2 N04735 O ring 4 1 Securus Cartridge Refer to Paragraph 4 5 5 Filter Body Available only with 082136 6 1 059855 Nut 7 1 059852 Drawback Screw 8 1 059854 Loose Pin 9 1 060062 Compression Spring 10 1 059853 Fixed Pin Figure 4 27 20 Securus Chamber P N 082136 1 2 3 4 5 3 2 9 6 7 8 10 11 12 13 14 15 16 17 18 ...

Page 59: ...2136 Item Qty Part No Description Notes 11 1 059851 Bolt 12 1 002181 Compression Spring 13 Filter Head Available only with 082136 14 1 06135 Cover Plate 15 2 012293 Tool Post Screw 16 1 059850 Socket RF type 17 1 MNR 0042 Securus II Monitor 18 1 CON 0319 Electrical Connector ...

Page 60: ...hamber Assembly 27 1 2 012293 Tool Post Screw 2 1 061237 Cover Plate 3 Filter Head Available only with 80144 4 2 N04736 Back up Ring 5 2 N04735 O ring 6 Filter Housing Available only with 80144 7 Filter Bottom Available only with 80144 8 1 Cartridge Refer to Paragraph 4 5 Figure 4 28 27 Chamber P N 080144 1 2 3 4 4 5 5 6 7 8 ...

Page 61: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing ...

Page 62: ...th 80145 2 2 N04736 Backup Ring 3 2 N04735 O ring 4 1 Securus Cartridge Refer to Paragraph 4 5 5 Filter Body Available only with 80145 6 1 ADP 0204 Adapter Right Angle 7 1 059850 Socket RF type 8 2 012293 Tool Post Screw 9 1 06135 Cover Plate 10 Filter Head Available only with 80145 11 1 059855 Nut Figure 4 29 27 Securus Chamber P N 080145 1 2 3 4 5 3 2 9 6 7 8 10 11 12 13 14 15 16 17 18 ...

Page 63: ...145 Item Qty Part No Description Notes 12 1 059852 Drawback Screw 13 1 059854 Loose Pin 14 1 060062 Compression Spring 15 1 059853 Fixed Pin 16 1 059851 Bolt 17 1 002181 Compression Spring 18 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC ...

Page 64: ...om Plug Available only with 80145 2 2 N04736 Backup Ring 3 2 N04735 O ring 4 1 Securus Cartridge Refer to Paragraph 4 5 5 Filter Body Available only with 80145 6 1 059855 Nut 7 1 059852 Drawback Screw 8 1 059854 Loose Pin 9 1 060062 Compression Spring 10 1 059853 Fixed Pin Figure 4 30 27 Securus II Chamber P N 080145 1 2 3 4 5 3 2 9 6 7 8 10 11 12 13 14 15 16 17 18 ...

Page 65: ...080145 Item Qty Part No Description Notes 11 1 059851 Bolt 12 1 002181 Compression Spring 13 Filter Head Available only with 80145 14 1 06135 Cover Plate 15 2 012293 Tool Post Screw 16 1 059850 Socket RF type 17 1 MNR 0042 Securus II Monitor 18 1 CON 0319 Electrical Connector ...

Page 66: ... an Oil and Water Separator a Dryer Chamber and a Purification Chamber Figure 5 1 shows the functional interconnection of all the components The Secu rus Electronic Moisture Monitor System is standard with the P12 Purification System Figure 5 1 P12 Purification System 1 Oil and Water Separator 2 Condensate Drain Valve 3 Safety Valve 4 Check Valves 5 Pressure Gauge 6 Dryer Chamber 7 Securus Chamber...

Page 67: ...ivery thus achieving constant optimum purification It also assures proper working conditions for the final stage of compression 5 2 1 7 Safety Valve The safety valve is the safety valve for the final stage of the compressor 5 2 1 8 Securus Electronic Moisture Monitor System The Securus Electronic Moisture Monitor System warns the operator in advance of expiration of the life of the cartridges The ...

Page 68: ...When cleaning the element record the num ber of operating hours as indicated on the hourmeter to ensure exact attention to the maintenance intervals Blow dry with compressed air 6 Lubricate the o rings with petroleum jelly Apply sparingly Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the micro filter element In the event you discover corrosion ...

Page 69: ...tridge with the T wrench 4 Dispose of the dirty cartridge in accordance with local state and federal regulations 5 Dry the inside of the chamber with a clean cloth and check for corrosion 6 Replace all corroded parts with new BAUER parts 7 Remove the shipping covering from the new cartridge and remove the protective cap from the bot tom of the cartridge 8 Lubricate the O rings with white petroleum...

Page 70: ...artridge if it is missing 3 Remove cartridge with the T wrench and inspect O rings 4 Replace O rings if necessary 5 Ensure protective caps and devices have all been removed 6 Replace cartridge following steps 8 7 to 11 11 in Paragraph 5 2 2 2 Figure 5 3 Cartridge Replacement NOTICE If air is detected bleeding out from the bottom of the chamber the cartridge has not been installed properly or is mi...

Page 71: ...ve 4 2 VAL 0047 Check Valves 5 1 GAG 0070W Pressure Gauge 6 1 067105 High Flow Dryer Chamber See Figure 5 6 7 1 067106 High Flow Securus Chamber See Figure 5 7 8 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC 9 1 080144 CO Removal Chamber See Figure 5 8 10 1 VAL 0142 Pressure Maintaining Valve Figure 5 4 P12 Purification System INLET 1 2 3 4 5 6 7 OUTLET 10 9 4...

Page 72: ...ng 3 1 061839 Sintered Filter Element Assembly Items 7 to 16 4 Separator Housing Available only with 055719 5 Separator Bottom Plate Available only with 055719 6 Separator Bottom Plug Available only with 055719 7 1 N038600 O ring 8 1 061830 Filter Element Top 9 2 N15541 O ring 10 2 N15540 O ring Figure 5 5 Oil and Water Separator 1 2 7 8 9 10 11 12 9 10 11 13 14 15 16 17 18 17 16 2 5 6 4 ...

Page 73: ...Qty Part No Description Notes 11 1 061836 Sintered Metal Filter Insert 12 1 061837 Sintered Metal Filter Insert 13 1 061831 Filter Element Bottom 14 1 N15542 Usit Ring 15 1 N00084 Acorn Nut 8 mm 16 6 NUT 0118 Hex Nut 6 mm 17 6 WAS 0024 Flat Washer 6 mm 18 3 061833 Hex Shaft M6 ...

Page 74: ...lug Available only with 067105 2 2 N17456 Back up Ring 3 2 N17455 O ring 4 Chamber Housing Available only with 067105 5 1 057065 Filter Head 6 Cover Plate Available only with 067105 7 2 012293 Tool Post Screw 8 1 067099 Dryer Cartridge Assembly MS AC 9 1 N15205 O ring Figure 5 6 27 High Flow Chamber Assembly 1 2 3 4 3 2 5 6 7 14 9 10 11 12 13 8 ...

Page 75: ...il 17 2013 Page 68 Figure 5 6 cont 27 High Flow Chamber Assembly Item Qty Part No Description Notes 10 1 067070 Sealing Cuff 11 1 N17454 O ring 12 1 N17453 O ring 13 1 N17457 Retaining Ring 14 1 065500 Bleed Valve ...

Page 76: ...em Qty Part No Description Notes 1 067106 Securus Chamber Assembly 27 High Flow 1 Chamber Housing Available only with 067106 2 1 N17458 Finned Plug 3 1 067088 Round Nut Figure 5 7 Securus Chamber Assembly 1 2 3 4 5 6 7 8 9 10 16 15 14 13 12 17 18 19 7 6 11 ...

Page 77: ...ailable only with 067106 9 1 059850 Socket RF Type 10 1 065500 Bleed Valve 11 1 067097 Securus Cartridge MS AC MS 12 1 N15205 O ring 13 1 067070 Sealing Cuff 14 1 N17454 O ring 15 1 N17453 O ring 16 1 N17457 Retaining Ring 17 2 012293 Tool Post Screw 18 Cover Plate Available only with 067106 19 Chamber Head Available only with 067106 N S 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Secu...

Page 78: ... Items 1 7 1 2 012293 Tool Post Screw 2 1 061237 Cover Plate 3 Filter Head Available only with 80144 4 2 N04736 Back up Ring 5 2 N04735 O ring 6 Filter Housing Available only with 80144 7 Filter Bottom Available only with80144 8 1 065562 CO Removal Cartridge HP HP HP Figure 5 8 CO Removal Chamber 1 2 3 4 4 5 5 6 7 8 ...

Page 79: ...gure 5 1 shows the functional interconnection of all the components The Secu rus Electronic Moisture Monitor System is standard Figure 5 9 P14 Purification System 1 Oil and Water Separator 2 Condensate Drain Valve 3 Safety Valve 4 Check Valves 5 Pressure Gauge 6 Dryer Chambers 7 Securus Chamber 8 Securus Indicator 9 CO Removal Chamber 10 Pressure Maintaining Valve INLET 1 2 3 4 5 6 OUTLET 4 8 9 7 ...

Page 80: ...f delivery thus achieving constant optimum purification It also assures proper working conditions for the final stage of compression 5 3 1 7 Safety Valve The safety valve is the safety valve for the final stage of the compressor 5 3 1 8 Securus Electronic Moisture Monitor System The Securus Electronic Moisture Monitor System warns the operator in advance of expiration of the life of the cartridges...

Page 81: ...n cleaning the element record the num ber of operating hours as indicated on the hourmeter to ensure exact attention to the maintenance intervals Blow dry with compressed air 6 Lubricate the o rings with petroleum jelly Apply sparingly Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the micro filter element In the event you discover corrosion rep...

Page 82: ... federal regulations 5 Dry the inside of the chamber with a clean cloth and check for corrosion 6 Replace all corroded parts with new BAUER parts 7 Remove the shipping covering from the new cartridge and remove the protective cap from the bot tom of the cartridge 8 Lubricate the O rings with white petroleum jelly Apply sparingly 9 Firmly install the new cartridge Be sure the cartridge snaps into p...

Page 83: ...d inspect O rings 4 Replace O rings if necessary 5 Ensure protective caps and devices have all been removed 6 Replace cartridge following steps 7 to 11 in Paragraph 5 3 2 2 Figure 5 11 Cartridge Replacement NOTICE If air is detected bleeding out from the bottom of the chamber the cartridge has not been installed properly or is missing Follow the instructions in Paragraph 5 2 2 3 Pull Out Thread On...

Page 84: ... Valve 4 2 VAL 0047 Check Valves 5 1 GAG 0070W Pressure Gauge 0 7500 psi 6 2 067105 High Flow Dryer Chamber See Figure 5 14 7 1 067106 High Flow Securus Chamber See Figure 5 15 8 1 N15095 Securus Indicator 110 120VAC 50 60 Hz 1 N15096 Securus Indicator 12 24 VDC 9 1 080144 CO Removal Chamber See Figure 5 16 10 1 VAL 0142 Pressure Maintaining Valve Figure 5 12 P14 Purification System INLET 1 2 3 4 ...

Page 85: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing ...

Page 86: ...g 3 1 061839 Sintered Filter Element Assembly Items 7 to 16 4 Separator Housing Available only with 055719 5 Separator Bottom Plate Available only with 055719 6 Separator Bottom Plug Available only with 055719 7 1 N038600 O ring 8 1 061830 Filter Element Top 9 2 N15541 O ring 10 2 N15540 O ring Figure 5 13 Oil and Water Separator 1 2 7 8 9 10 11 12 9 10 11 13 14 15 16 17 18 17 16 2 5 6 3 4 ...

Page 87: ...ator Item Qty Part No Description Notes 11 1 061836 Sintered Metal Filter Insert 12 1 061837 Sintered Metal Filter Insert 13 1 061831 Filter Element Bottom 14 1 N15542 Usit Ring 15 1 N00084 Acorn Nut 16 6 NUT 0118 Hex Nut 17 6 WAS 0024 Flat Washer 18 3 061833 Hex Shaft ...

Page 88: ... only with 067105 2 2 N17456 Back up Ring 3 2 N17455 O ring 4 Chamber Housing Available only with 067105 5 1 057065 Filter Head 6 Cover Plate Available only with 067105 7 2 012293 Tool Post Screw 8 1 067099 Dryer Cartridge Assembly MS AC 9 1 N15205 O ring 10 1 067070 Sealing Cuff Figure 5 14 27 High Flow Chamber Assembly 1 2 3 4 3 2 5 6 7 14 9 10 11 12 13 8 ...

Page 89: ...MNL 0096 April 17 2013 Page 82 Figure 5 14 cont 27 High Flow Chamber Assembly Item Qty Part No Description Notes 11 1 N17454 O ring 12 1 N17453 O ring 13 1 N17457 Retaining Ring 14 1 065500 Bleed Valve ...

Page 90: ...em Qty Part No Description Notes 1 067106 Securus Chamber Assembly 27 High Flow 1 Chamber Housing Available only with 067106 2 1 N17458 Finned Plug 3 1 067088 Round Nut Figure 5 15 Securus Chamber Assembly 1 2 3 4 5 6 7 8 9 10 16 15 14 13 12 17 18 19 7 6 11 ...

Page 91: ... N17456 Back up Ring 8 Chamber Bottom Plug Available only with 067106 9 1 059850 Socket RF Type 10 1 065500 Bleed Valve 11 1 067097 Securus Cartridge MS AC MS 12 1 N15205 O ring 13 1 067070 Sealing Cuff 14 1 N17454 O ring 15 1 N17453 O ring 16 1 N17457 Retaining Ring 17 2 012293 Tool Post Screw 18 Cover Plate Available only with 067106 19 Chamber Head Available only with 067106 ...

Page 92: ...Items 1 7 1 2 012293 Tool Post Screw 2 1 061237 Cover Plate 3 Filter Head Available only with 80144 4 2 N04736 Back up Ring 5 2 N04735 O ring 6 Filter Housing Available only with 80144 7 Filter Bottom Available only with80144 8 1 065562 CO Removal Cartridge HP HP HP Figure 5 16 CO Removal Chamber 1 2 3 4 4 5 5 6 7 8 ...

Page 93: ...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 compressor or its systems Do not wear loose clothing around machinery Loose clothing neckties rings wrists watches brace lets...

Page 94: ... ON OFF switch to disconnect the electrical supply Installer must provide an earth ground and maintain proper clearance for all electrical components All electrical installation must be in accordance with recognized national state and local electrical codes Do not use gasoline diesel fuel or other flammable products as a cleaning solution A compressor which has been used for gas service is unsuita...

Page 95: ... 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 b...

Page 96: ...shipping and handling only After instal lation and before operation these braces must be removed entirely Under no circumstances should the braces remain installed during operation or the manufacturer s warranty for the unit will be voided The braces are all tagged and labeled 6 2 2 Installation of the Unit 6 2 2 1 General The floor site must be capable of supporting the weight of the unit Positio...

Page 97: ...2 Cover the compressor with plastic sheets only if no condensation will form under the sheet 3 Remove the sheet from time to time and clean the outside of the unit 4 If this procedure cannot be followed or if the compressor will be out of service for more than 24 months please contact the BAUER Service Department for special instructions 6 3 2 Preparations Prior to preserving the compressor unit i...

Page 98: ...storage periods the oil will age in the compressor crankcase The oil must be drained at least every 24 months and replaced with fresh oil 2 The stated period can only be attained when the crankcase is sealed during the preservation period in accordance with the preservation requirements 3 After changing the oil the compressor must be operated according to the instructions above 4 Check the lubrica...

Page 99: ...ormal limits to override the pressure switch Be sure to reset the switch after checking 7 Check the interstage safety valves for leakage 8 Establish the cause of any faults and remedy 9 Stop the unit when it is running properly The compressor is then ready for operation ...

Page 100: ... finger tight plus up to an additional 1 2 turn 6 4 2 Torque Sequence Diagrams 6 4 3 Conversion Formulas F 9 5 C 32 C 5 9 x F 32 PSI BAR x 14 5 BAR PSI x 0 0689 Bolt or Screw Size Max Torque Hex and socket head 1 4 M 6 7 ft lbs 10 Nm Hex and socket head 5 16 M 8 18 ft lbs 25 Nm Hex and socket head 3 8 M 10 32 ft lbs 45 Nm Hex and socket head 1 2 M 12 53 ft lbs 75 Nm Hex and socket head 9 16 M 14 8...

Page 101: ...l Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association OSHA Occupational Safety Health Administration ODP open drip proof motor OEM Original Equipment Manufacturer PCB printed circuit board PLC Programable Logic Controller PMV pressure maintaining valve SC Securus Moisture Sensing Device Usage Lubricants O rings rubber and plastic parts filte...

Page 102: ...ams 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 6 5 2 Other Documents OEM Manuals and other BAUER manuals may be included in the documentation shipping package ...

Page 103: ...ns feel free to E mail us at documentation bauercomp com or fill out the form below and mail it to us Submitters Contact Information Unit Information Name ______________________________ Model Address _____________________________ Serial _____________________________ Block E mail ________________________ MFG Date Inaccuracies page ________ figure ________ paragraph ________ Suggested Corrections Ad...

Page 104: ...Bauer Compressors Inc Attn Documentation 1328 Azalea Garden Rd Norfolk VA 23502 1944 fold here fold here place tape or glue here postage here ...

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