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Bauer Compressors MAXI VERTICUS Instruction Manual And Replacement Parts List Download Page 34

MVT26

October 2003 

 Section 3

Page 33

Item Qty

Part No.

Description

Notes

◊

1

79704

1st Stage Piston and Cylinder Assembly130 mm Dia

1

1

79703

Cylinder

130 mm Dia

2

1

N2621

O-ring

3

4

N26036

Stud

4

1

79717

Piston Assembly

130 mm Dia

5

1

79718

Piston

6

1

N4109

Pin, Piston

7

2

N484

Ring, Retaining

8

1

N4642

Piston Ring Set

130 mm Dia

Figure 3.1-20

K180II 1st Stage Piston and Cylinder

1

2

3

8

5

6

7

7

4

Summary of Contents for MAXI VERTICUS

Page 1: ...nual and Replacement Parts List BAUER Compressors Inc Phone 757 855 6006 1328 Azalea Garden Road Fax 757 855 6224 Norfolk Virginia 23502 1944 www bauercomp com MAXI VERTICUS High Pressure Breathing Air Compressor MVT26 October 2003 MNL 0345 ...

Page 2: ......

Page 3: ...y must be read under stood and complied with prior to operating the product The instructions for long term storage over 90 days of this product are contained in Section A 3 Section A 5 is a set of forms which may be reproduced as needed to record operating hours purification cartridge adjusted operating hours scheduled maintenance actions or suggested corrections to this man ual If your unit is eq...

Page 4: ...t 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 specifies A dash in the Item Number column indicates that there is more than one part number appli cable to the preceding Item Number When placi...

Page 5: ...MVT26 October 2003 Section 1 Page 3 1 1 3 Revisions and Changes Ed Rev Change Date Notes Approval 1st Edition October 2003 JD Ed Rev Change Effected Pages Ed Rev Change Effected Pages ...

Page 6: ...3 No Title Page SECTION 2 OPERATIONS 2 5 Electric Motor Driven Units 14 2 5 1 Pre start Checks 14 2 5 2 Start up Procedure 14 2 5 3 Post Start Procedures 14 2 5 4 Shutdown Procedures 14 No Title Page SECTION 3 MAINTENANCE AND PARTS 3 1 IK150 II and IK180 II Compressor Blocks 15 3 1 1 Description 15 3 1 1 1 Air Flow Diagram 15 3 1 1 2 Component Location 16 3 1 2 Lubrication System 17 3 1 2 1 Descri...

Page 7: ...nd Installation 27 3 1 6 Repair and Troubleshooting 27 3 1 6 1 Repair 27 3 1 6 2 Troubleshooting 28 3 1 7 Replacement Parts List 30 3 2 4 Stage Automatic Condensate Drain System 58 3 2 1 Description 58 3 2 1 1 Compressor Operating 59 3 2 1 2 Condensate Draining 59 3 2 1 3 Start Unloading 60 3 2 1 4 Standstill Drainage 60 3 2 1 5 Condensate Drain Piping 60 3 2 1 6 Electrical Connections 60 3 2 1 7 ...

Page 8: ... 5 Check Valves 79 4 2 1 6 Bleed Valve 79 4 2 1 7 Pressure Maintaining Valve 79 4 2 1 8 Safety Valve 80 4 2 1 9 Securus Electronic Air Purification Monitoring System 80 4 2 1 9 1 Securus Cartridge 80 4 2 1 9 2 Securus Indicator 80 4 2 2 Maintenance 80 4 2 2 1 Coalescing Oil Water Separator 80 4 2 2 2 Cartridge Replacement 82 4 2 2 3 Leaking at the Safety Bore 82 No Title Page SECTION 5 COMPRESSOR ...

Page 9: ...4 Preventive Maintenance During Storage 101 A 3 5 Lubrication Oils for Preservation 102 A 3 6 Reactivating the Compressor Unit 102 A 4 Unpacking Handling and Installation 103 A 4 1 Unpacking and Handling 103 A 4 2 Installation of the Compressor Unit 103 A 4 2 1 General 103 A 4 2 2 Ventilation 104 A 4 2 2 1Outdoor Installation 104 A 4 2 2 2Indoor Installation 104 A 4 2 2 3Natural Ventilation 104 A ...

Page 10: ...nd Head 26 Figure 3 1 14 4th Stage Discharge Valve Removal 26 Figure 3 1 15 Assembly Tool 27 Figure 3 1 16 Using Special Tool 27 Figure 3 1 17 Crankcase Assembly 30 Figure 3 1 18 Complete Crankshaft Assembly 32 Figure 3 1 19 K150II 1st Stage Piston and Cylinder 33 Figure 3 1 20 K180II 1st Stage Piston and Cylinder 34 Figure 3 1 21 2nd Stage Piston and Cylinder Assembly 36 Figure 3 1 22 3rd Stage P...

Page 11: ...3 Figure 4 1 2 Compressor Unit Identification Plate 73 Figure 4 1 3 Purification System Dataplate typical 74 Figure 4 1 4 Cartridge Installation Dataplate typical 74 Figure 4 1 5 Correction Factor for Cartridge Operating Hours 76 Figure 4 1 6 Example Record of Adjusted Operating Hours 76 Figure 4 2 1 P5 Purification System 78 Figure 4 2 2 Oil and Water Separator 81 Figure 4 2 3 Cartridge Replaceme...

Page 12: ...MNL 0345 Page 10 Section 1 Base Edition No Title Page Section A Appendices Figure A 1 1 6 Bolt and 4 Bolt Torque Sequence 96 Figure A 1 2 Lifting Devices 103 ...

Page 13: ... System Securus Electronic Moisture Monitoring System Air Storage System Containment Fill Station Air Control Panel Carbon Monoxide Monitor Air cooled Interstage Coolers and Aftercooler Interstage and Final Separator with Manual Drains Interstage and Final Relief Valves Belt Guard designed to meet OSHA guidelines Inlet Filter High Temperature Switch with Indicating Light Hourmeter Low Oil Pressure...

Page 14: ...ting 1st stage 80 psig 5 5 bar Intermediate pressure 2nd stage 200 230 psig 14 16 bar Safety valve setting 2nd stage 260 psig 18 bar Intermediate pressure 3rd stage 950 1 000 psig 65 70 bar Safety valve setting 3rd stage 1 160 psig 80 bar Direction of rotation when facing flywheel CCW Compressor speed 900 1350 RPM Oil capacity 4 25 qts 4l Oil Pressure 870 psig 60 bar Recommended oil BAUER OIL 0024...

Page 15: ...llow the compressor to build up pressure Monitor the pressure gauge 2 Listen to the unit as it operates If excessive knocking or vibrations are observed shut down the unit 3 Allow the compressor to reach full pressure 4 Attach regulating filling device to the fill hose assembly Use only devices approved for the intended service 5 Adjust the fill pressure regulator to the proper fill pressure 2 5 4...

Page 16: ...ers are arranged 90 apart with the 1st and 2nd stage and the 3rd and 4th stage opposite each other These compressor blocks are particularly suitable for continuous operation because of their rugged design and corrosion resistant intermediate filter and cooler assemblies 3 1 1 1 Air Flow Diagram Figure 3 1 1 Four Stage Compressor Air Flow 1 Intake Manifold 2 1st Stage Cooler 3 2nd Stage Cooler 4 3r...

Page 17: ...rd Stage Cylinder 10 Compressed Air Outlet 11 Oil Drain Plug 12 Lifting Eyebolt 13 1st Stage Auxiliary Cooler IK180II Only 14 1st Stage Inter Cooler 15 4th Stage Cylinder 16 4th Stage After Cooler 17 Oil Pressure Regulating Valve 18 3rd 4th Inter Stage Pressure Valve 19 3rd Stage Separator 20 1st 2nd Inter Stage Pressure Valve 21 3rd Stage Cooler 22 2nd Stage Cylinder 23 Oil Filler with Sight Glas...

Page 18: ...ressure regulating valve 3 to the 4th stage cylinder The oil is then distributed by the guide piston of the 4th stage and lubricates all the moving parts of the com pressor block The oil pressure sensor 5 allows mounting for an optional oil pressure gauge or electronic pressure monitoring CAUTION This oil pump must be operated in the correct direction of rotation other wise no oil pressure will be...

Page 19: ...The amount of oil between the minimum and maximum marks is approximately 1 7 quarts 1 6 liters 3 1 2 5 Oil Change 1 Run the compressor until it is warm 2 Remove cap from Oil Filler Sight Gauge 3 See 3 1 2 Open the Oil Drain Plug 11 4 See Figure 3 1 5 Remove two bolts 1 with a 13mm wrench Remove cover 2 5 See Figure 3 1 6 Remove the Oil Filter 1 from the rubber gasket at the cover 6 Mount a new fil...

Page 20: ...ork It may also be necessary if the unit has been operated in the wrong direction of rotation 1 With the unit running open the condensate drain valves 2 Open Oil Pump Vent Plug 2 and wait until oil comes out bubble free 3 Replace Oil Vent Plug Figure 3 1 5 Removing the Oil Filter Cover Figure 3 1 6 Replacing the Oil Filter CAUTION To avoid damage after maintenance the following measures should be ...

Page 21: ...s to red and the Filter Element 3 should be replaced as follows 1 Open clips on Filter Housing 4 and remove Cover 2 2 Remove the Filter Element 3 3 Clean the inside of the Filter Housing with a damp cloth Take care to prevent any dust from entering the intake manifold 4 Replace the Filter Element 3 5 Mount the Cover 1 and fasten with the clips 6 Reset the Service Indicator 1 by pressing the button...

Page 22: ...o metallurgical stresses To prevent catastrophic failure with the possibility of damage injury or death the intermediate separator must be replaced after 85 000 load cycles A load cycle equals one depres surization repressurization The BAUER recommended frequency of condensate draining is every fifteen minutes and is a balance between maximizing the life of the separator chamber and maintaining th...

Page 23: ...ediate separator be properly serviced 3 1 4 2 1 2nd Stage Intermediate Separator See 3 1 8 1 Remove piping connected to the separator 2 Screw off the knurled nut 3 3 Remove separator head 2 4 Remove the center insert 5 5 Use hot soapy water to clean the center insert and the separator housing 1 6 Check condition of O rings 4 and replace as necessary 7 Rinse dry and reassemble 3 1 4 2 2 3rd Stage I...

Page 24: ...d be checked The outlet piping should be hot if the valves are operating properly Note that the inlet line to the valve heads should be warm to the touch 3 1 5 3 General Instructions for Changing the Valves Please observe the following instructions for valve maintenance 1 Always replace valves as a complete set 2 Carefully clean dirty valves Never use a sharp tool for this purpose Soak the valves ...

Page 25: ...the valves every 2000 operating hours to avoid fatigue failure 11 Use an assembly tool BAUER P N 011365 for all work on valve heads See Figure 3 1 15 3 1 5 4 Changing the 1st Stage Valves See Figure 3 1 11 3 1 5 4 1 Removal Procedure 1 Unscrew and remove cap nuts 4 and washers 3 2 Remove Valve Head Assembly 1 from studs in cylinder 3 Remove Valve 2 and unscrew and remove center screw 6 and washer ...

Page 26: ...tallation Procedure 1 Fit valves 6 9 with gaskets 7 and replace 2 Fit valve caps 3 with O Rings 5 and replace 3 Replace cap holder 2 in the proper position 4 Screw on hex nut 1 and tighten with a torque wrench to the torque value listed in the Appendix Figure 3 1 12 2nd and 3rd Stages Valve Heads and Valves 1 Hex Nut 2 Cap Holder 3 Valve Caps 4 Extraction Groove 5 O Rings 6 Inlet Valve 7 Valve Gas...

Page 27: ...osen the Discharge Valve 5 first by turning it with a 13mm wrench on the flat surfaces 5 Put two screwdrivers into the groove of the Discharge Valve body See Figure 3 1 14 6 Lift out Discharge Valve together with the O ring 4 3 1 5 6 2 Discharge Valve Installation Procedure 1 Check condition of O ring 4 and replace if necessary CAUTION Always change the intake and discharge valves of the 4th stage...

Page 28: ...a vise with the Inlet Valve 6 facing up 2 Unscrew the Inlet Valve 6 from the Valve Head 7 using the special tool Bauer p n 4555 645 sup plied with your unit See Figure 3 1 16 3 1 6 Repair and Troubleshooting 3 1 6 1 Repair Repair work can be carried out on the compressor block to a certain extent but a certain level of experi ence and skill is necessary It should be noted however that no repair sh...

Page 29: ...ve 3 Replace 4 Replace 5 Tighten Safety valves between stages releasing pressure 1 Intermediate pressure too high 2 Valves not closing properly 1 Service and clean valves 2 Service and clean valves Compressor running too hot 1 Insufficient supply of cool ing air 2 Intake or outlet valve not closing properly 3 Wrong direction of rotation 1 Check location for adequate ventilation 2 Check and clean v...

Page 30: ...ring 4 1 26281 Shaft Seal 5 1 N370 Self Locking Hex Nut 6 6 N58 Washer 7 6 78897 Bearing Cover 8 6 N3138 Stud 9 1 N18303 Roller Bearing 10 1 N3810 Circlip 11 1 N18304 Roller Bearing 12 1 N18432 Circlip 13 1 N2635 Circlip Figure 3 1 17 Crankcase Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 21 22 23 24 25 23 24 25 33 26 26 27 27 21 28 29 30 31 32 34 35 36 37 38 39 ...

Page 31: ...er 19 1 N4150 Stud 20 1 80197 Reducer 21 2 N293 Gasket 22 1 N314 Plug 23 12 N16 Washer 24 12 N312 Hex Head Screw 25 2 78571 Bracket 26 2 N4163 Gasket 27 2 N2796 Plug 28 1 N2447 Plug 29 1 N1316 Gasket 30 1 N4570 Plug 31 8 N102 Washer 32 8 N19496 Hex Screw 33 1 78578 Crankcase 34 1 78810 Oil Sight Gauge Assembly Items 35 39 35 1 N15412 O ring 36 1 61054 Plug 37 1 78808 Gasket 38 1 78569 Oil Fill 39 ...

Page 32: ...s 1 78934 Crankshaft Assembly K150 II Only 1 79442 Crankshaft Assembly K180 II Only 1 1 68587 Bushing 2 1 N4366 Dowel Screw 3 1 N108 Spring Washer 4 1 N57 Hex Nut 5 3 4220 Spacers 6 1 N18310 Circlip 7 1 N423 Circlip Figure 3 1 18 Complete Crankshaft Assembly 1 2 3 4 5 7 6 ...

Page 33: ...on and Cylinder Assembly120mm Dia 1 1 79017 Cylinder 120mm Dia 2 1 N2621 O ring 3 4 N26036 Stud 4 1 79720 Piston Assembly 120 mm Dia 5 1 79719 Piston 6 1 N2930 Pin Piston 7 2 N484 Ring Retaining 8 1 N2963 Piston Ring Set 120mm Dia Figure 3 1 19 K150II 1st Stage Piston and Cylinder 1 2 3 8 5 6 7 7 4 ...

Page 34: ...and Cylinder Assembly130 mm Dia 1 1 79703 Cylinder 130 mm Dia 2 1 N2621 O ring 3 4 N26036 Stud 4 1 79717 Piston Assembly 130 mm Dia 5 1 79718 Piston 6 1 N4109 Pin Piston 7 2 N484 Ring Retaining 8 1 N4642 Piston Ring Set 130 mm Dia Figure 3 1 20 K180II 1st Stage Piston and Cylinder 1 2 3 8 5 6 7 7 4 ...

Page 35: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing 34 ...

Page 36: ...MVT26 October 2003 Section 3 Page 35 Figure 3 1 21 2nd Stage Piston and Cylinder Assembly 6 9 8 7 9 10 2 1 5 4 3 ...

Page 37: ...48 2nd Stage Piston and Cylinder Assembly 1 1 60572 Cylinder 2 1 N3731 O ring 3 4 N215 Stud M8x25 4 4 WAS 0021 Washer Flat 8mm 5 4 NUT 0019 Nut Hex Lock M8 6 1 070010 Compressor Piston Assembly 7 1 N20907 Piston 8 1 N1429 Pin Piston 9 2 N484 Ring Retaining 10 1 N1461 Piston Ring Set ...

Page 38: ...Qty Part No Description Notes 1 060107 Piston and Cylinder Assembly 1 1 67057 Cylinder Guide 60mm Dia 2 1 N3731 O ring 3 1 67061 Cylinder 32mm Dia 4 1 N7063 O ring Figure 3 1 22 3rd Stage Piston and Cylinder 8 11 10 9 11 13 14 12 2 1 4 3 7 6 5 ...

Page 39: ...scription Notes 5 4 N17462 Stud M8x80 6 4 WAS 0021 Washer Flat 8mm 7 4 NUT 0019 Nut Hex Lock M8 8 1 070012 Piston Guide Assembly 60mm Dia 9 1 60087 Piston Guide 10 1 N15409 Pin Piston 11 2 N1665 Ring Retaining 12 1 070013 Piston Floating Assembly 13 1 N4378 Piston Floating 14 1 N16313 Piston Ring Set 32mm Dia ...

Page 40: ...sembly See 3 1 24 2 1 76754 Cylinder 3 1 N7063 O ring 4 4 N370 Self Locking Hex Nut 5 4 N58 Washer 6 4 N17462 Stud 7 1 79632 Guide Cylinder 8 1 N3731 O ring 1 070012 Piston Assembly Items 9 10 and 11 9 1 60087 Guide Piston 10 1 N15409 Piston Pin 11 2 N1665 Circlip Figure 3 1 23 4th Stage Piston and Cylinder Assembly 1 2 3 4 5 6 7 8 9 10 11 ...

Page 41: ...tion Notes 1 078043 Piston and Sleeve Assembly 1 Piston Available only with 078043 2 1 N23755 O ring 3 Piston Sleeve Available only with 078043 4 1 N2320 O ring 5 Piston Ring Set Available only with 078043 Figure 3 1 24 4th Stage Piston and Sleeve Assembly 1 2 3 4 5 ...

Page 42: ...scription Notes 1 79680 K180II 1st Stage Valve Head Assembly 1 1st Stage Valve Head 2 1 N26029 Plate Valve 3 4 N16 Washer 4 4 N644 Self Locking Hex Nut 5 1 N58 Washer 6 1 N150 Allen Screw M8x60 Figure 3 1 25 K180 1st Stage Valve Head 1 2 3 4 5 6 3 4 3 4 3 4 ...

Page 43: ...ge Valve Head 2 6 SCR 0180 Socket Head Cap Screw M8x35 3 1 N4067 Valve Inlet 4 1 N4068 Valve Discharge 5 2 56668 Gasket Valve 6 2 56183 Cap Valve 7 2 N3997 O ring 8 1 62924 Press Pad 9 2 N4190 Stud M10x45 10 2 WAS 0031 Washer Flat 10mm 11 2 NUT 0128 Nut Hex Lock M10 Figure 3 1 26 2nd Stage Valve Head AUS EIN 1 2 5 4 6 7 8 9 10 3 11 ...

Page 44: ...e Head 2 6 SCR 0180 Socket Head Cap Screw M8x35 3 1 N15273 Valve Inlet 4 1 N15274 Valve Discharge 5 2 56668 Gasket Valve 6 2 56183 Cap Valve 7 2 N3997 O ring 8 1 62924 Press Pad 9 2 N4190 Stud M10x45 10 2 WAS 0031 Washer Flat 10mm 11 2 NUT 0128 Nut Hex Lock M10 Figure 3 1 27 3rd Stage Valve Head Assembly AUS EIN 1 2 5 4 6 7 8 9 10 3 11 ...

Page 45: ...29 4th Stage Valve Head Assembly 1 1 07790 Intake Valve 2 1 65191 Valve Head 3 1 N2789 O ring 4 1 014121 Discharge Valve 5 1 14118 Valve Head Cover 6 1 71065 Stud 7 1 N3625 Gasket 8 1 N3623 Acorn Nut 9 6 N1282 Allen Screw Figure 3 1 28 4th Stage Valve Head Assembly 1 2 3 4 5 6 7 8 9 ...

Page 46: ...e Assembly 1 1 68623 V belt Pulley 2 6 55425 Fan Blade Support 3 18 79239 Blade Fan CCW 4 12 N19495 Hex Head Screw M6x16 5 12 WAS 0029 Washer Split Lock 6mm 6 1 68646 Washer 7 1 WAS 0002 Washer Split Lock 8 1 N15667 Hex Head Cap Screw M12x45 Figure 3 1 29 Flywheel Drive Assembly 6 7 8 1 3 2 5 4 ...

Page 47: ...lter Assembly 1 1 79679 Manifold Air Intake 2 3 N171 Socket Head Cap Screw 3 1 73036 Housing Intake Filter 4 1 79464 Flange 5 3 N19535 Allen Screw 6 1 N25886 Element Intake Filter 7 1 79465 Cover Filter Housing 8 1 N2221 Indicator Maintenance Figure 3 1 30 Intake Filter Assembly 1 2 3 4 5 6 7 8 ...

Page 48: ...bly 1 Filter Housing Available only with 077387 2 Filter Head Available only with 077387 3 1 13937 Collar Threaded Knurled 4 1 N3556 O ring 5 1 76613 Tube and Baffle 6 1 N1316 Gasket Cooper 7 1 N20215 Male Fitting N S 1 VAL 0169 Safety Valve Figure 3 1 31 2nd Stage Interfilter Assembly 2 4 5 1 3 6 7 ...

Page 49: ...388 2 Filter Head Available only with 077388 3 1 13937 Collar Threaded Knurled 4 1 12784 Plate Vortex 5 1 12785 Cone Baffle 6 1 12786 Screw Center 7 1 N2726 Element Filter 8 1 N3556 O ring 9 1 76613 Tube and Baffle 10 1 N1316 Gasket Copper 11 1 N20215 Fitting N S 1 VAL 0169 Safety Valve Figure 3 1 32 3rd Stage Interfilter Assembly 2 8 9 1 3 10 11 4 5 7 6 ...

Page 50: ...8 16 N58 Washer 9 14 N108 Lock Washer 10 12 N370 Self Locking Hex Nut 11 2 75496 Bushing Figure 3 1 33 K150 180 II Cooling System Assembly 5 6 7 8 10 9 1 2 3 4 5 57 54 11 28 42 20 41 42 28 30 1 2 3 4 5 57 54 11 28 42 20 41 42 28 30 1 2 4 5 57 54 11 28 42 20 41 42 28 30 50 49 23 13 12 56 16 32 15 17 43 29 55 29 47 34 39 33 31 46 45 44 18 36 37 35 29 19 35 28 30 29 34 33 31 32 15 16 24 25 26 27 15 8...

Page 51: ...Tubing 23 6 N61 Allen Screw 24 4 55799 Spacer 25 8 N1042 Self Locking Hex Nut 26 8 N102 Washer 27 8 N3494 Stud 28 8 N293 Gasket 29 8 N1316 Gasket 30 5 N20231 Connector 31 4 N4530 Plug 32 4 N2144 Lock Washer 33 3 N3610 Cap Screw 34 3 N20195 Connector 35 2 N20059 Connector 36 2 N20312 Fitting 37 2 N20060 Connector 38 2 N20260 Elbow 39 2 N724 Allen Screw 40 1 N842 Gasket 41 1 N20012 Connector 42 1 N2...

Page 52: ... 3 Page 51 Figure 3 1 33 cont K150 180 II Cooling System Assembly Item Qty Part No Description Notes 52 1 N7430 Cap Screw 53 1 N2003 Elbow Coupling 54 1 60709 Fan Screen 55 1 60717 Support 56 1 60716 Bracket 57 4 N542 Hex Screw ...

Page 53: ...d Stage Inter cooler Assembly 1 2 FER 0012 Ferrule 2 2 NUT 0057 Nut Tube 3 2 N16310 Insert Tube 4 6 60738 Clamp Tube 5 7 SCR 0133 Socket Head Cap Screw M6x40 6 14 WAS 0024 Washer Flat 6mm 7 7 NUT 0118 Nut Hex Lock M6 Figure 3 1 34 2nd Stage Intercooler 1 2 3 7 6 4 7 6 5 4 5 5 4 7 6 1 2 3 ...

Page 54: ... Intercooler 1 6 60738 Clamp Tube 2 7 SCR 0133 Socket Head Cap Screw M6x40 3 14 WAS 0024 Washer Flat 6mm 4 7 NUT 0118 Nut Hex Lock M6 5 4 60694 M Clamp Tube 6 2 N15119 Socket Fillister Head Screw M8x35 7 2 NUT 0062 Nut Hex M8 Figure 3 1 35 3rd Stage Intercooler 1 2 3 4 1 2 3 3 4 1 4 5 5 7 6 ...

Page 55: ...tes 1 076406 1st Stage Auxiliary Cooler IK180 II Only 1 2 N7443 Ferrule 2 2 N7435 Nut Tube 3 4 60694 M Clamp Tube 2 Groove 4 2 N17948 Countersunk Screw M8x40 DIN7991 8 8 5 2 NUT 0119 Nut Hex Lock M8 DIN985 8 A3A Figure 3 1 36 K180 1st Stage Auxiliary Cooler 1 2 1 2 3 3 5 4 ...

Page 56: ...ion Notes 1 078930 Lubricating System Assembly 1 1 080345 Lubricating System See next Figure 2 1 78421 Gasket 3 4 N503 Socket Head Screw 4 1 78928 Connecting Tube Assembly 5 1 N20002 Connector 6 1 N4501 Gasket Figure 3 1 37 Lubricating System Assembly 3 1 2 4 5 6 ...

Page 57: ... N25327 O ring 6 1 N3489 O ring 7 1 77774 Rubber Gasket 8 1 N25326 Filter Element 9 4 N1316 Gasket 10 1 81050 Regulating Valve 11 1 N20065 Straight Male Connector 12 1 N16309 Plug 13 1 N1049 Screw Cap 14 3 N52 Plug 15 2 N2889 Gasket 16 2 N25328 Socket Head Screw 17 1 177878 Oil Pump Case 18 2 N3489 O ring Figure 3 1 38 Lubricating System 1 2 3 4 5 6 7 9 10 11 12 13 14 9 15 16 9 14 17 14 9 18 8 ...

Page 58: ...rains the intermediate separators and the oil and water separator every 15 minutes during operation Additionally the automatic condensate drain system unloads the com pressor during the starting phase and drains these separators at shutdown of the compressor unit Figure 3 2 1 4 Stage Automatic Condensate Drain System 1 Solenoid valve 2 Condensate drain valve 3 Condensate drain manifold 4 Control a...

Page 59: ...the solenoid valve 1 for approximately 6 seconds The solenoid valve 1 opens and drains the condensation from the 2nd stage intermediate separator 2 Due to the pressure loss in the 2nd stage intermediate separator the control air for the 3rd stage condensate drain valve 4 is also removed As the pressure of the control air is dropping the piston of the 3rd stage con densate drain valve 4 becomes unl...

Page 60: ...sate drain manifold is equipped with a tube connector From here the condensation is directed into a collecting bottle by means of a tube to the pre separator elbow and a con densate drain separator 3 2 1 6 Electrical Connections For electrical connection of the automatic condensate drain refer to any included wiring diagrams 3 2 1 7 ACD Timer Automatic condensate drain timer controls the frequency...

Page 61: ... system The automatic condensate drain system must be serviced once a week as follows 1 Open all manual drain valves one after the other 2 Observe the drainage of condensation 3 If the system drains more than 2 ounces of liquid per stage either the system or the corresponding condensate drain valve is not working properly 4 Find the fault and remedy accordingly 5 If little or no condensation emerg...

Page 62: ... Item Qty Part No Description Notes 1 063761 Automatic Condensate Drain System 1 1 064007 Manifold 2 1 N16382 Solenoid Valve 3 1 064009 Condensate Drain Valve 4 1 064008 Condensate Drain Valve 5 1 N293 Gasket 6 1 N9155 Reducer Figure 3 2 4 4 Stage ACD System 4 2 3 1 5 6 ...

Page 63: ...Condensate Drain Valve 3 1 064007 Manifold 4 1 064004 Valve Connection 5 1 N2320 O ring 6 1 N3625 Gasket 7 1 N829 Allen Screw 8 1 N2507 O ring 9 2 N638 O ring 10 1 071224 Connecting Tube 11 1 N20305 Male Elbow 12 4 SCR 0133 Allen Screw 13 1 N16266 Plug Figure 3 2 5 ACD Manifold and Valves 12 1 6 7 8 2 10 11 3 4 5 9 13 ...

Page 64: ... Description Notes 1 064009 Condensate Drain Valve 1 1 064000 Top Flange 2 1 N16269 Sealing Ring 3 1 064003 Piston 4 1 N638 O ring 5 1 N4881 O ring 6 1 064001 Valve Body Figure 3 2 6 3rd Stage Condensate Drain Valve 1 2 3 4 5 6 7 8 9 10 11 14 13 15 15 12 16 ...

Page 65: ...ain Valve Item Qty Part No Description Notes 7 1 N2507 O ring 8 1 064005 Valve Seat 9 1 N4496 O ring 10 1 064002 Base Flange 11 1 064498 Drain Tap Seat 12 1 065500 Drain Tap Assembly 13 1 N16334 Male Tee 14 1 N15088 Hose 15 8 SCR 0150 Allen Screw 16 1 067458 Tool Set for Item 12 ...

Page 66: ...iption Notes 1 064008 Condensate Drain Valve 1 1 64000 Top Flange 2 1 064011 Spring 3 1 N16269 Sealing Ring 4 1 064003 Piston 5 1 N638 O ring 6 1 N4881 O ring Figure 3 2 7 Oil and Water Separator Condensate Drain Valve 1 2 3 4 5 6 7 8 9 10 11 14 13 15 12 16 16 17 ...

Page 67: ... Parts List Item Qty Part No Description Notes 7 1 064001 Valve Body 8 1 N2507 O ring 9 1 064005 Valve Seat 10 1 N4496 O ring 11 1 064002 Base Flange 12 1 064498 Drain Tap Seat 13 1 065500 Drain Tap Assembly 14 1 N16334 Male Tee 15 1 N15088 Hose 16 8 SCR 0150 Allen Screw 17 1 067458 Tool Set for 065500 ...

Page 68: ...in valve sticking 1 Check connections timer Replace if necessary 2 Clean or replace valve Condensate Drain Valve does not drain 1 Solenoid valve does not depressurize drain valve 2 No control medium avail able 3 Solenoid valve sticking 4 Drain valve sticking in open position 1 Check solenoid valve replace if necessary 2 Check supply lines 3 Clean or replace 4 Clean or replace ...

Page 69: ...sk 1 2 hour after start up for the first time or after maintenance Manual check of valve function 25 operating hours after first operation or mainte nance work Tighten valve head bolts and pressure studs Interval Task Daily before operating unit Check oil level Operate unit to final pressure and check final pres sure valve functions Weekly or as required Open manual condensate drain taps Annually ...

Page 70: ... V belts Service micronic intake filter Check all connections for leakage 1000 operating hours Manual check of valve function Clean sintered metal filter elements in interfilters 2000 operating hours Synthetic oil change Replace valves 3000 operating hours or as required Check pistons and piston rings ...

Page 71: ...sufficient maintenance To assist in this process the following maintenance control sheet is provided and may be copied as required The shaded boxes indicate when each maintenance task is due Enter the number of operating hours in these blocks and date and sign it at the bottom Operating Hours Maintenance Task 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 Annually Biennially Check driv...

Page 72: ...fore 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 to 1 100 psi 50 to 80 bar within the system to prevent moisture from entering the compressor and purification system Number and Type of Cartridges Processing Cap...

Page 73: ...he condensate drain valves They are opened approximately 1 3 of a turn to the left and held open until the condensate is completely drained The condensate drain valves close by spring pressure but if necessary may be tightened by hand to ensure they are completely air tight 4 1 5 Model Serial Number and Part Number Identification 4 1 5 1 Compressor Dataplate The model number date of manufacture an...

Page 74: ...ave this test equipment the recommended method of determining cartridge operating life is to maintain a written record of the volume of air processed by the purification system Each BAUER compressor block is rated to produce a standard volume of air per minute and by using this number and the air processing capability of the purification system it is possible to calculate the maxi mum operating ho...

Page 75: ... this form is used is shown in Figure 4 1 6 4 1 6 1 Calculating the Maximum Cartridge Operating Hours 1 From the purification system dataplate See Figure 4 1 3 on the unit determine the Air Processed cu ft 2 From the compressor unit dataplate See Figure 4 1 2 determine the Capacity CFM 3 Divide the Air Processed by the Capacity to obtain the Maximum Operating Time in minutes 4 Divide the Maximum O...

Page 76: ... i o n F a c t o r 3 0 2 5 2 0 1 5 1 0 0 5 0 0 41 5 50 10 59 15 68 20 77 25 86 30 104 40 F C Temperature Correction Factor F C 32 0 3 80 41 5 2 62 50 10 1 85 59 15 1 34 68 20 1 00 77 25 0 75 86 30 0 57 104 35 0 43 122 40 0 34 C o r r e c t i o n F a c t o r 3 0 2 5 2 0 1 5 1 0 0 5 0 0 41 5 50 10 59 15 68 20 77 25 86 30 104 40 F C Date Operating Hours Ambient Temp during Compression Correction Fact...

Page 77: ...MVT26 October 2003 Section 4 Page 77 4 1 7 Air Purification Cartridge Operating Hours Date Operating hours Ambient temp during compression Correction factor Adjusted cartridge hours Today Total ...

Page 78: ... Chamber is replaced with a Securus Purification Chamber 4 2 1 1 Chamber Each chamber is made up of an anodized aluminum alloy filter housing and a filtering cartridge There are two general types of filtering cartridges drying or purifying The cartridge type is determined by the ingredients packed in the cartridge The chamber is named after the type of cartridge it contains i e dryer chamber or pu...

Page 79: ...ce and before start up to drain the condensed liquids from the coalescing oil and water separator 4 2 1 5 Check Valves Valves allowing compressed air to flow in only one direction One is used to maintain pressure in the chamber when the compressor is not operating The other check valve prevents back flow from filled storage cylinders or tanks 4 2 1 6 Bleed Valve A manually operated valve used to r...

Page 80: ...Electronic Air Purification Monitoring System 4 2 1 9 2 Securus Indicator The operating condition of the Securus Air Purification System is indicated by the color and state of four LED s on the front of the Securus Indicator and is shown in the following table 4 2 2 Maintenance 4 2 2 1 Coalescing Oil Water Separator To remove the sintered metal filter proceed as follows 1 Disconnect the power and ...

Page 81: ...g the element record the number of operating hours to ensure exact attention to the maintenance intervals 9 Lubricate the threads and O rings as well as the threaded part of the sintered metal filter with petro leum jelly Apply sparingly 10 Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the sintered metal filter 11 In the event you discover corr...

Page 82: ...tridge 8 Lubricate the O rings with white petroleum jelly Apply sparingly 9 Install the new cartridge Be sure the cartridge snaps into place 10 Reinstall the chamber head 11 Close the bleed valve restore the power and reconnect the inlet supply line if applicable 4 2 2 3 Leaking at the Safety Bore 1 Remove the cartridge following steps 1 to 4 in Paragaph 4 2 2 2 2 Install cartridge if missing 3 Re...

Page 83: ...ription Notes 1 079416 Oil Water Separator Assembly 1 Separator Head Available only with 079416 2 2 N04736 Backup Ring 3 1 061860 Sintered Metal Filter 4 Separator Housing Available only with 079416 5 Bottom Plug Available only with 079416 Figure 4 2 4 Oil and Water Separator 1 2 2 3 4 5 ...

Page 84: ...1 061237 Cover Plate 3 80147 Filter Head Available only with 80144 4 2 N04736 Back up Ring 5 2 N04735 O ring 6 80158 Filter Housing Available only with 80144 7 80148 Filter Bottom Available only with80144 8 1 058827A Purification Cartridge MS AC MS HP 1 058825A Dryer Cartridge MS Figure 4 2 5 27 Chamber Assembly 1 2 3 4 4 5 5 6 7 8 ...

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

Page 86: ...lter 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 80159 Filter Head Available only with 80145 11 1 059855 Nut Figure 4 2 6 Securus Electronic Air Purification Monitoring Systema a The Securus Air Purification Monitoring System is a Factory Installed Option which may not apply to your equipment 1 2 3 4 ...

Page 87: ...r Purification Monitoring System 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 ...

Page 88: ...on of rotation as seen facing the flywheel is counterclockwise Observe the arrow on the compressor block Check the V belt regu larly for damage and wear See Paragraph 5 1 1 2 Replace if necessary Figure 5 1 1 Vertical Motor Mount typical 1 Compressor block 2 Compressor flywheel 3 V belt 4 Spring Tension Idler 5 Compressor mount 6 Electric motor 7 V belt sheave 1 2 3 4 5 6 7 ...

Page 89: ...r of the belts which results in premature failure Worn sheaves shorten belt life as much as 50 If the grooves are worn to the point where the belt bottoms slippage may result and the belts may burn If the side walls are dished out the bottom shoulder ruins the belt prematurely by wearing off the bottom corners 5 1 1 2 Check the V belt Check the V belt regularly for damage and wear Replace if neces...

Page 90: ...ry settings are Final Pressure Setting Minimum PMV Setting 2 000 5 000 psi 138 350 bar 2 175 psi 150 bar 6 000 psi 414 bar 3 000 psi 207 bar If readjustment does become necessary proceed as follows 1 Loosen the locking nut 1 2 Set the adjusting screw 2 to the required pressure using an appropriate hex type wrench 3 Turn clockwise to increase pressure counterclockwise to decrease pressure 4 Determi...

Page 91: ...e vents 2 Note the pressure registered on the pressure gauge The safety valve is adjusted at the factory to the required pressure and does not normally require mainte nance or readjustment In case readjustment does become necessary have the safety valve adjusted by a BAUER qualified technician contact the BAUER service department for details or return the valve to the factory Figure 6 1 2 Safety V...

Page 92: ...akage from the switch and or a change of operating set points may result 6 2 1 1 Operating Set Point Adjustment Secure the hex body 1 with an open end wrench Hand turn the adjustment sleeve 2 clockwise to increase the set point counterclockwise to decrease the set point note the orientation of the switch in Figure 6 2 1 The differential is fixed though the range varies according to the pressure se...

Page 93: ...icators Intermediate Pressure Gauges Indicate the pressure between compression stages Final Pressure Gauge Indicates the final operating pressure of the compressor Inlet Pressure Gauge Indicates the pressure applied to the inlet of the compressor Oil Pressure Gauge Indicates the compressor oil pressure All the indicators are mounted in the instrument panel Wire Code Lead Color Normally Closed Blue...

Page 94: ...cal Parts Item Qty Part No Description Notes 1 1 SWT 0160 Pressure Switch 7500 psi 2 1 SWT 0220 2 Position Selector Switch Illuminated Green 3 1 SWT 0119 Pressure Switch 360 1700 psi 4 1 LIT 0082 Light Green 1 LIT 0040 Light Red 1 LIT 0041 Light Yellow Figure 6 2 2 Electrical Parts 1 2 4 3 ...

Page 95: ...1 3 2 Indicators Item Qty Part No Description Notes 1 1 HMR 0021 Hourmeter 2 1 GAG 0006W 2 5 Indicator 200 psi 1 GAG 0007W 2 5 Indicator 600 psi 2 GAG 0008W 2 5 Indicator 1500 psi 1 GAG 0009W 2 5 Indicator 7500 psi Figure 6 2 3 Indicators 1 2 ...

Page 96: ...age is stopped Not more than finger tight plus up to an additional 1 2 turn A 1 2 Torque Sequence Diagrams A 1 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...

Page 97: ...sture NEC National 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 PMV pressure maintaining valve SC Securus Moisture Sensing Device Usage Lubricants O rings rubber and plastic parts filter housing thread...

Page 98: ...herwise 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 bracelets hand ...

Page 99: ...itch to disconnect the electrical supply Installer must provide an earth ground and maintain proper clearance for all electrical compo nents All electrical installation must be in accordance with recognized national state and local elec trical 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 unsuitable for ...

Page 100: ...ician 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 m...

Page 101: ...valve for approximately 5 minutes 4 After the 5 minutes shut the compressor unit down and completely drain all separators and filters Close all valves 5 Remove filter heads and lubricate the threads with petroleum jelly A 3 2 1 Units Equipped with a Filter System 1 Ensure that cartridges remain in the purification system chambers This will prevent oil from entering the outlet lines as a result of ...

Page 102: ... sight glass of the oil pressure regulator or if the oil pressure gauge indicates the prescribed pressure A 3 6 Reactivating the Compressor Unit 1 Remove the dust cap from the inlet port and install the intake filter 2 Check the oil level of the compressor If necessary change the oil 3 The motor must be thoroughly dry before applying power 4 For units with a purification system change all cartridg...

Page 103: ...nit may be furnished with one or more shipping braces for shipping and handling only After installation 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 compressor unit will be voided The braces are all tagged and labeled A 4 2 Installation of the Compressor Unit A 4 2 1 Gene...

Page 104: ...entilation During normal compression heat is generated by the compressor and by the drive motor engine For air cooled compressor units this heat needs to be vented away by sufficient ventilation A 4 2 2 1 Outdoor Installation It is recommended that all gasoline and diesel engine driven compressor units be installed outdoors Additionally electrically driven compressor units may be installed outdoor...

Page 105: ... ft Intake ft Exhaust ft 3 1 3 1 1 5 3 2 2 7 1 3 1 1 7 5 4 5 3 8 2 6 2 2 1 3 1 1 10 9 7 8 1 6 5 5 4 2 6 2 2 15 14 5 12 4 9 7 8 1 5 8 4 8 20 20 6 17 2 15 6 12 9 9 7 8 1 Drive hp Dependence on Room Size V and Height of Exhaust Opening h a a The intake sizes given in the above table are for a cooling air velocity of 1000 ft min BAUER recommends that the cooling air velocity be in the range of 600 ft ...

Page 106: ...ns A 4 2 3 2 Electrical Supply The machine is factory wired according to order If the voltage is to be changed consult the factory for instructions and necessary parts For standard models the only customer wiring necessary is from the customer supplied disconnect switch to the compressor unit s electrical enclosures All wiring should be done by a licensed electrician familiar with national state a...

Page 107: ...on 208V 230V 460V 208V 230V 460V 208V 230V 460V 2 7 5 6 8 3 4 12 10 5 6 14 14 14 3 10 6 9 6 4 8 17 5 15 8 14 14 14 5 16 7 15 2 7 6 25 25 12 10 12 14 7 5 24 2 22 11 40 30 17 5 8 10 14 10 30 8 28 14 50 40 20 8 8 12 15 46 2 42 21 60 60 30 6 6 10 20 59 4 54 27 90 80 40 4 4 8 25 74 8 68 34 100 100 50 3 4 8 30 88 80 40 125 100 60 2 3 8 40 114 104 52 175 150 80 0 1 6 50 143 130 65 200 200 100 3 0 2 0 4 6...

Page 108: ...MNL 0345 Page 108 Section A Base Edition A 5 Reproducible Forms A 5 1 Scheduled Maintenance Form Daily Para Date Signature ...

Page 109: ...VT26 October 2003 Section A Page 109 Weekly or as required Para Date Signature 500 Operating Hours Para Date Signature 1 000 Operating Hours Para Date Signature 2 000 Operating Hours Para Date Signature ...

Page 110: ...MNL 0345 Page 110 Section A Base Edition 3 000 Operating Hours Para Date Signature Annually Para Date Signature Biennially Every two years Para Date Signature ...

Page 111: ...MVT26 October 2003 Section A Page 111 A 5 2 Record of Operating Hours Date Minutes Total Date Minutes Total Subtotal Subtotal ...

Page 112: ...MNL 0345 Page 112 Section A Base Edition A 5 3 Purifier Cartridge Adjusted Operating Hours Date Operating hours Ambient temp during compression Correction factor Adjusted cartridge hours Today Total ...

Page 113: ...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 A 6 2 Other Documents OEM Manuals and other BAUER manuals may be included in the documentation shipping package ...

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