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G 120 II V

Page 100

1st Edition, Rev. 0 Chg. 2

6.13 Parts List for Models with a 20 Horsepower Motor

Figure 6-18.i

20 HP, 60 Hz

VAC/PH

Transformer

Pri. Fuses

Sec. Fuse

Starter

Relay

Term.

208/3

TRR-0090

FUS-0092

FUS-0019

SRT-0234

RLY-0180

TER-0174

230/3

TRR-0090

FUS-0092

FUS-0019

SRT-0241

RLY-0185

TER-0175

460/3

TRR-0090

FUS-0077

FUS-0019

SRT-0233

RLY-0177

TER-0175

Figure 6-18.j

20 HP, 50 Hz

VAC/PH

Transformer

Pri. Fuses

Sec. Fuse

Starter

Relay

Term.

220/3

TRR-0090

FUS-0092

FUS-0019

SRT-0241

RLY-0185

TER-0175

380/3

TRR-0096

FUS-0080

FUS-0019

SRT-0233

RLY-0177

TER-0175

400/3

TRR-0096

FUS-0080

FUS-0019

SRT-0233

RLY-0177

TER-0175

415/3

TRR-0096

FUS-0080

FUS-0019

SRT-0233

RLY-0177

TER-0175

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Summary of Contents for G 120 II V

Page 1: ...Compressors Inc Phone 757 855 6006 1328 Azalea Garden Road Fax 757 855 6224 Norfolk Virginia 23502 1944 www bauercomp com April 4 2013 1st Edition Rev 0 Chg 2 MNL 126509 Bauer Compressors Inc Mini Ver...

Page 2: ...change this information and has no obligation to update these materials This information is copyrighted by Bauer Compressors Inc and Bauer reserves to itself all rights to this publication Bauer s cu...

Page 3: ...Stop Button 5 2 1 2 Operator Interface 6 2 1 2 1 Run Screen 6 2 1 2 2 Main Menu Screen 7 2 1 2 2 1 Run 7 2 1 2 2 2 Alarms History 8 2 1 2 2 3 Status 8 2 1 2 2 4 Contact 8 2 1 2 2 5 Login 8 2 1 2 2 6...

Page 4: ...onent Description 51 3 2 2 1 Condensate Drain Piping 51 3 2 2 2 Electrical Connection 51 3 2 3 ACD Maintenance 51 3 2 4 ACD Replacement Parts List 52 3 3 CONDENSATE COLLECTOR 54 3 3 1 Condensate Colle...

Page 5: ...XL 6 1 OVERVIEW 75 6 2 ELECTRICAL PANEL 75 6 2 1 Wiring Diagram 76 6 2 2 Electrical Panel Interior Access 76 6 2 3 Optional Equipment 76 6 3 AC POWER REQUIREMENTS 76 6 4 ELECTRICAL PANEL COMPONENTS 7...

Page 6: ...ty Precautions 105 8 1 2 Safety Warning Labels 107 8 2 UNPACKING HANDLING AND INSTALLATION 108 8 2 1 Unpacking and Handling 108 8 2 2 Installation of the Compressor Unit 109 8 2 2 1 General 109 8 2 2...

Page 7: ...Cartridge Operating Hours 121 8 4 3 Record of Operating Hours 122 8 5 REFERENCE DATA 123 8 5 1 Tightening Torque Values 123 8 5 2 Torque Sequence Diagrams 123 8 5 3 Conversion Formulas 123 8 5 4 Appr...

Page 8: ...3 8 Inter stage Separator 20 Figure 3 9 Valve Operation 21 Figure 3 10 IK120II C G 1st Stage Valve 22 Figure 3 11 IK120 II C 1st Stage Valve Head and Plate Valve 23 Figure 3 12 IK120 II C G 2nd Stage...

Page 9: ...d Metal Filter Assembly 67 Figure 4 11 Cartridge Replacement 67 Figure 4 12 P1 Purification System Parts List 69 Figure 4 13 Oil and Water Separator Parts List 70 Figure 4 14 10 Chamber Parts List 71...

Page 10: ...ORS VALVES Figure 7 1 Indicators 101 Figure 7 1 Check Valve 103 Figure 7 2 Pressure Maintaining Valves PMV 103 Figure 7 3 Safety Valves 104 CHAPTER 8 APPENDIX Figure 8 1 Lifting Devices 108 Figure 8 2...

Page 11: ...or 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 empha...

Page 12: ...r The 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 hou...

Page 13: ...t 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...

Page 14: ...d stage 580 710 psig 40 49 bar Safety valve setting 2nd stage 870 psig 60 bar Direction of rotation when facing flywheel CCW Compressor speed 1 200 RPM Oil capacity 3 qts 2 8 liter Oil Pressure 60 85...

Page 15: ...ogy The PLC is equipped with a 200 day in battery to maintain the PLC s internal clock The software program is based on the pressure and use of the compressor The operator uses the Operator Interface...

Page 16: ...the status of the monitor is shown here 2 This reading shows the current run time of the compressor in hours Once the compressor is turned off this reading returns to zero For total hours on the unit...

Page 17: ...sensor on the compressor block 10 This space a reserved for units with inlet pressure sensors A continuous inlet pressure reading is provided This is mainly for units designed to compress natural or...

Page 18: ...k to the Main Menu screen The Maintenance schedule buttons allow the user to view the Maintenance schedule by calendar days or by hours See Table 2 1 2 2 The Light ON OFF button is used on some models...

Page 19: ...screen will return to the login screen with the new user level shown 2 1 2 2 6 Configuration The Configuration button is used to setup the features that make the unit There are a total of 4 pages in t...

Page 20: ...option The first page of the tools option is used for maintenance purposes The buttons are used to check the PLC and can only be used when the unit is OFF The second page is used to set the internal...

Page 21: ...the air pressure has increased to the set Operating Pressure the drive motor will automatically shutdown The Com pressor will automatically restart when the system s pressure drops below the set Star...

Page 22: ...onitor X Check Oil Level X Check Final Pressure Shutdown X Check Automatic Condensate Drain X Check V belt X Service Intake Filter X Check all connections for leaks X Inspect Compressor Valves X Check...

Page 23: ...000 Hours Check Oil Level X Check Final Pressure Shutdown X Check Automatic Condensate Drain X Check V belt X Service Intake Filter X Check all connections for leaks X Check fasteners for tightness X...

Page 24: ...RUN SCREEN On Off MAIN MENU RUN Changable Date LOGIN STATUS PARAMETERS CONFIGURATION TOOLS CONTACT Return to Run Screen Above ALARMS HISTORY Users 1 2 3 Current Status ACD Test Light Unit Settings 9...

Page 25: ...inders are splash lubricated The cylinders are arranged in a W configuration the 1st stage is in the center 2nd stage on the right and 3rd stage on the left looking from the filter side 3 1 2 Componen...

Page 26: ...condensate valves 14 An Automatic Condensate Drain system is available as an option The pressure maintaining valve 13 ensures that pressure is built up in the HP drying system from the start of deliv...

Page 27: ...m pressure valve 3 allows for oil pressure indication at a pressure gauge and or electronic oil pressure monitoring 3 1 4 2 Oil Level Check Check the oil level at the sight gauge on either side of the...

Page 28: ...cause excessive lubrication of the compressor and may result in a carbon buildup on the valves 3 1 4 3 Oil Change Interval Every 2 000 operating hours or biennially whichever comes first Figure 3 4 Oi...

Page 29: ...or repair or if the compressor has been run the wrong direction venting the oil pump may be necessary 1 Run the compressor with all condensate drains open to avoid building up pressure 2 Unscrew Scre...

Page 30: ...by a vortex plate 1 Figure 3 8 Inter stage Separator 1 Vortex Plate 2 Hollow Screw 3 Center Insert 4 O ring 5 Knurled Nut 6 Gasket 7 Fitting 8 Safety Valve WARNING The rapid depressurizing and repres...

Page 31: ...1 8 Valves and Heads 3 1 8 1 Functional Description The valve heads of the individual stages form the top part of the cylinders See Figure 3 9 The intake and pressure valves are fitted inside the valv...

Page 32: ...Use only satisfactory gaskets and O rings during reassembly Observe the correct sequence when reassembling After finishing all maintenance work on the valves turn the compressor manually using the fl...

Page 33: ...I C G 1st stage are in a combined plate valve under the valve head Refer to Figure 3 11 1 Remove Valve Head 1 2 Note orientation of Plate Valve 32 before removing it 3 Reassembly is the reverse of the...

Page 34: ...p 4 Using the special valve tool remove the Intake Valve 6 See Figure 3 13 5 Turn the Valve Head over and replace it on the metal pins 6 Remove the Cap Nut 1 7 Unscrew the Stud 2 approximately five tu...

Page 35: ...e the Intake Valve 6 using the special valve tool to tighten it 2 Check the intake valve functions correctly by blowing compressed air through the valve in the direction of flow 3 Secure the intake va...

Page 36: ...ure Valve 4 by putting two screwdrivers into the removal groove of the pressure valve body See Figure 3 16 It may be necessary to loosen the valve body first by turning it with a 13 mm wrench used on...

Page 37: ...lve head aluminum over the screw in thread of the intake valve in two places opposite one another Use a small drift pin approx imately 5 mm in diameter 4 Reinstall the Pressure Valve 4 by putting O ri...

Page 38: ...1 083399 Crankshaft complete IK120 II G C 3 1 N2638 Roller Bearing 4 2 N2635 Circlip 5 1 66209 Bearing Cap 6 1 N15406 Roller Bearing 7 1 N15265 O ring 8 1 66684 Cover 9 1 N170 Shaft Seal 10 1 N3745 O...

Page 39: ...O ring 15 2 N1506 Hex Head Bolt 16 8 N58 Washer 17 1 N4261 Gasket 18 1 N2796 Plug 19 2 N25475 Oil Sight Gauge 20 a 1 N1316 Gasket 21 1 N4570 Plug 22 2 78038 Support 23 4 WAS 0030 Spring Washer 24 4 NU...

Page 40: ...IK120 II C 1 1 80734 Cylinder IK120 II C 88 mm 2 c 1 N4654 O ring 3 1 069975 Piston Assembly IK120 II C 88 mm includes 4 6 4 2 N484 Circlip 5 1 Piston Pin 6 1 N1787 Piston Ring Set 7 4 N215 Stud 8 4...

Page 41: ...2 c 1 N7063 O ring 3 1 83404 Guide Cylinder 4 c 1 N2640 O ring 5 c 4 NUT 0119 Self Locking Hex Nut 6 4 WAS 0021 Washer 7 4 N2790 Stud 1 072249 Piston Assembly Complete Items 8 11 8 1 62487 Piston 9 2...

Page 42: ...480 Cylinder 3 c 1 N7063 O ring 4 1 83404 Guide Cylinder 5 c 1 N2640 O ring 6 c 4 NUT 0119 Self Locking Hex Nut 7 4 WAS 0021 Washer 8 4 N2790 Stud 9 1 072165 Guide Piston Assembly Items 10 12 10 Guide...

Page 43: ...cription Notes 1 078043 Piston and Sleeve Assembly 1 Piston Available only with 078043 2 a 1 N23755 O ring 3 Piston Liner Available only with 078043 4 1 N25376 Piston Ring Set Available only with 0780...

Page 44: ...27 Valve Head 1st Stage IK120 II C G 1 1 N26531 Plate Valve IK120 II C G 2 1 80709 Valve Head IK120 II C G 3 7 N102 Washer 4 6 N26568 Hex Head Screw 5 1 N26646 Hex Head Screw 6 1 N4869 O ring N S 1 73...

Page 45: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing...

Page 46: ...012841 5 1 Valve Plate Available only with 012841 6 1 Valve Seat Available only with 012841 7 a 1 240 Gasket 8 b 1 014582 Pressure Valve Assembly Items 9 15 20 9 b 1 012835 Pressure Valve Insert Items...

Page 47: ...37 Figure 3 23 cont 2nd Stage Valves and Valve Head KIT Qty Part No Description Notes 14 a 1 N3521 O ring 15 1 14332 Spring Washer 16 1 14124 Coupling 17 b 1 71064 Stud 18 a 1 N3625 Gasket 19 1 N84 Ca...

Page 48: ...sembly 3rd Stage 1 b 1 081409 Intake Valve 2 1 082087 Valve Head 3 a 1 N2789 O ring 4 b 1 014121 Pressure Valve 5 1 82086 Valve Head Cover 6 a 1 N124608 Stud 7 a 1 N3625 Gasket 8 1 88609 Cap Nut 9 6 N...

Page 49: ...art No Description Notes 1 82552 Flywheel Assembly 1 1 N1386 Shaft Key 2 1 82553 Hub 3 1 80975 Washer 4 1 N176 Split Washer 5 1 N26666 Bolt 6 1 82496 Flywheel 7 4 N108 Spring Washer 8 4 N19548 Allen S...

Page 50: ...es 1 081799 inter stage Separator Assembly 1 1 81148 Plate 2 1 81643 Hollow Screw 3 1 76613 Inset Assembly 4 a 1 N3556 O ring 5 1 13937 Knurled Ring 6 1 N1316 Gasket 7 1 N20215 Fitting 8 1 072935 Safe...

Page 51: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing...

Page 52: ...N4058 O ring 3 1 N25327 O ring 4 1 77774 Rubber Gasket 5 1 N25326 Filter Element 6 1 77878 Oil Pump Cover 7 2 N634 Allen Screw 8 2 N2889 Gasket 9 1 78421 Gasket 10 1 N24585 Gear Pump 11 2 N3489 O rin...

Page 53: ...4 2013 Page 43 Figure 3 27 cont Lubrication System Assembly KIT Qty Part No Description Notes 14 1 81050 Regulating Valve 15 4 N1316 Gasket 16 3 N52 Plug 17 1 83420 Connecting Tube Assembly 18 1 N2023...

Page 54: ...el Guard 5 1 81802 Safety Valve 1st Stage 11 bar 160 psi 6 1 072935 Safety Valve 2nd Stage 60 bar 870 psi 7 4 62773 Mounting Bracket 8 4 WAS 0024 Washer 9 4 NUT 0118 Self Locking Hex Nut 10 4 N3494 St...

Page 55: ...Plug 18 1 N7433 Screw Cap SS 19 2 N26751 Coupling 20 1 N20183 Connector 21 2 77894 Clamp 22 2 N2460 Washer 23 2 N19506 Hex Head Screw 24 1 78197 Tubing Assembly 25 3 78199 Stud 26 3 11887 Mounting Bra...

Page 56: ...t No Description Notes 1 1 SEN 0055 Pressure Sensor 0 30 psia 1 11 V 2 1 GAG 00011W Pressure Gauge 30 Hg 15 psi 3 1 FLR 0009 Filter Particulate gas tight 1 ELM 0040 Filter Element 40 m Figure 3 29 Inl...

Page 57: ...place 4 Replace 5 Tighten Safety valves between stages releasing pressure 1 inter stage pressure too high 2 Valves not closing properly 1 Service and clean valves 2 Service and clean valves Compressor...

Page 58: ...rk 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 should be carried out on the crank...

Page 59: ...y operated condensate drain valve A condensate manifold A condensate collector tank The automatic condensate drain system drains the intermediate separator and the oil and water separator every 15 min...

Page 60: ...rgizes the solenoid valve 1 for approximately 10 seconds The sole noid valve 1 opens and drains the condensation from the intermediate separator 2 This causes a pres sure loss in the intermediate sepa...

Page 61: ...on of the automatic 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 a If...

Page 62: ...iption Notes 1 DGM 2280 3 Stage Compressor ACD Reference only 1 1 N27288 Electric Coil 115 VAC or 1 N27757 Electric Coil 12 VDC 2 1 N27099 Solenoid Valve 3 1 PLT 0297 Blank Off Plate 4 1 MFD 0035 Mani...

Page 63: ...1 075169 Condensate Drain Valve Assembly 2 1 PLT 0297 Blank off Plate 3 2 N00638 O ring 4 1 MFD 0035 Condensate Manifold 5 2 N00829 Socket Head Cap Screw 6 2 N03625 Copper Gasket 7 1 N02507 O ring 8 1...

Page 64: ...er is not possible through simple methods therefore the condensate has to be completely removed It is most practical to collect this condensate in special containers and dispose of it entirely For the...

Page 65: ...t 3 2 ELM 0160 Fine Filter Element 4 2 ELM 0161 Coarse Filter Element 5 1 HUS 0050 Condensate Collector Inner 6 1 HUS 0060 Condensate Collector Outer 7 1 SWT 0265 Float Switch 8 1 TNK 0092 Condensate...

Page 66: ...accurate 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...

Page 67: ...Serial Number and Part Number Identification 4 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...

Page 68: ...umber of the cartridge installed in that chamber Figure 4 3 4 1 5 Breathing Air Purification System Configurations Purification System Number and Type of Cartridges Processing Capacity Dryer Purificat...

Page 69: ...mperature and its ability to cool the compressor will effect the operating life of the car tridge See Paragraph 4 1 7 2 for the method of calculating this adjustment factor The optimum place to measur...

Page 70: ...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 Purifica...

Page 71: ...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 T...

Page 72: ...II V Page 62 1st Edition Rev 0 Chg 2 4 1 7 3 Air Purification Cartridge Operating Hours Form Date Operating hours Ambient temp 18 F during compression Correction factor Adjusted cartridge hours Today...

Page 73: ...nts are a Oil and Water Separator and a Purification Chamber Figure 4 6 shows the functional interconnection of all the components Figure 4 6 P1 Purification System 1 Oil and Water Separator 2 Condens...

Page 74: ...ensate draining sub jects 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 pr...

Page 75: ...cular sieve to absorb oil and water 4 2 2 4 Cartridge Handling 4 Never open the protective packaging a cartridge comes in prior to its actual use The highly sensitive filter materials will absorb mois...

Page 76: ...1 Depressurize the system by means of the bleed valve 2 Remove the tubes connected to the side of the filter head 1 3 Unscrew and remove the filter head 4 Unscrew the sintered metal filter 2 from the...

Page 77: ...and shut off the inlet supply line if applicable 2 Depressurize the system by means of the bleed valve 3 Unscrew the chamber head using the special wrench supplied Figure 4 9 Oil and Water Separator F...

Page 78: ...ge 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 3 2 1 Leaking at the Safety Bore 1 Remove the cartridge...

Page 79: ...and Water Separator See Figure 4 13 2 1 011430 Condensate Drain Valve 3 2 VAL 0007 Check Valves 4 1 080143 10 Purification Chamber See Figure 4 14 5 1 VAL 0377 Bleed Valve 6 1 VAL 0053 Pressure Maint...

Page 80: ...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 06...

Page 81: ...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 058817...

Page 82: ...be checked Dirty or rusty sheaves impair the drive s efficiency and abrade the cover of the belts which results in premature failure Worn sheaves shorten belt life as much as 50 If the grooves are wo...

Page 83: ...on Notes G 120 II V 60 Hz 1 1 IK120 II C Compressor Block 2 1 BET 0214 V belt 3 1 IDL 0010 Idler with 1 PLY 0006 Idler Pulley 4 1 SHE 0139 Sheave 5 1 BUS 0002 Sheave Bushing 6 1 MTR 0033 Electric Moto...

Page 84: ...V Drive with Idler Item Qty Part No Description Notes G 120 II V 50 Hz 1 1 IK120 II C Compressor Block 2 1 BET 0259 V belt 3 1 IDL 0010 Idler with 1 PLY 0006 Idler Pulley 4 1 SHE 0321 Sheave 5 1 BUS...

Page 85: ...based on the pressure and use of the compressor The input output device for normal operation of the compressor unit is the Operator Interface MNR 0053 In an emergency the compressor is shutdown with t...

Page 86: ...an option in the Electrical Panel 6 3 AC Power Requirements The Electrical Panel must be supplied with electricity of the correct voltage phase and frequency to ensure proper operation Wiring and cond...

Page 87: ...ed in RAM is protected for 100 hours in event of a power loss Figure 6 3 PLC CNT 0078 1 Status LEDs 2 Output LEDs 3 Output Connections Cover 4 Expansion Access Door 5 Input Connections Cover 6 Input L...

Page 88: ...ck into place 10 Restore power and operate the unit 6 4 3 Installing a New Program The PLC program can be updated in two ways If a Bauer technician is on site they will connect directly to the PLC usi...

Page 89: ...used to monitor the run hours of the compressor It is powered by 120 VAC 6 4 6 Transformer and Fuses The Transformer is fitted with three fuses The primary coil of the transformer has two fuses The se...

Page 90: ...r The dial is set to the Full Load Amperage FLA of the electric motor at the factory If the Overload Relay is replaced set the dial to the FLA listed on the motor name plate or the label inside the El...

Page 91: ...ll first issue a Warning and then later an Alarm function The program is set up for a 90 warning and a 100 shutdown alarm for this counter feature The pro gram would be configured to reflect the follo...

Page 92: ...ystem 6 5 2 2 Securus II Transmitter See Figure 6 10 The Securus II Transmitter relays the operating condition of the Securus II Elec tronic Moisture Monitor System to the Operator Interface The Secur...

Page 93: ...il pressure the Oil Pressure Sensor will cause the alarm to be displayed on the Operator Interface 6 5 5 Compressor Overrun Timer The compressor has an timer where if the compressor runs continuously...

Page 94: ...will shutdown and the Alarm will be displayed on the Operator Interface 6 6 PLC Inputs and Outputs All PLC inputs are 24 VDC The power supply physically exists inside the PLC All PLC outputs are of a...

Page 95: ...urus II Monitor Alarm Q0 0 Motor Contactor I0 1 Overload Relay Q0 1 ACD 1 I0 2 Temperature Switch Q0 2 ACD Final I0 3 CO Monitor Alarm Q0 3 Audible Alarm I0 4 Condensate Alarm Q0 4 ACD 2 I0 5 Q0 5 ACD...

Page 96: ...ed 9 ACD 1 ACD1 Blue White 4 Q0 1 ACD Final ACDF Yellow Black 5 Q0 2 ACD Common ACD Com mon Orange White 21 Violet White 6 ACD 3 1SV Pink White 7 Q0 5 White Yellow 12 Panel Light 1LT White Brown 8 Q1...

Page 97: ...ite Orange 27 I1 0 Red Yellow 28 Condensate Alarm CA Gray 31 I0 4 Pink 32 CO Monitor Alarm COA White Black 33 I0 3 Red White 34 Securus II SEC II Black White 35 I0 0 Violet Orange 36 Black Orange 37 a...

Page 98: ...20 II V Page 88 1st Edition Rev 0 Chg 2 6 8 Replacement Parts List Item Qty Part No Description Notes 1 1 MNR 0053 Maple System Touch Panel 2 1 SWT 0308 Emergency Stop Switch Figure 6 14 Control Pane...

Page 99: ...Y 1058 XL Electrical Panel Front View 1 1 LBL 0167 Warning Label Disconnect Power 2 1 Voltage Label 3 1 HMR 0036 Hourmeter 1 GKT 0069 Gasket Hourmeter 4 1 OPR 0020 Overload Reset Button 5 1 IND 0005 A...

Page 100: ...nel Bottom View 1 1 CAB 0081 Cable PLC to ENC Connects to MNR 0053 2 1 CAB 0075 Cable 4 Receptacle Connector Connects to Air Pressure Sensor 3 1 CAB 0075 Cable 4 Receptacle Connector Connects to Oil P...

Page 101: ...1 2 3 4 5 9 8 6 10 7 This page is inserted to provide proper page sequencing...

Page 102: ...ical Panel 60 Hz Assembly Interior View 1 1 SPL 0077 Power Supply 24 VDC 1 3 A 2 1 Terminal See Figure 6 18 a to Figure 6 18 j 3 1 Motor Starter See Figure 6 18 a to Figure 6 18 j 4 1 Overload Relay S...

Page 103: ...6 1 CNT 0070 Analog Expansion Module 7 1 RLY 0116 Relay 24 VDC 10 amp 8 1 Transformer See Figure 6 18 a to Figure 6 18 j 9 2 Fuse Primary See Figure 6 18 a to Figure 6 18 j 10 1 Fuse Secondary See Fi...

Page 104: ...ical Panel 50 Hz Assembly Interior View 1 1 SPL 0077 Power Supply 24 VDC 1 3 A 2 1 Terminal See Figure 6 18 a to Figure 6 18 j 3 1 Motor Starter See Figure 6 18 a to Figure 6 18 j 4 1 Overload Relay S...

Page 105: ...og Expansion Module 7 1 RLY 0116 Relay 10 Amp 24 VDC 8 1 HOL 0111 Fuse Holder 25 Amp 400 V 1 Fuse Secondary See Figure 6 18 a to Figure 6 18 j 9 1 Transformer See Figure 6 18 a to Figure 6 18 j 10 2 F...

Page 106: ...0 1 TRR 0089 FUS 0090 FUS 0018 SRT 0233 RLY 0177 TER 0175 230 3 TRR 0089 FUS 0090 FUS 0018 SRT 0233 RLY 0174 TER 0175 460 3 TRR 0089 FUS 0029 FUS 0018 SRT 0233 RLY 0171 TER 0175 Figure 6 18 b 5 HP 50...

Page 107: ...R 0089 FUS 0090 FUS 0018 SRT 0241 RLY 0183 TER 0175 230 3 TRR 0089 FUS 0090 FUS 00118 SRT 0233 RLY 0175 TER 0175 460 3 TRR 0089 FUS 0029 FUS 0018 SRT 0233 RLY 0172 TER 0175 Figure 6 18 d 7 HP 50 Hz VA...

Page 108: ...30 1 TRR 0090 FUS 0092 FUS 0019 SRT 0241 RLY 0185 TER 0175 230 3 TRR 0090 FUS 0092 FUS 0019 SRT 0233 RLY 0177 TER 0175 460 3 TRR 0090 FUS 0077 FUS 0019 SRT 0233 RLY 0174 TER 0175 Figure 6 18 f 10 HP 5...

Page 109: ...RR 0090 FUS 0092 FUS 0019 SRT 0241 RLY 0183 TER 0175 460 3 TRR 0090 FUS 0077 FUS 0019 SRT 0233 RLY 0175 TER 0175 Figure 6 18 h 15HP 50 Hz VAC PH Transformer Pri Fuses Sec Fuse Starter Relay Term 220 3...

Page 110: ...30 3 TRR 0090 FUS 0092 FUS 0019 SRT 0241 RLY 0185 TER 0175 460 3 TRR 0090 FUS 0077 FUS 0019 SRT 0233 RLY 0177 TER 0175 Figure 6 18 j 20 HP 50 Hz VAC PH Transformer Pri Fuses Sec Fuse Starter Relay Ter...

Page 111: ...pressure applied to the inlet of the compressor Oil Pressure Gauge Indicates the compressor oil pressure Pressure Sensors Provide a signal to the PLC indicating air gas or oil pressure Temperature Sen...

Page 112: ...ure Range Thread Color Comments SEN 0035 0 8 700 psi 600 bar 1 4 NPT Yellow SEN 0049 0 8 700 psi 600 bar 1 4 G Blue SEN 0036 0 150 psi 10 34 bar 1 4 NPT Yellow SEN 0050 0 150 psi 10 34 bar 1 4 G Yello...

Page 113: ...readjustment 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 clockw...

Page 114: ...to the required pressure and do not normally require mainte nance or readjustment In case readjustment does become necessary have the safety valve adjusted by a Bauer qualified technician or return t...

Page 115: ...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 no...

Page 116: ...witch 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 reco...

Page 117: ...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 sw...

Page 118: ...be removed Handling of the unpacked unit should be performed using only the following devices See Figure 8 1 The compressor unit may be furnished with one or more shipping braces for shipping and hand...

Page 119: ...r flammable vapors such as paint solvents which may cause an internal fire Make sure that the intake air is unobstructed and moisture in the intake air is kept to a minimum It is important that units...

Page 120: ...exhaust opening in the oppo site wall close to the ceiling or in the ceiling As a basic rule of thumb the room should be ventilated sufficiently so as to prevent the ambient room temperature from exc...

Page 121: ...tion of the compressor and its air intake are significant to the quality of the air produced and the performance of the purification system Locating the air intake near other heat producing equipment...

Page 122: ...ocated outside inspect the inlet piping regularly to ensure nothing has obstructed or contaminated the air that is being taken in 8 2 4 Compressor Intake Piping It is best to keep intake piping as sho...

Page 123: ...and frequency Do not connect the compressor unit to a voltage other than the one specified on the name plate Provide all necessary cables and main fuses and a master disconnect switch The fuse protect...

Page 124: ...ollowing tables are provided as a guide for proper wire size NOTICE If this unit is equipped with an Air Kool system consult the Air Kool Section for electrical installation Figure 8 4 Incoming Power...

Page 125: ...a Dual element time delay fuse Amps Minimum Wire Sizeb b Normal Copper wire with THW THWN or XHHW insulation 208 V 230 V 460V 208 V 230 V 460V 208 V 230 V 460V 2 7 5 6 8 3 4 12 10 5 6 14 14 14 3 10 6...

Page 126: ...Tighten all couplings as required 3 After 10 minutes open the outlet valve and operate the compressor at adjusted minimum pressure using the pressure maintaining valve for approximately 5 minutes 4 A...

Page 127: ...ve 4 Check the lubrication of the compressor during the every six month brief operation 5 The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil pressure...

Page 128: ...G 120 II V Page 118 1st Edition Rev 0 Chg 2 8 4 Reproducible Forms 8 4 1 Scheduled Maintenance Form Daily Para Date Signature...

Page 129: ...MNL 126509 April 4 2013 Page 119 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 130: ...G 120 II V Page 120 1st Edition Rev 0 Chg 2 3 000 Operating Hours Para Date Signature Annually Para Date Signature Biennially Every two years Para Date Signature...

Page 131: ...MNL 126509 April 4 2013 Page 121 8 4 2 Air Purification Cartridge Operating Hours Date Operating hours Ambient temp 18 F during compression Correction factor Adjusted cartridge hours Today Total...

Page 132: ...G 120 II V Page 122 1st Edition Rev 0 Chg 2 8 4 3 Record of Operating Hours Date Minutes Total Date Minutes Total Subtotal Subtotal...

Page 133: ...dditional half turn 8 5 2 Torque Sequence Diagrams 8 5 3 Conversion Formulas F 9 5 C 32 C 5 9 x F 32 psi bar x 14 5 bar psi x 0 0689 Table 8 1 Torque Values Bolt or Screw Size Max Torque Hex and Socke...

Page 134: ...ves moisture NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association OSHA Occupational Safety Health Administration ODP Open Drip proo...

Page 135: ...wings 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 8 6 2 Other Documents OEM Manua...

Page 136: ......

Page 137: ...s 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 _...

Page 138: ...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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