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BF 100 - 6

Page 23

Special Edition, Rev. 0 Chg. 0

BAUER

COMPRESSORS

4.3.4

Preventive Maintenance During Storage

Operate the compressor once every six months as follows:

1. Remove the dust cap from the inlet port and install the inlet filter.

2. Open the outlet valve and allow the system to run approximately 5 minutes until there is outflow

from the valve and oil is visible in the sight glass of the oil regulating valve.

3. Shut down the compressor.

4. Open the condensate drain valves, depressurize the unit, then close the drain valves again.

5. Remove the intake filter and replace the dust cap on the inlet port.

4.3.5

Lubrication Oils for Preservation

1. After prolonged 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 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 regulator or if the oil pressure gauge indicates the prescribed pressure.

4.3.6

Reactivating the Compressor Unit

1. Remove any dust cap or tape from the inlet port and install an 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 cartridges.

5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper opera-

tion of the lubricating system.

6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final

pressure safety valve vents. On compressor units with a compressor control system, raise the pres-
sure switch setting the switch above normal 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.

Содержание BF 100-6

Страница 1: ...R Compressors Inc Phone 757 855 6006 1328 Azalea Garden Road Fax 757 855 6224 Norfolk Virginia 23502 1944 www bauercomp com September 30 2008 Special Edition Rev 0 Chg 0 MNL 093558 2008 Bauer Compressors Inc BAUER COMPRESSORS BF 100 6 Bottle Fill Panel ...

Страница 2: ...ials This information is 2008 Bauer Compressors Inc and Bauer reserves to itself all rights to this publication Bauer s customers have no right to repro duce rewrite modify license or permit anyone else s use of this information without the express writ ten permission of Bauer Compressors Inc EDITIONS REVISIONS AND CHANGES An Edition is the original or a complete rewriting of the entire Manual A R...

Страница 3: ...AINTENANCE 3 1 PRESSURE GAUGES 10 3 2 SAFETY VALVE 10 3 3 TUBE CONNECTIONS 10 3 4 PRESSURE HOSES 10 3 5 STORAGE BOTTLES 11 CHAPTER 4 APPENDIX 4 1 SAFETY 12 4 1 1 General Safety Precautions 12 4 1 2 Safety Warning Labels 14 4 2 UNPACKING HANDLING AND INSTALLATION 15 4 2 1 Unpacking and Handling 15 4 2 2 Installation of the Compressor Unit 16 4 2 2 1 Space Requirement 16 4 2 2 2 Ventilation 16 4 2 2...

Страница 4: ...23 4 3 5 Lubrication Oils for Preservation 23 4 3 6 Reactivating the Compressor Unit 23 4 4 REPRODUCIBLE FORMS 24 4 4 1 Scheduled Maintenance Form 24 4 4 2 Record of Operating Hours 27 4 5 REFERENCE DATA 28 4 5 1 Tightening Torque Values 28 4 5 2 Torque Sequence Diagrams 28 4 5 3 Conversion Formulas 28 4 5 4 Approved Lubricants Chart 29 4 5 5 Glossary of Abbreviations and Acronyms 29 4 6 ADDITIONA...

Страница 5: ...ION Figure 2 1 Air Storage Bottle Valve Operating Sequence 6 Figure 2 2 BFP 100 6 8 Figure 2 3 BFP 100 6 Safety Valves 9 CHAPTER 3 MAINTENANCE There are no Figures in this Chapter CHAPTER 4 APPENDIX Figure 4 1 Lifting Devices 15 Figure 4 2 Best Location 17 Figure 4 3 Determining the Method of Ventilation 18 Figure 4 4 Incoming Power Wiring Label 20 Figure 4 5 6 Bolt and 4 Bolt Torque Sequence 28 ...

Страница 6: ...e held accountable for any inaccuracies or the consequences thereof 1 1 1 Manual Safety Notices Important instructions concerning the endangerment of personnel technical safety or operator safety will be specially emphasized in this manual by placing the information in the following types of safety notices DANGER DANGER indicates an imminently hazardous situation which if not avoided will result i...

Страница 7: ... 1 000 hours b replaced every 2 000 hours and c replaced every 4 000 hours NS in the Item Number column indicates the part is not illustrated but is available When placing an order for spare parts please provide the following information to ensure delivery of the correct parts The model number date of manufacture and serial number can be found of the com pressor unit identification plate on the co...

Страница 8: ... includes the following The safety instructions applicable to this product They must be read understood and complied with prior to operating the product The instructions for installing this product They must be read understood and complied with prior to operating the product The instructions for long term storage over 90 days of this product ...

Страница 9: ...14 bar Ambient temperature range 32 105 F 0 40 C Inlet pressure gauge 0 7 500 psig 0 517 bar Adjustable pressure regulator 2 6 000 psig In 0 5 000 psig Out 2 6 000 psig In 0 400 psig Out 2 414 bar In 0 345 bar Out 2 414 bar In 0 27 6 bar Out BFP Basic Fill Panel Dimensions 27 H x 30 W x 10 D 68 6 cm H x 76 2 cm W x 27 3 cm D Figure 1 1 Wall Mounted Fill Panel BFP 100 6 1 Inlet Air Pressure Gauge 2...

Страница 10: ...ate regulators The regulators are set from left to right facing the con trols 4 500 psig 4 000 psig 300 psig and 200 psig The compressed air travels from the regulators through the regulator gauges down to the bottle fill valves and bottle fill gauges The air then exits the bottle fill panel through the back of the panel Figure 0 1 1 BFP 100 6 Flow 4 500 psig 4 000 psig 300 psig 250 psig Inlet in ...

Страница 11: ...the tank neck WARNING Never open the fill valve unless the bottle is connected to the fill hose Whipping of an unrestrained hose caused by high pressure air discharge can cause serious injury CAUTION The filling procedure should not be interrupted for more than 10 minutes to avoid increased CO2 levels in the air filling the bottle Figure 2 1 Air Storage Bottle Valve Operating Sequence 1 2 1 2 Clos...

Страница 12: ...e utilizing the fill yoke 2 1 2 Opening Sequence for Filling the Bottle 1 First open fill valve 1 2 Open bottle valve 2 3 Bottle will begin filling 4 During the filling process monitor bottle pressure on fill valve gauge and drain condensate at the compressor 2 1 3 Closing Sequence for After Filling the Bottle 1 First close the bottle valve 1 2 Close the fill valve 2 3 Remove fill yoke and store c...

Страница 13: ...rt No Description Notes 1 7 GAG 0009W Pressure Gauge 7 500 psi bar 2 2 REG 0003 Regulator 6 000 psi in 0 5 000 psi out 3 2 VAL 0076 Fill Valve needle valve 4 2 REG 0013 Regulator 6 000 psi in 0 400 psi out 5 4 GAG 0007W Pressure Gauge 600 psi bar Figure 2 2 BFP 100 6 1 1 1 5 3 2 4 3 5 ...

Страница 14: ...ESSORS Item Qty Part No Description Notes 1 1 VAL 0131 Safety Valve set to 275 psig 2 1 VAL 0167 Safety Valve set to 325 psig 3 1 VAL 0169 Safety Valve set to 4 400 psig 4 1 VAL 0169 Safety Valve set to 5 000 psig Figure 2 3 BFP 100 6 Safety Valves 1 2 3 3 ...

Страница 15: ...en hand operating be sure to hold the valve in an open position long enough to purge accumu lated foreign material from the seat area and then allow the valve to snap shut Do not paint oil or otherwise cover any interior or working parts of any safety valve They do not require any lubrication or protective coating to work properly When safety valves require repair service adjustments or set pressu...

Страница 16: ...y inspected internally every year Every three 3 years D O T bottles must be hydrotested Check local and state regulations regarding testing of ASME and or D O T bottles NOTE Some states require an annual visual inspection And hydrotesting requirements also differ from state to state and according to specific bottle types ...

Страница 17: ...emperature 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...

Страница 18: ...n the 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 un...

Страница 19: ... 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 regulation...

Страница 20: ...ng unpacked and the packaging to be removed Handling of the unpacked unit should be performed using only the following devices See Figure 4 1 The compressor unit 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 circum stances should the braces remain installed during operation or ...

Страница 21: ...erating the unit For this purpose a second warning plate should be provided at the remote control unit Observe and maintain an ambient temperature range of 43 to 113 F The area in which the compressor unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance 4 2 2 1 Space Requirement A space of 30 to 40 inches should be maintained on all sides for m...

Страница 22: ...nt or piping should be avoided or must be well insulated 4 2 2 2 3 Heat Flow Choice of Proper Ventilation Sufficient heat dissipation must be provided by proper ventilation as part of correct installation It is necessary to dissipate this heat by ventilation The heat generated in the compressor increases with more compression Approximately 70 of the heat generated during compression is in the comp...

Страница 23: ...ts 4 2 2 2 5 Natural Ventilation Natural ventilation should only be used up to a maximum drive power of 20 hp To determine the size of the required intake and exhaust openings refer to the following table Figure 4 3 Determining the Method of Ventilation Drive hp Intake and Exhaust Openings Dependent on Room Volume V and Height h V 1750 ft h 6 5 ft V 3500 ft h 10 ft V 7000 ft h 13 ft Intake ft Exha...

Страница 24: ...al state and national electrical regulations 4 2 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 ...

Страница 25: ...BAUER COMPRESSORS The label shown in Figure 4 4 indicates the where the incoming power is connected to the compressor unit s electrical enclosure This label must be removed before using the equipment Figure 4 4 Incoming Power Wiring Label ...

Страница 26: ...8 10 55 50 90 60 6 6 3 PHASE Motor hp Full Load Amps Fuse Ampsa a Dual element time delay fuse amps Minimum Wire Sizeb b Normal copper wire with THW THWN or XHHW insulation 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 ...

Страница 27: ...hen carry out the following checks 1 Check all pipes filters and valves including safety valves for leakage 2 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 After the 5 minutes shut the compressor unit down and completely drain all separators and fi...

Страница 28: ...instructions above 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 regulator or if the oil pressure gauge indicates the prescribed pressure 4 3 6 Reactivating the Compressor Unit 1 Remove any dust cap or tape from the inlet port and install an intake ...

Страница 29: ...MNL 093558 September 30 2008 Page 24 BAUER COMPRESSORS 4 4 Reproducible Forms 4 4 1 Scheduled Maintenance Form Daily Para Date Signature ...

Страница 30: ... 25 Special Edition Rev 0 Chg 0 BAUER COMPRESSORS 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 ...

Страница 31: ...MNL 093558 September 30 2008 Page 26 BAUER COMPRESSORS 3 000 Operating Hours Para Date Signature Annually Para Date Signature Biennially Every two years Para Date Signature ...

Страница 32: ...BF 100 6 Page 27 Special Edition Rev 0 Chg 0 BAUER COMPRESSORS 4 4 2 Record of Operating Hours Date Minutes Total Date Minutes Total Subtotal Subtotal ...

Страница 33: ...eakage is stopped Not more than finger tight plus up to an additional 1 2 turn 4 5 2 Torque Sequence Diagrams 4 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 Torque Values 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...

Страница 34: ...oves moisture NEC National Electrical Code NEMA National Electrical Manufacturers Association NFPA National Fire Protection Association OSHA Occupational Safety Health Administration ODP open drip proof motor 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 rubbe...

Страница 35: ...MNL 093558 September 30 2008 Page 30 BAUER COMPRESSORS 4 6 Additional Documents OEM Manuals and other BAUER manuals may be included in the documentation shipping package ...

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