Escolar Documentos
Profissional Documentos
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Vertecon
High Pressure Breathing Air Compressor Units
VA 10
VA 13
^ WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions
for the Vertecon 10 & 13 High Pressure Breathing Air Compressor Units.
You must read, understand and follow all safety precautions and instructions.
CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
1.1 HOW TO USE THIS MANUAL......................................................................................................................................... 1
1.1.1 Manual Safety Notices ....................................................................................................................................................... 1
1.2 HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2
1.3 HOW TO USE THE APPENDIX....................................................................................................................................... 3
1.4 SPECIFICATIONS ............................................................................................................................................................. 4
1.4.1 VA 10 ................................................................................................................................................................................. 4
1.4.1.1 Compressor Block .......................................................................................................................................................... 4
1.4.1.2 Compressor Drive .......................................................................................................................................................... 4
1.4.1.3 Purification System Applicability .................................................................................................................................. 4
1.4.2 VA 13 ................................................................................................................................................................................. 5
1.4.2.1 Compressor Block .......................................................................................................................................................... 5
1.4.2.2 Compressor Drive .......................................................................................................................................................... 5
1.4.2.3 Purification System Applicability .................................................................................................................................. 5
CHAPTER 9: - - - - - - - - - - - - - - - - - - - - - - - - APPENDIX
9.1 SAFETY............................................................................................................................................................................ 125
9.1.1 General Safety Precautions ............................................................................................................................................ 125
9.1.2 Safety Warning Labels ................................................................................................................................................... 127
9.2 UNPACKING, HANDLING AND INSTALLATION ................................................................................................. 128
9.2.1 Unpacking and Handling................................................................................................................................................ 128
9.2.2 Installation of the Compressor Unit ............................................................................................................................... 129
9.2.2.1 General........................................................................................................................................................................ 129
9.2.2.2 Ventilation .................................................................................................................................................................. 130
9.2.2.2.1 Outdoor Installation .................................................................................................................................................... 130
9.2.2.2.2 Indoor Installation....................................................................................................................................................... 130
9.2.2.2.3 Natural Ventilation ..................................................................................................................................................... 130
9.2.2.2.4 Forced Ventilation ...................................................................................................................................................... 131
9.2.2.3 Electrical Installation .................................................................................................................................................. 131
9.2.2.3.1 Electric Drive.............................................................................................................................................................. 131
9.2.2.3.2 Electrical Supply......................................................................................................................................................... 131
9.3 LONG TERM STORAGE............................................................................................................................................... 134
9.3.1 General ........................................................................................................................................................................... 134
9.3.2 Preparations.................................................................................................................................................................... 134
9.3.2.1 Units Equipped with a Filter System .......................................................................................................................... 134
9.3.3 Preserving the Compressor............................................................................................................................................. 134
9.3.4 Preventive Maintenance During Storage........................................................................................................................ 135
9.3.5 Lubrication Oils for Preservation ................................................................................................................................... 135
9.3.6 Reactivating the Compressor Unit ................................................................................................................................. 135
9.4 REPRODUCIBLE FORMS ............................................................................................................................................ 136
9.4.1 Scheduled Maintenance Form ........................................................................................................................................ 136
9.4.2 Record of Operating Hours ............................................................................................................................................ 139
9.5 REFERENCE DATA....................................................................................................................................................... 140
9.5.1 Tightening Torque Values.............................................................................................................................................. 140
9.5.2 Torque Sequence Diagrams ........................................................................................................................................... 140
9.5.3 Conversion Formulas ..................................................................................................................................................... 140
9.5.4 Approved Lubricants Chart............................................................................................................................................ 141
9.5.5 Glossary of Abbreviations and Acronyms ..................................................................................................................... 141
9.6 ADDITIONAL DOCUMENTS ...................................................................................................................................... 142
9.6.1 Diagrams and Drawings ................................................................................................................................................. 142
9.6.2 Other Documents............................................................................................................................................................ 142
^ DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This is limited to the most extreme situations.
^ WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
injury.
^ CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
NOTICE
NOTE advise of technical requirements that require particular attention by the operator or the mainte-
nance technician for proper maintenance and utilization of the equipment.
Information Example
Model Number TCom-25
Serial Number 32165
Date of Manufacture 02/2005
Quantity required 2
Part Number N04860
Part Description Valve
^ WARNING
The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-
threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer
Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.
1. Based on recharging an 80 cubic foot (air volume) tank from 500 to 3000 PSIG
2. Compressor capacity (FAD) is.referenced to standard inlet conditions and 80% of the compressors maximum working pressure. Tolerance on capacity 5%.
1.4.2 VA 13
Medium air
Charging Rate 13.0 scfm1
Free Air Delivery 10.8 scfm2
Inlet pressure atmospheric
Operating pressure, max. 6,000 psig (420 bar)
Ambient temperature range 43 to 113 F (5 to 45 C)
Weight approx. 720 lb. (327 kg)
1.4.2.1 Compressor Block
IK12.14 II Mod. 6
No. of stages 4
No. of cylinders 3
Cylinder bore, 1st stage 4.2 in. (105 mm)
Cylinder bore, 2nd stage 4.15/3.46 in. (105/88 mm)
Cylinder bore, 3rd stage 1.10 in. (28 mm)
Cylinder bore, 4th stage 0.47 in. (12 mm)
Piston Stroke 1.57 in. (40 mm)
Intermediate pressure, 1st stage 44 - 58 psig (3 - 4 bar)
Safety valve setting, 1st stage 73 psig (5 bar)
Intermediate pressure, 2nd stage 232 - 254 psig (16 - 17.5 bar)
Safety valve setting, 2nd stage 348 psig (24 bar)
Intermediate pressure, 3rd stage 986 - 1,131 psig (68 - 78 bar)
Safety valve setting, 3rd stage 1,378 psig (95 bar)
Direction of rotation when facing flywheel CCW
Compressor speed 1,420 RPM
Oil capacity 3 qts.(2.8 liters)
Oil Pressure 58 - 87 psig (4 - 6 bar)
Recommended oil (Synthetic) BAUER OIL-0024
Maximum Inclination 15 in all directions
1.4.2.2 Compressor Drive
1. Based on recharging an 80 cubic foot (air volume) tank from 500 to 3000 PSIG
2. Compressor capacity (FAD) is.referenced to standard inlet conditions and 80% of the compressors maximum working pressure. Tolerance on capacity 5%.
COMPRESSOR OFF
BCI NORFOLK, VA 11
1328 AZALEA GARDEN ROAD
PHONE 757-855-6006
1
10
2 3 4 5 6 7 8 9
1. Display Screen 5. Alarm Button 9. Enter Key
2. Start Button 6. Menu Button 10. Escape Key
3. Stop Button 7. Maintenance Instruction Button 11. Arrow Keys
4. Silence Audible Alarm/Clear Alarm Button 8. Shift Key
NOTICE
In an emergency the compressor is shutdown by pressing in the E-Stop Button.
NOTICE
If the value entered is too high or too low, the highest or lowest allowed
value will be entered automatically.
7. Press the Escape Key and repeat as necessary to return to the Menu or Home Screens.
NOTICE
All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme
conditions like high temperatures or high humidity may shorten the intervals significantly. If in doubt,
please contact the Bauer Product Support Department.
Home Screen
Compressor Off
BCI Norfolk, VA
1328 Azalea Garden Road
Phone 757-855-6006
Menu Screen
Home
Status
Parameter
Password Screen
Maintenance
Configuration Password Required
Calendar Password: ****
Hours Factory Default = 1328
Screen
Display Alarms
Operator Menu
Diagnostic Menu
Release Password
OR
Force I/O
FORCE INPUT
FORCE OUTPUT
UNFORCE ALL I/O
This portion of the software is to set the initial values and assist a trained Bauer technician in trouble-
shooting. It consists of the following selections.
2.9.1 The Display Alarms Menu
The Display Alarms Screen displays the last set of CPU alarms.
2.9.2 The Operator Menu.
1. View the CPU Status. Displays the PLC Model, PLC Firmware Version and the current mode of the
PLC.
2. The Set Date and Time Screen. Used to set the date and time initially or reset it as necessary.
3. The Select Language Screen. Changes the language in which the Operator Interface displays infor-
mation. Current default is English with Spanish and Portuguese planned as future options.
1 11
2
3
4 12
13
5
14
6
15
7
16
8
17
9 18
10 19
13
8 6 7 9
15 5 14
1 16
11 10
17
2
12
4 3
18 18 18
5 5
Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter
^ CAUTION
Replace the oil filter every oil change. Failure to do so will cause the filter to clog and the bypass valve to
open resulting in unfiltered oil being circulated and possible damage to the compressor.
4. (See Figure 3-6). Remove the two bolts (1) with a 13 mm wrench. Remove the oil filter cover (2)
5. (See Figure 3-7). Remove the oil filter (1) from the rubber gasket at the cover.
6. Mount a new filter element (P/N N25326) and replace and fasten oil filter cover.
7. Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the
sight gauge.
8. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation.
3.1.4 Intake Filter
A dry, micronic filter is used to filter the intake air, See Figure 3-8. The filter cartridge must be changed
at regular intervals. See the Maintenance Schedule for the recommended interval.
3
2
1
1. Knurled Nut 3. Filter Housing
2. Washer 4. Filter Element
1 3
2
4
8 4
5
2
3.1.5.1 Maintenance
The Intermediate Separator requires no maintenance.
^ WARNING
The rapid depressurizing and repressurizing of the intermediate separator during condensate draining
subjects it to 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 depressurization- repressurization. The Bauer recommended frequency of condensate draining is
every fifteen minutes and is a balance between maximizing the life of the oil and water separator cham-
ber and maintaining the quality of the delivered air.
3.1.6 Cooling
The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this pur-
pose the compressor is equipped with a fanwheel which draws the cooling air through the unit. The fan-
wheel is driven by the drive motor V-belt and is also used as the compressor flywheel.
3.1.6.1 Maintenance
When dirty, clean the finned tubes, valve heads and cylinders by blowing off the dirt and dust with low
pressure compressed air (80 -125 psi)
3.1.7 Compressor Valves and Heads
3.1.7.1 Functional Description
The valve heads of the individual stages form the top part of the cylinders. (See Figure 3-11).
Intake Discharge
The intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the
flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylin-
ders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve.
The intake and pressure valve of the 1st stage are in a combined plate valve under the valve head. (See
Figure 3-12).
TOP VIEW
Intake Side
Pressure Side
4 4
3 3
5 2
3.1.7.3.2 Reassembly
See Figure 3-13.
1. Replace the Plate Valve ensuring that the side marked TOP is really at the top and the stamped S
is on the intake side.
2. Place the Valve Head (2) on the cylinder and secure it with the Washers (3) and Hex Head Bolts (4).
Tighten these Bolts. (Refer to the torque table in the Appendix.)
3. Reconnect all tubing connections and lines to the Valve Head (2).
2
3
2
2
4
2
1
1
8
7
4
6
5
Figure 3-16 Using the Special Tool P/N 004555 Figure 3-17 Securing the Intake Valve
NOTICE
Valve seats and plate valves must not show any signs of wear or damage.
Replace damaged or worn parts.
3.1.7.5.2 Reassembly.
1. Replace the intake valve (6) using the special tool to tighten it.
^ CAUTION
The intake valve plate and valve spring must not be jammed.
2. Check the intake valve functions correctly by blowing compressed air through the valve in the
direction of flow.
3. Secure the intake valve by peening the valve head aluminum over the screw-in thread of the intake
valve in two places opposite one another. Use a small drift pin, approximately 5 mm in diameter.
(See Figure 3-17).
4. Insert the O-ring (4) and the pressure valve parts(5).
5. Check the pressure valve function and stroke by lifting the valve parts.
6. Ensure the stud (2) is unscrewed, then screw in the pressure plug (3)and tighten.
7. Screw the stud (2) in firmly, fit a new gasket and secure it with the cap nut (1).
8. Replace the valve head (7) on the cylinder and secure it with the screws (8).
9. Reconnect the intake and pressure lines.
10
8
7
5
4 1
3.1.7.6.2 Reassembly
1. Replace the intake valve (1) using the special tool to tighten it.
2. Check the intake valve functions correctly by blowing compressed air through the valve in the
direction of flow.
3. Reinstall the pressure valve (4) by putting O-ring (3) into valve head (2). Check it for abrasions.
4. Insert pressure valve through O-ring and into valve bore.
5. Put on valve head cover (5).
6. Reassemble valve head cover and valve head to cylinder. Torque bolts (9) to the proper value.
7. Screw in stud (6). Put on gasket (7). Screw on cap nut. (8).
6
11
12
13
2
15
3
28 4 1 16
14
18
17
8
9
10
26
27 19
25
16
5 4
29 22
7
30
20
21
23 22
19 24
11
10
9 2
3
4
5
8
6
5
7
3 11
10
6
7
8
7
1
2
3
4
5
16 15
6
7
14 8
9
7
12
13 11
10
4 4
3 3
5 2
2
3
2
2
4
2
1
8 9 1 2
6 5 7
10
3
4
Vertecon 10 & 13
15
14
13
16
12
11
4 1
10
9
8 2
7
3
5
6
2
10
8
7
5
4 1
8
7
5
4 3
2
1 5
3
2
1
7
11 65
4
47 26
10 89 30 27
44 42 27
1 46
43 9 45
31
27 7
2 32
4 5 4140 28
6 7 39 26
27 27 28 27
18 6
12 13 14 17 30 42 27 54
31
3 32 9
7 49 27
37 32
6 38 36 30
19 16 27 26 29 4 5 27
21 48 31
28
27 33
22 32
23
15 33
20
33 27
27 31 35
26 34
35
24 34
22 25
1
11
12
2
3
4
19 10
15
14
9
6
13
14
18
17 14
15
8
14 7 16
15
3.1.9 Troubleshooting
Preventive maintenance usually involves replacing the valves, gaskets, and sealing rings.
3.1.9.1 Troubleshooting Table
1
8
3
7
4
5 6
2 3 6
2 3 6
4 5
1 4 5
1
Control Pressure
Control Pressure Condensate
Condensate
Normal Operation Condensate Draining
4
1. Air Discharge 3. Float Level Switch
2. ACD Manifold 4. Manual Drain Valve
(models vary)
5
6
7
6
3 9
8
11
2
10 4 5 1 12
4
5
16
10
11
12
14 13
16
2
5
6
10
11
12
16
15
13 14
10
6
^ WARNING
Industrial Air Purification System cartridges do not remove Carbon Monoxide
and must not be used in breathing air applications.
Safety Safety
Vent Vent
PURIFICATION
CARTRIDGE TO BE
SYSTEM
INSTALLED
MODEL NO.
P12a 1 1 420,000
P14 a 2 1 650,000
P31 Combined 11,760
P41 1 28,700
P41 with Securus 1 47,000
P42 1 1 64,000
P42 with Securus 1 1 107,000
P43 2 1 100,000
P43 with Securus 2 1 164,000
a. P12 and P14 have the Securus Electronic Moisture Monitor System as standard equipment.
3.5
3.0
2.5
Conversion Factor
2.0
1.5
1.0
0.5
0.0
0 10 20 30 40 50
Ambient Temperature in C
C F Correction Factor
[(F - 32) x 5/9] [C x 9/5 +32]
50 122 0.21
40 104 0.34
30 86 0.58
20 68 1.00
10 50 1.81
0 32 3.44
8
Securus II
7
6
IN
OUT
5
3
4
1. Oil and Water Separator 5. Pressure Maintaining Valve
2. Condensate Drain Valve 6. Purification or Securus Chamber
3. Check Valves 7. Safety Valve
4. Bleed Valve 8. Securus II Transmitter
^ WARNING
The rapid depressurizing and repressurizing of the oil and water separator during condensate 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 predetermined number of cycles.
One load cycle equals one pressurization plus one depressurization.
Units operating between 3,000 and 5,000 psi = 130,000 load cycles (32,500 hours of operation)
Units operating between 5,000 and 6,000 psi = 55,000 load cycles (13,750 hours of operation
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 the quality of the delivered air.
The air leaving the final stage is cooled in the aftercooler to approximately 18 - 27 F (10 -15 C) above
ambient temperature and then enters the oil and water separator. The oil and water separator works by
means of a sintered metal filter which separates liquid oil and water particles from the compressed air.
4.2.2.2 Chamber
Each chamber is made up of an anodized aluminum housing and a filtering cartridge. There are two gen-
eral 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
purification chamber.
4.2.2.3 Cartridge
4.2.2.3.1 Cartridge Construction
The cartridge casing, top and bottom are aluminum and are packed with
one or more of the following.
1. A catalyst to convert carbon monoxide to carbon dioxide. Purification
Cartridge
2. Activated carbon which absorbs oil vapors effecting taste and odor.
3. Molecular sieve to absorb oil and water.
4.2.2.3.2 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 saturated and useless.
2. Used cartridges must be disposed of in accordance with local regu- Protective Cap
lations.
4.2.2.4 Condensate Drain Valve
A manually operated valve used for maintenance and before start-up to drain the condensed liquids from
the coalescing oil and water separator.
4.2.2.5 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.
Figure 4-8 Oil and Water Separator Figure 4-9 Sintered Metal Filter Assembly
2
3
2
1
The Securus II Transmitter is removed and replaced by rotating the blue plastic Securus II Transmitter
approximately turn. It is not necessary to disconnect or remove the DIN Connector.
NOTICE
If the DIN Connector is removed, ensure that it is replaced in exactly the same position,
otherwise electrical damage to the unit may occur.
Pull
Up
1. Disconnect the power and shut off the inlet supply line, if applicable.
2. Depressurize the system by means of the bleed valve.
3. If the chamber is part of the Securus II Moisture Monitor System, remove the Securus II Trans-
mitter. See Paragraph 4.2.3.2.
4. Unscrew the chamber head using the special wrench supplied.
5. Pull out the cartridge using the lifting ring on top of the cartridge.
6. Dry the inside of the chamber with a clean cloth and check for corrosion.
7. Replace all corroded parts with new Bauer parts.
8. Remove the shipping covering and the protective cap from the bottom of the cartridge.
9. Lubricate the O-rings with white petroleum jelly. Apply sparingly.
10. Install the new cartridge. Be sure the cartridge snaps into place.
11. Reinstall the chamber head.
12. Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable.
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 below.
8
Securus II
7
6
IN
OUT
5
3
a
2
b
3 c
c
4 b
f g
8 9 1 2
6 5 7
10
3
4
Vertecon 10 & 13
18
2 17
3
16
15
5
14
13
12
4
11
10
9
3 8
2 7
6
ION
AT
T
RO
4
5
ION
AT
T
RO
1
4
5
VA 10
1 1 IK12.14 II Compressor Block
2 1 BET-0227 V-belt
3 1 IDL-0010 Idler includes idler pulley
4 1 SHE-0220 V-belt Sheave
5 1 BUS-0002 Sheave Bushing
6 1 MTR-0052 Electric Motor 7.5 Hp, 1
1 MTR-0033 Electric Motor 7.5 Hp, 3
VA 13
1 1 IK12.14 II Compressor Block
2 1 BET-0227 V-belt
3 1 IDL-0010 Idler includes idler pulley
4 1 SHE-0139 V-belt Sheave
5 1 BUS-0002 Sheave Bushing
6 1 MTR-0036 Electric Motor 10 Hp, 1
1 MTR-0069 Electric Motor 10 Hp, 3
The Electrical Panel, ASY-1095, provides logical control and safety shutdowns for the compressor equip-
ment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorporated
into a proprietary software program permanently saved into PLC memory using EEPROM technology.
The software program used in this Electrical Panel is 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-0050. In an emergency the compressor is shutdown with the E-Stop Button.
6.2 Electrical Panel
This Electrical Panel is designed for use with 5, 7.5, 10, 15 or 20 horsepower electric motors. It is also
designed for supply voltages from 208 VAC to 460 VAC, single or three phase and 50Hz or 60 Hz. All
supply voltage options are not available with each horsepower rating.
The basic panel components consist of a Programmable Logic Controller (PLC), Motor Starter, Overload
Relay, Power Transformer, Fuses, Overload Reset Button, Hour Meter, terminal strips for internal wiring
MODEL: VA-12.2-E1/230V
SERIAL: 107282
Norfolk, VA 23502 USA
757-855-6006 www.bauercomp.com
BLOCK: P0808762/06
UL File No. E141433 MFG DATE: 12/2009
PANEL: ASY-1095 Use 600 VAC and 60 Degree Celsius
Copper Wire Only
Short Circuit Current: xx,xxx KA Terminal Wire Range Torque
MAXIMUM RATING (AC3) Line awg 10-3 45 in-lb
1 Ph 60 Hz Ground awg 14-2 35 in-lb
230V CONTROL FUSE LEGEND
10 HP 1FU 2FU 3FU
46 FLA ATQR - 3A ATQR - 3A TRM - 2A
1 2
3
8
7
1
1. Notch in the Terminal Block
Figure 6-7 Motor Starter (typical) Figure 6-8 Overload Relay (typical)
CNT-0075 CNT-0076
6.5 Alarms
The following paragraphs describe the warning and alarm conditions that are monitored and controlled
by the Electrical Panel.
6.5.1 Final Separator Warning
The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel,
approximately 3 inch diameter, located on the purification panel. To prevent fatigue failure of this ves-
sel, the PLC program monitors the pressurization and depressurization cycles of this separator and will
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 following values when it is built.
When the warning is displayed, the unit will still continue to function properly, but will prompt the oper-
ator to contact Bauer Compressors to make arrangements to replace the separator. When the Alarm level
has been achieved, the compressor will no longer function, and will require the replacement of the sepa-
rator. When this is accomplished, the unit can be reactivated by making adjustments to the PLC software.
Please contact Bauer Product Support for detailed instructions.
^ WARNING
Do not attempt to override this Separator Shutdown. This feature is provided to protect operating person-
nel from injury or death.
MNR-0042 Shown
NOTICE
If the DIN Connector is removed, ensure that it is replaced in exactly the same position,
otherwise electrical damage to the unit may occur.
Figure 6-12 High Temperature Switch Figure 6-13 Pressure Sensor (Typical)
NOTICE
The compressor condensate contains some oil, and accordingly, should be disposed of in accordance with
state and local regulations.
5
2
6
7
See the proper Figure for Part No. applicable to the Horsepower and Power Frequency supplied
with your unit.
2
1 2 3
4
1
5
The Carbon Monoxide (CO) Monitor is designed to provide continuous monitoring of the carbon
monoxide levels in breathing air.
The Carbon Monoxide Monitor is enclosed in a NEMA-4X case and operates on 12 VDC or 120
VAC.
NOTICE
Calibration is recommended every thirty days.
1. Before calibration, be sure that the test gas bottles in the calibration kit have an adequate amount of
gas in the them. Attach the fixed flow regulator to the gas bottle and then detach it. You should hear
a slight popping sound.
2. Turn on the compressor unit. The compressor itself does not have to run, because the test gas is
being substituted for the air supply from the compressor.
3. The compressor unit power needs to be applied to the unit for 15 minutes so the unit can stabilize.
If you attempt to calibrate before the end of this 15 minute period, TO SOON will appear on the
LCD Display.
4. Close Isolation Valve by turning counterclockwise until it stops. This will ensure that the air flow
from the compressor unit is shut off.
5. If the gas flow from the compressor unit was not shut off, a message SUPPLY OFF will appear.
If this message appears, shut off the supply air and then begin the calibration process again.
6. Connect the 20 ppm Carbon Monoxide Test Gas to the fixed flow regulator and connect it to the
Calibration Port of the Carbon Monoxide Monitor.
7. Turn the value on the Fixed Flow Regulator counterclockwise until the Carbon Monoxide Monitor
Flow Indicator shows between 0.5 and 0.8 SCFH.
8. The Display will count down from 60 seconds. At the conclusion, the display will prompt Car-
bon Monoxide G SET or CAL FAILED
9. The the display will prompt REMOVE Carbon Monoxide GAS.
10. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the
Calibration Port and disconnect the 20 ppm Carbon Monoxide Test Gas bottle from the fixed flow
regulator.
NOTICE
If the compressor is started before the test gas dissipates, it could lead to incorrect
Carbon Monoxide level readings.
12. Turn the compressor on, compressor must be running, adjust Inlet Regulator to 0.5-0.8 SCFH to
restore normal operations.
7.4.2 Troubleshooting a Calibration Failure
If the unit fails to calibrate, it maybe due to low pressure in Test Gas Bottles, mixing up the Test Gas
Bottles during calibration or an aging Carbon Monoxide Sensor Cell.
1. Ensure the Test Gas supply is adequate. See Paragraph 7.4.1 Step 1.
2. Initialize the Carbon Monoxide Monitor following the procedures in Paragraph 7.4.4. This will
allow for a greater percentage of compensation for the gas.
3. If the Test Gas is good and the Carbon Monoxide Monitor still refuses to calibrate, replace the Car-
bon Monoxide Sensor Cell. See Paragraph 7.4.3.
4. If it still doesnt calibrate, contact Bauer Product Support.
1. 20 ppm Carbon Monoxide Test Gas 2. Zero Test Gas 3. Fixed Flow Regulator
^ CAUTION
Be sure the power is disconnected from the unit.
2. Remove the four corner screws and open the Carbon Monoxide Monitor front cover.
3. Remove the screws that hold the Carbon Monoxide Sensor Cell cover.
4. Remove the Carbon Monoxide Sensor Cell from its socket by pulling it up from the circuit board.
5. Install a new Carbon Monoxide Sensor Cell.
^ CAUTION
Be sure the shorting wire is removed from the new Carbon Monoxide Sensor Cell.
6. Replace the Carbon Monoxide Sensor Cell Cover, ensuring the longer screw is in its indicated hole.
7. Reassemble the Carbon Monoxide Monitor and reconnect to power.
8. Let the new Carbon Monoxide Sensor Cell warm-up for an hour before doing the Initialization.
9. See Paragraph 7.4.4 for Carbon Monoxide Monitor Initialization procedures.
3 4 5
NOTICE
If the compressor is started before the test gas dissipates, it could lead to incorrect
Carbon Monoxide level readings.
17. Turn the compressor on, the compressor must be running, adjust Inlet Regulator to 0.5-0.8 SCFH to
restore normal operations.
1 2 3 4 5 6
1. Power Connection 5. Carbon Monoxide Sensor Cell Cover
2. Gas Inlet 6. Alarm Connections
3. Audible Alarm (not used) 7. Carbon Monoxide Sensor Cell
4. Remote Display Connection (only MNR-0033)
^ CAUTION
Except for the Carbon Monoxide Sensor Cell, all internal Carbon Monoxide monitor parts
are to be serviced only by the manufacturer.
Do not adjust factory settings with the setup menu Mode Buttons unless absolutely necessary and by a
trained technician. The only reason to access the setup information is to test the alarm relay interface of
the control system which simulates the compressor going into an alarm state. The following describes
how to access the TEST MODE.
^ CAUTION
Except for testing the Display LCD, adjusting the parameters set at factory incorrectly could be dangerous.
Adjustment, if necessary, must be done by a trained technician.
1. Unscrew the four large screws on all corners of the Front Cover (See Figure 7-3).
2. Lift the Front Cover carefully, to not harm any of the attached wires inside the Carbon Monoxide
monitor.
3. Find the two white mode buttons on the left side of the motherboard (See Figure 7-8). By briefly
depressing the top button six times it is possible to cycle through the set up parameters to access the
TEST MODE.
4. When TEST MODE is displayed simply depress the bottom Value Change Button. Depressing the
Value Change Button sends an input signal to the PLC, shutting down the compressor system and
NOTICE
The Remote Display must not be installed more than 100 feet from the Carbon Monoxide Monitor.
(See Figure 7-9) To calibrate the Remote Display, adjust the internal potentiometer with the compressor
system control switched on, so the Carbon Monoxide Monitor will be energized. However do not have
the compressor running, because the air supply from the compressor is unnecessary for the Remote Dis-
play setup.
1. To calibrate the Remote Display unit during normal operation of the compressor unit, make sure the
that both the compressor and Carbon Monoxide Monitor units are on.
2. Open the Remote Display (See Figure 7-9). Find the top potentiometer and adjust it to match the
Carbon Monoxide Monitor Carbon Monoxide display reading. Notice that the Carbon Monoxide
Monitor rounds off to whole numbers while the Remote Relay displays decimal places, so adjust as
close as possible.
3. When the display readings match, reassemble the Remote Relay. Realign readings if necessary.
3 4 5
TO CONNECTS TO
REMOTE COMPRESSOR
DISPLAY BOARD CONTROLS
A
WHT/BLK
CO Monitor
No Connection.
DP -.
DP +.
Not Used.
Not Used.
Not Used.
COM.
COM.
NC.
NC.
NO.
NO.
MNR-0029/MNR-0033
RED YELLOW
RELAY RELAY
POWER BOARD
CONNECTS TO
COMPRESSOR
CONTROLS
INCOMING
POWER
1702-113B
RED
120 VAC
RECORDER No Connection
OUTPUT
RED Jumper
INT PWR.
AC 1.
AC 2.
+24 VDC.
GND.
TRANSFORMER
A
EXT. 12V OPER.
No Connection.
DP -.
DP +.
GND.
12V
REMOVE JUMPER
MAX 18 AWG WIRE 12V OPERATION
+ + +
PWR SIG B/L
N/A
Remote Display Board N/A
MNR-0034 Display Adjustment Pot.
1 2 3
Figure 8-2 Check Valve Figure 8-3 Pressure Maintaining Valves (PMV)
2 2
1
1
The safety valves are adjusted at the factory 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 the valve to the factory (contact the Bauer Product Support Depart-
ment for details).
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.
DIRECTION OF ROTATION!
When switching on the machine, check the arrow to ensure correct direction of
rotation by the drive motor.
Chain Hoist
^ WARNING
Be sure the lifting devices are capable of handling the weight of the unit (see Paragraph 1.4 for the
approximate weight of the unit). Before lifting the unit, secure all loose or swinging parts to keep
them from moving. Stay clear of lifted load.
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 circumstances
should the braces remain installed during operation or the manufacturers warranty for the compressor
unit will be voided. All braces are tagged and labelled.
^ CAUTION
The inclination values listed in Paragraph 1.4 are valid only if the oil level of the compressor is level with
but does not exceed the upper mark of the oil dipstick or oil level sight glass.
If equipped with machine leveling feet, ensure the unit is leveled to prevent movement when operating.
To raise the unit at the leveling foot turn the leveling bolt clockwise. Lock the leveling foot in place with
the provided hex-nut once the unit is level. The maximum adjustment is 5/8 inch (16 mm). Do not exceed
this height. If additional height is required, use blocks or shims.
Leveling
Bolt
Locking
Leveling Nut
Foot
Ensure that the compressor air intake is supplied with fresh air. The intake air must not contain any
exhaust fumes or 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 draw in clean air. The quality of the incoming air determines the quality of the compressed air. This
is important even for industrial air, as any incoming fumes will also be compressed and will increase the
toxicity to anyone working with the compressed air.
If a remote control is provided, the unit must be equipped with a clearly visible plate warning the possi-
bility of the unit starting. As an additional measure, anyone starting the unit by remote control must make
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
Drive
Hp Intake (ft) Exhaust (ft) Intake (ft) Exhaust (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
Intake & Exhaust Openings Dependent on Room Volume (V) and Height (h)a
V = 1750 ft h = 8 ft V = 3500 ft h = 10 ft V = 7000 ft h = 13 ft
Drive Intake Exhaust Intake Exhaust Intake Exhaust
Hp (ft) cfm (ft) cfm (ft) cfm
25 3.3 3,300 3.2 3,200 3.0 3,000
30 4.0 3,960 3.8 3,840 3.6 3,600
40 5.3 5,280 5.1 5,120 4.8 4,800
50 6.6 6,600 6.4 6,400 6.0 6,000
60 7.9 7,920 7.7 7,680 7.2 7,200
75 9.9 9,900 9.6 9,600 9.0 9,000
100 13.2 13,200 12.8 12,800 12.0 12,000
125 16.5 16,500 16.0 16,000 15.0 15,000
150 19.8 19,800 19.2 19,200 18.0 18,000
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.min. to 2000 ft.min.
NOTICE
If this unit is equipped with an Air Kool system, consult the Air Kool Section for electrical installation.
The use of improperly sized wire can result in sluggish operation, unnecessary tripping of overload relays
and/or blowing of fuses. The following tables are provided as a guide for proper wire size
1 PHASE
Full Load Amps Fuse Ampsa Minimum Wire Sizeb
Motor
Hp 120 V 208 V 230 V 120 V 208 V 230 V 120 V 208 V 230 V
2 24 13.2 12 30 20 17.5 10 14
3 34 18.7 17 50 30 25 8 10 10
5 56 30.8 28 80 50 40 4 8 8
7.5 80 44 40 100 70 60 3 8 8
10 55 50 90 60 6 6
a. Dual element time delay fuse Amps.
3 PHASE
Full Load Amps Fuse Ampsa Minimum Wire Sizeb
Motor
Hp 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 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 30 20 4
60 169 154 77 250 200 100 40 30 3
75 211.2 192 96 300 300 150 300 250 1
100 273 248 124 400 350 175 500 350 20
125 343.2 312 156 500 400 200 2-40 2-30 30
150 396 360 180 600 500 250 2-300 2-40 40
a. Dual element time delay fuse Amps.
In the above tables, all values are based on 1996 NEC articles 430 and 310 (NFPA 70). These values are
provided as a general guide; however, the information given on the motor nameplate supersedes the
above information.
3
5 3
2 1 2 1
4 6
4
In an effort towards constant improvement, the Documentation section of Bauer Compressors, Inc.
would like to give you the opportunity to suggest improvements or corrections to this manual. If you
find any inaccuracies or have suggestions feel free to E-mail us at: documentation@bauercomp.com, or
fill out the form below and mail it to us:
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