Instruction Manual and Replacement Parts List

Offshore Compressors
High Pressure Breathing Air Air Compressors
O 13

April 30, 2012 1st Edition, Rev. 1 Chg. 1 MNL-0420

© Bauer Compressors, Inc.
BAUER Compressors, Inc. Phone: (757) 855-6006
1328 Azalea Garden Road Fax: (757) 855-6224
Norfolk, Virginia 23502-1944 www.bauercomp.com
 Offshore 13
This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication, but
Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set
forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use of this
information. All information supplied is in connection with sales of Bauer’s products, and is thus subject
to Bauer’s standard terms and conditions of sale. Bauer reserves the right to 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 customers have no right to reproduce,
rewrite, modify, license or permit anyone else’s use of this information, without the express written per-
mission of Bauer Compressors, Inc.

^ WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions
for the Offshore 13 High Pressure Breathing Air Air Compressors.
You must read, understand and follow all safety precautions and instructions.

1st Edition August 25, 2006

Rev Chg Date Notes Auth

0 0 Aug. 25, 2006 Derived from MNL-0417 JD
Changed Oil Pressure Gauge GAG-0006W to GAG-0042W
0 1 Dec. 1, 2006 JD
and Overrun Timer setting procedure
0 2 Feb. 16, 2007 Updated 4 Stage ACD Solenoid JD
0 3 Mar. 21, 2007 Change to Separator P/N 079416 Life Span JD
0 4 Nov. 14, 2007 Update ACD Solenoid P/N AC DC JD
0 5 Jan. 17, 2008 Changed Safety Valve P/N’s SS
0 6 Mar. 19, 2008 Added Flywheel to Parts List SS
0 7 Oct. 10, 2008 Changed Drive Chapter SS
0 8 Oct. 15, 2008 Corrected Compressor Block Cooling System P/N 078584 CLA
0 9 Nov. 3, 2008 Deleted instruction to peen 4th Stage Intake Valve CLA
0 10 Aug. 10, 2009 Added CO & H2S Monitor Sections SS
0 11 Jan. 26, 2010 Updated CO Monitor Calibration Procedures SS
0 12 Aug. 18, 2010 Updated Safety Valve P/N’s, Added cold weather opt. Elect. SS
1 0 July 20, 2011 Converted to Siemens Electrical SS
1 1 Apr. 30, 2012 Updated Compressor Block Chapter SS

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MNL-0420
Table of Contents

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 DESCRIPTION AND SPECIFICATIONS ....................................................................................................................... 4
1.4.1 Unit Specifications ............................................................................................................................................................. 4
1.4.1.1 O 13 ................................................................................................................................................................................ 4
1.4.1.2 Compressor Block, IK12.14 II........................................................................................................................................ 4
1.4.1.3 Compressor Drive........................................................................................................................................................... 4
1.4.1.4 Purification System Applicability .................................................................................................................................. 4

CHAPTER 2: - - - -OPERATING INSTRUCTIONS; MAPLE SYSTEM

2.1 DESCRIPTION.................................................................................................................................................................... 5
2.1.1 Emergency 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.................................................................................................................................................................................. 8
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 Configuration.................................................................................................................................................................. 9
2.1.2.2.7 Parameters..................................................................................................................................................................... 10
2.1.2.2.8 Tools ............................................................................................................................................................................. 10
2.2 STARTING AND STOPPING UNIT .............................................................................................................................. 10
2.2.1 Before Starting. ................................................................................................................................................................ 10
2.2.2 To Start Unit..................................................................................................................................................................... 11
2.2.3 To Stop Unit. .................................................................................................................................................................... 11
2.3 SCREEN FLOW ................................................................................................................................................................ 14

CHAPTER 3: - - - - - - - - - - - -IK 12.14 II COMPRESSOR BLOCK

3.1 MAINTENANCE AND PARTS ....................................................................................................................................... 15
3.1.1 Component Location ........................................................................................................................................................ 15
3.1.2 Air Flow Diagram ............................................................................................................................................................ 15
3.1.3 Lubrication System .......................................................................................................................................................... 16
3.1.3.1 Type of Oil.................................................................................................................................................................... 17
3.1.3.2 Oil Level Check............................................................................................................................................................ 17
3.1.3.3 Oil Change .................................................................................................................................................................... 18
3.1.4 Intake Filter ...................................................................................................................................................................... 19
3.1.5 Intermediate Separators.................................................................................................................................................... 20
3.1.5.1 Maintenance.................................................................................................................................................................. 21
3.1.6 Cooling ............................................................................................................................................................................. 21
3.1.6.1 Maintenance.................................................................................................................................................................. 21
3.1.7 Compressor Valves and Heads......................................................................................................................................... 21

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3.1.7.1 Functional Description..................................................................................................................................................21
3.1.7.2 General Instructions for Changing the Valves..............................................................................................................22
3.1.7.3 Changing the IK12.14 II 1st Stage Valves ...................................................................................................................22
3.1.7.3.1 Removal ........................................................................................................................................................................22
3.1.7.3.2 Reassembly ...................................................................................................................................................................23
3.1.7.4 Changing the 2nd Stage Valves ....................................................................................................................................24
3.1.7.5 Changing the 3rd Stage Valves.....................................................................................................................................25
3.1.7.5.1 Removal ........................................................................................................................................................................25
3.1.7.5.2 Reassembly. ..................................................................................................................................................................26
3.1.7.6 Changing the 4th Stage Valves .....................................................................................................................................27
3.1.7.6.1 Removal ........................................................................................................................................................................27
3.1.7.6.2 Reassembly ...................................................................................................................................................................28
3.1.8 Replacement Parts List .....................................................................................................................................................29
3.1.9 Troubleshooting................................................................................................................................................................49
3.1.9.1 Troubleshooting Table ..................................................................................................................................................49
3.1.9.2 Repair Instructions ........................................................................................................................................................50
3.2 FOUR STAGE AUTOMATIC CONDENSATE DRAIN SYSTEM .............................................................................51
3.2.1 Description .......................................................................................................................................................................51
3.2.1.1 Compressor Operating ..................................................................................................................................................52
3.2.1.2 Condensate Draining.....................................................................................................................................................52
3.2.1.3 Start Unloading .............................................................................................................................................................53
3.2.1.4 Standstill Drainage........................................................................................................................................................53
3.2.1.5 Condensate Drain Piping ..............................................................................................................................................53
3.2.1.6 Condensate Drain Separator .........................................................................................................................................53
3.2.2 ACD Maintenance ............................................................................................................................................................53
3.2.3 Replacement Parts List .....................................................................................................................................................54
3.2.4 Trouble shooting...............................................................................................................................................................61

CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

4.1 INTRODUCTION..............................................................................................................................................................62
4.1.1 General Purification System Procedures ..........................................................................................................................62
4.1.2 Chamber Safety Bore .......................................................................................................................................................62
4.1.3 Manual Condensate Drainage...........................................................................................................................................63
4.1.4 Model, Serial Number and Part Number Identification ...................................................................................................63
4.1.4.1 Compressor Dataplate...................................................................................................................................................63
4.1.4.2 Purification System Dataplate ......................................................................................................................................63
4.1.4.3 Cartridge Installation Dataplate ....................................................................................................................................63
4.1.5 Breathing Air Purification System Configurations ..........................................................................................................64
4.1.6 Industrial Purification System Configurations .................................................................................................................65
4.1.7 Cartridge Operating Life ..................................................................................................................................................65
4.1.7.1 Calculating the Maximum Cartridge Operating Hours.................................................................................................66
4.1.7.2 Calculating the Adjusted Cartridge Operating Hours...................................................................................................66
4.1.7.3 Air Purification Cartridge Operating Hours Form........................................................................................................68
4.2 P2 PURIFICATION SYSTEM MAJOR COMPONENTS............................................................................................69
4.2.1 Configuration Options ......................................................................................................................................................69
4.2.2 Component Description....................................................................................................................................................70
4.2.2.1 Oil and Water Separator ...............................................................................................................................................70
4.2.2.2 Chamber........................................................................................................................................................................71
4.2.2.3 Cartridge .......................................................................................................................................................................71
4.2.2.3.1 Cartridge Construction..................................................................................................................................................71
4.2.2.3.2 Cartridge Handling .......................................................................................................................................................71
4.2.2.4 Condensate Drain Valve ...............................................................................................................................................71

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MNL-0420
4.2.2.5 Check Valves ................................................................................................................................................................ 71
4.2.2.6 Bleed Valve .................................................................................................................................................................. 72
4.2.2.7 Pressure Maintaining Valve.......................................................................................................................................... 72
4.2.2.8 Safety Valve.................................................................................................................................................................. 72
4.2.2.9 Securus II® Electronic Moisture Monitor System ........................................................................................................ 72
4.2.2.9.1 Securus® Cartridge ...................................................................................................................................................... 72
4.2.2.9.2 Securus II® Transmitter ............................................................................................................................................... 72
4.2.3 Maintenance ..................................................................................................................................................................... 72
4.2.3.1 Oil and Water Separator ............................................................................................................................................... 72
4.2.3.2 Removal of the Securus II® Transmitter..................................................................................................................... 74
4.2.3.3 Cartridge Replacement ................................................................................................................................................. 75
4.2.3.4 Leaking at the Safety Bore ........................................................................................................................................... 75
4.2.4 Replacement Parts List..................................................................................................................................................... 77

CHAPTER 5: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

5.1 DESCRIPTION, HORIZONTAL SLIDING .................................................................................................................. 83
5.2 MAINTENANCE OF THE V-BELT AND SHEAVE .................................................................................................... 84
5.2.1 Checking the Sheave. ....................................................................................................................................................... 84
5.2.2 Checking the V-belt ......................................................................................................................................................... 84
5.2.3 V-belt tension ................................................................................................................................................................... 84
5.3 MAINTENANCE OF THE DRIVE MOTOR / ENGINE ............................................................................................. 84
5.4 OFFSHORE 13 DRIVE REPLACEMENT PARTS LIST ............................................................................................ 85

CHAPTER 6: - - - - - - - - - - ELECTRICAL PANEL, ASY-1095 XL

6.1 OVERVIEW....................................................................................................................................................................... 86
6.2 ELECTRICAL PANEL .................................................................................................................................................... 86
6.2.1 Wiring Diagram................................................................................................................................................................ 87
6.2.2 Electrical Panel Interior Access ....................................................................................................................................... 87
6.2.3 Optional Equipment ......................................................................................................................................................... 87
6.3 AC POWER REQUIREMENTS...................................................................................................................................... 87
6.4 ELECTRICAL PANEL COMPONENTS....................................................................................................................... 88
6.4.1 Programable Logic Controller (PLC)............................................................................................................................... 88
6.4.2 Replacing the PLC ........................................................................................................................................................... 89
6.4.3 Installing a New Program................................................................................................................................................. 89
6.4.4 Installing an EEPROM..................................................................................................................................................... 89
6.4.5 Hourmeter......................................................................................................................................................................... 90
6.4.6 Transformer and Fuses ..................................................................................................................................................... 90
6.4.7 Motor Starter. ................................................................................................................................................................... 91
6.4.8 Overload Relay................................................................................................................................................................. 91
6.4.9 Starter Reset ..................................................................................................................................................................... 91
6.4.10 Power Supply ................................................................................................................................................................... 92
6.5 ALARMS ............................................................................................................................................................................ 92
6.5.1 Final Separator Warning .................................................................................................................................................. 92
6.5.2 Securus® Electronic Moisture Monitor System................................................................................................................ 93
6.5.2.1 Securus® Cartridge ...................................................................................................................................................... 93
6.5.2.2 Securus II® Transmitter................................................................................................................................................. 93
6.5.3 Compressor High Temperature ........................................................................................................................................ 94
6.5.4 Compressor Low Oil Pressure.......................................................................................................................................... 94
6.5.5 Compressor Overrun Timer ............................................................................................................................................. 94

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6.5.6 Carbon Monoxide Monitor Alarm....................................................................................................................................94
6.5.7 Condensate Fault ..............................................................................................................................................................95
6.5.8 Motor Starter Overload Trip.............................................................................................................................................96
6.6 PLC INPUTS AND OUTPUTS ........................................................................................................................................96
6.6.1 Analog Inputs to the PLC. ................................................................................................................................................96
6.7 WIRING HARNESS LAYOUT .......................................................................................................................................97
6.8 REPLACEMENT PARTS LIST ......................................................................................................................................99
6.9 PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR.......................................................................102
6.10 PARTS LIST FOR MODELS WITH A 7.5 HORSEPOWER MOTOR....................................................................103
6.11 PARTS LIST FOR MODELS WITH A 10 HORSEPOWER MOTOR.....................................................................104
6.12 PARTS LIST FOR MODELS WITH A 15 HORSEPOWER MOTOR.....................................................................105
6.13 PARTS LIST FOR MODELS WITH A 20 HORSEPOWER MOTOR.....................................................................106

CHAPTER 7:- - - - - - - - - - - - CARBON MONOXIDE MONITOR

7.1 DESCRIPTION ................................................................................................................................................................107
7.1.1 Component Description..................................................................................................................................................108
7.1.1.1 Isolation Valve ............................................................................................................................................................108
7.1.1.2 High Pressure to Low Pressure Regulator ..................................................................................................................108
7.1.1.3 Relief Valve ................................................................................................................................................................108
7.1.1.4 Solenoid Valve............................................................................................................................................................108
7.1.1.5 Inlet Regulator ............................................................................................................................................................108
7.1.1.6 Carbon Monoxide Monitor .........................................................................................................................................108
7.1.1.6.1 Carbon Monoxide Sensor Cell....................................................................................................................................108
7.1.1.7 Test Gas Storage .........................................................................................................................................................108
7.2 CARBON MONOXIDE MONITOR SETUP................................................................................................................108
7.3 OPERATION ...................................................................................................................................................................109
7.4 MAINTENANCE .............................................................................................................................................................109
7.4.1 Calibrating Carbon Monoxide Monitor..........................................................................................................................109
7.4.2 Troubleshooting a Calibration Failure............................................................................................................................110
7.4.3 Carbon Monoxide Sensor Cell Replacement (See Figure 7-5) ......................................................................................110
7.4.4 Carbon Monoxide Monitor Initialization .......................................................................................................................111
7.4.4.1 Setting the LP Regulator.............................................................................................................................................112
7.4.4.2 Initialization Calibration .............................................................................................................................................112
7.4.5 Carbon Monoxide Monitor Test Mode Buttons .............................................................................................................115
7.5 REMOTE DISPLAY SETUP ........................................................................................................................................116
7.6 REPLACEMENT PARTS LIST ....................................................................................................................................118

CHAPTER 8:- - - - - HYDROGEN SULFIDE MONITOR (MNR-0008)

8.1 DESCRIPTION ................................................................................................................................................................121
8.2 HYDROGEN SULFIDE MONITOR SETUP ...............................................................................................................121
8.3 OPERATION ...................................................................................................................................................................122
8.4 RESETTING MIN/MAX READINGS ..........................................................................................................................123
8.5 ALARMS ..........................................................................................................................................................................123
8.5.1 Alarm 1...........................................................................................................................................................................123
8.5.2 Fail..................................................................................................................................................................................123
8.5.3 Low DC Power ...............................................................................................................................................................123

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8.6 SETTING ALARM 1 SETPOINT ................................................................................................................................. 124
8.7 MAINTENANCE............................................................................................................................................................. 124
8.7.1 Daily ............................................................................................................................................................................... 124
8.7.2 Monthly .......................................................................................................................................................................... 124
8.7.3 Quarterly......................................................................................................................................................................... 125
8.7.3.1 Setting the Zero Reading ............................................................................................................................................ 125
8.7.3.2 Calibrating the Span ................................................................................................................................................... 126
8.7.4 Hydrogen Sulfide Monitor Fuse Replacement............................................................................................................... 127
8.7.5 Sensor Replacement ....................................................................................................................................................... 127
8.8 TROUBLESHOOTING .................................................................................................................................................. 129
8.9 REPLACEMENT PARTS LIST .................................................................................................................................... 131

CHAPTER 9: - - - - - - - - - - - - - - - - INDICATORS & VALVES

9.1 DESCRIPTION................................................................................................................................................................ 132
9.2 REPLACEMENT PARTS LIST .................................................................................................................................... 132
9.3 NONADJUSTABLE VALVES ....................................................................................................................................... 134
9.4 PRESSURE MAINTAINING VALVE .......................................................................................................................... 134
9.5 SAFETY VALVES .......................................................................................................................................................... 135

CHAPTER 10: - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

10.1 SAFETY............................................................................................................................................................................ 136
10.1.1 General Safety Precautions ............................................................................................................................................ 136
10.1.2 Safety Warning Labels ................................................................................................................................................... 138
10.2 UNPACKING, HANDLING AND INSTALLATION ................................................................................................. 139
10.2.1 Unpacking and Handling................................................................................................................................................ 139
10.2.2 Installation of the Compressor Unit ............................................................................................................................... 140
10.2.2.1 General........................................................................................................................................................................ 140
10.2.2.2 Ventilation .................................................................................................................................................................. 141
10.2.2.2.1 Outdoor Installation .................................................................................................................................................... 141
10.2.2.2.2 Indoor Installation....................................................................................................................................................... 141
10.2.2.2.3 Natural Ventilation ..................................................................................................................................................... 141
10.2.2.2.4 Forced Ventilation ...................................................................................................................................................... 142
10.2.2.3 Electrical Installation .................................................................................................................................................. 142
10.2.2.3.1 Electric Drive.............................................................................................................................................................. 142
10.2.2.3.2 Electrical Supply......................................................................................................................................................... 142
10.2.2.3.3 Pneumatic Leaks......................................................................................................................................................... 144
10.3 LONG TERM STORAGE .............................................................................................................................................. 145
10.3.1 General ........................................................................................................................................................................... 145
10.3.2 Preparations.................................................................................................................................................................... 145
10.3.2.1 Units Equipped with a Filter System .......................................................................................................................... 145
10.3.3 Preserving the Compressor............................................................................................................................................. 145
10.3.4 Preventive Maintenance During Storage........................................................................................................................ 146
10.3.5 Lubrication Oils for Preservation ................................................................................................................................... 146
10.3.6 Reactivating the Compressor Unit ................................................................................................................................. 146
10.4 REPRODUCIBLE FORMS ............................................................................................................................................ 147
10.4.1 Scheduled Maintenance Form ........................................................................................................................................ 147
10.4.2 Record of Operating Hours ............................................................................................................................................ 150
10.5 REFERENCE DATA....................................................................................................................................................... 151

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10.5.1 Tightening Torque Values..............................................................................................................................................151
10.5.2 Torque Sequence Diagrams............................................................................................................................................151
10.5.3 Conversion Formulas......................................................................................................................................................151
10.5.4 Approved Lubricants Chart ............................................................................................................................................152
10.5.5 Glossary of Abbreviations and Acronyms .....................................................................................................................152
10.6 ADDITIONAL DOCUMENTS.......................................................................................................................................153
10.6.1 Diagrams and Drawings .................................................................................................................................................153
10.6.2 Other Documents............................................................................................................................................................153

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MNL-0420
List of Figures

CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
Figure 1-1 Compressor Identification Label ............................................................................................................................. 2

CHAPTER 2: - - - -OPERATING INSTRUCTIONS; MAPLE SYSTEM

Figure 2-1 MNR-0053............................................................................................................................................................... 5
Figure 2-2 PLC & Battery......................................................................................................................................................... 5
Figure 2-3 Maple System; Run Screen ..................................................................................................................................... 6
Figure 2-4 Maple System; Home Screen .................................................................................................................................. 7
Figure 2-5 Status Screen ........................................................................................................................................................... 8
Figure 2-6 Login Screens .......................................................................................................................................................... 9
Figure 2-7 Parameters Screen ................................................................................................................................................. 10
Figure 2-8 Operator Interface Screen Flow............................................................................................................................. 14

CHAPTER 3: - - - - - - - - - - - -IK 12.14 II COMPRESSOR BLOCK

Figure 3-1 IK12.14 II Compressor Block, Front View ........................................................................................................... 15
Figure 3-2 Air Flow Diagram.................................................................................................................................................. 16
Figure 3-3 Lube Oil Circuit..................................................................................................................................................... 17
Figure 3-4 Oil Sight Glass....................................................................................................................................................... 18
Figure 3-5 Oil Filler ................................................................................................................................................................ 18
Figure 3-6 Removing the Oil Filter Cover .............................................................................................................................. 18
Figure 3-7 Replacing the Oil Filter ......................................................................................................................................... 18
Figure 3-8 Intake Filter ........................................................................................................................................................... 19
Figure 3-9 Intermediate Separators ......................................................................................................................................... 20
Figure 3-10 Valve Operation..................................................................................................................................................... 21
Figure 3-11 1st Stage Valve Operation ..................................................................................................................................... 22
Figure 3-12 1st Stage Valve Head and Valves.......................................................................................................................... 23
Figure 3-13 2nd Stage Valves ................................................................................................................................................... 24
Figure 3-14 3rd Stage Valve Head and Valves ......................................................................................................................... 25
Figure 3-15 Using the Special Valve Tool................................................................................................................................ 26
Figure 3-16 Securing the Intake Valve ..................................................................................................................................... 26
Figure 3-17 4th Stage Valve Head and Valves ......................................................................................................................... 27
Figure 3-18 Removing the 4th Stage Pressure Valve ............................................................................................................... 28
Figure 3-19 Crankcase Assembly ............................................................................................................................................. 29
Figure 3-20 1st/2nd Stage Piston and Cylinder......................................................................................................................... 31
Figure 3-21 3rd Stage Piston and Cylinder ............................................................................................................................... 32
Figure 3-22 4th Stage Piston and Cylinder ............................................................................................................................... 33
Figure 3-23 1st Stage Valve Head and Valve ........................................................................................................................... 34
Figure 3-24 2nd Stage Valves and Valve Head ........................................................................................................................ 35
Figure 3-25 3rd Stage Valves and Valve Head ......................................................................................................................... 37
Figure 3-26 4th Stage Valves and Valve Head ......................................................................................................................... 39
Figure 3-27 Flywheel ................................................................................................................................................................ 40
Figure 3-28 Intermediate Separator, 2nd Stage......................................................................................................................... 41
Figure 3-29 Intermediate Separator, 3rd Stage ......................................................................................................................... 42
Figure 3-30 Intake Filter ........................................................................................................................................................... 43

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Figure 3-31 Cooling System......................................................................................................................................................45
Figure 3-32 Lubrication System................................................................................................................................................47
Figure 3-33 4 Stage Automatic Condensate Drain System .......................................................................................................51
Figure 3-34 ACD Operation Diagrams .....................................................................................................................................52
Figure 3-35 4 Stage ACD System .............................................................................................................................................54
Figure 3-36 ACD Manifold and Valves ....................................................................................................................................55
Figure 3-37 3rd Stage Condensate Drain Valve........................................................................................................................57
Figure 3-38 Oil and Water Separator Condensate Drain Valve ................................................................................................59

CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

Figure 4-1 Cartridge Safety Venting .......................................................................................................................................62
Figure 4-2 P0 & P31 Safety Venting.......................................................................................................................................62
Figure 4-3 Purification System Dataplates (typical) ...............................................................................................................63
Figure 4-4 Correction Factor for Cartridge Operating Hours .................................................................................................67
Figure 4-5 Example Record of Adjusted Operating Hours .....................................................................................................67
Figure 4-6 P2 and P2S Purification System ............................................................................................................................69
Figure 4-7 Oil and Water Separator ........................................................................................................................................70
Figure 4-8 Oil and Water Separator Labels.............................................................................................................................71
Figure 4-9 Oil and Water Separator ........................................................................................................................................73
Figure 4-10 Sintered Metal Filter Assembly .............................................................................................................................73
Figure 4-11 Removal of the Securus II® Transmitter...............................................................................................................74
Figure 4-12 Cartridge Replacement ..........................................................................................................................................75
Figure 4-13 P2S Purification System Parts List ........................................................................................................................77
Figure 4-14 Oil and Water Separator Parts List ........................................................................................................................78
Figure 4-15 27” Chamber Assembly Parts List.........................................................................................................................79
Figure 4-16 Securus II® Electronic Moisture Monitor System Parts List .................................................................................81

CHAPTER 5:- - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

Figure 5-1 Horizontal Motor Mount (typical) .........................................................................................................................83
Figure 5-2 Sliding Motor Base ................................................................................................................................................83
Figure 5-3 V-belt Deflection ...................................................................................................................................................84
Figure 5-4 Offshore 13 Drive ..................................................................................................................................................85

CHAPTER 6:- - - - - - - - - - - ELECTRICAL PANEL, ASY-1095 XL

Figure 6-1 ASY-1095 XL........................................................................................................................................................86
Figure 6-2 Electrical Panel Label ............................................................................................................................................87
Figure 6-3 PLC, CNT-0078.....................................................................................................................................................88
Figure 6-4 Connector Block Removal.....................................................................................................................................88
Figure 6-5 Hourmeter ..............................................................................................................................................................90
Figure 6-6 Transformer and Fuses ..........................................................................................................................................90
Figure 6-7 Motor Starter (typical) ...........................................................................................................................................91
Figure 6-8 Overload Relay (typical)........................................................................................................................................91
Figure 6-9 Power Supply.........................................................................................................................................................92
Figure 6-10 Securus II® Transmitter..........................................................................................................................................93
Figure 6-11 High Temperature Switch......................................................................................................................................94
Figure 6-12 Pressure Sensor (Typical) ......................................................................................................................................94
Figure 6-13 Carbon Monoxide Monitor ....................................................................................................................................95

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MNL-0420
Figure 6-14 Condensate Level Float Switch ............................................................................................................................. 95
Figure 6-15 Electrical Panel, Front View.................................................................................................................................. 99
Figure 6-16 Electrical Panel, Bottom View ............................................................................................................................ 100
Figure 6-17 Electrical Panel, Interior...................................................................................................................................... 101

CHAPTER 7: - - - - - - - - - - - - CARBON MONOXIDE MONITOR

Figure 7-1 CO Monitor, MNR-0029 ..................................................................................................................................... 107
Figure 7-2 Remote Display ................................................................................................................................................... 107
Figure 7-3 Carbon Monoxide Monitor Flow Diagram.......................................................................................................... 108
Figure 7-4 Basic Calibration Kit & Test Gases..................................................................................................................... 110
Figure 7-5 Carbon Monoxide Sensor Cell Removal............................................................................................................. 111
Figure 7-6 Carbon Monoxide Monitor Initialization ............................................................................................................ 112
Figure 7-7 Carbon Monoxide Monitor Internal Components ............................................................................................... 114
Figure 7-8 Mode Buttons Close-up....................................................................................................................................... 115
Figure 7-9 Remote Display ................................................................................................................................................... 117
Figure 7-10 Carbon Monoxide Monitor Assembly - Standard ............................................................................................... 118
Figure 7-11 Calibration Components...................................................................................................................................... 119
Figure 7-12 Carbon Monoxide Monitor Schematic ................................................................................................................ 120

CHAPTER 8: - - - - - HYDROGEN SULFIDE MONITOR (MNR-0008)

Figure 8-1 H2S Monitor, MNR-0008 ................................................................................................................................... 121
Figure 8-2 H2S Sensor, SEN-0028 ....................................................................................................................................... 121
Figure 8-3 H2S Components................................................................................................................................................. 122
Figure 8-4 Normal LCD Display .......................................................................................................................................... 122
Figure 8-5 Control Buttons ................................................................................................................................................... 124
Figure 8-6 Calibration Kit, H2S Monitor, KIT-0226............................................................................................................ 126
Figure 8-7 Sensor Replacement ............................................................................................................................................ 128
Figure 8-8 Replacement Parts ............................................................................................................................................... 131

CHAPTER 9: - - - - - - - - - - - - - - - - INDICATORS & VALVES

Figure 9-1 Indicators ............................................................................................................................................................. 132
Figure 9-2 Check Valve ........................................................................................................................................................ 134
Figure 9-3 Pressure Maintaining Valves (PMV)................................................................................................................... 134
Figure 9-4 Safety Valves....................................................................................................................................................... 135

CHAPTER 10: - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

Figure 10-1 Lifting Devices .................................................................................................................................................... 139
Figure 10-2 Leveling Feet ....................................................................................................................................................... 140
Figure 10-3 Incoming Power Wiring Label ............................................................................................................................ 143
Figure 10-4 6 Bolt and 4 Bolt Torque Sequence..................................................................................................................... 151

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CHAPTER 1: INTRODUCTION
1.1 How To Use This Manual
This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-
ucts listed on the front cover.
All instructions in this manual should be observed and carried out as written to prevent damage or prema-
ture wear to the product or the equipment served by it.
If your unit is equipped with nonstandard accessories and or options, supplemental information is nor-
mally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.
While every effort is made to ensure the accuracy of the information contained in this manual, Bauer
Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the con-
sequences thereof.
1.1.1 Manual Safety Notices
Important instructions concerning the endangerment of personnel, technical safety or operator safety will
be specially emphasized in this manual by placing the information in the following types of safety
notices.

^ DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death 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.

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MNL-0420
1.2 How to Use the Replacement Parts List
• A lozenge  in the Item Number column indicates the part number for a complete assembly.
• a dagger (†) in the Qty column with or without an ellipse (…) in the Part Number column means the
part 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 spec-
ifies.
• A dash (—) in the Item Number column indicates that there is more than one part number applicable
to the preceding Item Number.
• 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
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 compressor
unit identification plate on the compressor unit frame.

Information Example
Model Number MVT 13
Serial Number 131365
Date of Manufacture 01/2012
Part Number VAL-0169
Part Description Valve
Part Quantity Required 1

Figure 1-1 Compressor Identification Label

BAUER COMPRESSORS, INC.

NORFOLK, VA 23502 U.S.A. (757) 855-6006

MODEL NO.
BLOCK NO.
SERIAL NO.
QUANTITY
MFG. DATE

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^ 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.

1.3 How to Use the Appendix

Information contained in the Appendix to this manual 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.
• Reproducible Forms
• Reference Data
• Torque Values
• Torque Sequence
• Conversion Formulas
• Approved Lubricants
• Glossary of Abbreviations & Acronyms
• Additional Documents

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MNL-0420
1.4 Description and Specifications
1.4.1 Unit Specifications
All specifications are subject to change without prior notice.
1.4.1.1 O 13
Medium air
Charging Rate 13 scfm (368 l/min)1
Free Air Delivery 10.8 scfm (306 l/min)2
Inlet pressure atmospheric
Operating pressure, max. 6,000 psig (420 bar)
Ambient temperature range 40 - 115 °F (5 - 45 °C)
with extreme temperature option added 40 - 140 °F (5 - 60 °C)
Weight approx. 1,200 lbs (540 kgs)
1.4.1.2 Compressor Block, IK12.14 II
No. of stages 4
No. of cylinders 3
Cylinder bore, 1st stage 4.1 in. (105 mm)
Cylinder bore, 2nd stage 3.46 - 4.1 in. (88 - 105 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 45 - 60 psig (3 - 4 bar)
Safety valve setting, 1st stage 75 psig (5 bar)
Intermediate pressure, 2nd stage 230 - 255 psig (16 - 17.5 bar)
Safety valve setting, 2nd stage 350 psig (24 bar)
Intermediate pressure, 3rd stage 985 - 1,130 psig (68 - 78 bar)
Safety valve setting, 3rd stage 1,380 psig (95 bar)
Direction of rotation when facing flywheel CCW
Compressor speed 1,180 RPM
Oil capacity 3 qts (2.8 liters)
Oil Pressure 60 - 85 psig (4 - 6 bar)
Recommended oil (Synthetic) BAUER OIL-0024
Maximum Inclination 15° in all directions
1.4.1.3 Compressor Drive

Model Voltage Frequency Phase Power RPM Type Bauer P/N

-E3 208 - 460 VAC 60 Hz 3 10 Hp 3,600 TEFC MTR-0143

1.4.1.4 Purification System Applicability

The Bauer P2S Purification System with the Securus II® Electronic Moisture Monitoring System®is the
standard purification system supplied.

1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG

2. Referenced to standard inlet conditions of 68°F and 36% humidity at 14.70 psia.

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CHAPTER 2: OPERATING INSTRUCTIONS; MAPLE SYSTEM
2.1 Description
The following instructions apply to units that use the Maple System touchscreen operator interface,
MNR-0053 with program 31L.
Figure 2-1 MNR-0053

SECURUS

The Electrical Panel Assembly will provide logical control and safety shutdowns for the compressor
equipment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorpo-
rated into a proprietary software program permanently saved into PLC memory using EEPROM technol-
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 to
communicate with the PLC which is located in the electrical enclosure.

Figure 2-2 PLC & Battery

200 DAY
BATTERY

PLC

2.1.1 Emergency Stop Button

A Normally Closed switch when pulled out, when the E-Stop Button is pressed in, it disconnects the
main power source, turning off the compressor, draining the ACD system and stopping air delivery to

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MNL-0420
the consuming devices. This button is to be used in case of emergency. Normal operational stops should
be accomplished using the operator interface.
2.1.2 Operator Interface
The Operator Interface is a 4.3 inch, 256 color, 8 bit LCD with touchscreen operation. The Operator
Interface is the input/output device for normal operation of the compressor unit. The compressor system
is ready and able to operate after the Emergency Stop Switch is pulled out and the red “COM” status light
illuminates. The red status light will continuously strobe to show that the unit is ready.
2.1.2.1 Run Screen
The initial screen after startup allows control and monitoring of the compressor unit.
Figure 2-3 Maple System; Run Screen
4 5

(CO) MONITOR 6
SECURUS 7
1

8
2
9
3 10

1. Securus / Secant Status 6. Closes Window (goes to main menu)

2. Current Run Time 7. Current Time & Date
3. Next Maintenance Due Status 8. Final Pressure (from sensor)
4. Status Lights 9. Current Oil Pressure (from sensor)
5. ON & OFF Buttons 10. Inlet Pressure (if equipped with sensor)

1. If the unit is equipped with a CO monitor, the words (CO) monitor are shown here. Also if the unit
is equipped with a Securus or Seccant monitor, 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 check the status screen.
3. This reading tells when the next maintenance is due on the compressor.

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4. These lights show the status of electrical connections and communication. The red light strobes
continuously to show communication is established with the PLC. The green light indicates that the
PLC has power, and the yellow light indicates power is coming into the unit.
5. The ON and OFF buttons control the compressor. These buttons should be used for normal starting
and stopping of the compressor. In an emergency the Emergency Stop button should be used.
6. This X button closes the Run screen and goes to the main menu screen. The compressor may still be
operating when returning to the main menu screen.
7. The current time and date are shown here. This data can be corrected only by user levels 2 and 3.
8. The final pressure reading is displayed here. It is received from the final pressure sensor near the
outlet.
9. This oil pressure reading displays a continuous pressure from the compressor. This reading is taken
from the oil pressure 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 industrial gases.

2.1.2.2 Main Menu Screen

Figure 2-4 Maple System; Home Screen

2 6
3 7
8
4
5 9

1. User Level Status 4. Status Button 7. Configuration Button

2. Run Screen Button 5. Contact Information Button 8. Parameters Button
3. Alarm History Button 6. Login Button 9. Tools Button

The home screen is the main screen used to navigate to the other 8 options. All of the option screens can
be viewed but critical changes can only be made by user levels 2 & 3. Critical changes control the func-
tions of the compressor. This feature is added to prevent unintentional changes to the unit’s functions.

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MNL-0420
2.1.2.2.1 Run
This button returns the user to the RUN screen, See Paragraph 2.1.2.1 for further information.
2.1.2.2.2 Alarms History
This button displays the history of alarms. The date of the alarm history can be changed with the drop
down arrow or the forward and backward arrows adjacent to the date. To return to the Main Menu screen
touch the X in the upper right corner.
2.1.2.2.3 Status
The status button takes the user to the status screen. The status screen allows the user to view the Current
Run Time, Total Run Time, Minutes till next ACD cycle, current Separator Count, and the Current Final
Pressure.

Figure 2-5 Status Screen

1. Calendar / Hour Selection
2. ACD Test Button
3. Return Button
3 4. View Maint. Schedule
1
4 5. Light ON / OFF Button
25.01
15.0
514

2 5

The options on the Status screen are shown in Figure 2-5. The Selection button allows the operator to
select maintenance warnings by the calendar schedule or the hourly maintenance schedule. The ACD
Test button is used to perform an ACD test. Pressing this button opens the ACD valve and the operator
should be able to hear the ACD draining. The Return button takes the user back 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 equipped with lights.
This button toggles the light on and off.
2.1.2.2.4 Contact
Pressing the contact button displays contact information for maintenance and assistance for your unit. It
can only be edited by users 2 & 3.
2.1.2.2.5 Login
The login button takes the user to the login screen. The default option is User l, Operator. No password is
needed to operate the compressor at this user level. At this user level the operator can operate the unit and
explore all the other menu screens but cannot change parameters or configuration settings. User 2, Level
1, can operate the compressor and also is allowed to change some parameters and configuration settings.

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User 3, Factory Level, has total access to the unit and can change all parameters and configuration set-
tings.

Figure 2-6 Login Screens

To change the user level press the “USER” button, select the desired user, and press “OK”. Then press
the button below the words “Enter Password” and press the password numbers on the keypad. After
entering the proper password press “ENT” on the keypad to enter the password. If the password is incor-
rect an “Invalid Password” screen will pop up. The only option on the screen is to click “OK”. If the pass-
word is accepted the 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
this option. The first two pages consist of 8 features which a unit may have. The third page is used to set
the final pressure sensor limit. The fourth page is used to set the inlet pressure sensor limit. Similar to the
Parameter’s settings changing the Configuration settings will change how the unit operates so only users
2 & 3 are allowed to change them. Pressing the X button returns the user to the main menu screen.

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MNL-0420
2.1.2.2.7 Parameters
This button takes the user to the parameters screens. There are a total of 9 screens. These parameters are
set at the factory for each specific unit. Changing these parameters will change how the unit operates, so
only users 2 and 3 are allowed to change them. If user 1, Operator, tries to change a parameter a window
will pop up stating “Access Denied”. To change a parameter just touch the number which needs to be
changed and a keypad will pop up. Punch in the new number and press the “ENT” key.

Figure 2-7 Parameters Screen

Pressing the Pressure Units button toggles the run screen pressures between PSI and BAR.
Pressing the X button will return the screen to the main menu.
2.1.2.2.8 Tools
Like the Parameters and Configuration options only users 2 & 3 can make changes or use this 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 calendar/clock and to
select the language displayed on the monitor. English, Spanish, and Portuguese are the current choices.
More languages may be added at a later date. The third page offers activation of the Anybus (internet)
Server, to turn off or on the key beeping sound, or to clear the alarm history. The final button “START” is
used to save the current set parameters to the internal EEPROM. If this button is pressed the current set-
ting are saved to the memory and a status bar of the operation will be shown.

2.2 Starting and Stopping Unit

2.2.1 Before Starting.
1. Check the compressor oil level, See Chapter 3.
2. Ensure that all panels and guards are properly installed.
3. If the unit is equipped with doors, ensure all doors are closed.
4. Ensure that the E-Stop Button is pulled out.

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2.2.2 To Start Unit.
Press the green START Button on the Run Screen. (See Figure 2-3)
If the pressure in the system is lower than the set “Start Pressure”, the drive motor will start up powering
the compressor. If the system’s pressure is higher than the set “Start Pressure” or when 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 “Start Pressure”.

^ WARNING
Once started the compressor and drive motor will start and stop automatically.
Stay clear of all moving parts whenever unit has power.

2.2.3 To Stop Unit.

Press the red STOP Button on the Run screen..

NOTICE
In an emergency the compressor is shutdown by pressing
in the Emergency Stop Button.

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MNL-0420

Table 2-1: Calendar Maintenance Interval Tasks

Task Monthly Annually Every Two Years

Calibrate CO Monitor 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 all fasteners for tightness X
Change Synthetic Oil X
Replace Compressor Oil Filter X
Replace Compressor Valves X
Replace CO Monitor Sensor X

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Table 2-2: Operating Hours Maintenance Interval Tasks

250 500 1,000 2,000 3,000

Task
Hours Hours Hours Hours 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
Inspect Compressor Valves X
Change Synthetic Oil X
Replace Oil Filter X
Replace Compressor Valves X
Inspect Pistons and Pistons Rings X

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 MNL-0420

April 30, 2012

2.3 Screen Flow

Figure 2-8

RUN SCREEN MAIN MENU

On
Off
START UP
Operator Interface Screen Flow

RUN ALARMS STATUS CONTACT LOGIN CONFIGURATION PARAMETERS TOOLS

HISTORY

Return to Changable Current Contact Users Unit Setup Unit Settings Maint.
Run Screen Date Status Info 1, 2, & 3 9 pages Check
Above for Help PLC
Pressure
ACD Test Sensor Set Internal
Limits Clock
Light Set Language

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CHAPTER 3: IK 12.14 II COMPRESSOR BLOCK
3.1 Maintenance and Parts
The IK12.14 II compressor block is used to compress air up to 6,000 psi. This compressor is a four stage,
three cylinder air cooled, oil lubricated reciprocating compressor. The cylinders are arranged in a “W”
configuration, the 1st/2nd stage vertical stepped cylinder is in the center, 3rd stage on the right and 4th
stage on the left looking from the intake filter side. This compressor block is particularly suitable for con-
tinuous operation because of their rugged design and corrosion resistant intermediate filter and cooler
assemblies.
3.1.1 Component Location

Figure 3-1 IK12.14 II Compressor Block, Front View

1 11
2

3
4 12
13
5
14
6

15
7
16
8
17

9 18

10 19

1. Intake Filter 8. 3rd Stage Intercooler 15. Oil Filter Housing

2. 1st Stage Safety Valve 9. Oil Drain Plug 16. 2nd Stage Separator
3. 2nd Stage Intake Manifold 10. Condensate Drain Connector 17. 2nd Stage Intercooler
4. Oil Filler Neck 11. 1st Stage Valve Head 18. Compressed Air Outlet
5. 4th Stage Cylinder 12. 2nd Stage Pressure Manifold 19. 4th Stage Aftercooler
6. 3rd Stage Safety Valve 13. 3rd Stage Cylinder
7. 3rd Stage Separator 14. 2nd Stage Safety Valve

3.1.2 Air Flow Diagram

Refer to Figure 3-2. The air is drawn in through intake filter (1), compressed to the final pressure in cylin-
ders (2, 3, 4, and 5) and cooled by intercoolers (6, 7 and 8) and aftercooler (9). The safety valves (13, 14,
15 and 16) protect from overpressure in the individual stages. The compressed air is filtered by intermedi-

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MNL-0420
ate separator (10 and 11) and oil and water separator assembly (12). The intermediate separator (10 and
11) and oil and water separator (12) are drained by condensate valves (18). The pressure maintaining
valve (17) keeps the pressure constant within the separators (10, 11 and 12).

Figure 3-2 Air Flow Diagram

13

8 6 7 9

15 5 14
1 16
11 10
17
2
12
4 3

18 18 18

1. 1st Stage Cylinder 10. Intermediate Separator after 2nd Stage

2. 2nd Stage Cylinder 11. Intermediate Separator after 3rd Stage
3. 3rd Stage Cylinder 12. Oil and Water Separator
4. 4th Stage Cylinder 13. 1st Stage Safety Valve
5. Air Filter 14. 2nd Stage Safety Valve
6. 1st Stage Intercooler 15. 3rd Stage Safety Valve
7. 2nd Stage Intercooler 16. 4th Stage Safety Valve (Final Pressure)
8. 3rd Stage Intercooler 17. Pressure Maintaining Valve
9. 4th Stage Aftercooler 18. Manual Condensate Drain Valves

3.1.3 Lubrication System

Refer to Figure 3-3. The compressor is provided with forced-feed lubrication. The oil pressure is pro-
duced by a low speed gear pump. The oil pressure is approximately 73 psi.
The oil pump (1) is coupled to and driven by the crankshaft. It pumps oil through the oil filter (2) and a
minimum pressure valve (3) to the 4th stage cylinder. The oil is then distributed by the guide piston (4) of
the 4th stage and lubricates all the moving parts of the compressor block.
The minimum pressure valve allows for oil pressure indication at a pressure gauge and/or electronic oil
pressure monitoring.

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Figure 3-3 Lube Oil Circuit

5 5

1. Oil Pump 4. Guide Piston

2. Oil Filter 5. Oil Sight Glass
3. Minimum Pressure Valve
3.1.3.1 Type of Oil
For proper care and maintenance of the compressor, using the correct oil is of vital importance. Due to the
thermal load on the compressor only high quality oil should be used. You are recommended to restrict
oils to those which have been approved by Bauer Compressors, Inc. and are listed in Unit Specifications
found in the paragraph titled Compressor Specifications in Chapter 1.
3.1.3.2 Oil Level Check
Check the oil level at the sight gauge on either side of the compressor block (See Figure 3-4) every day
before putting the compressor into operation. Oil level must be between the minimum and maximum
marks. Oil level must never be below the minimum mark as this will cause severe damage due to lack of
lubrication. Oil level must also not exceed the maximum mark as this will cause excessive lubrication of
the compressor and may result in a carbon buildup on the valves.

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MNL-0420

Figure 3-4 Oil Sight Glass Figure 3-5 Oil Filler

Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter

3.1.3.3 Oil Change

See the Maintenance Schedule for the recommended interval.
1. Run the compressor until it is warm then shut it down.
2. (See Figure 3-5). Remove the cap from the oil filler neck.
3. Drain oil while it is still warm by means of the oil drain plug.

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^ 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.

Figure 3-8 Intake Filter

3 2
1
1. Knurled Nut 3. Filter Housing
2. Washer 4. Filter Element

1. Unscrew and remove Knurled Nut (1)

2. Remove Washer (2) and Filter Housing (3).

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MNL-0420
3. Discard Filter Element (4) and replace with new Filter Element Bauer.
4. Reassemble in reverse order.
3.1.5 Intermediate Separators
Intermediate separators are mounted on the compressor between the 2nd and 3rd stage and between the
3rd and 4th stages. These separators are designed to remove oil and water which accumulates due to the
cooling of the medium after the compression process. Separation is achieved by means of centrifugal
action.

Figure 3-9 Intermediate Separators

8 4

5
2

1. Vortex Plate 4. O-ring 7. Fitting

2. Hollow Screw 5. Knurled Nut 8. Safety Valve
3. Center Insert 6. Gasket

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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 3-10).

Figure 3-10 Valve Operation

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.

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MNL-0420
The intake and pressure valve of the 1st stage are in a combined plate valve under the valve head. (See
Figure 3-11).

Figure 3-11 1st Stage Valve Operation

TOP VIEW
Intake Side

Pressure Side

3.1.7.2 General Instructions for Changing the Valves

• Always replace valves as a complete set.
• Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and
clean with a soft brush.
• Check the individual components for excessive wear. If the valve seat or valve discs are dented,
replace the valves.
• Check the valve space in the valve heads for dirt, and clean if necessary.
• 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 flywheel
and check whether all items have been correctly installed.
• 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and
retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.
• Remove and check the valves every 1,000 operating hours, unless otherwise specified.
• Replace the valves every 2,000 operating hours to avoid fatigue failure, unless otherwise specified.
3.1.7.3 Changing the IK12.14 II 1st Stage Valves
3.1.7.3.1 Removal
See Figure 3-12 and proceed as follows:
1. Remove all tubing connections and lines from the Valve Head (2).
2. Remove Hex Head Bolts (4) and Washers (3)
3. Remove the Plate Valve (1).
4. Clean Plate Valve, preferably in a ultrasonic cleaner, and check for damage.
5. Replace worn or damaged parts.

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6. Check the underside of the Valve Head for flatness using a precision straightedge. If necessary use
an emery cloth to smooth out the surface.

Figure 3-12 1st Stage Valve Head and Valves

4 5

3 3

6 2

1. Plate Valve 4. Plate Valve Bolt

2. Valve Head 5. Hex Head Bolts
3. Washer 6. O-ring

3.1.7.3.2 Reassembly
See Figure 3-12.
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).

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3.1.7.4 Changing the 2nd Stage Valves

Figure 3-13 2nd Stage Valves

2
3
2
2
4
2
1

1. Manifold 4. Pressure Valve

2. Gasket 5. Allen Screw
3. Intake Valve

See Figure 3-13 and proceed as follows:

1. Remove the lines from the intake and pressure manifolds (1).
2. Remove the Allen Screws (5).
3. Remove gaskets (2) and replace with new ones.
4. Clean intake valve (3) and pressure valve(4) and check for wear or damage.
5. Reassemble in reverse order of above.

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Figure 3-14 3rd Stage Valve Head and Valves

1
8

7
4

6
5

1. Cap Nut 5. Pressure Valve

2. Stud 6. Intake Valve
3. Pressure Plug 7. Valve Head
4. O-ring 8. Allen Screw

3.1.7.5 Changing the 3rd Stage Valves

3.1.7.5.1 Removal
See Figure 3-14 and proceed as follows:
1. Remove the intake and pressure lines from the valve head (7).
2. Remove the Allen Screws (8) holding the valve head onto the cylinder.
3. Replace two of the screws with two 8 mm diameter metal pins of any length.
4. Use these pins as a holding fixture by securing them in a vise with the valve head on top.
5. Using the special valve tool, remove the intake valve (6) (See Figure 3-15).
6. Turn the valve head over and replace it on the metal pins.
7. Remove the cap nut (1) and unscrew the stud (2) approximately five turns.
8. Remove the pressure plug (3) and take out the valve parts.
9. Clean the intake and pressure valves and check for wear and damage
10. Clean the valve head. check that the intake and pressure valve bores are in perfect condition.
11. Using a precision straightedge, check that the underside of the valve head is flat. If necessary use an
emery cloth to smooth out the surface.

Page 25 1st Edition, Rev. 1 Chg. 1

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Figure 3-15 Using the Special Valve Tool Figure 3-16 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 3-16).
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.

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Figure 3-17 4th Stage Valve Head and Valves

10

8
7

5
4 1

1. Intake Valve 6. Stud

2. Valve Head 7. Gasket
3. O-ring 8. Cap Nut
4. Pressure Valve 9. Gasket
5. Valve Head Cover 10. Bolt

3.1.7.6 Changing the 4th Stage Valves

3.1.7.6.1 Removal
See Figure 3-17 and proceed as follows:
1. Remove the intake and pressure lines from the valve head (2).
2. Remove the cap nut (8) and loosen stud (6) three or four turns.
3. Remove the bolts (9) holding the valve head onto the cylinder and take off valve head cover (5).
4. Remove the pressure valve by putting two screwdrivers into the removal groove of the pressure
valve body. See Figure 3-18. It may be necessary to loosen the valve body first by turning it with a
13 mm wrench used on the flat surfaces.
5. Insert two 8 mm diameter metal pins, any length, in the holes in the valve head and secure them in a
vise with the valve head on top of the vise. The intake valve should be facing up.
6. Using the special valve tool (See Figure 3-15), remove the intake valve (1).

Page 27 1st Edition, Rev. 1 Chg. 1

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Figure 3-18 Removing the 4th Stage Pressure Valve

3.1.7.6.2 Reassembly
1. Replace the intake valve (1) 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. 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).

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3.1.8 Replacement Parts List

Figure 3-19 Crankcase Assembly

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

# KIT Qty Part No. Description Notes

 1 076743 Crankcase assembly
1 … 1 076740 Crankcase
2 … 1 083466 Crankshaft, complete
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-ring
11 … 1 61054 Plug
12 a.. 1 N15412 O-ring
13 … 1 73830 Oil Filling Pipe

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MNL-0420
Figure 3-19 (cont.) Crankcase Assembly

# KIT Qty Part No. Description Notes

14 … 1 N4776 O-ring
15 … 2 SCR-0020 Allen Screw
16 … 8 WAS-0021 Washer
17 … 2 N4261 Gasket
18 … 2 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 NUT-0076 Hex Nut
25 … 4 WAS-0031 Washer
26 … 4 N350 Hex Head Screw
27 … 6 SCR-0113 Hex Head Screw
28 … 3 N19487 Countersunk Screw
29 … 1 N2375 Coupling
30 … 1 N25638 Ball Valve oil drain valve

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Figure 3-20 1st/2nd Stage Piston and Cylinder

11
10

1
2
9
3
4

5
8
6
5
7

# KIT Qty Part No. Description Notes

 1 84240 1st/2nd Stage Cylinder Assembly
1 … 1 80729 Stepped Cylinder
2 ..c 1 N4654 O-ring
 1 84238 Piston Assembly Item 3 - 8
3 … 1 N28554 Guide Ring
4 … 1 N25842 Piston Ring Set, 1st Stage
5 … 2 N484 Circlip
6 … 1 84212 Stepped Piston
7 … 1 N25396 Piston Ring Set, 2nd Stage
8 … 1 N1216 Piston Pin
9 … 4 N215 Stud
10 … 4 WAS-0021 Washer
11 ..c 4 NUT-0119 Self Locking Hex Nut

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Figure 3-21 3rd Stage Piston and Cylinder

3 11
10

6
7

8
7

# KIT Qty Part No. Description Notes

 1 78335 3rd Stage Cylinder Assembly
1 … 1 67940 Cylinder
2 ..c 1 N7063 O-ring
3 … 1 83404 Guide Cylinder
4 ..c 1 N2640 O-ring
 1 78334 Piston Assembly Items 5 - 8
5 … 1 N19833 Piston Ring Set
6 … 1 67942 Piston
7 … 2 N484 Circlip
8 … † — Piston Pin Available only with 78334
9 … 4 N2790 Stud
10 … 4 WAS-0021 Washer
11 ..c 4 N370 Self Locking Hex Nut

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Figure 3-22 4th Stage Piston and Cylinder

1
2

3
4

5
16 15
6
7

14 8

9
7

12
13 11

10

# KIT Qty Part No. Description Notes

 1 083457 4th Stage Cylinder Assembly
1 a.. 1 N4868 O-ring
2 … 1 082480 Cylinder
3 … 1 N27318 Screw
4 ..c 1 N7063 O-ring
5 … 1 083404 Guide Cylinder
6 ..c 1 N2640 O-ring
 1 072165 Guide Piston Assembly Items 7 - 9
7 … 2 N484 Circlip
8 … 1 N858 Guide Piston
9 … 1 N1429 Piston Pin
10 … 4 N2790 Stud
 1 078045 Piston and Sleeve Assembly Items 11 - 14
11 … † — Piston Sleeve Available only with 078045
12 … † — Piston Pin Available only with 078045
13 … 1 N23810 Piston Ring Set
14 a.. 1 N23755 O-ring
15 ..c 4 NUT-0119 Self Locking Hex Nut
16 … 4 WAS-0021 Washer

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Figure 3-23 1st Stage Valve Head and Valve

4 5

3 3

6 2

# KIT Qty Part No. Description Notes

 1 083652 1st Stage Valve Head Assembly
1 … 1 N26531 Plate Valve
2 … 1 080677 Valve Head
3 … 7 N102 Washer
4 … 1 N26646 Hex Head Screw
5 … 6 N26568 Hex Head Screw
6 a.. 1 N1539 O-ring

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Figure 3-24 2nd Stage Valves and Valve Head

2
3
2
2
4
2
1

# KIT Qty Part No. Description Notes

 1 073435 Valve Head, 2nd Stage
1 … 2 78562 Manifold
2 a.. 4 56668 Gasket
3 .b. 1 N4067 Intake Valve
4 .b. 1 N4068 Pressure Valve
5 … 8 SCR-0133 Allen Screw

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4
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Figure 3-25 3rd Stage Valves and Valve Head

15
14

13

16
12

11
4 1
10
9

8 2
7
3
5
6
2

# KIT Qty Part No. Description Notes

 1 069792 3rd Stage Valve Head Assembly
1 … 1 14123 Valve Head
2 a.. 2 240 Gasket
3 .b. 1 012836 Intake Valve
4 … 1 014582 Pressure Valve Assembly Items 5, & 10 - 15
5 .b. 1 012835 Pressure Valve Insert Items 2 & 6 - 9
6 … † — Valve Seat Available only with 012835
7 … † — Valve Plate Available only with 012835
8 … 1 1026 Spring
9 … † — Valve Insert Available only with 012835
10 a.. 1 N3521 O-ring
11 … 1 14332 Spring Washer
12 … 1 14124 Coupling
13 .b. 1 71064 Stud
14 a.. 1 N3625 Gasket

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MNL-0420
Figure 3-25 (cont.) 3rd Stage Valves and Valve Head

# KIT Qty Part No. Description Notes

15 … 1 N84 Cap Nut
16 … 6 SCR-0180 Allen Screw

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Figure 3-26 4th Stage Valves and Valve Head

10

8
7

5
4 1

# KIT Qty Part No. Description Notes

 1 082096 4th Stage Valve Head Assembly
1 .b. 1 81409 Intake Valve
2 … 1 82087 Valve Head
3 a.. 1 N2789 O-ring
4 .b. 1 014121 Pressure Valve Includes Item 3
5 … 1 82086 Valve Head Cover
6 a.. 1 N124608 Stud
7 a.. 1 N3625 Gasket
8 … 1 88609 Cap Nut
9 … 6 N17730 Hex Head Cap Screw
10 … 6 N58 Gasket

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MNL-0420

Figure 3-27 Flywheel

8
7

5
4 3
2

# KIT Qty Part No. Description Notes

 1 082552 Flywheel Assembly
1 … 1 N1386 Feather Key
2 … 1 082553 Fanwheel Hub
3 … 1 080975 Washer
4 … 1 N176 Spring Washer
5 … 4 N26666 Screw
6 … 1 082496 Fanwheel
7 … 4 N108 Spring Washer
8 … 4 N19548 Screw

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Figure 3-28 Intermediate Separator, 2nd Stage

1 5

# KIT Qty Part No. Description Notes

 1 080690 Intermediate Separator Assembly Items 1 - 7
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 081810 Safety Valve, 2nd Stage 24 bar

Page 41 1st Edition, Rev. 1 Chg. 1

MNL-0420

Figure 3-29 Intermediate Separator, 3rd Stage

1 5

# KIT Qty Part No. Description Notes

 1 081799 Intermediate Separator Assembly Items 1 - 7
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 122787 Safety Valve, 3rd Stage 100 bar

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Figure 3-30 Intake Filter

3
2
1

# KIT Qty Part No. Description Notes

 1 79577 Intake Filter Assembly
1 … 1 N4870 Knurled Nut
2 … 1 N3313 Washer
3 … 1 79574 Filter Housing, Front
4 a.. 1 N25950 Filter Element
5 … 1 79575 Filter Housing, Back
6 … 1 N19502 Hex Head Bolt
7 … 1 N3374 Clamp

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6 5 7

10
3
4
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Figure 3-31 Cooling System

3
2 4
12
35 24
1 29 11
10 36 11
9 11 24
11 39 40
8 11 3411 30
12 33 28
11
37
13 28 11 34 11 12
5 6 14 30 24
29 11
15 11
11 30
7 38
16 12
11
24 11
17 32 28
18 29
31
19 11
20 30
18
28
11 29
24
22 25
27
21 23 26

# KIT Qty Part No. Description Notes

 1 81294 Cooling System Assembly
1 … 3 N370 Hex Nut Self-Locking
2 … 3 N58 Washer
3 … 1 078200 Fan Guard
4 … 1 081303 1st - 2nd Stage Intercooler
5 … 3 011887 Double Strap Bracket
6 … 3 078199 Stud
7 … 1 078584 Connecting Tube
8 … 1 N20202 Straight Male Reducer
9 … 1 N293 Gasket
10 … 1 N20231 Straight Male Connector
11 … 18 N1316 Gasket
12 … 4 N26751 Connector, Banjo Fitting
13 … 1 071148 Straight Male Connector
14 … 1 056983 Gasket
15 … 1 N20208 Straight Male Connector
16 … 1 078301 Aftercooler
17 … 4 N03313 Washer

Page 45 1st Edition, Rev. 1 Chg. 1

MNL-0420
Figure 3-31 (cont.) Cooling System, IK12.14 II

# KIT Qty Part No. Description Notes

18 … 12 N1042 Hex Nut, Self-Locking
19 … 4 N23498 Hexagon Screw
20 … 16 062773 Tube Clamp
21 … 16 N03494 Stud
22 … 8 WAS-0024 Washer
23 … 1 078195 3rd - 4th Stage Intercooler
24 … 5 N20059 Straight Male Connector
25 … 4 077894 Clamp
26 … 4 N19506 Hexagon Screw
27 … 4 N02460 Washer
28 … 4 N20195 Straight Male Connector
29 … 4 N3610 Screw Cap
30 … 4 N04530 Plug
31 … 1 122787 Safety Valve, 3rd Stage 100 bar, includes gasket
32 … 1 078352 Connecting Tube
33 … 1 081306 Connecting Tube
34 … 2 N20014 Male Connector
35 … 1 81801 Safety Valve, 1st Stage 5 bar, includes gasket
36 … 1 N20201 Straight Male Connector
37 … 1 N00052 Plug
38 … 1 81810 Safety Valve, 2nd Stage 24 bar, includes gasket
39 … 1 078300 Connecting Tube
40 … 1 80696 Inter Cooler Assembly

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Figure 3-32 Lubrication System

1
11

12
2

3
4

19 10
15
14
9
6

13
14
18

17 14
15
8
14 7 16
15

# KIT Qty Part No. Description Notes

 1 83417 Lubrication System Assembly
 1 081075 Lubricating System Items 1 - 15
1 … 1 77885 Oil Filter Cover
2 … 1 N04058 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

Page 47 1st Edition, Rev. 1 Chg. 1

MNL-0420
Figure 3-32 (cont.) Lubrication System

# KIT Qty Part No. Description Notes

9 … 1 N24585 Gear Pump
10 … 2 N3489 O-ring
11 … 2 N19506 Hex Head Screw
12 … 2 N58 Washer
13 … 1 81050 Regulating Valve
14 … 4 N1316 Gasket
15 … 3 N52 Plug
16 … 4 N19551 Allen Screw
17 … 1 83420 Connecting Tube Assembly
18 … 1 N20237 Male Connector
19 … 1 78421 Gasket

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3.1.9 Troubleshooting
Preventive maintenance usually involves replacing the valves, gaskets, and sealing rings.
3.1.9.1 Troubleshooting Table

Trouble Cause Remedy

No oil pressure 1. Low oil level 1. Check oil level.

1. Last stage piston worn 1. Operate compressor with

2. Last stage pressure valve final stage valve head
Oil foam in crankcase defective removed. If oil flows con-
tinuously out of cylinder,
replace piston and sleeve.
2. Replace last stage valves.

1. Condensate drain valves or 1. Tighten and reseal.

fittings leaking. 2. Replace.
2. Premature opening of final 3. Replace.
Compressor output insufficient safety valve. 4. Replace.
3. Piston rings worn 5. Tighten.
4. Excessive piston clearance
5. Pipes leaking

1. Intermediate pressure too 1. Service and clean valves.

Safety valves between stages high 2. Service and clean valves.
releasing pressure 2. Valves not closing properly

1. Insufficient supply of cool- 1. Check location for adequate

ing air ventilation
Compressor running too hot. 2. Intake or outlet valve not 2. Check and clean valves,
closing properly replace as necessary
3. Wrong direction of rotation. 3. Check arrow on compressor
and correct accordingly.

1. Improper maintenance of 1. Service filters, change puri-

filters, purifier cartridge fier cartridge.
Oil residue in delivered air saturated. 2. Change to proper oil and
2. Wrong oil type clean valves.

1. Electrical phases not con- 1. Reverse two of the three

Compressor rotates in wrong nected properly phase leads at the switch
direction box. Do NOT change the
leads at the motor terminal.

Page 49 1st Edition, Rev. 1 Chg. 1

MNL-0420
3.1.9.2 Repair Instructions
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 should be carried out on the crank-
shaft nor on the bearings. Also safety valves are not repaired but always replaced.

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3.2 Four Stage Automatic Condensate Drain System
3.2.1 Description
The automatic condensate drain system operates electro-pneumatically and is comprised of the follow-
ing:
A condensate manifold Two pneumatically operated condensate drain valves
An electrically controlled solenoid valve A condensate separator/silencer
A condensate collector bottle Electronically controlled by the PLC
The automatic condensate drain system drains 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 3-33 4 Stage Automatic Condensate Drain System

1
8

2
3
7
4

5 6
1. Solenoid valve 6. Oil and water separator condensate connection
2. Condensate drain valve 7. Manual condensate drain valve
3. 2nd Stage intermediate separator condensate 8. Drain manifold
4. Condensate collection tank 9. Control air connection
5. 3rd Stage intermediate separator condensate

Page 51 1st Edition, Rev. 1 Chg. 1

MNL-0420

Figure 3-34 ACD Operation Diagrams

2 3 6
2 3 6
4 5 4
1 1 5

Control Pressure
Control Pressure Condensate
Condensate
Normal Operation Condensate Draining

1. Solenoid Valve 4. 3rd Stage Condensate Drain Valve

2. 2nd Stage Intermediate Separator 5. Oil and Water Separator Condensate Drain Valve
3. 3rd Stage Intermediate Separator 6. Oil and Water Separator

3.2.1.1 Compressor Operating

The normally open solenoid valve (1) controls the condensate draining of the 2nd stage intermediate sep-
arator (2). The normally open 3rd stage condensate drain valve (4) controls the condensate draining of the
3rd stage intermediate separator (3). The normally open oil and water separator condensate drain valve
(5) controls the condensate draining of the oil and water separator (6). The control air for the 3rd stage
condensate drain valve (4) is taken from the 2nd stage intermediate separator (2). The control air for the
oil and water separator condensate drain valve (5) comes from the 3rd stage intermediate separator (3).
As the compressor is started, the solenoid valve (1) is electrically energized and closes. This allows the
pressure to buildup in the intermediate separators (2 and 3). This pressure buildup results in control air
closing both condensate drain valves (4 & 5).
3.2.1.2 Condensate Draining
Every 15 minutes the Timer de-energizes the solenoid valve (1) for approximately 6 seconds. The sole-
noid 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 unloaded and the remaining control air is vented through a relief port.
Then the piston of the drain valve is fully raised by pressure from the 3rd stage separator, and the conden-
sate is drained. This in turn causes a pressure loss in the 3rd stage intermediate separator (3) and the con-
trol air for the oil condensate drain valve (5) is removed and the oil and water separator condensate drain
valve opens and drains the oil and water separator (6).

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3.2.1.3 Start Unloading
The unloading of the compressor during the starting phase is possible because of the lack of control air
immediately after starting the unit. As the unit is switched on the solenoid valve (1) is energized and
closes. After the compressor has attained nominal speed, pressure builds in the intermediate separators (2
and 3) and the control air closes the condensate drain valves (4 and 5). Once these valves close, the com-
pressor delivers to the consuming device.
3.2.1.4 Standstill Drainage
At compressor shutdown, the solenoid valve (1) is de-energized and opens. This drains the condensate
and relieves the pressure in the 2nd stage intermediate separator (2). This action in turn removes the con-
trol air form the condensate drain valves (4 & 5) which open and drain and relieves the pressure in the 3rd
stage intermediate separator (3) and oil and water separator (6).
3.2.1.5 Condensate Drain Piping
The outlet opening of the condensate 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 Condensate Drain Separator
The condensate drainage is a mixture of oil, water and air. The Condensate Drain Separator is utilized to
separate the oil and water from the air. The oil and water is then piped to the Condensate Collector Bottle
where the oil and water mixture is stored until it can be disposed of properly.
3.2.2 ACD Maintenance
The condensate drain valves are provided with manual drain valves to verify correct operation 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.
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 emerges, the automatic system is operating properly.
6. The condensate collection bottle should be emptied regularly. Due care must be taken to ensure that
any oil which is drained with the condensate is disposed of properly. Check local, state and federal
regulations.

Page 53 1st Edition, Rev. 1 Chg. 1

MNL-0420

3.2.3 Replacement Parts List

Figure 3-35 4 Stage ACD System

4
3

2
5
6

Item Qty Part No. Description Notes

 1 063761 Automatic Condensate Drain System
1 1 MFD-0035 Manifold
2 1 N16381 Solenoid Valve 12 VDC
— 1 N16382 Solenoid Valve 115 VAC
3 1 064009 Condensate Drain Valve
4 1 064008 Condensate Drain Valve
5 1 N1028 Gasket
6 1 RED-0058 Reducer

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Figure 3-36 ACD Manifold and Valves

13

7
6
3 9
8

11
2
10 4 5 1 12

Item Qty Part No. Description Notes

1 1 064009 Condensate Drain Valve
2 1 064008 Condensate Drain Valve
3 1 MFD-0035 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 … Connecting Tube
11 1 ELL-0027 Male Elbow
12 4 SCR-0133 Allen Screw

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10
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Figure 3-37 3rd Stage Condensate Drain Valve

1
15

4
5

7
8
9

15 10
11

14 12
13

Item Qty Part No. 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

Page 57 1st Edition, Rev. 1 Chg. 1

MNL-0420
Figure 3-37 (cont.) 3rd Stage Condensate Drain 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 065500

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Figure 3-38 Oil and Water Separator Condensate Drain Valve

1
16
2

5
6

8
9
10

11
12

16
15
13 14

Item Qty Part No. Description 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
7 1 064001 Valve Body

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MNL-0420
Figure 3-38 (cont.) Oil and Water Separator Condensate Drain Valve Parts List

Item Qty Part No. Description Notes

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
N.S. 1 067458 Tool Set for 064008

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3.2.4 Trouble shooting

Trouble Cause Remedy

1. Solenoid valve receives no 1. Check connections, Timer.

electrical signal Replace if necessary.
Solenoid Valve does not drain.
2. Plunger of drain valve 2. Clean or replace valve.
sticking

1. Solenoid valve does not 1. Check solenoid valve,

depressurize drain valve. replace if necessary
2. No control medium avail- 2. Check supply lines
Condensate Drain Valve does not
able. 3. Clean or replace
drain.
3. Solenoid valve sticking. 4. Clean or replace
4. Drain valve sticking in open
position

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CHAPTER 4: PURIFICATION SYSTEM
4.1 Introduction
The purpose of all Bauer breathing air purification systems is to remove carbon monoxide, oil, water,
taste and odor from the compressed air stream before final delivery.
The purpose of all Bauer industrial air purification systems is to remove oil and water from the com-
pressed air stream before final delivery.

^ WARNING
Industrial Air Purification System cartridges do not remove Carbon Monoxide
and must not be used in breathing air applications.

4.1.1 General Purification System Procedures

1. Keep an 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. 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.
4.1.2 Chamber Safety Bore
The chambers in all Bauer purification systems are designed to prevent pressurization if the cartridge is
missing, not seated properly or damaged (See Figure 4-1 & See Figure 4-2). Without a cartridge properly
in place the safety bore is not sealed, the air escapes into the atmosphere, no pressure can be built up and
thus it is ensured that unfiltered air is not supplied to the consuming device. If air is escaping from the
safety bore remove and check cartridge. If necessary replace the cartridge or O-rings.

Figure 4-1 Cartridge Safety Venting Figure 4-2 P0 & P31 Safety Venting

Safety Safety
Vent Vent

Safety Safety
Vent Vent

Cartridge Installed No Cartridge Installed

correctly or Installed incorrectly Cartridge Installed No Cartridge or Installed
Correctly Incorrectly

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4.1.3 Manual Condensate Drainage
The condensate must be drained from the oil and water separator before changing any cartridge, before
beginning each filling procedure and in the absence of an Automatic Condensate Drain (ACD) system,
every fifteen minutes during the filling procedure. This is done by slowly opening the condensate drain
valves. They are opened approximately 1/3 of a turn to the left and held open until the condensate is com-
pletely drained. The condensate drain valves close by spring pressure but if necessary may be tightened
by hand to ensure they are completely air tight.
4.1.4 Model, 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 electrical enclosure and frame.

Figure 4-3 Purification System Dataplates (typical)

Purification System Cartridge Installation

PURIFICATION
CARTRIDGE TO BE
SYSTEM
INSTALLED
MODEL NO.

MAX. PRESSURE psig CARTRIDGE FOR

AIR PROCESSED cu. ft. CARTRIDGE NO.
O-RING 1328 Azalea Garden Road - Norfolk Virginia 23502-1944
BACK-UP RING Phone: (757) 855-6006 Fax: (757) 855-8224
LBL- LBL-

4.1.4.2 Purification System Dataplate

Refer to the compressor unit purification system data plate (See Figure 4-3) on the compressor front to
determine your purification system model and specifications.
4.1.4.3 Cartridge Installation Dataplate
The function performed by each chamber in the purification system is determined by the type of cartridge
installed in that chamber. Refer to the cartridge installation data plate on the chamber to determine the
purpose and part number of the cartridge installed in that chamber. (See Figure 4-3).

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4.1.5 Breathing Air Purification System Configurations

Purification System Number and Type of Cartridges Processing Capacity

Dryer Purification Securus® cubic ft (ft)3
P0 Combined 3,200
P1 … 1 … 15,000
P2 … 1 … 40,000
P2 with Securus® … … 1 67,000
P4 1 1 … 60,000
P5 1 1 … 90,000
P5 with Securus® 1 … 1 150,000
P10 2 1 140,000
P10 with Securus® 2 … 1 230,000

P12a 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
P81 1 1 124,000
P81 with Securus® 1 ... 1 198,000
a. P12 and P14 have the Securus® Electronic Moisture Monitor System as standard equipment.

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4.1.6 Industrial Purification System Configurations

Purification System Number and Type of Cartridges Processing Capacity

Dryer Purification Securus® cubic ft (ft)3
P0 Combined 3,200
P1 … 1 … 15,000
P2 … 1 … 40,000
IP2 with Securus® … … 1 67,000
P4 1 1 … 60,000
P5 1 1 … 90,000
IP5 with Securus® 1 … 1 150,000
P10 2 1 140,000
IP10 with Securus® 2 … 1 230,000
P31 Combined 11,760
IP41 with Securus® … … 1 47,000
IP42 with Securus® 1 … 1 107,000
IP43 with Securus® 2 … 1 164,000

4.1.7 Cartridge Operating Life

Every Bauer Purification System is designed to process a certain volume of air before the cartridges
require replacement. By using special test equipment that measures the quality of air at the outlet any
quality reduction may be detected. However as most compressor owners do not have 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 hours before the cartridges need to be replaced. See Paragraph 4.1.7.1 for the method of
determining this figure.
The ambient air temperature 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 measure the temperature is at the inlet to the final separator as this best reflects the
temperature of the air as it enters the chambers. Experience has shown that this temperature is approxi-
mately 18 °F above the ambient temperature. Therefore for the purpose of calculating cartridge operating
life use the Ambient Air Temperature plus 18 °F.
A form titled Air Purification Cartridge Operating Hours is found in Paragraph 4.1.7.3 and in the
Appendices. It is used for recording the ambient temperature, operating time and adjustment factor. It

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is suggested that it be copied, placed in a protective folder and kept with the unit to record the adjusted
operating hours. An example of how this form is used is shown in Figure 1-5.
4.1.7.1 Calculating the Maximum Cartridge Operating Hours
1. From the purification system data plate (See Figure 4-3) on the purification chamber determine the
Air Processed (cu.ft.)
2. From the paragraph titled Compressor Specifications in the instruction manual for your compressor
unit determine the Charging Rate in SCFM of your compressor.
3. Divide the Air Processed by the Charging Rate to obtain the Maximum Operating Time in minutes
4. Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours.
5. Record the answer on the Air Purification Cartridge Operating Hours form.

4.1.7.2 Calculating the Adjusted Cartridge Operating Hours

1. Using the Air Purification Cartridge Operating Hours form (FORM-0018) record the Date, Operat-
ing Hours and Ambient Air Temperature plus 18 °F.
2. Using either the graph or the chart in Figure 1-4 determine the Correction Factor.
3. Divide the Operating Hours by the Correction Factor and record it under the column labeled Today.
4. Add the hours recorded in Today to the previous Total and record it as the current Total.
5. When the Total approaches the Maximum Operating Hours replace the Cartridges.

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Figure 4-4 Correction Factor for Cartridge Operating Hours

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

Figure 4-5 Example Record of Adjusted Operating Hours

Operating Ambient Temp. Correction Adjusted Cartridge Hours

Date
Hours during Compression Factor Today Total
Op hrs
10/19/04 8 92°F (33 °C) 0.48 16.67 Corr. factor 16.66

11/01/04 4 45°F (7.2 °C) 2.25 1.78 Total hrs 18.44

+Today hrs

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MNL-0420

4.1.7.3 Air Purification Cartridge Operating Hours Form

Operating Ambient temp. Correction Adjusted cartridge hours

Date
hours during compression factor Today Total

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4.2 P2 Purification System Major Components
The P2 Purification System major components are a Oil and Water Separator, and a Purification Cham-
ber. Figure 4-6 shows the functional interconnection of all the components.
4.2.1 Configuration Options
Some Bauer Compressors have the P2 Purification System as an option rather than a standard item, there-
fore, this chapter may not apply to your unit.
The P2 Purification System is also available with the Securus II® Electronic Moisture Monitor System as
a factory installed upgrade. This option replaces the standard purification chamber with a Securus® Purifi-
cation Chamber. A Securus II® Transmitter and associated wiring are also added. If this option was not
purchased, portions of this chapter about the Securus® Electronic Moisture Monitor System do not apply.

Figure 4-6 P2 and P2S Purification System

8
Securus II

7
6
IN

7
5 6
IN
OUT

3 OUT

5
3

1
2

3
2
4 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

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4.2.2 Component Description

4.2.2.1 Oil and Water Separator

^ 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.

Figure 4-7 Oil and Water Separator

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Figure 4-8 Oil and Water Separator Labels

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
2. Activated carbon which absorbs oil vapors effecting taste and Cartridge
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 Protective Cap
regulations.
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.

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4.2.2.6 Bleed Valve
A manually operated valve used to release the pressure in the chamber before maintenance.
4.2.2.7 Pressure Maintaining Valve
The pressure maintaining valve ensures that pressure is built up in the system from the start of delivery,
thus achieving constant optimum purification. It also assures proper working conditions for the final
stage of compression.
4.2.2.8 Safety Valve
The safety valve is located on the coalescing oil and water separator and acts as the safety valve for the
final stage of the compressor.
4.2.2.9 Securus II® Electronic Moisture Monitor System
The Securus II® Electronic Moisture Monitor System is a factory installed option which warns the opera-
tor in advance of expiration of the life of the cartridges. The Securus II® Transmitter receives signals
concerning the condition of the drying agent inside the Securus® cartridge from the attached sensors and
supplies the appropriate control signals whenever the preset threshold values have been reached.
4.2.2.9.1 Securus® Cartridge
The Securus® Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide,
activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor
components of the Securus® Electronic Moisture Monitor System.
4.2.2.9.2 Securus II® Transmitter
The Securus II® Transmitter relays the operating condition of the Securus II® Electronic Moisture Moni-
tor System to the operator control interface. The Securus II® issues a warning when the Securus® cartridge
is approaching saturation, to warn the user to prepare to change the Securus® cartridge. Once the Securus®
cartridge has reached total saturation the Securus II® monitor will issue an alarm condition to the operator
interface and shut down the unit. Once the Securus® cartridge is replaced the compressor unit can be
restarted.
4.2.3 Maintenance
4.2.3.1 Oil and Water Separator
To remove the sintered metal filter proceed as follows: (See Figure 4-9). Disconnect the power and shut
off the inlet supply line if applicable.
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 filter head.
5. Remove the center screw (3) to remove the sintered metal filter.
6. Clean the sintered metal filter using hot soapy water. Blow dry with compressed air.
7. After cleaning the element, record the number of operating hours to ensure exact attention to the
maintenance intervals.
8. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter with petro-
leum jelly. Apply sparingly.

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9. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the
sintered metal filter.
10. In the event you discover corrosion, replace the corroded parts with new Bauer parts.
11. Reinstall the sintered metal filter assembly and filter head.
12. Replace all removed tubes, close all valves and check for leaks.

Figure 4-9 Oil and Water Separator Figure 4-10 Sintered Metal Filter Assembly

2
3

1. Filter Head 3. Center Screw 1. Threaded Insert 4. Outer Filter

2. Sintered Metal Filter 4. O -rings 2. Filter Bottom 5. Filter Head
3. Inner Filter

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MNL-0420
4.2.3.2 Removal of the Securus II® Transmitter.

Figure 4-11 Removal of the Securus II® Transmitter

2
1

1. Securus II® Transmitter 2. DIN Connector

The Securus II® Transmitter is removed and replaced by rotating the blue plastic Securus II® Transmit-
ter approximately ½ 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.

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4.2.3.3 Cartridge Replacement

To change the purification cartridge, proceed as follows. (See Figure 4-12)

Figure 4-12 Cartridge Replacement

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 in Paragraph 4.2.3.4t.

4.2.3.4 Leaking at the Safety Bore

1. Remove the cartridge following steps 1. to 4. in Paragraph 4.2.3.2.
2. Install cartridge if missing.

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MNL-0420
3. Remove cartridge and inspect O-rings.
4. Replace O-rings if necessary.
5. Ensure protective caps and devices have all been removed.
6. Replace cartridge following steps 8. to 11. in Paragraph 4.2.3.2

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4.2.4 Replacement Parts List

Figure 4-13 P2S Purification System Parts List

8
Securus II

7
6
IN

OUT

5
3

Item Qty Part No. Description Notes

1 1 079416 Oil and Water Separator See Figure 4-14
2 1 011430 Condensate Drain Valve
3 2 VAL-0007 Check Valves
4 1 VAL-0377 Bleed Valve
5 1 VAL-0053 Pressure Maintaining Valve
6 1 080144 27” Purification Chamber See Figure 4-15
or 1 080145 Securus® Chamber See Figure 4-16
7 1 VAL-0169 Safety Valve
8 1 MNR-0042 Securus II® Transmitter 24 VDC

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MNL-0420

Figure 4-14 Oil and Water Separator Parts List

a
2

b
3 c

c
4 b

f g

Item Qty Part No. Description Notes

 1 079416 Oil and Water Separator Assembly
1 † — Separator Head Available only with 079416
2 2 N04586 O-Ring
3 1 061860 Sintered Metal Filter
3a 1 N15133 O-Ring
3b 2 N04496 O-Ring, small
3c 2 N04385 O-Ring, large
3d 1 061858 Sleeve Element, large
3e 1 061859 Sleeve Element, small
3f 1 N07091 O-Ring
3g 1 061857 Screw
4 † — Separator Housing Available only with 079416
5 † — Bottom Plug Available only with 079416

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Figure 4-15 27” Chamber Assembly Parts List

1
2
3

4
5

8
5
4

Item Qty Part No. Description Notes

 1 80144 Chamber Assembly 27”
1 2 012293 Tool Post Screw
2 1 061237 Cover Plate
3 † — Filter Head Available only with 80144
4 2 N04736 Back-up Ring
5 2 N04735 O-ring
6 † — Filter Housing Available only with 80144
7 † — Filter Bottom Available only with 80144
8 1 058827A Purification Cartridge MS/AC/MS/HP

Page 79 1st Edition, Rev. 1 Chg. 1

 This page is inserted to provide proper page sequencing

8 9 1 2
6 5 7

10
3
4
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Figure 4-16 Securus II® Electronic Moisture Monitor System Parts List

18

2 17

3
16

15
5
14

13

12

4
11

10
9
3 8
2 7
6

Item Qty Part No. Description Notes

 1 80145 Securus® Chamber Assembly Replaces 80144 In P2S
1 † — Bottom Plug Available only with 80145
2 2 N04736 Backup Ring
3 2 N04735 O-ring
4 1 060037A Securus® Cartridge
5 † — Filter Body Available only with 80145
6 1 059855 Nut
7 1 059852 Drawback Screw
8 1 059854 Loose Pin
9 1 060062 Compression Spring
10 1 059853 Fixed Pin

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MNL-0420
Figure 4-16 (cont.) Securus II® Electronic Moisture Monitor System Parts List

Item Qty Part No. Description Notes

11 1 059851 Bolt
12 1 002181 Compression Spring
13 † — Filter Head Available only with 80145
14 1 06135 Cover Plate
15 2 012293 Tool Post Screw
16 1 059850 Socket, RF type
17 1 MNR-0042 Securus II® Transmitter 24 VDC
18 1 CON-0319 Connector

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CHAPTER 5: COMPRESSOR DRIVE SYSTEM
5.1 Description, Horizontal Sliding
The compressor is powered by the drive motor or engine through a V-belt. The direction of rotation, as
seen facing the flywheel, is counterclockwise. Observe the arrow on the compressor block below.

Figure 5-1 Horizontal Motor Mount (typical)

6
7
8

1 2 3 4
1. Compressor Block Flywheel 5. Electric Motor
2. V-belt 6. V-belt Sheave
3. Driveshaft Key 7. Sheave Bushing
4. Electric Motor Mount 8. Electric Motor Sliding Base
The electric motor is secured on a sliding base. To obtain the correct belt tension loosen the 4 motor bolts
(1). There are two bolts on the opposite side of the motor, not shown in picture. Slide the motor away
from the compressor until only 3/8” belt deflection is obtained using the adjustment bolts (2). Then
tighten the 4 motor bolts (1) and recheck belt deflection.

Figure 5-2 Sliding Motor Base

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5.2 Maintenance of the V-belt and Sheave
5.2.1 Checking the Sheave.
Before a new drive belt is installed, the condition of the sheave should be checked. A dirty or rusty
sheave impairs the drive’s efficiency and abrades the cover of the belt, which results in premature failure.
A worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bot-
toms, slippage may result and the belt may burn. If the side wall is “dished out,” the bottom shoulder
ruins the belt prematurely by wearing off the bottom corners.
5.2.2 Checking the V-belt
Inspect the V-belt regularly for damage and wear. Replace if necessary.
5.2.3 V-belt tension
V-belt tension is adjusted by sliding the motor or engine until pressing down on the V-belt between the
sheaves results in an approximate deflection of 3/8” (10 mm). (See Figure 5-3).

Figure 5-3 V-belt Deflection

Approximate Deflection
3 “ (10 mm)
8

5.3 Maintenance of the Drive Motor / Engine

For maintenance of the electric motor or gas/diesel engine refer to the OEM manual, if included, or see an
instruction plate attached to the motor. If maintenance instructions are shown for the motor, they super-
sede these general instructions.

^ WARNING
Always disconnect the electrical power before working on the motor.

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5.4 Offshore 13 Drive Replacement Parts List

Figure 5-4 Offshore 13 Drive

6
7
8

1 2 3 4

Item Qty Part No. Description Notes

1 1 IK 12.14 II Compressor Block
2 1 BET-0049 V-belt
3 1 — Keystock
4 1 MTS-0421 Motor Mount
5 1 MTR-0143 Electric Motor 10 Hp, 3 Phase, TEFC
6 1 SHE-0139 V-belt Sheave
7 1 BUS-0002 Sheave Bushing
8 1 BAS-0004 Sliding Motor Base

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CHAPTER 6: ELECTRICAL PANEL, ASY-1095 XL
6.1 Overview
The following instructions apply to units that use Electrical Panel, ASY-1095 XL including Operator
Interface, MNR-0053.

Figure 6-1 ASY-1095 XL

The Electrical Panel, ASY-1095 XL, provides logical control and safety shutdowns for the compressor
equipment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorpo-
rated into a proprietary software program permanently saved into PLC memory using EEPROM tech-
nology. 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-0053. 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, Over-
load Relay, Power Transformer, Fuses, Overload Reset Button, Hour Meter, terminal strips for internal
wiring and connectors for attachment to wire harnesses. The panel is built to match the horsepower,
voltage, phase and frequency of the customer’s requirements.

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6.2.1 Wiring Diagram
The wiring diagram for your specific Compressor Unit is stored inside the Electrical Panel. If a wiring
diagram for your machine is not found inside the Electrical Panel, then please call Bauer Compressors
Product Support Group for a replacement. Please have the serial number of the compressor available; it
is written on a label (See Figure 6-2) inside the Electrical Panel door.
6.2.2 Electrical Panel Interior Access
The interior of the Electrical Panel is accessed by using a coin or screwdriver to turn the latch on the
front of the Electrical Panel.
6.2.3 Optional Equipment
Optional equipment which may also be housed in the Electrical Panel are any of five Communication
Modules. An EEPROM Memory Module is also be 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 conduit selection must be in accordance with all national, state and
local codes. The customer is responsible for providing a means of disconnection from the power source
and protection from instantaneous short circuit. The Electrical Panel voltage and phase are displayed on
the exterior of the Electrical Panel as well as being written on a label (See Figure 6-2) on the inside of
the Electrical Panel door. In this example shown, the panel is wired for 230 volt, single phase, serial
number 107282.

Figure 6-2 Electrical Panel Label

MODEL: VA-12.2-E1/230V

E
SERIAL: 107282

L
Norfolk, VA 23502 USA
K:
BLOCK: P0808762/06
P

P
757-855-6006 www.bauercomp.com
UL File No. E141433 MFG
G DATE: 12/2009

M
PANEL: ASY-1095 Use 600 VAC and 60 Degree Celsius
Copper Wire Only

A
Short Circuit Current: xx,xxx
, KA Terminal Wire Range Torque

S
MAXIMUM RATING G (AC
(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

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6.4 Electrical Panel Components
6.4.1 Programable Logic Controller (PLC)
The PLC is 24 I/O and 120 VAC. The data stored in RAM is protected for 100 hours, in event of a
power loss.
Figure 6-3 PLC, CNT-0078

1 2
3

8
7

1. Status LEDs 6. Input LEDs

2. Output LEDs 7. DIN Rail Clip
3. Output Connections Cover 8. Communications Ports
4. Expansion Access Door 9. Optional EEPROM
5. Input Connections Cover

Figure 6-4 Connector Block Removal

1
1. Notch in the Terminal Block

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6.4.2 Replacing the PLC
Replacing the PLC does not require removal of any wiring as the connections are made with push in Con-
nector Blocks. To replace the PLC proceed as follows.
1. Turn off unit and disconnect from main power supply.
2. Lift the Input Connections Cover. See Figure 6-3, Item 5.
3. Insert a small flat bladed screwdriver in the notch in the back center of the Connector Block. Gently
pry the Connector Block loose. See Figure 6-4.
4. Repeat Steps 2 and 3 for the to the Connector Block on the Output side of the PLC.
5. The Power Connector on the side opposite side from the DIN Rail Clip, Figure 6-3, Item 7, is
removed by pulling it straight out from the PLC.
6. Unclip the PLC from the DIN Rail by using a small flat bladed screwdriver to pull the DIN Rail
Clip out until the PLC is free.
7. Replace the PLC and slide the DIN Rail Clip in with the screwdriver until it is secure.
8. Replace the Power Connector by pushing it into the socket in the side of the PLC.
9. The Connector Blocks are replaced by pushing them gently down onto corresponding pins until
they click 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 using a notebook computer. Another method to install a new program is to use an External
EEPROM cartridge. The EEPROM would be programmed at the Bauer factory and shipped either to the
customer or to a authorized distributor.
6.4.4 Installing an EEPROM
To install or replace an EEPROM Cartridge proceed as follows:
1. Turn off unit and disconnect from main power supply.
2. Lift straight up to remove the EEPROM cover. Keep the cover. See Figure 6-3, Item 9.
3. The EEPROM is keyed to fit only one way and requires minimal force to insert it.
4. Push the EEPROM down until it snaps into place.
5. If the EEPROM is being retained in the PLC, restore power to the unit and operate as normal.
6. If the EEPROM is for a software update and is to be returned to Bauer or a distributor continue as
follows.
7. Restore power to the unit.
8. After the software has initialized and the Home Screen is displayed, shutdown the unit and discon-
nect from the main power source.
9. Restore power to the unit. After the software has initialized a second time and the Home Screen is
displayed, shutdown the unit and disconnect from the main power source.

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10. Remove the EEPROM and replace the EEPROM protective cover.
11. Restore power and operate the unit.
6.4.5 Hourmeter
The panel is equipped with an Hourmeter. The Hourmeter is not resettable and used to monitor the run
hours of the compressor. It is powered by 120 VAC.

Figure 6-5 Hourmeter

6.4.6 Transformer and Fuses

The Transformer is fitted with three fuses. The primary coil of the transformer has two fuses. The sec-
ondary coil of the transformer has one fuse. See Paragraph 6.9 to Paragraph 6.13 for the proper Bauer
Part Numbers.

Figure 6-6 Transformer and Fuses

1. Transformer 3. Primary Fuses

2. Secondary Fuse

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6.4.7 Motor Starter.
See Figure 6-7. This application will require an across the line IEC starter with thermal overloads and
its size will be based on the voltage and motor horsepower. Control voltage is 120 VAC. See Paragraph
6.9 to Paragraph 6.13 for the proper Bauer Part Number.
6.4.8 Overload Relay
See Figure 6-8.The overload relay provides thermal overload protection and its size will be based on
the voltage and motor horsepower. 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 Electrical Panel. The Overload Relay plugs into the Motor Starter. See Para-
graph 6.9 to Paragraph 6.13 for the proper Bauer Part Number.

Figure 6-7 Motor Starter (typical) Figure 6-8 Overload Relay (typical)

6.4.9 Starter Reset

There is a starter reset push button on the front of the Electrical Panel. Should the electric motor have
overloaded and tripped out during normal operation, then depressing this button after giving the motor
some time to cool, will reset the overload relay.

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6.4.10 Power Supply
The Power Supply is a 24 Volt 1.3 Amp Power Supply used to provide power to the optional Commu-
nications Modules and Operator Interface, MNR-0053. It is not standard in all models.

Figure 6-9 Power Supply

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 ves-
sel, approximately 3¾ inch diameter, located on the purification panel. To prevent fatigue failure of this
vessel, 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.

Table 6-1: Final Separator Warning and Shutdown Cycle Count

Maximum Compressor Pressure Warning Shutdown

5,000 psi 117,000 cycles 130,000 cycles

6,000 psi 49,500 cycles 55,000 cycles

When the warning is displayed, the unit will still continue to function properly, but will prompt the
operator 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
separator. When this is accomplished, the unit can be reactivated by making adjustments to the PLC
software. Please contact Bauer Product Support for detailed instructions.

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^ WARNING
Do not attempt to override this Separator Shutdown. This feature is provided to protect operating person-
nel from injury or death.

6.5.2 Securus® Electronic Moisture Monitor System

The compressor purification system may be equipped with an optional Securus II® Electronic Moisture
Monitor System. The Securus II® Electronic Moisture Monitor System warns the operator in advance of
expiration of the life of the cartridges. The Securus II® Transmitter receives signals concerning the con-
dition of the drying agent inside the Securus® cartridge from the attached sensors and supplies the
appropriate control signals whenever the preset threshold values have been reached.
6.5.2.1 Securus® Cartridge
The Securus® Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide,
activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor
components of the Securus II® Electronic Moisture Monitor System.
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 Securus II® issues a warning when the
Securus® cartridge is approaching saturation, to warn the user to prepare to change the Securus® car-
tridge. On a Securus® Warning condition, the compressor will run normally and the warning will be
shown on the Operator Interface. Once the Securus® cartridge has reached total saturation the Securus
II® Transmitter will issue an alarm condition to the Operator Interface and shut down the unit. Once the
Securus II® cartridge is replaced it is possible to restart the compressor. The Securus II® Transmitter is
removed and replaced by rotating the blue plastic Securus II® Transmitter approximately ½ turn. It is
not necessary to disconnect or remove the DIN Connector.

Figure 6-10 Securus II® Transmitter

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NOTICE
If the DIN Connector is removed, ensure that it is replaced in exactly the same position, otherwise electri-
cal damage to the unit may occur.

6.5.3 Compressor High Temperature

See Figure 6-11. The compressor high temperature switch is mounted on the high pressure compressor
block, on the third, fourth or fifth stage head, depending on model. Under normal operating conditions,
the switch is closed. On a high temperature condition, the compressor will shutdown and the alarm will
be displayed on the Operator Interface.

Figure 6-11 High Temperature Switch Figure 6-12 Pressure Sensor (Typical)

6.5.4 Compressor Low Oil Pressure

See Figure 6-12. The compressor Oil Pressure Sensor is located on the back of the compressor block,
mounted with the oil pressure gauge. During start-up of the compressor, the oil pressure sensor is
bypassed for a time period set in the program by OIL PRESS TD parameter. This allows the oil
pressure to stabilize at operating pressure before the an alarm is sensed. After this initial time period,
should the compressor lose oil 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 for a number of hours set by
the OVERRUNTIMER parameter, the compressor will shutdown, and the alarm will be displayed
on the Operator Interface. This is done to secure the equipment if it were to be started and left unat-
tended.
6.5.6 Carbon Monoxide Monitor Alarm
See Figure 6-13. The compressor system may be equipped with an optional Carbon Monoxide Monitor.
This consists of an electronic module that samples the compressed air supply. The unit will provide a
continuous display of the Carbon Monoxide level in ppm, parts per million.The unit should be cali-
brated with a test gas monthly. Refer to the manual section on the Carbon Monoxide Monitor. If the
Carbon Monoxide level becomes excessively high, then the monitor will alarm with a red light. The
alarm relay in the Carbon Monoxide Monitor is connected to the PLC. Refer to Wiring Diagram for

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additional information. On a Carbon Monoxide Alarm condition, the compressor will shutdown, and
the alarm will be displayed on the Operator Interface.

Figure 6-13 Carbon Monoxide Monitor

6.5.7 Condensate Fault

See Figure 6-14. The compressor condensate level switch is located in the condensate collection tank,
below the Automatic Condensate Drain separator. The switch is N.O., Normally Open, and is con-
nected to the PLC. Refer to wiring diagram for additional information. As the condensate tank fills up
the Condensate Level Float Switch rises until it closes. At this time the compressor will shutdown and
the alarm will be displayed on the Operator Interface. The operator should drain the condensate from
the tank and resume operation of the equipment.

Figure 6-14 Condensate Level Float Switch

Condensate
Level
Switch

NOTICE
The compressor condensate contains some oil, and accordingly, should be disposed of in
accordance with state and local regulations.

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6.5.8 Motor Starter Overload Trip

The compressor overload relay is located in the Electrical Panel, See Figure 6-8. Under normal operat-
ing conditions, the switch is open. On an Overload Trip of the motor, the compressor 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 relay type, and are powered through the control transformer supplying 120 VAC single phase to the
various loads. Please refer to Wiring Diagram for the as built specifications.

Table 6-2: PLC Inputs Table 6-3: PLC Outputs

I0.0 Securus 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 Inlet Solenoid Valve or ACD 3

I0.6 Q0.6

I0.7 Seccant Monitor Alarm Q0.7

I1.0 High Inlet Pressure Switcha Q1.0 Unloader Solenoid Valve

I1.1 Low Inlet Pressure Switcha Q1.1 Panel Light

I1.2

I1.3

I1.4

I1.5
a. Applies only to compressors for mediums other than air

6.6.1 Analog Inputs to the PLC.

The Air Pressure Switch and the Oil Pressure Switch are connected in parallel and provide their input to
the PLC through PLC Input Terminal M.

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6.7 Wiring Harness Layout

Table 6-4: Wiring Harness, HNS-0116

Description Legend Wire Colors Pin PLC IN PLC Out

CO Brown/White 1

CO Monitor (Optional) CO SV Black/Yellow 2

CO Common Gray/White 22

Black 3
E-Stop Pushbutton
1PB White/Red 9

ACD 1 ACD1 Blue/White 4 Q0.1

ACD Final ACDF Yellow/Black 5 Q0.2

ACD Common ACD Common Orange/White 21

Violet/White 6

Pink/White 7
Inlet Solenoid Valve or ACD 3
1SV White/Yellow 12 Q0.5

White/Brown 8
Panel Light
1LT Red/Orange 11 Q1.1

White/Violet 10
Unloader Solenoid Valve
3SV Red/Blue 14 Q1.0

Blue/Yellow 13
Audible Alarm
1AA White 15 Q0.3

Brown/Yellow 16
Seccant Monitor Alarm
SA Black/Brown 17 I0.7

Violet/Black 18
Low Inlet Pressure Switcha
5PS White/Blue 19 I1.1

Spare Blue/Orange 20

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Table 6-4: Wiring Harness, HNS-0116

Description Legend Wire Colors Pin PLC IN PLC Out

Yellow 23
Temperature Switch
1TS Violet 24 I0.2

Blue 25
Not Assigned
Orange 26 I0.6

White/Orange 27
a
High Inlet Pressure Switch
3PS Red/Yellow 28 I1.0

Gray 31
Condensate Alarm
CA Pink 32 I0.4

White/Black 33
CO Monitor Alarm
COA Red/White 34 I0.3

Black/White 35

Securus II Violet/Orange 36

SEC II Black/Orange 37 I0.0

a. Applies only to compressors for mediums other than air

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6.8 Replacement Parts List

Figure 6-15 Electrical Panel, Front View

Item Qty Part No. Description Notes

 1 ASY-1095 XL Electrical Panel Front View
1 1 OPR-0020 Overload Reset Button
2 1 MNR-0053 Control Monitor, touchscreen (Interface)
3 1 SWT-0308 Emergency Stop push button
4 1 HMR-0036 Hourmeter
& 1 GKT-0069 Gasket, Hourmeter
5 1 IND-0005 Audible Alarm option

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Figure 6-16 Electrical Panel, Bottom View

Item Qty Part No. Description Notes

 1 ASY-1095 XL Electrical Panel Bottom View
1 2 CAB-0075 Cable, 4 Receptacle Connector Connects to Pressure Sensors
2 1 HNS-0116 Wiring Harness, 37 Receptacle

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Figure 6-17 Electrical Panel, Interior

5
1

6
3
4

7
8

Item Qty Part No. Description Notes

 1 ASY-1095 XL Electrical Panel Interior View
1 1 SPL-0077 Power Supply 1.3 Amp, 24 V DC
2 1 TER-0175 Starter Terminals
3 1 — Motor Starter See Figure 6-17.a to Figure 6-17.j
4 1 — Overload Relay See Figure 6-17.a to Figure 6-17.j
5 1 CNT-0078 PLC Controller
6 1 — Transformer See Figure 6-17.a to Figure 6-17.j
7 2 — Fuse, Primary See Figure 6-17.a to Figure 6-17.j
8 1 — Secondary Fuse See Figure 6-17.a to Figure 6-17.j

 See the proper Figure for applicable Horsepower & Power Frequency supplied with your unit.

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6.9 Parts List for Models with a 5 Horsepower Motor

Figure 6-17.a 5 HP, 60 Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

208/1 TRR-0089 FUS-0090 FUS-0018 SRT-0233 RLY-0177 TER-0175
208/3 TRR-0089 FUS-0090 FUS-0018 SRT-0233 RLY-0174 TER-0175
230/1 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 6-17.b 5 HP, 50 HZ

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

220/3 TRR-0089 FUS-0092 FUS-0018 SRT-0233 RLY-0174 TER-0175
380/3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0171 TER-0175
400/3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0171 TER-0175
415/3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0171 TER-0175

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6.10 Parts List for Models with a 7.5 Horsepower Motor

Figure 6-17.c 7.5 HP, 60 Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

208/1 TRR-0089 FUS-0090 FUS-0018 SRT-0241 RLY-0186 TER-0175
208/3 TRR-0089 FUS-0090 FUS-0018 SRT-0233 RLY-0176 TER-0175
230/1 TRR-0089 FUS-0090 FUS-0018 SRT-0241 RLY-0183 TER-0175
230/3 TRR-0089 FUS-0090 FUS-0018 SRT-0233 RLY-0175 TER-0175
460/3 TRR-0089 FUS-0029 FUS-0018 SRT-0233 RLY-0172 TER-0175

Figure 6-17.d 7.5 HP, 50 Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

220/3 TRR-0089 FUS-0092 FUS-0018 SRT-0233 RLY-0175 TER-0175
380/3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0173 TER-0175
400/3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0173 TER-0175
415/3 TRR-0095 FUS-0077 FUS-0018 SRT-0233 RLY-0173 TER-0175

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6.11 Parts List for Models with a 10 Horsepower Motor

Figure 6-17.e 10 HP, 60 Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

208/1 TRR-0090 FUS-0092 FUS-0019 SRT-0234 RLY-0180 TER-0174
208/3 TRR-0090 FUS-0092 FUS-0019 SRT-0233 RLY-0177 TER-0175
230/1 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 6-17.f 10 HP, 50 Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

220/3 TRR-0090 FUS-0092 FUS-0019 SRT-0241 RLY-0186 TER-0175
380/3 TRR-0096 FUS-0080 FUS-0019 SRT-0233 RLY-0175 TER-0175
400/3 TRR-0096 FUS-0080 FUS-0019 SRT-0233 RLY-0175 TER-0175
415/3 TRR-0096 FUS-0080 FUS-0019 SRT-0233 RLY-0175 TER-0175

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6.12 Parts List for Models with a 15 Horsepower Motor

Figure 6-17.g 15 HP, 60Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

208/3 TRR-0090 FUS-0092 FUS-0019 SRT-0241 RLY-0185 TER-0175
230/3 TRR-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 6-17.h 15HP, 50 Hz

VAC/PH Transformer Pri. Fuses Sec. Fuse Starter Relay Term.

220/3 TRR-0090 FUS-0092 FUS-0019 SRT-0241 RLY-0186 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-0176 TER-0175

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6.13 Parts List for Models with a 20 Horsepower Motor

Figure 6-17.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 6-17.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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CHAPTER 7: CARBON MONOXIDE MONITOR
7.1 Description
The Carbon Monoxide (CO) Monitor is a factory installed option which may have been ordered with
your unit.
The Carbon Monoxide Monitor, Bauer P/N; MNR-0029, is a standalone assembly, which may be
installed on a compressor unit or trailer.(See Figure 7-1).
The Carbon Monoxide Monitor, Bauer P/N; MNR-0033 (See Figure 7-2) appears outwardly identical to
MNR-0029 but is designed for use with a remote display, which can be located up to 100 feet from the
compressor unit. The Remote Display, Bauer P/N; MNR-0034, is powered by the Carbon Monoxide
Monitor, MNR-0033.

Figure 7-1 CO Monitor, MNR-0029 Figure 7-2 Remote Display

2
1 2 3

4
1
5

1. LCD Display 5. Air Inlet Connection 1. CO Monitor, MNR-0033

2. Flow Indicator 6. Zero Cal Set Switch 2. Remote Display, MNR-0034
3. Electrical Power Connection 7. Calibration Port
4. Front Cover Screw

• 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.

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• Calibration adjustment is performed automatically by the internal microprocessor.
• The Carbon Monoxide Sensor Cell has a life expectancy of one and a half to three years if the calibra-
tion check is done every 30 days as recommended.
7.1.1 Component Description
The following are the major components for the standard and trailer Carbon Monoxide Monitor Assem-
bly installations. See Figure 7-3.

Figure 7-3 Carbon Monoxide Monitor Flow Diagram

Relief Valve
165 psi
Inlet Regulator
Isolaon Valve (less than 10 to 15 psi)

6,000 psi Monitor

from compressor

High to Low Solenoid

Pressure Regulator Valve

7.1.1.1 Isolation Valve

Controls the input of air from the compressor to the Carbon Monoxide Monitor.
7.1.1.2 High Pressure to Low Pressure Regulator
Typically set for 50 psi out with 5,000 psi in.
7.1.1.3 Relief Valve
A relief valve which is factory set to 165 psi to prevent over-pressurization of the Carbon Monoxide
Monitor.
7.1.1.4 Solenoid Valve
Allows air to flow to the Carbon Monoxide Monitor when the compressor is running.
7.1.1.5 Inlet Regulator
A regulator the operator uses to set the appropriate rate of flow (0.5 to 0.8 SCFH) to the Carbon Monox-
ide Monitor.
7.1.1.6 Carbon Monoxide Monitor
The Carbon Monoxide Monitor contains the LCD Display, Flowmeter, Microprocessor, Carbon Monox-
ide Sensor Cell, Air Inlet Connection and the Calibration Port.
7.1.1.6.1 Carbon Monoxide Sensor Cell.
The Carbon Monoxide Sensor Cell is an electrochemical element inside the Carbon Monoxide Monitor
which senses the amount of Carbon Monoxide in the airstream and produces an analog electrical signal
for the control and display functions of the Carbon Monoxide Monitor.
7.1.1.7 Test Gas Storage
This provides a place to keep Calibration Gas bottles so that the Carbon Monoxide Monitor can be cali-
brated in all situations. Normally these are only found only in trailer installations.
7.2 Carbon Monoxide Monitor Setup
The initial setup of the Carbon Monoxide Monitor is done prior to shipping the unit.

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7.3 Operation
1. Start the compressor unit.
2. The LCD Display will show introductory messages and a warm up countdown (WARM XX).
3. After the warm up countdown of 120 seconds, the instrument will display Carbon Monoxide level
readings.
4. The Inlet Regulator may be adjusted at any time to set the flow level from 0.5 to 0.8 SCFH on the
Flow Indicator.
5. If the compressor is not running then a LOW FLOW indication will show on the display.
6. If carbon monoxide readings remain high or below zero calibration may be needed.
7.4 Maintenance
7.4.1 Calibrating Carbon Monoxide Monitor.

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.

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11. Allow 10 minutes for the remaining gas in the Carbon Monoxide Sensor Cell to dissipate after the
calibration process.

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 doesn’t calibrate, contact Bauer Product Support.

Figure 7-4 Basic Calibration Kit & Test Gases

1. 20 ppm Carbon Monoxide Test Gas 2. Zero Test Gas 3. Fixed Flow Regulator

7.4.3 Carbon Monoxide Sensor Cell Replacement (See Figure 7-5)

When Carbon Monoxide test gas fails to show a gas response during calibration, a new Carbon Monox-
ide Sensor Cell is required. Most Carbon Monoxide Sensor Cells will last from one and a half to three
years. After installing a new Carbon Monoxide Sensor Cell, an initialization step permits the Carbon
Monoxide Sensor Cell to be calibrated to zero regardless of the background air. Caution must be taken
that the inlet air is free of carbon monoxide or an Impurity Free Air test gas is used for the initial cali-
bration.

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1. Disconnect the power from the unit.

^ 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.

Figure 7-5 Carbon Monoxide Sensor Cell Removal

7.4.4 Carbon Monoxide Monitor Initialization

Initialization of the Carbon Monoxide Monitor will need to be done if a calibration fails, the Carbon
Monoxide Sensor is replaced or any other maintenance on the internal components of the Carbon Monox-
ide Monitor System was performed.

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7.4.4.1 Setting the LP Regulator

Figure 7-6 Carbon Monoxide Monitor Initialization

3 4 5

(See Figure 7-6)

1. Attach a Pressure Gauge (0 -100 psi) to the Outlet (1) of the Regulator (3).
2. Apply 5,000 psi to the Regulator (3) using Isolation Valve (2).
3. Loosen Jam Nut (4).
4. Using an Allen wrench turn the regulator adjusting screw (5) until the Pressure Gauge reads 50 psi
with an input pressure of 5,000 psi.
5. Tighten Jam Nut (4), Remove Pressure Gauge and reattach Outlet Connection.

7.4.4.2 Initialization Calibration

1. Before calibration, be sure that the test gas bottles in the Calibration Kit (See Figure 7-4) 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.

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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. Depress the Zero Cal Set Switch on the front of the Carbon Monoxide Monitor with a paper clip for
approximately 30 seconds.
7. Connect the Zero Gas bottle to the Fixed Flow Regulator and connect it to the Calibration Port of
the Carbon Monoxide Monitor.
8. Turn the valve on the Fixed Flow Regulator counterclockwise until the Carbon Monoxide Monitor
Flow Indicator shows between 0.5 and 0.8 SCFH.
9. The Display should read ZERO CAL and will count down from 60 seconds. At the conclusion,
the display prompts, REMOVE ZERO GAS.
10. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the
Calibration Port.
11. Disconnect the Zero Gas Bottle and the display will indicate 20 ppm CAL GAS REQUIRED
12. 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.
13. Turn the valve on the Fixed Flow Regulator counterclockwise until the Carbon Monoxide Monitor
Flow Indicator shows between 0.5 and 0.8 SCFH.
14. The Display will count down from 60 seconds. At the conclusion, the display will prompt to
REMOVE Carbon Monoxide GAS.
15. 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.
16. Allow 10 minutes for the remaining gas in the Carbon Monoxide Sensor Cell to dissipate after the
calibration process.

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.

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Figure 7-7 Carbon Monoxide Monitor Internal Components

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)

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7.4.5 Carbon Monoxide Monitor Test Mode Buttons

^ 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.

Figure 7-8 Mode Buttons Close-up

1. Mode Scroll Button 2. Value Change Button

1. Unscrew the four large screws on all corners of the Front Cover (See Figure 7-1).
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.

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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
annunciating a high Carbon Monoxide alarm (reference the electrical section of this manual for
more information). TEST MODE also sounds the auxiliary horn (if installed) and activates the solid
squares on Front Cover LED Readout.
5. The top mode button must be depressed again to return to Normal Mode.
6. Replace Front Cover and screw in place.

7.5 Remote Display Setup

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.

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Figure 7-9 Remote Display

1. Remote Display Calibration Screw

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7.6 Replacement Parts List

Figure 7-10 Carbon Monoxide Monitor Assembly - Standard

3 4 5

Item Qty Part No. Description Notes

 ASY-0890 Carbon Monoxide Monitor Assembly
1 1 MNR-0029 Carbon Monoxide Monitor
2 1 VAL-0076 Isolation Valve
3 1 REG-0043 High - Low Pressure Regulator
4 1 VAL-0432 Safety Valve 145 psi
5 1 VAL-0348 Solenoid Valve 115 VAC
or 1 VAL-0349 Solenoid Valve 12 VDC
6 1 REG-0060 Inlet Regulator
N.S. 1 SEN-0025 Carbon Monoxide Sensor Cell

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Figure 7-11 Calibration Components

1 3

Item Qty Part No. Description Notes

1 1 CYL-0016 CO Test Gas 20 ppm
2 1 CYL-0020 CO Test Gas, Zero Gas 0 ppm
3 1 KIT-0190 Calibrating Regulator & Hose

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Figure 7-12 Carbon Monoxide Monitor Schematic

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

1 INT. 24V OPER

1
– +
No Connection.

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.

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CHAPTER 8: HYDROGEN SULFIDE MONITOR (MNR-0008)
8.1 Description
The Hydrogen Sulfide (H2S) Monitor is a factory installed option which may have been ordered with
your unit.
The Hydrogen Sulfide Monitor, Bauer P/N; MNR-0008, is a standalone assembly, which may be installed
on a compressor unit or trailer.(See Figure 8-1). The H2S sensor; SEN-0028 is can be attached to the
monitor directly but is normally located near the compressor intake.

Figure 8-1 H2S Monitor, MNR-0008 Figure 8-2 H2S Sensor, SEN-0028

• The Hydrogen Sulfide (H2S) Monitor is designed to provide continuous monitoring of ambient H2S
levels near the compressor intake.
• The H2S Monitor is enclosed in a NEMA-4X case and operates on 12 VDC or 120 VAC.
• Calibration adjustment is performed automatically by the internal microprocessor.
• The H2S Sensor Cell has a life expectancy of two to three years if the calibration check is done every 3
months as recommended.

8.2 Hydrogen Sulfide Monitor Setup

The initial setup of the Carbon Monoxide Monitor is done prior to shipping the unit. The customer should
not need to complete any tasks in order to utilize the H2S monitor.

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Figure 8-3 H2S Components

9
1
10
11
12

2
3
13

6 7 8
1. Fail LED 8. Controller Terminal
2. Power Switch 9. Alarm LEDs
3. Power Supply 10. LCD Display
4. AC Fuses 11. Contrast Setscrew
5. AC In Terminal 12. Control buttons
6. Alarm Terminal 13. Sensor Terminal
7. Buzzer

8.3 Operation
1. Start the compressor unit.
2. The LCD Display will show the firmware version when the monitor is first powered up and will
then count down a one minute warm-up period before normal operation begins. During normal
operations the display will indicate the current gas reading and the name of the target gas.

Figure 8-4 Normal LCD Display

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NOTICE
To prevent unwanted alarms during warm-up, the alarm circuits are
not active during the warm-up period.

8.4 Resetting Min/Max Readings

The reset switch may be used to view and reset the minimum and maximum gas readings.

NOTICE
Minimum and maximum readings are reset if the monitor is turned off.

1. While the monitor is in normal operation, press and hold the reset button for 5 seconds.
2. The display will indicate the minimum reading on the bottom line and the maximum reading on
the top line for approximately 3 seconds. Then the display will change to <RESET> TO CLEAR.
3. To return to normal operation without resetting the readings, wait approximately 5 seconds. Do not
press the reset button. The monitor will return to normal operation.
4. To reset the readings, press and hold the reset button while the <RESET> TO CLEAR message is
displayed. Hold the button until the display indicates Min/MAX Is Reset. The monitor will return
to normal operation in about 5 seconds.

8.5 Alarms
8.5.1 Alarm 1
Bauer Compressors utilizes only Alarm 1 for the H2S monitor. When the monitor gets a reading at or
above Alarm 1’s set point, it will sound the alarm with a pulsing tone and the A1 LED will light up. The
LCD display will alternate the current gas reading and the ALARM-1 message. When the gas reading
falls below the alarm 1 setpoint, press the reset button to reset the alarm 1 circuit. The alarm should
silence and the monitor should return to normal operation.
8.5.2 Fail
The H2S monitor is also equipped with a fail condition alarm. The fail alarm will be triggered if the H2S
sensor’s wiring is disconnected or it senses other defective components. When a fail condition is present
the FAIL alarm LED will light up and the gas reading will be replaced by the FAIL message. The buzzer
will sound a steady tone. A fail condition can not be reset with the reset button.
8.5.3 Low DC Power
This condition only applies when DC power is used as a power source. The H2S monitor senses a low
power condition when the DC power source is 18.5 volts or less. When this condition is present the FAIL
LED will light up. The Low Power message and the actual voltage of incoming DC power will alternate
on the LCD display. No audible alarm will be given.

^ WARNING
While in a low power condition the H2S monitor is NOT an active gas monitor.

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Once the DC voltage is increased to 19 volts or above the low power alarm will clear and the monitor will
begin its warm-up sequence.
8.6 Setting ALARM 1 Setpoint
The H2S monitor is set to factory default settings at time of manufacture. The customer should ensure the
alarm point is set correctly for their needs.

Figure 8-5 Control Buttons

Control button location can be found

in Figure 8-3 at #12

1. To enter configuration mode press and hold the UP/YES and ENTER control buttons for 5 sec-
onds. Release the buttons when ENTER Config? is displayed on the LCD screen.
2. Press the DOWN/NO button to return to normal operation or the UP/YES button to enter configu-
ration mode.The target gas (H2S) and scale will be displayed for a few seconds before the first
parameter, alarm-1 setpoint, is displayed.
3. Adjust current displayed parameter using the UP/YES and DOWN/NO buttons. Once the correct
setting is achieved press the ENTER button to move on to the next parameter.
4. Press the ENTER button through the remaining parameters (approximately 16) until SAVE IT?
YES/NO appears on the LCD display.
5. Press the UP/YES button to save the change. Config Saved will display on the screen for a few
seconds then the monitor will return to normal operation.
Other parameters can be adjusted to meet customer’s needs. Consult the attached OEM for further
instructions.
8.7 Maintenance
8.7.1 Daily
Verify a display reading of 0 ppm H2S on the controller. Investigate any significant changes in the dis-
play reading.
8.7.2 Monthly
This procedure describes a test to verify that the H2S detector responds properly to hydrogen sulfide. The
following describes the test using the H2S calibration kit (KIT-0226).

NOTICE
This test will cause the alarm to sound. Be sure to put the controller into calibration mode
or disable external alarms before performing this test.

1. Place the controller into calibration mode or disable external alarms.

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2. Verify that the controller display reading is 0ppm.
3. Screw the calibration cup onto the bottom of the H2S sensor.
4. Screw the regulator onto the calibration cylinder
5. Use the sample tubing to connect the regulator to the calibration cup.
6. Open the regulator by turning the knob counterclockwise until gas begins to flow. Allow the gas to
flow for 2 minutes.
7. Verify the reading is within ± 10% of the cylinder gas concentration.

NOTICE
If the reading is not within ± 10%, calibrate the detector as described in Paragraph 8.7.3.

8. Close the regulator by turning the knob clockwise.

9. Unscrew the regulator from the calibration cylinder.
10. Unscrew the calibration cup from the sensor.
11. Once the controller display reading falls below the alarm setpoint, return the monitor to normal
operation mode.
8.7.3 Quarterly
Calibrate the H2S monitor quarterly. (See Figure 8-6).

^ WARNING
While in calibration mode the H2S monitor does not actively monitor gas levels.

NOTICE
Calibration is recommended every three months. More frequent calibration may be
necessary depending on application and environment.

8.7.3.1 Setting the Zero Reading

1. Screw calibration cup onto the H2S sensor.
2. Screw the regulator onto the zero air cylinder, if zero gas is to be used.

NOTICE
If the H2S sensor is in a fresh air environment, zero gas does not need to be
applied to detector head before adjusting the zero reading.

3. Connect regulator to calibration cup using the sample tubing.

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Figure 8-6 Calibration Kit, H2S Monitor, KIT-0226

4
1
5

1. Calibration Gas 4. Calibration Cup

2. Stylus (to press buttons) 5. Sample Tubing
3. Regulator

4. While in normal operation mode press and hold the UP/YES button for 5 seconds. Release the but-
ton when the Calib? YES/NO screen appears.
5. To enter the Calibration Mode press the UP/YES button. The display indicate the target gas (H2S)
and CAL Mode for a few seconds before showing Fresh Air Adjust?.
6. Verify the detector sensor is in a fresh-air environment. (if necessary, use zero gas air cylinder).
7. If using zero gas Open the regulator to let the zero gas flow for 2 minutes.
8. Press and release the ENTER button. The monitor will perform a fresh air adjustment then display
SPAN with Cal Gas?

8.7.3.2 Calibrating the Span

1. Screw calibration cup onto the H2S sensor
2. Screw the regulator into the calibration gas cylinder.
3. Connect the regulator to the calibration cup using the sample tubing.
4. Press the UP/YES button to enter the gas calibration mode.On the top line of the LCD display,
APPLY will alternate with SPAN Gas. The current gas reading will show on the bottom line.
5. Apply calibration gas to detector head by turning the regulator knob counterclockwise. Allow gas
to flow for 2 minutes.

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6. Adjust the gas reading up or down, using the UP/YES and DOWN/NO buttons, to match the cali-
bration gas concentration. When finished press the ENTER button.
7. The LCD display will indicate SPAN Gas PASS for a few seconds, then SPAN Gas SAVED
before indicating Leaving CAL Mode.
8. Once the unit leaves the calibration mode it will alternately display REMOVE CAL GAS and the
normal operation screen.
9. Remove the calibration gas cylinder, regulator, tubing, and calibration cup from the monitor. Store
the calibration components in the calibration kit.
10. After 1 minute the unit will return to normal operations.

8.7.4 Hydrogen Sulfide Monitor Fuse Replacement

(Figure 8-3)
The H2S monitor has 2 replaceable AC fuses. To replace them follow the below procedures:
1. Turn off or unplug all incoming power to the monitor
2. Open the housing door, then place the power switch in the off position.
3. Locate the 2 vertical fuse holders above the AC terminal strip.
4. Use a flat blade screwdriver to rotate the applicable fuse holder ¼ turn counterclockwise. The fuse
holder will release from the socket.
5. Remove the fuse holder from the socket, then remove the fuse from the fuse holder.
6. Replace the fuse with the appropriate replacement fuse. Then place the fuse holder in the socket.

NOTICE
Verify that the replacement fuse is the same type and rating as the fuse you are replacing.
See Parts list and the end of this chapter.

7. Push the fuse holder into the socket and turn the holder ¼ turn clockwise to secure it in the socket
8. Plug in or turn on all incoming power.
9. Place the monitor’s power switch in the ON position and verify that the monitor completes it’s
warm-up sequence and enters normal operation.
10. close and secure the housing door.

8.7.5 Sensor Replacement

^ CAUTION
The sensor contains electrolyte which is a diluted acid. Do not disassemble the sensor when
replacing it with a new one. If sensor electrolyte comes in contact with skin wash affected area
thoroughly with soap and water.

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Figure 8-7 Sensor Replacement

Turn Off Power Unscrew Housing Cap

Pull Out Sensor Replace With New Sensor

1. Turn off the monitor, using the monitor’s power switch.

2. Turn off power to the monitor.
3. Unscrew the detector housing cap from the detector housing.
4. Unplug and remove the H2S sensor.
5. Carefully plug the replacement sensor into the socket that is located in the detector housing.
NOTICE
Match the sensor’s male pins with the four female sockets. Be careful not to bend the pins.

6. Screw the detector housing cap onto the detector housing.

7. Turn on power to the monitor.
8. Turn on power switch in the monitor.
^ CAUTION
Allow the replacement sensor to warm up 5 minutes before you continue with the next step.

9. Calibrate the sensor as described in Paragraph 8.7.3.

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8.8 Troubleshooting
Symptom Probable Cause Recommended Action
• Display backlight is off and • Power wiring is disconnected 1. Verify wiring to power
the display screen is blank or misconnected source is correct and secure.
• One or both AC fuses are 2. At monitor verify the wir-
blown ing to the AC terminals is
correct and secure
• Display cable is disconnected
3. Check continuity of the AC
or misconnected
Fuses
4. Verify display cable is con-
nected.
• Monitor alarms while sensor • Monitor experiencing false 1. Verify sensor wiring is
readings remain at 0 readings due to RFI or EMI properly shielded.
• Sensor Head wiring discon- 2. Verify Sensor wiring is cor-
nected, misconnected or rect and secure
intermittent 3. Verify power and sensor
wiring is routed through
separate conduit hubs on
bottom of monitor.
4. Increase alarm on delay set-
ting in config. mode.
• Display reading flickers • Monitor experiencing false 1. Verify sensor wiring is
often readings due to RFI or EMI. properly shielded.
• Noise filter setting is too low. 2. Verify sensor wiring is cor-
rect and secure.
• Zero suppression setting is
3. Verify power and sensor
too low.
wiring is routed through
• Display screen is malfunc- separate conduit hubs on
tioning. bottom of monitor.
4. Increase the zero suppres-
sion setting in config. mode.
• Buzzer does not sound • Buzzer is disconnected or 1. Verify wiring to alarm
audible alarm during alarm misconnected. buzzer and terminals of con-
conditions. troller is correct and secure.
• Buzzer is malfunctioning.
• Buzzer sounds weak or
broken.
• Buzzer does not silence when • Reset Switch is disconnected 1. Verify wiring to Reset
switch is pressed. or misconnected. Switch is correct and secure.
• Alarm circuit does not reset • Reset Switch is malfunc- 2. Replace reset switch.
when button pressed after tioning.
alarm condition passes

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Symptom Probable Cause Recommended Action
• Fail condition indicated. • Sensor Wiring disconnected/ 1. Verify sensor wiring is cor-
misconnected. rect and secure
• Sensor's zero reading is too 2. Calibrate sensor.
low 3. Replace H2S sensor.
• Sensor malfunctioning.
• Sensor responds slowly or • Calibration cylinder is low, 1. Verify calibration cylinder
not at all out-dated, or defective. contains adequate supply of
• Unable to set zero or • Sensor is malfunctioning fresh test sample.
response reading during cali- 2. Replace sensor.
bration.
• Sensor requires frequent cali-
bration.

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8.9 Replacement Parts List

Figure 8-8 Replacement Parts

1 2

INSIDE

1 1 MNR-0008 Hydrogen Sulfide Monitor Assembly

2 1 SEN-0028 H2S Sensor
3 1 KIT-0226 Calibration Kit

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MNL-0420
CHAPTER 9: INDICATORS & VALVES
9.1 Description
The Hour Meter is used to record the number of hours the unit has been operated.
The unit is also equipped with one or more of the following pressure indicators.
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.
Pressure Sensors - Provide a signal to the PLC indicating air, gas, or oil pressure.
Temperature Sensors - Provides temperature readings for the PLC.

9.2 Replacement Parts List

Figure 9-1 Indicators

1 2 3 4

Item Qty Part No. Description Notes

1 1 HMR-0036 Hour Meter
2 —1 — 2.5” Pressure Indicator See Table 9-1:
3 —2 — Pressure Sensor See Table 9-2:
4 1 N30545 Temperature Sensor Optional

1.Number of pressure gauges and type vary with model

2.Number of pressure sensors and type vary with model

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Table 9-1: Pressure Gauges, 2.5” PSI & BAR

Part Number Pressure Range
GAG-0042W 0 - 100 psi (6.89 bar)
GAG-0006W 0 - 200 psi (13.79 bar)
GAG-0007W 0 - 600 psi (41.37 bar)
GAG-0008W 0 - 1,500 psi (103.42 bar)
GAG-0031W 0 - 3,000 psi (207 bar)
GAG-0009W 0 - 7,500 psi (517 bar)
GAG-0015 0 - 10,000 psi (689.5 bar)

Table 9-2: Pressure Sensors

Part Number Pressure 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 Yellow
SEN-0051 0 - 1,450 psi (100 bar) 1/4 NPT Green
SEN-0052 0 - 870 psi (60 bar) 1/4 NPT Grey
SEN-0053 0 - 232 psi (16 bar) 1/4 NPT Khaki
SEN-0054 0 - 14.5 psi (1 bar) 1/4 NPT Red
SEN-0055 0 - 30 psi (2 bar) 1/4 NPT Red Class I, Div 2, Groups A,B,C,D
SEN-0046 0 - 150 psi (10.34 bar) 1/4 NPT Red Class I, Div 2, Groups A,B,C,D
SEN-0047 0 - 7,500 psi (517 bar) 1/4 NPT Red Class I, Div 2, Groups A,B,C,D

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9.3 Nonadjustable Valves
The condensate drain valve, bleed valve and check valves are not adjustable. The condensate drain valve
and bleed valve have seats and seals which should be replaced if the valve leaks. Check valves are not
adjustable or repairable and must be replaced if they malfunction.

Figure 9-2 Check Valve Figure 9-3 Pressure Maintaining Valves (PMV)

2 2
1
1

9.4 Pressure Maintaining Valve

The pressure maintaining valve is adjusted at the factory to the required pressure and does not normally
require maintenance or 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 clockwise to increase pressure, counterclockwise to decrease pressure.
4. Determine if the PMV is properly adjusted:
a. Depressurize the final separator and purifier chamber by slowly opening the bleed valve.
b. Close the bleed valve and start the compressor.
c. Observe the final pressure gauge and note the pressure at which the valve opens (delivers).
d. If the pressure is not at the specified pressure ± 100 psi, readjust the PMV.

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9.5 Safety Valves

Figure 9-4 Safety Valves

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).

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CHAPTER 10:APPENDIX
10.1 Safety
10.1.1 General Safety Precautions
• Read the operating manual before installing or operating this compressor unit. Follow appropriate
handling, operation and maintenance procedures from the very beginning. The maintenance schedule
contains measures required to keep this compressor unit in good condition. Maintenance is simple,
but must be executed regularly to achieve safe operation, maximum efficiency and long service life.
• We recommend that all maintenance work be recorded in a service book, showing the date and details
of the work carried out. This will help to avoid expensive repairs caused by missed maintenance
work. If it is necessary to make a Claim against the warranty, it will help to have proof that regular
maintenance has been carried out and that the damage has not been caused by insufficient mainte-
nance.
• This compressor unit must be installed, operated, maintained and repaired only by authorized, trained
and qualified personnel.
• Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the
installation and operation of this compressor and accessories before operating the unit.
• Do not operate this unit in excess of its rated capacity, speed, pressure, temperature, 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 with-
stand.
• Keep safety guards in place.
• Do not modify the compressor or its systems.
• Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, brace-
lets, hand rags, etc. are potential hazards.
• Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes
of escape and post such routes.
• Make sure you are equipped with all required safety equipment; hearing protection, safety glasses,
hard hats, safety shoes and fire extinguisher.
• Visually inspect the unit before starting. Remove and or replace any loose or broken components,
tools, valves, missing equipment, etc.
• Do not tamper with, modify, or bypass safety and shutdown equipment.
• Do not tighten or adjust fittings or connections under pressure.
• The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to
ensure system compatibility of flex joints and flexible hose can result in mechanical failure, property
damage, and serious injury or death.
• The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous.
• Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced
fan can fly apart and create an extremely dangerous condition.

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• Allow the compressor to cool before servicing. Whenever the compressor is shut down and over-
heating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase.
Premature opening of the crankcase of an overheated unit can result in an explosion.
• Incorrect placement of the inlet and pressure valves in a compressor cylinder head can cause an
extremely dangerous condition. Refer to the appropriate section of this manual before installing or
replacing valves.
• Before doing any work involving maintenance or adjustment, be sure the electrical supply has been
disconnected, and the complete compressor system has been vented of all internal pressure. Failure to
follow these warnings may result in an accident causing personal injury and/or property damage.
• Before working on the electrical system, be sure to disconnect the electrical supply from the system at
the circuit breaker or other manual disconnect. Do not rely on 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 unsuitable for air applications. Should the
purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the
purchaser and/or user assumes all liability resulting therefrom without any responsibility being
assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any
agreement for resale of this compressor.
• The use of repair parts other than those listed in this manual or purchased from Bauer Compressors,
Inc. 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
non-approved repair parts are installed.

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10.1.2 Safety Warning Labels

Notes, labels and warning signs are displayed on the compressor unit according to model, application or
equipment and may include any of the following.

HOT SURFACES DO NOT TOUCH!

Danger of burning if cylinders, cylinder heads, or pressure lines of individual
compressor stages are touched.

HIGH VOLTAGE!
Life threatening danger of electrical shock. Maintenance work on electric units
or operating equipment should be carried out by a qualified electrician or by a
person supervised by a qualified electrician according to electrical regulations.
AUTOMATIC COMPRESSOR CONTROL
UNIT MAY START WITHOUT WARNING!
Before carrying out maintenance and repair work, switch off at the main switch
and ensure the unit will not restart.

THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT!

The instruction manual and all other applicable instructions, regulations, etc.
must be read and understood by the operating personnel before using the
machine.

HEARING PROTECTION MUST BE WORN!

Hearing protectors must be worn when working on a machine which is running.

DIRECTION OF ROTATION!
When switching on the machine, check the arrow to ensure correct direction of
rotation by the drive motor.

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10.2 Unpacking, Handling and Installation
10.2.1 Unpacking and Handling
This compressor unit is packaged according to the requirements for shipping via the requested type of
carrier service. It is possible that the compressor unit could have been damaged during shipping. For this
reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to
the shipping company immediately.
Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for
clearance between the item being unpacked and the packaging to be removed.
Handling of the unpacked unit should be performed using only the following devices. See Figure 10-1.

Figure 10-1 Lifting Devices

Chain Hoist

Fork Lift Hand Truck

1. Forklift 2. Chain Hoist 3. Hand Truck

^ 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 manufacturer’s warranty for the compressor
unit will be voided. All braces are tagged and labelled.

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10.2.2 Installation of the Compressor Unit

10.2.2.1 General
The floor site must be capable of supporting the weight of the unit. Secure the compressor unit to the
floor using ½” lag bolts. Position the unit so that it is level. Permissible inclination of the compressor unit
is listed in Paragraph 1.4.

^ 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.
Raise the unit with a forklift or crane to raise the unit at the leveling foot. Loosen the locking nut and turn
the leveling bolt clockwise to desired height. Lock the leveling foot in place with the provided hex-nut
once the desired height is achieved. Set the unit back down on the floor and check adjusted height. If fur-
ther adjustment is needed repeat.

Figure 10-2 Leveling Feet

Before Raising After Raising

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
sure that no one is checking or operating the unit. For this purpose, a second warning plate should be pro-
vided at the remote control unit.

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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.

Observe and maintain an ambient temperature range of 40 - 115 °F (5 - 45 °C).

The area in which the compressor unit is installed should be well lit and easily accessible to facilitate ser-
vicing and routine maintenance.
10.2.2.2 Ventilation
During normal compression, heat is generated by the compressor and by the drive motorengine. For air-
cooled compressor units, this heat needs to be vented away by sufficient ventilation.
10.2.2.2.1Outdoor Installation
It is recommended that all gasoline and diesel engine driven compressor units be installed outdoors. Elec-
trically driven compressor units may be installed outdoors only if enclosed with weatherproof enclosure
panels.
10.2.2.2.2Indoor Installation
The best location to install the compressor unit indoors is against an outside wall with a suitably large air
vent in front of the cooling fan. Additionally, it is necessary to position an 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 exceeding 105 °F (41 °C). Additional heat generating equipment or piping should be
avoided or must be well insulated.
10.2.2.2.3Natural Ventilation
Natural ventilation should only be used up to a maximum drive power of 20 Hp. Units with higher pow-
ered drives should incorporate forced ventilation. To determine the size of the required intake and
exhaust openings for natural ventilation, refer to the following table:

Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)
V = 1750 ft³ h = 6.5 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft
Drive
Hp Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²)
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

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10.2.2.2.4Forced Ventilation
Forced ventilation should be utilized on units with drive power higher than 20 Hp. For units with lower
powered drive natural ventilation may be used. To determine the size of the required intake and exhaust
openings for forced ventilation, refer to the following table

Intake & Exhaust Openings Dependent on Room Volume (V) and Height (h)a
V = 1750 ft³ h = 8 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft
Drive Intake Exhaust Intake Exhaust Intake Exhaust
Hp (ft²) cfm (ft²) cfm (ft²) 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.

10.2.2.3 Electrical Installation

10.2.2.3.1Electric Drive
When making the electrical connections to the system, the following instructions are mandatory:
• Comply with all local, state and federal regulations concerning electrical installation.
• Arrange for the electrical connections to be made by a certified electrician only.
• Ensure that the motor voltage, control unit voltage, and frequency conform with the main voltage 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 protection for
the compressor must be carried out in compliance with local, state and national electrical regulations.
10.2.2.3.2Electrical 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 electrical enclosure. All wiring should be done by a licensed electrician familiar
with national, state and local electrical codes.

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The label shown in Figure 10-3 indicates where the incoming power is connected to the compressor unit
electrical enclosure. This label must be removed before using the equipment.

NOTICE
If this unit is equipped with an Air Kool system, consult the Air Kool Section for electrical installation.

Figure 10-3 Incoming Power Wiring Label

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.

b. Normal Copper wire with THW, THWN, or XHHW insulation.

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MNL-0420

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.

b. Normal Copper wire with THW, THWN or XHHW insulation.

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.
10.2.2.3.3Pneumatic Leaks
Each unit is tested prior to leaving the manufacturing facility. All loose or leaking fittings are tightened
prior to shipping. During the shipping process pneumatic connections may work loose and leaks may
develop. Ensure each unit is leak tested prior to being placed in full operational usage.

^ WARNING
Never tighten or adjust fittings or connections under pressure. Always depressurize first.

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10.3 Long Term Storage
10.3.1 General
If the compressor unit will be out of service for more than six months, it should be preserved in accor-
dance with the following instructions:
1. Make sure that the compressor is kept indoors in a dry, dust-free room.
2. Cover the compressor with plastic sheets only if no condensation will form under the sheet.
3. Remove the sheet from time to time and clean the outside of the unit.
4. If this procedure cannot be followed, or if the compressor will be out of service for more than 24
months, please contact Bauer Product Support for special instructions.
10.3.2 Preparations
Prior to preserving the compressor unit, it must be run until warm, i.e., up to the specified service pres-
sure. Operate the unit for approximately 10 minutes, then 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 filters.
Close all valves.
5. Remove filter heads and lubricate the threads with petroleum jelly.

10.3.2.1 Units Equipped with a Filter System

1. Ensure that cartridges remain in the purification system chambers. This will prevent oil from enter-
ing the outlet lines as a result of preservation procedures.
2. Remove the intake filterintake pipe completely.

10.3.3 Preserving the Compressor

1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet
port while the compressor is running. Keep the shut-off valve and the condensate drain valves open.
2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before
shutting the compressor unit down.
3. Close the shut-off valve and condensate drain valves.
4. Close the inlet port with a dust cap and/or tape.

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10.3.4 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.

10.3.5 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.

10.3.6 Reactivating the Compressor Unit

1. Remove any dust cap or tape from the inlet port and install an intake filter cartridge.
2. Change the oil, ensuring proper oil level when refilled.
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.

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10.4 Reproducible Forms
10.4.1 Scheduled Maintenance Form

Daily Para. Date Signature

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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

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3,000 Operating Hours. Para. Date Signature

Annually. Para. Date Signature

Biennially. (Every two years) Para. Date Signature

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10.4.2 Record of Operating Hours

Date Minutes Total Date Minutes Total

Subtotal: Subtotal:

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10.5 Reference Data
10.5.1 Tightening Torque Values

1. Unless otherwise specified in text, the torque values in Table 1 apply.

2. The indicated torque values are valid for bolts in greased condition.
3. Self locking nuts must be replaced on reassembly
4. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more
than finger tight plus up to an additional half turn.

Table 10-1: Torque Values

Bolt or Screw Size Max. Torque
Hex and Socket Head 1/4 in (6 mm) 7 ft-lb. (9.5 N m)
Hex and Socket Head 5/16 in (8 mm) 18 ft-lb. (24.4 N m)
Hex and Socket Head 3/8 in (10 mm) 32 ft-lb. (43.4 N m)
Hex and Socket Head 1/2 in. (12 mm) 53 ft-lb. (71.9 N m)
Hex and Socket Head 9/16 in (14 mm) 85 ft-lb. (115.3 N m)
Hex and Socket Head 5/8 in (16 mm) 141 ft-lb. (191.2 N m)

10.5.2 Torque Sequence Diagrams

Figure 10-4 6 Bolt and 4 Bolt Torque Sequence

3
5 3

2 1 2 1

4 6
4

10.5.3 Conversion Formulas

°F = 9/5 °C + 32 °C = 5/9 x (°F - 32)
psi = bar x 14.5 bar =psi x 0.0689

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10.5.4 Approved Lubricants Chart

Unless otherwise specified in text, use the lubricants in Table 2.

Table 10-2: Lubricant Chart

Usage Lubricants
O-rings, rubber and plastic parts; filter housing
Parker Super “O” Lube
threads, sealing rings
Bolts, nuts, studs, valve parts, Copper gaskets and
tube connection parts (threads, cap nut and com- Never-Seez® NSWT, Pipe Dope or teflon tape
pression rings)
DOW Corning 732 or equivalent silicone com-
Paper gaskets
pound applied on both sides before assembly,
DOW Corning 732 or equivalent temperature resis-
High temperature connections
tant compound,
Tube connection ferrules, Never-Seez® NSWT

10.5.5 Glossary of Abbreviations and Acronyms

AC Activated Charcoal, removes odor and taste
ACD Automatic Condensate Drain
ASME American Society of Mechanical Engineers
CW Clock Wise
CCW Counter-Clockwise
CGA Compressed Gas Association
DIN Deutsches Institut für Normung
DOT Department of Transportation
E1 single phase electrical supply (Electric 1)
E3 three phase electrical supply (Electric 3)
HP Hopcalite, a chemical catalyst which converts carbon monoxide to carbon dioxide
IAW In Accordance With
MS Molecular Sieve, removes 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
PLC Programmable Logic Controller
PMV Pressure Maintaining Valve
SC Securus® moisture sensing device

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10.6 Additional Documents
10.6.1 Diagrams and Drawings
Any included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound next to the back
cover in a hardcopy manual or included as a separate file on a CD.
10.6.2 Other Documents
OEM Manuals and other Bauer manuals may be included in the documentation shipping package.

Page 153 1st Edition, Rev. 1 Chg. 1

 C O R R E C T IO NS & C O M M E NT S

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: [email protected], or fill
out the form below and mail it to us:

Submitters Contact Information: Unit Information:

Name: ______________________________ Model:

Address: _____________________________ Serial#:

(number & street)

_____________________________ Block#:
(city, state \ zip)
E-mail: ________________________ MFG Date:
(optional)

Inaccuracies: page# ________ figure# ________ paragraph# ________

Suggested Corrections:

Additional Comments:
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place
postage
here

Bauer Compressors, Inc.

Attn: Documentation
1328 Azalea Garden Rd.
Norfolk, VA 23502-1944

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tape or glue here