INSTRUCTION MANUAL aaa AND REPLACEMENT PARTS LIST 015-E/D HIGH PRESSURE OFFSHORE BREATHING AIR COMPRESSOR UNIT BAUER COMPRESSORS, INC. 1828 Azalea Garden Road + Norfolk, Virginia 28502-1944 Phone: (757) 855-6006 * Fax: (757) 855-6224INSTRUCTION MANUAL AND REPLACEMENT PARTS LIST 015-E/D HIGH PRESSURE OFFSHORE BREATHING AIR COMPRESSOR UNIT noon CLE. Serial no. Edition May 1995 BAUER COMPRESSORS, INC. 1328 Azalea Garden Road ses Norfolk, Virginia 23502-1944 Underwriters Telephone: (804) 855-6008 Laboratories Inc.eINTRODUCTION This manual contains operating instructions and maintenance schedules for O15-E/D high pressure offshore breathing sir compressor units manufactured by’ Bauer Compressors, Inc. of Norfotk, Virginia, USA. All instructions in this manual should be observed and carried out as written to prevent damage and premature wear to the equipment and the unit(s) served by it, If these operating instructions are not followed and/or changes are made to the unit without prior written authorization, including the use of maintenance parts not supplied by Bauer, any claims under warranty shall be void. Please contact our customer service department at the numbers listed on the front of this manual should you need any further assistance. While every effort is made to ensure the accuracy of the information contained in this manual, Bauer will not, under any circumstances, be held accountable for any inaccuracies or the consequences thereof. 595BXINTRODUCTION NOTICE Layout and use of instruction manuals | : : Operating this unit can be dangerous unless the operator possesses a sufficient knowledge of high pressure compressor systems. For this reason, it is advised that the personnel using the unit reed this instruction manual first. This instruction manual and spare parts catalog incorporates a building block format, This ‘means that the table of contents may contain headings which are not applicable to your unit, and that the text may contain information on options which you have not requested. Any information ‘on options not included on your unit may be safely ignored. When ordering spare parts, be certain that the items you order are relevant 10 your specific unit. ‘The organization of the instruction manuals is such that from one manual to the next, the section numbers always correspond to the same section titles, ie., Section | always covers Operation and a Safety Precautions, Section 2 is General Information, Section 3 is Installation, etc. A If your unit is equipped with non-standard accessories and/or options, information thereon will be , included in the annex. ii 595Bxgaa a = ‘TABLE OF CONTENTS Title Page OPERATING AND SAFETY PRECAUTIONS GENERAL SAFETY PROCEDURES. SAFETY WARNINGS . COMPRESSOR BLOCK DESIG COMPRESSOR UNIT DESIGN. INSTALLATION UNPACKING AND HANDLING. 7 INSTALLATION OF THE COMPRESSOR UNIT. LUBRICATION FUNCTIONAL DESCRIPTION. TYPE OF OI. OIL CHANGE. OIL LEVEL CHECK.. VENTING THE OTL PUMP OIL PRESSURE REGULATOR AIR-INTAKE SYSTEM. REMOTE INTAKE CONNECTION... INTERMEDIATE FILTER FUNCTIONAL DESCRIPTION .. MAINTENANCE 00.01 FILTER SYSTEM GENERAL... OVERVIEW OF THE PURIFICATION SYSTEMS. DESCRIPTION OF THE PURIFICATION SYSTEM COMPONENTS. MAINTENANCE OF THE PURIFICATION SYSTEM PRESSURE MAINTAINING VALVE DESCRIPTION... MAINTENANCE iiiINTRODUCTIO! Section 10. u 12. 1B. ‘TABLE OF CONTENTS (Continsed) Title Page SAFETY VALVES FUNCTIONAL DESCRIPTION ............ we VALVE HEADS AND VALVES FUNCTIONAL DESCRIPTION .... INITIAL OPERATIONAL CHECK OF THE VALVES GENERAL (NSTRUCTIONS FOR CHANGING THE VALVES..... CHANGING THE 1ST STAGE VALVES .. CHANGING THE 2ND AND 3RD STAGE VALVES... CHANGING THE 4TH STAGE VALVES, CONDENSATE DRAIN SYSTEM. MANUAL CONDENSATE DRAIN SYSTEM .......eccsseteneeree AUTOMATIC CONDENSATE DRAIN SYSTEM .....secsesneeeeee IDL ELECTRICAL CONTROL SYSTEM. HOLDING RELAY PRINTED CIRCUIT BOARD. SELECTOR SWITCHES....... ELECTRICAL ENCLOSURE ... PRESSURE SWITCHES. FINAL STAGE TEMPERATURE SWITCH AUDIBLE ALARM HOURMETER.. ACD TIMER... EMERGENCY STOP PUSH! BUTTON. COMPRESSOR DRIVE SYSTEM GENERAL.. ELT MAINTENANCE MAINTENACNE OF THE DRIVE MOTOR,INTRODUCTION Section 15. 16. i. 18, 19. 20, 21. 2, TABLE OF CONTENTS (Continued) Title Page COOLING SYSTEM DESCRIPTION... MAINTENANCE. AIR STORAGE SYSTEM DESCRIPTION........ OPERATION .. MAINTENANCE AIR DELIVERY AIR OUTLET. FILLING PROCEDURE. OPERATION OPERATION .. MAINTENANCE SCHEDULE, GENERAL... CALENDAR SCHEDULE.. HOURS OF OPERATION SCHEDULE. MAINTENANCE AS REQUIRED... MAINTENANCE RECORD.. STORAGE, PRESERVATION GENERAL ...oecscseeenen PREPARATIONS.. PRESERVING THE COMPRESSOR. 7 PRESERVING THE DRIVE... .ccccnssoroursnntsnnnnsnnmvanantnn enon 202, PREVENTIVE MAINTENANCE DURING STORAGI REACTIVATING THE COMPRESSOR UNI’ REPAIR INSTRUCTIONS REPAIR, ‘TROUBLESHOOTING GENERAL INSTRUCTIONS 59SBXINTRODUCTION tal) TABLE OF CONTENTS (Continued) Section Title ‘Page 23. TABLES TIGHTENING TORQUE VALUES... LUBRICATION CHART CONVERSION TABLE PSI TO BAR. CONVERSION TABLE °F TO°C.. 24, ANNEX Glossary of Abbreviations Drawings and accessory documentation Document no. + Purification system operating schedule FOR-0018 + Explanation of model name.. - FOR-0267 + Drawing of the K-15 H compressor block. KB-013578-874 + Drawing of the compressor unit, standard ASY-0262 + Drawing of the compressor unit, w/options.. ASY-0197 + Electrical wiring diagram..... DGM-0578 * Air-flow diagram .... .DGM-0069 Change Notice 1 Changes which differ from the previous edition are marked with a vertical line, Change No. Change date 0 Basic edition May 1995 5981 Ll OPERATING AND SAFETY PRECAUTIONS GENERAL SAFETY PROCEDURES & WARNINGS, Read the operating manual before installing or operating this compressor unit. Follow appro- priate handling, operation and maintenance procedures from the very beginning. The mainte- nance plan 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, Consult and follow all federal, state, and local regulations, laws and codes covering the instal- lation and operation of this compressor and accessories before operating this unit. Refer to NFPA 70 conceming the installation of this compressor unit, For units equipped with internal combustion engines, reference also NPFA 37. This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel. ‘The use of plastic or non-metallic bowis on line filters without metal guards can be hazardous. Instalter must provide en earth ground and maintain proper clearance for all electrical compo- nents (OSHA 1910.302 - 308). Ali electrical installation must be in accordance with recog- nized national, state, and local electrical codes. Before working on the elecirical system, be sure to disconnect the electrical supply from the system by use of a manual disconnect switch. Do not rely on the starter to disconnect the elec trical supply. For engine driven units, the battery cables should be disconnected before working on the compressor unit. Do not operate this unit in excess of its rated capacity, speed, pressure, temperature, or other- vwise than in accordance with the instructions contained in this manual. Operation of this unit ‘excess of the conditions set forth in this manual will subject the unit to limits which it may rot be designed to withstand ‘Whenever the compressor is shut down and overheating is suspected, « minimum period of 1S 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 discharge valves in a compressor cylinder head can cause an extremely hazardous condition. Refer to the appropriate chapter of this instruction manual before installing or replacing valves. ‘A pressure safety valve must be installed in the discharge piping between the compressor and any possible restriction, such as block valve, check valve, aftercooler, or air dryer. Failure to install such a relief valve could result in personal injury or damage to the compressor.' i Ll OPERATING AND SAFETY PRECAUTIONS Sanco + If any of the provisions contained in this list (especially concerning safety) do not comply swith local provisions of law, the safer provision must be applied. + Piping subject to temperatures in excess of 175° F (80° C) which may be exposed to personnel must be suitably guarded or insulated, + Allow the compressor to coot before servicing, + Limits (pressure values, temperature values, time settings, etc.) must be permanently marked. + Donot operate the compressor on other than nameplate voltage. Serious bodily harm and/or system damage may occut. + Do not operate the compressor in areas where there is a possibility of drawing in inflammable or toxic fumes. + Do not play with compressed air. Pressurized air can cause serious injuries. + Avoid ignition voltage shock. Avoid contacting breakerless magneto and battery ignition systems. + Provide adequate fire protection. Make sure fire extinguishers are accessible, Select alternate routes of escape and post such routes, + Keep safety guards in place + Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats, safety shoes and fire extinguisher. + Visually inspect the compressor or unit before restarting, Remove and or replace any loose or broken components, tools, valves, missing equipment, etc. * Do net modify the compressor unit oF its systems, + Do not tamper with, modify or bypass the compressor unit and shutdown equipment. + Do not exceed maximum allowable compressor unit pressures and temperatures. + The operator is responsible for keeping the machine in safe operating condition. If parts ant accessories are not considered to be reliable for safe operation, they must be replaced immedi- ately. Periodically check all safety devices, temperature and pressure gauges to make sure tha the control system is governing the unit operation within the proper limits. + Keep the operating manual available for the operators, and take care that operation and main- tenance are performed according to the instructions. Enter all operating data, executed mainte- nance measures, etc. in a log. Observe all relevant safety provisions. + Failure to follow any of these procedures or the following warnings may result in an accident causing personal injury of property damage. 12 aOPERATING AND SAFETY PRECAUTIONS Do not wear loose clothing around machinery. Loose clothing; neckties, rings, wrist watches, bracelets, hand rags, etc. are potential hazards, Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbalanced fan can fly apart and create an extremely dangerous condition. Properly ventilate the engine operating area. Internal combustion engine exhaust products are toxic and can cause injury or death when inhaled. BAUER air-compressors equipped with a BAUER purification system are suitable for use in breathing air service; however, suitable intake air is just as important as the quality of the puri- fication system to ensure high quality breathing air. BAUER purification systems exceed the CGA Grade E breathing air requirements when proper inlet conditions are satisfied. In the absence of such purification, BAUER air-compressors are not considered as able to produce air of breathing quality. For a compressor to be capable of use for breathing air service, it must be fitted with specialized equipment (such as a BAUER purification system) to properly filter and/or purify the air to meet all applicable federal, state, and local laws, rules, regulations and codes, such as, but not limited to, OSHA 29 CFR 1910.134, Compressed Gas Association commodity specification G-7.1-1989, Grade E breathing air, and/or Canadian Standards Association. Should the purchaser or user fail to add such special- ized equipment and proceed to use the compressor for breathing air service, the purchaser/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 the resale of this compressor. The use of repair parts other than those included within the BAUER approved parts list may create hazardous conditions over which BAUER has no control. Such hazardous 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 The use of plastic pipe or rubber hose in place of steel tube or iron pipe; soldered joints; or failure to insure systerg compatibifity of flex joints and flexible hose can result in mechanical iailure, property damage, and serious injury or death. Compressed air and electricity are a dangerous combination Before doing any work involving maintenance or adjustment, be sure the electrical supply has been cut off and the entire 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. 1-3 27DlL OPERATING AND SAFETY PRECAUTIONS + Disconnect the main power before opening any access door or attempting any service. The compressor could start automatically. Compressed air and electricity are a dangerous combi- nation. + Use only recommended oil in your compressor, Failure to do so may cause excessive carbon deposits and system damage and may void your warranty. + Inspect the air/oil separator, oil, and air-filter according to the maintenance schedule. Dirt, oxidized oi and increased air velocity may cause carbon build-up, property damage and/or severe injury or death. + Extreme care should be taken when the compressor is not operating. With the selector switch in the “ON” or “AUTO” position, it may start automatically. + This compressor system is not suitable fac EAN, Nitrox, or any other gas-mix application. + When planning the installation of a BAUER high pressure compressor, itis both essential and desirable that a high pressure receiver be included in the system downstream of the compressor. The receiver should be sized so that the compressor is stopped and restarted no more than four times each hour. The primary reasons are for (1) economics and (2) motor protection, The usual operating protocol for a high pressure compressor system is to control the compressor by turning it or or off via start/stop device such as a pressure switch. In this case the pressure switch is set to tum off the compressor at the customer's required working pres- sure and to automatically restart the compressor when the pressure in the receiver falls to a predetermined lower pressure. By operating the system in this energy conserving manner, the compressor is running only when it needs to re-charge the receiver. Itis our position that the inclusion of an adequately sized receiver is of sufficient importance in establishing a trouble free system that we have addressed the issue in our warranty policy; which states that AN INAPPROPRIATE SERVICE OR DUTY CYCLE OR AN IMPROPER INSTALLATION CAN BE CAUSE FOR REJECTING WARRANTY CLAIMS. If the purchaser needs assistance in sizing a receiver or needs advice as to the suitability of a compressor model for a specific application, service or duty cycle, we urge you to call us, Our Engineering Department will be happy to assist yout Listed regulations were selected based on possible relationship to equipment supplied by BAUER Compressors, Inc. and is by no means a complete listing of all applicable rules and regulations governing the uses of compressed air and gases, Consult and follow all national, state, and local regulations, laws, and codes governing the installation and operation of this ‘compressor and/or accessories before operating this equipment. The following are selected excerpts from the “Cade of Federal Regulations” (CFR) for the ‘USE, SAFETY, AND MAINTENANCE OF DIVING COMPRESSORS, SUPPLY HOSES, AND COMPRESSED GAS CYLINDERS’,OPERATING AND SAFETY PRECAUTIONS. 197.310 AIR-COMPRESSOR SYSTEM. ‘A compressor used to supply breathing air to a diver must have a volume tank that is built and stamped in accordance with section VIII, division! of the ASME code with a check valve on the inlet side, a pressure gauge, a relief valve, and a drain valve. It must be tested after every repair, modification, or alteration to the pressure boundaries as required by 197.462, and have intakes that are located away from areas containing exhaust fumes of internal combustion engines or other hazardous contaminants, an efficient filtration system, and slow-opening, shut-off valves when the allowable working pressure of the system exceeds 500 psig. 197.312 BREATHING SUPPLY HOSE Each breathing supply hose must have a maximum working pressure that is equal to or exceeds the maximum working pressure of the section of the breathing supply system in which used, and the pressure equivalent of the maximum depth of the dive relative to the supply source plus 100 psig, It must have a bursting pressure of four times its maximum working pressure, have connectors that are made of corrosion resistant material and are resis- tant to accidental disengagement, and have a maximum working pressure that is at least equal to the maximum working pressure of the hose to which they are attached, and resist kinking by being made of kink-resistant materials or having exterior support. Each umbilical must meet requirements of the paragraph above and be marked from the diver or open bell end in 10-foot intervals to 100 feet and in S0-foot intervals thereafter. 197.336 PRESSURE PIPING Piping systems that are not an integral part of the vessel or facility, carrying fluids under pres- sures exceeding 15 psig must meet the ANSI Code, have the point of connection to the inte- gral piping system of the vessel or facility clearly marked, and be tested after every repair, modification or alteration to the pressure boundaries as set forth in 197.462. 197,338 COMPRESSED GAS CYLINDERS Each compressed gas cylinder must meet the following specifications: + Be stored in a ventilated area + Be protected from excessive heat + Be prevented from falling + Be tested after any repair, modification, or alteration to the pressure boundaries as set forth in 197.462 + Meet the requirements of 49CFR 173.34 and 49 CFR 178 subpart C 1-5 27Di 1 OPERATING AND SAFETY PRECAUTIONS a ES 197.340 BREATHING GAS SUPPLY A primary breathing gas supply for SCUBA diving must be sufficient to support the diver $ the duration of the planned dive through his return to the dive location or planned pick point, A diver-carried reserve breathing gas supply for SCUBA diving must be sufficient allow the diver to return to the dive location or planned pick-up point from the greatest dep: of the planned dive. Compressed air used for breathing mixtures must possess the fallowing: + Be 20 to 22 percent oxygen by volume + Have no objectionable odor | | + Have no more than 1,000 parts per million of carbon dioxide, 20 parts per million carbo | | monoxide, 5 milligrams per cubic meter of solid and liquid particulate including oil, and 2 parts per million of hydro-carbons (includes methane and aii other hydcacarbans expresse | as methane). | 197.346 DIVER'S EQUIPMENT. ty Each diver using SCUBA must have the following: + Self-contained underwater breathing equipment + A primary breathing gas supply with a cylinder pressure gauge readable by a diver ducing the dive A diver-carried reserve breathing gas supply provided by a manual reserve (J valve) or an independent reserve cylinder connected and ready for use + Face mask + Inflatable flotation device \ + Weight belt capable of quick release | : + Knife + Swim fins or shoes + Diving wristwatch. + Depth gauge Each diver diving outside the no-decompression limits, deeper than 130 fsw, or using mixes gas must have a diver-cartied reserve breathing gas supply except when using a heavy-weig diving outfit or when diving in a physically confining area, Cn 16 297OPERATING AND SAFETY PRECAUTIONS 197.480 BREATHING GAS TESTS The diving supervisor shall insure for the following: + The output of each air-compressor is tested and meets the requirements of 197.340 for quality and quantity by means of samples taken at the connection paint to the distribution system every 6 months, and after every repair or modification. + Purchased supplies of breathing mixtures supptied to a diver are checked before being placed on line for certification that the supply meets the requirements of 197,340, and (2) noxious or offensive odor and oxygen percentage. + Each breathing supply system is checked, pricr to commencement of diving operations, at the umbifical ot underwater breathing apparatus point for the diver, for noxious or offensive ‘odor and presence of oil mist. + Each breathing supply system, supplying mixed-gas to a diver, is checked, prior to the commencement of diving operations, at the umbilical or underwater breathing apparatus conection point for the diver and for the percentage of oxygen 197.456 BREATHING SUPPLY HOSES ‘The diving supervisor shall insure the following: + Bach breathing supply hose is pressure tested prior to being placed into initial service and every 24 months thereafter to 1.5 times its maximum working pressure. + Each breathing supply hose assembly, prior to being placed into initial service and after any: repair, modification, or alteration, is tensile tested by subjecting each hose-to-fitting connec tion to a 200 pound axial load, and passing a visual examination for evidence of separation, slippage or other damage to the assembly. + Bach breathing supply hose is periodically checked for damage and contamination which is 1ikely to affect pressure integrity, and the purity of the breathing mixture delivered to the diver. + The open ends of each breathing supply hose are taped, capped, or plugged when not in use. To meet the requirements of checking for damaged hose, each breathing supply hose must be carefully inspected before being shipped to the dive Location, visually checked during daily ‘operation, and checked for noxious or offensive odor before each diving operation. 197.462 PRESSURE VESSELS AND PRESSURE PIPING The diving supervisor shall insure that each volume tank, cylinder, PVHO, and pressure piping system has been examined and tested every (2 months; and after any repair, modifica- cn 17 2970OPERATING AND SAFETY PRECAUTIONS tion or alteration to the extent necessary to determine that they are in condition and fit for thi service intended. The following test must be made to meet the annual requirements of the above paragraph: + Internal and external visual examination for mechanical damage or deterioration, Ifa defect is found that may impair the safety of the pressure vessel, a hydrostatic test must be performed. + Leak test + Pneumatic test + Hydrostatic test every fifth year instead of the pneumatic test ‘The following tests must be made after any repair, modification or alteration to meet th annual requirements of this section: + Internal and extemal visual examination for correctness and adequacy of repair, modifica tion, or alteration + Leak test + Hydrostatic test when the repair, modification or alteration affects the pressure boundary When the pneumatic test on pressure vessels is conducted, proceed as follows: + The test pressure must be the maximum allowable working pressure stamped on the pres sure vessel + The test may be conducted only after suitable precautions are taken to protect personnel ani equipment. ‘When the pneumatic test on pressure piping is conducted: + The test pressure must be na less than 90 percent of the setting of the relief device, + The test may be conducted only after suitable precautions are taken to protect personnel ani equipment, When a hydrostatic test on a pressure vessel is made, the test pressure must be the following: + 1¥; times the pressure stamped on the pressure vessel built to division 2 of the ASME Code. «+ 1y,times the pressure stamped on the pressure vessel built to division 1 of the ASME Code ‘When a hydrostatic test on pressure piping is conducted, the test must be conducted in accor dance with the ANSI Code. ‘When the leak test on pressure vessels or pressure ing is conducted proceed as follows: + The test must be conducted ~with the breathing mixture normally used in service,OPERATING AND SAFETY PRECAUTIONS: + The sest must be conducted at the maximum allowable working pressure. + The test pressure must be maintained for a minimum of 10 minutes to allow for checking all joints, connections, and regions of high stress for leakage. The following are excerpts from the “Code of Federal Regulations” (CFR) 29 as used by OSHA. Because of differing uses and compressor types; please refer to CFR 29 1910.95 (Occupational Noise Exposure) to determine whether or not hearing protection will be required. Inspection of Compressed Gas Cylinders Each employer shal! determine that compressed gas cylinders under his control are in a safe condition to the extent that this can be determined by visual inspection, Visual and other inspections shall be conducted as prescribed in the Hazardous Materials Regulations of the Department of Transportation (49 CFR parts 171-179 and 14 CER pact 103). Where those regulations are pct applicable, visual and other inspections shall be conducted in accordance | 1910.101 COMPRESSED GASES (GENERAL REQUIREMENTS) | with Compressed Gas Association Pamphlets C-6-1968 and C-8-1962. Compressed Gases The in-plant handling, storage, and utilization of all compressed gases in cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks shall be in accordance with Compressed Gas Association Pamphlet P-1-1965. Safety Relief Devices for Compressed Gas Containers ‘Compressed gas cylinders, portable tenks, and cargo tanks shall have pressure relief devices installed and maintained in accordance with Compressed Gas Association pamphlets S-1.1- 1963 and 1965 addenda and -1.2-1963. 1910.134 RESPIRATORY PROTECTION Air Quality Compressed air, compressed oxygen, liquid air, and liquid oxygen used for respiration shall be of high purity. Oxygen shall meet the requirements of the United States Pharmacopoeia for medical or breathing oxygen. Breathing air shall meet at least the requirements of the specifi- cation for Grade D breathing air as described in Compressed Gas Association Commodity Specification G-7.1-1966. Compressed oxygen shall not be used in supplied-air respirators or LeL OPERATING AND SAFETY PRECAUTIONS in open circuit self-contained breathing apparatus that have previously used compressed ai ‘Oxygen must never be used with air line respirators. Breathing air may be supplied to respirators from cylinders or air-compressors, Cylinder shall be tested and maintained as prescribed in the Shipping Container Specification Regule tions of the Department of Transportation (49 CFR part 178). The compressor for supplyin air shall be equipped with the necessary safety and standby devices. A breathing air-typ ‘compressor shall be used. Compressors shall be constructed and situated so as to avoid entr of contaminated air into the system and suitable in-line air purifying sorbent beds and filter installed to further assure breathing air quality. A receiver of sufficient capacity to enable th respirator wearer to escape from a contaminated atmosphere in event of compressor failur and alarms to indicate compressor failure and overheating shall be installed in the system. an oil-lubricated compressor is used, it shall have a high-temperature or carbon monoxid alarm, or both. If only a high-temperature alarm is used, the air from the compressor shall b frequently tested for carbon monoxide to insure that it meets specifications, Air line couplings shall be incompatible with outlets for other gas systems to prevent ina¢ vertent servicing of air line respirators with non-respirable gases or oxygen. Breathing gas containers shall be marked in accordance with the American National Standar Method of Marking Portable Compressed Gas Containers to Identify the Materis Contained,Z48.1-1954; Federal Specification BB-A-1034a, June 21, 1968, Air, Compresse for Breathing Purposes; or Interim Federal Specification GG-B-00675b, April 27, 196: Breathing Apparatus, Self-Contained 1910.169 Air-receivers General Requirements Application This section applies to compressed air receivers, and other equipment used in providing an utilizing compressed air for performing operations such as cleaning, drilling, hoisting, an chipping. This section does not deal with the special problems created by using compresse air to convey materials nor the problems created when men work in compressed air as i tunnels and caissons. This section is not intended to apply to compressed air machinery an equipment used on transportation vehicles such as steam railroad cars, electric railway car and automotive equipment. ‘New and existing equipment All new air-receivers installed after the effective date of these regulations shall be constructe in accordance with the 1968 edition of the A.S.ME. Boiler and Pressure Vessel Code, Sectio VIII, All safety valves used shall be constructed, installed, and maintained in accordance wit the A.S.M.E. Boiler and Pressure Vessel Code, Section VIL Edition 1968. 1-10 297OPERATING AND SAFETY PRECAUTIONS Ss S Installation and Equipment Requirements Installation Air-receivers shall be so installed that all drains, hand holes, and manholes therein are easily accessible. Under no circumstances shall an air-receiver be buried underground or located in an inaccessible place. Drains and traps A Grain pipe and valve shall be installed at the lowest point of every air receiver to provide for the removal of accumulated oil and water. Adequate automatic traps may be installed in addi- tion to drain valves. The drain valve on the air-receiver shall be opened and the receiver completely drained frequently and at such intervals as to prevent the accumulation of exces- sive amounts of liquid in the receiver. Gauges and valves Every air receiver shall be equipped with an indicating pressure gauge (so located as to be readily visible) and with one or more spring-loaded safety valves. The total relieving capacity of such safety valves shall be such as to prevent pressure in the receiver from exceeding the maximum allowable working pressure of the receiver by more than 10 percent. No valve of any type shall be placed berween the air-receiver and its safety valve or valves. Safety appli- ances, such as safety valves, indicating devices and controlling devices, shall be constructed, located, and installed so that they cannot be readily rendered inoperative by any means, including the elements. All safety valves shall be tested frequently and at regular intervals to determine whether they are in good operating condition. 1910.219 MECHANICAL POWER TRANSMISSION APPARATUS. CARE OF EQUIPMENT General All power-transmission equipment shall be inspected at intervals not exceeding 60 days and kept in good working condition at all times. Shafting Shafting shall be kept in alignment, ftee ftom rust and excess oil or grease. Where explosives, explosive dusts, flammable vapors or flammable liquids exist, the hazard of static sparks from shafting shall be carefully considered. Bearings Bearings shall be kept in alignment and properly adjusted, Pulleys 1-11 297D1. OPERATING AND SAFETY PRECAUTIONS ates Pulleys shall be kept in proper alignment to prevent belts from running off. Care of Belts Inspection shall be made of belts, lacings, and fasteners and such equipment kept in g repair. 1910,243 GUARDING OF PORTABLE POWERED TOOLS PNEUMATIC POWERED TOOLS AND HOSE Air Hose Hose and hose connections used for conducting compressed air to utilization equipmeit s be designed for the pressure and service to which they are subjected 1-12 32A GENERAL TECHNICAL DATA! Compressor model Medium Delivery Inlet pressure Operating pressure, max Ambient temperature range Compressor block No. of stages No. of cylinders Cylinder bore, Ist stage Cylinder bore, 2nd stage Cylinder bore, 3rd stage Cylinder bore, 4th stage Piston stroke Divection of rotation, viewing flywheel Oil capacity Oil, petroleum Oil, synthetic. TEFC motor? Operating voltage Power Speed Frequency Frame size Subject to change without prior notice, O1S-E3 air 17 scfm (481 min)? atmospheric 5000 psig (350 bar) 32° to 105° F (0° to 40° C) Ks 4 4 4.72in, (120 mm) 2.367 in. (60 mm) 1.26 in. G2 mm) 0.55 in, (14 mm) 1.97 in, (50 mm) ccw 4.25 quarts (4D Bauer P/N: OIL-0001 Bauer P/N: OIL-0002 MTR-0095 208-460, 3 phase 15 hp 3505 rpm 60 Hz 254.7 1 2. Compressor capacity referenced 0 standard inlet conditions. 3 Diesel engines available upon request. 2-1 Po ‘595BX2 22 224 222 23 234 GENERAL COMPRESSOR BLOCK DESIGN: General The K-15 H compressor block is used to compress air in the high pressure range up to 5000 psi (350 bar). This block is a four stage, four cylinder, air cooled reciprocating piston compressor. The cylinders are arranged diagonally with the Ist and 2nd stages and the 5rd and 4th stages positioned apposite to each other. The 4th stage oylinder is lubricated by means of the forced-feed lubrication system, The other cylinders are splash-lubricated This compressor block is particularly suitable for continuous operation because of its rugged design and the corrosion resistant intermediate filter and cooler assemblies. All valves have free access for time saving maintenance. There is no need for dismantling of pipes or pressure gauges. Compressor Block Components The design of the compressor block and its major components are indicated in the following illustration and in the drawings in the annex. Intake filter Oil dipstick Condensate drain valve Oil fill plug Imer-filter, 2nd/3rd stage Inter-filter, 3rd/ath stage Safety valve, Ist/Ind stege Safety valve, 2nd/3rd stage Safety valve, 3rd/Sth stage Cog belt cover Air ouet Ree BS cause Fig, 2.1 K-15 H compressor block, rear view (il pump side) COMPRESSOR [INIT DESIGN General The O15-E/D high pressure offshore air-compressor units are used for applications in the high pressure range, up to 5000 psig (350 bar), They feature a four-stage, four- cylinder, air-cooled high pressure K-15 H compressor block. Po 22 595BXGENERAL EF These compressor units are manufactured with the drive motor suspended beneath the compressor block. The system is mounted within a frame and enclosed by an optional enclosure assembly. Standard equipment includes an oil and water separator after the final stage, purification, a control panel with a selector switch, a final pressure safety valve, a pressure maintaining valve and an air outlet with fittings. Approximate unit weight: O15-E 1775 - 1900 Ibs. ois 2000 - 2100 Ibs. 23.2 Compressor Unit Components ‘The compressor unit is comprised of the following major assemblies; + Compressor block + Drive motor + Frame and panel assembly + Automatic condensate drain system + Purification system (P4) + Upto PS SECURUS purification* + Electrical control system + Fill hose assembiy + CO monitort + Hy$ monitor * + CO monitor calibration kit* The design of the compressor unit and some of its components are indicated in the following illustration and in the drawings in the annex. Roof panel Compressor air outlet Instrument panel Electrical enclosure Tiedown ting Forklift slot a Frame ‘Access panel 7 Lifting lugs. weyaunaune 4, Optional secessory. Fig, 2.2 O15-E/D air-compressor unit a | 2-3 595BX,GENERAL Compressor Unit Air-flow Reference the flow diagram in the Annex, section 24, Ambient air is drawn into the compressor unit through the intake filter (Fl) by t compressor first stage (1) where it is compressed to a pressure of approximately 50 | B.S bar). The compressed air leaves the first stage and passes through an intercoo before entering the second stage (I!) where is it further compressed to approximat 230 psi (16 bar). When the compressed air leaves the second stage, it is routed throu another intercooler and an intes-filter before entering the third stage (UII) where it compressed to approximately 945 psi (65 bar). The compressed air leaves the third sta and passes through another intercooler and inter-filter before entering the fourth sta (I) where it is compressed to the final pressure of-the compressor unit (see | compressor unit data plate). After being compressed to the final pressure of the compressor unit, the compressed from the fourth stage passes through an aftercooler, a coalescing separator and a che valve (CV1) before flowing into the purification system (P). A check valve (CVI) an pressure maintaining valve (PMV1) are located downstream of the purification syster3 INSTALLATION 3.1 UNPACKING AND HANDLING ‘This compressor unit is packaged according to the requirements for shipping via the requested type of carrier service. Itis possible that the compressor unit coutd 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 to be unpacked and the packaging to be removed, Handling of the unpacked unit should be performed only by the following methods if applicable. Note, for trailer mounted compressor nits, ensure that the towing vehicle is capable of pulling the weight of the trailer unit. CAUTION Be sure that the lifting devices are capable of handling the weight of the unit (see chapter 2 for the weight of the compressor unit). Before lifting the unit, secure all loose or swinging parts ta keep them from moving, Stay clear of lifted load 2) over head hoist, ») forklift ©) pallet jack Fig. 3.1 Lifting devices 3.2 INSTALLATION OF THE COMPRESSOR UNIT 3.21 General A machine base is not necessary; however, for units with a fill st the unit to the floor using '4” lag bolts, In the event of a bottle failure, a substantial amount of energy will be released; this additional measure will help secure the unit. The floor/site must be capable of supporting the weight of the unit, Position the unit so that it is level. Permissible inclination of the compressor unit is 10° forward/backward, 10° rightleft.! 1. Those values are valid only ifthe oil level ofthe compressor in normal position is level with bul does not exeeed the upper mark of the cil dipstick or oil level sight glass. 3-1 297A,3. INSTALLATION Ensure that the compressor contain any inflammable vapors or exhaust 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, For units with insular pneumatic controls, connect an instrument grade air supply line of the correct pressure to the pneumatic air inlet port for operation of the pneumatic controls, TE a remote control is provided, the unit must be equipped with a clearly visible plate warning the possibility of the unit starting. e.g. WARNING This unitis operated by remote control and could start without waming. 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 waming plate should be provided at the remote control unit. For units with a hydraulic motor, connect the appropriate hydraulic lines to the inlet and ‘outlet ports. Consult the factory for proper flow and pressute specifications. The hose or tube should be suitable for use with hydraulic oils and of correct size. For bare head models, make sure that the discharge pipe from the compressor to the ‘outlet has room to expand due to heat and does not come into contact with inflammable materials. Do not exert force at the air outlet valve; the connecting pipe must be fitted without tension. Observe and maintain an ambient temperature range of 32° to 105° F. Fec installation in temperatures outside of this ambient temperature range, the unit can be modified for correct operation. Such technical modifications should be made in the proposal stage. The compressor unit should be weil lit and easily accessible to facilitate servicing and routine maintenance, This 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. The braces are all tagged and labeled accordingly. 32.2 Ventilation During normal compression, heat is generated by the compressor and by the drive motor/engine. For air-cooled compressor units, this heat needs to be vented away by suificient ventilation. 3-2 2974INSTALLATION Outdoor installation It is recommended that all gasoline and diesel engine? driven compressor units be installed outdoors. Additionally, electrically driven compressor units may installed outdoors only if enclosed with weatherproof enclosure panels.” Itis important that units equipped with a gasoline or diesel engine? 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 ir. Situate the compressor unit such that the engine exhaust is located down-wind of the compressor alr-intake so that the engine exhaust is blown away from the unit, If applicable, the pre- fitter should be located 6 fe above the ground and 7 fe upwind from the engine exhaust muffler (ee fig. 3.2).Tum the compressor unit when the direction of the wind changes. Ia inclement weather, a compressor unit installed outdoors should be located under a tarp of lean-to structure i€ it is not equipped with weatherproof enclosure panels on ; , 3.2 Locating the compressor prefilter of Indoor installation ‘engine driven units? (CGIDV shown) ‘The best location to install the compressor unit indoors is against an outside wall with « suitably large air vent in front of the cooling fan, Additionally, it is necessary to position. ‘an exhaust opening in the opposite wall, close to the ceiling or in the ceiling. Asa basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room temperature from exceeding 105° F. Additional heat generating equip ment or piping should be avoided or must be well insulated. Natural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of the requiced intake and exhaust openings, consider the following rable: -2. not available on all models 3-3 195A3. INSTALLATION [intake and Exhaust Openings Dependent on Room Volume (V) and Height! Drive V=1750 V=3500 V = 7000 hp h=658 h= loft n= 13 ft Inwke | Exhaust | Intake | Exhaust | Intake | Exhaus 2) 7h Shut off Element saturated flashing red 4 CT | sh ob 7h Shut of Element missing or continuous red 4 yt} cable failure sb eh 7 i, Connection for extemal warning lamps. 7-7 8c2 1A TAA FILTER SYSTEM a MAINTENANCE OF THE PURIFICATION SYSTEM Mechanical Oil and Water Separator The mechanical oil and water separator is maintenance-free with the exception of annual visual inspection. Replace the separator if corrosion is detected during 1 inspection. The condensation is drained at regular intervals by the automatic condens drain. PO Purification ‘WARNING ‘The PO purification system filter housing is subject to dynamic loading. The} are designed to operate for up to 4,500 (@ 4,700 psi) and63,000 (@ 3,200 psi) load cycles. (Lload cycle = 1 pressurization, I depressurization) After reaching the maximum number of load cycles, the PO filter housing should be replaced, Before starting the compressor and every 15 to 30 minutes during operation, open condensate drain valves at the base of the purifier cylinder and allow the accumula condensation to drain. At start up, this serves a double purpose, as the drain valves m ‘be open to provide an unloaded start If your compressor is equipped with an autom condensate drain,!* this step is not necessary. To replace the cartridge (see fig. 7.1): + Disconnect the power and depressurize the system by means of the bleed valve. + Unserew and remove the top section (7) of the cylinder. Remove and discard the cartridge. + Remove and discard the plug on the end of the new cartridge, + Place the new cartridge into the cylinder and press it down to snap it into place. NOTE Never remove the spare element from its packaging prior to actual use. Otherwise highly sensitive filling material will absorb moisture from the ambient air a become saturated and therefore useless. 14, Not standard or necessarily avsilable on all models.1 FILTER SYSTEM 7.4.3 Coalescing Oil and Water Separator (Single Element Type) (P1 through P10) The sintered metal micro-filter element requires maintenance » every 1000 hours. To remove the sintered filter element, proceed as follows (fig. 7.10): + Disconnect the power and shut off the inlet supply line if applicable. Depressurize the system by means of the bleed valve, + Remove the tubes connected to the side of the filter head (2). Unscrew and remove the filter head. + Unscrew the micro-filter element (1) from the filter head. 0 Remove the center serew (3) to remove the filter element, Fig. 7.10 Coalescing it + Clean the sintered filter element using hot soapy water: Blow schaoe ae dry with compressed air, When cleaning the element, record the ‘element. type number of operating hours as indicated on the hourmeter to ensure exact attention to the maintenance intervals. + Lubricate the threads and o-rings as well as the threaded part of the micro-filter with petroleum jelly. Apply sparingly. + Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the micro-filter element. In the event you discover corrosion, replace the cotroded parts with new BAUER parts. NOTE The condensation produced during the compression process must be drained every 15 minutes or automatically if equipped with an automatic condensate drain, See chapter (2, 7.4.4 Coalescing Oil and Water Separator (Dual Element Type) (@12 and Pid) ‘The sintered metal micro-filter requires maintenance every 1000 hours. To remove the micro-filter element (fig. 7.11), proceed as follows: + Disconnect the power and shut off the inlet supply line if applicable. Depressurize the system by means of the bleed valve. + Remove the tubes connected to the side of the filter head. Unscrew and remove the filter head (1). ON SS 79 $97c1 TAS FILTER SYSTEM + Unscrew the micro-filter element (2) from filter head. Unscrew the acom nut (3) from the center stud to remove the micro-filter element. Unscrew the hex nuts (4) from the end plate to remove the filter inserts. * Clean the sintered filter element using hot soapy water. ‘When cleaning the element, record the number of operating hours as indicated on the hourmeter to ensure exact attention to the maintenance intervals. Blow dry with compressed air. + Lubricate the o-ings with petroleum jelly. Apply sparingly. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the micro-filter element. In the event you discover corrosion, replace the corroded parts with new BAUER parts. NOTE The condensation produced during the compression process must be drained regularly by means of the auto- matic condensate drain; see chapter 12. Fig, 7.11 Coalescing ‘and water separato Dryer and Purification Chambers dual element type (Pi through P14) Maintenance Intervals CAUTION On units with the optional SECURUS® indicator, when the preliminary warning sig appears, the cartridges of all filters within the system should be changed. When SECURUS® indicator shuts down the system, the filters must be changed. If your unit is not equipped with a SECURUS®, the life-span of the filter system m be calculated and recorded on FOR-0018 in the annex, chapter 24, using the cfim of unit (see chapter 2) and the processing capacity of the system (section 7.2), There is no set time of filter element exhaustion unless testing equipment capabl measuring the quality of the air at the outlet is available. If your unit is equipped wi SECURUS® system, you have positive indication (the warning light) when eles replacement is needed. If not, operator experience and accurate record keeping of o ating hours is necessary. A useful form is provided in the annex for record keeping of purification opers hours. We suggest you place a copy of it in a protective folder and keep it on han recording operating hours daily. ‘When operating at temperature other than 68°F, divide the number of hours operat that temperature by the correction factor as indicated in the chart and graph below.(errr 7 FILTER SYSTEM The entries in this table and graph are based on estimated filter element life time, On. units equipped with a SECURUS® system monitor, the actual saturation of the element is reported by the electronic monitor, For example, if the unit were operated for three hours at 85°F, rather than record three hours of operation on FOR-0018 in the annex the effective hours of operation would be calculated and recorded: 3 hours divided by a factor of 0.57 yields 3,3 hours. Maintenance Instrnctions To change the dryet and purifier elements, proceed as follows. + Disconnect the power and shut off the inlet supply line if applicable. Depressurize the system by means of the bleed valve. + Unscrew the filter head using the special wrench supplied. See fig. 7.12. + Pull out the cartsidge. Smaller diameter cartridges (PI through P10) are fitted with a Tifting cing to facilitate removal. + Dry the inside of the filter housing with a clean cloth and check for corrosion. Replace all corraded parts with new BAUER parts. Lubricate the o-rings with white petroleum jelly. Apply sparingly. + Remove and discard the plug on the end of the new cartridge. + Install the new filter cartridge. 5 Reinstall the filter head. + Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable. CAUTION If the new cartridge is installed incorrectly air will vent through the vent hole on the purifier chamber. If this occurs the cartridge must be reinstalled properly. 15. The lager diameter purification cartridges (P12 and P14) may be se-packed by a qualified factory tained technician (contact BAUER Compressors, Inc for details) or sent back to the factory for re= Packing: F311 B97CFig. 7.12 Element changeBL 8.2 1 PRESSURE MAINTAINING VALVE DESCRIPTION A pressure maintaining valve (PMV) and a check valve are provided downstream of the cil and water separator of filter system, respectively. Refer to the flow diagram in the annex. ‘The pressure maintaining valve ensures that pressure is built-up in the filters even from the start of delivery, thus achieving a constant, optimum filtration. Depending on the opeceting pressure of the compressor unit, the PMV is adjusted to one of the following pressures: Final pressure setting Minimum PMV setting, 2,000 - 5,000 psi (138 - 350 bar) approx. 2,175 psi (150 bar) 6,000 psi (414 bar)! approx. 3,000 psi (207 bar) The check valve prevents back-flow from filled storage cylinders or tanks. MAINTENANCE “The pressure maintaining valve is adjusted at the factory to the required pressure and normally does not require regular maintenance or readjustment. In case readjustment becomes necessary, loosen the locking ring (2) fig. 8.1. Set the adjusting screw (1) to the required pressure using an appropriate hex type wrench. Tum clockwise to increase pressure, counterclock- wise to decrease pressure. To determine if the PMV is properly adjusted: + Depressurize the final separator (and purification chambers, if so equipped) by slowly opening the manual bleed vaive. + Close the manual bleed valve and start the compressor. If your unit is equipped with a storage system, the 3-way valve should be in the direct fill position and the fill hose should be open Sour + Observe the final pressure gauge and note the pressure at which the valve opens (delivers). If the pressure is not within range of the specified pres- sure, # 200 psi (see 8.1 above), readjust the PMV, maintaining valve Not available for all models, see chapter 2 8-1 297894 92 SAFETY VALVES FUNCTIONAL DESCRIPTION ‘This compressor unit is protected by safety valves. For multiple stage compressors, the intermediate pressure safety valves are adjusted and set, generally 10% above the proper operating pressure of the corresponding compression stage. The safety valve for protection of the final stage is adjusted at the factory to the oper- ating pressure of the unit according to the order, approximately 10% over the specified pressure of the unit. See chapter 2 for the maximum allowable pressure setting of the ‘compressor unit, MAINTENANCE Ifa safety valve is found to be defective, replace it with a new one. If a safety valve vents, the inlet or discharge valve in the next higher stage may not be closing properly. The cause of the trouble is usually the inlet valve of the next stage. See also chapter 11. The intermediate stage safety valves are not adjustable, but must be replaced if there is a problem. The fina! pressure safety valve set pressure has been preset at the factory to the required pressure and normally does not require regular maintenance or readjustment. In case readjustment of the final pressure safety valve becomes necessary, have the safety valve adjusted by a qualified factory trained technician (contact BAUER Compressors, Inc, for details) or sent back to the factory 9-1 297EPRESSURE GAUGES 101 DESCRIPTION This compressor may be equipped with the following gauges: + Intermediate pressure gauges, one for each stage of compression, to indicate the pres- sure after the corresponding stage. + A final pressure gauge to indicate the final operating pressure.! + An oil pressure gauge to indicate the compressor oil pressure.! + An inlet pressure gauge to indicate the pressure applied to the inlet of the compressor.’ The pressure gauges are mounted in the instrument panel. For correct pressure ranges for the above gauges see chapter 2. 10.2 MAINTENANCE Observe the pressure gauges daily to be sure that the automatic control system is goveming the compressor within its proper limits. If a pressure gauge indicates exces- sive pressure and the corresponding safety valve does not vent, check the pressure gauge for proper operation. Also, if the pressure gauge indicates the pressure as being too low, check the gauge for proper operation. To check a suspect gauge, remove the gauge and check for wear and tear, accuracy, and proper functioning by comparing it to a precision test gauge or a dead weight tester. Replace all broken or damaged gauges immediately. 1. Not standard on all units 10-1 297AI Wt uz 113 VALVE HEADS AND VALVES FUNCTIONAL DESCRIPTION The valve heads of the individual stages form the upper part of the cylinders. The intet and discharge valves are fitted inside the valve heads. ‘When the piston moves downwards, the resultant vacuum in the piston cylinder opens the inlet valve. When the piston moves upwards, the inlet valve is closed and the discharge valve opened by the pressure created in the compression process. So 4 Intake Discharge Fig. 11.1 Valve function INITIAL OPERATIONAL CHECK OF THE VALVES After approximately half an hour of operation, the valves should be checked. The outlet piping should be hot if the valves are operating properly. Do not touch the outlet piping with bare hands, use a thermometer.' Note that the inlet line to the valve heads should be warm to the touch, If the inlet pipe to the second stage valve head heats up excessively and the first stage safety valve opens, either the inlet or the discharge valve of the second stage is malfunc- tioning, It is therefore necessary to remove the valve head and to check and clean these valves or replace them. GENERAL INSTRUCTIONS FOR CHANGING THE VALVES Please observe the following instructions for valve maintenance: + Always replace valves as a complete set. + Observe the correct sequence when reassembling. + Remove and check the valves every 750 - 800 operating hours. + Replace the valves every 2000 operating hours to avoid fatigue failure. + Use an assembly tool (BAUER P/N: 011365) for work on valve heads (see fig. 11.2), is are provided with Some! Hel L19sGi. VALVE HEADS AND VALVES 11.4 CHANGING THE 1ST STAGE VALVES Itis not necessary to remove the valve head (2) when servicing or replacing the Ist s valves, Reference fig. 11.3 and proceed as follows, Valve head gasket Valve head Fiat washer Hex head cap screw Valve gasket Inlet valve Inlet valve cover Discharge valve Discharge valve cov war auaune 10 Flat washer 11. Socket head cap screw 12 Male connector 13. Flange gasket 14 Intake pipe 15 Hex head cap screw 16. Split lock washer 17 Hex nut 18 Socket head cap screw . Fig. 11.3 Valve head and valves, Ist stage + Remove the intake pipe (14) and disconnect the tube connection (12) and the disch tubing. + Unscrew the socket head cap screws (11, 18) and remove the inlet and discharge v covers (7, 9) to remove the valves and gaskets (5, 6, 8). + Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valve petroleum solvent (e.g. Varsol) and then clean them with a soft brush. Check valve space in the valve head for dirt, and clean it if necessary,1. 18 181 VALVE HEADS AND VALVES + Check the individual components for excessive wear. Use only satisfactory gaskets and o-rings during reassembly. If the valves are dented or damaged, replace them, If the valves do not conform ta the fotlowing tolerances, they must be replaced: Intake valve stroke Discharge valve stroke Number of valve plates + Replace the valve gaskets and valves and reassemble in the reverse order. + After finishing all maintenance work on the valves, turn the compressor mannally using the flywheel and to ensure that all items have been correctly installed. * 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and retorque valve screws; otherwise, the gasket set may leak. CHANGING THE 2ND AND 3RD STAGE VALVES ‘Removal of the Discharge Valves To remove the discharge valves of the 2nd and 3rd stages reference fig, 11.7 and proceed as follows: + Remove the dome nut (1) and the copper gasket (2). Discard the gasket. This gasket should always be replaced with a new gasket + Unscrew and remove the socket set screw (3) and the discharge valve cover (4) 10 semove the spring washer (5) and the o-ring (6), The o-ring should be in perfect condi- tion: undamaged and non-porous. Replace it if necessary. + Extract the discharge valve assembly (7). Discard the valve gasket (12) and replace it with a new gasket. + Carefully clean diny valves. Never use a sharp toot for this purpose. Soak the valves in 4 petroleum solvent (e.g. Varsol) and then clean them with a soft brush. Check the valve epace in the valve head for dirt, and clean it if necessary + The valve spring should be clean so as to not dampen its resiliency. There should not be any visible gap between the valve seat (11) and the valve plate (10). + Check the individual components for excessive wear. Use only satisfactory gaskets and o-rings during reassembly. If the valve seat or valve plate are dented or damaged, replace the valves, The valve spring is reusable if it shows no outside scuffing and the ‘spring ends have not picked up on the next coil. Po 1i-3 11950in. ‘VALVE HEADS AND VALVES + The sealing surface of the valve seat must be in good condition: devoid of pitting cracking. The maximum valve seat width is 3/64” (1.0 mm). See fig. 11.4 + Clean and inspect the valve plate (10). The maximum acceptable groove depth m hot exceed 1/128” (0.2 mm). See fig. 11.6. + Check the tolerance of the inside diameter of the valve body (8). The valve body mu not show any grooves at ID 17 + 0.1 mm, See fig, 11.5. max 1.0 mm vee" Fig, 114 Permissible tolerances, valve seats i Fig. 11.6 Permissible tolerances, valve plates valve body and caver Fig. 11.5 Permissible tolerances, The following limits should also be observed: Discharge valve spring Specified length . 2 24mm Discharge valve stroke (2nd stage) | Mune Discharge valve stroke (3¢d stage) wn ‘Valve seat bore diameter 2nd stage 3rd stage If the above tolerances have been exceeded, the valve assembly (7) should be replace 4 usDome nut Copper gasket Socket set screw Discharge valve cover Spring washer O-ring Discharge valve assembly Discharge valve poppet Compression spring Discharge valve plate Discharge valve seat ES earausune 11.5.2 Removal of the Inlet Valves head (22). the piston cylinder. il. VALVE HEADS AND VALVES US 12 3 14 15 16 17 18 19 20 2 2 Fig. 11.7 Vaive head and valves, 2nd and 3rd stages Valve gasket Tube connections Socket head cap screw Safety valve connection Copper gasket Inlet valve assembly Inlet valve cover Compression spring. Inlet valve plate Inlet valve seat Valve head To remove the 2nd and 3rd stage inlet valves, it is necessary to first dismantle the respective valve heads. Reference fig. 11.7 and proceed as follows. + Remove the tube nuts, nibes and ferrules from the tube connections (13) to the valve + Unscrew and remove the socket head cap screws (14) and lift the valve head (22) from + Unscrew the valve cover (18) from the bottom of the valve head (22) using the special ‘tool which is part of the tool set delivered with the unit. See fig. 12.8. Po 11956VALVE HEADS AND VALVES + Extract the inlet valve assembly (17) and discard the valve gasket (12). Replace the gasket with a new gasket, + Carefully clean dirty valves, Never use a sharp tool for this purpose. Soak the valves in a petroleum solvent (e.g. Varsol) and then clean them with a soft brush. Check the valve space in the valve head for dirt, and clean it if neces- sary. + The valve spring should be clean 50 as to not dampen its resiliency. There should aot be any visible gap between the valve seat (21) andthe Fig. 11.8 Inlet valve removal valve plate (20). Check the individual components for excessive wear. Use only satisfactory gask and o-rings during reassembly. If the valve seat or valve plate is dented or damag replace the valve, The valve spring is reusable if it shows no outside scuffing and spring ends have not picked up on the next coil, + Inspect the vaive seat (21). The sealing surface must be in good condition: devoid tting or cracking. The maximum valve seat width is 3/64” (1.0 mm). See fig, 11.4 Clean and inspect the valve plate (20). The maximum acceptable groove depth m not exceed 1/128" (0.2 mm). See fig. 11.6. + Check the tolerance of the inside diameter of the valve cover (18). It must not sh any grooves at ID 17 +0.1 mm. See fig. 11.5. The following tolerances should also be observed: Inlet valve spring Inlet valve stroke (2nd stage) Inlet valve stroke (3rd stage) Valve seat bore diameter If any of the above tolerances have been exceeded, the valve assembly (17) should replaced, 11-6 us153 VALVE HEADS AND ‘Reassembly of the Valve Head and Valves To reassemble the valve head and valves, proceed as follows: + Before fitting the intake valve to the valve head, itis recommended to grease the valve plate slightly and place it correctly on the valve seat, making reassembly easier. Also, 4 punch inserted through the intake and outlet bores as shown in fig. 11.9 helps ensure correct reassembly of the components Fig, 11.9 Reassembly of the Fig. 11.10 Application of sealing valves compound + After having assembled the inlet valve, peen the valve head twice, once on either side of the valve, to lock the threads in place. + Apply a temperature-esistant, non-age-hardening RTV sealing compound to the sealing surface of the valve head (fig. 11.10). + Torque the valve head cap screws (14) to 18 ft-lb (25 Nm) in accordance with the sequence shown in fig. 11.11 before tightening the socket set screw &% % @) in order to avoid damage to the 8). valve body (8). y Ds + Tighten the socket set screw (3) with 4 & the appropriately sized hex key. * Position the gesket (2) and dome nut Fig. 11.11 Torque sequence, 2nd, 3rd and (1) and tighten it with an open end 4th stage valve heads wrench. tL-7 1195611. 16 1.6.1 VALVE HEADS AND VALVES Ee + Reinstall the tube connections (13) to the valve head (22). + After finishing all maintenance work on the valves, tum the compressor ma using the flywheel and check whether ali items have been correctly installed. + 30 minutes after restarting the compressor, stop the unit, let it coal down to ar temperature, and retighten valve studs and dome nuts. Otherwise the gasket se cause a leak. CHANGING THE 4TH STAGE VALVES Dome nut Copper gasket Socket set screw O-ring Discharge valve Inlet valve Valve head ‘Valve head cover Socket head cap screw eeu aueune Fig. 11.12 Valve head, 4th stage Removal of the Discharge Valve The discharge valve (5) is inserted into the valve head (7). It is seated by an o-ri and fixed to the valve head with a set screw (3), To remove the 4th stage disc valve, reference fig. 11.12 and proceed as follows, + Remove the dome nut (1) and the copper gasket (2) and then unscrew the sock serew (3) three or four tums. Replace the copper gasket with a new gasket i daraaged. | ce ne 11-8LL 11.6.2 be VALVE HEADS AND VALVES + Remove the socket head cap screws (9) that secure the valve head (7) to remove the valve head cover (8). + Put two screwdrivers into the groove of the discharge valve body (see fig. 11.13) to lift ‘out the discharge valve (5) together with the o-ring (4). If necessary, loosen the valve first, using a 13 mm open-end wrench on the flat surfaces. Fig. 11,13 Removal of the 4th stage discharge valve * Carefully clean dirty valves. Never use a sharp tool for this purpose, Soak the valves in a petroleum solvent (eg, Varsol) and then clean them with a soft brush. Check the vaive space in the valve head for dirt, and clean it if necessary. + Check the individual components for excessive weer. Use only satisfactory gaskets and o-rings during reassembly. The o-ring (4) should be in perfect condition (undam- aged and non-porous), If the discharge valve dented or damaged, replace the valve. + If the discharge valve (5) does not close tightly, it should be replaced. The bore diam- ‘eter of the valve seat should be 4.0 mm. ‘Removal of the Inlet Valve To remove the inlet valve (6), itis necessary to dismantle the valve head (7). Reference fig. 11.12 proceed as follows: + Remove the tube connections to the valve head (7). + Unscrew and remove the socket head cap screws (9) to remove the valve head cover @). + Extract the inlet valve (6) using the special tool which is part of the tools set delivered with the unit, See fig. 11.8. + Carefully clean diny valves. Never use a sharp tool for this purpose. Soak the valves ia ‘ petroleum solvent (e.g. Varsol) and then clean them with a soft brush, Check the valve space in the valve head for dirt, and clean it if necessary. 1-9 1198Gua VALVE HEADS AND VALVES —————. $$ ESS + Check the individual components for excessive wear. Use only satisfactory gasket and o-sings during reassembly. If the inlet valve is dented or damaged, replace th valve. + The inlet valve (6) should be replaced if it no longer closes tightly. The bore diamete of the valve seat should be 4.0 mm. 14.63 Reassembly of the 4th Stage Valves and Valve Head + Reassemble the inlet valve (6) in the reverse sequence of its removal. + After reassembling the inlet valve, peen the valve head twice, once on either side o the valve, to lock the threads in place. + Insert the discharge valve (5) with the o-ring (4) into the valve head (7). * Position the valve head cover (8). ‘Do not use sealing compound on the fourth stage valve head. + Insert and torque the socket head cap screws (9) to 18 fb (25 Nm = 2.5 kgm) i accordance with the sequence shown in fig. LL.LL before tightening the socket se screw (3) in order to avoid damage to the valve body (8). + Screw in the set screw (3) by hand, Fit the copper gasket (2) and the dome nut (1) an tighten with an open end wrench, + Reinstall the tube connections to the valve head (7). + Check the valves against the following: 0.8 mm 12mm ‘Minimum... Maximum. Inlet valve stroke Discharge valve stroke « After finishing all maintenance work on the valves, turn the compressor manuall, 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 ambier temperature, and retighten valve screws and dome nut. Otherwise the gasket set ma cause a leak. 11-10 L9se12. CONDENSATE DRAIN SYSTEM DESCRIPTION This compressor unit is equipped with either a manual or an automatic condensate drain system, The condensate drain system is provided to drain condensation that is collected. in the intermediate filters and the final separator. ‘A manual condensate drain system consists of interconnecting tubing and manual drain valves on the intermediate filters and the final separator. The manual drains on the inter- mediate filters and the final separator are tubed via a common drain pipe to a condensate collection bottle! or ta an outlet on the frame of the compressor unit. ‘An automatic condensate drain (ACD) system! automatically drains the condensation that is collected in the intermediate filters and final separator. This automatic draining is performed periodically as governed by an ACD timer which regulates the electrical supply to the ACD solenoid valves. The drain cycle is typically set at 15 minutes, When the compressor unit is turned off, the intermediate drain valves will remain open to allow any condensation in the intermediate drain valves to drain while the compressor unit is not being operated, The main components of the ACD system are indicated in the following illustration and in the drawings located in the annex. ACD solencid valve coil ACD solenoid valve Condensate drain valve Condensate drain valve Control pressure connection from 2nd stage intermediate filter 6 Control pressure connection from 3rd stage intermediate filter 7 Condensate connection from 2nd stage intermediate filer 8 Condensate connection from 3rd stage intermediate filter 9 Condensate connection from final separator 10 ACD outlet (tube connector) 11 ACD manifold 12 Vent line, solenoid valve to manifold Fig. 12.1 ACD system 13° Bracket 14 Manual condensate drain valve wens 1. Not standard on all models. 12-1 196K122 1221 pe CONDENSATE DRAIN SYSTEM OPERATION ‘Manual Condensate Drain System Periodically open the condensate drain valves (V1) during operation to empty the in mediate filter(s) and final separator, A period of fifteen minutes will be most effect Ensure that any oil which is drained with the condensation is disposed of properly. ‘Open the drain valves (V1) while the compressor unit is not in operation to allow condensation to drain and to depressurize the compressor block. Close the drain val (V1) prior to start up. Automatic Condensate Drain System “White the compressor unit is tumed off, the ACD solenoid valve (SV1) is de-energi and open allowing the 2nd stage intermediate filter to be fully drained of condensat and depressurized (reference the pneumatic flow diagram in the annex), The condens drain valve (CDV1) to the 3rd stage intermediate filter is also open, allowing the stage intermediate filter to be fully drained and depressurized. The condensate dé valve (CDV2) to the final separator is normally closed by a spring assisted plun which acts against pressure in the final separator, therefor, the final. separator will drain nor depressurize continuously while the compressor unit is tumed off. ~ ‘Tuming the compressor unit on energizes the normally open ACD solenoid valve (8 which then closes. As system pressure builds, control pressure is applied to the cord sate drain valves (CDV1 & CDV2), closing the normally open drain valve to the stage intermediate filter. Every 15 minutes, the ACD timer de-energizes the ACD solenoid valve (SV1) approximately 10 seconds. During this drain period, the ACD sotencid valve (SV1) open and drain the 2nd stage intermediate filter. The pressure loss in the 2nd stage in mediate filter during this drain period reduces the control pressure responsible closing the coridensate drain valve (CDV1) to the 3rd stage intermediate filter, thus, condensate drain valve (CDVE) to the 3rd stage intermediate filter opens and drains 3rd stage intermediate filter. When the system pressure is at operating pressure, the condensate drain valve (CD to the final separator remains closed by control pressure taken from 3rd stage inten diate filter and by an intemal spring, Pressure loss in the 3rd stage intermediate f during drainage decreases the control pressure to the condensate drain valve (CDV2) the final separator. This pressure differential opens the condensate drain valve (CD to drain the final separator, The final separator will draia until the spring in the cond sate drain valve can overcome the separator pressure. After the drain period, the ACD timer will energize the ACD solenoid valve (SV1 start the next drain cycle. 12-2 112.3 CONDENSATE DRAIN SYSTEM ‘When the compressor unit is tured off, the ACD solenoid valve (SV1) de-enengizes and opens which drains the 2nd stage intermediate filter. The pressure loss due to the draining in the 2nd stage intermediate filter reduces the control pressure responsible for closing the condensate drain valve (CDV) to the 3rd stage intermediate filter, thus, the condensate drain valve (CDV1) to the 3rd stage intermediate filter opens and drains the 3rd stage intermediate filter. Likewise, the control pressure governing the operation of the condensate drain valve (CDV2) to the final separator decreases which opens the final separator drain valve. The final separator will drain untit the pressure in the final sepa- ator is less than the spring pressure (approximately 1000 psig) in the condensate drain vaive; however, the intermediate filters will continue to drain and remain open while the compressor unit is not being operated Condensation from the inter-filter’s oll and water separator(s) is drained ftom the compressor unit. The condensate pre-separator removes liquid condensation. The liquid collected in the condensate pre-separator then flows directly into the collecting bottle (CDB1 or to an outlet at the frame by means of a tube. The remaining aerosol conden- sation particles and mist are collected in the silencer separator (SS1). The silencer sepa- rator also empties into the collecting bottle (CDB1)* or to an outlet at the frame by means of its own tube, The collection bottle may be equipped with a limit switch? and an indicator light? so that when the collection bottle is full, the indicator light will illuminate as a reminder to empty the collection bottle. Check locat, state and federal regulations to properly dispose of any oil that has been drained with the condensation. The separator/silencer removes more than 99.99% of all oil aerosols and silences the noise level by more than 35 dB(A), The end result is clean and silent ambient air. The fine construction of the filtration material with an extensive hollow volume (approx. 90%) results in a substantial collection of solid matter particles. The service life is accordingly high and the pressure drop is extremely low. MAINTENANCE Manual drain systems are maintenance free unless a drain valve becomes defective, Replace defective manual drain valves with new valves. Automatic drain systems are provided with manual drain valves to verify that the ACD system is working properly. Check the ACD system at least once a week as follows: + While the compressor u the manual drain valves, is running and immediately following a drain period, open 2, Notnecessarly standard or available on all modeis. 12-3 196KCONDENSATE DRAIN SYSTEM. [BAL * Observe the drainage of condensation. If more than 2 ounces of liquid drains fr i given drain valve, either the ACD system or the corresponding condensate drain \ E is not working properly. Check the system again by closing the manual drain vs I : and then opening the drain valves again in the next drain cycle. If there is still much drainage, find the fault and remedy accordingly. If litte or no condenss emerges, the automatic system is operating properly. | + Replace the separator/silencer filter element with each oil change. i To remedy problems, see Troubleshooting, section 22. 12-4ELECTRICAL CONTROL SYSTEM 13.1 GENERAL This section describes the standard electrical control and ¢lectronic monitoring system of the compressor unit. For schematic diagrams reference the annex, section 24. The electrical equipment of the compressor unit consists of the follawing. » Holding relay + Holding relay (3-position)! + Printed circuit board + Onoff switch ‘+ Hand/oti/auto switch! + Final pressure switch + Final pressure switch (low pressure)! « Oil pressure switch * High temperature switch + Audible alarm! + ACD timer? + Hourmeter + Emergency stop push-button! ‘Unless specially ordered with the compressor unit, a main switch and fuse must be supplied by the customer (see Section 3 for electrical instalfation). 132 HOLDING RELAY! ‘The hoiding retay prevents che compressor unit from restarting when power has been restored after an acci- dental loss of power has shut the system down (Le, a power outage). This relay is 2 120VAC, medium power, multi-contact DPDT or 4PDT holding relay. Technical Data Ambient temperature range ~45°C 0 55°C Contact current rating 108 CLT Frequency Sov Hix UY t Fig. 13.1 Holding relay 1. Optionat accessory. 2. Not standard on all en 13-1 59SP13. 133 13.4.1 13.4.2 13.8 13.5.1 ELECTRICAL CONTROL SYSTEM CONTROL RELAY ‘The control relay controls the operation of the compressor unit by sending and rece electrical signals from the various components of the electrical system. The control is located in the electrical enclosure. Tris a 120VAC, medium power, multi-contact DPDT holding relay. Technical Data Ambient temperature range ~A5°C to 55°C Contact current rating 104 — Frequency 50/60 Hz ‘TIME DELAY RELAY Description Fig. 13.2 Coatral rel ‘The time delay relay is provided in order to delay the actua- tion of the off pressure switch (see Section 13.7) for 40 seconds at compressor start-up. to allow the compressor sufficient time to build up the oil pressure to the standard y operating pressure range. If the oil pressure does not reach the actuation point of the oil pressure switch within 40 seconds, the oil pressure switch will shut the compressor system down, The time delay relay is a 120VAC delay on operate DPDT adjustable (1.0 to 180 seconds) time delay relay. The time delay relay is located on the NEMA 4 electrical enclosure. Maintenance Fig. 13.3 Time delay ‘The time delay relay is set at the factory at 40 seconds. If the relay should require ac ment, it can be adjusted by turning the knob to the proper setting, SELECTOR SWITCHES Off/On Setector Switch ‘The offon selector switch controls the operation of the compressor unit. If the swi inthe “OFF” position, the unit will not operate, When the switch is tured to the position, the unit will automatically start and stop to maintain the final pressure bet the high and low set points of the final pressure switch. CL 13-2OFF ON \ a HAND AUTO Fig. 13.4 Off/on selector switch Fig. 13.5 Selector switch (3 position) 13.5.2 Hand/Off/Auto Selector Switch? The hand/off/auto selector switch controls the operation of the compressor unit. If the switch is in the “OFF” position, the unit will not operate. When the switch is tumed to the “AUTO” position, the unit will automatically start and stop to maintain the final pressure between the high and low set points of the final pressure switch. In the “HAND” position, the automatic switch-off function is disabled and the unit builds up pressure and then unloads while the motor continues running. 136 | ELECTRICAL ENCLOSURE The electrical enclosure is a NEMA type 4X enclosure intended for indoor or outdoor use primarily to provide a degree of protection against corrosion windblown dust and rain, splashing water, and hose-directed water, and to be undamaged by the formation of ic on the enclosure. The enclosure houses the control relays. The enclosure meets hose- down, external icing, and corrosion resistance design tests. It is not intended to provided protection against other conditions such as intemal condensation or internal icing. It is manufactured with American Iron and Steel Institute type 304 stainless steel or equiva- Tent material to provide a degree of protection against specific corrosive agents. The enclosure is UL listed. 13,7 PRESSURE SWITCHES 13.7.1 Final Pressure Switch The automatic switching of the compressor unit off and on is governed by the final pres- sure switch. The value of this switch is adjustable, 3. Optional accessory on some models, 133 sosELECTRICAL CONTROL SYSTEM ‘The approximate actustion value (differential) of the final pressure switch is fix whatever pressure setting is required for proper operation of the unit. This switch never be set above the original order pressure, If the pressure actuator is exposed to system or surge pressures greater than maximum pressure rating printed on the device nameplate, leakage from the act and/or a change of operating set points nay result. 13.7.2 Oil Pressure Switch The compressor oil pressure is monitored by the compressor oif pressure switch. At pressure, the pressure switch is open. IF the compressor does not build sufficient oil save withia 40 seconds after start-up or if the oil pressure drops below the preset v. during operation, the pressure switch will open, the warning lamp will light and compressor unit will shut down, The approximate actuation value (differential) of the oif pressure switch is fixed at whatever pressure setting is required for proper operation of the unit This switch must never be set above the ofiginal order pressure, If the pressure actuator is exposed to system or surge pres- 2 sures greater than the maximum pressure rating printed on the device nameplate, leakage from the actuator and/or a change of operating set points may result. 13.7.3 Set Point Adjustment 1 Secure the hex body (1) with an open end wrench, Hand tum the adjustment sleeve (2) clockwise to increase the set point, counterclockwise to decrease the set point (note the orientation of the switch in the figure). Fig. 13.6 Pressure swi 13.7.4 Switch characteristics Adjustable range, final pressure 4000 to 7500 psig Adjustable range, final pressure (low*) 1650 to 4400 psig Adjustable sange, oil pressure 430 10 1700 psig Actuation differential range, final pressure 350 to 800 psig Actuation differential range, final pressure dow*} 200 to 500 psig Actuation differential range, oil pressure 70 to 250 psig Contact rating 5 Amps @ 125/250VAC ‘Temperature range 40° to 165° F 4, Low final pressure sting is optional. 13-4 :13. 13.8 139 13.9.1 13.9.2 53.10 ELECTRICAL CONTROL SYSTEM. WIRE CODE Lead Color Nonnally Closed_ Blue Common Purple [Normally Open Red FINAL STAGE TEMPERATURE SWITCH, This temperature switch is a positive.acting, bimetal snap disc which is open at the correct temperature, ie., in operating position. The temperature switch is located in the output pipe of the final stage cylinder. As the temperature reaches the tamper-proof predetermined set point, the disc snaps to provide a rapid positive contact action (closes). When the temperature becomes exces- sive, the system will be shut down. A warning light will indicate the fault. AUDIBLE ALARMS Description The audible alarm is a 120V, 60 Hz vibration hom designed for use in non-hazardous locations. Whenever a fault occurs during operation of the unit, the alarm will sound in a continuous monotone at 68 to 80 dB(A) at 2 fi until the selector switch is turned to the “OFF” posi- tion. For electrical connections, reference the wiring diagrams in the annex of this manual. Maintenance Fig. 13.7 Audible alarm The hom should be tested monthly to ensure continuous service. HOURMETER The compressor unit is equipped with 2 120V hourmeter. It is mounted on the electrical enclosure or on the instrument panel at the front of the compressor unit. The hourmeter is provided to record the number of hours the unit is in opera- tion, The hourmeter will be in operation while the compressor unit is running. Fig. 13.8 Hourmeter 5. Optional on some models. 13-5 S95P— 1 ELECTRICAL CONTROL SYSTEM 13.11 ACD TIMER (with ACD System®) ‘The automatic condensate drain timer controls the frequency of the drain inter- vals and the duration of the drain period of automatic condensate drain systems. The timer is a 120V, solid state, encapsulated, recyeling timer. Both the on and the off times are adjustable. Its range is 1-100 minutes on, 0.1-10 seconds off. Fig. 13.9 ACD timer 13.12 EMERGENCY STOP PUSH-BUTTON® 13.12.41. Description The emergency stop switch is a maintained push-pull type push-button switch. 1 is supplied with a normally closed single pole single throw contact block. The red mushroom cap type head of the emergency stop switch is highly visible and offers a large target which 1s converiem for gloved hand operation or emergency situations. 1312.2 Operation To stop the compressor in case of emergency, depress the Snebutton, The anit wi " Fig, 13.10 Emergen emergency stop push-button. The unit will shut down. oe aahonee 6. Optional accessory on some models, 13-614.1 142 COMPRESSOR DRIVE SYSTEM GENERAL The compressor is driven by the drive motor by one or more v-belts. The direction of rotation, as seen facing the 1 flywheel, is counterclockwise, Observe the arow on the compressor block. Check the v-belt(s) regularly for 2 damage and wear (see chapter 19). Replace v-belts as necessary. ~— 1 Compressor block a 3 2. Compressor flywheel oo 3 Compressor mount 77 4 Electric drive motor 4 5 Drive sheave Yo 6 Swing motor mount 6 7 Vibration isolator 8 V-belt 5 V-BELT MAINTENANCE Fig. 14.1 Compressor drive system Check the Sheaves. Before a new drive belt is installed, the condition of the sheaves should be checked. Dimy or rusty sheaves impair the drive's efficiency and abrades the cover of the belt(s), which will result in premature failure. ‘Wom sheaves shorten belt life as much as 50%, If the grooves are wom to the point where a belt bottoms, slippage may result and that belt may burn. If the side walls are “dished out,” the bottom shoulder ruins the belt prematurely by wearing off the bottom comers. Check the v-belt(s) regularly for damage and wear (see chapter 19 for recommended intervals), Replace belts as necessary, V-belt tension is adjusted automatically by the ‘weight of the motor, which is mounted on a hinged motor plate For maximum service on multiple belt drives, replace all drive belts with a complete new matched set of belts. Never reuse an old belt to replace one belt in a set, Used belts are normally worn in their cross sections and stretched to some extent. A new belt will ride higher in the sheave, travel faster and operate at a much higher tension than used belts; The cord center of a new belt may rupture, allowing it to elongate. If this occurs ‘the belt will cease to accept its full share of the load, leaving the drive under-belted and wasting a new belt. 14-1 AorCOMPRESSOR DRIVE SYSTEM, i 143 MAINTENANCE OF THE DRIVE MOTOR 143.1 Single Phase Motor! This is a ball bearing motor. the bearings have been given initial lubrication at t Eactory. Motors which have been in storage for over a year should be relubricated. As general guide for longer operating life, motors should be lubricated as follows, RECOMMENDED LUBRICATION PERIODS' ‘Speed Frame | Standard | Severe | Extreme {RPM) Size Conditions” | Conditions® | Conditions* — == = 140-180 45 yrs. 18 mos. ‘9 mos. 1200 210-280 | 4.0yes. 16 mos. 8 mos. or less 320-400 3.5 yrs. 14 mos. T mos. 440-508 3.0 yrs. 12 mos. 6 mos. $10 2.5 yrs. Y2mos._| 6 mas. 1200 140-180 | 3.0 yrs. 12 mos. 6 mos. 101800 j 210-280 ) 25 yrs. 10 mos, 5 mos, 320-400 2.0 yrs. 9 mos 4 mos, 440-508 13 yrs. 8 mos. 4 mos, 510 Lo yrs. 6 mos. 3 mos. ‘Over 1800 all 6 mos. 3mos. 3 mos. FOr POET Bean, SVE HE ABSVE VALUES By F b. Standard conditions consist of eight hours/day of operation, normal or tight loading and/or clean 100°F maximum aribient conditions. «. Severe conditions consist of twenty four hours/day of operation, shock loadings, vibration ‘andlor dirty of dusty 100° to 150* F arabient conditions. 4. Exireme conditions consist of heavy shock or vibration and diy and/or dusty 100° to 150°F ambient conditions. We recommend using one of the following greases (or equivatens) for matar lubric tion: Grease Manufactorer SRI no. 2 Chevron Dofium R. Shell Oil Co. Premium RB Texaco Inc. 1. not available on all medels 14-2 49143.2 COMPRESSOR DRIVE SYSTEM. Do not mix grease. Keep grease clean, Different types of grease or brands of the same grease should not be mixed. To lubricate the motor, remove the slotted head grease serew and insert a2 to 3 inch string of grease into each hole. Inspect the motor at regular intervals, Keep the motor clean and the vent openings clear (see chapter 2 for motor frame size), ‘Three Phase Motor Frames 143T thru 2567 are furnished with double sealed or shielded ball bearings, prelubricated prior to installation. Grease fittings are not supplied and bearings are designed for an average of 100,000 hours of operation under standard conditions. Frames 284T thru NS87UZ are furnished with double shielded, open ball or roller bearings (depending on hp and/or speed). It is necessary to relubricate anti-friction bearing motors periodically. These motors have been lubricated prior to test; however, it is recommended to apply approximately 1 oz. (30 g) of lithium based grease after extended storage or inactivity to compensate for any settling that may occur. Oil leakage around the bearing caps indicates overpacking, The excess grease should be purged out by running the motor temporarily with the relief open. Use only clean grease, Do not mix petroleum grease and silicone grease in the motor bearings. Do not mix greases of different brands. The mixing of different types of thick- ‘eners may destroy the composition and physical properties of the grease. In the event that a different grease is required by the end user, the following steps can be taken. Using the instructions for lubrication, open the grease outlet and purge the system as much as possible of the old or unwanted grease. Repeat this operation after one week of service. We recommend using one of the following greases (or equivalent) for motor lubrication: Grease Manufacturer SRI Chevron Unirex #2 Exxon Polyrex Exxon Dolium R Shell 143 aorF14. COMPRESSOR DRIVE SYSTEM Frequency of Lubrication® syne. FRAME TYPE OF SERVICE RANGE | RANGE — {stanDARD| SEVERE = HEAT ee] 3600 | eats. 286TS_ | 12 Mos ‘4 Mos. $24TS-NBETUSS | 9Mos | 3Mos r waTaseT | Yeas | 3 Year | . 1800 2847-3267, ‘FYeas_ | 15 Yeus 3eaT-sesT | 23 Years | 10Mox qeeranrtZ_ | 2 Yeas |S Mos SOSUS-NSE7UZ | 1S Yewrs | 6Mos. 1437-256T T Yeas | 3 Years” 4200 2eeT326T | 4 Years | 13 Yen slower [| S0Taa7TZ [3 Years | _1 Year SOSUSHISWTUZ | 2¥eas | 8Mos a. The above table shows typical lubrication schedules Ww be used unless otherwise specified by the motor’s grease nameplate. b. It is recommended to replace the bearings after the time shown, ‘SERVICE CONDITIONS from dust [Eight hours/day, ight (o normal STANDARD |loading, clean condition free Iditions, | Twenty-four hours/day, or light SEVERE |to normal shock loading vibra- tion, exposure to dirt or dust con-| Far vary aevere conditions where he tare aubjet'o high vibation of heavy shock loading nd vibration ase 1 3 of the valu sown ite seven able 4COOLING SYSTEM 181 DESCRIPTION ‘The cylinders of the compressor as well 26 the intercoplers and aftercooler are air- cooled, For this purpose, the compressor is equipped with a fan which draws cooling air through the fan cover from the surroundings. The fan is driven by the drive engine! motor by means of one or more v-belts and is also used as the flywheel. Refer to chapter 3, compressor installation, for proper cooling air supply. 1s 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). 15-1 aieCOOLING SYSTEM 15.1 DESCRIPTION The cylinders of the compressor as well a8 the intercoolers and aftercooler are air- cooled. For this purpose, the compressor is equipped with a fan which deaws cooling air through the fan cover from the surroundings. The fan is driven by the drive engine! motor by means of one or mote v-belts and is also used as the flywheel, Refer to chapter 3, compressor installation, for proper cooling air supply. 152 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). 15-1 2970COMPRESSED AIR STORAGE SYSTEM 16.1 DESCRIPTION The air storage system! consists of one or more D.O.T. or AS.ME. storage vessels with line valves, safety valves, intercon- necting tubing, pressure gauges, check valves and a bottle rack. D.OLT. vessels are approved by the Depart- ment of Transportation for portable usage. D.O.T, systems are available at 4500 psi and Fig. 16.1 Typical two bottle 6000 psi. ASME. storage system ASME. vessels conform to the American Society of Mechanical Engineers codes for permanent installation. These vessels have working pressures of 5250 psig and 6600 psig and a safety factor of 4 to 1. A safety valve is provided on each vessel to protect against excess pressure, It is preset atthe factory and sealed, It should not be adjusted Specifications VESSEL. ‘DOT 4500 PSI | DOT 6000 PSI ASME $000 PST ‘Material Lightweight steel | Lightweight stecl | Steel ASME SA 372, alley alloy Class V Type A AISI 4130 ‘Volume 444 ef @ 4500 psi_| 309 ef @ 6000 psi | 420 ef @ 5000 psi Working pres- | 4500 psi 6000 psi 5000 psi Test pressure | 6730 pai 10,000 pst 7500 pst Diameter 9 ine" 9900" Ey Height 55 whalve 35" wivalve 5a" wo valve Weight 144 Tbs, 188 bs MOTs. Valve CGA 347 CGA 702 ‘Standard valve supplied Fiokeh Zine Chromae | Zine Chromate | Zine Chromate primer primer primer 1. Optional accessory. tL 16-1 898C16, 162 16.2.2 16.2.2 16,3 163.1 16.3.2 163.3 16.3.4 COMPRESSED AIR STORAGE SYSTEM. OPERATION ‘Slow and Fast Fil To slow fill (fll directly from the compressor), open the shut-off valve located ot gauge panel and close the bottle valves; tum counterclockwise to open, clackwis close valves. To fast fill, open she bottle valves and the shut-off valve located on the gauge pi Turn counterclockwise to open valves, clockwise to close. To Fill Storage Vessels Close the shut-off valve and open the bottle valves. Tum counterclackwise to o} clockwise to close valves. MAINTENANCE Pressure Gauges Observe the pressure gauges daily. Ifthe readings of any of the gauges seem to be in rect, remove the gauge and check for wear and tear, accuracy, and proper functioning comparing it to a precision test gauge or a dead weight tester. Replace all broker damaged gauges immediately. * Storage Bottles All storage bottles should be visually inspected intemally every year. Every five years, D.O.T, bottles must be hydrotested. Check local and state regulations regard testing of ASME and/or D.O.T. bottles. Some states require an annual visual inspect and hydcotesting requirements also differ from state 1o state. Safety Valves Develop a regular program of visual inspection, tocking for clogged drains discharge pipe, dirt build-up in and around the valve seat, and broken or missing pe Avoid operating the safety valve, as even one opening can result in leakage. Do not paint, oi or otherwise cover any interior or working parts of any safety va They do not require any lubrication or protective coating to work properly. When sa valves require repair, service adjustments or set pressure changes, work must be acc plished by the manufacturer or holders of “V", “UV" and/or “WR” certifications. ‘Tube Connections Pipe connections (swivel nuts): Tighten just firmly enough so that leakage is stop (finger tight plus up to an additional 1/2 tum as necessary). 16-2 aCOMPRESSED AIR DELIVERY 171 AIROUTLET The air outlet on this compressor unit consists of either a bulkhead connector in the panelling or a swivel connector after the pressure maintaining valve. For the location of the air outlet, refer to the outline dimensional drawing(s) in the Annex, chapter 24, 172 FILLING PROCEDURE 17.2.1 Connecting the Air Bottle Connect to the air bottle valve (fig. 17.1) using a fill hose with the CGA-346 fill adapter for 2215 psi SCBA bottles, the CGA-347 adapter for 4500 psi SCBA bottles or a DIN or yoke adapter for SCUBA bottles. Note: The CGA-347 fill adapter seals on 4500 psi rated bottle valves, but vents on tower rated pressure bottles, Also, the illustrations below might differ slightly from actual fill assembly due to variations in design. 17.2.2 Filling the Air Bottle Close the bleed vaive (1) on the fill hose (fig. 17.2) or on the adapter. Open the filling valve (2) and then the bottle valve (3), Start the compressor unit and drain the condensa- tion from the compressor regularly during filling, Fig. 17.1 Connecting the air bottle Fig, 17.2 Filling the air bottle Po 17-1 297817. COMPRESSED AIR DELIVERY 172.3 Removing the Air Bottle After reaching the final bottle pressure, tum off the compressor unit. Close the bottle valve (1) and then close the filling valve (2). See fig. 17.3. Open the bleed valve (3) to vent the residual pressure-in the fill hose or in the adapter. Disconnect the fill adapter (4) from the air bottle valve. During the filling procedure, the bottles will warm up due to the compression process. After removal, allow the bottles to cool down and the bottle pressure. to drop. The bottles may then be reconnected and topped off to the respective maximum filling pressure. Fig. 17.3 Removing the air bottle Both adapters for SCBA bottle valves use a unique o-ring sealed tip. Light finger t ening assures a complete bubble-tight seal to the bottle valve, even when the v seating area has been slightly scratched or dented, ‘Compressed air SCBA bottle filling valves for a pressure in excess of 2215 psi (155 are standardized (CGA). Connectors for 2215 psi and 4500 psi are different and ca be accidentally used with the wrong type botte. 17-2OPERATION 18.1 PREPARATION FOR OPERATION: All compressor units are tested prior to delivery to the customer, so there should be no problem putting the unit into operation after correct installation. Observe the following points: + All compressor units are delivered with cil in the crankcase. Prior to first operation check the oif fevel according to chapter 4. When putting the unit into operation following a storage period of three (3) months or mare, drain the preservative oil and fill with compressor off according to the instructions in chapter 4. + Prior to initial operation or immediately following maintenance work, wm the compressor manually using the flywheel to ensure that all parts are turning freely. + Immediately after switching on the system for the first time, check the rotation of the motor for agreement with the arrow on the unit. If the motor tums in the wrong direc- tion, the phases are not connected properly. Shut down the unit immediately, discon nect the power supply and inter-change two of the three phase feads in the switch box. ‘Never change leads at the motor terminals,’ + Pticr to each operation check the oil level according to chapter 4 and determine whether maintenance is necessary in accordance with chapter 19, » Open the outlet vaive?This valve must be open during operation. Close only for servicing the compressor to prevent air escaping from connected receivers. 182 START-UP AND SRUT-DOWN: NOTE Audible knocking during stan-up is due to the final stage floating piston. This knock- ing disappears as soon 25 theres pressure between the stages and the piston is running syachronous with the other pistons. Therefore, this knocking can be ignored. To start Energize the main power source, Tum the selector switch to “ON”. ‘To stop: Tura the selector switch to “OFF”, Disconnect main power source. Emergency stop:? Depress the emergency stop push-button, Unit wilt shut down, 1, Thyce phase units orig 2. Not standard om all models. 3. Optional accessory. be 18-1 $9su18.3 183.1 4 OPERATION Safety shut-downs The unit will automatically shut off for any one of the following malfunctions: ‘Malfunction light + High CO content* High co* + High temperature, compressor High temperature + Insufficient oil pressure Low oil pressure + Excessive motor current No light Correct the malfunction before restarting the compressor unit. To restart after a malfunction shutdown other than excessive motor current, tur th selector switch to “OFF” and back to “ON”. ‘To restart after shutdown for excessive motor current, tum the selector switch to “OFF ress the reset button, then turn the selector switch back to “ON”. SEQUENCE OF OPERATION (UNITS WITH ELECTRIC DRIVE) All item designations and line numbers in the following text refer to electrical wiriny diagram #DGM.0578 in the Annex, section 24. + By applying power to lines Li, L2 and L3, the control circuit is energized through th contcal transformer ITRR (line 1) and fuse EFU (line 1). Amber power on light 1L (ine 20) illuminates. + Tum selector switch 18S (lines 6) 10 the “ON” position. The motor starter coil 1M (line 7) is energized, the starter contacts 1M (lines L1, L2, £3 and 13) closes to star the motor IMTR and energize the hourmeter 1HM (line 13). Safety Shut-downs The unit will automatically shutdown for any one of the following malfunctions: NOTE When the compressor shuts down due to a fault, always remedy the problem before restarting the compressor. Refer to Troubleshooting, section 22, for assistance. + 10L (line 6) Thermal overload relay: When motor is drawing too many amperes, 10 will open to stop the motor IMR. To restart the compressor, tum the selector swit 1S (line 6} to the “OFE” position to cool down the motor. Press reset button and the tum 1SS to the “ON” position. Optional accessory, 18-2 9518, 18.3.2 183.3 Lee OPERATION + 2P§ (lines 8, S) Low oil pressure switch: When the compressor oil falls below a preset pressure, 2PS (line 8) will open to stop the motor IMTR, Fault is indicated by 4LT Cine 6). To restart the compressor, turn the selector switch 1SS (line 6) to the “OFF” position, After correcting the fault, tum 18S to the “ON” position, + ITS (line 10) High temperature switch: When the final stage cylinder head exceeds a preset temperature, ITS will close to stop the motor IMTR. Fault is indicated by SLT line 11). To restart the compressor, turn the selector switch 1SS (line 6) to the “OFF” position to cool down the compressor and then turn 1SS to the “ON” position, Standard Controls + IPS (line 6) Air pressure switch: Will open at preset pressure to de-energize motor starter coil IM (line 7) to stop IMTR and 1HM., When the system pressure drops below the differential of IPS (closing IPS), the unit will start automatically and begin to pressurize the system. + 1HM (line 13) Hourmeter: Registers the running time of both the motor and the compressor. + ISY (line 14): The ACD solenoid valve. + ITMR (lines 14, 15 and 16) ACD timer: De-energizes 1SV (line 14) at set time inter- vals to automatically drain the condensation. + 2CR (lines 6, 10 and 11): The control relay for ITS. + ITDR (lines 6, 7 and 9) Time delay relay: Bypasses 2PS on start-up. ‘Optional Controls + 28S “HAND-OFF-AUTO” Selector switch: Allows for constant speed in the “HAND” position and start-stop operation in the “AUTO” position. 3SV (line 4) must be used for optional constant speed unloading. + 1AL (line 12) Audible alarm: Sounds an audible alarm on fauit shutdown. + 28V (line 3): A constant speed unloader solenoid valve, + 1CO (lines 17, 18} CO monitor: Shuts down the compressor when excessive carbon monoxide is present in the compressed air. + ISC (line 5) SECURUS purification monitor system: Monitors the rising moisture level in the purifier and indicates when the purifier cartridges require replacement before the cartridge’s life expires completely. + 1 CR or 4CR control relay: Prevents the motor from restarting automatically when the power is restored after a power failure. + 3CR: The control relay for the CO monitor, 18-3 595U18,3,2 18.3.3 OPERATIO! + 2PS (lines 8, 9) Low oil pressure switch: When the compressor oil falls below a preset pressure, 2PS (ine 8) will open to stop the motor IMTR. Fault is indicated by 4LT (ine 6). To restart the compressor, turn the selector switch 1SS (line 6) to the “OFF” position. After correcting the fault, 1um ISS to the “ON” position. + ITS (ine 10) High temperature switch: When the final stage cylinder head exceeds a preset temperature, ITS will close to stop the motor IMTR. Fault is indicated by SLT (line 11). To restart the compressor, turn the selector switch 1SS (line 6) to the “OFF” position to cool down the compressor and then turn 1SS to the “ON” position. Standard Controls + IPS (line 6) Air pressure switch: Will open at preset pressure to de-energize motor starter coil IM (line 7) to stop IMTR and 1HIM. When the system pressure drops below the differential of 1PS (closing 1PS), the unit will start automatically and begin to pressurize the system, + THM (line 13) Hourmeter: Registers the running time of both the motor and the compressor. + ISV ine 14): The ACD solenoid valve. + ITMR (lines 14, 15 and 16) ACD timer: De-energizes 1SV (line 14) at set time inter- vals to automatically drain the condensation. + 2CR ines 6, 10 and 11): The control relay for ITS. + TTDR (lines 6, 7 and 9) Time delay relay: Bypasses 2PS on start-up. Optional Controls + 28§ “HAND-OFF-AUTO” Selector switch: Allows for constant speed in the “HAND” position and start-stop operation in the “AUTO” position, 3SV (line 4) must be used for optional constant speed urtoading + IAL (line 12) Audible alarm: Sounds an audible alarm on fault shutdown. + 2SV (line 3): A constant speed unloader solenoid valve. + 1CG (lines 17, 18) CO monitor: Shuts down the compressor when excessive carbon monoxide is present in the compressed air. + ISC (ine 5) SECURUS purification monitor system: Monitors the rising moisture level in the purifier and indicates when the purifier cartridges require replacement before the cartridge’s life expires completely. + 1 CR or 4CR control relay: Prevents the motor from restarting automatically when the power is restored after a power failure, + 3CR: The control relay for the CO monitor. 18-3 595U18. OPERATIO! z + IPB (ine 5): A push button emergency stop switch. + 3PS: A cut-in pressure switch for the dual pressure option. + ITGS: The on/off toggle switch for the CO monitor. + 2TGS (line 15) Toggle switch: Manual bypass for the ACD system, allows th ator to check the function af the ACD. 184191 —_— 19. MAINTENANCE SCHEDULE GENERAL This chapter provides a schedule necessary to maintain your compressor unit at both the operation and service levels. This schedule covers service activities as well as maintenance routines which are performed on a regular basis. The required scheduled maintenance services are considered essential to the proper operation, safety and performance of your unit, We recommend that the operator perform the operational inspections, These actions are matters of day-to-day care that are important to the proper operation of the unit. If any abnormal conditions are noted by the operator, bring them to the attention of a qualified service technician as soon as possible. The service technician should also perform these routine operational inspections when servicing the unit during scheduled maintenance intervais to ensure that the unit is in good working order. Scheduled maintenance work is not covered by warranty, the owner is tesponsible for the labor, service parts, and lubricants used to complete these tasks. Please contact BAUER Compressors parts sales department for any questions regarding recommended service parts, lubricants, and fluids conforming to BAUER specifications and can peovide information on BAUER authorized service representatives worldwide, BAUER Compressor’ service department is also available for any questions regarding maintenance work on your unit. These departments can be reached by fax or phone using the numbers [isted on the cover of this manual Is is recommended that all maintenance work be recorded in @ maintenance record. Showing the date, details of work carried out and the signature or stamp of the person or concem performing the work will help to avoid expensive repairs caused by missed ‘maintenance work, If it is necessary to have maintenance performed under warranty, it will help to have proof that regular maintenance work has been carried out and that the damage has not been caused by insufficient maintenance. Please consult our warranty statement included in your documentation package for complete warranty information. ‘The step-by-step maintenance procedures are described in the referenced chapters, NOTE For maintenance intervals and instrvctions for accessories such as CO monitors, engines, AC generators, trailers and battery charges reference the respective opers- tor's manuals! included in the documentation package. SET TATE TET TOTES 19-1 2976Suda emngay JO 189) $69] } syjaq-a OAup [18 yedsui] Santen Aajes 118 Jo Somes 152] waauta[? sayy ayEIUT aae;doyl ‘suonoouuoo wiaishs reaunoas oedsu| 497 ‘Sun|Jouss 10 $9049 40} 50504 je 199dsU| ‘wey Buyjooo.aaqn Ky 190dsu] seq aaup qe 195d5u | sprend pe ro0dsuy| SUIS} PEOY BApeA Jo anb30} y9auD| ‘a8ueyo [10 s0ssaxiwoo ut-yea1g| ‘Sudid/Bungea yo 1s01 9] wt-yeosg| seniva QV $924] dotworpur aotasas say7yj ayerut 39245} sowendo| 12 Tun ay oy afiewep 10) 49903] aowmadg |b ‘Susfoxo poys 30} Y9qD) sowed] 1% ‘SuOMTEAgIA TeUAFORNGe 105 Y>ON sored] _1z Spunos jeusouge 30) U=Ist7] sowed) 17 49] sreUMoUd/ayjmeapAy Oy 4994] sorndo] 7 sBupeas aumssaid 2049] aunssaud jt0 sossasdwoa 52943] soyedo| > 1249] [10 s0ssaxdm09 42049] 19-2 soins 30 } ardent | 090001 | gos £1 | 00001 | ovoE | oo0z | ooo } cos | oct | os | 8 sor SVL TONWNALNIVA, 19, MAINTENANCE SCHEDULE491 “suontpubo ataAzs s9pun smnoY 000 FEO 9 wepmypa| 91 “sduneaq so10u! aausp 2a] oe ee | ‘Rese soperadas soja pouiy 200,doy) vorommal| ot 18}98524 amssaud 19g wadsuy wwpmmses | i | I sup uoysid 7 suoystd yoodsuy wma] souse sroduco urdu |p wwrtmaay| 9b S185594 ammssoxd aysy Padsuys | worounay| { rt ‘se(Sradis 10 want ww, [emer py ‘sSuruado quan 7 dursnoy 1o}ow wear] 2 derumaoy,| ct EA BePoHMAL) St & | wemon| 9 [ a [Leeman] o's . ‘SiuoM2}> yRpaus PasoyUIS UeA}D| & [fear a ‘SaaTea z0sse1dwo9 uway9 7p 190d5u)| F tf eomeal + lio Gnoqus) sssoiduioo ate BU LT ownysos| 61 “UUme ajgipre omy 1525 & | [room Sq Pf emvs.0 | siden | con aot | 0st }00008 | 900€ | noo ; oor | ons | oct } os | 8 = YL oweio MSV BONYNALNIVA a20, 20.1 203 STORAGE, PRESERVATION GENERAL If the compressor will be out of service for several months, it should be preserved in accordance with the following instructions: Make sure that the compressor is kept indoors in a dry, dust-ftee room. Cover the compressor with plastic sheets only if no condensation will form under the sheet. Remove the sheet from time to time and dry the outside of the unit. T€ this procedure cannot be followed, or if the compressor will be out of service for more than 24 months, please contact the BAUER Service Department for special instructions. PREPARATIONS Ptior to preserving the compressor unit, it must be run until warm, i.¢., up to the speci- fied service pressure, Operate the unit for approximately 10 minutes, then carry out the following checks: + Check all pipes, filters and valves (including safety valves) for leakage. + Tighten all couplings, as required. + After 10 minutes, open the outlet valve and operate the compressor at adjusted minimum pressuce (see chapter 8) using the pressure maintaining valve for approxi- mately 5 minutes + After the 5 minutes, shut the compressor unit down and completely drain all separators and filters. Close all valves. + Remove filter heads and lubricate the threads with white petroleum jelly. For units equipped with a filter system: + Ensure that filer elements remain in the filters! This will prevent oil from entering the outlet lines as a result of preservation procedures. + Remove the intake filter/intake pipe completely. PRESERVING THE COMPRESSOR + Operate the compressor again and slowly spray approximately 0.35 oz. (10 ¢c) of oil, into the inlet port while the compressor is cunaing (Far oll type, see chapter 2). Keep the shut-off valve open and the condensate drain valves closed, + After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before shutting the compressor unit down, + Close the shut-off vaive. bo 20-1 297A,STORAGE, PRESERVATION + Close the inlet port with a dust cap and/or tape. 20.4 PRESERVING THE DRIVE 20.4.1 Units with an Electric Motor Store the motor in a clean, dry location. Cover completely with plastic, Leave opening for ventilation. Maintenance during storage Every two montis, rotate the shaft. Every six months, give the winding a megger test. A minimum of 10 megohms recommended. For motors with grease fittings, add grease as necessary (see chapter 14). 204.2 Units with an Hydraulic Motor! For preservation instructions during storage of hydraulic motors, reference Hydraulic Motor Manual 20.4.3 Units with a Combustion Engine! For preservation instructions during storage of combustion engines, reference Engine Owner's Manual 20.5 PREVENTIVE MAINTENANCE DURING STORAGE Operate the compressor once every three months as follows: + Remove the dust cap from the inlet port and instal the inlet filter. + Open the outlet valve and allow the system to run approximately 5 minutes until is outflow from the valve and oil is visible in the sight glass of the oil regulating va + Shut down the compressor. + Open the condensate drain valves, depressurize the unit, then close the drain val again. + Remove the intake filter and replace the dust cap on the inlet port. 1, Not available on all models, 20-2 220, STORAGE, PRESERVATION + Close the inlet port with a dust cap and/or tape. 204 PRESERVING THE DRIVE 204.1 Units with an Electric Motor Store the motor in a clean, dry location. Cover completely with plastic, Leave opening for ventilation. Maintenance during storage Every two months, rotate the shaft. Every six months, give the winding a megger test. A minimum of 10 megohms recommended. For motors with grease fittings, add grease as necessary (see chapter 14). 204.2 Units with an Hydraulic Motor? For preservation instructions during storage of hydraulic motors, reference ‘Hydraulic Motor Manual. 20.4.3 Units with a Combustion Engine! For preservation instructions during storage of combustion engines, reference Engine Owner's Manual 20.8 PREVENTIVE MAINTENANCE DURING STORAGE Operete the compressor once every three months as follows: + Remove the dust cap ftom the inlet port and install the inlet filter. + Open the outlet valve and allow the system to run approximately 5 minutes until t is outflow from the valve and cil is visible in the sight glass of the oil regulating vs + Shut down the compressor. + Open the condensate drain valves, depressurize the unit, then close the drain va again. + Remove the intake filter and replace the dust cap on the inlet port. 1. Not available on all models.STORAGE, PRESERVATION Lubrication Oils for Preservation + After prolonged storage periods, the oil will age in the compressor. The oil must be drained at least every 36 months and replaced with fresh ci + The stated period can only be attained when the crankcase is sealed during the preser- vation period in accordance with the preservation requirements. + After changing the oil, the compressor must be operated according to the instructions above. + Check the lubrication of the compressor in accordance with chapter 4 during the every-three-month brief operation or when turning the compressor. 206 REACTIVATING THE COMPRESSOR UNIT + Remove the dust cap from the inlet port and instal! che intake filter, + Check the oil level of the compressor. If necessary, change the oil and oil filter. + The motor must he thoroughly dry before applying power. «+ For units with a filter system, change all filter cartridges. + Run the compressor with open outlet valve for approximately $ minutes, Check for Proper operation of the lubricating system, + After 5 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 pressure switch setting the switch above normal limits to override the pressure switch. Be sure to reset the switch after checking. + Check the interstage safery valves for leakage + Establish the cause of any faults from the troubleshooting table, chapter 22, and temedy, + Stop the unit when it is running properly. The compressor is then ready for operation. 20-3 29782 211 22.2 REPAIR INSTRUCTIONS REPAIR Preventive maintenance usually involves replacing the gaskets and sealing rings and carrying out the «maintenance work (see chapter 19). Maintain your unit and carry out minor repairs as recommended in this instruction manual, For major repairs and/or overhaul, call BAYER Compressors, Inc, or a factory authorized service representative, Safety valves may not be repaired. They must be replaced. General rules for servicing the compressor block + Always clean the compressor extemnaily before starting a repair. + Check the hoses and fittings regularly for feaks, Use soapy water to detect leaks. Repair leaky equipment immediately. A small haitline crack could suddenly burst and cause serious injury. + Never repair any high pressure components by soldering or welding. + Assembly is basically carried out in the reverse order of the disassembly. Any addi- tional procedures will be noted. Tubing and pipe connections Leaks at the fittings will be the most common. These may generally be repaired by tightening the joint. Please note that the compression type coupling fittings are capable of exerting exireme force on the tubing and should not be tightened more than is required to seal the joiat. To improve the sealing of the pipe connections and to facilitate installation, the following should be observed: + Apply a thin Jeyer of Never-Seez NSWT or equivalent (refer to the table in chapter 23) on the outside of the ferrule during assembly. + Lubricate the threads of the connector with Never-Seez NSWT or similar PFTE base grease to facilitate future disassembly. CAUTION Small diameter, thick wall tubing can be severely distorted by excessive tightening. ARer constructing a new joint and inspecting it for leaks, it should be opened and inspected for distortion, then retightened no more than is required to seal the joint. 21-1 297A,TROUBLESHOOTING 22.4 GENERAL INSTRUCTIONS ‘This troubleshooting guide has been prepared to assist you with your compressor. If you need parts or further assistance, call your nearest BAUER distributor. Isolation of the problem encountered should normally proceed from the general to the specific, beginning with the determination of the area in which the particular fault occurs. The riext step in the isolation process is to determine the specific part suspected of being faulty, When such isolation procedures are followed logically and correctly through a step-by-step pattern of check and slimination, the fault can be traced accurately to its source without unnécessary delay or replacement of parts. Problem Cause ‘Remedy Drive motor/engine! The motor hums, the (One phase is missing, Check the phase voltage. machine does not start “Engine! does not operate Reference the engine properly, manual. Compressor block No oil pressure ‘Air sapped in oil pump. ‘Vent pump and line Oil pump drive not correct. Check drive - see work- shop manual. Gil sight glass exhibits bubbles. Oil foam in the crankcase ‘Not available on all models. Oil pressure regulator dirty. Final stage piston wom. Final stage discharge valve defective Improper maintenance of filers. Filter element saturated. Wrong cit type 22-1 Clean and readjust oil pres- sure regulator. Rotate Aywheel by hand with final valve head re- moved. If oil flows contin- uously from the cylinder, replace piston and liner. Replace. Service filters, Change filter elements. ‘Use correct oil and clean. ted 297E22, TROUBLESHOOTING Problem Cause Remedy ———__——___—____| ‘Compressor does not Condensate drain valves or fittings | Tighten and reseal attain final pressure. leaking, Premature opening of final safety | Replace safety valve, valve Piston rings wom or excessive _| Replace. See workshe piston clearance manual. ‘Compressor output Intake filter clogged. Replace filter element insufficient. ; , i Ist stage valves not closing Check and clean. Rep : properly. if necessary. . Pipes leaking. Re-tighten. Safety valves between | Intermediate pressure too high. | Check valves, chapter easi . . stages releasing Pressure. | «195 not closing property. Replace. Excessive oil consumption | Check all cylinders. Replace rings and pist i as required, | Compressor works Drive belt slipping. Check drive belt. Rep irregularly. or tighten. i Outlet flow restriction. | Clogged final separator. Remove metal micro ‘ ‘element. Clean or rep! I Pressure maintaining valve set too | Check PMV for corre | high. : ‘opening pressure. PMV operates at wrong | Incorrect setting. Reset. ' pressure. . Dirt on valve seat. Clean, Reset. Damaged valve seat. Replace. ‘Compressor fails to Faulty pressure switch. Remove, clean and in presswize ‘switch. Repair of repli ACD not working properly. Check solenoid funet Check drain valves. C repair or replace. 22-222. TROUBLESHOOTING ns Fr ima ‘Compressor tuning too _| Insufficient supply of fresh cooling | Check location - max, hot. air, ambient temp, +113°F 4s°c). Intet or discharge valves not Check and clean valves, closing properly. Replace wom parts. ‘Wrong direction of rotation. See arrow on compressor. Remedy accordingly. Pressure higher than aormal dueto | Remove inlet and inlet and/or discharge valve oper | discharge valves. Clean or ating improperly. replace. Intercoolers clogged. Remove and clean, Aftercooler dirty. Clean finaed tubes by blowing with low pressure air (80-125 psi). Cooling air fan running but not ‘Check v-belts. Tension or delivering due to wom or loose v- | replace. belts. Automatic Condensate Drain Condensate drain valve | 3-way sofenoid valve faulty or not | Check solenoid valves. not opening receiving electrical signal Replace if necessary, Check for voltage from timer. Replace timer if necessary. No control air available. Check supply lines. Solenoid valve not venting due te} Check electrical control continuous electrical signal. and timer. Condensate drain valve piston Dismantle and ciean drain jammed, valve, Replace piston if necessary. Valve filter etement plugged. Replace valve element. 22-322. TROUBLESHOOTING Problem Cause ‘Remedy ‘Automatic condensate 3-way solenoid valve not venting | Check solenoid valve. drain valve not closing | drain valves. Replace if necessary. Condensate drain valves dirty, | Dismantle and clean dra stuck and/or leaking, valves. Electric Control System ‘Control does not switch on | No control voltage. Check feed line. ‘Control fuse defective. Replace fuse, eliminate cause. Control current fine cut off, line or | Tighten terminal or reps terminal loose. line. ‘Thermal overload relay triggered, | Clear faults as described the following. ‘Thermal overload relay for | Current consumption too high. | Check compressor drive drive motor triggered . Overload relay set too low, Correct setting, Comtrol does not switch | Final pressure switch set too high. | Correct setting, off, final pressure safe . valve vents Yl Final pressure safety valve Replace safety valve. defective, Final pressure switch defective. | Replace switch. 22-423. TABLES 23.1 TIGHTENING TORQUE VALUES NOTE Unless otherwise specified in text, the following tightening torque values apply. The indicated torque values are valid for bolts in greased condition, Replace self-retaining nuts on reassembly. Hex and socket head 1/4” (M6) ‘7 ft. Ibs. (10 Nm) Hex and socket head | 5/16" (M8) 18 f ibs, (@3 Nm) [Hex and socket head | 3/8” (M10) | __32 ft Ibs. (45 Nmp Hex and sockethead | 12" (412) | _ 53 Ibs. (75 Nm) Hex and socket head | 9/16” (M 14) 85 ft. tbs. (120 Nm) Hex and socket head | 5/8” (M 16) 141 ft-lbs (200 Nm) Pipe connections (swivel nuts): Tighten just firmly enough so that leakage is stopped (finger tight plus up to an additional 1/2 turn as necessary). NOTE: Check for leakage of the complete system from time to time by brushing all fitings and couplings with soapy water or spraying with leak test spray. Repair any leaks, 23.2 LUBRICATION CHART If not stated elsewhere, use the following lubricants: Usage Lubrication O-rings, rubber and plastic parts, filter | Parker “O Lube | housing threads Sealing rings Parker “O” Lube Bolts, auts, studs, valve parts, copper gas- | Never-Seez NSWT, Pipe Dope or teflon kets and tube connections (threads, cap | tape | mut and compression rings) Paper gaskets Apply silicon compound on Both sides before assembly, i.c., DOW Coming 732 High temperature connections Temperature resistant compound, ie., DOW Coming 732 Ferrules of tube connections Never-Seez NSWT 23-1 095A23. 23.3 TABLES CONVERSION TABLE PSI TO BAR B 3 u i % % % B n B 3 Fo u a a 3 3 Ef 3s ES: % 2 bas 3300. z 2 C3 5500 x B V8. y600 | 38 B 166 : 3300 ¥ a5 Ln ASO 5300 « 36 Le z ee ‘$906. w B | ip a ee} 8 33. 80: 3 6100 a Fy 20 ete em | 2 0 207 1200, 300 8 Er ae 7 ae 400 4% R 32 600 | 4 7, 38 23 sao | 38 Bu 6700 4 3 6200 46 oo) a 7000 “ ne | 4 no | reo | 5 00] a 7300 is 7600 a re | 2 7800 ¥ 7300) s 000 5 8100 FE #200 46 =a x ‘8400, a 8500 3 600 9 Es 32 700 ca ss 3 300 € 336 woo) 7 32 sooo | 8 a $00 3100 & 3 ant 9300 8 wo au 3300 4“ 23.2 c23. 23.4 TABLES CONVERSION TABLE °F TO °C 200 392 23-3+ Glossary of abbreviations + Schematic wiring dingram(s) + Outline dimensional drawing(s) + Pneumatic diagram(s) + Accessory documentation + Special drawings, if applicable ‘Any special documentation supersedes and/or supplements the respective paragraphs! figures of this Instruction Manuel.Glossary of Abbreviations and Acronyms ACD automatic condensate drain ASME American Society of Mechanical Engineers BCI BAUER Compressors, Inc. BSPP British standard pipe, parallel BSPT British standard pipe, tapered BKM BAUER Kompressoren Miinchen (GmbH) CCW counterclockwise CGA Compressed Gas Association ‘CNG compressed natural gas CSA Canadian Standards Association CW clockwise DIN Deutsches Institut ftir Normung DOT Department of Transportation EL single phase electrical supply E3 three phase electrical supply EXP explosion proof (motor) FAD free air delivered FGD free gas delivered FLA full load amperes ISO International standards organization NC normally closed ‘NEC National Electrical Code NFPA National Fire Protection Association NEMA National Electrical Manufacturers Association NO normally open NPT National pipe thread OSHA Occupational Safety & Health Administration ODP open drip-proof (motor) PCB printed circuit board PLC programmable logic controller PMY pressure maintaining valve PRS priority/sequential (system) SAE Society of Automative Engineers TEEC totally enclosed fan cooled (motor) VRS vapor recovery systemEXPLANATION OF MODEL NAME MODEL NAME BREAKDOWN STANDARD UNITS K230V-40-E3 ¥1 = Single phase electric motor driven E3 = Three phase electric motor driven D = Diesel engine driven G = Gasoline engine driven HYD = Hydraulic motor driven NG = Natural gas engine driven Motor/engine horse power V= Vertical BP= Basic Package Compressor block numbers B= Medium pressure ait BK = Booster C= Natural gas CB = Medium pressure natural gas G = Inert/non-aggressive gas I= Industrial air = Breathing air KV = Medium pressure (2 cylinder) KVB = Medium pressure (2 cylinder) KWB = Medium pressure (3 cylinder) O = Offshore application Lrg |EXPLANATION OF MODEL NAME MODEL NAME BREAKDOWN FS36-E3 [= UTILUS/CAPITANO/MARINER C-E3 | AIRSTREAM/UNICUS IV/VERTICUS/ATAC/TRAILERS, EL = Single phase electric motor driv E3 = Three phase electric motor drive G = Gasoline engine driven D= Diesel engine driven Charging rate (scfm) FS = Air-Stream VT = Verticus ATAC = Articulated Transportable A Charging Unit DDTR = Dual Drive Trailer TR=Trailer E1 = Single phase electric motor driv. E3= Three phase electric motor driv G = Gasoline engine driven G/DV = Gasoline engine driven/dive D = Diesel engine driven D/DY = Diesel engine driven/dive ver HYD = Hydraulic motor driven C =Capitano M = Mariner U lus DOM II=Dominus-II ‘02/97 FOR.‘When operating at temperatures other than 68°F, divide the number of hours operated at that tem- perature by the correction factor as indicated in the chart and graph below. OPERATING SCHEDULE FOR PURIFICATION SYSTEM Separator inlet temperanure 30 — ie | das [ °F °c | i 20 32 0 3.80 a: 41 5 2.62 I so | 1.35 5s os 39 18 134 i ; $8 e 1.00 41 50 59 68 77 06 104"r 7 25 0.75 S 10 45 20 25 30 400 86 30 057 ‘Separate ine tmperatre 104 35 0.43 122 40 034 Operating hours Ambient temp. during compression Correction ‘Adjusted cartridge hours eg. TAG |B or Ae an foe [—- : (0295 FOR- 0018OPERATING SCHEDULE FOR PURIFICATION SYSTEM. When operating at temperatures other than 68°F, divide the number of hours operated at that tem- perature by the correction factor as indicated in the chart and graph below. factor Ambient temp. uring compression 0 44 50 59 68 77 86 104" S 10 1§ 20 25 30 40° ‘Separator inlet ermperatice Adjusted cartridge hours (0295 FOR- 0018Correction | Adjusted cartridge ho Factor Today Ambient temp. during compression ‘Operating ‘hours: 0255 FORCOMPANY CONFIDENTIAL ‘Wa roa ard ll ermon Maren 9 a obey GP AALES toegremora moses connec Seal re tece a eres Sracty nancy any wey atone 13 rman of BAER Covgreaner meant20 se seu mn 25 anus 2 M6: (SDE OL DPSTIOX 7 we —4 canons vor | SEPARATOR — Dirt. arene same Is cam \ (se Tei NO STAGE WTER-FRTER 6m: AO STARE =, TE, waa ore =: wsanae sm ae \Le arcane vanes vere sce non Sane See we Semone erat ETT oweRIGHT SIDE REARorale e, LEFT SIDE COMPANY CONFIDENTIAL The downg and of Morwaten eter the ooery oF BALES Compress, nero" exrfearot rd mast et be rede DDG oF cones I ioe Sec fo aism Upon Serr ee re 10 D8 aety of rerecty fh ary way date o te fiers of BAUER Cmeeone, Teoria sores: RRR OSTAMCE FcR MARTE (AND COOL A-ALOW, 30 ACL SES, Gar. wr ersiers on “Ts DRAWS REFLECTS CURRENT DESION 410 CSRRCT To Ounce vereouT PRR ROTCE SEKGE OF ROTATION COUNTERCLOOOSE AS Weaver FACNG HE PLP, SOE, Be see worme, Be eeeS0I$ 1437 avy Sas 2HOWY| neuaee Dranray Piva ia 2b weISSUE REVISION pare] av |APvo, SeToRr VALE [CO HONTOR TEST VALVE RAN/BLEED VALVE FEWPERATURE SHIT [Aca SOL=NOD vaLve [co MGNRTOR REDE VALVE [FOURTH STAGE RELEP VALVE THRO STAGE ELEY VALVE SECOND STAGE RELEF VALVE [FRST STAGE RELEF VALVE [EO NeMTOR TEST CYLNOET PRESSURE REGULATOR [co WoneTOR REGULATOR Pease ee [FRAL PRESSURE SuiTOH iE fou PRESSURE SATTCA PRESSURE NANTADG VALVE [co weneon TEST CYLADEN PREISURE CGE ou PiESouRe CAUSE — [FOURTH STAGE PRESSURE GAUGE sl lalslz| a 3 TaD STAGE PRESSURE GaUcE [Secon STAGE PRESSURE GAUGE FRST STAGE PRESSURE CAUCE, ORE ATTNG [ot PRESSURE REGAATOR i jou eure gi EdausT MARR, [co TOR SEGRUS NOCATOR [RCET FLIER MANTOUIEE WOKATOR lala] Low CONTROL VALVE [CRANiCASe vENT/ABEDBAC FLTER intake PUTER a}3)3} [eo ncneTOR TEST GAS CVLNDER foreck vaive a [ComoENSATE DRAW VALVE [CCMOENSATE ORAN BOTTLE PLRFCATION: PL = STANOARO JCONCENSATE SevARATOR INTEROAFTER STAGE COOLER F7O/C|O® [COPTESSOR STAGE “D_IBAUER COMPRESSORS, INC. ‘MOPrOLK. RGN FLOW DIAGRAM OSE £ O5-DREPLACEMENT PARTS LIST 015-E/D HIGH PRESSURE OFFSHORE BREATHING AIR COMPRESSOR UNIT Edition May 1995 BAUER COMPRESSORS, INC. Seen unin ssonvote @) Underwriters ‘Telephone: (804) 855-6006 Laboratories Ine.eREPLACEMENT PARTS LIST ‘TABLE OF CONTENTS Assembly Section code Compressor block Filter system Condensate drain system Instrument panel Frame and enclosure panels Drive system Accessories atmouaowp Illustrated parts not having item numbers are shown for assembly purposes only and are not available for sales as individual components. These parts can be attained by ordering the complete assembly. N.S. in the item column indicates an item which is not shown in the illustration, but is nevertheless available, ‘When placing an order for spare parts, please give the following information to ensure correct delivery. Unit model and year Serial number Quantity required Description and part number Bee Example: For unit 015-E/D, 1995 model, S/N 24416, 2 o-rings, part number NO4385 are required. S9SBXREPLACEMENT PARTS LIST ‘TABLE OF CONTENTS Assembly Section code Compressor block A Filter system B Condensate drain system c Instrument panel D Frame and enclosure panels E Drive system F Accessories G Ilustrated parts not having item numbers are shown for assembly purposes only and are not available for sales as individual components. These parts can be attained by ordering the complete assembly. NGS. in the item column indicates an item which is not shown in the illustration, but is nevertheless available, When placing an order for spare parts, please give the following information to ensure correct delivery. Unit model and year Serial number Quantity required Description and part number pee Example: For unit 015-E/D, 1995 model, S/N 24416, 2 o-rings, part number NO4385 are required, bo S9SBK,ae 2RER REPLACEMENT PARTS LIST B Revision record Rev. no. Date Revision ° ‘May 1995, Basic editionREPLACEMENT PARTS LIST Assembly Upper crankcase; K-15 H. Crankshait/connecting rods; K-15 Lower crankcase; K-15 H. Piston and cylinders, K-15 H Cooling system; K-15 H.... Air-intake filter; K-15 H. Lubrication system; K-15 H Inter-filters and safety valves, K-15 H. Ist stage valve head; K-15 H. 2nd & 3rd stage valve head; K-15 H 4th stage valve head; K-15 H..... Compressor blockUpper crankcase; K-13 H B22R age no UE auaed Hf tgREPLACEMENT PARTS LIST a PRESSOR! | ‘Upper crankease KASH Item Qty _ Part no. Description Notes 1 1 'NOO170 Shaft seal @30x47x8, DIN 3760 2 6 055799 Spacer @18x8.5xSmm, DIN 1798 3 6 —SCR-0180 Socket head cap screw M8x35, DIN 912-8.8 4 1 014228 Bearing cover KISH 3 1 003177 Bearing cover gasket 9292x265x0,5mm 6 1 00633. —Ball bearing 30x80x27 7 1 0047S Ball bearing. 40x90x23, DIN 625 8 1 NO1363 Shaft key A8x7x45, DIN 6885 9 1 014012 Crankshaft/connecting rods assy 50 hub, complete 10-1“ NOO169 Ball bearing 25x62x17, open n 1 -N02906 Shaft seal 42x55x7, DIN 3760 12 1003733 Bearing cover gasket ©62.5x90x0.5mm, 13 1 012392 Bearing cover G92x62x55mm bore, DIN 7168 14 4“ NOI361._-—Countersunk socket head cap screw M6x15, DIN 7991 15. 1 007835 Upper crankcase KISH 16 1 (0SSO8r Oil filler cap Ye" BSPPm wio-ring 7 1 0s724a Crankcase vent separator 2" BSPP&2Omm 18 1 006192 Gasket ©62x80x2mm, rubber 19 3 006200 Retaining clamp Steel, DIN 17222 20° 1 006181 Separator housing 1" BSPPm 2 1 004416 Gasket @40x34x2mm, fibre 22 1 —-NO1031_—s~Piipe adapter 1"BSPPm x I"BSPP£, 80mm Ig 23° 1 TUB-R-O1IS Flexible tube! 2" OD x 1" ID, PVC 24 1 CMP.0035_— Worm gear hose clamp O11/16" to O14", ABA 25 2 -NO10S9 Copper gasket A12x15,5x1,5, DIN 7603 26 1012393 Dipstick tube K-15 H, side 271 tzaga Oil dipstick K-ISH, side 28 It ‘'NO1338 O-ring, @9.25x1.78, NBR, 80 Duro 29° 1012563 Dipstick tube K-15, rear 301013560 Oil dipstick K-15 H, rear, 110mm 1g 31 1 NO3521 O-ring ©21.82x3.53, FKM, 75 Duro 1. specify length on orderSf geg 8 S84 apt ag ED tran 3 Upper crankcase (continued); K-15 HItem Quy Partno. 32 2 006190 33 1 NO9339 34 1 WAS-0030 35 1 087521 36 2 001492 37 1 -No4467 38 1 SCR-0197 REPLACEMENT PARTS LIST SE ‘Upper crankcase (continued) KISH Description Crankease vent separator Socket head cap screw Split lock washer Lifting tube Flat washer Eye bolt, Socket head cap screw Notes 1” BSPPm x 20mm ID hose ‘M10x25, DIN 6912-8.8, A3A. 10mm, DIN 127-st, A3A M10, 16 ODx159mm lg, DIN 2391 10.5.1D x 37.5 OD x 3mm MIO, DIN 580-steel, ASA M12x16, DIN 933-8.8, A3A 29THA-7 REPLACEMENT PARTS LIST I MPR SONS | Crankshaft/connecting rods KISH Tem Qty Partno. _Description Notes 1 1 Crankshaft assembly! 50 hub 2 Lo Crankshaft! 3 Lom Counterweight! 4 1 N04366 Hex head fitting screw ‘MB&x60, DIN 609-8.8 5 1 NUT-0062 Hex nut MB, DIN 934-8, ASA 6 1 WAS-0001 Split lock washer 8mm, DIN 127-st, ASA 7 1 NO1363 Shaft key ABx7x45, DIN 6885 8 4 Inner race! For needle bearing 9 3 Shaft spacer! 10 E Connecting rod! 3rd stage rT 1 Connecting rod! 4th stage 12 bo Connecting rod! Ist stage 13 1 Connecting rod! 2nd stage 14 Som Shaft spacer! @35.1x52x0.3mm 151 014012 Crankshaf¥connecting rod assy. 50 hub, complete J, not sold separately 297REPLACEMENT PARTS LIST aaa 2. not sold separately Lower crankcase KASH Item Qty Partno, Description Notes 1 7 NUT-0062 Hex nut M8, DIN 934-8, AJA 2 7 WAS-0021 Flat washer mm, DIN 125B-st, A3A. 3 7 Noooss Stud ‘MB8x30, DIN 835-8.8 4 1 012386 Crankcase gasket K-15H 3 2 012388 Lower crankcase K-SH 6 1 No4499 “Fitting gasket 216.7x24x1 5-0 7 1 ADP-0019 Adapter 3/8” BSPPm x 3/8” NPTE 8 2 FTG-0022 Hose barb fiting 3/8” NPTm x 3/8” hose 9 2 CMP-0003 Worm gear hose ciamp 3/8" to 7/8" 10 1 HOS-R-0033 it hose! 3/8” ID, 200 psi, red u 1 CON-0013 Bulkhead connector 8mm S tube 121 004704 Camshaft KISH 131 NO0O91-—_—Ball bearing 220x47x14, DIN 625, open 14 1 Og0149 Bearing cover gasket 47 5x74.6x0.5mm 151 005348 Bearing cover @47.5x75x40mm bore 16 3: WAS-0024 Flat washer 6mm, DIN 125-st, ASA 17 3 SCR-0065 Hex head cap screw M6x16, DIN 933-8.8, A3A, 18 §— NOIBI3.— Split lock washer 6mm, DIN 7980, A3A. 19 5 SCR-O145_— Socket head cap screw M6x20, DIN 912-88, A3A mf (012382 Cog belt gear 22 T10/21-1 211“ NOO086 ‘Shaft seal 20x40x7, DIN 3760 22 1 Ball bearing? KISH 23 1 Cog belt pinion? K-1SH 24-1 OL2400 Pinion spacer K-SH 28 1 o12aas Tensing bracket K-ISH 26 1 No2460-— Flat washer 8mm, DIN 9021-st, A3A. 27 J SCR.O136 Socket head cap screw ‘M8x25, DIN 912-8.8, A3A 28 1 + Ball bearing seat” K-1SH 29 1 Retaining ring? K-1SH 30 1 SCR-0179 Socket head cap screw ‘M8x30, DIN 912-8.8, A3A 31k 012729 Cog belt gear Syachroflex 1. specify length on order nn ASD 2978hose FEE yas ae HD beansREPLACEMENT PARTS LIST Lower crankcase (continued) KISH Hem Qty Partno.__Description Notes 32 2 = NOO6S4 Split lock washer 8mm, DIN 7980, A3A. 33 2 SCR-0136 Socket head cap screw ‘M8x25, DIN 912-8.8, A3A 34 f NO2874 Cog belt 10x720x16mm 35 1 012402 Belt guard K-ISH 36 1 WAS-0001 — Split lock washer 8mm, DIN 127, A3A. 371012695 Cog belt pinion assembly Synchroflex A-ll 297Piston‘and cylinders; K-15 H s on PS) oi ae al 22 3 a ai | IREPLACEMENT PARTS LIST Piston and cylinders 1. not sold separately K-1SH Item Qty _Partno. __ Description Notes 1 1 072164 Piston assembly 120x83mm Ig 2 8 —_ Retaining ring! 320x1.5, DIN 472 3 t 057246 Piston cylinder Di26mm 4 1 NO3732. O-ring ©126.72x1.78, FKM, 75 Duro 5S 1 070010 ~—_—~Piston assembly 260x76mm Ig 6 1 057248 Piston cylinder eomm 7 3 NO3731 O-ring 69,571.78, NBR, 70 Duro 8 1 072865 Guide piston assembly Bo0x59mIn 1g 9 1 070013 Floating piston @32x112mm ig 10° 1 087250 Stepped piston cylinder 232/60mm 1 7216s Guide piston assembly 60xS9mm lg 12, 1 057252 Stepped piston cylinder 214/60mm 3001 — Piston pin! 14 1 ‘NO2963 Piston ring set B120mm_ 1S 2 NI6313_——_—Piston ring set 232mm 16 16 =-NOO2I1S’ Stud M8x25, DIN 835-8.8 17 16 WAS-0021 Flat washer 8mm, DIN 125B-st, A3A 18 16 NUT-0119 Hex tock nut M8, DIN 985-8, A3A 9 3 _ Piston pin! 20° 1 —NOl461—_—_—~Piston ring set ‘60mm 212 -NO2320Onting ©21.95x1.78, FKM, 75 Duro 22 1 014585 Piston and sleeve assembly = Dl4mm 230-1 NO3860, O-ring, ©28.12x1.78, FKM, 75 Duro 24 1065094 Fined cooling plate Air-cooled ee A-13 297Cooling system; K-15 H saree Fs Sh apg BS 880RREPLACEMENT PARTS LIST Cooling system K-1SH Item Qty _Partno. __Description Notes 1 1 011226 Cooling fan shroud K-SH 2 1 014834 Compressor flywheel “A” only, 2 groove, 13,06"PD 1 057315 Compressor flywheel! 3V sec, 2 groove, 13.06"PD 3 8 — WAS-0001 Split lock washer 8mm, DIN 127, A3A 4 1 SCR-0039 Socket head cap screw M10x70, DIN 912-8.8, A3A 5 1 WAS-0030 Split lock washer 10mm, DIN 127, A3A 6 18 065460 Fan blade CCW, 145mm ig, DIN 7168 7 6 085425 Fan blade support 3-blade 8 12 WAS-0029 Split lock washer 6mm, DIN 127, A3A. 9 1 012540 Air deflector panel KH 10 3 SCR-O106 Hex head cap screw M6x12, DIN 933-8.8, A3A 11 TL_-WAS-0024 Flat washer 6mm, DIN 125B-st, A3A 12 12 SCR.0065 Hex head cap screw ‘M6x16, DIN 933-8.8, A3A 13. 1 SCR-O136 Socket head cap screw 8x25, DIN 912-8.8, A3A 14-8 -—-NO3786.— Stud M6x30, DIN 835-8.8 15 15 NUT-O1I8 Hex lock mut (M6, DIN 985-8, A3A 16 1070047 Aftercooler Air-cooled, complete 17-8 SCR-0179 Socket head cap screw M8x30, DIN 912-8.8, A3A 18 20 WAS-0021 Flat washer 8mm, DIN 125B-st, A3A 19 4 ~—«-NO3468.-——_Slotted flat head screw M6xS0, DIN 963-5.8, A3A 20 «2014370 P-clamp 18mm ID x M8, DIN 1016 21 6 =~ NUT-0062 Hex aut M8, DIN 934-8, A3A 22 4 «= NOO7I9. Hex head cap screw ‘M8x10, DIN 933-8.8, A3A 23 4 SCR-0159 Socket head cap screw M8x20, DIN 912-8.8, A3A. 24 4 (012759 Fan shroud support KISH 25 4 =~ WAS-0024 Flat washer 6mm, DIN 12SB-st, ASA 2 172771 Intercooler Ist stage, complete 7 1 Ons Intercooler 3rd stage, complete 2 1014581 Male branch tee 12mm L tube x "BSPTm 29° 1 NO2919 Cap with rim 2" BSPTE 301014052 Connecting tube from tee to 2nd stage 312014057 Mounting bracket Intercoolerfinter-filter 1. for gas and diesel units A1S 297x % Bd $ z g z 2 € & § 2 3 oo z 5 3 9 eeaee of or aan fpog 22 885 : A-16REPLACEMENT PARTS LIST SCR-O111 Cooling system (continued) K-isH Tem Qty Partno. _Description Notes 320 «1~«(O72773 Intercooler 2nd stg, air-cooled, complete 332 SCR-O113. Hex head cap screw M&x4p, DIN 933-8.8, A3A 341012282 Cooler bracket Intercooler/aftercooler 35 3 ~—-NO3039_-—Socket head cap screw 6x50, DIN 912-8.8, A3A 36-24 -NO3049 Disc spring D18x6.2x0.7, DIN 2093 374 (012867 Tube clamp S-groove, 24mm OD tube 38 «1012961 Clamp assembly Intercooler 39 «$= NUT-O119.- Hex lock nut MB, DIN 985-8, A3A 40 2 SCR-0136 Socket head cap screw M&x25, DIN 912-8.8, AIA 4t 4 =~ No2460 Flat washer mm, DIN 9021-st, A3A. 42 1 013441 Tube clamp 4-groove 43 4 (012850 Tube clamp 20x55x3mm, DIN 1018 44-1 001492 Flat washer 10.5 1Dx37.5 OD x 3mm 45 1 WAS-0001 —Splitlock washer 8mm, DIN 127, A3A. 464 Hex head cap screw 8x20, DIN 933-8.8, AZA A-I7Hage JN BEHE got ao JY anave a deeasz Air-intake filter; K-15 HREPLACEMENT PARTS LIST —_—_—_—$—$—$— —$ $$$ ars Air-intake filter Item _Qy Part no. 1. not sold separately 2. specify length on order Slotted hex head fitting screw Air-intake filter assembly Worm gear hose clamp 1 1 -NO3032 2 1 NO3033 3 Loo 4 1 NO3029 5 bom 6 1 NUT.0026 7 1 -Nos074 8g 1 086372 9 2 CMP.0025 10 1 TUB-R-0035 it 1 057692 Notes ‘M8, DIN 557-5, ASA M8x30,DIN 609Sz-5.6, A3A_ For 056372 C1633 For 056372 M6, DIN 315-8, A3A, nylock 2” OD x 1 15/16" Dx 200mm Ig, black rubber Complete @1 1/16" to B2” DA" ID x 14" OD, PVC 14” OD neckLubrication system; K-15 HREPLACEMENT PARTS LIST Lubrication system K-ISH Item Qty _Partno, Description Notes 1 1 NO1D28-—— Copper gasket A21x26x1.5, DIN 7603 2 1 -NO2447 Hex head pipe plug Y"BSPPm, DIN 910-magnetized 3 1 On77B Oil supply tube K-15 H, 6mm OD x Imm wall 4 1 ELL-010 Male stud elbow 6mm L tube x 1/8” BSPTm S31 —-NO3224_—— Copper gasket ‘A28x34x2, DIN 7603 6 1 069594 Oil pressure regulator K-SH 71 CON-0143-—-Male connector 6mm L tube x 1/8” BSPPm B 1012828 Oil return tube K-1SH 9 1 012830 Hex nipple Mi2 x MI2-1.5 10 2 — NO10S9 Copper gasket A12x15.5x1.5, DIN 7603 ML 002010 Oi pump gasket for NOO083 12 1 ~—-No0083-—— (Oil pump. 1700 Him, 80 bar, 6m L tube 13 ft — FEROO2 Ferule 6mm LIS, steel 14 3 WAS-0021 Flat washer 8mm, DIN 125B-st, A3A 15-3 SCR-0136—Socket head cap screw M8x25, DIN 912-8.8, A3A. 16 1 SCR-0197 Hex head cap screw M12x16, DIN 912-8.8, AZA_ 171059833 Regulator housing cap For 059594 18 1 TUB-R-0010 Round tube! 6mm OD x Imm wall, 3048S 1 specify length on order A214 2978Inter-filters and safety valves; K-15 HREPLACEMENT PARTS LIST Inter-filters and safety valves K-15SH Item Qty _ Partne. Description Notes 1 1 067612 Inter-filter, 2nd stage 1160 psi, complete 2 1 067612 Inter-filter, 3rd stage 1160 psi, complete 3 4 014369 P- clamp 48mm ID, DIN 1016 4 4 = NUT-0062— Hex nut ‘M8, DIN 934-8, A3A 5 4 = WAS-0021 Flat washer 8mm, DIN 125B-st, A3A_ 6 4 SCR-0025 Hex head cap screw M8x30, DIN 933-8.8, ASA. 7 2, TEE-0023 Male branch tee 6mm L tube x 1/8” BSPTm 8 1 -No40s1 Copper gasket Al0x15x1, DIN 7603 9 1 PLU-0028 —- Hex head pipe plug 1/8” BSPPm, DIN 910, A3A. 10 i 012886 Safety valve 1160 psi, 3/8” BSPPm W 2 004479 Copper gasket @8x14x2, DIN 7603 12 2 008263 Copper gasket @10x14x2, DIN 7603 13 1 610255 Safety valve 80-102 psi, 4” BSPPF 14 1 010254 Safety valve 261 psi, 10mm LL £ Ws 1 072776 Connecting tube Inter-filter to 4th stage 16 1 072774 Connecting tube Tnter-filter to 3rd stage 7 2 013930 Anter-filter head V150, V177 18 2 014150 Inter-filter housing! 1160 psi (80 bar) 19 2 013937 Threaded collar Knurled, M54-1.5 20 3 -NO1316 Copper gasket A13x20x1.5 DIN 7603 2 2 068410 Drain valve body, for 011430 22 2 013283 Drain valve seat for 011430 23 2 055888 Drain valve tap w/spring for 011430 24 2 (012784 Vortex plate 32 ODx 10.5 Dx Imm 25 2 (012785 Baffle cone 27 OD x 24.5mm Ig 26 2 =~ -N02726 Inter-filter element 17K13x30 Ig 27 2 012786 Center screw M10-1x53mm Ig 28 2 NO35S6 O-ring @45x2, FKM, 70 Duro 29-2 ~—«011430 Manual drain valve? ye" BSPTm x 4mm ID hose 30 4 = CON-0266 Male connector 12mm LL tube x 1/4” BSPTm 31 3 -No4s30 Tube plug. 6mm L/S 1. not sold separate 2. Units without ACD only Lo A-23 29THREPLACEMENT PARTS LIST Inter-filters and safety valves (continued) KISH tem Qty _ Part no. Description. Notes : 32 «2~s(OONAISI Inter-filter head assembly Complete 33 1 NO3525 Male connector 10mm L tube x 3/8" BSPPm 34-2 NO1054.——Hose clamp 710 G9mm, A3A, crimp type 35-2“ HOS-R-O01S Flexible hose? 6mm ID x 8mm OD, polyamide, clear : 36 1 ELL-0010 Male elbow 6mm L tube x 1/8” BSPTm 37 2 GKT-0016 Fitting gasket! D10.4x16x2, U 38 2 ~~ ADP-0035_—_—Pipe adapter 1/8" BSPPm x 1/8” NPTE 39 2 CON-0047 Connector? Ye? NETE x 1/8” NPTm 40-1 GAG-0007$ Pressure gauge? 0-600 psi, 224", ve" NPTm, UC 411 GAG-0008S Pressure gauge? 0-1500psi, 2214", “"NETm, UC 42 1 ADP-0021 Pipe adapter Ye" BSPPm x 4" NPTE 43 1 TEE-0014 Male branch tee? ye NPTm 44 1 CON-0078 Male connector? 8mm S tube x 4" NPTm 45 1 GAG-0006S Pressure gauge? 0-200 psi, 22%", 4” NPTm, UC 3. specify length on order 2 & g 8 2a ” x ¥ 3 3 & a $ & £ éREPLACEMENT PARTS LIST Ist stage valve head KISH tem Qty Partno. __Description Notes 1 1 012228 Valve head gasket Ist stage, K-15 2 1 012229 Valve head Ast stage, 60 R1 3 4 WAS-0031 Flat washer 10mm, DIN 125B-st, A3A 4 4 SCR0196 Hex screw M10x55, DIN 933-8.8, AJA 5 4 005298 Valve gasket B70x65x1, copper 6 1 056406 Inet valve 60R, K-ISH 7 1 000601 Inlet valve cover K-ISH 8 1 056407 Discharge valve OOR KISH 9 1 012570 Discharge valve cover K-ISH 10 8 ~—- WAS-0021 Flat washer 8mm, DIN 125B-st, A3A. 3 4 SCR-0181 Socket head cap screw M8x40, DIN 912-8.8, A3A 12-1 CON-0191 Male connector 15mm L tube x 1/2” BSPPm 13 1 005523 Intake pipe gasket @36x64x2/11,5 x 2mm thick 14 1042601 Intake pipe K-1SH is 2 SCR-O117 Hex head cap screw M10x40, DIN 933-8.8, A3A_ 16 2 WAS-0030 Split lock washer 10mm, DIN 127, A3A Ww 2 NUT-0076 Hex nut ‘M10, DIN 934-8, ASA 18 4 SCR-0182 Socket head cap screw ‘MBx45, DIN 912-8.8, ASA 1 1072761 ‘Valve head assembly Ist stage, K-15 H A-27 29TH2ud & 3rd stage valve heads; K-15 H A-28REPLACEMENT PARTS LIST ———_—————<—$$ 2nd & 3rd stage valve heads K-SH Item Qty Partno. _Description Notes 1 1 014087 2nd stage valve head K-15 H, 2nd stage, complete 1 058245 3rd stage valve head K-15 H, 3rd stage, complete 2 1 014583 Discharge valve assembly 2nd stage 1 014582 Discharge valve assembly 3rd stage 3 1 012840 Discharge valve insert 2nd stage 1 012835 Discharge valve insert 3rd stage 4 1 012841 Inlet valve assembly 2nd stage- L 012836 Inlet valve assembly 3rd stage 5 2 000240 ‘Valve gasket 25x16x1.5 mm 6 2 Valve seat! 7 2 Valve plate! 8 1 ‘Compression spring! Cylindrical 9 l= Valve piston! 10 1--NO3521—O-ting 21.82x3,53, FKM, 75 Duro ul 1 014332 ——_—Dise spring @35.5x29,1x1.25, DIN 2093 12 1014124 Valve cover Finned, M28-1.5xM8, DIN 7168 131 071064 Socket set screw M&x25, DIN 913 14-1 NOB625.——Copper gasket A8x14x1.5, DIN 7603 Is 1 NOO084 = Dome nut MB, DIN 1587, A3A. 16 Doe Spring! 7 Los Valve cover! 18 6 — SCR-0180 Socket head cap screw M8x35, DIN 912-8.8, A3A 19 1 014125 Valve head 2nd stage, bare 1 014123 Valve head 3rd stage, bare 20 2 + CON-0266 Male connector 12mm LL tube x 1/4" BSPTm 21-1 NOI316 Copper gasket A13x20x1.5, DIN 7603 22 1 CON-0190 Male connector for 2nd stage 10mm L tube x 1/4” BSPPm 1 CON-0041 Male connector for 3rd stage 6mm S$ tube x 1/4" BSPPm 23-1 BAL-0001 Precision ball 12mm, DIN 5401-A2 1. not sold separately A-29 297KREPLACEMENT PARTS LIST 4th stage valve head K-SH Ttem Qty __Partno. _Description Notes 1 1 007790 Inlet valve 4th stage 2 1 014117 ‘Valve head 4th stage, bare 3 1 014121 Discharge valve 4th stage 4 1 NO2789°— sting @15.6x1.78, FKM, 90 Duro 5 1 0141s ‘Valve cover 4th stage 6 1 071065 Socket set screw MB8-1x25, DIN 913 7 1 NO3625 Copper gasket Agx14x1.5, DIN 7603 a 1 NO3623— Capnut MB-1, DIN 917, A3A 9 6 —SCR-0183 Socket head cap screw ‘M8x70, DIN 912-8,8, A3A 10 1 CON-0266 Male connector 12mm LL tube x 1/4” BSPTm W 1 NO1316 Copper gasket A13x20x1.5, DIN 7603 121 (087788 Thermowell fitting ‘M5 f threaded port 13° | -FER0003. Femnute 8mm LIS, steel 141 NUT-0013. Tube nut 8mm S steel, M16x1.5 1s 1014089 ‘Valve head assembly 4th stage 16 1 SWT-0006 Temperature swith NO, 320°F, 124 1 SWT-0015 Temperature switch NC, 320° F, 124REPLACEMENT PARTS LIST 9 Assembly Purification system; PO w/TRIPLEX® .. Oil and water separator; 5076 psi Oil and water separator; 6092 psi. Oil and water separator; coalescing (high-flow type Putifier/dryer assembly; P1 through P10, $076 psi Purifiet/dryer assembly; P1 through P10, 6092 psi SECURUS® assembly; P2, PS & P10, 5076 psi. SECURUS® assembly; P2, PS & P10, 6092 psi Dryer assembly; P12 & P14, SECURUS® assembly; P12 & P14 Dryer cartridge; P12 & P14... CO removal assembly; P12 & P14. Safety valves; 300 to 6500 psi Pressure maintaining valves; 300 scfm. Constant speed unloader device; for units w/3-position switch .. CHAPTER B Purification systemsPurification system; PO w/TRIPLEX® Ee B-2 295REPLACEMENT PARTS LIST ———————__ oer sss | Purification system PO w/TRIPLEX® Item Qty Part no. Description Notes 1 1 NIS598 Retaining ting S5x2, DIN 472-A3A 2 1 063438 Glide ring for PO purifier ce Filter cover! Kaurled 4 1 o6ill4 Safety valve? 1450-5076 psi (100-350 bar) 5 2 Nosss6 O-ring ©59,92x3.53 FKM, 90 Duro 6 1 No4as66 O-ring 29,19x2.62 NBR, 70 Duro 7 1 (No3824 O-ring @7.59x2.62 NBR, 70 Duro 8 1 059183 ‘TRIPLEX® Purifier cartridge ‘MS/AC/HP/MS 1 057679 ‘TRIPLEX® Purifier cartridge AC/MS/MS 1 058596 TRIPLEX® Purifier cartridge ACIMS 1 059491 TRIPLEX® Purifier cartridge MS/ACIHP 9 Lom Filter housing! PO purification WO 1 a Filter base! PO purification M2 N16334 Banjo fitting 4mm flex tube x MS m 12 «1 N16SO4 Socket head pipe plug w/seal 1/8” BSPP, DIN 908 -A4 13 2 NIG304 Socket head pipe plug w/seal 1/4” BSPP, DIN 908 -A4 14 1 CON-0061 Male connector w/seal 8mm $ tube x 1/4” BSPPm 151 064498 Drain tap seat For 073793 16 1 073793 Condensate drain tap Complete 171 063666 Male connector wi/seal 6mm S tube x 1/4” BSPPm 18 1 NI65S4 O-ring 6x15 FKM, 90 Duro 191 -N22754 Pressure pin Smm OD X 42mm Ig 20 1 075269 ‘Valve piston 9mm OD x 14mm Ig, PTFE 21 2+ N04602 Fitting gasket Ul4x18.7x1.5 22 1 991038 Pressure maintaining valve seat_ 4” BSPPm, for 058037 23° 1 058037 Pressure maintaining valve 44" BSPPF, 5076 psi 24 1 ADP.0021 —Pipe adapter Ye" BSPPm x 4" NPTE 25° 1 057937 PMV cover For 058037 26 4° SCR-0177 Socket head cap screw M6x60, DIN 912 1. not sold separately 2. specify final pressure on order B-3 2978@ * ia a & = ° & & 2 o 5 5 < 5 5 & 4 5 a 29 B-4REPLACEMENT PARTS LIST Purification system (continued) Po w/TRIPLEX® Item Qty Part no. Description Notes 27° 1062211 Filter housing w/PMV Complete 28 4° Ni6591 O-ring @5x1.5 FKM, 90 Duro 29 1 -VAL-0176 Check valve ‘U4"NPTm in x 1/4"NPTF out 30 «1 (057935 Slotted adjustment screw ‘28-15, for 058037 31 1 002623 Compression spring Cylindrical 32 1 087762 Spring seat For 058037 33 1 091037 ‘Valve body YA"BSPPF, for 058037 34 1 058165 U-bolt M8, DIN 668 35 1 058159 Separator mount KU-FH/KC-FH/KM-FH 36 2 No02862 Flat washer 8mm, DIN 7349-st, ASA 37 2 =No00084 Dome nut ‘M8, DIN 1587 38 1 067458 Tool set For 073793 39 1 N04465 Slotted set screw M4x10, DIN 553 40 1 N03837 ‘Hex lock nut M4, DIN 985-8, A3A 41 2 057904 Nozzle orifice For 057997 42 1 N23206 Compression spring Cylindrical 4a 1 090965 Flat washer @5x9x2mm, brass 44 1 RNG-0082 Shaft seal @5x8x2.3mm PTFE, form FUOit and water separator; 5076 psiREPLACEMENT PARTS LIST Oil and water separator! 5076 psi i Item Qty Part no. Description Notes 11 090050 Oil and water separator 5076 psi 20 Lom ‘Separator head? 9/16” -18 UNF female 3. 2 NO4736 Back-up ring 263.96x1.52, NBR, 90 Duro 4 2 NOS735 O-ring @62.87x5.33 FKM, 90 Duro 5 1 NIS133 O-ring @28.24x2,62, NBR,70 Duro 6 1 061860 Micro-filter element Coalescing Toko Separator housing” 100mm OD x 73mm ID Bool Bottom plug? Vs" BSPPE 9 2 CMP.0004 ———Unistrut clamp 37/8” pipe, 4” tube 1. optional accessory 2. not sold separately B-7 2978Oil and water separator; 6092 psi BB 2978REPLACEMENT PARTS LIST Oil and water separator BAUER 6092 psi Trem Qty Part no. Description Notes 11 090150 Oil and water separator 6092 psi 2 01 Separator head! 9/16" -18 UNF female 3 2 N04586 ‘O-ring @59.92x3.53 FKM, 90 Duro 4 1 061860 Micro-filter element Coalescing 5 1 NISI33 O-ring ©28.24x2.62 NBR,70 Duro 6 1 Separator housing! 95mm OD x 85mm ID 7 1 Bottom plug ye" BSPPE B 2 Unistrut clamp 3%” OD tube 1. not sold separately B-9 2978Oil and water separator; coalescing (high flow-type) B-10B-10 z e z 2 = € z 3 Z 3 8 Oil and water separator;REPLACEMENT PARTS LIST | ne EES SONS || Oil and water separator 1. item not sold separately coalescing (high-flow type) Item Qty Part no. Description Notes 1 1 055719 Oil and water separator assembly _Coalescing (high-flow type) 2 bom Separator head! For 055719 3 2 NO2894 = O-ring 285.32x3.63, NBR, 90 Duro 4 1 061839 Micro-filter element Complete, dual insert 5 1 NO3860— O-ring @25.12x1.78 FKM, 75 Duro 6 1 061830 Filter element top end For 061839 7 2 NISS41—Onting @47.29x2.62 FKM, 75 Duro 8 2 NISS40 O-ring 937,772.62 FKM, 75 Duro 9 1 061836 Sintered metal insert Coalescing 10 1061837 Sintered metal insert Coalescing M1 061831 Filter element bottom end For 061839 12 1 061832 Threaded rod MB, DIN 975-8.8 13 L NIS542 Fitting gasket ‘U3.3x13.3xImm 14 1 N00084. Dome nut MB, DIN 1587, AA 1S 6 NUT-O118 Hex locknut M6, DIN 985-8, A3A 16 6 — WAS-6024 Flat washer ‘6mm, DIN 125B-st, A3A 173061833 Hex shaft spindle M6 18 1 Separator housing! For 055719 oy 4 Separator bottom pla For 055719 20 1 Separator bottom plug! For 055719 21 1 CON-0040 Male connector 6mm S tube x 4” BSPPm. 22 2 ~«—«-NO4616 ‘Fitting gasket U21.$x28.7x2.5mm 23° 2 =~ ADP.0022 Adapter 1/2” BSPPm x 1/2” NPTE 24 1 CON-0142 Male connector 12mm $ tube x 1/2” NPTm B-llPurifier/ dryer assembly; Pl through P10, 5076 psi ~~ oT er eo 1 B-12 291REPLACEMENT PARTS LIST Purifier/dryer assembly PI through P10, 5076 psi tem Qty Part no. Desorption Notes Pland P4 11 058813 Purifier assembly w/o cartridge PL and P4, 10”, $076 psi 2 1 0588218 Purifier cartridge MS/AC/MS/HP, 10” 1 058819 Dryer cartridge MS, 10" 3 2 012293 ‘Tool post screw Mio 4 1 061237 Cover plate 5076 psi purifiers, 3048S Sob mee Filter head! 6 2 Nos736 Back-up ring 63.76x1.52, NBR, 90 Duro 7 2 Nos73s O-ring 262.87x5 33 FKM, 90 Duro 8 lt Filter housing! 9 1 - Filter bottom! 10 1 061231 Filter head assembly Complete 11 2 CMP-0004 ~———Unistrut clamp 37/8” pipe, 4” tube NS. NOs731 O-ring 12.37x2.62 NBR, 70 Duro NS. NOSS66 O-ring 9,19x2.62 NBR, 70 Duro P2, PS and P10 1 1 0seg14 Purifier chamber assembly 27", 5076 psi 2 1 058827A Purifier cartridge MS/ACMS/HP, 27” 1 058825 Dryer cartridge MS, 27” 3 2 012293 Tool post screw MIO 4 1 061237 Cover plate 5076 psi putifiers, 3048S Sol owe Filter head! 6 = 2 NOA736 Back-up ring 263.96x1.52, NBR, 90 Duro 7 2 NOS735 O-ting 262.87x5.33 FKM, 90 Duro 8 Looe Filter housing! 9 Lom Bottom plug! 10 1 061231 Filter head assembly Complete U2 CMP.0004——Unistrut clamp 37/8” pipe, 4" tube 1. not sold separatelyPurifier/ dryer assembly; P1 through P10, 6092 psiREPLACEMENT PARTS LIST Purifier/dryer assembly PI through P10, 6092 psi Item Qty Part no. Description Notes Pl and P¢ 1 1 065481 Purifier assembly w/o cartridge P1-and P4, 10°, 6092 psi 2 1 0588214 Pusifier cartridge ‘MS/AC/MS/HP, 10” 1 058819 Dryer cartridge MS, 10” 3 2 912293 Tool post screw Mio 4 1 065490 Cover plate 6092 psi putifiers, 3048S sol Filter head! 6 2 NOs736 Back-up ring ©63,76x1.52, NBR, 90 Duro 7 2 NOA735 O-ring ©62.87x5.33 FKM, 90 Duro 8 1 Filter housing! 9 dae Filter bottom! 101m Filter head assembly! 12 CMP-0039-——‘Unistrut clamp 4” pipe, 414” tube NS. No4731 O-ting G12.37x2.62 NBR, 70 Duro NS. NO4566 O-ring @9.19x2.62 NBR, 70 Duro P2, PS and P10. 1 2 065485 Purifier chamber assembly 27", 6092 psi 2 1 0588274 Purifier cartridge ‘MS/AC/MS/HP, 27” 1 0588254, Dryer cartridge ‘MS, 27" 3 2 032293 Tool post screw M10 4 1 065490 Cover plate 6092 psi purifiers, 304SS Solow Filter head! 6 2 No0s736 Back-up ting 63,96x1.52, NBR, 90 Duro 7 2 NO4738 O-ring 262,87x5.33 FKM, 90 Duro 8 1 Filter housing! 9 1 Bottom plug’ 10 1 Filter head assembly! n 2 Unistrut clamp 4” pipe, 474" tube 1. Bot sold separately B-15REPLACEMENT PARTS LIST SECURUS® assembly 2, PS and P10, 5076 psi Ra7 Ttem Qty Part no. Description Notes 1 1 060082 SECURUS® chamber assembly 27”, 5076 psi 2 1 0600378 Purifier cartridge, SECURUS® © MS/AC/MS/SC/HP, 27" 3 2 012293 Tool post screw Mio 4 1 059850 Socket BNC, 750 SL oe Filter head! for SECURUS® chamber 6 1 002181 ‘Compression spring Cylindrical 7 1 059851 Bolt for SECURUS® chamber 8 1 089853 Fixed pin foe SECURUS® chamber 9 1 060062 Compression spring Cylindrical 10 1 089854 Loose pin for SECURUS® chamber Nt -NG639T Maintenance kit HEF-insert w/drawback screw 12 1 0S98s5 ‘Nut for SECURUS® chamber 13 2 NO4736 Back-up ting 263.96x2,52, NBR, 90 Duro 14 2 Noss O-sing 62.87x5,33 FKM, 90 Duro Woot Filter housing! for SECURUS® chamber wool om Bottom plug! for SECURUS® chamber 17 1 Ntso95 SECURUS® indicator 110-127 VAC, 50/60 Hz 1 N15096 SECURUS® indicator 12-24 VDC, GS 18 2 CMP.0004 —_Unistrut clamp 3.7/8” pipe, 4” tube 19 1 060135 Cover plate for 5076psi SECURUS® 3048S 1 not sold separately 5 |SECURUS® assembly; P4, PS and P10, 6092 psiREPLACEMENT PARTS LIST SECURUS® assembly P4, PS and P10, 6092 psi BAUER 1. not sold separately B-19 item _Qty Part no. Description Notes 11 065486, SECURUS® chamber assembly 27", 6092 ps 2 1 060037A Purifier cartridge, SECURUS' ‘MS/AC/MS/SC/ED, 27” 3 2 012293 Too! post screw Mio 4 1059850 Socket BNC, 750 Sol me Filter head! for SECURUS® chamber 6 1 o02i8i ‘Compression spring Cylindrical 7 4 059851 Bolt for SECURUS® chamber 8 1 059853 Fixed pin for SECURUS® chamber 9 1 060062 Compression spring Cylindrical 10 1059854 Loose pin. for SECURUS® chamber 11 Nos391 Maintenance kit HEF-insert w/drawback screw i2 1 059855 Nut for SECURUS® chamber 132 NOs736 Back-up ring 63.96x1.52, NBR, 90 Duro 142 No4735 O-ting 262.87x5,33 FKM, 90 Duro Cr . Filter housing! for SECURUS® chamber 16 of Bottom plug for SECURUS® chamber 171 Nis095 SECURUS® indicator 110-127 VAC, 50/60 Hz 1 15096 SECURUS® indicator 12-24 VDC, GS 18 2 CMP-0039——_‘Unisteut clamp 4” pipe, 414” tube 19 1 065490 Cover plate For 6092 psi chamber , 3048S 2978= aq 3 = 5 3 = g 3 a & 8 4 3 3 ec A 278, B-20REPLACEMENT PARTS LIST Dryer chamber P12 and P14 Ttem Qty Part no. Description Notes 12 NITASS O-ring 123.19x5.33 NBR, 90 Duro 2 2 NIT4S6 Backup ring 124.54x1,52 NBR, 90 Duro 3 Looe Bottom plug! For high-flow purifiers 4 ft 073793 Bleed valve Complete, M10-1 5 1 067099 Dryer cartridge MS/MS/MS, high-flow, 27" 6 lm Filter housing! ‘High-flow type 7 1 N15205 O-ring 40.87x3,53, NBR, 90 Duro 8 1 067070 Bushing seal For high-flow cartridges 9 1 NITAS4 O-ring @53.57x3,53, NBR, 90 Duro 10 1 NI7453 O-ring 47.22x3,53, NBR, 90 Duro uo NI7457 Retaining ring, A40, DIN 7993, Roi Cartridge casing! Without filter compounds 13 1 012293 Tool post screw Mio aol ms Cover plate! For filter head 15° 1 057065 Filter head! For purifiers, high-flow type 16 1 067458" Tool kit For 073793 {7 1 067105 Purifier chamber? High-flow 27”, 5076 psi 1. not sold separately 2. cartridge not included. UC B-21 2978B-22 SECURUS® chamber; P12 and P14REPLACEMENT PARTS LIST SECURUS® chamber Pi2 and Pi4 Item Qty Part no. Description. Notes 1 1 NI7458 Fined plug Type SA 401 2 1 067088 Round nut For SECURUS® chamber 3. 1 067072 Packing sleeve For SECURUS® chamber 4 1 067093 Tapered pin For SECURUS® chamber 5S 2 (NI7455 O-ring ©123.19x5.33 NBR, 90 Duro 6 2 NIT7456 Back-up ring @124.54x1,52 NBR, 90 Duro Tol om Filter bottom plug! For SECURUS® chamber 8 1 059850 Socket BNC, 752 9 1 073793 Drain tap Complete, M10-1 1 1 Filter bottom plug assembly! Complete Molo Filter housing! 5076 psi, 27” 2 1 Filter cartridge casing! Withont filtering compounds 131 N1S205 O-ring @40,87x3.53, NBR, 90 Duro 141967070 Bushing seal For purification cartridges 1s 1 NITASA O-ring, 53.57%3.53, NBR, 90 Duro 16) NI7453° O-ting @47.22x3.53, NBR, 90 Duro 17117457 Retaining ring ‘Ad0, DIN 7993 18 1 067097 SECURUS® cartridge MS/ACIMS, High-flow, 27” 19-2 012293 Too! post screw Milo 2 1 Cover plate! For filter head, high-flow aol Filter head! For high-flow type 22 1 067106 SECURUS® chamber high-flow 27", 5076 psi 1. not sold separately be B23 2978Dryer cartridges; P12 and P14 2978 B-24REPLACEMENT PARTS LIST Dryer cartridges PI2 and Pit Item Qty Part no. Description Notes 1 1 NUT-0033 ‘Hex nut M12, DIN 934-8, plain 2 2 067082 Spring pad For 967098 3 1 067098 Compression spring Cylindrical 4 4 067117 Bafile plate For purifier cartridges $1 667100 Threaded rod For MS cartridge 6 1 067077 ‘Threaded rod For MS/AC cartridge 7 4 Molecular sieve and/or Cartridge contents Activated Carbon! 1. This cartridge may be repacked by a qualified factory trained technician (contact BAUER Compressors, Inc, {or details) oF sent back (othe factory for repecking, td B-25 2978,CO. removal chamber; P12 and P14 B-26 2978f REPLACEMENT PARTS LIST S7aNTS ——_—$—$ $$ S$

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