BAUER INSTRUCTION MANUAL AND REPLACEMENT PARTS LIST G220V-25-E3 & G220V-30-E3 HIGH PRESSURE INDUSTRIAL GAS COMPRESSOR UNITS Model Serial no. Edition May 1995 MNL-0012 BAUER COMPRESSORS, INC. | 1928 Azalea Garden Road Underwriters Norfolk, Virginia 23502-1944 Laboratories Inc.» ‘Telephone: (787) 855-6006 “Telefax: (757) 855-6224BAUERTRODUCTION BAUER This manual contains operating instructions and maintenance schedules for the G220V high pressure industrial gas compressor unit manufactured by Bauer Compressors, Inc. of Norfolk, Virginia, USA. All instructions in this menual 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 nurbers 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.=7NE]S 51 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 read 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 to 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, i.e., Section 1 always covers Operation and Safety Precautions, Section 2 is General Information. Section 3 is Installation, ete. If your unit is equipped with non-standard accessories andlor options, information thereon will be included in the annex. 0595BMINTRODUCTION ee Change Notice I Changes which differ from the previous edition are marked with a vertical line. Edition/Revision Date Notes Approval Basic Edition November 1994 | Revision 1 May 1995 Revision 2 December 1999 | Area Code Change JH J Edition/Revision Pages Edition/Revision Pages | Revision2 | Cover | | | i i | 0595BMBAUERINTRODUCTIO! BAUER ‘COMPRESSORS TABLE OF CONTENTS Section Title Page 1 OPERATING AND SAFETY PRECAUTIONS SAFETY WARNINGS... Il 2 GENERAL TECHNICAL DATA COMPRESSOR BLOCK DESIGN. COMPRESSOR UNIT DESIGN.. 3. INSTALLATION UNPACKING AND HANDLING... INSTALLATION OF THE COMPRESSOR UNIT 4. LUBRICATION FUNCTIONAL DESCRIPTION TYPE OF OIL... OIL CHANGE OIL LEVEL CHECK. OIL PUMP... OIL SEPARATOR OIL NOZZLE. CRANKCASE HEATER...... 5. GAS INLETSYSTEM DESCRIPTION..... MAINTENANCE, 6. INTERMEDIATE FILTER DESCRIPTION... MAINTENANCE... cA FILTER SYSTEM GENERAL. OVERVIEW OF THE PURIFICATION SYSTEMS DESCRIPTION OF THE PURIFICATION SYSTEM COMPONENTS...... MAINTENANCE OF THE PURIFICATION SYSTEM ssc esse 0595BMTRODUCTI ae ER TABLE OF CONTENTS (Continued) Section Title Page 8. PRESSURE MAINTAINING VALVE DESCRIPTION... MAINTENANCE 9. SAFETY VALVES FUNCTIONAL DESCRIPTION MAINTENANCE... 10. PRESSURE GAUGES DESCRIPTION. MAINTENANCE i. VALVE HEADS AND VALVES FUNCTIONAL DESCRIPTION... Sree Il INITIAL OPERATIONAL CHECK OF THE VALVES. MeL GENERAL INSTRUCTIONS FOR CHANGING THE VALVES Mel eel OL 10-1 CHANGING THE IST STAGE VALVES 2 CHANGING THE 2ND STAGE VALVES 3 CHANGING THE 3RD STAGE VALVES... Aled CHANGING THE 4TH STAGE VALVES. AALS 2. AUTOMATIC CONDENSATE DRAIN DESCRIPTION...... vel 2-L OPERATION : 2-1 CONDENSATE DRAIN PIPING... 12-2 ELECTRICAL CONNECTION... 123 MAINTENANCE... 123 13. ELECTRICAL CONTROL SYSTEM GENERAL...... MONITORING MODULE. ELECTRICAL ENCLOSURE wssrssese SELECTOR SWITCHES... IGNITION SWITCH CYCLE COUNTER... PRESSURE SWITCHES. 13-1 woel3eL 13-2 133 133 0595BM,Section 14, 15. 16. 1. 18. 19. INTRODUCTION TABLE OF CONTENTS (Continued) Title Page ACD TIMERS... 13-6 ACD TIME DELAY RELAY ; soseesnenne OT HOURMETER.... ; eeeneneeneeentenreeneetemeeree S21] TEMPERATURE SWITCHES AUDIBLE ALARM .. AMMETER ; EMERGENCY STOP PUSH-BUTTON. ACD SOLENOD VALVES..... COMPRESSOR DRIVE SYSTEM. GENERAL... V-BELT MAINTENANCE..... MAINTENACNE OF THE DRIVE MOTOR. COOLING SYSTEM DESCRIPTION. MAINTENANCE... old] 14-1 14-3 AIR STORAGE SYSTEM DESCRIPTION... OPERATION .. MAINTENANCE, 16-1 16-2 16-2 GAS DELIVERY GAS OUTLET...... 171 OPERATION PREPARATION FOR OPERATION... START-UP AND SHUT-DOWN.. SEQUENCE OF OPERATION .. SAFETY SHUTDOWNS CONTROL FUNCTIONS ul BL 18-1 18-2 18-3 18-3 MAINTENANCE SCHEDULE GENERAL. ee eee 1 CALENDAR SCHEDULE...... 19-1 0595BMINTRODUCTI: aye [5] TABLE OF CONTENTS (Continued) Section Title HOURS OF OPERATION SCHEDULE.. MAINTENANCE AS REQUIRED. 20. STORAGE, PRESERVATION GENERAL... PREPARATIONS. stn PRESERVING THE COMPRESSOR. PRESERVING THE DRIVE..... PREVENTIVE MAINTENANCE DURING STORAGE.. REACTIVATING THE COMPRESSOR UNIT... 2. REPAIR INSTRUCTIONS REPAIR. eee WORKSHOP INSTRUCTIONS 22, TROUBLESHOOTING GENERAL INSTRUCTIONS. 23, TABLES TIGHTENING TORQUE VALUES. LUBRICATION CHART... CONVERSION TABLE PSI TO BAR. CONVERSION TABLE °F TO °C.sessonssssse 24. ANNEX Glossary of Abbreviations Drawings and accessory documentation Document no. - FOR-0013 . FOR-0267 .. DGM-0444 sss DGM-0653 + Purification system operating schedule... + Explanation of model name. + Electrical wiring diagram... + Air-flow diagram ...... 0595BM1 OPERATING AND SAFETY PRECAUTIONS BAUER 1.1 SAFETY WARNINGS + Failure to follow any of these warnings may result in an accident causing personal injury or property damage. + Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the installation and operation of this compressor and accessories before operating the unit. + The use of plastic or non-metallic bowls on line filters without metal guards can be dangerous. + Installer must provide an earth ground and maintain proper clearance for all electrical components (OSHA 1910.302 - 308). + All electrical installation must be in accordance with recognized national, state, and local electrical codes. Before working on the electrical system, be sure to disconnect the electrical supply from the system by use of a manual disconnect switch. Do not rely on the star‘er to disconnect the electrical supply. + Do not operate these units in excess of their rated capacity, speed, pressure, temperature, or otherwise than in accordance with the instructions contained in this manual, Operation of this, unit in excess of the conditions set forth in this manual will subject the unit to limits which it may not be designed to withstand. + Whenever the compressor is shut down and overheating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase. Premature opening of the crankcase of an overheated unit can result in an explosion. Incorrect placement of the inlet and discharge valves in a compressor cylinder head can cause an extremely dangerous condition. Refer to the appropriate section of this instruction manual before installing or replacing valves. + Allow the compressor to cool before servicing. + 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 unit before restarting. Remove and /or replace any loose or broken components, tools, valves, missing equipment, etc. + A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser/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 LlOPERATING AND SAFETY PRECAUTIONS + The use of repair parts other than those included within the Bauer approved parts list may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-threating, 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 join's; or failure to insure system compatibility of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death, + Compressed gas and electricity are a dangerous combination. Before doing any work involving maintenance or adjustment, be sure the electrical supply has been disconnected, and the complete compressor system has been vented of all internal pressure, Failure to follow these wamings may result in an accident causing personal injury and/or property damage. + Do not modify the compressor or its systems. + Do not tamper with, modify, or bypass safety and shutdown equipment. + Do not exceed maximum allowable pressures and temperatures. + Do not wear loose clothing around machinery. Loose clothing; neckties, rings, wrists watches, bracelets, hand rags, ete. are potential hazards. Replace damaged fan blades promptly. Fan assemblies must remai unbalanced fan can fly apart and create an extremely dangerous con: in proper balance. An on. 12 595A21 TECHNICAL DATA! Compressor model Medium Delivery Inlet pressure Operating pressure, max. Ambient temperature range Compressor block No. of stages No. of eylinders Cylinder bore, Ist stage Cylinder bore, 2nd stage (stepped) Cylinder bore, 3rd stage Cylinder bore, 4th stage Piston stroke Direction of rotation, viewing flywheel Oil capacity Oil, synthetic ODP motor Operating voltage Power Speed Frequency Frame size 1. Subject to change without prior notice. GENERAL G220V-25-E3 inert and non-aggressive gases? 32-39 scfm (910 to 1090 //min)3 atmospheric + 2.9 psig, (0.2 bar) 5000 psig (350 bar)* 32° to 105° F (0° to 40° C) 1K 22.0 4 3 5.12 in. (130 mm) 5.12/4.33 in, (130/110 mm) 1.42 in. 36 mm) 0.63 in. (16 mm) 3.15 in. (80 mm) ccw 8.5 quarts (8 2) Bauer P/N: OIL-0019 MTR-0046 208-460V, 3 phase 25 hp (18.6 kw) 1765 rpm. 60 Hz 284-T 2. nitrogen (N), neon (Ne), carbon dioxide (CO), earbon monoxide (CO), argon (Ar) and helium (He) 3. Based on 14.7 psia inlet pressure, 3600 psig discharge pressure @ 60°F inlet temperature. FGD correc- tion factors: N=1, He=0.85, New0.9, COg=1, Ar=0.85 4. argon (Ar) and helium (He) maximum working pressure = 3200 psig (220 bar) 2-1 59SBM5 7 GENERAL ——— 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 (stepped) Cylinder bore, 3rd stage Cylinder bore, 4th stage Piston stroke Direction of rotation, viewing flywheel Oil capacity Oil, synthetic ODP motor Operating voltage Power Speed Frequency Frame size nitrogen (N), neon (Ne), carbon dioxide (CO,), carbon monoxide (CO), argon (At) and helium (He) 6. Based on 14.7 psia inlet pressure, 3600 psig discharge pressure @ 60°F inlet temperature. FGD corres tion factors: N=1, He=0.85, Ne=0.9, CO,=1, Ar=0.85, argon (At) and (He) helium maximum working pressure = 3200 psig (220 bar) G220V-30-E3 inert and non-aggressive gases’ 32-39 sofin (910-1090 min)? atmospheric 5000 psig (350 bar)” 32° to 105° F (0° to 40° C) 5 IK 22.0C 4 3 5.12 in, (130 mm) 5.12/4.33 in, (130/110 mm) 1.42 in, (36 mm) 0.63 in. (16 mm) 3.15 in. (80 mm) ccw 8.5 quarts (8.2) Bauer P/N: OIL-0019 MTR-0067 208-460V, 3 phase 30 hp (22.4 kw) 3525 rpm 60 Hz 284-TS 2-2 595BM22 2.21 2.2.2 23 2.3.1 GENERAL COMPRESSOR BLOCK DESIGN General The IK 22.0 C compressor block is used to compress gas in the high pressure range up to 5000 psi (350 bar), This block is a four-stage, three-cylinder, air-cooled reciprocating piston compressor. The cylinders are arranged in a W configuration, the Ist and 2nd stages are housed in a common stepped cylinder, the 3rd stage is to the right, and the 4th to the left viewed from the flywheel. The Ist, 2nd and 4th stages are lubricated by means of the forced-feed lubrication system, The 3rd stage cylinder is 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 drawing in the annex. Wo 12 13°14 1 2 3 4 1 Inlet filter 2 Safety valve, 3rd stage im 3 Cylinder, 4th stage 4 Valve head, 4th stage 5 Safety valve, 2nd stage 6 Inter-filter 7 Oil pump 8 — Compressor crankcase 9 — Oil and water separator 10 Safety valve, Ist stage 11 Safety valve, 2nd stage 12 Cylinder, 3rd stage 13. Valve head, 2nd stage 14 Cylinder, 1st/2nd stage COMPRESSOR UNIT DESIGN 109 87 65 General Fig, 2.1 IK 22.0 C Compressor block The G220V-E3 high pressure gas compressor unit is used for applications in the high pressure range, up to 5000 psig (350 bar), It features a four-stage, three-cylinder, air cooled high pressure IK 22.0 C compressor block. 23 59SBMGENERAL These compressor units are manufactured with the drive motor mounted beneath the compressor block. The system is mounted within a frame and may be enclosed by an optional enclosure assembly. Standard equipment includes an oil and water separator after the final stage, a control panel with a selector switch and a final pressure safety valve, a pressure maintaining valve, a gas outlet with fittings, and an automatic conden- sate drain system. Approximate unit weight: 1200 Ibs. 23.2 Compressor Unit Components The compressor unit is comprised of the following major assemblies + compressor block + drive motor + frame assembly * automatic condensate drain system ‘ficall 8 3 + purification system’ + fill hose assembly’ + electrical control system + enclosure assembly® The design of the compressor unit and some of its components are indicated in the following illustration and in the drawings in the annex. Compressed gas outlet Instrument panel Roof panel® Access panel® 7 Cooling air-intake panel® Frame CO monitor® electrical enclosure Compressor oil drain emrauaune Fig. 2.2 G220V-E3 gas compressor unit 8. optional accessory 2-4 59SBM2. 2.3.3 GENERAL eal Compressor Unit Gas Flow Reference the flow diagram in the annex, section 24. Pipeline quality gas is drawn into the compressor through the inlet buffer tank? (IBT1) and the inlet filter (F1) by the compressor’s first stage (I) where it is compressed to a pressure of approximately 37 to 43 psi (2.5 to 3 bar). The compressed gas leaves the first stage and passes through an intercooler before entering the second stage (II) where is it further compressed to approximately 189 to 218 psi (13 to 15 bar). When the compressed gas leaves the second stage, it is routed through another intercooler and an inter-filter before entering the third stage (III) where it is compressed to approximately 798 to 870 psi (55 to 60 bar). The compressed gas leaves the third stage and passes through another intercooler and inter-filter before entering the fourth stage (IV) where it is compressed to the final pressure of the compressor unit (see the compressor unit data plate) After being compressed to the final pressure of the compressor unit, the compressed gas from the fourth stage passes through an aftercooler, a mechanical and a coalescing sepa- rator and a check valve (CV1) before flowing into the purification system? (P). A check valve (CV1) and a pressure maintaining valve (PMV1) are located downstream of the purification system, 9. optional accessory 2-5 59SBM2. GENERAL 2-6 595BM3. INSTALLATION 3.1 UNPACKING AND HANDLING This compressor unit is packaged according to the requirements for shipping vie the requested type of carrier service. It is possible that the compressor unit could have been damaged during shipping. For this reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to the shipping company immediately. Unpack the compressor unit carefully. Serious damage could result by not checking for clearance between the item to be unpacked and the packaging to be removed, Handle the unpacked unit using only the following methods. For trailer mounted compressor units, ensure that the towing vehicle is capable of pulling the weight. CAUTION: Be sure that the lifting devices are capable of handling the weight of the unit (see section 2 forthe weight ofthe compressor unit), Before lifting the unit, secure al loose or swinging parts to keep them from moving. Stay clear of lifted load. a) over head hoist b) forklift ©) pallet jack Fig. 3.1 Lifting devices 32 INSTALLATION OF THE COMPRESSOR UNIT ‘The installer should follow the recommendations for installation as described in the latest edition of NEPA 52. 3.2.1 General A machine base is not necessary; however, for units with a fill station, you should bolt the unit to the floor using 14” 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° rightieft.! 1, These values are valid unly if the oil level of the compressor in normal position is tevet with but does not exceed the upper mark of the oil dipstick or oil level sight glass. 3-1 0595B3. INSTALLATION __——_]}$5$5S NAN $$ ui i. ic 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, If 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 unit is 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 warning 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 pressure 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 outlet valve; the connecting pipe must be fitted without tension. Observe and maintain an ambient temperature range of 32°F to 105°F. For 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 well 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. 3.2.2 — Ventilation During normal compression, heat is generated by the compressor and by the drive motor. For air-cooled compressor units, this heat needs to be vented away by sufficient ventila- tion. Outdoor installation It is recommended that engine driven compressor units be installed outdoors. Addition- ally, electrically driven compressor units may be installed outdoors only if enclosed with weatherproof enclosure panels.” 2. Not standard or necessarily available on all units 3-2 059SBINSTALLATION BAUER In inclement weather, a compressor unit installed outdoors should be located under a tarp or lean-to structure if it is not equipped with weatherproof enclosure panels. Indoor installation Gas compressor units, when installed indoors, must have provisions to vent away expelled gas from the compressor unit's safety valve(s) and condensate drain system, Gas compressor units are provided with a vent port(s) to which a vent stack? or suitable outlet piping must be attached in order to vent away (outside of the building) or recover expelled gas. A vapor recovery system? recovers gas removed during condensate separation. Units without a vapor recovery system or a vent stack need both gas vents routed away from the compressor unit. It is recommended to pipe the two vent ports to a common vent pipe WARNING Failure to vent away expelled gas from the vent port(s) can result in asphyxiation, The best location to install the compressor unit indoors is against an outside wall with a suitably large air vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the 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 (40°C). Additional heat generating equipment 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 required intake and exhaust openings, consider the following table [intake and Exhaust Openings Dependent on Room Volume (V) and Height (h) Drive V=1750 V=3500 f 1000 fe hp h=65it oft 13 ft Intake | Exhaust | Intake | Exhaust | Intake | Exhaust (fe) (fe) (fe) (ft) (fe) (fe) 3 13 a _ - - 5 32 27 13 il 75 45 38 26 22 13 il 10 9.7 81 6.5 5.4 2.6 22 15 14.5 124 | 97 8.1 58 48 20 20.6 172 15.6 12.9 97 8.1 3, Not standard or necessarily available on all units 333 05958,3. 3.2.3 INSTALLATION If the natural ventilatior the installation of a fan in the exhaust opening. Reference NFPA 70, National Electric Code, when installing ventilation fans in hazardous areas. To determine the required intake opening and exhaust flow required with a fan, consider the following table: sufficient, the circulation of cooling air can be increased by Dependence on Room Size (V) and Height of Exhaust Opening (h)* Drive V= 1750 f° V=3500 fF V = 7000 fe hp h=8ft h=10ft h=13 ft Intake | Exhaust | Intake | Exhaust | Intake | Exhaust (#2) cfm, (@) cfm (fe) fin 25 33 3300 32 3200 3.0 3000 30 40 3960 38 3840 36 3600 40 33 5280 3 5120 48 4800 30 66 6600 64 6400 60 6000 60 79 7920 77 7680 72 7200 75 9.9 ‘9900 96 9600 9.0 9000 100 13.2 13200 12.8 12800 12.0 12000 125 16.5 16500 16.0 16000 15.0 15000 150 19.8 19800 192 19200 18.0 18000 4 Electrical Installation When making the electrical connections to the system, it is mandatory to observe the following instructions: + Comply with all local, state and federal regulations conceming electrical installation, + Ensure that the motor voltage, control unit voltage, and/or frequency conform with the + Provide all necessary cables and main fuses and a master disconnect switch. The + NEMA 4 electrical enclosures* are not explosion-proof and should be mounted at 1. The intake sizes given in the above table are for a cooling air velocity of 1000 ft/min. Bauer recommends that the cooling air velocity be in the range of 600 ft min. to 2000 ft/min Arrange for the electrical connections to be made by a certified electrician only. main voltage and frequency. Do not connect the compressor unit to a voltage other than the one specified on the nameplate. fusing of the compressor must be carried out in compliance with the regulations of the local, state and national electrical authorities. 4 least 15 feet away from the compressor unit, Not standard or necessarily available forall units. 3-4 05958INSTALLATION + After wiring the main power leads to the compressor unit via conduit, a conduit seal must be installed within 18” of the electrical enclosure box.> The conduit seal should be filled with an approved conduit sealant. All other conduit seals are installed at the factory prior to shipment of the compressor unit. Electrical Supply The machine is factory wired according to order. If the voltage is to be changed, consult the factory for instructions and necessary parts. The only customer wiring necessary is the leads from the power cable which must be connected to LI/L2/L3 (or L1/L2 for 1 phase) and ground, and, for units with a remote mounted electrical enclosure, the wiring between the electrical enclosure and the compressor unit, See the wiring diagrams in the Annex. All wiring should be done by a licensed electrician familiar with national, state and local electrical codes. The use of improperly sized wire can result in sluggish operation, unnecessary tripping of overload relays and/or blowing of fuses. The following table is provided as a guide for proper wire size. 3 PHASE Motor Full Load Amps Fuse Amps* Minimum Wire Size hp 208V | 230V | 460V | 208V | 230V | 460V | 208V | 230V | 460V 2 7.82 6.8 34 12 10 5.6 14 14 14 3 | 96 | 48 | i75 | 15 8 4 4 4 5 17.5 15.2 76 25 25 12 10 12, 14 75 | 233 [| 2 nf # | 30 | ims[ 8 io | 14 10 32.2 28 4 50 40 20 8 8 12 is | 43 [| @ | 2 oo [ 6 | 30 6 6 10 20 | 621 | 34 [| 27 | 90 | 80 [| 40 4 4 8 25 78.2 68 34 100 100 50 3 4 8 30 92.0 80 40 125 100 60 2 3 8 40 | 120 | 104 | 52 | 175 | 150 | 80 0 I 6 50 150 130 65 200 200 100 000 2/0 4 60 177 154 77 250 200 100 0000 3/0 3 [75 221_[ 192 96 | 300 [| 300 | 150 | 300 | 250 1 Too | 285 | 248 | 124 | 400 | 380 | 175 | 300 | 350 | 20 125 | 359 | 312 | 156 | 500 | 400 | 200 | 2-40 [230 | 3/0 {150 414 360 180 600 500 250 2-300 2-4/0 4/0 1, dual element time delay fuse amps ». normal copper wire with THW, THWN or XHHW insulation 5, Conforming to 1993 NEC, Article 501 3-5 0595B4. dual element time delay fuse amps », normal copper wire with THW, THWN or XHHW insulation 3. INSTALLATION 1 PHASE Motor | Full Load Amps | Fuse Amps* | Minimum Wire hp Size 208V_| 230V_| 208V | 230V | 208V | 230V 2 13.2 12 20 175 12 14 3 18.7 17 30 25 10 10 5 30.8 28 50 40 8 8 1S 44 40 70 60 8 8 i [| 3s | 30 [| 9 | © 6 6 In the above table, all values are based on 1993 NEC. These values are provided as a general guide; however, th above information. 3-6 formation given on the motor nameplate supersedes the 059584. LUBRICATION aa ER 4.1 FUNCTIONAL DESCRIPTION The compressor is equipped with a forced lubrication system. Fig. 4.1 shows the mode of operation, the items given in the following relate to this figure. The oil pump (1), equipped with a regulating valve, is driven by the crankshaft through pinion gears. The oil pump draws the oil from the oil sump (6) and pumps it through the oil filter (2). This filter is equipped with a replaceable element which efficiently elimi- nates particles as small as 10 micron from the oil. After the oil filter (2), the oil flow is split. 1, Through the injection tube (3) The oil enters the stepped pistons of the Ist/2nd stage. It is sprayed from below against the piston head of the stepped piston and thus lubricates the pistons and cylinders of the Ist and 2nd stages. Returning oil drips to the rotating crankshaft and connecting rods where itis agitated to lubricate the moving parts of the compressor. 2. Through the 2nd tube (7) the oil is forced via an oil jet (8) to the 4th stage cylinder where it lubricates the piston and piston rings. From there the oil flows back into the oil sump through the oil return line (9). The oil pressure in the lubricating system is indicated on the oil pressure gauge (5) and monitored by an oil pressure switch (4). 1 Oil pump with regulating valve 2 Oil filter Mn 3 Injection tube yy 4 Oil pressure s switch _ 5 Oil pressure : gauge 6 Oil sump 7 Tube to 4th stage cylinder Oil jet Oil return line 41 39684, LUBRICATION ——]—_$—$—————_ ———— —— 42 TYPE OF OIL, For proper care and maintenance of the compressor, using an oil of the correct viscosity is of vital importance, Depending on the application of the compressor, the requirements placed on the lubricating oils are as follows: + Low deposits + No carbonizing effect, especially in the valves + Good anti-corrosive properties + Minimal emulsification of the condensate in the crankcase + Physiological and toxicological suitability, if applicable Due to the thermal load on the compressor, only high quality oil should be used. It is recommended that you restrict oils to the following, which have a proven record of success and are specified with the above characteristics 4.2.1 Operation under normal conditions For operation during the run-in period, to ensure proper seating of the piston rings, and for operation under normal conditions, use petroleum-based compressor oil (for BAUER PIN see section 2). It is suitable for operation under ambient temperatures between 40°F (5°C) and 95°F (35°C). 42.2 Operation under Severe Conditions For operation under severe operating conditions such as continuous running and/or high ambient temperatures, we recommend the use of synthetic compressor oil (for BAUER PIN see section 2). This oil can also be used under normal conditions. When using this oil, the change intervals are longer than that of petroleum-based cil 43 OIL CHANGE Change the oil regularly according to the maintenance schedule in section 19. See section 2 for oil type and crankcase cap: 43.1 Changing the Type of Oil If a petroleum oil is used on subsequent oil changes, no problems should arise, but: CAUTION To avoid severe damage to the compressor unit when changing from a petroleum oil to a synthetic oil, the following measures must be followed: 4-2 39684, LUBRICATION =e + Drain the petroleum oil completely, following the instructions in section 4.3.2. + Change the oil filter. Flush the crankcase and clean the separator to remove oil deposits, « Fill the compressor with synthetic oil. + After approximately 100 operating hours, check the oil for contamination. Change the oil again if necessary. + Perform consecutive oil changes according to section 4.3.2. 4.3.2 Oil Change Procedure + Run the compressor until it is warm. Turn off the compressor. Disconnect the electrical power, Shut off the inlet supply, if applicable + Vent any residual pressure from the system by opening and then closing the manual drain valves/bleed valves on the buffer tank, separators and purification system. + Open the filler cap slowly, allowing any residual pressure to vent from the crankcase. Remove the cap/dipstick from the oil filler neck. + Place a suitable oil drain pan beneath the drain plug on the side of the unit, Remove the oil drain plug (1) labelled “OLL DRAIN” located at the bottom of the service end of the unit. + Open the oil drain valve, if so equipped, by rotating the hand lever (2) counterclockwise (the valve in the following illustration is shown in the closed position), CLOSE + Allow the warm oil to drain. + Close the oil drain valve, if so equipped, by rotating the hand lever (2) clockwise. OPEN = Reinstall the oil drain plug. &_ ENG + Remove the oil pan. Dispose of the used oil in a safe manner complying with all local waste Fig. 4.2 Oil drain valve disposal codes + To fill with oil, pour oil slowly into the oil filler neck. Wait five (5) minutes after filling, reinstall the filler cap and inlet supply (if applicable) and reconnect the electric power, then start the compressor unit. Check the operation of the oil pump. It is working properly if the oil pressure gauge indicates 28 to 43 psi (2 to 3 bar), If the gauge does not indicate the proper pressure, the oil pump may not be working properly. 43 396B44 45 45.1 45.2 4.6 LUBRICATION OTL LEVEL CHECK Check the oil level sight glass (2) daily before starting the compressor. If the oil level is not between the minimum and maximum marking in the view glass, add or drain as necessary. To add or drain oil, vent the pressurized crankcase by slowly removing the oil fill cap (3). See fig. 4.3 The oil level must not exceed the maximum level mark. This will cause excessive lubrication of the compressor and may result in coking of the valves. OL PUMP Description Fig. 4.3 Lubrication components The compressor lubrication system features a gear pump with an integrated pressure relief valve. The pressure is set to 35 psi (2.5 bar). In case of malfunction, the oil pump cannot be repaired but must be replaced as a complete unit, Maintenance To reduce the wear to the internal parts of the compressor, the oil pump is fitted with a full-flow oil filter. The filter element should be changed with every oil change. Filter replacement (fig. 4.3) + Unscrew the filter element (1) from the oil plump (4). + Lubricate the sealing ring of the new oil filter element and screw on the filter element until the seal touches the sealing surface. Then tighten the filter element another half tum by hand, Never overtighten or use tools when installing a filter element OIL SEPARATOR The compressor block is equipped with an oil sepa- rator in the crankcase vent line (fig. 4.4). This device separates liquid oil particles from the crankcase vent line (1), The oil particles are then fed back into the oil sump through the oil return line (3), ‘The vent line is connected to the intake manifold by line (2) The oil separator requires no maintenance. Fig, 4.4 Oil separator 4-4 39684, 47 471 47.2 48 LUBRICATION BAUER OIL NOZZLE Description The lubrication of the internal compressor parts is controlled by the oil nozzle (see fig, 4.5). Maintenance Prolonged running with contaminated oil and/or oil filter will lead to clogging of the nozzle, reducing the oil flow to the rotating parts of the compressor. If the nozzle becomes clogged, remove and clean it according to the following procedure. + Disconnect the pressure lines from the oil nozzle (3) by removing the tube nuts (1). + Remove the two self-locking hex nuts (2) securing the nozzle assembly to the crankcase, Pull out the nozzle (3) + Wash the nozzle assembly in gasoline to remove deposits. Remove the old sealing compound from the crankcase and the nozzle sealing surfaces. Blow dry with low pressure compressed air, + Install a new o-ring seal and apply a thin layer of silicone compound on the sealing Fig. 4.5 Oil nozzle surfaces before reassembling, CRANKCASE HEATER! ‘When operating the unit in temperatures below the normal temperature range, a crank- case heater is required to warm the oil for better flow. The crankcase heater operates automatically according to the thermostat control 1. Optional accessory, not available on all models. 4-5 3968LUBRICATIO! 4-6 396B5.1 S.L1 5.1.2 GAS INLET SYSTEM. INLET PRESSURE REDUCTION! The compressor draws the gas to be compressed from a gas pipeline which should be fitted with a shut-off valve. In order for the compressor to work properly, itis necessary to supply the compressor with gas at a constant pressure; therefore, a pressure reducing regulator in the inlet line is necessary if the supply pressure fluctuates or exceeds the maximum inlet pressure (see Section 2.1 for inlet pressure range). Depending on the model and order, this unit can be fitted with a 1 stage or a 2 stage pressure reduction system. Inlet Buffer Tank! The unit may be equipped with a buffer tank between the compressor inlet and the regu- lator. The buffer tank compensates for the pulsations caused by the Ist stage piston. A safety valve will vent gas to the atmosphere if the inlet pressure is too high. In addi- tion, the inlet pressure is monitored by the minimum and maximum inlet pressure switches which will shut the unit down on a high or low pressure fault. Refer to the pneumatic flow diagram in the annex, Chapter 24, and to the Electrical Control System, Chapter 13 For optimum operation, the unit should have a well regulated inlet set between 1! and 5 psig. Exceeding 5 psig may cause a high inlet pressure fault and unit shutdown. Drop- ping to less than 1% psig may cause a low inlet pressure fault. Pressure Reducing Regulator The pressure reducing regulator located on the gas vapor return line before the compressor inlet, is used to maintain a reduced tank outlet pres- sure while providing gas flow to the compressor inlet, The set pressure of the regulator should be approximately Y4-1 psi above the gas supply pressure; if not, reset the pressure according to the instructions below. Loosen the locknut (2) atop the regulator spring case, While monitoring the pressure with the gauge provided on the regulator piping, rotate the adjusting screw (1) clockwise to increase set pressure or counterclockwise to decrease it. When desired pressure regulation is achieved, tighten the locknut (2) Fig. 5.1 Pressure reducing regulator Optional accessory 5-1 796N,5.1.3 52 5.2.1 5.2.2 GAS INLET SYSTEM Maintenance Drain any accumulated moisture from the inlet buffer tank once a week or more or less frequently depending upon the amount of moisture drained, ‘The ASME tank should be visually inspected internally for corrosion every yeat. Drain any accumulated condensate from the receiver once a week or more or less frequently depending upon the amount of moisture drained from the receiver. Check local and state regulations regarding testing of ASME bottles. Some states require an annual visual inspection, and hydrotesting requirements also differ from state to state. INLET FILTER Description BAUER gas compressor units are fitted with a special inlet filter with a gas-tight housing mounted directly at the inlet of the Ist stage valve head. A safety valve will vent gas to the gas vent port if the inlet pressure is too high. In addition, the inlet pressure is monitored by a minimum and maximum inlet pressure switch which will shut the unit down on high or low pressure fault. Refer to Section 13 Inlet Filter Maintenance Annually or every 500 operating hours, whichever comes first, the filter element must be serviced as follows: Nut Cover Filter element Filter housing Gas inlet Safety valve AuRwNe Fig, 5.2 Inlet filter + Shut off the gas supply. + Vent gas via the drain petcocks on the ACD valves and inlet buffer tank. + Remove the nut (1) and cover (2) from the filter base (4). See fig. 5.1. 5-2 796NGAS INLET SYSTEM Remove the filter element (3) and clean inside out. ih a brush or by blowing + Tum the cartridge 90° after cleaning, Replace a filter element that has become plugged or dirty. Use only original spare elements. + Clean inside the filter housing with a damp cloth. Take care to prevent dust from entering the inlet manifold. 5-3 796N,5-4 796N6. INTERMEDIATE FILTERS/FINAL SEPARATORS — 6.1 INTERMEDIATE FILTERS 6.1.1 General An inter-filter is provided in the compression circuit of the compressor block after each compressor stage. These filters are designed to remove excessive moisture accumulation resulting from the cooling in the intercooler after the compression process in the previous stage. The inter-filters for the Ist and 2nd stages are integral to the respective intercoolers, where as the 3rd and 4th stage separators are insular. These use a centrif- ugal insert to separate the water and oil from the compressed air (see fig. 6.1) for the final oil and water separator. See section 6.2. 6.1.2 Maintenance of the Inter-Filters The inter-filters are drained at regular intervals by the automatic condensate drain system. Ensure that the automatic condensate drain system is operating properly and draining the inter-filters during operation. See section 12. The inter-filters are maintenance-free. Filter head Centrifugal insert Filter spacer Filter housing, Threaded collar Hex nut Stud Fig, 6.1 Interfilter after the 3rd stage6. INTERMEDIATE FILTERS/FINAL SEPARATORS, 62 | MECHANICAL OIL AND WATER SEPARATOR 62.1 Description The compressed medium leaving the final stage is cooled in the after-cooler to approximately 10 to 15 ° C (18-27° F) above ambient temperature and then enters the oil and water separator. Separator of the condensate produced by the re-cooling after the compression process is achieved by means of a centrifugel insert (1). The condensate is drained regularly by the automatic condensate drain system, refer to chapter 12. 6.2.2 Maintenance of the Mechanical Oil and Water Separator The mechanical oil and water separator is maintenance-free b with the exception of an annual visual inspection. Replace the Fig. 6.2 Mechanical oil separator if corrosion is detected during this inspection. The _ and water separator condensation is drained at regular intervals by the automatic condensate drain. NOTE ‘The condensation produced during the compression process must be drained regularly by means of the automatic condensate drain; see section 12 6-2 396B63 6.3.1 6.3.2 INTERMEDIATE FILTERS/FINAL SEPARATORS a ESS ORS || COALESCING OIL AND WATER SEPARATOR Description CAUTION The coalescing oil and water separator is subject to dynamic loading, It is designed to operate for up to $5,000 load cycles (1 load cycle = 1 pressurization and 1 depressur- ization). After reaching the maximum number of load cycles, the oil and water separa- tor should be replaced. The compressed gas leaving the mechanical separator after the final stage enters a coalescing oil and water separator. The oil and water separator uses a sintered micro filter element which reliably separates liquid oil and water particles from the compressed gas. During operation of the unit, do not exceed the maximum recommended amount of four cycles per hour. If it is possible to regulate the operation of the unit to one cycle every ‘two hours, this would be an optimum between usage and actual life. Maintenance of the Coalescing Oil and Water Separator The sintered metal micro-filter element requires maintenance every 1000 hours. To remove the sintered filter element, » proceed as follows: * Disconnect the power and shut off the inlet supply line. 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, Remove the center screw (3) to remove the filter element. + Clean the sintered filter element using hot soapy water, Blow dry with compressed air. When cleaning the element, record the 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 Fig. 6.3 Coalescing oil of the micro-filter with petroleum jelly. Apply sparingly. and water separator + 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 6-3 396BINTERMEDIATE FILTERS/FINAL SEPARATORS 6-4 3968TA 12 T21 BAUE FILTER SYSTEM GENERAL All compressor units are equipped with a coalescing oil and water separator after the final stage. In addition, the larger units may be equipped with a mechanical oil and water separator. To complement these separators, all BAUER compressor units can be equipped with a purification system; purification systems are optional for industrial and ‘gas compressor units. Reference the compressor unit purification label to determine what purification system the unit is equipped with. If an optional regenerative dryer is supplied with the unit, reference the dryer manual, WARNING Gas compressor units compressing carbon monoxide should not use purification systems with Hopcalite (HP) OVERVIEW OF THE PURIFICATION SYSTEMS P1 Purification System The processing capacity of this purification system is approximately 15,000 cubic feet.! See fig. 7.1 for the arrangement of the system components. 1 Coalescing oil and water separator Safety valve Condensate drain connection Check valve Purifier chamber Bleed valve Pressure maintaining valve aaueen Fig, 7.1 Pl purification system 1, based on a 70°F inlet temperature TH 119487. FILTER SYSTEM 12.2 2 Purification System The processing capacity of this purification system is approximately 40,000 cubic feet. See fig. 7.2 for the arrangement of the system components. Coalescing oil and water separator Safety valve Condensate drain connection Check valve Purifier chamber SECURUS electronic purification monitor? Bleed valve 8 Pressure maintaining valve 72.3 P4 Purification System The processing capacity of this purification system is _approxi- mately 60,000 cubic feet.* See fig. 73 for the arrangement of the system components. Coalescing oil and water separator Safety valve Condensate drain connection Check valve Dryer chamber Purifier chamber Bleed valve Pressure maintaining valve eIaannene Fig. 7.3 P4 purification system 2, Based on a 70°F inlet temperature. SECURUS electronic purification system monitor increases the pro- ‘cessing capacity to 67,000 cubic ft 3, optional accessory 4, based on a 70°F inlet temperature 7-2 11944FILTER SYSTEM PS Purification System The processing capacity of this purification system is approximately 90,000 cubic feet.> See fig. 7.4 for the arrangement of the system components. Coalescing oil and water separator Safety valve Condensate drain connection Check valve Dryer chamber Purifier chamber SECURUS indicator® Bleed valve Pressure maintaining valve P10 Purification System The processing capacity of this purifica- { ‘ Fig. 7.4 PS purification system raFILTER SYSTEM P12 Purification System The processing capacity of this purification system is approximately 420,000 cubic feet.’ See fig. 7.6 for the arrangement of the system components Coalescing oil and water separator Pressure gauge Bleed valve Dryer chamber Purification chamber SECURUS purification monitor Pressure maintaining valve Check valveFILTER SYSTEM 73 DESCRIPTION OF THE PURIFICATION SYSTEM COMPONENTS 73.1 Mechanical Oil and Water Separator? A mechanical oil and water separator provided after the final stage eliminates liquid oil and water by the centrifugal action of its helical insert (fig. 7.8). The oil and water separator is mounted at the filter mounting rack of the compressor frame. 7.3.2 Coalescing Oil and Water Separator! WARNING Coalescing oil and water seprtors are subject to dynamic loading. They are designed to operate for up to 55,000 (P2 and up) and 85,000 (P1) load cycles. (1 load eycle = 1 pressurization, 1 depressurization) Fig. 7.5 Mechanical oil After reaching the maximum number of load eycles, the | and water separator oil and water separator should be replaced. The compressed medium leaving the final stage is cooled in the aftercooler to approxi- mately 20° to 30° F (10° to 15° C) above ambient temperature and then enters a coalescing oil and water separator. The oil and water separator works by means of a sintered metal micro-filter element which reliably separates liquid oil and water particles from the compressed gas. During operation of the unit, do not exceed the maximum recommended amount of four cycles per hour. 73.3 Dryer and Purifier Chambers!! The chambers are made of anodized aluminum alloy. The casings of the dryer and puri- fier cartridges as well as the cover and bottom are aluminum. The dryer cartridges are packed with molecular sieve (MS) which absorbs oil and water. The purifier carcridges are packed with hopcalite (HP), a catalyst which converts carbon monoxide to carbon dioxide, activated carbon (AC), which absorbs oil vapors effecting taste and odor, molecular sieve (MS), as in the dryer cartridges, and, for units with a SECURUS indi- cator,!! a SECURUS sensor (SC). 7.3.4 Moisture Indicator! This visual indicator is connected in line to monitor the moisture level in the pressurized flow. The moisture indicator is equipped with a window through which an indicator card may be viewed. The card is divided into sections which progressively change color from 9. Not standard or necessarily available on all models. 7-5 T194HtFILTER SYSTEM OM blue to pink as the moisture level increases. When excessive moisture is indicated, the dryer cartridges should be changed. Normally, cartridges should be changed when 40 to 60% relative humidity is indicated downstream of the dryer chamber. Under high pres- sure, 60% relative humidity is still a very dry gas. 7.3.5 Securus Indicator!” ‘The SECURUS indicator receives signals concerning the condition of the drying agent inside the purifier element from the attached sensors and furnishes appropriate control signals whenever the preset threshold values have been reached. The annular sensor inside the purifier element head senses changes in capacitance caused by the saturation within the surrounding drying agent. The signal path from the sensor leads through a spring pin contact, which forms the connection between the element and the filter head, to the pressure-resistant bushing in the filter head and continues through the center conductor of the coaxial cable to the SECURUS indicator. The signal return is effected through the cable shield to the element tube. The four operating conditions of the SECURUS system are reported by three relays (normally open contacts). Simultaneously with the closing of the relay contacts, the following built-in luminescent diodes illuminate: 1. Continuous green - unit in operation. 2. Flashing yellow - element change pre-warning 3. Flashing red - compressor shut down because the element is saturated 4. Continuous red - compressor shut down because of missing element or cable failure If the yellow diode is flashing, the green diode will continue to illuminate because the unit is still operational with the yellow If none of the lamps are illuminated, indicating that no relay contact is closed, the SECURUS indicator is either not receiving operating voltage or the electronics within the unit have failed. After applying operating voltage to the indicator, it will take about 0.5 seconds to close the respective relay contact and to light the applicable diode. During this time interval, the status of the element is checked. An erroneous lighting or flickering of the lamps should not occur. Terminal utilization (AC version) Terminal 1; Main connection, hot Terminal 5: Contact, green light Terminal 2: Main connection, neutral Terminal 6: Contact, red light Terminal 3: System ground wire Terminal 7: Contact, yellow light Terminal 4: Common 10, Not standard or necessarily available on all models. 16 1194H14 TA 142 FILTER SYSTE! Maximum permissible contact load is 250 VAC, 6 amps. ‘Terminal utilization (12 - 24V DC version) Terminal 1: Positive polarity, power supply Terminal 2 or 3: Negative polarity, power supply (terminals 2 and 3 are connected inside the unit. The other terminals are utilized in the same manner as in the AC version, The cable shield is connected to terminal 3 inside the unit. Mode of operation Normal Element serviceable | green 4 sk AW Element approaching | green + vem 4 Pre-wamning | «aturation flashing yellow sh a? Shut of Element saturated flashing red 4 a» ob Element missing or Shut off Fi continuous red 4 cable failure sb : » i. Connection for external warning lamps. System status Indicator light | Contact position! MAINTENANCE OF THE PURIFICATION SYSTEM. Mechanical Oil and Water Separator The mechanical oil and water separator is maintenance-free with the exception cf an annual visual inspection, Replace the separator if corrosion is detected during this inspection. The condensation is drained at regular intervals by the automatic condensate drain, 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. TI L194H