Bauer Mini Verticus, G 120 II V Instruction Manual And Replacement Parts List
Instruction Manual and Replacement Parts List
Mini Verticus
High Pressure Gas Compressor Units
G 120 II V
April 4, 2013 1st Edition, Rev. 0 Chg. 2 MNL-126509
© Bauer Compressors, Inc.
BAUER Compressors, Inc. Phone: (757) 855-6006
1328 Azalea Garden Road Fax: (757) 855-6224
Norfolk, Virginia 23502-1944 www.bauercomp.com
G 120 II V
This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication, but
Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information set forth
herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use of this information. All information supplied is in connection with sales of Bauer’s products, and is thus subject to
Bauer’s standard terms and conditions of sale. Bauer reserves the right to change this information and has
no obligation to update these materials. This information is copyrighted by Bauer Compressors, Inc., and
Bauer reserves to itself all rights to this publication. Bauer’s customers have no right to reproduce, rewrite,
modify, license or permit anyone else’s use of this information, without the express written permission of
Bauer Compressors, Inc.
^ WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions
for the G 120 II V High Pressure Gas Compressor Units.
You must read, understand and follow all safety precautions and instructions.
1st Edition August 30, 2011
Rev Chg Date Notes Auth
0 1 Nov. 8, 2011 Added 50 Hz model SS
0 2 Apr. 4, 2013 Updated Block P/N’s SS
Page i 1st Edition, Rev. 0 Chg. 2
MNL-126509
Table of Contents
CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION
1.1 HOW TO USE THIS MANUAL.........................................................................................................................................1
1.1.1 Manual Safety Notices .......................................................................................................................................................1
1.2 HOW TO USE THE REPLACEMENT PARTS LIST....................................................................................................2
1.3 HOW TO USE THE APPENDIX.......................................................................................................................................3
1.4 UNIT SPECIFICATIONS ..................................................................................................................................................4
1.4.0.1 Compressor Drive ..........................................................................................................................................................4
1.4.0.2 Purification System Applicability ..................................................................................................................................4
1.4.0.3 Pressure Switch Settings.................................................................................................................................................4
1.4.0.3.1 Inlet Pressure Switch Settings ........................................................................................................................................4
1.4.0.3.2 Final Pressure Switch Setting ......................................................................................................................................... 4
CHAPTER 2:- - - -OPERATING INSTRUCTIONS; MAPLE SYSTEM
2.1 DESCRIPTION.................................................................................................................................................................... 5
2.1.1 Emergency Stop Button .....................................................................................................................................................5
2.1.2 Operator Interface ..............................................................................................................................................................6
2.1.2.1 Run Screen...................................................................................................................................................................... 6
2.1.2.2 Main Menu Screen.......................................................................................................................................................... 7
2.1.2.2.1 Run..................................................................................................................................................................................7
2.1.2.2.2 Alarms History................................................................................................................................................................8
2.1.2.2.3 Status .............................................................................................................................................................................. 8
2.1.2.2.4 Contact............................................................................................................................................................................8
2.1.2.2.5 Login............................................................................................................................................................................... 8
2.1.2.2.6 Configuration..................................................................................................................................................................9
2.1.2.2.7 Parameters.....................................................................................................................................................................10
2.1.2.2.8 Tools .............................................................................................................................................................................10
2.2 STARTING AND STOPPING UNIT...............................................................................................................................10
2.2.1 Before Starting. ................................................................................................................................................................ 10
2.2.2 To Start Unit.....................................................................................................................................................................11
2.2.3 To Stop Unit. .................................................................................................................................................................... 11
2.3 SCREEN FLOW................................................................................................................................................................14
CHAPTER 3:- - - - - - - - - - - - - - - - - - - - - - IK120 II C & G
3.1 MAINTENANCE AND PARTS.......................................................................................................................................15
3.1.1 Description ....................................................................................................................................................................... 15
3.1.2 Component Location ........................................................................................................................................................15
3.1.3 Air Flow Diagram ............................................................................................................................................................ 16
3.1.4 Compressor Lubrication................................................................................................................................................... 17
3.1.4.1 Description....................................................................................................................................................................17
3.1.4.2 Oil Level Check............................................................................................................................................................17
3.1.4.3 Oil Change Interval.......................................................................................................................................................18
3.1.4.4 Oil Change.................................................................................................................................................................... 19
3.1.5 Venting the Oil Pump.......................................................................................................................................................19
3.1.5.1 Gas Intake System ........................................................................................................................................................ 19
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G 120 II V
3.1.6 Inter-stage Separator.........................................................................................................................................................20
3.1.6.1 Maintenance..................................................................................................................................................................21
3.1.7 Cooling .............................................................................................................................................................................21
3.1.7.1 General..........................................................................................................................................................................21
3.1.8 Valves and Heads .............................................................................................................................................................21
3.1.8.1 Functional Description..................................................................................................................................................21
3.1.8.2 General Instructions for Changing the Valves..............................................................................................................22
3.1.8.3 Changing the IK120 II C & G, 1st Stage Valve ...........................................................................................................23
3.1.8.4 Removing the IK120 II C & G, 2nd Stage Valves. ......................................................................................................24
3.1.8.5 Reassembling the Valves of the 2nd Stage. ..................................................................................................................25
3.1.8.6 Removing the IK120 II C & G, 3rd Stage Valves ........................................................................................................26
3.1.8.7 Reassembling the Valves of the 3rd Stage....................................................................................................................27
3.1.9 Replacement Parts List.....................................................................................................................................................28
3.1.10 Troubleshooting and Repair .............................................................................................................................................47
3.1.10.1 Troubleshooting Table ..................................................................................................................................................47
3.1.10.2 Repair Instructions ........................................................................................................................................................48
3.2 THREE STAGE AUTOMATIC CONDENSATE DRAIN SYSTEM...........................................................................49
3.2.1 Description .......................................................................................................................................................................49
3.2.1.1 Normal Operation .........................................................................................................................................................50
3.2.1.2 Condensate Drain..........................................................................................................................................................50
3.2.1.3 Start Unloading .............................................................................................................................................................50
3.2.1.4 Standstill Drainage........................................................................................................................................................51
3.2.2 Component Description....................................................................................................................................................51
3.2.2.1 Condensate Drain Piping ..............................................................................................................................................51
3.2.2.2 Electrical Connection....................................................................................................................................................51
3.2.3 ACD Maintenance............................................................................................................................................................51
3.2.4 ACD Replacement Parts List............................................................................................................................................52
3.3 CONDENSATE COLLECTOR .......................................................................................................................................54
3.3.1 Condensate Collector Replacement Parts List .................................................................................................................55
CHAPTER 4:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM
4.1 INTRODUCTION..............................................................................................................................................................56
4.1.1 General Purification System Procedures..........................................................................................................................56
4.1.2 Chamber Safety Bore .......................................................................................................................................................56
4.1.3 Manual Condensate Drainage...........................................................................................................................................57
4.1.4 Model, Serial Number and Part Number Identification ...................................................................................................57
4.1.4.1 Compressor Dataplate...................................................................................................................................................57
4.1.4.2 Purification System Dataplate ......................................................................................................................................58
4.1.4.3 Cartridge Installation Dataplate ....................................................................................................................................58
4.1.5 Breathing Air Purification System Configurations ..........................................................................................................58
4.1.6 Industrial Purification System Configurations .................................................................................................................59
4.1.7 Cartridge Operating Life ..................................................................................................................................................59
4.1.7.1 Calculating the Maximum Cartridge Operating Hours.................................................................................................60
4.1.7.2 Calculating the Adjusted Cartridge Operating Hours...................................................................................................60
4.1.7.3 Air Purification Cartridge Operating Hours Form........................................................................................................62
4.2 P1 PURIFICATION SYSTEM.........................................................................................................................................63
4.2.1 Major Components ...........................................................................................................................................................63
4.2.2 Component Description....................................................................................................................................................64
4.2.2.1 Oil & Water (condensate) Separator.............................................................................................................................64
4.2.2.2 Chamber........................................................................................................................................................................65
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MNL-126509
4.2.2.3 Cartridge .......................................................................................................................................................................65
4.2.2.4 Cartridge Handling ....................................................................................................................................................... 65
4.2.2.5 Condensate Drain Valve...............................................................................................................................................65
4.2.2.6 Check Valves................................................................................................................................................................ 65
4.2.2.7 Bleed Valve .................................................................................................................................................................. 66
4.2.2.8 Pressure Maintaining Valve..........................................................................................................................................66
4.2.2.9 Safety Valve..................................................................................................................................................................66
4.3 MAINTENANCE............................................................................................................................................................... 66
4.3.1 Oil and Water Separator...................................................................................................................................................66
4.3.2 Cartridge Replacement.....................................................................................................................................................67
4.3.2.1 Leaking at the Safety Bore ...........................................................................................................................................68
4.4 REPLACEMENT PARTS LIST......................................................................................................................................69
CHAPTER 5:- - - - - - - - - - - - COMPRESSOR DRIVE; G 120 II V
5.1 VERTICAL COMPRESSOR DRIVE.............................................................................................................................. 72
5.2 MAINTENANCE OF THE V-BELT AND SHEAVES.................................................................................................. 72
5.2.1 Check The Sheaves. ......................................................................................................................................................... 72
5.2.2 Check the V-belt...............................................................................................................................................................72
5.3 REPLACEMENT PART LIST ........................................................................................................................................73
CHAPTER 6:- - - - - - - - - - ELECTRICAL PANEL, ASY-1058 XL
6.1 OVERVIEW.......................................................................................................................................................................75
6.2 ELECTRICAL PANEL ....................................................................................................................................................75
6.2.1 Wiring Diagram................................................................................................................................................................76
6.2.2 Electrical Panel Interior Access .......................................................................................................................................76
6.2.3 Optional Equipment .........................................................................................................................................................76
6.3 AC POWER REQUIREMENTS...................................................................................................................................... 76
6.4 ELECTRICAL PANEL COMPONENTS....................................................................................................................... 77
6.4.1 Programable Logic Controller (PLC)...............................................................................................................................77
6.4.2 Replacing the PLC ...........................................................................................................................................................78
6.4.3 Installing a New Program.................................................................................................................................................78
6.4.4 Installing an EEPROM.....................................................................................................................................................78
6.4.5 Hourmeter.........................................................................................................................................................................79
6.4.6 Transformer and Fuses .....................................................................................................................................................79
6.4.7 Motor Starter. ................................................................................................................................................................... 80
6.4.8 Overload Relay................................................................................................................................................................. 80
6.4.9 Starter Reset .....................................................................................................................................................................80
6.4.10 Power Supply ................................................................................................................................................................... 81
6.5 ALARMS............................................................................................................................................................................81
6.5.1 Final Separator Warning ..................................................................................................................................................81
6.5.2 Securus
6.5.2.1 Securus® Cartridge ...................................................................................................................................................... 82
6.5.2.2 Securus II
6.5.3 Compressor High Temperature ........................................................................................................................................ 83
6.5.4 Compressor Low Oil Pressure..........................................................................................................................................83
6.5.5 Compressor Overrun Timer .............................................................................................................................................83
6.5.6 Condensate Fault ..............................................................................................................................................................83
6.5.7 Motor Starter Overload Trip ............................................................................................................................................84
®
Electronic Moisture Monitor System................................................................................................................82
®
Transmitter.................................................................................................................................................82
April 4, 2013 Page iv
G 120 II V
6.6 PLC INPUTS AND OUTPUTS ........................................................................................................................................84
6.6.1 Analog Inputs to the PLC.................................................................................................................................................85
6.7 WIRING HARNESS LAYOUT .......................................................................................................................................86
6.8 REPLACEMENT PARTS LIST ......................................................................................................................................88
6.9 PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR.........................................................................96
6.10 PARTS LIST FOR MODELS WITH A 7½ HORSEPOWER MOTOR......................................................................97
6.11 PARTS LIST FOR MODELS WITH A 10 HORSEPOWER MOTOR.......................................................................98
6.12 PARTS LIST FOR MODELS WITH A 15 HORSEPOWER MOTOR.......................................................................99
6.13 PARTS LIST FOR MODELS WITH A 20 HORSEPOWER MOTOR.....................................................................100
CHAPTER 7:- - - - - - - - - - - - - - - - -INDICATORS & VALVES
7.1 DESCRIPTION................................................................................................................................................................101
7.2 REPLACEMENT PARTS LIST ....................................................................................................................................101
7.1 NONADJUSTABLE VALVES .......................................................................................................................................103
7.2 PRESSURE MAINTAINING VALVE...........................................................................................................................103
7.3 SAFETY VALVES...........................................................................................................................................................104
CHAPTER 8:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX
8.1 SAFETY............................................................................................................................................................................105
8.1.1 General Safety Precautions.............................................................................................................................................105
8.1.2 Safety Warning Labels ...................................................................................................................................................107
8.2 UNPACKING, HANDLING AND INSTALLATION..................................................................................................108
8.2.1 Unpacking and Handling................................................................................................................................................108
8.2.2 Installation of the Compressor Unit ...............................................................................................................................109
8.2.2.1 General........................................................................................................................................................................109
8.2.2.2 Ventilation ..................................................................................................................................................................110
8.2.2.2.1 Outdoor Installation ....................................................................................................................................................110
8.2.2.2.2 Indoor Installation.......................................................................................................................................................110
8.2.2.2.3 Natural Ventilation .....................................................................................................................................................110
8.2.2.2.4 Forced Ventilation ......................................................................................................................................................111
8.2.3 Intake Air........................................................................................................................................................................111
8.2.3.1 Inside Air Source ........................................................................................................................................................111
8.2.3.2 Outside Air Source......................................................................................................................................................112
8.2.4 Compressor Intake Piping ..............................................................................................................................................112
8.2.5 Installation Procedures ...................................................................................................................................................113
8.2.6 Electrical Installation......................................................................................................................................................113
8.2.6.1 Electric Drive..............................................................................................................................................................113
8.2.6.2 Electrical Supply.........................................................................................................................................................113
8.2.7 Pneumatic Leaks.............................................................................................................................................................115
8.3 LONG TERM STORAGE...............................................................................................................................................116
8.3.1 General ...........................................................................................................................................................................116
8.3.2 Preparations ....................................................................................................................................................................116
8.3.2.1 Units Equipped with a Filter System ..........................................................................................................................116
8.3.3 Preserving the Compressor.............................................................................................................................................116
8.3.4 Preventive Maintenance During Storage........................................................................................................................117
8.3.5 Lubrication Oils for Preservation ...................................................................................................................................117
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MNL-126509
8.3.6 Reactivating the Compressor Unit .................................................................................................................................117
8.4 REPRODUCIBLE FORMS............................................................................................................................................118
8.4.1 Scheduled Maintenance Form........................................................................................................................................118
8.4.2 Air Purification Cartridge Operating Hours...................................................................................................................121
8.4.3 Record of Operating Hours ............................................................................................................................................122
8.5 REFERENCE DATA.......................................................................................................................................................123
8.5.1 Tightening Torque Values..............................................................................................................................................123
8.5.2 Torque Sequence Diagrams ........................................................................................................................................... 123
8.5.3 Conversion Formulas .....................................................................................................................................................123
8.5.4 Approved Lubricants Chart............................................................................................................................................124
8.5.5 Glossary of Abbreviations and Acronyms .....................................................................................................................124
8.6 ADDITIONAL DOCUMENTS ......................................................................................................................................125
8.6.1 Diagrams and Drawings.................................................................................................................................................125
8.6.2 Other Documents............................................................................................................................................................125
April 4, 2013 Page vi
G 120 II V
List of Figures
CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION
Figure 1-1 Compressor Identification Label .............................................................................................................................2
CHAPTER 2:- - - - OPERATING INSTRUCTIONS; MAPLE SYSTEM
Figure 2-1 MNR-0053...............................................................................................................................................................5
Figure 2-2 PLC & Battery .........................................................................................................................................................5
Figure 2-3 Maple System; Run Screen......................................................................................................................................6
Figure 2-4 Maple System; Home Screen...................................................................................................................................7
Figure 2-5 Status Screen............................................................................................................................................................8
Figure 2-6 Login Screens ..........................................................................................................................................................9
Figure 2-7 Parameters Screen..................................................................................................................................................10
Figure 2-8 Operator Interface Screen Flow.............................................................................................................................14
CHAPTER 3:- - - - - - - - - - - - - - - - - - - - - - IK120 II C & G
Figure 3-1 IK120 II C & G Compressor Blocks, Front View .................................................................................................15
Figure 3-2 Air Flow Diagram..................................................................................................................................................16
Figure 3-3 Lubrication Oil Circuit ..........................................................................................................................................17
Figure 3-4 Oil Sight Glass.......................................................................................................................................................18
Figure 3-5 Oil Filler Cap .........................................................................................................................................................18
Figure 3-6 Removing the Oil Filter Cover ..............................................................................................................................18
Figure 3-7 Replacing the Oil Filter .........................................................................................................................................18
Figure 3-8 Inter-stage Separator..............................................................................................................................................20
Figure 3-9 Valve Operation.....................................................................................................................................................21
Figure 3-10 IK120II C & G, 1st Stage Valve............................................................................................................................22
Figure 3-11 IK120 II C 1st Stage Valve Head and Plate Valve................................................................................................23
Figure 3-12 IK120 II C & G, 2nd Stage Valve Head and Valves .............................................................................................24
Figure 3-13 Using the Special Valve Tool ................................................................................................................................25
Figure 3-14 Securing the Intake Valve......................................................................................................................................25
Figure 3-15 IK120 II C & G, 3rd Stage Valve Head and Valves..............................................................................................26
Figure 3-16 Removing the 3rd Stage Pressure Valve ...............................................................................................................27
Figure 3-17 Crankcase Assembly..............................................................................................................................................28
Figure 3-18 Piston and Cylinder, 1st Stage...............................................................................................................................30
Figure 3-19 Piston and Cylinder, 2nd Stage..............................................................................................................................31
Figure 3-20 Piston and Cylinder, 3rd Stage ..............................................................................................................................32
Figure 3-21 Piston and Sleeve, 3rd Stage..................................................................................................................................33
Figure 3-22 1st Stage Valve Head and Valve, IK120 II C & G................................................................................................34
Figure 3-23 2nd Stage Valves and Valve Head.........................................................................................................................36
Figure 3-24 3rd Stage Valves and Valve Head .........................................................................................................................38
Figure 3-25 Flywheel ................................................................................................................................................................39
Figure 3-26 Inter-Stage Separator .............................................................................................................................................40
Figure 3-27 Lubrication System Assembly...............................................................................................................................42
Figure 3-28 Cooling System......................................................................................................................................................44
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MNL-126509
Figure 3-29 Inlet Assembly....................................................................................................................................................... 46
Figure 3-30 Automatic Condensate Drain ................................................................................................................................49
Figure 3-31 ACD Operation Diagrams .....................................................................................................................................50
Figure 3-32 ACD System..........................................................................................................................................................52
Figure 3-33 ACD Valve and Manifold Assembly ....................................................................................................................53
Figure 3-34 Condensate Collector.............................................................................................................................................54
Figure 3-35 Condensate Collector.............................................................................................................................................55
CHAPTER 4:- - - - - - - - - - - - - - - - PURIFICATION SYSTEM
Figure 4-1 Cartridge Safety Venting.......................................................................................................................................57
Figure 4-2 P0 & P31 Safety Venting ...................................................................................................................................... 57
Figure 4-3 Purification System Dataplates (typical) ............................................................................................................... 57
Figure 4-4 Correction Factor for Cartridge Operating Hours ................................................................................................. 61
Figure 4-5 Example Record of Adjusted Operating Hours.....................................................................................................61
Figure 4-6 P1 Purification System ..........................................................................................................................................63
Figure 4-7 Oil and Water Separator ........................................................................................................................................64
Figure 4-8 Oil and Water Separator Labels ............................................................................................................................65
Figure 4-9 Oil and Water Separator ........................................................................................................................................67
Figure 4-10 Sintered Metal Filter Assembly.............................................................................................................................67
Figure 4-11 Cartridge Replacement ..........................................................................................................................................67
Figure 4-12 P1 Purification System Parts List.......................................................................................................................... 69
Figure 4-13 Oil and Water Separator Parts List........................................................................................................................70
Figure 4-14 10” Chamber Parts List .........................................................................................................................................71
CHAPTER 5:- - - - - - - - - - - - COMPRESSOR DRIVE; G 120 II V
Figure 5-1 Vertical Drive with Idler (typical)......................................................................................................................... 72
Figure 5-2 G 120 II V Drive with Idler .................................................................................................................................. 73
CHAPTER 6:- - - - - - - - - - ELECTRICAL PANEL, ASY-1058 XL
Figure 6-1 ASY-1058 XL and MNR-0053 ............................................................................................................................. 75
Figure 6-2 Electrical Panel Label............................................................................................................................................ 76
Figure 6-3 PLC, CNT-0078 ....................................................................................................................................................77
Figure 6-4 Connector Block Removal ....................................................................................................................................77
Figure 6-5 Hourmeter..............................................................................................................................................................79
Figure 6-6 Transformer and Fuses ..........................................................................................................................................79
Figure 6-7 Motor Starter (typical) ........................................................................................................................................... 80
Figure 6-8 Overload Relay (typical) .......................................................................................................................................80
Figure 6-9 Power Supply......................................................................................................................................................... 81
Figure 6-10 Securus II
Figure 6-11 High Temperature Switch......................................................................................................................................83
Figure 6-12 Pressure Sensor (Typical)...................................................................................................................................... 83
Figure 6-13 Condensate Level Float Switch .............................................................................................................................84
Figure 6-14 Control Pane .......................................................................................................................................................... 88
Figure 6-15 Electrical Panel, Front View.................................................................................................................................. 89
Figure 6-16 Electrical Panel, Bottom View .............................................................................................................................. 90
®
Transmitter ......................................................................................................................................... 82
April 4, 2013 Page viii
G 120 II V
Figure 6-17 Electrical Panel, Interior, 60 Hz ............................................................................................................................92
Figure 6-18 Electrical Panel, Interior, 50 Hz ............................................................................................................................94
CHAPTER 7:- - - - - - - - - - - - - - - - -INDICATORS & VALVES
Figure 7-1 Indicators .............................................................................................................................................................101
Figure 7-1 Check Valve.........................................................................................................................................................103
Figure 7-2 Pressure Maintaining Valves (PMV)...................................................................................................................103
Figure 7-3 Safety Valves .......................................................................................................................................................104
CHAPTER 8:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX
Figure 8-1 Lifting Devices ....................................................................................................................................................108
Figure 8-2 Leveling Feet .......................................................................................................................................................109
Figure 8-3 Example of Air Intake Piping..............................................................................................................................113
Figure 8-4 Incoming Power Wiring Label ............................................................................................................................114
Figure 8-5 6 Bolt and 4 Bolt Torque Sequence.....................................................................................................................123
Page ix 1st Edition, Rev. 0 Chg. 2
MNL-126509
CHAPTER 1: INTRODUCTION
1.1 How To Use This Manual
This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. products listed on the front cover.
All instructions in this manual should be observed and carried out as written to prevent damage or premature wear to the product or the equipment served by it.
If your unit is equipped with nonstandard accessories and or options, supplemental information is normally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.
While every effort is made to ensure the accuracy of the information contained in this manual, Bauer
Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof.
1.1.1 Manual Safety Notices
Important instructions concerning the endangerment of personnel, technical safety or operator safety will
be specially emphasized in this manual by placing the information in the following types of safety
notices.
^ DANGER
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or seri-
ous injury. This is limited to the most extreme situations.
^ WARNING
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
injury.
^ CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or mod-
erate injury. It may also be used to alert against unsafe practices.
NOTICE
NOTE advise of technical requirements that require particular attention by the operator or the mainte-
nance technician for proper maintenance and utilization of the equipment.
April 4, 2013 Page 1
G 120 II V
1.2 How to Use the Replacement Parts List
• A lozenge in the Item Number column indicates the part number for a complete assembly.
• a dagger (†) in the Qty column with or without an ellipse (…) in the Part Number column means the
part is illustrated for assembly purposes only and is not available for sale as an individual component.
This part can be obtained by ordering the complete assembly.
• AR in the Qty column means that the item is cut or manufactured to the size which the customer specifies.
• A dash (—) in the Item Number column indicates that there is more than one part number applicable
to the preceding Item Number.
• The letters in the columns labeled Kit indicate the number of operating hours when the part is to be
replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000
hours.
• NS in the Item Number column indicates the part is not illustrated but is available.
When placing an order for spare parts, please provide the following information to ensure delivery of the
correct parts. The model number, date of manufacture and serial number can be found of the compressor
unit identification plate on the compressor unit frame.
Information Example
Model Number VC 120
Serial Number 143156
Date of Manufacture 02/2013
Part Number VAL-0500
Part Description Valve
Part Quantity Required 1
Figure 1-1 Compressor Identification Label
BAUER COMPRESSORS, INC.
NORFOLK, VA 23502 U.S.A. (757) 855-6006
MODEL NO.
BLOCK NO.
SERIAL NO.
QUANTITY
MFG. DATE
Page 2 1st Edition, Rev. 0 Chg. 2
MNL-126509
^ WARNING
The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-
threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer
Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.
1.3 How to Use the Appendix
Information contained in the Appendix to this manual includes the following.
• The safety instructions applicable to this product. They must be read, understood and complied with
prior to operating the product.
• The instructions for installing this product. They must be read, understood and complied with prior to
operating the product.
• Reproducible Forms
• Reference Data
• Torque Values
• Torque Sequence
• Conversion Formulas
• Approved Lubricants
• Glossary of Abbreviations & Acronyms
• Additional Documents
April 4, 2013 Page 3
1.4 Unit Specifications
All specifications are subject to change without prior notice.
G 120 II V 7.5 Hp
Medium Nitrogen, Helium and Argon
Capacity 6.8 scfm (193 l/min)
Inlet pressure 0 - 3 psig (0 - 0.21 bar)
Operating pressure, max. 5,000 psig (350 bar)
Ambient temperature range 40 - 115 °F (5 - 45 °C)
Compressor Block
IK120 II C Mod. 5
No. of stages 3
No. of cylinders 3
Cylinder bore, 1st stage 3.46 in. (88 mm)
Cylinder bore, 2nd stage 1.42 in. (36 mm)
Cylinder bore, 3rd stage 0.55 in. (14 mm)
Piston Stroke 1.57 in.(40 mm)
Intermediate pressure, 1st stage 85 - 100 psig (6 - 7 bar)
Safety valve setting, 1st stage 130 psig (9 bar)
Intermediate pressure, 2nd stage 580 - 710 psig (40 - 49 bar)
Safety valve setting, 2nd stage 870 psig (60 bar)
Direction of rotation when facing flywheel CCW
Compressor speed 1,200 RPM
Oil capacity 3 qts. (2.8 liter)
Oil Pressure 60 - 85 psig (4 - 6 bar)
Recommended oil BAUER OIL-0024
Maximum Inclination 15° in all directions
G 120 II V
1.4.0.1 Compressor Drive
Model Voltage Freq. Phase Power Type FL Amp Bauer P/N
-E3 208, 230, 460 VAC 60 Hz 7.5 Hp ODP 20, 18, 9 MTR-0033
-E3 380, 400, 415 VAC 50 Hz 7.5 Hp ODP 10.5, 10, 9.5 MTR-0208
1.4.0.2 Purification System Applicability
The G 120 II V is standardly equipped with the Bauer P1 or Oil Removal Filtration System.
1.4.0.3 Pressure Switch Settings
1.4.0.3.1 Inlet Pressure Switch Settings
Low Inlet Pressure 0.0 psig
High Inlet Pressure 1.5 psig
1.4.0.3.2 Final Pressure Switch Setting
Final Pressure 2,400 psig
Restart Pressure 1,900 psig
Final Safety Valve 2,800 psig
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MNL-126509
SECURUS
CHAPTER 2: OPERATING INSTRUCTIONS; MAPLE SYSTEM
2.1 Description The following instructions apply to units that use the Maple System touchscreen operator interface, MNR-0053 with program 31L.
Figure 2-1 MNR-0053
The Electrical Panel Assembly will provide logical control and safety shutdowns for the compressor
equipment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorporated into a proprietary software program permanently saved into PLC memory using EEPROM technology. The PLC is equipped with a 200 day in battery to maintain the PLC’s internal clock. The software
program is based on the pressure and use of the compressor. The operator uses the Operator Interface to
communicate with the PLC which is located in the electrical enclosure.
2.1.1 Emergency Stop Button
A Normally Closed switch when pulled out, when the E-Stop Button is pressed in, it disconnects the
main power source, turning off the compressor, draining the ACD system and stopping air delivery to
the consuming devices. This button is to be used in case of emergency. Normal operational stops should
be accomplished using the operator interface.
Figure 2-2 PLC & Battery
200 DAY
BATTERY
PLC
April 4, 2013 Page 5
G 120 II V
2.1.2 Operator Interface
The Operator Interface is a 4.3 inch, 256 color, 8 bit LCD with touchscreen operation. The Operator
Interface is the input/output device for normal operation of the compressor unit. The compressor system
is ready and able to operate after the Emergency Stop Switch is pulled out and the red “COM” status light
illuminates. The red status light will continuously strobe to show that the unit is ready.
2.1.2.1 Run Screen
The initial screen after startup allows control and monitoring of the compressor unit.
Figure 2-3 Maple System; Run Screen
45
(CO) MONITOR
SECURUS
1
6
7
8
2
9
3
1. Securus / Secant Status
2. Current Run Time
3. Next Maintenance Due Status
4. Status Lights
5. ON & OFF Buttons
1. If the unit is equipped with a CO monitor, the words (CO) monitor are shown here. Also if the unit
is equipped with a Securus or Seccant monitor, the status of the monitor is shown here.
6. Closes Window (goes to main menu)
7. Current Time & Date
8. Final Pressure (from sensor)
9. Current Oil Pressure (from sensor)
10. Inlet Pressure (if equipped with sensor)
10
2. This reading shows the current run time of the compressor in hours. Once the compressor is turned
off this reading returns to zero. For total hours on the unit check the status screen.
3. This reading tells when the next maintenance is due on the compressor.
4. These lights show the status of electrical connections and communication. The red light strobes
continuously to show communication is established with the PLC. The green light indicates that the
PLC has power, and the yellow light indicates power is coming into the unit.
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MNL-126509
5. The ON and OFF buttons control the compressor. These buttons should be used for normal starting
and stopping of the compressor. In an emergency the Emergency Stop button should be used.
6. This X button closes the Run screen and goes to the main menu screen. The compressor may still be
operating when returning to the main menu screen.
7. The current time and date are shown here. This data can be corrected only by user levels 2 and 3.
8. The final pressure reading is displayed here. It is received from the final pressure sensor near the
outlet.
9. This oil pressure reading displays a continuous pressure from the compressor. This reading is taken
from the oil pressure sensor on the compressor block.
10. This space a reserved for units with inlet pressure sensors. A continuous inlet pressure reading is
provided. This is mainly for units designed to compress natural or industrial gases.
2.1.2.2 Main Menu Screen Figure 2-4 Maple System; Home Screen
1
2
3
4
5
1. User Level Status
2. Run Screen Button
3. Alarm History Button
The home screen is the main screen used to navigate to the other 8 options. All of the option screens can
be viewed but critical changes can only be made by user levels 2 & 3. Critical changes control the functions of the compressor. This feature is added to prevent unintentional changes to the unit’s functions.
2.1.2.2.1 Run
This button returns the user to the RUN screen, See Paragraph 2.1.2.1 for further information.
4. Status Button
5. Contact Information Button
6. Login Button
7. Configuration Button
8. Parameters Button
9. Tools Button
6
7
8
9
April 4, 2013 Page 7
G 120 II V
1
2
3
4
5
25.01
15.0
514
2.1.2.2.2 Alarms History
This button displays the history of alarms. The date of the alarm history can be changed with the drop
down arrow or the forward and backward arrows adjacent to the date. To return to the Main Menu screen
touch the X in the upper right corner.
2.1.2.2.3 Status
The status button takes the user to the status screen. The status screen allows the user to view the Current
Run Time, Total Run Time, Minutes till next ACD cycle, current Separator Count, and the Current Final
Pressure.
Figure 2-5 Status Screen
1. Calendar / Hour Selection
2. ACD Test Button
3. Return Button
4. View Maint. Schedule
5. Light ON / OFF Button
The options on the Status screen are shown in Figure 2-5. The Selection button allows the operator to
select maintenance warnings by the calendar schedule or the hourly maintenance schedule. The ACD
Test button is used to perform an ACD test. Pressing this button opens the ACD valve and the operator
should be able to hear the ACD draining. The Return button takes the user back to the Main Menu screen.
The Maintenance schedule buttons allow the user to view the Maintenance schedule by calendar days or
by hours (See Table 2-1& 2-2). The Light ON / OFF button is used on some models equipped with lights.
This button toggles the light on and off.
2.1.2.2.4 Contact
Pressing the contact button displays contact information for maintenance and assistance for your unit. It
can only be edited by users 2 & 3.
2.1.2.2.5 Login
The login button takes the user to the login screen. The default option is User l, Operator. No password is
needed to operate the compressor at this user level. At this user level the operator can operate the unit and
explore all the other menu screens but cannot change parameters or configuration settings. User 2, Level
1, can operate the compressor and also is allowed to change some parameters and configuration settings.
User 3, Factory Level, has total access to the unit and can change all parameters and configuration settings.
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MNL-126509
Figure 2-6 Login Screens
To change the user level press the “USER” button, select the desired user, and press “OK”. Then press the
button below the words “Enter Password” and press the password numbers on the keypad. After entering
the proper password press “ENT” on the keypad to enter the password. If the password is incorrect an
“Invalid Password” screen will pop up. The only option on the screen is to click “OK”. If the password is
accepted the screen will return to the login screen with the new user level shown.
2.1.2.2.6 Configuration
The Configuration button is used to setup the features that make the unit. There are a total of 4 pages in
this option. The first two pages consist of 8 features which a unit may have. The third page is used to set
the final pressure sensor limit. The fourth page is used to set the inlet pressure sensor limit. Similar to the
Parameter’s settings changing the Configuration settings will change how the unit operates so only users
2 & 3 are allowed to change them. Pressing the X button returns the user to the main menu screen.
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2.1.2.2.7 Parameters
This button takes the user to the parameters screens. There are a total of 9 screens. These parameters are
set at the factory for each specific unit. Changing these parameters will change how the unit operates, so
only users 2 and 3 are allowed to change them. If user 1, Operator, tries to change a parameter a window
will pop up stating “Access Denied”. To change a parameter just touch the number which needs to be
changed and a keypad will pop up. Punch in the new number and press the “ENT” key.
Figure 2-7 Parameters Screen
Pressing the Pressure Units button toggles the run screen pressures between PSI and BAR.
Pressing the X button will return the screen to the main menu.
2.1.2.2.8 Tools
Like the Parameters and Configuration options only users 2 & 3 can make changes or use this option. The
first page of the tools option is used for maintenance purposes. The buttons are used to check the PLC and
can only be used when the unit is OFF. The second page is used to set the internal calendar/clock and to
select the language displayed on the monitor. English, Spanish, and Portuguese are the current choices.
More languages may be added at a later date. The third page offers activation of the Anybus (internet)
Server, to turn off or on the key beeping sound, or to clear the alarm history. The final button “START” is
used to save the current set parameters to the internal EEPROM. If this button is pressed the current setting are saved to the memory and a status bar of the operation will be shown.
2.2 Starting and Stopping Unit
2.2.1 Before Starting.
1. Check the compressor oil level, See Chapter 3.
2. Ensure that all panels and guards are properly installed.
3. If the unit is equipped with doors, ensure all doors are closed.
4. Ensure that the E-Stop Button is pulled out.
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MNL-126509
2.2.2 To Start Unit.
Press the green START Button on the Run Screen. (See Figure 2-3)
If the pressure in the system is lower than the set “Start Pressure”, the drive motor will start up powering
the compressor. If the system’s pressure is higher than the set “Start Pressure” or when the air pressure
has increased to the set “Operating Pressure”, the drive motor will automatically shutdown. The Compressor will automatically restart when the system’s pressure drops below the set “Start Pressure”.
^ WARNING
Once started the compressor and drive motor will start and stop automatically.
Stay clear of all moving parts whenever unit has power.
2.2.3 To Stop Unit.
Press the red STOP Button on the Run screen..
NOTICE
In an emergency the compressor is shutdown by pressing
in the Emergency Stop Button.
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Table 2-1: Calendar Maintenance Interval Tasks
Task Monthly Annually Every Two Years
Calibrate CO Monitor
Check Oil Level
Check Final Pressure Shutdown
Check Automatic Condensate Drain
Check V-belt
Service Intake Filter
Check all connections for leaks
Inspect Compressor Valves
Check all fasteners for tightness
Change Synthetic Oil
Replace Compressor Oil Filter
Replace Compressor Valves
X
X
X
X
X
X
X
X
X
X
X
X
Replace CO Monitor Sensor
X
Page 12 1st Edition, Rev. 0 Chg. 2
MNL-126509
Table 2-2: Operating Hours Maintenance Interval Tasks
Task
Check Oil Level
Check Final Pressure Shutdown
Check Automatic Condensate Drain
Check V-belt
Service Intake Filter
Check all connections for leaks
Check fasteners for tightness
Inspect Compressor Valves
Change Synthetic Oil
Replace Oil Filter
Replace Compressor Valves
250
Hours
X
X
X
500
Hours
X
X
X
X
1,000
Hours
X
2,000
Hours
X
X
X
3,000
Hours
Inspect Pistons and Pistons Rings
X
April 4, 2013 Page 13
2.3 Screen Flow
START UP
RUN SCREEN
On
Off
MAIN MENU
RUN
Changable
Date
LOGIN
STATUS PARAMETERSCONFIGURATION TOOLSCONTACT
Return to
Run Screen
Above
ALARMS
HISTORY
Users
1, 2, & 3
Current
Status
ACD Test
Light
Unit Settings
9 pages
Unit Setup Maint.
Check
PLC
Set Internal
Clock
Set Language
Contact
Info
for Help
Pressure
Sensor
Limits
Figure 2-8 Operator Interface Screen Flow
G 120 II V
Page 14 1st Edition, Rev. 0 Chg. 2
MNL-126509
CHAPTER 3: IK120 II C & G
3.1 Maintenance and Parts
3.1.1 Description
The IK120 II C & G compressors are used to compress gases up to a maximum of 5,000 psi. Both compressors are three cylinder, three stage air cooled, oil lubricated reciprocating compressors. The 3rd stage
cylinder is lubricated by means of the forced feed lubrication system, while the other cylinders are splash
lubricated. The cylinders are arranged in a “W” configuration, the 1st stage is in the center, 2nd stage on
the right and 3rd stage on the left looking from the filter side.
3.1.2 Component Location Figure 3-1 IK120 II C & G Compressor Blocks, Front View
1. Intake Connector
2. Oil Filler
3. 2nd Stage Safety Valve
4. 3rd Stage Cylinder
5. Oil Filter Housing
April 4, 2013 Page 15
6. Inter-stage Separator
7. 2nd Stage Intercooler
8. Condensate Drain Connector
9. Final Safety Valve
10. 1st Stage Safety Valve
11. Crankcase Relief Valve
12. Gas Outlet Connector
13. 1st Stage Intercooler
14. Oil and Water Separator
Figure 3-2 Air Flow Diagram
14
11
4
9
2
1
3
8
5
14
12
Purification
System
13
10
6
7
G 120 II V
1. Intake Manifold
2. 1st Stage Cylinder
3. 2nd Stage Cylinder
4. 3rd Stage Cylinder
5. 1st Stage Intercooler
6. 2nd Stage Intercooler
7. 3rd Stage Aftercooler
3.1.3 Air Flow Diagram
Refer to Figure 3-2. The gas is drawn in through intake connector (1), compressed to the final pressure in
cylinders (2, 3, 4,) and cooled by intercoolers (5, 6) and after cooler (7). The safety valves (8,9, 10) protect from overpressure in the individual stages. The compressed gas is purified by Inter-stage separator
(11) and oil and water separator assembly (12). The Inter-stage separator (11) and oil and water separator
(12) are drained by condensate valves (14). An Automatic Condensate Drain system is available as an
option. The pressure maintaining valve (13) ensures that pressure is built up in the HP drying system
from the start of delivery, thus achieving constant optimum drying.
8. 1st Stage Safety Valve
9. 2nd Stage Safety Valve
10. 3rd Stage Safety Valve (Final Pressure)
11. Inter-stage Separator
12. Oil and Water Separator
13. Pressure Maintaining Valve
14. Manual Condensate Drain Valve
Page 16 1st Edition, Rev. 0 Chg. 2
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3
2
4
1
5
5
Figure 3-3 Lubrication Oil Circuit
1. Oil Pump
2. Oil Filter
4. Guide Piston
5. Oil Sight Glass
3. Minimum Pressure Valve
3.1.4 Compressor Lubrication
3.1.4.1 Description
Refer to Figure 3-3. The compressor is provided with forced-feed lubrication. The oil pressure is produced by a low speed gear pump (1). The oil pressure is approximately 73 psi (5 bar).
The oil pump (1) is coupled to and driven by the crankshaft. It pumps oil through the oil line filter (2) and
a minimum pressure valve (3) to the 3rd stage cylinder. The oil is then distributed by the guide piston (4)
of the 3rd stage and lubricates all the moving parts of the compressor block.
The minimum pressure valve (3) allows for oil pressure indication at a pressure gauge and/or electronic
oil pressure monitoring.
^ CAUTION
The Oil Pump operates only when the compressor is rotating in the correct direction. If the compressor is
rotating backwards, no oil pressure will build up damaging the compressor.
3.1.4.2 Oil Level Check
Check the oil level at the sight gauge on either side of the compressor block (See Figure 3-4) every day
before putting the compressor into operation. Oil level must be between the minimum and maximum
notches. Oil level must never be below the minimum mark as this will cause severe damage due to lack of
April 4, 2013 Page 17
G 120 II V
lubrication. Oil level must also not exceed the maximum mark as this will cause excessive lubrication of
the compressor and may result in a carbon buildup on the valves.
Figure 3-4 Oil Sight Glass Figure 3-5 Oil Filler Cap
Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter
3.1.4.3 Oil Change Interval
Every 2,000 operating hours or biennially; whichever comes first.
Page 18 1st Edition, Rev. 0 Chg. 2
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3.1.4.4 Oil Change
1. Run the compressor until it is warm then shut it down.
2. (See Figure 3-5). Remove the cap (1) from the oil filler neck.
3. Drain oil while it is still warm by means of the oil drain plug.
^ CAUTION
Replace the oil filter every oil change. Failure to do so will cause the filter to clog and the bypass valve to
open resulting in unfiltered oil being circulated and possible damage to the compressor.
4. (See Figure 3-6). Remove the two bolts (1) with a 13 mm wrench. Remove the oil filter cover (2)
5. (See Figure 3-7). Remove the oil filter (1) from the rubber gasket at the cover.
6. Mount a new filter element (P/N N25326) and replace and fasten oil filter cover.
7. Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the
sight gauge.
8. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation.
3.1.5 Venting the Oil Pump
(See Figure 3-7) If no or low oil pressure builds up after starting the unit, especially after maintenance
or repair or if the compressor has been run the wrong direction, venting the oil pump may be necessary.
1. Run the compressor with all condensate drains open to avoid building up pressure.
2. Unscrew Screw Cap (2) and Plug and wait until Oil comes out free of air bubbles.
3. Retighten Plug and Screw Cap.
4. Check Oil Level (See Paragraph 3.1.4.2) and replace oil as necessary.
3.1.5.1 Gas Intake System
In order for these compressors to work satisfactorily, it is absolutely essential to supply the medium at a
constant pressure. Therefore a pressure reducer in the intake line is necessary if the supply pressure is
above atmospheric pressure or fluctuating. An intake expansion tank between the pressure reducer and
the compressor may also be necessary to compensate for the pressure surges caused by the 1st stage piston.
April 4, 2013 Page 19
G 120 II V
1
2
3
4
5
6
7
8
3.1.6 Inter-stage Separator
An inter-stage separator is mounted on the compressor block. This separator is designed to remove oil
and water which accumulates due to the cooling of the medium after the compression process. Separation
is achieved by means of centrifugal action provided by a vortex plate (1).
Figure 3-8 Inter-stage Separator
1. Vortex Plate
2. Hollow Screw
3. Center Insert
4. O-ring
^ WARNING
5. Knurled Nut
6. Gasket
7. Fitting
8. Safety Valve
The rapid depressurizing and repressurizing of the inter-stage separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of
damage, injury or death the inter-stage separator must be replaced after 85,000 load cycles. A
load cycle equals one depressurization- repressurization.
Page 20 1st Edition, Rev. 0 Chg. 2
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