Instruction Manual and Replacement Parts List
Mini Verticus
High Pressure Air Compressor Unit
ImVT 120 II (AP)
June 11, 2009 1st Edition, Rev. 0 Chg. 10 MNL-0408
© 2009 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
ImVT 120 II Mini Verticus
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 © 2009 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 ImVT 120 II Mini Verticus High Pressure Air Compressor Unit.
You must read, understand and follow all safety precautions and instructions.
EDITIONS, REVISIONS AND CHANGES
• An Edition is the original or a complete rewriting of the entire Manual.
• A Revision occurs whenever a complete Section or Appendix is rewritten or added.
• A Change occurs when individual pages, drawings or tables are changed.
1st Edition January 25, 2006
Rev Chg Date Notes Auth
0 1 Feb. 16, 2006 Changed to PMV setting JD
0 2 Mar. 1, 2006 Changed Fig 8-3 item 5 P/N SWT-0257 to SWT-0256 JD
0 3 Mar. 16, 2006 Added Digital Pressure Switch to Chapter 8 JD
0 4 May 8, 2006 Changed Figure 1-2 to Digital pressure Switch JD
0 5 June 6, 2006 Replace Solenoid Valve N16382 with P/N N27009 & N27288 JD
0 6 Nov. 1, 2006 Changed DGM-2279 to DGM-2280 & P/N from N20320 to N02320 JD
07
0 8 Mar. 22, 2007 Change to Separator P/N 079416 Life Span JD
0 9 May 21, 2007 Edited for Active Powers 460 V, 3 phase JD
Jan. 2, 2007
Changed 1st Stage Valve Head Assembly P/N to 080688
& Corrected 1st Stage Valve Head Illustrations
JD
0 10 June 11, 2009 Corrected 1st Stage Piston P/Ns SS
Page i 1st Edition, Rev . 0 Chg. 10
MNL-0408
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 COMPRESSOR UNIT DESIGN........................................................................................................................................ 4
1.4.1 Compressor Unit Major Assemblies .......................................................... ........................................................................4
1.5 TECHNICAL SPECIFICATIONS.....................................................................................................................................6
1.5.1 Compressor Block..............................................................................................................................................................6
1.5.2 Compressor Drive Motor ...................................................................................................................................................6
1.5.3 Purification System Applicability......................................................................................................................................6
CHAPTER 2:- - - - - - - - PLC CONTROLLED UNIT OPERATIONS
2.1 PRE-START CHECKS.......................................................................................................................................................7
2.2 START-UP PROCEDURE .................................................................................................................................................7
2.3 POST START PROCEDURES ..........................................................................................................................................7
2.4 NORMAL OPERATIONS..................................................................................................................................................7
2.5 SHUTDOWN PROCEDURES...........................................................................................................................................7
2.6 ELECTRIC PANEL COMPONENTS .............................................................................................................................8
2.6.1 Emergency Stop Switch. ....................................................................................................................................................8
2.6.2 Starter Reset .......................................................................................................................................................................8
2.6.3 Compressor Control Switch...............................................................................................................................................9
2.6.3.1 2-Position (Standard).................................... ..................................................................................................................9
2.6.4 Indicator Lamps..................................................................................................................................................................9
2.6.4.1 PLC Warning and Alarm Lamps....................................................................................................................................9
2.6.4.1.1 Warning Lamp - Amber..................................................................................................................................................9
2.6.4.1.2 Alarm Lamp - Red..................................................................................... .....................................................................9
2.6.5 Hourmeter...........................................................................................................................................................................9
2.6.6 PLC Control ....................................................................................................................................................................... 9
2.7 WARNINGS ........................................................................................................................................................................9
2.7.1 One Flash - Final Separator Warning.................................................................................................................................9
2.7.2 Two Flashes - Securus Monitor (Optional)......................................................................................................................10
2.8 ALARMS............................................................................................................................................................................10
2.8.1 One Flash - Compressor High Temperature ....................................................................................................................10
2.8.2 Two Flashes - Compressor Low Oil Pressure..................................................................................................................10
2.8.3 Three Flashes - Compressor Overtime............................................ ........................................ .........................................10
2.8.4 Four Flashes - Securus Monitor .......................................................................................................................................10
2.8.5 Five Flashes - Carbon Monoxide Monitor (Optional) .....................................................................................................11
2.8.6 Six Flashes - Final Separator Shutdown ............................................ ..............................................................................11
2.8.7 Seven Flashes - Condensate Fault (OPT).........................................................................................................................11
2.8.8 On Steady - Motor Starter Overload Trip ........................................................................................................................11
June 11, 2009 Page ii
ImVT 120 II Mini Verticus
CHAPTER 3:- - - - - - - - - - - - - - MAINTENANCE AND PARTS
3.1 COMPRESSOR BLOCKS - IK120 II..............................................................................................................................12
3.1.1 Description .......................................................................................................................................................................12
3.1.2 Component Location ........................................................................................................................................................12
3.1.3 Air Flow Diagram............................................................................................................................................................. 13
3.1.4 Compressor Lubrication...................................................................................................................................................13
3.1.4.1 Description....................................................................................................................................................................13
3.1.4.2 Type of Oil....................................................................................................................................................................14
3.1.4.3 Oil Level Check............................................. ..................................... ..........................................................................15
3.1.4.4 Oil Change....................................................................................................................................................................16
3.1.5 Venting the Oil Pump.................................................... ...................................................................................................16
3.1.6 Intake Filter. .....................................................................................................................................................................17
3.1.6.1 Description....................................................................................................................................................................17
3.1.7 Intermediate Separator............................................................................... .......................................................................18
3.1.7.1 Maintenance..................................................................................................................................................................18
3.1.8 Cooling .............................................................................................................................................................................19
3.1.8.1 General..........................................................................................................................................................................19
3.1.9 Valves and Heads............................................................................................................................................................. 19
3.1.9.1 Functional Description..................................................................................................................................................19
3.1.9.2 General Instructions for Changing the Valves..............................................................................................................20
3.1.9.3 Changing the IK120 II 1st Stage Valves .................................... ..................................................................................20
3.1.9.4 IK120 II 2nd Stage Valves............................................................................................................................................22
3.1.9.4.1 Removing the Valves of the 2nd Stage.........................................................................................................................22
3.1.9.4.2 Reassembling the Valves of the 2nd Stage....................................................... ............................................................23
3.1.9.5 IK120 II 3rd Stage Valves............................................................................................................................................24
3.1.9.5.1 Removing the Valves of the 3rd Stage .........................................................................................................................24
3.1.9.5.2 Reassembling the Valves of the 3rd Stage....................................................................................................................25
3.1.10 Replacement Parts List.....................................................................................................................................................26
3.1.11 Troubleshooting................................................................................................................................................................44
3.1.11.1 Troubleshooting Table..................................................................................................................................................44
3.2 THREE STAGE AUTOMATIC CONDENSATE DRAIN SYSTEM...........................................................................45
3.2.1 Description .......................................................................................................................................................................45
3.2.1.1 Normal Operation.........................................................................................................................................................46
3.2.1.2 Condensate Drain..........................................................................................................................................................46
3.2.1.3 Start Unloading.............................................................................................................................................................46
3.2.1.4 Standstill Drainage........................................................................................................................................................ 47
3.2.2 ACD Maintenance............................................................................................................................................................47
3.2.3 ACD Replacement Parts List................................................................................................
3.3 CONDENSATE COLLECTOR.......................................................................................................................................52
3.3.1 Condensate Collector Replacement Parts List .................................................................................................................53
............................................48
CHAPTER 4:- - - - - - - - - - IK120 II MAINTENANCE SCHEDULE
4.1 IK120 II MAINTENANCE INTERVALS.......................................................................................................................54
4.1.1 Maintenance Records ....................................................................................................................................................... 54
CHAPTER 5:- - - - - - - - - - - - - - - AIR PROCESSING SYSTEM
5.1 GENERAL..........................................................................................................................................................................55
5.1.1 General Purification System Procedures..........................................................................................................................55
Page iii 1st Edition, Rev . 0 Chg. 10
MNL-0408
5.1.2 Chamber Safety Bore .......................................................................................................................................................55
5.1.3 Manual Condensate Drainage ................................ ..........................................................................................................56
5.1.4 Model, Serial Number and Part Number Identification ...................................................................................................56
5.1.4.1 Compressor Dataplate...................................................................................................................................................56
5.1.4.2 Purification System Dataplate......................................................................................................................................56
5.1.4.3 Cartridge Installation Dataplate....................................................................................................................................56
5.1.4.4 Air Processing Cartridge Operating Hours Form.........................................................................................................57
5.2 P2S PURIFICATION SYSTEM MAJOR COMPONENTS .........................................................................................58
5.3 COMPONENT DESCRIPTION......................................................................................................................................59
5.3.1 Oil and Water Separator ........................................................... ... .................................................................................59
5.3.2 Chamber ...........................................................................................................................................................................60
5.3.3 Cartridge...........................................................................................................................................................................60
5.3.3.1 Cartridge Construction..................................................................................................................................................60
5.3.3.2 Cartridge Handling.......................................................................................................................................................60
5.3.4 Condensate Drain Valve...................................................................................................................................................61
5.3.5 Check Valves....................................................................................................................................................................61
5.3.6 Bleed Valve......................................................................................................................................................................61
5.3.7 Pressure Maintaining Valve .............................................................................................................................................61
5.3.8 Safety Valve.....................................................................................................................................................................61
5.3.9 Securus
5.3.9.1 Securus
5.3.9.2 Securus
5.4 MAINTENANCE...............................................................................................................................................................62
5.4.1 Oil and Water Separator...................................................................................................................................................62
5.4.2 Cartridge Replacement.....................................................................................................................................................63
5.4.2.1 Leaking at the Safety Bore ....................................................... ..................................... ...............................................64
5.5 REPLACEMENT PARTS LIST......................................................................................................................................65
®
Electronic Moisture Monitor System................................................................................................................61
®
Cartridge........................................................................................................................................................61
®
Indicator ........................................................................................................................................................61
CHAPTER 6:- - - - - - - - - - - - - - -COMPRESSOR UNIT DRIVE
6.1 VERTICAL SELF TENSIONING....................................................................................................................................70
6.2 MAINTENANCE OF THE V-BELT AND SHEAVES..................................................................................................70
6.2.1 Check the Flywheel and Sheave.......................................................................................................................................70
6.2.2 Check the V-belt...............................................................................................................................................................70
CHAPTER 7:- - - - - - - - - - - ELECTRICAL PANEL ASSEMBLY
7.1 OVERVIEW.......................................................................................................................................................................71
7.2 OPTIONS ...........................................................................................................................................................................72
7.3 AC POWER REQUIREMENTS......................................................................................................................................72
7.3.1 Transformer and Fuses.....................................................................................................................................................74
7.4 ELECTRIC PANEL COMPONENTS ...........................................................................................................................74
7.4.1 Motor Starter. ...................................................................................................................................................................74
7.4.2 Overload Relay......................................................... ..................................... ...................................................................74
7.4.3 Emergency Stop Switch. ..................................................................................................................................................75
7.4.4 Starter Reset .....................................................................................................................................................................75
7.4.5 Compressor Control Switches..........................................................................................................................................76
7.4.5.1 2-Position (Standard).................................... ................................................................................................................76
7.4.5.2 3-Position Compressor Control Switch (Factory Installed Option). ...........................................................................76
7.4.5.2.1 For Breathing Air Units.................................................... ....................................... .....................................................76
June 11, 2009 Page iv
ImVT 120 II Mini Verticus
7.4.5.2.2 For Industrial Units.......................................................................................................................................................76
7.4.6 Indicator Lamps................................................................................................................................................................76
7.4.6.1 PLC Warning and Alarm Lamps..................................................................................................................................76
7.4.6.1.1 Warning Lamp - Amber................................................................................................................................................76
7.4.6.1.2 Alarm Lamp - Red......................................... ..................................... ..........................................................................76
7.4.7 Hour meter........................................................................................................................................................................76
7.4.8 PLC Control......................................................................................................................................................................76
7.4.8.1 PLC LED’s ...................................................................................................................................................................77
7.4.9 Compressor PLC Program Versions ................................................................................................................................78
7.4.10 PLC Inputs and Outputs ...................................................................................................................................................78
7.5 WARNINGS ...................................................................................................................................................................... 79
7.5.1 One Flash - Final Separator Warning...............................................................................................................................79
7.5.2 Two Flashes - Securus Monitor Warning............................................................. ............................................................80
7.6 ALARMS............................................................................................................................................................................80
7.6.1 One Flash - Compressor High Temperature .....................................................................................................................81
7.6.2 Two Flashes - Compressor Low Oil Pressure..................................................................................................................81
7.6.3 Three Flashes - Compressor Overrun Timer.................................................................................................................... 81
7.6.4 Four Flashes - Securus Monitor .......................................................................................................................................81
7.6.5 Five Flashes - Carbon Monoxide Monitor Alarm ............................................................................................................82
7.6.6 Six Flashes - Final Separator Shutdown...........................................................................................................................82
7.6.7 Seven Flashes - Condensate Fault....................................................................................................................................83
7.6.8 On Steady - Motor Starter Overload Trip.........................................................................................................................84
7.7 INSTALLING A NEW PROGRAM................................................................................................................................84
7.7.1 Installing a new program using an EEPROM cartridge ...................................................................................................85
7.8 OVERRUN TIMER...........................................................................................................................................................86
7.8.1 Adjusting the Overrun Timer ...........................................................................................................................................86
7.9 WIRE HARNESS CONNECTIONS ...............................................................................................................................87
7.10 REPLACEMENT PARTS LIST......................................................................................................................................88
7.11 TROUBLE SHOOTING GUIDE......................................................................................................................................89
7.11.1 Compressor Will Not Start...............................................................................................................................................89
7.11.2 Compressor Is Shutdown, Alarm Code Flashing Sequence.............................................................................................89
7.11.2.1 One Flash - Compressor High Temperature .................................................................................................................89
7.11.2.2 Two Flashes - Compressor Low Oil Pressure ..............................................................................................................89
7.11.2.3 Three Flashes - Compressor Overtime ................................................................ .........................................................89
7.11.2.4 Four Flashes - Securus
7.11.2.5 Five Flashes - Carbon Monoxi de Moni tor Alarm ........................................................................................................90
7.11.2.6 Six Flashes - Final Separator Shutdown................................................ ................................. ......................................90
7.11.2.7 Seven Flashes -Condensate Fault .................................................................................................................................90
7.11.2.8 On Steady - Motor Over load Trip................................................................................................................................91
7.11.2.9 Eight Flashes - High Inlet Pressure (Gas Compressors Only)......................................................................................91
7.11.2.10 Nine Flashes - Low Inlet Vacuum (Gas Compressors Only) .................................... ...................................................91
7.12 CHECK COMPRESSOR ROTATION DIRECTION...................................................................................................92
7.13 PLC INDUSTRIAL COMPRESSOR WIRING DIAGRAM .......................................................................................93
®
Alarm............................................................................................. ........................................90
CHAPTER 8:- - - - - - - - PNEUMATIC VALVES AND CONTROLS
8.1 NONADJUSTABLE VALVES .........................................................................................................................................94
8.2 PRESSURE MAINTAINING VALVE.............................................................................................................................94
8.3 SAFETY VALVES.............................................................................................................................................................95
Page v 1st Edition, Rev . 0 Chg. 10
MNL-0408
8.4 DIGITAL PRESSURE SWITCH.....................................................................................................................................96
8.5 PROGRAMMING THE PRESSURE SWITCH............................................................................................................96
8.5.1 Selecting The Display Units.............................................................................................................................................97
8.5.2 Selecting The Unit Display ............................................................................................... ...............................................97
8.5.3 Selecting The On Point For The Pressure Switch............................................................................................................97
8.5.4 Selecting The Off Point For The Pressure Switch. ..........................................................................................................98
8.5.5 locking And Unlocking The Switch................................................................................................................................. 98
8.6 REPLACEMENT PARTS LIST......................................................................................................................................99
CHAPTER 9:- - - - - - - - - - - - - - - - - - - - - - - - APPENDIX
9.1 SAFETY............................................................................................................................................................................100
9.1.1 General Safety Precautions ............................................................................................................................................100
9.1.2 Safety Warning Labels...................................................................................................................................................102
9.2 UNPACKING, HANDLING AND INSTALLATION .................................................................................................103
9.2.1 Unpacking and Handling................................................................................................... .............................................103
9.2.2 Installation of the Compressor Unit...............................................................................................................................104
9.2.2.1 General........................................................................................................................................................................104
9.2.2.2 Ventilation..................................................................................................................................................................104
9.2.2.2.1 Outdoor Installation....................................................................................................................................................104
9.2.2.2.2 Indoor Installation.......................................................................................................................................................105
9.2.2.2.3 Natural Ventilation .....................................................................................................................................................105
9.2.2.2.4 Forced Ventilation......................................................................................................................................................106
9.2.2.3 Electrical Installation..................................................................................................................................................106
9.2.2.3.1 Electric Drive..............................................................................................................................................................106
9.2.2.3.2 Electrical Supply.........................................................................................................................................................106
9.3 LONG TERM STORAGE...............................................................................................................................................109
9.3.1 General ...........................................................................................................................................................................109
9.3.2 Preparations....................................................................................................................................................................109
9.3.2.1 Units Equipped with a Filter System..........................................................................................................................109
9.3.3 Preserving the Compressor.............................................................................................................................................109
9.3.4 Preventive Maintenance During Storage........................................................................................................................110
9.3.5 Lubrication Oils for Preservation...................................................................................................................................110
9.3.6 Reactivating the Compressor Unit .................................................................................................................................110
9.4 REPRODUCIBLE FORMS............................................................................................................................................111
9.4.1 Scheduled Maintenance Form................................................. .......................................................................................111
9.4.2 Record of Operating Hours ............................................................................................................................................114
9.5 REFERENCE DATA.......................................................................................................................................................115
9.5.1 Tightening Torque Values..............................................................................................................................................115
9.5.2 Torque Sequence Diagrams ...........................................................................................................................................115
9.5.3 Conversion Formulas .....................................................................................................................................................115
9.5.4 Approved Lubricants Chart............................................................................................................................................116
9.5.5 Glossary of Abbreviations and Acronyms .....................................................................................................................116
9.6 ADDITIONAL DOCUMENTS ......................................................................................................................................117
9.6.1 Diagrams and Drawings.................................................................................................................................................117
9.6.2 Other Documents............................................................................................................................................................117
June 11, 2009 Page vi
ImVT 120 II Mini Verticus
List of Figures
CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION
Figure 1-1 Compressor Identification Plate ..............................................................................................................................2
Figure 1-2 ImVT 120 II (AP) Front Panel.................................................................................................................................4
Figure 1-3 ImVT 120 II (AP) Rear View..................................................................................................................................5
CHAPTER 2:- - - - - - - - PLC CONTROLLED UNIT OPERATIONS
Figure 2-1 Electrical Panel Front ..............................................................................................................................................8
CHAPTER 3:- - - - - - - - - - - - - - MAINTENANCE AND PARTS
Figure 3-1 IK120 II Compressor Block...................................................................................................................................12
Figure 3-2 Air Flow Diagram..................................................................................................................................................13
Figure 3-3 Lubrication Oil Circuit ..........................................................................................................................................14
Figure 3-4 Oil Sight Glass........................................ ...............................................................................................................15
Figure 3-5 Oil Filler Cap.................................. .......................................................................................................................15
Figure 3-6 Removing the Oil Filter Cover..............................................................................................................................15
Figure 3-7 Replacing the Oil Filter ........................................... ........................................ ......................................................15
Figure 3-8 Intake Filter............................................................................................................................................................17
Figure 3-9 Intermediate Separator...........................................................................................................................................18
Figure 3-10 Valve Operation...................................... ........................................ .......................................................................19
Figure 3-11 IK120II Plate Valve...............................................................................................................................................19
Figure 3-12 IK120 II 1st Stage Valve .......................................................................................................................................21
Figure 3-13 IK120 II 2nd Stage Valves ....................................................................................................................................22
Figure 3-14 Using the Special Tool, P/N 0820 48 .....................................................................................................................23
Figure 3-15 Securing the Intake Valve......................................................................................................................................23
Figure 3-16 IK120 II 3rd Stage Valves.....................................................................................................................................24
Figure 3-17 Removing the 3rd Stage Pressure Valve ...............................................................................................................25
Figure 3-18 Crankcase Assembly..............................................................................................................................................26
Figure 3-19 Piston and Cylinder, 1st Stage, IK120 II ...............................................................................................................28
Figure 3-20 Piston and Cylinder, 2nd Stage..............................................................................................................................29
Figure 3-21 Piston and Cylinder, 3rd Stage ..............................................................................................................................30
Figure 3-22 Piston and Sleeve, 3rd Stage..................................................................................................................................31
Figure 3-23 1st Stage Valve Head and Valve, IK120 II............................................................................................................32
Figure 3-24 2nd Stage Valves and Valve Head.........................................................................................................................34
Figure 3-25 3rd Stage Valves and Valve Head .....................................................................................
Figure 3-26 Flywheel ............................................... .................................... .............................................................................37
Figure 3-27 Intermediate Separator........................................ ....................................... ............................................................38
Figure 3-28 Intake Filter................................................................. ...........................................................................................39
Figure 3-29 IK120 II Cooling System.......................................................................................................................................40
Figure 3-30 Lubrication System Assembly...............................................................................................................................42
Figure 3-31 Automatic Condensate Drain.................................................................................................................................45
Figure 3-32 ACD Operation Diagrams .....................................................................................................................................46
Figure 3-33 ACD System...................................................................................... ....................................................................48
....................................36
Page vii 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-34 ACD Manifold Assembly......................................................................................................................................49
Figure 3-35 Condensate Drain Valve Assembly.......................................................................................................................50
Figure 3-36 Condensate Collector...................................................... ........................................ ...............................................52
Figure 3-37 Condensate Collector...................................................... ........................................ ...............................................53
CHAPTER 4:- - - - - - - - - -IK120 II MAINTENANCE SCHEDULE
There are no Figures in this Chapter
CHAPTER 5:- - - - - - - - - - - - - - - AIR PROCESSING SYSTEM
Figure 5-1 Cartridge Safety Venting.......................................................................................................................................55
Figure 5-2 Purification System Dataplates (typical)...............................................................................................................56
Figure 5-3 P2S Purification System........................................................................................................................................58
Figure 5-4 Oil and Water Separator...................................... ..................................................................................................59
Figure 5-6 Cartridge.......................................................................................... ......................................................................60
Figure 5-5 Oil and Water Separator Labels ............................................................................................................................60
Figure 5-7 Oil and Water Separator...................................... ..................................................................................................63
Figure 5-8 Sintered Metal Filter Assembly.............................................................................................................................63
Figure 5-9 Cartridge Replacement..........................................................................................................................................63
Figure 5-10 P2S Purification System........................................................................... .............................................................65
Figure 5-11 Oil and Water Separator........................................................................................................................................66
Figure 5-12 Securus
®
Electronic Moisture Monitor System.....................................................................................................68
CHAPTER 6:- - - - - - - - - - - - - - -COMPRESSOR UNIT DRIVE
Figure 6-1 Vertical Motor Mount (typical).............................................................................................................................70
CHAPTER 7:- - - - - - - - - - - ELECTRICAL PANEL ASSEMBLY
Figure 7-1 Electrical Panel Assembly.....................................................................................................................................71
Figure 7-2 Electrical Panel Label............................................................................................................................................73
Figure 7-3 Transformer and Fuses ..........................................................................................................................................73
Figure 7-4 Motor Starter and Overload Relay ........................................................................................................................74
Figure 7-5 Electrical Panel Assembly.....................................................................................................................................75
Figure 7-6 PLC CNT-0052 ..................................... ..................................... ...........................................................................77
Figure 7-7 Status Lights.................................. ...................................................................... ..................................................77
Figure 7-8 Securus
Figure 7-9 High Temperature Switch......................................................................................................................................81
Figure 7-10 Low Oil Pressure Switch.......................................................................................................................................81
Figure 7-11 CO Monitor ...................................................... ........................................ .............................................................82
Figure 7-12 Condensate Level Float Switch.............................................................................................................................83
Figure 7-13 PLC Programming Port.........................................................................................................................................84
Figure 7-14 PLC EEPROM.................................................. .....................................................................................................85
Figure 7-15 Overrun Timer Adjustment .......................................... ....................................... ..................................................86
Figure 7-16 Electrical Panel......................................................................................................................................................88
Figure 7-17 Checking Compressor Rotation Direction.............................................................................................................92
®
System.................................................................................................................................................... 80
June 11, 2009 Page viii
ImVT 120 II Mini Verticus
CHAPTER 8:- - - - - - - - PNEUMATIC VALVES AND CONTROLS
Figure 8-1 Pressure Maintaining Valve...................................................................................................................................94
Figure 8-2 Safety Valve.................................... .......................................................................................................................95
Figure 8-3 Digital Pressure Switch......................................................................... .................................................................96
Figure 8-4 Switches and Valves..............................................................................................................................................99
CHAPTER 9:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX
Figure 9-1 Lifting Devices .......................................................................................... ..........................................................103
Figure 9-2 Incoming Power Wiring Label ............................................................................................................................107
Figure 9-3 6 Bolt and 4 Bolt Torque Sequence .....................................................................................................................115
Page ix 1st Edition, Rev. 0 Chg. 10
MNL-0408
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 serious 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 moderate 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 maintenance technician for proper maintenance and utilization of the equipment.
June 11, 2009 Page 1
ImVT 120 II Mini Verticus
BAUER
COMPRESSORS
BAUER COMPRESSORS, INC.
NORFOLK, VIRGINIA U.S.A
LBL-004
MODEL NO.
BLOCK NO.
CAPACITY
CFM
CHG. RATE
CFM
MOTOR HP
SPEED
RPM
SERIAL NO.
PRESSURE
PSIG
VOLTS
PH
HZ AMPS
DATE OF MANUFACTUREDATE OF MANUFACTURE
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 TCom-25
Serial Number 32165
Date of Manufacture 02/2005
Quantity required 2
Part Number N04860
Part Description Valve
Figure 1-1 Compressor Identification Plate
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^ WARNING
The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be
life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore,
Bauer Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are
installed.
1.3 How to Use the Appendix
Information contained in the Appendix to this manual includes the following.
• The safety instructions applicable to this product. They must be read, understood and complied with
prior to operating the product.
• The instructions for installing this product. They must be read, understood and complied with prior to
operating the product.
• The instructions for long term storage (over 90 days) of this product.
• Reproducible Forms
• Reference Data
• Torque Values
• Torque Sequence
• Conversion Formulas
• Approved Lubricants
• Glossary of Abbreviations & Acronyms
• Additional Documents
June 11, 2009 Page 3
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1.4 Compressor Unit Design
The ImVT 120 II Mini Verticus high pressure compressor unit is used for applications in the high
pressure range, up to 5000 psig (350 bar). The compressor units of this series are manufactured with a
standard type frame with enclosure panels. Standard equipment includes an automatic condensate drain
system, instrument panel with oil pressure and interstage pressure, hourmeter, and a P2 purification sys-
®
tem with Securus
ticus compressors is 700 to 750 lbs.
1.4.1 Compressor Unit Major Assemblies
The compressor unit is comprised of the following major assemblies.
Compressor Block Drive Motor Base and Frame Assembly
Automatic Condensate Drain System Electric Control System Enclosure Panels
Figure 1-2 ImVT 120 II (AP) Front Panel
moisture monitoring system. The approximate weight of the ImVT 120 II Mini Ver-
1. Compressor Control Switch
2. Warning Lamp
3. Alarm Lamp
4. Hourmeter
Page 4 1st Edition, Rev . 0 Chg. 10
5. Motor Reset Button
6. Emergency Stop Switch
7. Compressor Oil Pressure Gauge
8. Interstage Air Pressure Gauges
MNL-0408
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Figure 1-3 ImVT 120 II (AP) Rear View
1. Securus® Monitor
2. Securus® Chamber
3. Final Pressure Switch
4. Pressure Maintaining Valve
5. Air Outlet
6. Check Valves
7. Purification Chamber Vent Valve
8. Final Pressure Gauge
9. Securus® Chamber Wrench Holder
June 11, 2009 Page 5
1.5 Technical Specifications
All technical data is subject to change without prior notice.
Medium Air
Free Air Delivery 7.0 scfm ((198 l/min)
Inlet pressure atmospheric
Operating pressure, max. 5,000 psig (350 bar)
Ambient temperature range 41 to 113 °F (5 to 45 °C)
1.5.1 Compressor Block
IK120 II Mod. 7
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 87 - 102 psig (6 - 7 bar)
Safety valve setting, 1st stage 131 psig (9 bar)
Intermediate pressure, 2nd stage 464 -711 psig (40 - 49 bar)
Safety valve setting, 2nd stage 870 psig (60 bar)
Direction of rotation when facing flywheel CCW
Compressor speed 1,385 RPM
Oil capacity 2.96 qts.(2.8 liters)
Oil Pressure 58 - 87 psig (4 - 6 bar)
Recommended oil BAUER OIL-0024
Maximum Inclination 10° in all directions
ImVT 120 II Mini Verticus
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1.5.2 Compressor Drive Motor Model Voltage, Phase, Frequency Power RPM Type Part No.
-E3 208-460 VAC, 3Φ, 60 Ηz 7.5 Hp 3,600 ODP MTR-0033
1.5.3 Purification System Applicability
®
The purification system supplied with this order is the P2 system with the Securus
Moisture Monitor-
ing System.
1. Referenced to standard inlet conditions of 68°F and 60% humidity at sea level.
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CHAPTER 2: PLC CONTROLLED UNIT OPERATIONS
2.1 Pre-start Checks
1. Ensure that all scheduled maintenance is completed.
2. Check compressor oil level. Refer to Chapter 3.
3. Check Emergency Stop Switch is pulled out.
2.2 Start-up Procedure
(See Figure 2-1)
1. Verify that all connections downstream of the compressor are secure.
2. Apply electric power to the unit.
3. Pull out Emergency Shop Switch.
4. Turn the Compressor Control Switch to the ON position.
2.3 Post Start Procedures
1. Allow the compressor to build up pressure. Monitor the pressure gauge.
2. Listen to the unit as it operates. If excessive knocking or vibrations are observed shut down the unit.
3. Allow the compressor to reach full pressure.
2.4 Normal Operations
The compressor will operate automatically as needed while the Control Switch is in the ON position,
The Emergency Stop Switch is pulled out, power is applied to the control circuit and there are no fault
conditions.
2.5 Shutdown Procedures
1. Verify all bottle valves and fill valves are closed.
2. Turn the Compressor Control Switch to the OFF position.
3. Leave Emergency Stop Switch pulled out for at least 8 hours every 30 days to maintain the charge
on the internal PLC battery and preserve the PLC operating memory.
4. If the compressor is to remain idle for six months or longer, refer to the Appendix titled, Long Term
Storage for preservation instructions.
June 11, 2009 Page 7
2.6 Electric Panel Components
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See Figure 2-1
Figure 2-1 Electrical Panel Front
ImVT 120 II Mini Verticus
1. Compressor Control Switch
2.6.1 Emergency Stop Switch.
The Emergency Stop Switch is a switch with a large, red mushroom head. The button must be pulled
out for the unit to operate. In an emergency, depress the push button, which will shutdown the electric
motor and all other periphery devices. Do not use the Emergency Stop Switch for securing the equipment under normal operation, use the Compressor Control Switch. The PLC operating memory is maintained by a internal battery in the PLC. Removing all power from the compressor will allow the battery
to discharge over a 30 day period. To recharge the PLC battery apply power to the unit, put the Control
Switch in the OFF position, pull out the Emergency Stop Switch, and allow the battery to charge for at
least 8 hours every 30 days.
2.6.2 Starter Reset
The Starter Reset is a blue push button with the lette r “R” at its center. Pushing this button will reset the
thermal overload relay on the motor starter. Should the electric motor have overloaded and tripped out
Page 8 1st Edition, Rev . 0 Chg. 10
2. Warning Light
3. Alarm Light
4. Hourmeter
5. Starter Reset
6. Emergency Stop Switch
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during normal operation, then depressing this button after giving the motor starter some time to cool,
will reset the overload relay portion of the motor starter. An Overload Fault is indicated by the red
Alarm Light on steady (not flashing).
2.6.3 Compressor Control Switch
2.6.3.1 2-Position (Standard)
OFF Position - The Compressor Control Switch switch must be in the OFF position when securing the
compressor system.
ON Position - The Compressor Control Switch switch must be in the ON position to operate the compressor system. When positioning the switch to the ON position, it will illuminate Green. The compressor will start and stop automatically based on the status of the pressure switch.
2.6.4 Indicator Lamps
2.6.4.1 PLC Warning and Alarm Lamps
2.6.4.1.1 Warning Lamp - Amber
The Warning Lamp is a LED lamp for long trouble free life. This lamp will flash a code IAW the logic
of the PLC. See Paragraph 2.7.
2.6.4.1.2 Alarm Lamp - Red
The Alarm Lamp is a LED lamp for long trouble free life. This lamp will flash a code IAW the logic of
the PLC. See Paragraph 2.8.
2.6.5 Hourmeter
The panel is supplied with an hourmeter. The hourmeter is not resettable and used to monitor the run
hours of the compressor. It is powered with a 120 VAC signal supplied from the auxiliary contact on
the motor starter.
2.6.6 PLC Control
This panel will be controlled with a T elemecanique 16 I/O Twido Programmable Logic Controller . This
unit will provide logical operations to the overall system that includes the high pressure compressor,
purification systems, and other accessories.
2.7 Warnings
The amber Warning Lamp located on the control panel flashes warning codes with a 0.5 second on, 0.5
second off sequence with a distinct pause between sequences. In addition the light will illuminate on
initial start up for a period of 5 seconds, to serve as a lamp test function. The lamp is a LED lamp for
long trouble free life.
2.7.1 One Flash - Final Separator Warning
The compressor unit is equipped with a final separator. To prevent fatigue failure of this pressure vessel, the PLC program monitors the pressurization, de-pressurization cycles of the separator and will
first issue a Warning, and then an Alarm. The program is set up to provide the warning at 90% of the
maximum recommended number of cycles. The program is configured to reflect these values when it is
built. When the warning is illuminated, the unit will still continue to function properly, but will prompt
the operator to contact Bauer Compressors for making arrangements to replace the Final Separator.
When the Alarm level has been achieved, the compressor will no longer function, and will require the
replacement of the Final Separator . Once the Final Separator is repla ced, the unit can be re-activated by
making adjustments to the PLC. Please contact Bauer Product Support for detailed instructions on this
procedure.
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^ WARNING
Do not attempt to override the Separator Shutdown Warning.
This feature is provided to protect personnel from injury or death.
2.7.2 Two Flashes - Securus Monitor (Optional)
The compressor purification system may be equipped with an optional Securus® Electronic Moisture
Monitor. This consists of a control module and cable connected to the purification chamber. It functions
as a capacitive sensor, sensing the moisture in the purified air. When the chemicals in the purification
cartridges have reached the point where they retain a set level of moisture, the Securus® monitor will
issue a warning via the amber Warning Light. On a Securus® Warning condition, the compressor will
run normally, the PLC I7 lamp will illuminate, and the warning code will flash. This warning is meant
to prompt the operator to schedule replacement of the purification cartridge.
2.8 Alarms
The red Warning Light located on the control panel flashes warning codes with a 0.5 second on, 0.5
second off sequence with a distinct pause between sequences.In addition the light will illuminate on initial start up for a period of 5 seconds, to serve as a lamp test function. The lamp is a LED lamp for long
trouble free life.
2.8.1 One Flash - Compressor High Temperature
The compressor high temperature switch is located on the compressor block, third, fourth or fifth stage
head, depending on model. Under normal operating conditions, the switch is closed and the I1 lamp on
the PLC is illuminated. On a high temperature condition, the compressor will shutdown, the I1 lamp
will extinguish, and the alarm code will flash.
2.8.2 Two Flashes - Compressor Low Oil Pressure
The compressor oil pressure switch is located on the back of the compressor block, mounted with the
oil pressure gauge. The switch is N.O., Normally Open, and is connected to the PLC on terminal I2.
During startup of the compressor, the oil pressure switch is bypassed for a period of 45 seconds to allow
the oil pressure to stabilize, then the switch will close. Then should the compressor lose oil pressure, the
compressor will shutdown, the I2 lamp will extinguish, and the alarm code will flash.
2.8.3 Three Flashes - Compressor Overtime
The compressor has an overtime function, where if the compressor runs continuously for 5 hours, then
the compressor will shutdown, and the alarm code will flash. This is done to secure the equipment if it
were to be started and left unattended.
2.8.4 Four Flashes - Securus Monitor
®
The compressor purification system is equipped with a Securus
Electronic Moisture Monitor. This
consists of a control module and cable connected to the purification chamber. It functions as a capacitive sensor, sensing the moisture in the purified air. When the chemicals in the purification cartridge has
reached the point where it retains a set level of moisture, the Securus
®
the red Alarm Light. On a Securus
ALARM condition, the compressor will shutdown, the PLC I5
®
monitor will issue an alarm via
lamp will be illuminated, and the alarm code will flash.
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2.8.5 Five Flashes - Carbon Monoxide Monitor (Optional)
The compressor system may be equipped with an optional Carbon Monoxide Monitor. This consists of
an electronic module that samples the compressed air supply. The unit will provide a continuous display of the CO level in PPM, parts per million. If the CO level becomes excessively high, then the red
alarm light on the face of the monitor will illuminate. At the same time the alarm relay in the CO Monitor which is connected to the PLC I4 will generate a CO ALARM condition.The compressor will shutdown, the I4 lamp will illuminate, and the alarm code will flash.The unit should be calibrated with a
test gas monthly. Refer to the chapter titled CO Monitor for this procedure.
2.8.6 Six Flashes - Final Separator Shutdown
^ WARNING
Do not attempt to override the Final Separator Shutdown. This feature is
provided to protect operating personnel from injury or death.
The high pressure-breathing compressor is equipped with a final separator. To prevent fatigue failure of
this vessel, the PLC program monitors the pressurization, de-pressurization cycles of the separator and
will issue a Warning, and then later an Alarm. The program is set up to provide a warning at 90% of the
maximum recommended number of cycles. The program is configured to reflect these values when it is
built. When the warning is illuminated, the unit will still continue to function properly, but will prompt
the operator to contact Bauer Compressors for making arrangements to replace the separator. When the
Alarm level has been achieved, the compressor will no longer function, and will require the replacement of the separator . Once this is accomplished, the unit can be re-activated by making adjustments to
the PLC. Please contact Bauer Product Support for detailed instructions
2.8.7 Seven Flashes - Condensate Fault (OPT)
The optional compressor condensate level float switch is located in the condensate collection tank.
Under normal operating conditions, the switch is open and the I6 lamp on the PLC is off. On a high
condensate level the float switch will close, the compressor will shutdown, the PLC I6 lamp will illuminate, and the alarm code will flash. The operator should drain the condensate from the tank and resume
operation of the equipment.
NOTICE
The compressor condensate contains some oil, and accordingly, should be disposed of in accordance with state and local regulations.
2.8.8 On Steady - Motor Starter Overload Trip
The compressor overload relay is located in the electrical enclosure, directly beneath the motor starter.
The relay is Normally Open and is not connected to the PLC, but is connected directly to the red Alarm
Light. Under normal operating conditions, the switch is open. On an Overload Trip of the motor, the
compressor will shutdown, and the Alarm Light will be illuminated steady (no flash sequence).
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CHAPTER 3: MAINTENANCE AND PARTS
3.1 Compressor Blocks - IK120 II
3.1.1 Description
The IK120 II compressors are used to compress air up to 5000 psi. The compressor is a three cylinder,
three stage air cooled, oil lubricated reciprocating compressor. 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. The compressor block are particularly suitable for continuous operation because of it’s rugged design and corrosion resistant intermediate filter and cooler assemblies.
3.1.2 Component Location
Figure 3-1 IK120 II Compressor Block
1. 1st Stage Cylinder
2. Intake Filter
3. Oil Filler Neck
4. 3rd Stage Cylinder
5. 2nd Stage Safety Valve
6. Oil Filter Housing
7. 2nd Stage Intermediate Separator
8. 2nd Stage Intercooler
9. Condensate Drain Connection
10. 1st Stage Safety Valve
11. Aftercooler
12. 2nd Stage Cylinder
13. 1st Stage Intercooler
14. Oil Drain Tap
15. Air Outlet Connection
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Purification
System
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3.1.3 Air Flow Diagram
Refer to Figure 3-2. The air is drawn in through intake filter (1), compressed to the final pressure in cylinders (2, 3, 4,) and cooled by intercoolers (5, 6) and aftercooler (7). The safety valves (8,9, 10) protect
from overpressure in the individual stages. The compressed air is filtered by intermediate separator (11)
and oil and water separator assembly (12). The intermediate 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 purification system
from the start of delivery , thus achieving constant optimum purification. The parts in the shaded box are
part of the Purification System which may be a factory installed option.
Figure 3-2 Air Flow Diagram
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
8. 1st Stage Safety Valve
9. 2nd Stage Safety Valve
10. Final Pressure Safety Valve
11. Intermediate Separator
12. Oil and Water Separator
13. Pressure Maintaining Valve
14. Manual Condensate Drain 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.
June 11, 2009 Page 13
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The minimum pressure valve (3) allows for oil pressure indication at a pressure gauge and/or electronic
oil pressure monitoring.
Figure 3-3 Lubrication Oil Circuit
1. Oil Pump
2. Oil Filter
4. Guide Piston
5. Oil Sight Glass
3. Minimum Pressure Valve
3.1.4.2 Type of Oil
For proper care and maintenance of the compressor, using the correct oil is of vital importance. Due to
the thermal load on the compressor only high quality oil should be used. You are recommended to
restrict oils to those which have been approved by us and are listed in the compressor block specifications found in Chapter 1.
Page 14 1st Edition, Rev . 0 Chg. 10
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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 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 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.
June 11, 2009 Page 15
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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 tap.
^ 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
Venting of the Oil Pump may be necessary if after maintenance work, oil pressure is low or not built up
after starting the unit, or if the unit should have been running backwards because of a wrong phase
sequence.
1. Open all the condensate drain valves to avoid building up pressure.
2. Start the compressor.
3. See Figure 3-7. Loosen the cap screw and plug (2) and wait until oil pours out free of air bubbles.
4. Tighten the cap screw and plug.
5. Stop compressor, close all condensate drain valves and check oil level.
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3.1.6 Intake Filter.
Figure 3-8 Intake Filter
4
1. Knurled Nut
2. Washer
3
3. Filter Housing
4. Filter Element
2
1
3.1.6.1 Description
A dry, micronic filter is used to filter the intake air, see Figure 3-8
The filter cartridge must be changed at regular intervals. See the Maintenance Schedule for the recom-
mended interval.
1. Unscrew and remove Knurled Nut (1)
2. Remove Washer (2) and Filter Housing (3).
3. Discard Filter Element (4) and replace with new Filter Element Bauer Part Number N25950.
4. Reassemble in reverse order.
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3.1.7 Intermediate Separator
An intermediate separator is mounted on the compressor between the 2nd and 3rd stage. 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 3-9 Intermediate Separator
1. Vortex Plate
2. Hollow Screw
3. Center Insert
4. O-ring
5. Knurled Nut
6. Gasket
7. Fitting
8. Safety Valve
^ WARNING
The rapid depressurizing and repressurizing of the intermediate separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or
death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one
depressurization- repressurization. The Bauer recommended frequency of condensate draining is every
fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and
maintaining the quality of the delivered air.
3.1.7.1 Maintenance
The Intermediate Separator P/N 081799 requires no maintenance.
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3.1.8 Cooling
3.1.8.1 General
The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this
purpose the compressor is equipped with a fanwheel which draws the cooling air through the unit. The
fanwheel is driven by the drive motor V-belt and is also used as the compressor flywheel.
3.1.9 Valves and Heads
3.1.9.1 Functional Description
The valve heads of the individual stages form the top part of the cylinders. (See Figure 3-10). The
intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the
flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylinders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve.
Figure 3-10 Valve Operation
Intake Discharge
Figure 3-11 IK120II Plate Valve
TOP VIEW
Intake Side
Pressure Side
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3.1.9.2 General Instructions for Changing the Valves
• Always replace valves as a complete set.
• Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and
clean with a soft brush. If possible, use an ultrasonic cleaner.
• Check the individual components for excessive wear. If the valve seat or valve discs are dented,
replace the valves.
• Check the valve space in the valve heads for dirt, and clean if necessary.
• Use only satisfactory gaskets and O-rings during reassembly.
• Observe the correct sequence when reassembling.
• After finishing all maintenance work on the valves, turn the compressor manually using the flywheel
and check whether all items have been correctly installed.
• 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and
retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.
• Remove and check the valves every 1000 operating hours.
• Replace the valves every 2000 operating hours to avoid fatigue failure.
3.1.9.3 Changing the IK120 II 1st Stage Valves
The intake and pressure valve of the IK120 II 1st stage are in a combined plate valve under the valve
head. Refer to Figure 3-12 and proceed as follows:
1. Remove all tubing connections and lines from the Valve Head (2).
2. Remove all Hex Head Screws.
3. Remove Valve Head (2).
4. Note orientation of Plate Valve (1) before removing it.
5. Reassembly is the reverse of the above steps.
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Figure 3-12 IK120 II 1st Stage Valve
5
6
7
1. Plate Valve
2. Valve Head
3. Washer
4. Hex Head Screw
4
3
2
1
5. Hex Head Screw
6. Washer
7. O-ring
June 11, 2009 Page 21
3.1.9.4 IK120 II 2nd Stage Valves
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3.1.9.4.1 Removing the Valves of the 2nd Stage
Figure 3-13 IK120 II 2nd Stage Valves
ImVT 120 II Mini Verticus
1. Cap Nut
2. Stud
3. Pressure Plug
4. O-ring
5. Pressure Valve Insert
6. Intake Valve
7. 2nd Stage Valve Head
8. Allen Screw
See Figure 3-13 and proceed as follows:
1. Remove the intake and pressure lines from the Valve Head (7).
2. Remove the screws (8) holding the Valve Head (7) onto the cylinder.
3. Insert two 8mm diameter metal pins, any length, in the holes in the valve head and secure them in a
vise with the valve head on top.
4. Using the special tool provided with the unit, remove the intake valve (6) (See Figure 3-14).
5. Turn the valve head over and replace it on the metal pins.
6. Remove the cap nut (1).
7. Unscrew the stud (2) approximately five turns.
8. Remove the pressure plug (3) and take out the valve parts.
9. Clean the intake and pressure valves and check for wear.
10. Clean and check the valve spring.
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11. Clean the valve head. Check that the intake and pressure valve bores are in perfect condition.
12. Using a precision straightedge, check that the underside of the valve head is flat. If necessary use an
emery cloth to smooth out the surface.
Figure 3-14 Using the Special Tool, P/N 082048 Figure 3-15 Securing the Intake Valve
^ CAUTION
In order to avoid damaging the special tool or the valve when using the tool, ensure that it is pushed properly and firmly into the valve so that it will not tilt when it is turned.
NOTICE
Valve seats and plate valves must not show any signs of wear or damage.
Replace damaged or worn parts.
3.1.9.4.2 Reassembling the Valves of the 2nd Stage.
1. Replace the intake valve (6) using the special tool to tighten it.
^ CAUTION
The intake valve plate and valve spring must not be jammed.
2. Check the intake valve functions correctly by blowing compressed air through the valve in the
direction of flow.
3. Secure the intake valve as follows: (See Figure 3-17) Peen the valve head aluminum over the screwin thread of the intake valve in two places opposite one another. Us e a small drift pin, approximately
5mm in diameter.
4. Insert the O-ring (4) and the pressure valve parts(5).
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5. Check the pressure valve function and stroke by lifting the valve parts.
6. Ensure the stud (2) is unscrewed, then screw in the pressure plug (3)and tighten.
7. Screw the stud (2) in firmly, fit a new gasket and secure it with the cap nut (1).
8. Replace the valve head (7) on the cylinder and secure it with the screws (8).
9. Reconnect the intake and pressure lines.
3.1.9.5 IK120 II 3rd Stage Valves
3.1.9.5.1 Removing the Valves of the 3rd Stage Figure 3-16 IK120 II 3rd Stage Valves
1. Intake Valve
2. Valve Head
3. O-ring
5. Valve Head Cover
6. Stud
7. Gasket
8. Cap Nut
9. Allen Screw
10. Washer
4. Pressure Valve
1. Remove the intake and pressure lines from the valve head (2).
2. Remove the cap nut (8) and loosen stud (6) three or four turns.
3. Remove the screws (9) holding the valve head onto the cylinder and take off valve head cover (5).
4. Remove the 3rd stage pressure valve by putting two screwdrivers into the removal groove of the
pressure valve body. See Figure 3-17. It may be necessary to loosen the valve body first by turning
it with a 13 mm wrench used on the flat surfaces.
Page 24 1st Edition, Rev . 0 Chg. 10
MNL-0408
5. Insert two 8mm diameter metal pins, any length, in the holes in the valve head and secure them in a
vise with the valve head on top of the vise. The intake valve (1) should be facing up.
6. Using the special tool (See Figure 3-14) provided with the unit, remove the intake valve (1).
Figure 3-17 Removing the 3rd Stage Pressure Valve
3.1.9.5.2 Reassembling the Valves of the 3rd Stage
1. Replace the intake valve (1) using the special tool to tighten it.
2. Check the intake valve functions correctly by blowing compressed air through the valve in the
direction of flow.
3. Secure the intake valve as follows: (See Figure 3-17) Peen the valve head aluminum over the screwin thread of the intake valve in two places opposite one another. Us e a small drift pin, approximately
5mm in diameter.
4. Reinstall the pressure valve (4) by putting O-ring (3) into valve head (2). Check it for abrasions.
5. Insert pressure valve through O-ring and into valve bore.
6. Put on valve head cover (5).
7. Reassemble valve head cover and valve head to cylinder. Torque screws (9) to the proper value.
8. Screw in stud (6). Put on gasket (7). Screw on cap nuts (8).
June 11, 2009 Page 25
3.1.10 Replacement Parts List
Figure 3-18 Crankcase Assembly
ImVT 120 II Mini Verticus
8
27
28
16
6
2
3
4
9
10
26
25
5
4
7
29
30
19
1
23
24
11
12
22
13
14
15
16
20
21
17
18
19
22
# KIT Qty Part No. Description Notes
◊ 1 076743 Crankcase assembly
1 … 1 076740 Crankcase
2 … 1 083399 Crankshaft, complete IK120 II
3 … 1 N2638 Roller Bearing
4 … 2 N2635 Circlip
5 … 1 66209 Bearing Cap
6 … 1 N15406 Roller Bearing
7 … 1 N15265 O-ring
8 … 1 66684 Cover
9 … 1 N170 Shaft Seal
10 … 1 N3745 O-ring
11 … 1 61054 Plug
12 … 1 N15412 O-ring
Page 26 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-18 (cont.) Crankcase Assembly
# KIT Qty Part No. Description Notes
13 … 1 73830 Oil Filling Pipe
14 … 1 N4776 O-ring
15 … 2 SCR-0020 Allen Screw
16 … 8 WAS-0021 Washer
17 a.. 2 N4261 Gasket
18 … 2 PLU-0040 Plug
19 … 2 N25475 Oil Sight Gauge
20 … 1 N1316 Gasket
21 … 1 N4570 Plug
22 … 2 78038 Support
23 … 4 WAS-0030 Spring Washer
24 … 4 NUT-0076 Hex Nut
25 … 4 WAS-0031 Washer
26 … 4 N350 Hex Head Screw
27 … 6 SCR-0113 Hex Head Screw
28 … 3 N16126 Countersunk Screw
29 … 1 N2375 Coupling
30 … 1 N25638 Ball Valve
June 11, 2009 Page 27
Figure 3-19 Piston and Cylinder, 1st Stage, IK120 II
1
2
3
4
4
5
7
8
9
6
ImVT 120 II Mini Verticus
# KIT Qty Part No. Description Notes
◊ 1 080826 Piston and Cylinder Assembly IK120 II
1 … 1 080734 Cylinder IK120 II
2 ..c 1 N4654 O-ring
3 … 1 069975 Piston Assembly Items 3 - 61Piston
5 … 1 N802 Piston Pin
6 … 1 N1787 Piston Ring Set
4 … 2 N484 Circlip
7 … 4 N215 Stud
8 … 4 WAS-0021 Washer
9 ..c 4 NUT-0119 Self Locking Hex Nut
Page 28 1st Edition, Rev . 0 Chg. 10
MNL-0408
1
2
3
4
5
6
7
8
9
9
10
11
Figure 3-20 Piston and Cylinder, 2nd Stage
# KIT Qty Part No. Description Notes
◊ 1 062889 Cylinder Assembly
1 … 1 062477 Cylinder
2 ..c 1 N7063 O-ring
3 … 1 080383 Guide Cylinder
4 ..c 1 N2640 O-ring
5 … 4 NUT-0119 Self Locking Hex Nut
6 … 4 WAS-0021 Washer
7 … 4 N2790 Stud
◊ 1 072249 Piston Assembly, Complete Items 8 - 11
8 … 1 062487 Piston
9 … 2 N484 Circlip
10 … 1 N1429 Piston Pin
11 … 1 N2647 Piston Ring Set
June 11, 2009 Page 29
Figure 3-21 Piston and Cylinder, 3rd Stage
1
2
3
4
5
6
7
8
9
10
11
12
13
ImVT 120 II Mini Verticus
# KIT Qty Part No. Description Notes
◊ 1 083400 Cylinder Assembly
1 … 1 078043 Piston and Sleeve Assembly (See Figure 3-22)
2 a.. 1 N4868 O-ring
3 … 1 082480 Cylinder
4 ..c 1 N7063 O-ring
5 … 1 083404 Guide Cylinder
6 ..c 4 NUT-0119 Self Locking Hex Nut
7 … 4 WAS-0021 Washer
8 … 4 N2790 Stud
9 ..c 1 N2640 O-ring
10 … 1 072165 Guide Piston Assembly Items 11 - 13
11 … † – Guide Piston Available only with 072165
12 … † – Piston Pin Available only with 072165
13 … 2 N484 Circlip
Page 30 1st Edition, Rev . 0 Chg. 10
MNL-0408
1
2
3
4
Figure 3-22 Piston and Sleeve, 3rd Stage
# KIT Qty Part No. Description Notes
◊ 1 078043 Piston and Sleeve Assembly
1 … † — Piston Available only with 078043
2 a.. 1 N23755 O-ring
3 … † — Piston Liner Available only with 078043
4 … 1 N25376 Piston Ring Set
June 11, 2009 Page 31
Figure 3-23 1st Stage Valve Head and Valve, IK120 II
ImVT 120 II Mini Verticus
5
6
7
4
3
2
1
# KIT Qty Part No. Description Notes
◊ 1 080688 1st Stage Valve Head Assembly IK120II
1 .b. 1 N26531 Plate Valve IK120 II
2 … 1 080677 Valve Head IK120 II
3 … 6 Washer
4 … 6 N1262 Allen Screw
5 … 1 N28108 Allen Screw
6 … 1 WAS-0021 Washer
7 … 1 N1539 O-ring
Page 32 1st Edition, Rev . 0 Chg. 10
1
2
3
4
5
9
8
6
10
7
This page is inserted to provide proper page sequencing
Figure 3-24 2nd Stage Valves and Valve Head
20
ImVT 120 II Mini Verticus
19
18
17
16
8
15
1
7
6
2
5
4
13
12
11
14
9
10
3
7
# KIT Qty Part No. Description Notes
◊ 1 069955 2nd Stage Valve Head Assembly
1 … 1 14123 Valve Head
2 .b. 1 012841 Intake Valve Assembly Items 3 - 7
3 … † – Intake Valve Body Available only with 012841
4 … † – Spring Available only with 012841
5 … † – Valve Plate Available only with 012841
6 … † – Valve Seat Available only with 012841
7 a.. 2 240 Gasket
8 … 1 014582 Pressure Valve Assembly Items 9, 15 - 20
9 .b. 1 012835 Pressure Valve Insert Items 10 - 14
10 … † – Valve Seat Available only with 012835
11 … † – Valve Plate Available only with 012835
12 … 1 1026 Spring
Page 34 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-24 (cont.) 2nd Stage Valves and Valve Head
# KIT Qty Part No. Description Notes
13 … † – Valve Insert Available only with 012835
14 a.. 1 N3521 O-ring
15 … 1 14332 Spring Washer
16 … 1 14124 Coupling
17 .b. 1 71064 Stud
18 a.. 1 N380 Gasket
19 … 1 N84 Cap Nut
20 … 6 SCR-0180 Allen Screw
June 11, 2009 Page 35
Figure 3-25 3rd Stage Valves and Valve Head
1
2
3
4
5
6
7
8
9
10
ImVT 120 II Mini Verticus
# KIT Qty Part No. Description Notes
◊ 1 082096 Valve Head Assembly
1 .b. 1 081409 Intake Valve
2 … 1 082087 Valve Head
3 … 1 N2789 O-ring
4 .b. 1 014121 Discharge Valve
5 … 1 082086 Valve Head Cover
6 .b. 1 N3738 Stud
7 a.. 1 N3625 Gasket
8 … 1 N3589 Acorn Nut
9 … 6 N17730 Screw
10 … 6 N58 Washer
Page 36 1st Edition, Rev . 0 Chg. 10
MNL-0408
1
2
3
4
5
6
7
8
Figure 3-26 Flywheel
# KIT Qty Part No. Description Notes
◊ 1 082552 Flywheel Assembly
1 … 1 N1386 Feather Key
2 … 1 082553 Fanwheel Hub
3 … 1 080975 Washer
4 … 1 N176 Spring Washer
5 … 4 N26666 Screw
6 … 1 082496 Fanwheel
7 … 4 N108 Spring Washer
8 … 4 N19548 Screw
June 11, 2009 Page 37
Figure 3-27 Intermediate Separator
ImVT 120 II Mini Verticus
4
8
1
2
3
5
6
7
# KIT Qty Part No. Description Notes
◊ 1 081799 Intermediate Separator Assembly
1 … 1 81148 Plate
2 … 1 81643 Hollow Screw
3 … 1 76613 Inset Assembly
4 … 1 N3556 O-ring
5 … 1 13937 Knurled Ring
6 … 1 N1316 Gasket
7 … 1 N20215 Fitting
8 … † — Safety Valve See Figure 3-29
Page 38 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-28 Intake Filter
7
6
5
4
3
2
1
# KIT Qty Part No. Description Notes
◊ 1 079577 Intake Filter Assembly
1 … 1 N4870 Knurled Nut
2 … 1 N3313 Washer
3 … 1 79574 Filter Housing, Front
4 a.. 1 N25950 Filter Element
5 … 1 79575 Filter Housing, Back
6 … 1 N19502 Hex Head Bolt
7 … 1 N3374 Clamp
June 11, 2009 Page 39
Figure 3-29 IK120 II Cooling System
29
28
4
27
26
3
32
33
20
12
13
25
24
12
12
11
21
22
23
12
13
14
15
6
1
12
11
12
13
5
16
17
18
12
19
11
19
12
2
10
8
9
7
31
30
ImVT 120 II Mini Verticus
# KIT Qty Part No. Description Notes
◊ 1 083456 IK120II Cooling System
1 … 1 081309 Intercooler, 1st to 2nd Stage
2 … 1 078195 Intercooler, 2nd to 3rd Stage
3 … 1 070724 Aftercooler
4 … 1 078200 Fanwheel Guard
5 … 1 081802 Safety Valve, 1st Stage
6 … 1 072935 Safety Valve, 2nd Stage
7 … 8 062773 Mounting Bracket
8 … 8 WAS-0024 Washer
9 … 8 NUT-0118 Self Locking Hex Nut
10 … 8 N3494 Stud
11 … 4 N20059 Fitting
Page 40 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-29 (cont.) IK120 II Cooling System
# KIT Qty Part No. Description Notes
12 … 9 N1316 Gasket
13 … 3 N20195 Male Connector
14 … 1 N4530 Plug
15 … 1 N3610 Cap
16 … 1 N20327 Tee
17 … 1 N15175 Plug
18 … 1 N7433 Cap
19 … 2 N26751 Coupling
20 … 1 N20183 Connector
21 … 2 77894 Clamp
22 … 2 N2460 Washer
23 … 2 SCR-0020 Allen Screw
24 … 1 N52 Plug
25 … 1 78197 Tubing Assembly
26 … 3 78199 Stud
27 … 3 11887 Mounting Bracket
28 … 3 WAS-0021 Washer
29 … 3 NUT-0119 Self Locking Hex Nut
30 … 1 N20310 Fitting
31 … 1 083454 Tubing Assembly
32 … 1 71148 Fitting
33 … 1 56983 Gasket
June 11, 2009 Page 41
Figure 3-30 Lubrication System Assembly
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
15
16
16
16
17
17
18
ImVT 120 II Mini Verticus
# KIT Qty Part No. Description Notes
◊ 1 081075 Lubricating System Includes Items 1 - 15
1 … 1 077885 Oil Filter Cover
2 … 1 N4058 O-ring
3 … 1 N25327 O-ring
4 … 1 77774 Rubber Gasket
5 a.. 1 N25326 Filter Element
6 … 1 77878 Cover Plate
7 … 2 N25328 Allen Screw
8 … 2 N2889 Gasket
9 … 1 78421 Gasket
10 … 1 N24585 Gear Pump
11 … 2 RNG-0070 O-ring
12 … 2 N19506 Hex Head Screw
Page 42 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-30 (cont.) Lubrication System Assembly
# KIT Qty Part No. Description Notes
13 … 2 WAS-0021 Washer
14 … 1 077970 Regulating Valve
15 … 4 N1316 Gasket
16 … 3 N52 Plug
17 … 1 076757 Connecting Tube Assembly
18 … 1 N2037 Male Connector
June 11, 2009 Page 43
ImVT 120 II Mini Verticus
3.1.11 Troubleshooting
3.1.11.1 Troubleshooting Table
Trouble Cause Remedy
No oil pressure Low oil level Check oil level
Oil foam in crankcase
Compressor output insufficient
Safety valves between stages
releasing pressure
Compressor running too hot.
1. Last stage piston worn
2. Last stage pressure valve
defective
1. Condensate drain valve(s)
or fittings leaking.
2. Premature opening of final
safety valve.
3. Piston rings worn
4. Excessive piston clearance
5. Pipes leaking
1. Intermediate pressure too
high
2. Valves not closing properly
1. Insufficient supply of cooling air
2. Intake or outlet valve not
closing properly
3. Wrong direction of rotation.
1. Operate compressor with
final stage valve head
removed. If oil flows continuously out of cylinder,
replace piston and sleeve.
2. Replace last stage valves.
1. Tighten and reseal.
2. Clean and adjust final
safety valve.
3. Replace
4. Replace
5. Tighten
1. Service and clean valves.
2. Service and clean valves.
1. Check location for adequate
ventilation
2. Check and clean valves,
replace as necessary
3. Check arrow on compressor
and correct accordingly.
Oil residue in delivered air
Compressor rotates in the wrong
direction
Page 44 1st Edition, Rev . 0 Chg. 10
1. Improper maintenance of
filters, purifier cartridge
saturated.
2. Wrong oil type
Electrical phases not connected
properly
1. Service filters, change purifier cartridge.
2. Change to proper oil and
clean valves.
Reverse two of the three phase
leads at the switch box. Do NOT
change the leads at the motor terminal.
MNL-0408
123
4
5
3.2 Three Stage Automatic Condensate Drain System
3.2.1 Description
The automatic condensate drain system operates electropneumatically and is comprised of the following:
• An electrically controlled solenoid valve.
• A pneumatically operated condensate drain valve
• A condensate manifold
• A condensate collection system
The automatic condensate drain system drains the intermediate separator and the oil and water separa-
tor every 15 minutes during operation. Additionally the automatic condensate drain system unloads the
compressor during the starting phase and drains these filters at shutdown of the compressor unit.
Figure 3-31 Automatic Condensate Drain
1. Solenoid Valve
2. Blank off Plate
4. Condensate Drain Valve
5. Manual Condensate Drain
3. ACD Manifold
June 11, 2009 Page 45
Figure 3-32 ACD Operation Diagrams
Normal Operation
Condensate Draining
Condensate
Control Air
2
1
4
Condensate
Control Air
2
1
3
4
3
ImVT 120 II Mini Verticus
1. Solenoid Valve
2. Intermediate Separator
3. Oil and Water Separator
4. Condensate Drain Valve
3.2.1.1 Normal Operation
The normally open solenoid valve (1) controls the condensate draining of the intermediate separator
(2). The normally open condensate drain valve (4) controls the condensate draining of the oil and water
separator. The two valves (1 & 4) are connected together in cascade mode. This means that the operational state (open or closed) of the solenoid valve (1) causes the same state in the condensate drain
valve (4) to occur. The control air for operating the condensate drain valve (4) is taken from the intermediate separator (2).
As the compressor is started, the solenoid valve (1) is electrically energized and closes. This allows the
pressure to buildup in the intermediate separator. This pressure buildup results in control air pressing
the piston into the valve seat, closing the condensate drain valve (4).
3.2.1.2 Condensate Drain
Every 15 minutes the timer deenergizes the solenoid valve (1) for approximately 10 seconds. The solenoid valve (1) opens and drains the condensation from the intermediate separator (2). This causes a
pressure loss in the intermediate separator and the control air for the condensate drain valve (4). As the
pressure of the control air is dropping, the piston of the condensate drain valve (4) becomes unloaded
and the control air is momentarily vented through a relief port. Then the piston of the drain valve is
fully raised by pressure from the final separator, and the condensate is drained.
3.2.1.3 Start Unloading
The unloading of the compressor during the starting phase is possible because of the lack of control air
immediately after starting the unit. As the unit is switched on the solenoid valve (1) is energized and
Page 46 1st Edition, Rev . 0 Chg. 10
MNL-0408
closes. After the compressor has attained nominal speed, pressure builds in the intermediate separator
and the control air closes the condensate drain valve (4). Once the valve closes, the compressor delivers
to the consuming device.
3.2.1.4 Standstill Drainage
At compressor shutdown, the solenoid valve (1) is deenergized and opens. This drains the condensate
and relieves the pressure in the intermediate filter (2). This action in turn removes the control air form
the condensate drain valve which opens and drains and relieves the pressure in the oil and water separator.
^ CAUTION
The condensate drain interval is adjusted at the factory. If the regular operating time of the compressor
unit is less than the drain cycle, adjust the timing relay accordingly to ensure regular draining of the oil
and water separator. If the compressor is shut of f be fore the f irst drain cycle is completed, the timing r elay
would be reset each time causing the drain cycle to be started again. The condensate drain cycle would
never be completed, which could result in flooding of the separator and damage to the connected systems.
3.2.2 ACD Maintenance
The condensate drain valves are provided with manual drain valves to verify correct operation of the
automatic system.
The automatic condensate drain system must be serviced once a week as follows:
1. Open all manual drain valves one after the other.
2. Observe the drainage of condensation.
a. If the system drains more than 2 ounces of liquid per stage, either the system or the corresponding
condensate drain valve is not working properly.
b. Find the fault and remedy accordingly.
3. If little or no condensation emerges, the automatic system is operating properly.
4. The condensate collection tank should be emptied regularly. Due care must be taken to ensure that
any oil which is drained with the condensation is disposed of properly. Check local, state and federal regulations.
June 11, 2009 Page 47
3.2.3 ACD Replacement Parts List
Figure 3-33 ACD System
7
ImVT 120 II Mini Verticus
10
11
9
8
4
1
2
3
5
Item Qty Part No. Description Notes
◊ 1 DGM-2280 3 Stage Compressor ACD Reference only
1 1 N27288 Solenoid Coil 115 VAC 50/60 Hz
2 1 N27099 Solenoid Valve
3 1 N01028 Copper Gasket
4 1 RED-0058 Reducer Bushing
5 2 N01316 Copper Gasket
6 1 CON-0061 Male Connector
7 1 PLU-0004 Plug
8 1 070615 Male Connector w/Nozzle
9 1 064009 Condensate Drain Valve
10 1 GKT-0016 Copper Gasket
11 1 CON-0143 Male Connector
6
Page 48 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-34 ACD Manifold Assembly
4
5
6
3
2
1
7
8
9
10
Item Qty Part No. Description Notes
1 1 PLT-0297 Blanking Plate
2 2 N00638 O-ring
3 1 MFD-0035 ACD Manifold
4 2 N00829 Socket Head Cap Screw
5 2 N03625 Copper Gasket
6 1 Elbow
7 1 Connecting Tube
8 1 Female Connector
9 1 N02507 O-ring
10 1 064004 Valve Connection
11 1 N02320 O-ring
11
June 11, 2009 Page 49
Figure 3-35 Condensate Drain Valve Assembly
1
2
3
4
5
6
7
8
9
10
11
14
13
15
15
12
16
ImVT 120 II Mini Verticus
Item Qty Part No. Description Notes
◊ 1 064009 Condensate Drain Valve Assembly
1 1 064000 Top Flange
2 1 N16269 Seal Ring
3 1 064003 Valve Piston
4 1 N00638 O-ring
5 1 N04881 O-ring
6 1 064001 Valve Body
Page 50 1st Edition, Rev . 0 Chg. 10
MNL-0408
Figure 3-35 (cont.) Condensate Drain Valve Assembly
Item Qty Part No. Description Notes
7 1 N2507 O-ring
8 1 064005 Valve Seat
9 1 N04496 O-ring
10 1 064002 Base Flange
11 1 064498 Condensate Drain Tap Seat
12 1 065500 Condensate Drain Tap
13 1 N16334 Banjo Fitting
14 AR TUB-R-0038 Tubing
15 8 SCR-0150 Socket Head Cap Screw
16 1 067458 Tool Set
June 11, 2009 Page 51
ImVT 120 II Mini Verticus
3.3 Condensate Collector
During compression the water content of the air is also compressed. The resulting water is removed
after each compression stage and is collected through the automatic condensate drain system.
This water, additionally, has a small oil content. The separation of oil and water is not possible through
simple methods; therefore the condensate has to be completely removed. It is most practical to collect
this condensate in special containers and dispose of it entirely.
For these compressor units a metal housing and tank assembly is used. A float level switch is also
included. The condensate is drained from the tank assembly by the manual drain valve into a separate
container for proper disposal.
Figure 3-36 Condensate Collector
1
2
3
1. Air Discharge
2. ACD Manifold
4
3. Float Level Switch (opposite side)
4. Manual Drain Valve
Page 52 1st Edition, Rev . 0 Chg. 10
MNL-0408
1
2
3
4
5
6
7
8
9
10
3.3.1 Condensate Collector Replacement Parts List
Figure 3-37 Condensate Collector
Item Qty Part No. Description Notes
1 1 CAP-0056 Condensate Collector Cover
2 1 GKT-0050 Gasket
3 2 ELM-0160 Fine Filter Element
4 2 ELM-0161 Coarse Filter Element
5 1 HUS-0050 Condensate Collector
6 1 SWT-0265 Float Switch
7 1 TNK-0092 Condensate Collection Tank
8 1 VAL-0386 Manual Drain Valve
9 1 PLU-0011 Plug
10 1 MFD-0035 ACD Manifold
June 11, 2009 Page 53
CHAPTER 4: IK120 II MAINTENANCE SCHEDULE
4.1 IK120 II Maintenance Intervals
Interval Maintenance Work
ImVT 120 II Mini Verticus
Daily before operating unit
½ hour after maintenance work Check screws and fittings for tightness
500 operating hours
1,000 operating hours Valve Check
2,000 operating hours
3,000 operating hours Check pistons and piston rings
Annually
Biennially Change Synthetic Oil, if operated for less than 2,000 hours
Check Oil Level
Operate unit to final pressure and check final pressure switch
Service micronic intake filter
Check all connections for leakage
Change Synthetic Oil and Change Oil Filter
Replace Valves
Check opening pressure of final safety valve.
Service micronic intake filter
NOTICE
All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme
conditions like high temperatures, humidity or continuous operation may shorten the intervals signifi-
cantly. If in doubt, please contact the Bauer service department.
4.1.1 Maintenance Records
We recommend that all maintenance work be recorded, showing the date and details of the work carried
out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to
make a claim against the warranty , it will help to have proof that regular maintenance has been carried out
and that the damage has not been caused by insufficient maintenance.
Page 54 1st Edition, Rev . 0 Chg. 10
MNL-0408
CHAPTER 5: AIR PROCESSING SYSTEM
5.1 General
The purpose of all Bauer air processing systems is to remove oil and water from the compressed air
stream before final delivery. For this reason Bauer air processing systems are installed immediately
before the compressed air delivery point.
^ WARNING
Air Processing System cartridges do not remove carbon monoxide and therefore must not be used in
breathing air applications
5.1.1 General Purification System Procedures
1. Keep an accurate record of operating hours to ensure exact attention to maintenance intervals
2. Change all cartridges before reactivating a compressor unit that has been out of service more than
three months. Leave cartridges in the unit as long as it is out of service.
3. While out of service keep all condensate drain valves closed. Maintain a pressure of 700 to 1,100
psi (50 to 80 bar) within the system to prevent moisture from entering the compressor and air processing system.
5.1.2 Chamber Safety Bore
The chambers in all Bauer air processing systems are designed to prevent pressurization if the cartridge is
missing, not seated properly or damaged (See Figure 5-1). Without a cartridge properly in place the
safety bore is not sealed, the air escapes into the atmosphere, no pressure can be built up and thus it is
ensured that unfiltered air is not supplied to the consuming device. If air is escaping from the safety bore
remove and check cartridge. If necessary replace the cartridge or O-rings.
Figure 5-1 Cartridge Safety Venting
Safety
Vent
Safety
Vent
Cartridge Installed
No Cartridge Installed
June 11, 2009 Page 55
ImVT 120 II Mini Verticus
5.1.3 Manual Condensate Drainage
The condensate must be drained from the oil and water separator before changing any cartridge, before
beginning each filling procedure and in the absence of an Automatic Condensate Drain System, every fifteen minutes during the filling procedure. This is done by slowly opening the condensate drain valves.
They are opened approximately 1/3 of a turn to the left and held open until the condensate is completely
drained. The condensate drain valves close by spring pressure but if necessary may be tightened by hand
to ensure they are completely air tight.
5.1.4 Model, Serial Number and Part Number Identification
5.1.4.1 Compressor Dataplate
The model number, date of manufacture and serial number can be found on the compressor unit identification plate in the main electrical enclosure and frame.
5.1.4.2 Purification System Dataplate Refer to the compressor unit purification system dataplate (See Figure 5-2) on the compressor front to determine your air processing system model and specifications.
Figure 5-2 Purification System Dataplates (typical)
Purification System Cartridge Installation
PURIFICATION
SYSTEM
MODEL NO.
MAX. PRESSURE
AIR PROCESSED
O-RING
BACK-UP RING
psig
cu. ft.
LBL-
CARTRIDGE TO BE
INSTALLED
CARTRIDGE FOR
CARTRIDGE NO.
1328 Azalea Garden Road - Norfolk Virginia 23502-1944
Phone: (757) 855-6006 Fax: (757) 855-8224
LBL-
5.1.4.3 Cartridge Installation Dataplate The function performed by each chamber in the air processing system is determined by the type of cartridge installed in that chamber. Refer to the cartridge installation dataplate on the chamber to determine the purpose and part number of the cartridge installed in that chamber. (See Figure 5-2).
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5.1.4.4 Air Processing Cartridge Operating Hours Form
Date
Operating
hours
Ambient temp.
during compression
Correction
factor
Adjusted cartridge hours
Today Total
June 11, 2009 Page 57
ImVT 120 II Mini Verticus
5.2 P2S Purification System Major Components
The P2S Purification System major components are a Oil and Water Separator, and a Securus® Electronic Moisture Monitor System Purification Chamber. Figure 5-3 shows the functional interconnection
of all the components. A Securus® Indicator and associated wiring are also added.
Figure 5-3 P2S Purification System
6
7
IN
OUT
5
3
4
2
1
2
1. Oil and Water Separator
2. Check Valves
3. Bleed Valves
4. Pressure Maintaining Valve
3
5. Purification Chamber
6. Securus Indicator
7. Safety Valve
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5.3 Component Description
5.3.1 Oil and Water Separator
^ WARNING
The rapid depressurizing and repressurizing of the oil and water separator during condensate draining subjects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or
death the oil and water separator (P/N 079416) must be replaced after a predetermined number of cycles.
One load cycle equals one pressurization plus one depressurization.
Units operating between 3,000 and 5,000 psi = 130,000 load cycles (32,500 hours of operation)
Units operating between 5,000 and 6,000 psi = 55,000 load cycles (13,750 hours of operation
The BAUER recommended frequency of condensate draining is every fifteen minutes and is a balance
between maximizing the life of the separator chamber and maintaining the quality of the delivered air.
The air leaving the final stage is cooled in the aftercooler to approximately 18 - 27°F (10 -15°C) above
ambient temperature and then enters the oil and water separator. The oil and water separator works by
means of a sintered metal filter which separates liquid oil and water particles from the compressed air .
Figure 5-4 Oil and Water Separator
June 11, 2009 Page 59
ImVT 120 II Mini Verticus
Protective Cap
Figure 5-5 Oil and Water Separator Labels
5.3.2 Chamber
Each chamber is made up of an anodized aluminum housing and a filtering cartridge. There are two
general types of filtering cartridges, drying or purifying. The cartridge type is determined by the ingredients packed in the cartridge. The chamber is named after the type of cartridge it contains, i.e. dryer
chamber or purification chamber.
5.3.3 Cartridge
5.3.3.1 Cartridge Construction
The cartridge casing, top and bottom are aluminum and are packed with one or more of the following.
1. A catalyst to convert carbon monoxide to carbon dioxide.
2. Activated carbon which absorbs oil vapors effecting taste and odor.
3. Molecular sieve to absorb oil and water.
Figure 5-6 Cartridge
5.3.3.2 Cartridge Handling
1. Never open the protective packaging a cartridge comes in prior to its actual use. The highly sensitive filter materials will absorb moisture from the atmosphere becoming saturated and useless.
2. Used cartridges must be disposed of in accordance with local regulations.
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5.3.4 Condensate Drain Valve
A manually operated valve used for maintenance and before start-up to drain the condensed liquids
from the coalescing oil and water separator.
5.3.5 Check Valves
Valves allowing compressed air to flow in only one direction. One is used to maintain pressure in the
chamber when the compressor is not operating. The other check valve prevents back-flow from filled
storage cylinders or tanks.
5.3.6 Bleed Valve
A manually operated valve used to release the pressure in the chamber before maintenance.
5.3.7 Pressure Maintaining Valve
The pressure maintaining valve ensures that pressure is built up in the system from the start of delivery,
thus achieving constant optimum purification. It also assures proper working conditions for the final
stage of compression. The Pressure Maintaining Valve is preset at the factory. The nominal setting is
2,000 PSI.
5.3.8 Safety Valve
The safety valve is located on the coalescing oil and water separator and acts as the safety valve for the
final stage of the compressor.
5.3.9 Securus® Electronic Moisture Monitor System
The Securus® Electronic Moisture Monitor System is a factory installed option which warns the operator in advance of expiration of the life of the cartridges. The Securus® Indicator receives signals concerning the condition of the drying agent inside the Securus® cartridge from the attached sensors and
supplies the appropriate control signals whenever the preset threshold values have been reached.
5.3.9.1 Securus® Cartridge
The Securus® Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide,
activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor
components of the Securus® Electronic Moisture Monitor System.
5.3.9.2 Securus® Indicator
®
The operating condition of the Securus
Electronic Moisture Monitor System is indicated by the color
and state of four LED’s on the front of the Securus® Indicator and is shown in the following table.
NOTICE
After applying power it will take about ½ second for the appropriate LED to illuminate.
®
During this time the status of the Securus
Electronic Moisture Monitor System is tested.
June 11, 2009 Page 61
ImVT 120 II Mini Verticus
Color State Indication Compressor Unit Status
Green Steady Satisfactory The unit is in operation
Yellow Flashing Cartridge Change Pre-warning The unit is in operation. The green
LED will also illuminate.
Red Flashing Cartridge Change Required The unit is shutdown and can not be
started until the cartridges are
changed.
Red Steady Cable Failure or Missing Cartridge The unit is shutdown.
No LEDs Illuminate No operating voltage or electronic failure The unit is shutdown.
5.4 Maintenance
5.4.1 Oil and Water Separator
T o remove the sintered metal filter proceed as follows: (See Figure 5-7). Disconnect the power and shut
off the inlet supply line if applicable.
1. Depressurize the system by means of the bleed valve.
2. Remove the tubes connected to the side of the filter head (1).
3. Unscrew and remove the filter head.
4. Unscrew the sintered metal filter (2) from the filter head.
5. Remove the center screw (3) to remove the sintered metal filter.
6. Clean the sintered metal filter using hot soapy water. Blow dry with compressed air.
7. After cleaning the element, record the number of operating hours to ensure exact attention to the
maintenance intervals.
8. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter with petroleum jelly. Apply sparingly.
9. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the
sintered metal filter.
10. In the event you discover corrosion, replace the corroded parts with new BAUER parts.
11. Reinstall the sintered metal filter assembly and filter head.
12. Replace all removed tubes, close all valves and check for leaks.
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1
2
3
4
Figure 5-7 Oil and Water Separator Figure 5-8 Sintered Metal Filter Assembly
1. Filter Head
2. Sintered Metal Filter
3. Center Screw
4. O -rings
5.4.2 Cartridge Replacement
To change the purification cartridge, proceed as follows. (See Figure 5-9)
Figure 5-9 Cartridge Replacement
1. Disconnect the power and shut off the inlet supply line, if applicable.
2. Depressurize the system by means of the bleed valve.
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ImVT 120 II Mini Verticus
3. Unscrew the chamber head using the special wrench supplied.
4. Pull out the cartridge using the lifting ring on top of the cartridge.
5. Dry the inside of the chamber with a clean cloth and check for corrosion.
6. Replace all corroded parts with new BAUER parts.
7. Remove the shipping covering and the protective cap from the bottom of the cartridge.
8. Lubricate the O-rings with white petroleum jelly. Apply sparingly.
9. Install the new cartridge. Be sure the cartridge snaps into place.
10. Reinstall the chamber head.
11. Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable.
NOTICE
If air is detected bleeding out from the bottom of the chamber, the cartridge has not been installed properly
or is missing. Follow the instructions in Paragraph 5.4.2.1
5.4.2.1 Leaking at the Safety Bore
1. Remove the cartridge following steps 1. to 4. in Paragraph 5.4.2.
2. Install cartridge if missing.
3. Remove cartridge and inspect O-rings.
4. Replace O-rings if necessary.
5. Ensure protective caps and devices have all been removed.
6. Replace cartridge following steps 8. to 11. in Paragraph 5.4.2
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5.5 Replacement Parts List Figure 5-10 P2S Purification System
7
IN
6
OUT
5
3
4
2
1
2
3
Item Qty Part No. Description Notes
1 1 079416 Oil and Water Separator See Figure 5-11
2 2 VAL-0007 Check Valves
3 2 VAL-0377 Bleed Valve
4 1 VAL-0053 Pressure Maintaining Valve
5 1 080145 Securus® Chamber See Figure 5-12
6 1 N15095 Securus® Indicator See Figure 5-12
7 1 VAL-0169 Safety Valve
June 11, 2009 Page 65
Figure 5-11 Oil and Water Separator
ImVT 120 II Mini Verticus
1
2
3
4
2
5
Item Qty Part No. Description Notes
◊ 1 079416 Oil and Water Separator Assembly
1 † … Separator Head Available only with 079416
2 2 N04586 O-Ring
3 1 061860 Sintered Metal Filter
4 † … Separator Housing Available only with 079416
5 † … Bottom Plug Available only with 079416
Page 66 1st Edition, Rev . 0 Chg. 10
1
2
3
4
5
9
8
6
10
7
This page is inserted to provide proper page sequencing
Figure 5-12 Securus® Electronic Moisture Monitor System
2
ImVT 120 II Mini Verticus
6
7
3
5
4
3
2
8
9
10
17
16
15
14
13
12
11
1
18
Item Qty Part No. Description Notes
®
◊ 1 80145 Securus
Chamber Assembly
1 † … Bottom Plug Available only with 80145
2 2 N04736 Backup Ring
3 2 N04735 O-ring
4 1 060037 Securus
®
Cartridge
5 † … Filter Body Available only with 80145
6 1 ADP-0204 Adapter, Right Angle
7 1 059850 Socket, RF type
8 2 012293 Tool Post Screw
9 1 06135 Cover Plate
10 † … Filter Head Available only with 80145
11 1 059855 Nut
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Figure 5-12 (cont.) Securus® Electronic Moisture Monitor System
Item Qty Part No. Description Notes
12 1 059852 Drawback Screw
13 1 059854 Loose Pin
14 1 060062 Compression Spring
15 1 059853 Fixed Pin
16 1 059851 Bolt
17 1 002181 Compression Spring
18 1 N15095 Securus® Indicator 110 - 120VAC, 50 - 60 Hz
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1
2
3
4
5
6
7
r
o
t
a
t
i
o
n
CHAPTER 6: COMPRESSOR UNIT DRIVE
6.1 Vertical Self Tensioning
The compressor is driven by the drive motor through a V-belt. The direction of rotation, as seen facing
the flywheel, is counterclockwise. Observe the arrow on the compressor block. Check the V-belt regularly for damage and wear. See Paragraph 6.2.2. Replace if necessary.
Figure 6-1 Vertical Motor Mount (typical)
1. Compressor block
2. Compressor flywheel
3. Compressor mount
4. V-belt
6.2 Maintenance of the V-belt and Sheaves
5. V-belt sheave
6. Electric motor
7. Swinging motor mount
6.2.1 Check the Flywheel and Sheave.
Before a new drive belt is installed, the condition of the flywheel and the sheave should be checked. A
dirty or rusty sheave impairs the drive’s efficiency and abrades the cover of the belt, which results in
premature failure. A worn sheave shorten belt life as much as 50%. If the groove is worn to the point
where the belt bottoms, slippage may result and the belts may burn. If the side walls are “dished out,”
the bottom shoulder ruins the belt prematurely by wearing off the bottom corners.
6.2.2 Check the V-belt
Check the V-belt regularly for damage and wear. Replace if necessary. V-belt tension is adjusted automatically by the weight of the motor, which is mounted on a hinged motor plate.
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CHAPTER 7: ELECTRICAL PANEL ASSEMBLY
7.1 Overview Figure 7-1 Electrical Panel Assembly
The Electrical Panel Assembly uses a micro Programmable Logic Controller, Motor Starter, transformer and switches manufactured by Telemecanique. This controller model is called TWIDO. The
control system 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 program permanently saved into PLC memory using EEPROM technology . There are normally
six PLC programs used in this Electrical Panel Assembly, based on the pressure and use of the compressor. The program version used can be identified by the white sticker on the face of the PLC. The
panel is pre-wired and fused for the horsepower and voltage of the compressor. Active Power mainly
uses 460 volt, 3 phase, 60 Hz supply.
NOTICE
Other configurations and options are also available by special order. Some components and programs
listed may be altered by these special orders.
June 11, 2009 Page 71
ImVT 120 II Mini Verticus
The basic panel components consist of a 16 I/O PLC Controller, Motor Starter with Overload Relay,
Control Power Transformer with fuses, Alarm and Warning Lights, Compressor Control Switch, Hourmeter, Emergency Stop Switch, Starter Reset, Audible Alarm, terminal strip for wire connections and
wire harness.
To run the compressor, the Emergency Stop Switch must be pulled out and the Compressor Control
Switch must be in the ON position; at this point, the switch illuminates green and the compressor sys-
tem is ready and able to operate. If the pressure in the system drops to approximately 4500 psi1, the air
pressure switch will close, and the compressor will start. All other functions of the compressor are automatic. When the air pressure has increased, and the pressure switch opens, then the compressor will
shutdown. All of these functions are accomplished through the use of a Programmable Logic Controller. When use of the equipment is complete, the Compressor Control Switch should be placed in the Of f
position.
7.2 Options
This panel will electrically support all commonly available compressor options offered by Bauer Compressors. These include:
• The Securus® Electronic Moisture Monitoring System to monitor the air, and provide first a warning,
and later an alarm, to prompt the operator to replace the high pressure purification cartridges.
• The Carbon Monoxide Monitor is used to continuously sample the air that is compressed for use in
the system. Again, the unit will alarm and shut down the compressor if unsafe levels are detected. The
Carbon Monoxide Monitor also comes with a Calibration Kit to ensure accurate readings are being
taken.
• The Condensate High Level Alarm will alarm and shutdown the compressor when the condensate
level becomes too high. This Alarm is activated by a float switch in the ACD Condensate Collection
Tank. This alarm prompts the operator to drain the condensate and prevents spilled condensate.
7.3 AC Power Requirements
The panel will need to be supplied with the appropriate voltage(460), phase(3), and frequency(60Hz)
power to ensure proper operation. Wiring and conduit selection must be in accordance with all national,
state and local codes. The customer is responsible for providing a disconnection means and protection
from instantaneous short circuit.The pre-wired panel voltage and phase is written on a label (See Figure
7-2) on the inside of the electrical panel door. In this example shown, the panel is wired for 460 volt,
three phase. If a schematic for your machine is not found inside the electrical panel, then please call
Bauer Compressors Product Support Group for a replacement. Please have the Serial number of the
compressor available.
1. The pressure mentioned is only an example; the switch differential is approximately 10% of the set-point, and is not adjustable.
Page 72 1st Edition, Rev . 0 Chg. 10
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Figure 7-2 Electrical Panel Label
This electrical panel will power up to a single 50 HP NEMA Design B motor at 460 VAC. The panel is
provided with a 120 VAC, 200 VA, single-phase transformer for powering 120-volt loads. 120 VAC
single-phase panel loads are as follows:
AC Power Available Light Negligible
Warning & Alarm lights Negligible
ACD coils (up to 4) 35 W each maximum, with 3 max energized
Motor Starter coil (max) 26.0 VA (sealed, max)
CO Monitor Solenoid valve 8 W
CO Monitor power 0.9 W
Securus® Electronic Moisture Monitor System 20.4 VA
PLC Controller 22.0 VA
Figure 7-3 Transformer and Fuses
June 11, 2009 Page 73
ImVT 120 II Mini Verticus
7.3.1 Transformer and Fuses
The transformer is fitted with three fuses. The input to the transformer has two fuses. For 460 VAC
operation, use two Bauer P/N FUS-0077 rated at 1 amp. The secondary of the transformer is fitted with
one fuse. Use one Bauer P/N FUS-0018, rated at 2 amps.
^ CAUTION
Before operating the compressor, care should be taken to ensure the voltage and phase of the power supply are the same. A qualified electrician should make these checks.
7.4 Electric Panel Components
7.4.1 Motor Starter.
This application will require an across the line IEC starter with thermal overloads. Control voltage is
120 VAC. The 3 phase 460 volt motor starter, part number SRT-0196, will support up to 32 Amps continuous. The coil within the starter can be replaced with part number COI-0017.
7.4.2 Overload Relay
The overload relay provides thermal overload protection. The overload relay used on the 460 V, 7.5 HP
3 phase assembly is RLY-0138. The relay must be set to match the motor’s Full Load Amps. Refer to
the motor nameplate.
Figure 7-4 Motor Starter and Overload Relay
1
2
1. Motor Starter 2. Overload Relay
Page 74 1st Edition, Rev . 0 Chg. 10
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Figure 7-5 Electrical Panel Assembly
1
2
3
4
5
6
1. Compressor Control Switch
2. Warning Light
3. Alarm Light
7.4.3 Emergency Stop Switch.
There is a Emergency Stop Switch on the panel. This is a 22 mm device with a 40mm mushroom head.
The button must be pulled out for the unit to operate. In an emergency, depress the push button, which
will shutdown the electric motor and all other periphery devices. Do not use the Emergency Stop
Switch for securing the equipment under normal operation. Use the Compressor Control Switch. The
PLC operating memory is maintained by a internal battery in the PLC. Removing all power from the
compressor will allow the battery to discharge over a 30 day period. Apply power to the unit by pulling
out the Emergency Stop Switch, and leave on for at least 8 hours every 30 days.
7.4.4 Starter Reset
There is a blue 22mm push button on the door of the electrical enclosure with the letter “R” at its center .
Pushing this button will reset the thermal overload relay on the motor starter. Should the electric motor
have overloaded and tripped out during normal operation, then depressing this button after giving some
time to cool, will reset the overload relay portion of the motor starter.
4. Hourmeter
5. Starter Reset
6. Emergency Stop Switch
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ImVT 120 II Mini Verticus
7.4.5 Compressor Control Switches
7.4.5.1 2-Position (Standard)
OFF Position - The selector switch must be in the OFF position when securing the compressor system.
ON Position - The selector switch must be in the ON position to operate the compressor system. When
positioning the switch to the ON position, it will illuminate Green. The compressor will start and stop
automatically based on the status of the pressure switch.
7.4.5.2 3-Position Compressor Control Switch (Factory Installed Option).
7.4.5.2.1 For Breathing Air Units
OFF - The selector switch must be in the OFF position when securing the compressor system.
ON - The selector switch must be in the ON position to operate the compressor system. When position-
ing the switch to the ON position, it will illuminate Green. The compressor will start and stop automatically based on the status of the pressure switch.
ACD Test - This switch position will cause all condensate drains to blow down. It is spring returned to
ON Position when released.
7.4.5.2.2 For Industrial Units
OFF - The selector switch must be in the OFF position when securing the compressor system.
AUTO- The selector switch must be in the ON position to operate the compressor system. When posi-
tioning the switch to the ON position, it will illuminate Green. The compressor will start and stop automatically based on the status of the pressure switch.
CONTINUOUS - This switch position, maintained, will allow the compressor to build up to final pressure, then will activate an unloading valve. When demand is re-established, the unloading valve is deenergized and compression will begin again.
7.4.6 Indicator Lamps
7.4.6.1 PLC Warning and Alarm Lamps
7.4.6.1.1 Warning Lamp - Amber
The lamp (LIT-0128) has a 22 mm base and a LED lamp for long trouble free life. This lamp should
flash a code IAW, In Accordance With, the logic of the controller. See Paragraph 7.5.
7.4.6.1.2 Alarm Lamp - Red
The lamp (LIT-0127) has a 22 mm base and a LED lamp for long trouble free life. This lamp should
flash a code IAW the logic of the controller. See Paragraph 7.6.
7.4.7 Hour meter
The panel will be supplied with an hour meter (HMR-0029). The hour meter is not resettable and used
to monitor the run hours of the compressor . It is powered with a 120 VAC signal supplied from the auxiliary contact on the motor starter.
7.4.8 PLC Control
This panel is controlled with a Telemecanique 16 I/O Twido Programmable Logic Controller. This unit
provides logical operations to the overall system that includes the high pressure compressor, purification systems, and other accessories.
Page 76 1st Edition, Rev . 0 Chg. 10
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Figure 7-6 PLC CNT-0052 Figure 7-7 Status Lights
Input LED’s
Inputs
Status
Lights
Program
Version
PWR
120 VAC Supply
7.4.8.1 PLC LED’s
There are three separate groups of LED’s on the PLC. See Figure 7-7.
Outputs
0 1 2 3 4 5 6 7 8
0 1 2 3 4 5 6
RUN
ERR
STAT
Output LED’sStatus LED’s
OUT
IN
1. The Input Status LED’s are in the top row.
2. The Output Status LED’s are on the right hand side of the bottom row
3. The PLC Status Lights are on the left hand side of the bottom row and indicate the following.
a. PWR - The supply voltage to the PLC is correct.
b. RUN - On when the program is running. Flashes when program execution is stopped.
c. ERR - Illuminates red on application fault.
d. STAT - Indicates the status of an application variable.
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ImVT 120 II Mini Verticus
7.4.9 Compressor PLC Program Versions
The version of PLC program loaded into your compressor package is denoted with a small white sticker
in the front of the PLC. Please refer to this number when calling Bauer Compressors Product Support.
Table 7-1: PLC Program Versions
Description 5,000 psi 6,000 psi
Breathing Air Compressor without Unloader v2.45 v2.35
Industrial Compressor Unit with Unloader
a
v2.64 v2.54
Gas Compressor Unit vG1.46 vG1.36
Unicus III with 1 ACD Solenoid vU3.4 vU1.4
Unicus III with 2 ACD Solenoids — vU2.4
Industrial Unit with 4 ACD Solenoids v3.1 v3.0
a. Active Power’s PLC program
7.4.10 PLC Inputs and Outputs
All PLC inputs are 24 VDC. The power supply physically exists inside the PLC. All PLC outputs are of
a relay type, and are powered through the control transformer supplying 120 VAC single phase to the
various loads. Please refer to unit schematic for the as built specifications.
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Table 7-2: PLC Inputs - Industrial Compressor
I0
I1 High Temperature Switch Q1 ACD 1
I2 Oil Pressure Switch Q2 ACD Final
I3 Final Air Pressure Switch Q3 Alarm Indicator
I4 CO Monitor Alarm Q4 Not Used
I5 Securus® Alarm Q5 Unloader Valve
I6 Condensate Alarm Q6 Warning Indicator
I7 Securus® Warning
I8 Continuous Switch (1SS)
7.5 Warnings
Compressor Control Switch (1SS)
Warning codes are flashed with a 0.5 second on / 0.5 second off sequence with the Amber light located
on the control panel. In addition the light will illuminate on initial start up for a period of 5 seconds, to
serve as a lamp test function. The lamp has a 22 mm base and a LED lamp for long trouble free life.
Table 7-3: PLC Outputs - Industrial
Compressor
Q0 Motor Starter
7.5.1 One Flash - Final Separator Warning
The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel, approximately 3-3/4 inch diameter, located on the purification panel, beside the compressor. To
prevent fatigue failure of this vessel, the PLC program monitors the pressurization / de-pressurization
cycles of this separator and will issue a Warning, and then later an Alarm function.
The program is set up for a 90% warning and a 100% shutdown alarm for this counter feature. The program would be configured to reflect the following values when it is built.
Table 7-4: Final Separator Warning and Shutdown Cycle Count
Maximum Compressor Pressure Warning Shutdown
5,000 psi 117,000 cycles 130,000 cycles
6,000 psi 49,500 cycles 55,000 cycles
When the warning is illuminated, the unit will still continue to function properly, but will prompt the
operator to contact Bauer Compressors for making arrangements to replace the separator. When the
Alarm level has been achieved, the compressor will no longer function, and will require the replacement of the separator . When this is accomplished, the unit can be re-activated by making adjustments to
the PLC. Please contact Bauer Product Support for detailed instructions.
June 11, 2009 Page 79
ImVT 120 II Mini Verticus
^ WARNING
Do not attempt to override this Separator Shutdown. This feature is provided
to protect operating personnel from injury or death.
7.5.2 Two Flashes - Securus Monitor Warning
The compressor purification system may be equipped with an optional Securus® Electronic Moisture
Monitor System. This consists of a control module and cable connected to the purification chamber. It
functions as a capacitive sensor, sensing the moisture in the purified air. When the chemicals in the
purification cartridges have reacted with moisture to a point where they are beginning to sense a change
in the moisture content, then the Securus® Monitor will illuminate it’ s amber light.At the same time , the
warning relay in the Securus® module which is connected to the PLC on terminal I7.
On a Securus® Warning condition, the compressor will run normally, the I7 lamp will illuminate, and
the warning shows on the LCD Display. This warning is meant to prompt the operator to schedule
replacement of the purification cartridges in the near future.
Figure 7-8 Securus® System
The Warning relay is wired normally open. The relay is wired into a wire harness using the Black /
Orange and V iolet / Orange color wires. Refer to unit schematic for additional information. Under nor mal operating conditions, the relay is open and the I7 lamp on the PLC is off.
7.6 Alarms
Alarm codes are flashed with a 0.5 second on / 0.5 second off sequence with the Red light located on
the control panel. In addition the light will illuminate on initial start up for a period of 5 seconds, to
serve as a lamp test function. The lamp has a 22 mm base and a LED lamp for long trouble free life.
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7.6.1 One Flash - Compressor High Temperature
The compressor high temperature switch is located on the high pressure breathing air compressor, on
the third, fourth or fifth stage head, depending on model. The switch is N.C., Normally Closed, and is
connected to the PLC on terminal I1. The switch is wired into a wire harness using the Yellow and Violet color wires. Refer to unit schematic for additional information. Under normal operating conditions,
the switch is closed and the I1 lamp on the PLC is illuminated. On a high temperature condition, the
compressor will shutdown, the I1 lamp will extinguish, and the alarm code will flash.
Figure 7-9 High Temperature Switch Figure 7-10 Low Oil Pressure Switch
7.6.2 Two Flashes - Compressor Low Oil Pressure
The compressor oil pressure switch is located on the high pressure breathing air compressor, on the
back of the block, mounted with the oil pressure gauge. The switch is N.O., Normally Open, and is connected to the PLC on terminal I2. The switch is wired into a wire harness using the Orange and Blue
color wires. Refer to unit schematic for additional information. During startup of the compressor, the
oil pressure switch is bypassed in the program for a period of 45 seconds. When the oil pressure has stabilized, the switch should be closed. Should the compressor lose oil pressure, then the compressor will
shutdown, the I2 lamp will extinguish, and the alarm code will flash.
7.6.3 Three Flashes - Compressor Overrun Timer
The compressor has an overtime function, where if the compressor runs continuously for 5 hours, then
the compressor will shutdown, and the alarm code will flash. This is done to secure the equipment if it
were to be started and left unattended.
7.6.4 Four Flashes - Securus Monitor
®
See Figure 7-8. The compressor purification system may be equipped with a Securus
Electronic Moisture Monitor System. This consists of a control module and cable connected to the purification chamber. It functions as a capacitive sensor, sensing the moisture in the purified air. When the chemicals in
the purification cartridges have reacted with moisture to a point where they are no longer suitable for
purifying the air, then the Securus® Module will illuminate it’s red light. At the same time the alarm
relay in the Securus
®
module is connected to the PLC on terminal I5. On a Securus® alarm condition, the
compressor will shutdown, the I5 lamp will be illuminated, and the alarm shows on the LCD Display.
The warning relay is wired N.O., normally open. The switch is wired into a wire harness using the
June 11, 2009 Page 81
ImVT 120 II Mini Verticus
Black / White and Violet / Orange color wires. Refer to unit schematic for additional information.
Under normal operating conditions, the relay is open and the I5 lamp on the PLC is off.
7.6.5 Five Flashes - Carbon Monoxide Monitor Alarm
The compressor system may be equipped with an optional Carbon Monoxide Monitor. This consists of
an electronic module that samples the compressed air supply. The unit will provide a continuous display of the CO level in PPM, parts per million. If the CO level becomes excessively high, then the monitor will alarm with a red light. In turn, the alarm relay in the CO Monitor is connected to the PLC on
terminal I4. The unit should be calibrated with a test gas monthly. Refer to the manual section on the
CO Monitor.
The relay is wired N.O., normally open. The switch is wired into a wire harness using the White / Black
and Red / White color wires. Refer to unit schematic for additional information. Under normal operating conditions, the relay is open and the I4 lamp on the PLC is off. On a CO ALARM condition, the
compressor will shutdown, the I4 lamp will be illuminated, and the alarm code will flash.
Figure 7-11 CO Monitor
7.6.6 Six Flashes - Final Separator Shutdown
^ WARNING
Do not attempt to override the Final Separator Shutdown. This feature is provided to protect operating personnel from injury or death.
The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel, approximately 3-3/4 inch diameter, located on the purification panel, beside the compressor. To
prevent fatigue failure of this vessel, the PLC program monitors the pressurization cycles of this separator and will issue a W arning, and then later an Alarm function. The program is set up for a 90% warning
and a 100% shutdown alarm for this counter feature. The program would be configured to reflect these
values when it is built.
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MNL-0408
Table 7-5: Final Separator Warning and Shutdown Cycle Count
Maximum Compressor Pressure Warning Shutdown
5,000 psi 117,000 cycles 130,000 cycles
6,000 psi 49,500 cycles 55,000 cycles
When the warning is illuminated, the unit will still continue to function properly, but will prompt the
operator to contact Bauer Compressors for making arrangements to replace the separator. When the
Alarm level has been achieved, the compressor will no longer function, and will require the replacement of the separator . When this is accomplished, the unit can be re-activated by making adjustments to
the PLC. Please contact Bauer Product Support for detailed instructions.
7.6.7 Seven Flashes - Condensate Fault
The compressor condensate level switch is located in the condensate collection tank, below the ACD,
Automatic Condensate Drain separator. The switch is N.O., Normally Open, and is connected to the
PLC on terminal I6. The switch is wired into a wire harness using the Grey and Pink color wires. Refer
to unit schematic for additional information. Under normal operating conditions, the switch is open
and the I6 lamp on the PLC is off. On a high condensate condition, the compressor will shutdown, the
I6 lamp will illuminate, and the alarm code will flash. The operator should drain the condensate from
the tank and resume operation of the equipment.
Figure 7-12 Condensate Level Float Switch
NOTICE
The compressor condensate contains some oil, and accordingly, should be disposed of in accordance with
state and local regulations.
June 11, 2009 Page 83
ImVT 120 II Mini Verticus
7.6.8 On Steady - Motor Starter Overload Trip
The compressor overload relay is located in the electrical enclosure, directly beneath the motor starter.
See Figure 7-4. The relay is Normally Open and is not connected to the PLC, but is connected directly
to the red alarm light. Under normal operating conditions, the switch is open. On an Overload Trip of
the motor, the compressor will shutdown, and the Alarm light will be illuminated steady (no flash
sequence).
7.7 Installing a New Program
The PLC program c an be updated in two ways. If a Bauer technician is on-site, they could connect
directly to the PLC using a notebook computer. Using a licensed version of TwidoSoft® software,
changes can be made and downloaded to the PLC directly.Another method to install a new program is
to use an External EEPROM cartridge (CNT-0051). The EEPROM would be programmed at the Bauer
factory and shipped either to the customer or to a authorized distributor.
Figure 7-13 PLC Programming Port
1
2
3
1. PLC Programming Port
2. Overrun Timer Adjustment
3. Comm. Port
When handling the cartridge, do not touch the pins. The cartridges electrical elements are sensitive to static electricity.
5
6
4
4. Programming Monitor
5. Status LEDs
6. Program Version Installed
^ CAUTION
Page 84 1st Edition, Rev . 0 Chg. 10
MNL-0408
EEPROM Cartridge
PLC with cartridge removed. PLC with EEPROM Installed
Figure 7-14 PLC EEPROM
^ CAUTION
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.
7.7.1 Installing a new program using an EEPROM cartridge
1. Disconnect main power to your unit
2. Open the electrical enclosure door
3. Open the bottom terminal cover on the Twido controller
4. Remove the cartridge cover
5. Push the EEPROM cartridge into the cartridge connector until it “clicks”.
6. Close the terminal cover.
7. Reconnect main power to the unit.
8. Pull out the Emergency Stop pushbutton.
9. At power up, the new program will automatically be downloaded to the T wido controller. When the
red error light on the front of the Twido controller stops blinking, the download is complete.
10. Disconnect main power to your unit
11. Remove the EEPROM cartridge
12. Replace the cartridge cover
June 11, 2009 Page 85
ImVT 120 II Mini Verticus
7.8 Overrun Timer
(See Figure 7-13). All versions of the PLC program contain an Overrun Timer that will shut the compressor off after a certain amount of continuous running. The length of time can be set to 5 hours (factory standard) or from 6 to 24 hours in two hour increments. It can also be bypassed entirely eliminating
the Overrun Timer. Active Power’s default setting is “Bypassed”
Figure 7-15 Overrun Timer Adjustment
11 o’clock
8 hr. Overrun
then shutdown
1 o’clock
bypass overrun
timer
9 o’clock
5 hr. Overrun
then shutdown
See Figure 7-13 #2 for overrun timer location
7.8.1 Adjusting the Overrun Timer
(See Figure 7-15). The setting is determined by rotating the Overrun Timer Adjustment.
1. Begin by gently rotating the Overrun Timer Adjustment fully Counter-Clockwise to 9 o’clock. If it
is desired that the compressor shut down after five hours of continuous running, then leave it at this
position.
2. If it is desired that the compressor shut down after six hours or more hours of continuous running,
rotate the Overrun Timer Adjustment Clockwise .
3 o’clock
compressor
will not run
NOTICE
The compressor will not operate if the Overrun Timer Adjustment is
rotated fully Clockwise to the 3 o’clock position.
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MNL-0408
7.9 Wire Harness Connections
Device Description PLC In PLC Out Wire Colors Pin
1TS Compressor High Temp. Switch I1 —
2PS Compressor Oil Pressure Switch I2 —
1PS Compressor Air Pressure Switch I3 —
CS Condensate High Level Switch I6 —
CO Monitor Power — Brown/White 1
CO Mon.
Yellow 23
Violet 24
Blue 25
Orange 26
Red 29
Brown 30
Grey 31
Pink 32
Neutral — Red/Blue 14
CO SV CO Monitor Solenoid Valve — — Black/Yellow 2
Red/White 34
LAH CO Monitor Alarm Contact I4 —
White/Black 33
Securus Power — Black 3
SEC
Neutral — White 15
Securus® Warning I7 — Black/Orange 37
SEC W
Neutral — Violet/Orange 36
SEC A Securus Alarm I5 — Black/White 35
Black/Brown 17
3 PS Air Inlet Pressure Switch I8 —
Brown/Yellow 18
Automatic Condensate Drain #1 — Q1 Blue/White 4
ACD1
a
Neutral — Orange/White 21
ACD Final
b
Final ACD Coil Q2 Yellow/Black 5
Second ACD Coil Q4 Violet/White 6
ACD 2
Neutral — Grey/White 22
ACD 3 Third ACD Coil Q5 Pink/White 7
a. If the unit is equipped with one ACD Solenoid, it is connected to ACD1.
b. If the unit is equipped with two ACD Solenoids, they are connected to ACD1 and ACD Final.
June 11, 2009 Page 87
7.10 Replacement Parts List
1
23 4 5
6
7
8
9
10 11
12 13
14
15
Figure 7-16 Electrical Panel
ImVT 120 II Mini Verticus
Item Qty Part No. Description Notes
◊ — ASY-0819 Electrical Box
1 1 SWT-0240 Control Switch 2 Position (standard)
— 1 SWT-0242 Control Switch 3 Position, Industrial Units
— 1 SWT-0259 Control Switch 3 Position, Breathing Air Units
2 1 LIT-0128 Light Assembly Amber
3 1 LIT-0127 Light Assembly Red
4 1 HMR-0029 Hourmeter
5 1 CNT-0052 PLC Controller
6 1 SUR-0005 Surge Suppressor
7 18 STR-0034 Terminal Block
8 1 OPR-0014 Starter Reset Button
9 1 SWT-0244 Emergency Stop Switch
10 1 SRT-0196 Motor Starter
11 1 RLY-0138 Overload Relay
12 1 HNS-0051 Wiring Harness Socket
13 1 TRR-0062 Transformer
14 2 FUS-0077 Fuse, 1 Amp Primary for 460 VAC
15 1 FUS-0018 Fuse, 2 Amp Secondary
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MNL-0408
7.11 Trouble Shooting Guide
7.11.1 Compressor Will Not Start
Possible Cause or Problem Corrective Action
Emergency Stop Switch not pulled out. Pull out Switch.
Selector Switch not in ON position. Turn switch to ON.
Lights on PLC not illuminated Check voltage and phases
Air Pressure not low enough to close pressure switch. PLC input I3 should be illuminated.
7.11.2 Compressor Is Shutdown, Alarm Code Flashing Sequence.
7.11.2.1 One Flash - Compressor High Temperature Investigate or Possible Cause Corrective Action
Compressor is hot Improve compressor ventilation
Temperature switch electrical connector unplugged Reconnect plug
Temperature switch failure, check that PLC Input I1 is
on.
7.11.2.2 Two Flashes - Compressor Low Oil Pressure Investigate or Possible Cause Corrective Action
Low Oil Pressure after oil and filter change. Restart 1or 2 more times.
Check Oil Pressure with Gauge, if lower than specified Check Oil Level
Check Oil Pressure with Gauge, if in specified range Reset Pressure Switch
7.11.2.3 Three Flashes - Compressor Overtime Investigate or Possible Cause Corrective Action
Replace High Temperature Switch
Replace Oil Filter
Check Compressor Rotation Direction
The compressor is shut down after 5 hours of continuous
operation
June 11, 2009 Page 89
Turn Compressor Control Switch to OFF
then back to ON.
ImVT 120 II Mini Verticus
7.11.2.4 Four Flashes - Securus® Alarm Investigate or Possible Cause Corrective Action
Securus® Cable disconnected Reconnect Securus® Cable
Securus® Cartridge saturated or expired. Replace all purification system cartridges
7.11.2.5 Five Flashes - Carbon Monoxide Monitor Alarm Investigate or Possible Cause Corrective Action
Monitor is not operating with proper pressure and flow Adjust as required.
Monitor is not properly calibrated Calibrate Monitor
If above checks are okay
a. A typical source of carbon monoxide is engine exhaust. Ensure compressor intake is from a fresh air source to prevent premature consumption of the purification cartridges.
Replace Purifications Cartridges
a
7.11.2.6 Six Flashes - Final Separator Shutdown Investigate or Possible Cause Corrective Action
Final Separator has reached maximum number of Pres-
Replace Final Separator
surization Cycles.
7.11.2.7 Seven Flashes -Condensate Fault Investigate or Possible Cause Corrective Action
Check Condensate Level, if full Drain and properly dispose of Condensate
Tank contents.
Check Condensate Level, if not full Clean switch.
If above checks are okay Replace switch
Page 90 1st Edition, Rev . 0 Chg. 10
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