mnl-75028 i280

Instruction Manual and Replacement Parts List

BAUER Compressors, Inc. Phone: (757) 855-60061328 Azalea Garden Road Fax: (757) 855-6224Norfolk, Virginia 23502-1944 www.bauercomp.com

January 8, 2007 Special Edition Rev. 0 Chg. 0 MNL- 75028© 2006 Bauer Compressors, Inc.

BAUERCOMPRESSORS

Industrial Air CompressorI280I280-100-E3 Veritas

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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 © 2006 Bauer Compressors, Inc., and Bauer reserves to itself all rights to this publication. Bauer�s customers have no right to reproduce, rewrite, modify, license or permit anyone else�s use of this information, without the express written per-mission of Bauer Compressors, Inc.

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.

^ WARNING ^

This Instruction Manual and Replacement Parts List contains safety information and instructions for the I280 Industrial Air Compressor.You must read, understand and follow all safety precautions and instructions.

Special Edition January 8, 2007

Rev Chg Date Notes Auth

0 0 01/08/2007 JD

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TABLE OF CONTENTS

CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION

1.1 HOW TO USE THIS MANUAL......................................................................................................................................... 11.1.1 Manual Safety Notices ....................................................................................................................................................... 1

1.2 HOW TO USE THE REPLACEMENT PARTS LIST .................................................................................................... 2

1.3 HOW TO USE THE APPENDIX....................................................................................................................................... 3

1.4 I280-100-E3 VERITAS ........................................................................................................................................................ 41.4.1 Compressor Block .............................................................................................................................................................. 41.4.2 Compressor Drive .............................................................................................................................................................. 41.4.3 Purification System Applicability ...................................................................................................................................... 4

CHAPTER 2: - - - - - - - - - - - - - - - - - - - - - - - OPERATION

2.1 PRE-START CHECKS ....................................................................................................................................................... 5

2.2 START-UP PROCEDURE ................................................................................................................................................. 5

2.3 POST START PROCEDURES .......................................................................................................................................... 5

2.4 SHUTDOWN PROCEDURES ........................................................................................................................................... 5

2.5 LIGHT TOWER SEQUENCES ......................................................................................................................................... 62.5.1 Red Light............................................................................................................................................................................ 62.5.2 Amber Light ....................................................................................................................................................................... 62.5.3 Green Light ........................................................................................................................................................................ 62.5.4 Audible Alarm.................................................................................................................................................................... 6

2.6 ELECTRIC PANEL COMPONENTS ............................................................................................................................. 72.6.1 Compressor Control Panel ................................................................................................................................................. 72.6.1.1 ON Button....................................................................................................................................................................... 72.6.1.1.1 ACD Test ........................................................................................................................................................................ 72.6.1.2 OFF/ Clear Button .......................................................................................................................................................... 82.6.1.2.1 Compressor Overtime.................................................................................................................................................... 82.6.1.3 Alarm / Reset Button ...................................................................................................................................................... 82.6.1.3.1 Final Separator Count .................................................................................................................................................... 82.6.2 LCD Display ...................................................................................................................................................................... 82.6.3 Starter Reset ....................................................................................................................................................................... 82.6.4 Hourmeter........................................................................................................................................................................... 92.6.5 Emergency Stop Switch. .................................................................................................................................................... 92.6.6 Programmable Logic Controller......................................................................................................................................... 9

2.7 WARNINGS ........................................................................................................................................................................ 92.7.1 Final Separator Shutdown .................................................................................................................................................. 9

2.8 ALARMS .............................................................................................................................................................................. 92.8.1 Compressor High Temperature .......................................................................................................................................... 92.8.2 Compressor Low Oil Pressure............................................................................................................................................ 92.8.3 Final Separator Shutdown ................................................................................................................................................ 102.8.4 Condensate Fault .............................................................................................................................................................. 102.8.5 Motor Fault...................................................................................................................................................................... 10

3.1 CONTROL SKID............................................................................................................................................................... 113.1.1 Operating Instructions ...................................................................................................................................................... 11

3.2 AUTOMATIC ALTERNATION PANEL OPERATION.............................................................................................. 12

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3.2.1 Start-up Procedure ...........................................................................................................................................................123.2.2 Fault Conditions ...............................................................................................................................................................123.2.3 Shutdown Procedures .......................................................................................................................................................13

CHAPTER 4:- - - - - - - - - - - - - - IK28.0 COMPRESSOR BLOCK

4.1 MAINTENANCE AND PARTS .......................................................................................................................................144.1.1 Description .......................................................................................................................................................................144.1.2 Air Flow Diagram............................................................................................................................................................154.1.3 Lubrication System...........................................................................................................................................................174.1.3.1 Oil Level Check ............................................................................................................................................................184.1.3.2 Oil Change Procedure ...................................................................................................................................................184.1.3.3 Oil Filter........................................................................................................................................................................194.1.3.3.1 Oil Filter Removal ........................................................................................................................................................194.1.3.4 Oil Pump .......................................................................................................................................................................204.1.3.5 Oil Pressure Setting ......................................................................................................................................................204.1.3.6 Oil Strainer....................................................................................................................................................................204.1.3.7 Oil Jet ............................................................................................................................................................................214.1.4 Cooling System ................................................................................................................................................................224.1.4.1 Maintenance..................................................................................................................................................................224.1.5 Compressor Valves and Valve Heads ..............................................................................................................................234.1.5.1 Initial Operational Check of the Valves .......................................................................................................................234.1.5.2 General Instructions for Changing the Valves..............................................................................................................234.1.5.3 Changing the 1st Stage Valves. ....................................................................................................................................244.1.5.3.1 Removal Procedure.......................................................................................................................................................244.1.5.3.2 Installation Procedure ...................................................................................................................................................254.1.5.4 Changing the 2nd Stage Valves ....................................................................................................................................254.1.5.4.1 Installation Procedure ...................................................................................................................................................264.1.5.5 Changing the 3rd Stage Valves.....................................................................................................................................264.1.5.6 Removal Procedure.......................................................................................................................................................264.1.5.7 Inspection......................................................................................................................................................................264.1.5.7.1 Installation Procedure ...................................................................................................................................................274.1.5.8 Changing the 4th Stage Valves .....................................................................................................................................274.1.5.8.1 Removal Procedures .....................................................................................................................................................284.1.5.8.2 Installation Procedures..................................................................................................................................................284.1.6 Intake Filter ......................................................................................................................................................................294.1.6.1 Dust Collector ...............................................................................................................................................................294.1.6.2 Filter Replacement ........................................................................................................................................................294.1.7 Intermediate Separators ....................................................................................................................................................304.1.8 Oil and Water Separator ...................................................................................................................................................314.1.9 Replacement Parts List .....................................................................................................................................................324.1.10 Troubleshooting................................................................................................................................................................544.1.11 Repair Instructions............................................................................................................................................................564.1.11.1 Preventive maintenance ................................................................................................................................................564.1.11.2 Repair work...................................................................................................................................................................564.1.11.3 Cylinders and pistons....................................................................................................................................................564.1.11.4 Piston Ring Gap ............................................................................................................................................................57

4.2 AUTOMATIC CONDENSATE DRAIN SYSTEM .......................................................................................................584.2.1 Description .......................................................................................................................................................................584.2.2 Compressor Normal Operation.........................................................................................................................................594.2.3 Condensate Draining ........................................................................................................................................................604.2.3.1 Intermediate Separators ................................................................................................................................................604.2.3.2 Oil and Water Separator ..............................................................................................................................................604.2.4 Start Unloading.................................................................................................................................................................61

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4.2.5 Standstill Drainage ........................................................................................................................................................... 614.2.6 Condensate Drain Piping.................................................................................................................................................. 614.2.7 Electrical Connections...................................................................................................................................................... 614.2.8 ACD Maintenance............................................................................................................................................................ 614.2.9 Replacement Parts List..................................................................................................................................................... 624.2.10 Trouble shooting .............................................................................................................................................................. 70

CHAPTER 4: - - - - - - - - -CONDENSATE COLLECTING SYSTEM

4.1 DESCRIPTION.................................................................................................................................................................. 714.1.1 Theory of Operation ......................................................................................................................................................... 71

4.2 MAINTENANCE ............................................................................................................................................................... 72

4.3 REPLACEMENT PARTS LIST ...................................................................................................................................... 73

CHAPTER 5: - - - - - - - - - - - - - - MAINTENANCE SCHEDULE

5.1 K28.0 COMPRESSOR BLOCK....................................................................................................................................... 745.1.1 Preventive Maintenance Tasks......................................................................................................................................... 745.1.2 Maintenance Intervals ...................................................................................................................................................... 755.1.3 Maintenance Records ...................................................................................................................................................... 76

CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

6.1 DESCRIPTION, HORIZONTAL SLIDING .................................................................................................................. 77

6.2 MAINTENANCE OF THE V-BELT AND SHEAVE .................................................................................................... 776.2.1 Checking the Sheave. ....................................................................................................................................................... 776.2.2 Checking the V-belt ......................................................................................................................................................... 776.2.3 V-belt tension ................................................................................................................................................................... 77

6.3 MAINTENANCE OF THE DRIVE MOTOR ................................................................................................................ 78

CHAPTER 7: - - - - - - - - - - - ELECTRICAL PANEL ASSEMBLY

7.1 OVERVIEW ....................................................................................................................................................................... 80

7.2 AC POWER REQUIREMENTS...................................................................................................................................... 807.2.1 Transformer and Fuses ..................................................................................................................................................... 817.2.2 Soft Start........................................................................................................................................................................... 81

7.3 ELECTRIC PANEL COMPONENTS ........................................................................................................................... 827.3.1 Emergency Stop Switch. .................................................................................................................................................. 827.3.2 Starter Reset ..................................................................................................................................................................... 827.3.3 Audible Alarm.................................................................................................................................................................. 827.3.4 Hourmeter......................................................................................................................................................................... 837.3.5 PLC Control ..................................................................................................................................................................... 837.3.5.1 PLC LED�s ................................................................................................................................................................... 847.3.6 Compressor PLC Program Versions ................................................................................................................................ 847.3.7 PLC Inputs and Outputs ................................................................................................................................................... 84

7.4 WARNINGS ...................................................................................................................................................................... 857.4.1 Final Separator Warning .................................................................................................................................................. 85

7.5 ALARMS ............................................................................................................................................................................ 857.5.1 Compressor High Temperature ........................................................................................................................................ 857.5.2 Compressor Low Oil Pressure.......................................................................................................................................... 867.5.3 Compressor Overrun Timer ............................................................................................................................................. 86

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7.5.4 Final Separator Shutdown ................................................................................................................................................867.5.5 Condensate Fault ..............................................................................................................................................................877.5.6 Motor Fault ......................................................................................................................................................................89

7.6 INSTALLING A NEW PROGRAM ................................................................................................................................897.6.1 Installing a New Program Using an EEPROM Cartridge ................................................................................................91

7.7 OVERRUN TIMER ...........................................................................................................................................................927.7.1 Adjusting the Overrun Timer ...........................................................................................................................................92

7.8 WIRE HARNESS CONNECTIONS ...............................................................................................................................93

7.9 REPLACEMENT PARTS LIST ......................................................................................................................................94

7.10 TROUBLE SHOOTING GUIDE......................................................................................................................................967.10.1 Compressor Will Not Start ...............................................................................................................................................967.10.2 Compressor Is Shutdown, Alarm Code Flashing Sequence. ............................................................................................967.10.2.1 Compressor High Temperature.....................................................................................................................................967.10.2.2 Compressor Low Oil Pressure ......................................................................................................................................967.10.2.3 Compressor Overtime ...................................................................................................................................................967.10.2.4 Securus® Alarm.............................................................................................................................................................977.10.2.5 Final Separator Shutdown.............................................................................................................................................977.10.2.6 -Condensate Fault .........................................................................................................................................................977.10.2.7 Motor Over load Fault ..................................................................................................................................................97

7.11 WIRING DIAGRAMS.......................................................................................................................................................98

CHAPTER 8:- - - - - - - - - - - - - DIGITAL PRESSURE SWITCH

8.1 INTRODUCTION..............................................................................................................................................................99

8.2 PROGRAMMING THE PRESSURE SWITCH. ...........................................................................................................998.2.1 Selecting the Display Units. ...........................................................................................................................................1008.2.2 Selecting the On Point for the Pressure Switch..............................................................................................................1008.2.3 Selecting the Off Point for the Pressure Switch. ............................................................................................................1008.2.4 Locking and Unlocking the Switch ................................................................................................................................101

CHAPTER 9:- - - - - - - - - - - - - - - - - - - - - CONTROL SKID

9.1 REPLACEMENT PARTS LIST ....................................................................................................................................1029.1.1 Regulator Control Panel .................................................................................................................................................1029.1.2 Automatic Alternation Panel ..........................................................................................................................................103

CHAPTER 10: - - - - - - - PNEUMATIC VALVES AND CONTROLS

10.1 NONADJUSTABLE VALVES .......................................................................................................................................104

10.2 PRESSURE MAINTAINING VALVE...........................................................................................................................104

10.3 SAFETY VALVES ...........................................................................................................................................................10510.3.1 Dome Load Regulator ....................................................................................................................................................105

CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

11.1 SAFETY ............................................................................................................................................................................10911.1.1 General Safety Precautions.............................................................................................................................................10911.1.2 Safety Warning Labels ...................................................................................................................................................111

11.2 UNPACKING, HANDLING AND INSTALLATION..................................................................................................11211.2.1 Unpacking and Handling................................................................................................................................................112

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11.2.2 Installation of the Compressor Unit ............................................................................................................................... 11311.2.2.1 General........................................................................................................................................................................ 11311.2.2.2 Ventilation .................................................................................................................................................................. 11311.2.2.2.1 Outdoor Installation .................................................................................................................................................... 11311.2.2.2.2 Indoor Installation....................................................................................................................................................... 11311.2.2.2.3 Natural Ventilation ..................................................................................................................................................... 11411.2.2.2.4 Forced Ventilation ...................................................................................................................................................... 11411.2.2.3 Electrical Installation .................................................................................................................................................. 11511.2.2.3.1 Electric Drive.............................................................................................................................................................. 11511.2.2.3.2 Electrical Supply......................................................................................................................................................... 115

11.3 LONG TERM STORAGE............................................................................................................................................... 11711.3.1 General ........................................................................................................................................................................... 11711.3.2 Preparations.................................................................................................................................................................... 11711.3.2.1 Units Equipped with a Filter System.......................................................................................................................... 11711.3.3 Preserving the Compressor............................................................................................................................................. 11711.3.4 Preventive Maintenance During Storage........................................................................................................................ 11811.3.5 Lubrication Oils for Preservation................................................................................................................................... 11811.3.6 Reactivating the Compressor Unit ................................................................................................................................. 118

11.4 REPRODUCIBLE FORMS ............................................................................................................................................ 11911.4.1 Scheduled Maintenance Form ....................................................................................................................................... 11911.4.2 Record of Operating Hours ........................................................................................................................................... 122

11.5 REFERENCE DATA....................................................................................................................................................... 12311.5.1 Tightening Torque Values.............................................................................................................................................. 12311.5.2 Torque Sequence Diagrams ........................................................................................................................................... 12311.5.3 Conversion Formulas ..................................................................................................................................................... 12311.5.4 Approved Lubricants Chart ............................................................................................................................................ 12411.5.5 Glossary of Abbreviations and Acronyms ..................................................................................................................... 124

11.6 ADDITIONAL DOCUMENTS ...................................................................................................................................... 12511.6.1 Diagrams and Drawings ................................................................................................................................................. 12511.6.2 Other Documents............................................................................................................................................................ 125

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LIST OF FIGURES

CHAPTER 1:- - - - - - - - - - - - - - - - - - - - - INTRODUCTION

There are no Figures in this Chapter

CHAPTER 2:- - - - - - - - - - - - - - - - - - - - - - - OPERATION

Figure 2-1 Light Tower .............................................................................................................................................................6Figure 2-2 Electrical Control Panel...........................................................................................................................................7Figure 2-3 Compressor Control Panel.......................................................................................................................................8Figure 3-1 Regulation Panel....................................................................................................................................................11Figure 3-2 Automatic Alternation Panel .................................................................................................................................12

CHAPTER 4:- - - - - - - - - - - - - - IK28.0 COMPRESSOR BLOCK

Figure 4-1 K28.0 Compressor Block, Front View (Oil Pump Side) .......................................................................................14Figure 4-2 K28.0 Air Flow Diagram.......................................................................................................................................15Figure 4-3 K28.0 Lubrication Oil Flow ..................................................................................................................................17Figure 4-4 K28.0 Oil Level Check ..........................................................................................................................................18Figure 4-5 K28.0 Oil Drain Plug.............................................................................................................................................19Figure 4-6 K28.0 Oil Filter......................................................................................................................................................19Figure 4-7 K28.0 Oil Pump.....................................................................................................................................................20Figure 4-8 K28.0 Oil Jet..........................................................................................................................................................21Figure 4-9 K28.0 V-Belt Tension Adjustment ........................................................................................................................22Figure 4-10 Valve Function.......................................................................................................................................................23Figure 4-11 Cross Section of the 1st Stage Valve Head and Valves.........................................................................................24Figure 4-12 Cross Section of the 2nd Stages Valve Heads and Valves ....................................................................................25Figure 4-13 Cross Section of the 3rd Stages Valve Heads and Valves.....................................................................................26Figure 4-14 Screwdriver Value Removal..................................................................................................................................27Figure 4-15 Cross Section of the 4th Stage Valve Head and Valves ........................................................................................27Figure 4-16 Intake Filter............................................................................................................................................................29Figure 4-17 Cross Section of a Separator..................................................................................................................................30Figure 4-18 K28.0 Crankcase....................................................................................................................................................32Figure 4-19 Driving Gear ..........................................................................................................................................................34Figure 4-20 K28.0 1st/2nd Stage Piston and Cylinder ..............................................................................................................35Figure 4-21 K28.0 3rd Stage Piston and Cylinder ....................................................................................................................36Figure 4-22 K28.0 4th Stage Piston and Cylinder.....................................................................................................................38Figure 4-23 K28.0 1st Stage Valve Head..................................................................................................................................40Figure 4-24 2nd Stage Valve Head ...........................................................................................................................................42Figure 4-25 3rd Stage Valve Head ............................................................................................................................................44Figure 4-26 4th Stage Valve Head ............................................................................................................................................45Figure 4-27 K28.0 Flywheel......................................................................................................................................................46Figure 4-28 K28.0 Fanwheel.....................................................................................................................................................47Figure 4-29 K28.0 Intake Filter.................................................................................................................................................48Figure 4-30 Lubrication System................................................................................................................................................50Figure 4-31 K28.0 Oil Pump and Fanwheel Drive....................................................................................................................52Figure 4-32 Checking the Piston Ring Gap...............................................................................................................................57Figure 4-33 4 Stage Automatic Condensate Drain System.......................................................................................................58Figure 4-34 ACD, Normal Operation........................................................................................................................................59

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Figure 4-35 ACD, Condensate Draining................................................................................................................................... 60Figure 4-36 ACD System......................................................................................................................................................... 62Figure 4-37 Automatic Condensate Drain Unit ........................................................................................................................ 63Figure 4-38 1st and 2nd Stage Condensate Drain Valve .......................................................................................................... 64Figure 4-39 3rd Stage Condensate Drain Valve........................................................................................................................ 65Figure 4-40 4th Stage Condensate Drain Valve........................................................................................................................ 66Figure 4-41 Manual Condensate Drain Valve........................................................................................................................... 68Figure 4-42 4th Stage Separator................................................................................................................................................ 69

CHAPTER 4: - - - - - - - - -CONDENSATE COLLECTING SYSTEM

Figure 4-43 Component Locations............................................................................................................................................ 71Figure 4-44 Condensate Collecting System.............................................................................................................................. 73

CHAPTER 5: - - - - - - - - - - - - - - MAINTENANCE SCHEDULE

There are no Figures in this Chapter

CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

Figure 6-1 Horizontal Motor Mount (typical)......................................................................................................................... 77Figure 6-2 V-belt Deflection ................................................................................................................................................... 78Figure 6-3 ............................................................................................................................................................................... 79

CHAPTER 7: - - - - - - - - - - - ELECTRICAL PANEL ASSEMBLY

Figure 7-1 Electrical Panel Label............................................................................................................................................ 80Figure 7-2 Transformer and Fuses .......................................................................................................................................... 81Figure 7-3 Soft Start................................................................................................................................................................ 82Figure 7-4 Electrical Panel Assembly..................................................................................................................................... 82Figure 7-5 PLC........................................................................................................................................................................ 83Figure 7-6 High Temperature Switch...................................................................................................................................... 86Figure 7-7 Low Oil Pressure Switch ....................................................................................................................................... 86Figure 7-8 Condensate Tank Component Locations............................................................................................................... 88Figure 7-9 Soft Motor Start..................................................................................................................................................... 89Figure 7-10 PLC Programing Port ............................................................................................................................................ 90Figure 7-11 PLC EEPROM (Typical)....................................................................................................................................... 91Figure 7-12 Overrun Timer Adjustment ................................................................................................................................... 92Figure 7-13 Electrical Panel Exterior........................................................................................................................................ 94Figure 7-14 Electrical Panel, Interior ........................................................................................................................................ 95

CHAPTER 8: - - - - - - - - - - - - - DIGITAL PRESSURE SWITCH

Figure 8-1 Digital Pressure Switch ......................................................................................................................................... 99

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CHAPTER 9:- - - - - - - - - - - - - - - - - - - - - CONTROL SKID

Figure 9-1 Back of Regulator Control Panel.........................................................................................................................102Figure 9-2 Automatic Alternation Panel ...............................................................................................................................103

CHAPTER 10: - - - - - - - PNEUMATIC VALVES AND CONTROLS

Figure 10-1 Pressure Maintaining Valve.................................................................................................................................104Figure 10-2 Safety Valves .......................................................................................................................................................105Figure 10-3 System Relief Valve and Drain Valve.................................................................................................................106Figure 10-4 Digital Pressure Switch and PMV .......................................................................................................................107Figure 10-5 .............................................................................................................................................................................108

CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

Figure 11-1 Lifting Devices ....................................................................................................................................................112Figure 11-2 6 Bolt and 4 Bolt Torque Sequence.....................................................................................................................123

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CHAPTER 1: INTRODUCTION1.1 How To Use This Manual

This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-uct(s) listed on the front cover.

All instructions in this manual should be observed and carried out as written to prevent damage or pre-mature wear to the product or the equipment served by it.

If your unit is equipped with nonstandard accessories and/or options, supplemental information is nor-mally included in other documentation; i.e. OEM Manuals or additional Bauer Manuals.

While every effort is made to ensure the accuracy of the information contained in this manual, Bauer Compressors, Inc. will not, under any circumstances be held accountable for any inaccuracies or the consequences thereof.

1.1.1 Manual Safety NoticesImportant 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.

^ NOTE ^

NOTE advise of technical requirements that require particular attention by the operator or the maintenance technician for proper maintenance and utilization of the equipment.

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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 ellipis (�) in the Part Number column means the part is illustrated for assembly purposes only and is not available for sale as an individual component. This part can be obtained by ordering the complete assembly.

� AR in the Qty column means that the item is cut or manufactured to the size which the customer spec-ifies.

� A dash (�) in the Item Number column indicates that there is more than one part number applicable to the preceding Item Number.

� The letter(s) 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 com-pressor unit identification plate on the compressor unit�s frame.

Information Example

Model Number TCOM25

Serial Number 32165

Date of Manufacture 02/2005

Quantity required 2

Part Number N04860

Part Description Valve

^ 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.

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1.3 How to Use the AppendixInformation 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.

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1.4 I280-100-E3 Veritas Medium airCharging Rate 145.0 scfm1

Free Air Delivery 121.0 scfm2

Inlet pressure atmosphericOperating pressure. 5,000 psig Ambient temperature range 40° - 115° FWeight Approximately 5,000 lb.

1.4.1 Compressor Block IK28.0 Mod. 3No. of Stages 4No. of Cylinders 3Cylinder Bore, 1st Stage 8.5 in (215 mm0)Cylinder Bore, 2nd Stage 8.5/7.3 in (215/185 mm)Cylinder Bore, 3rd Stage 1.96 in (50 mm)Cylinder Bore, 4th Stage 0.94 in (24 mm)Piston Stroke 4.9 in 125 mm)Direction of Rotation, when facing flywheel CounterclockwiseIntermediate Pressure, 1st Stage 36 -50 psi (2.5 - 3.5 Bar)Safety Valve Setting, 1st Stage 75 psi (5.0 Bar)Intermediate Pressure, 2nd Stage 200 - 230 psi (14 - 16 Bar)Safety Valve Setting, 2nd Stage 350 psi (24 Bar)Intermediate Pressure, 3rd Stage 950 - 1000 psi (65 - 70 Bar)Safety Valve Setting, 3rd Stage 1160 psi (80 Bar)Maximum Compressor Speed 1200 RPMOil Capacity Approximately 31.7 Qts. (30 l)Oil Pressure 43 - 57 psi (3 - 4 bar)Recommended Oil Bauer OIL-0024Maximum Inclination 10° to all sides Maximum Operating Pressure 5,000 psig

1.4.2 Compressor Drive

1.4.3 Purification System Applicability The I280 is not equipped with a Bauer Purification System.

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

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

Voltage Frequency Phase Power Type BAUER PN

208 - 460 VACa

a.The motor has be renameplated to 440 VAC60 Hz 3 φ 100 HP TEFC MTR-0236

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CHAPTER 2: OPERATION2.1 Pre-start Checks

1. Ensure that all scheduled maintenance is completed.

2. Check compressor oil level. Refer to Chapter 3.

3. Drain ASME Bottle of liquid

4. Drain Condensate Collection Tank

5. Check path of Cooling Air Flow for freedom from obstructions.

6. Check for adequate clearance on all sides of unit.

7. Check for and remove all sources of possible air contamination.

8. Check Compressed Air Output Connection for security.

9. Check Emergency Stop Switch is pulled out.

2.2 Start-up Procedure

1. Verify that all connections downstream of the compressor are secure.

2. Apply electric power to the unit.

3. Press the ON button on the Compressor Control Panel. (See Figure 2-3).

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 Shutdown Procedures

1. Verify all bottle valves and fill valves are closed.

2. Press the OFF button on the Compressor Control Panel. (See Figure 2-3).

3. Leave Emergency Stop Switch pulled out and the main circuit breaker is ON 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 for long term storage preservation instructions.

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2.5 Light Tower Sequences

2.5.1 Red LightIf the red light is illuminated the compressor is in an Alarm status. Check the Compressor Control Panel for details.

2.5.2 Amber LightIf the amber light is illuminated the compressor is in a warning status. Check the Compressor Control Panel for details.

2.5.3 Green LightIf the green light is flashing the compressor is in Standby and may start at any time.

If the green light is illuminated steady the compressor is running.

2.5.4 Audible AlarmThe Audible Alarm is a 110db electronic horn that sounds during alarm and warning conditions. Vari-ous sounds are possible by setting the DIP switches on the back of the Audible Alarm.

Figure 2-1 Light Tower

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2.6 Electric Panel Components

2.6.1 Compressor Control PanelThe Compressor Control Panel is a backlite LCD panel.

2.6.1.1 ON Button The Compressor Control Panel ON button must be pressed to operate the compressor system. When the ON button is pressed the LCD display will read COMPRESSOR ON. The compressor will start and stop automatically based on the status of the pressure switch.

2.6.1.1.1 ACD Test Pressure and hold ON Button for 1 second to test the ACD System.

Figure 2-2 Electrical Control Panel

1. Compressor Control Panel2. Hourmeter

3. Emergency Stop Button4. Audible Alarm5. Starter Reset

1

2

3

4

5

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2.6.1.2 OFF/ Clear ButtonThe Compressor Control Panel OFF button must be pushed to secure the compressor system.When the OFF button is pressed the LCD display will read COMPRESSOR OFF. The OFF / CLEAR Button is also used to clear the display of any alarm messages.

2.6.1.2.1 Compressor OvertimeIf the OFF / CLEAR Button is held for one second, the compressor overtime setting is shown on the LCD Display. This setting can be changed by rotating the left potentiometer located on the front of the PLC while pressing and holding the OFF / CLEAR Button. Release the OFF / CLEAR Button to exit the compressor overtime screen.

2.6.1.3 Alarm / Reset ButtonDuring an alarm or warning condition the Audible Alarm will sound. Press the ALARM RESET Button to silence the Audible Alarm. Any warnings or alarms will continue to be displayed on the LCD Dis-play.

2.6.1.3.1 Final Separator CountIf the unlabeled Button is held for one second, the Final Separator Count will be shown on the LCD Display. The maximum number of cycles that the separator can accumulate before the unit will enter an alarm condition is also shown. Release the unlabeled Button to exit the Final Separator Count screen.

2.6.2 LCD DisplayA visual display of the compressor operating conditions, warnings and alarms.

2.6.3 Starter ResetThe Starter Reset is a blue push button with the letter �R� at its center. Pushing this button will reset the soft start. Should the electric motor have overloaded and tripped out during normal operation, then depressing this button after giving the motor starter some time to cool, will reset the soft start.

Figure 2-3 Compressor Control Panel

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2.6.4 HourmeterThe 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.

2.6.5 Emergency Stop Switch.The Emergency Stop Switch is a switch with a mushroom head located immediately to the right of the Audible Alarm. 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 Con-trol Panel OFF Button. 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.

2.6.6 Programmable Logic ControllerThe electrical panel contains a Telemecanique 24 I/O Twido Programmable Logic Controller. This unit will provide logical operations to the overall system that includes the high pressure compressor, purifi-cation systems, and other accessories.

2.7 Warnings

2.7.1 Final Separator Shutdown

The high pressure 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 triggered, the LCD Display turns Amber, the unit continues 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 adjust-ments to the PLC. Please contact Bauer Product Support for detailed instructions

2.8 Alarms

2.8.1 Compressor High TemperatureThe 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 LCD Display turns Red and show the Alarm condition and remedies.

2.8.2 Compressor Low Oil PressureThe 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

^ WARNING ^

Do not attempt to override the Final Separator Shutdown. This feature is provided to protect operating per-sonnel from injury or death.

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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 com-pressor will shutdown, the I2 lamp will extinguish, and the and the LCD Display turns Red and show the Alarm condition and remedies.


The high pressure compressor is equipped with a final separator. To prevent fatigue failure of this ves-sel, 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 replace-ment 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

2.8.4 Condensate FaultThe compressor condensate level float switch is located in the condensate collection tank. Under normal operating conditions, the switch is closed and the I6 lamp on the PLC is on. On a high condensate level the float switch will open, the compressor will shutdown, the PLC I6 lamp will extinguish, and the LCD Display turns Red and show the Alarm condition and remedies. The operator should drain the condensate from the tank and resume operation of the equipment.

2.8.5 Motor FaultThe compressor system is equipped with an Allen-Bradley SMC-3 Soft Start Motor Controller which is located inside the electrical enclosure. When a motor fault occurs, I0 on the PLC will illuminate and the compressor will shut down. The backlight of the LCD Display turns Red and show the Alarm condition and remedies. A more complete description of the Motor Fault can be determined by the flashing LED and flash code description on the front of the SMC-3.

^ WARNING ^


^ NOTE ^

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

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3.1 Control Skid

3.1.1 Operating InstructionsSee Figure 3-1

1. Select which Regulation Panel will be used for the filling process (#1 or #2).

2. Close all Vent Valves (3 and 7).

3. Open Storage Shutoff Valve (1).

4. Set Pressure Adjustment Regulator (4) to desired fill pressure. The fill pressure is indicated on the Dome Pressure Gauge (5).

5. Open Fill Shutoff Valve (8).

6. Use Vent Valves (3 and 7) to vent system before maintenance of high flow regulation panels.

Figure 3-1 Regulation Panel

1. Storage Shutoff Valve2. Storage Pressure Gauge3. Inlet Pressure Vent Valve4. Pressure Adjustment Regulator

5. Dome Pressure Gauge6. Fill Pressure Gauge7. Dome Pressure Vent Valve8. Fill Shutoff Valve

^ NOTE ^

Verify fill pressure by reading Dome Pressure Gauge.

^ NOTE ^

When fill pressure is achieved, the Dome Regulator will stop the filling process.

1 2 3 4 5 6 7 8

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3.2 Automatic Alternation Panel Operation

An Automatic Alternation Panel is used with two or more compressor units to equalize the run times on the compressor units. Without an Automatic Alternation Panel one compressor would take domi-nance over the other. This causes the operating hours on each compressor to get out of balance making Maintenance Schedules harder to maintain.

3.2.1 Start-up ProcedureSee Figure 3-2

1. Ensure the Compressor Control Panel on each Compressor Unit is indicating COMPRESSOR OFF. If it is not press the OFF button on the Compressor Control Panel.

2. Turn the OFF/ON Selector Switch (2) on the Automatic Alternation Panel to the ON position.The ON/OFF Selector Switch will illuminate.

3. Select the Compressor Unit to be used first by pressing the ON button on the Compressor Control Panel.

4. Select and turn on the other Compressor Units by pressing the ON button on each Compressor Unit Compressor Control Panel. Allow the compressor to build up pressure and listen to the unit as it operates. If excessive knocking or vibrations are observed shut down the unit.

5. Verify that the Compressor Status Lights on Automatic Alternation Panel are flashing or are illumi-nated.

6. The Compressor Units will now automatically alternate with demand.

3.2.2 Fault Conditions

1. When a compressor has a fault that condition is relayed to the Automatic Alternation Panel. The Light Tower on the Compressor Unit with the fault will illuminate and the Compressor Status Light

Figure 3-2 Automatic Alternation Panel

1. Compressor Status Lights 2. OFF/ON Switch

1

2

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of the Faulted Compressor Unit will be off. The Compressor Control Panel will indicate the type of fault and suggested maintenance action.

2. Before performing any maintenance on the Compressor Unit turn the compressor off by pressing the OFF button on the Compressor Control Panel.

3. The Automatic Alternation Panel will make one of the remaining compressors first automatically.

4. When the fault condition is corrected and Compressor Unit is ready to be returned to service, press-ing the ON button on the Compressor Control Panel will restart the compressor and the correspond-ing light on the Alternation Panel will indicate the Compressor Unit is available.

3.2.3 Shutdown Procedures

1. Verify all bottle valves and fill valves are closed.

2. Turn each Compressor Unit by pressing the OFF button on the Compressor Control Panel.

3. Turn the OFF/ON Selector Switch (2) on the Automatic Alternation Panel to the OFF position.

4. If the compressor is to remain idle for six months or longer, refer to the Appendix titled, Long Term Storage for preservation instructions.

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CHAPTER 4: IK28.0 COMPRESSOR BLOCK4.1 Maintenance and Parts

4.1.1 DescriptionThe K28.0 compressor block is used to compress air to pressures up to 5,000 psi (350 bar). The com-pressor block is of a four stage, three cylinder design, whereby 1st and 2nd Stage are housed in one common stepped cylinder. The 1st/2nd Stage Cylinder is positioned vertically, the 3rd Stage Cylinder to the right, viewing at the Flywheel. The 4th Stage Cylinder on the left forms the second leg of the T arrangement. The 1st/2nd Stage Cylinder is lubricated by means of the forced-feed lubrication system, the other cylinders are splash lubricated.

Figure 4-1 K28.0 Compressor Block, Front View (Oil Pump Side)

1. Cylinder, 1st/2nd Stage2. Safety Valve, 1st Stage3. Safety Valve, 3rd Stage

4. Condensate Separator, 1st Stage5. Oil Filler/Dipstick6. Cylinder, 4th Stage

7. Flywheel8. Cylinder, 3rd Stage9. Intake Filter

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4.1.2 Air Flow DiagramFor the mode of operation refer to the flow diagram. See Figure 4-2.

The 1st Stage (2) of the compressor draws in atmospheric air through Intake Filter (1). In the 1st Stage the air is compressed to a pressure of approximately 43 psi (3 bar).

After the 1st Stage, there is a condensate Separator (10). The condensate is drained via a 1st Stage Sole-noid Valve (18) which is also used for start unloading.

The compressed air entering the 2nd Stage is cooled by the 1st Stage Cooler (6). In the 2nd Stage (3) the air is further compressed to approximately 215 psi (15 bar). Leaving the 2nd Stage the air passes through 2nd Stage Cooler (7) and 2nd Stage Separator (11) to the 3rd Stage (4).

Figure 4-2 K28.0 Air Flow Diagram

1. Intake Filter2. 1st Stage3. 2nd Stage 4. 3rd Stage5. 4th Stage6. 1st Stage Cooler 7. 2nd Stage Cooler8. 3rd Stage Cooler9. Aftercooler

10. 1st Stage Separator 11. 2nd Stage Separator 12. 3rd Stage Separator 13. Oil and Water Separator14. 1st Stage Safety Valve 15. 2nd Stage Safety Valve16. 3rd Stage Safety Valve 17. Final Safety Valve

18. 1st Stage Solenoid Valve 19. 2nd Stage Solenoid Valve, 20. 3rd Stage Solenoid Valve 21. 4th Stage Solenoid Valve 22. 1st Stage Condensate Drain Valve 23. 2nd Stage Condensate Drain Valve 24. 3rd Stage Condensate Drain Valve 25. 4th Stage Condensate Drain Valve

2

6

10

14 16

12

1

9 8 7

15

11 13

17

18 19 20 21

22 23 24 25

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In the 3rd Stage the air is further compressed to approximately 990 psi (68 bar). Leaving the 3rd Stage the air passes through 3rd Stage Cooler (8) and 3rd Stage Separator (12) to the 4th Stage (5).

In the 4th Stage the air is finally compressed to the respective operating pressure of the compressor unit. On leaving the 4th Stage the air is passed through Aftercooler (9) and enters the Oil and Water Separator (13) where remaining liquid oil and water particles are removed from the air utilizing a cen-trifugal type separator.

After the Oil and Water Separator there is a Pressure Maintaining Valve. This valve keeps a steady minimum pressure of approximately 2,175 psi (150 bar) within the separators ensuring their optimum efficiency.

After the Pressure Maintaining Valve the air then passes through a Check Valve, which prevents the delivered air from flowing back from the connected systems into the compressor.

At the outlet connection the air is delivered to the connected pressure systems.

The intermediate pressures of the individual stages are monitored by Safety Valves (14) to (16). Final pressure is monitored by the Final Safety Valve (17).

The condensate resulting from the recooling after the compression process is drained automatically by the Automatic Condensate Drain System fitted as standard on the compressor block. Condensate from the Separators (10), (11) and (12) and Oil and Water Separator (13) is drained regularly by pneumati-cally operated Condensate Drain Valves (22) to (25). Each drain valve is controlled by its own Solenoid Valve (18) to (21). The condensate is drained via a common manifold into a collection bottle for dis-posal.

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4.1.3 Lubrication SystemThe compressor is provided with a forced-feed lubrication system. See Figure 4-3.

The Oil Pump with Regulating Valve (2) is driven by the crankshaft through pinion gears. The Oil Pump draws the oil from the crankcase Oil Sump (3), through Oil Strainer (1)and pumps it through the Oil Filter (4). This filter is fitted with a replaceable cartridge which efficiently eliminates particles larger than 10 microns from the oil.

The oil enters the 1st/2nd Stage Cylinder through Injection Pipe (7), it is sprayed from below against the piston head of the stepped piston where it is atomized and lubricates pistons and cylinders. Drip oil reaches the rotating crankshaft with its connecting rods where it is agitated to lubricate the moving parts of the compressor.

The oil pressure in the lubricating system is indicated at Oil Pressure Gauge (5) and monitored by Oil Pressure Switch (6). If the oil pressure falls below 26 psi (1.8 bar), the Oil Pressure Switch reports the failure to the monitoring unit which in turn shuts off the compressor.

Figure 4-3 K28.0 Lubrication Oil Flow

1. Oil Strainer2. Oil Pump with Regulating Valve3. Oil Sump4. Oil Filter

5. Oil Pressure Gauge6. Oil Pressure Switch7. Injection Pipe

1234

5 6 7

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4.1.3.1 Oil Level Check

1. Check oil level every day prior to putting compressor into operation.

2. Remove the Dipstick, wipe it off with a lint-free cloth, and then reinsert the Dipstick tightly.

3. Remove the Dipstick again. Note the oil level which must be between the minimum and maximum notches, Figure 4-4.

4. Oil level must not exceed maximum as this will cause excessive lubrication of compressor and result in valves sooting up.

4.1.3.2 Oil Change ProcedureSee Figure 4-5. When changing oil, also change the lubricating Oil Filter.

1. Run compressor until it is warm. And then turn the compressor off and unscrew the Oil Dipstick.

2. Remove the Oil Drain Plug on the crankcase housing or, on units with an Oil Drain Hose, remove hose union nut from the frame or housing.

3. Drain the oil into a suitable container.

4. Change gasket and reinstall Oil Drain Plug.

5. Remove Oil Filter Cartridge (See Paragraph 4.1.3.3.1) and replace with a new Oil Filter Cartridge, Bauer P/N N2620.

6. Fill with fresh oil until the upper mark of the Dipstick is reached, approximately 32 quarts (30 liters).

7. Wait a few minutes before putting unit into operation. During operation, check oil pressure on gauge. Gauge should read 43 to 57 psi (3 to 4 bar).

^ NOTE ^

Make sure that the Dipstick is completely screwed in before the oil level is checked.

Figure 4-4 K28.0 Oil Level Check

MAX

MIN

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4.1.3.3 Oil FilterSee Figure 4-6. To reduce the wear to the compressor internal parts, the Oil Pump is fitted with a full-flow Oil Filter. The Oil Filter should be changed with every oil change. See the chapter titled Mainte-nance Schedule for intervals.

4.1.3.3.1 Oil Filter Removal

1. Unscrew used Oil Filter.

2. Lubricate the sealing ring of the new Oil Filter and fill filter with fresh oil.

3. Screw the new Oil Filter on until the seal touches the surface. From this position tighten the Oil Fil-ter another half turn by hand. Never over-tighten or use tools for installation.

Figure 4-5 K28.0 Oil Drain Plug Figure 4-6 K28.0 Oil Filter

1. Oil Drain Plug 1. Oil Filter

1

1

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4.1.3.4 Oil PumpThe pressure regulating valve of the Oil Pump is adjustable. The pressure is set at the factory to 50 psi (3.5 bar). In case of malfunction, the Oil Pump cannot be repaired but must be replaced.

4.1.3.5 Oil Pressure SettingRefer to Figure 4-7 and proceed as follows:

1. Remove Cap Nut (1).

2. Loosen Lock Nut (2) and turn Adjustment Screw (3) clockwise to increase pressure, counter-clock-wise to reduce pressure.

3. Oil pressure should be 50 psi (3.5 bar) at nominal compressor speed.

4. Lock Adjustment Screw with Lock Nut in new position.

5. Start compressor to verify the new setting.

6. Readjust if necessary.

7. Fit Cap Nut with a new Copper Washer (4) when setting is according to specification.

4.1.3.6 Oil Strainer

Figure 4-7 K28.0 Oil Pump

1. Cap Nut2. Lock Nut3. Adjustment Screw

4. Copper Washer5. Oil Strainer6. Oil Suction Line

4 23

1

6

5

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To prevent larger particles from entering the Oil Pump, the Oil Suction Line is equipped with an Oil Strainer (Figure 4-7).

1. Drain the compressor oil by removing Oil Drain Plug (See Figure 4-5) on crankcase or unit frame.

2. Remove Oil Suction Line (6) by disconnecting the swivel nuts at both ends of the Oil Suction Line.

3. Unscrew Oil Strainer (5).

4. Clean the Oil Strainer and dry with clean, compressed air.

5. Always use a new sealing ring on reassembly.

4.1.3.7 Oil JetSee Figure 4-8. The lubrication of the compressor internal parts is controlled by the Oil Jet. Prolonged running with contaminated oil and/or oil filter will lead to clogging of the Oil Jet, reducing the oil flow to the rotating parts of the compressor.

1. Disconnect pressure line from Oil Jet (3) by undoing Fitting (1).

2. Remove two Self-Locking Nuts (2) securing the jet assembly to the crankcase and pull out Oil Jet.

3. Wash the Oil Jet assembly to remove deposits. Remove old sealing compound from crankcase and Oil Jet sealing surfaces.

Figure 4-8 K28.0 Oil Jet

1. Fitting 2. Self-Locking Nuts 3. Oil Jet

2

3 1

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4. Install a new O-Ring and apply a thin layer of silicone rubber on the sealing surface of the Oil Jet.

4.1.4 Cooling SystemSee Figure 4-9. The cylinders of the compressor block, the Intermediate Coolers and the Aftercooler are air-cooled by two Fanwheels (1) which draw the cooling air from the Flywheel side. Observe cooling air flow on installation of the compressor unit.

The Fanwheels are driven by the compressor crankshaft through V-belts. Each Fanwheel is driven by two V-belts on a Pulley (2).

4.1.4.1 MaintenanceSee Figure 4-9. The tension of the V-belts needs to be checked regularly, and if required, the belts should be adjusted as follows:

1. Remove Fanwheel guard.

2. Turn compressor manually using the Fanwheel (1) and check the condition of the V-belts over their full length. Change belts if required.

3. Loosen Hex Nut (4) on the eccentric shaft by holding the eccentric shaft against the Hexagon (3).

4. Turn the eccentric shaft by means of the Hexagon (3) until the correct belt tension has been achieved. Correct belt tension is when both belts can be pressed down in the center by approxi-mately 0.39 to 0.79 inches (10 to 20 mm) using thumb pressure.

5. Tighten the Hex Nut (4) counter-acting with Hexagon (3).

Figure 4-9 K28.0 V-Belt Tension Adjustment

1. Fanwheel2. V-Belts Pulley

3. Hexagon4. Hex Nut

3/8" to 3/4"1 to 2 cm(10 to 20 mm)

1

2

3 4

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6. Reinstall Fanwheel guard.

4.1.5 Compressor Valves and Valve HeadsSee Figure 4-10. The Valve Heads of the individual stages form the top part of the cylinders. The Intake and Pressure Valves are fitted inside the Valve Heads. The valves are operated by the flow of the medium. On the suction stroke, the Intake Valves open and the medium flows into the cylinders. At the start of the compression stroke the Intake Valve closes and the medium opens the Pressure Valve.

4.1.5.1 Initial Operational Check of the ValvesAfter roughly half an hour's operation, valves should be checked. Note that the intake line to the Valve Heads should be warm and outlet piping should be hot. Valves are then operating properly.

4.1.5.2 General Instructions for Changing the ValvesPlease observe the following instructions for valve maintenance:

� Always replace valves as a complete set.

� Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in an appropriate cleaning solution and clean with soft brush.

� Check individual components for excessive wear. If the valve seat and valve disks are dented, replace the valves.

� Valve Head screws must be tightened with a torque wrench (see tightening torque values in the Appendix).

� Check the valve space in the Valve Heads for dirt and clean, if necessary.

Figure 4-10 Valve Function

^ WARNING ^

Do not touch the outlet piping with bare hands, use a thermometer.

Intake Pressure

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� Use only satisfactory Gaskets and O-Rings on reassembly.

� Observe the correct sequence when reassembling.

� Before starting the unit, turn the compressor manually using the Flywheel and check whether all items have been correctly installed.

� 30 minutes after restarting the compressor unit, stop the unit, let it cool down to ambient temperature, and retighten Valve Studs and Cap Nuts. Otherwise valves could work loose due to setting of the gaskets.

� Remove and check the valves every 1,000 operating hours.

� Replace the valves every 2,000 operating hours to avoid fatigue failure.

4.1.5.3 Changing the 1st Stage Valves.See Figure 4-11. The 1st Stage Valves are located in the Valve Head of the 1st/2nd Stage Cylinder.

4.1.5.3.1 Removal Procedure.

1. Unscrew and remove Cap Nut (1).

2. Unscrew Stud (3) a number of turns.

3. Check, and if required, replace Gasket (2).

4. Remove Valve Cover Nuts (11) and take off Valve Cover (4).

5. Check O-Ring (10) and replace if required.

6. Take off Valve Cap (5) and extract the valve.

Figure 4-11 Cross Section of the 1st Stage Valve Head and Valves

1. Cap Nut2. Gasket3. Stud4. Valve Cover

5. Valve Cap6. Pressure Valve7. Valve Gasket8. Inlet Valve

9. Valve Head10. O-Ring11. Valve Cover Nut

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2

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7. Check Valve Gasket (7) and replace, if required.

4.1.5.3.2 Installation Procedure

1. Fit new valve with Gasket (2) and locate Valve Cap (5).

2. Fit Valve Cover (4) with O-Ring (10) and fasten with Valve Cover Nuts (11).

3. Tighten Valve Cover Nuts diagonally using a torque wrench to the correct value.

4. Tighten Stud (3) using an allen wrench and screw on Cap Nut (1) and Gasket (2).

4.1.5.4 Changing the 2nd Stage ValvesSee Figure 4-12. The 2nd Stage Valves are located directly on the side of the 1st/2nd Stage Cylinder. One Inlet and one Outlet Valve are provided.

The 2nd Stage Valves are removed and reinstalled as follows:

1. Remove Cap Nut (12).

2. Check Gasket (11) and replace if necessary.

3. Unscrew Stud (10) a number of turns.

4. Remove Nuts (9) and take off Valve Cover.

5. Check O-Ring (7) and replace if necessary.

6. Remove Valve Cap (4) and take out valve.

Figure 4-12 Cross Section of the 2nd Stages Valve Heads and Valves

1. Discharge Valve2. Intake Valve3. O-Ring4. Valve Cap

5. Manifold6. Allen Screw7. O-Ring

8. Valve Cover9. Nut10. Stud

11. Gasket12. Cap Nut13. Valve Gasket

1 1339 27 4

4

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7. Check Valve Gasket (13) and replace if necessary.4.1.5.4.1 Installation Procedure

1. Fit new valve with Gasket (13) and locate Valve Cap (4).

2. Fit Valve Cover (8) with O-Ring (7) and fasten with Nuts (9). Use a torque wrench to tighten Nuts to the correct value.

3. Tighten Stud (10) using an allen wrench and screw on Cap Nut (12) with Gasket (11).

4.1.5.5 Changing the 3rd Stage ValvesSee Figure 4-13. The 3rd Stage Valves are located in the 3rd Stage Valve Head. Two Inlet and two Out-let Valves are provided.

4.1.5.6 Removal Procedure

1. Unscrew and remove Hex Nuts (1).

2. Loosen Studs (3) a couple of turns.

3. Remove six Allen Screws (not shown) from Valve Head Cover and remove Valve Cover (4).

4. Insert two screwdrivers into Extraction Groove (12) of the Valve Cap (5) and lift out Valve Cap with O-Ring (6) (See Figure 4-14).

5. Check O-Ring (6) and replace if required.

6. Remove Inlet Valve (7) and Discharge Valve (10).

4.1.5.7 Inspection

Figure 4-13 Cross Section of the 3rd Stages Valve Heads and Valves

1. Hex Nut2. Lock Washer3. Stud4. Value Cover

5. Valve Cap6. O-Ring7. Inlet Valve8. Gasket

9. Valve Head Gas-ket

10. Discharge Valve11. Valve Head12. Extraction Groove

10

8

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1. Check Valve Gasket (8) and replace if required.

2. Clean Inlet Valve (7) and Discharge Valve (10) and check function.

3. Replace any faulty parts.

4.1.5.7.1 Installation Procedure

1. Fit new valves with Gaskets (8) and locate Valve Caps (5) with O-Rings (6).

2. Fit Valve Cover (4) and secure with six Allen Screws. Tighten Allen Screws diagonally to the valve.

3. Tighten Studs (3) by hand.

4. Screw on Hex Nut (1) and tighten with torque wrench while holding Studs in position with a screw-driver.

4.1.5.8 Changing the 4th Stage ValvesSee Figure 4-15. The valves are located in the Valve Head of the 4th Stage. The Inlet Valve is com-prised of a Valve Disk (8) and a Wavy Washer (7).The Inlet Valve Seat is machined directly into the Cylinder Liner (10) of the 4th Stage Piston.The Discharge Valve consists of the Discharge Valve Seat (13), Discharge Valve Disk (14), Discharge Valve Spring (3), and Stroke Limiter (1).

The Valve Head comprises the Bottom Section (9) and the Top Section (4). The Valve Head is secured to the cylinder by means of the Valve Head Screw (5).

Figure 4-14 Screwdriver Value Removal

^ CAUTION ^

The Valve Cap of the Inlet Valve protrudes 0.118 inches (3 mm) more out of the Valve Head than the Valve Cap for the Discharge Valve. Make sure that Studs are turned out far enough before installing Valve Cover.

Figure 4-15 Cross Section of the 4th Stage Valve Head and Valves

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The procedure for removal and reinstallation of the valves is as follows:

4.1.5.8.1 Removal Procedures

1. Loosen the inlet and discharge Pipe on the Valve Head.

2. Loosen and remove Valve Head Screw (5).

3. Take off Valve Head, Top Section (4) and Stroke Limiter (1) with O-Ring (2). This releases the Discharge Valve Disk (14) and Discharge Valve Spring (3).

4. Check spring for satisfactory condition and resiliency preferably by comparing with a new spring.

5. Replace spring if necessary.

6. Check O-Ring (2) and replace if necessary.

7. Insert two screwdrivers into the Extraction Groove of the Discharge Valve Seat (13) and lift Valve Seat with O-Ring (11).

8. Check, and if required, replace O-Ring (11) and Backing Ring (12).

9. Remove Wavy Washer (7) and Inlet Valve Disk (8).

10. Check Inlet Valve Seat on Piston Liner (10). If scored, remove Piston Liner, take out Piston and lap Valve Seat.

4.1.5.8.2 Installation Procedures

1. Turn Flywheel on compressor manually until piston protrudes from the Cylinder Liner (10).

1. Stroke Limiter2. O-Ring3. Discharge Valve Spring4. Valve Head, Top Section5. Valve Head Screw6. Extraction Groove7. Wavy Washer

8. Inlet Valve Disk9. Valve Head, Bottom Section10. Piston Liner11. O-Ring12. Backing Ring13. Discharge Valve Seat14. Discharge Valve Disk

1 4

1 3

1 21 1

1 2 3 4 5

67

8

91 0

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2. Locate the Inlet Valve Disk (8) and the Wavy Washer (7), both of which are prevented from side slip by the piston.

3. Insert the Discharge Valve Seat (13) in the bottom section of the Valve Head (9), taking care to avoid damaging the Inlet Valve Disk and Wavy Washer.

4. Place Discharge Valve Spring (3) and Discharge Valve Disk (14) on Stroke Limiter (1) and locate this in the top section of the Valve Head. Place the top section of the Valve Head on the bottom sec-tion.

5. Screw in Valve Head Screws (5) and tighten down diagonally using a torque wrench.

6. Tighten inlet and discharge Pipe Couplings..

4.1.6 Intake FilterA dry Micronic Filter is used to filter intake air. See Figure 4-16

4.1.6.1 Dust CollectorThe Dust Collector (3) needs emptying at regular intervals, especially under heavy dust conditions. When emptying the Dust Collector, the Filter Element should be left untouched, it is sufficient to merely check the hand-tightness of the Wing Nut on the Filter Element. Check, however, whether any large particles obstruct the outside of the Filter Element and remove them.

4.1.6.2 Filter ReplacementThe Filter cartridge should be changed if the vacuum pressure in the Filter has reached the maximum possible value. This is determined from the Vacuum Gauge (6). The maximum permissible vacuum pressure has been reached if the red indicator is visible.

Change Filter Element as follows:

Figure 4-16 Intake Filter

1. Filter Housing2. Filter Element3. Dust Collector4. Wing Nut

5. Sealing Ring6. Vacuum Gauge7. Clamp Screw

3 4 5 2 1

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1. Remove and empty the Dust Collector (3).

2. Loosen Clamp Screw (7).

3. Loosen Wing Nut (4) holding Filter Element (2), taking care not to lose the round washer under-neath the Wing Nut.

4. Remove Filter Element, note that the finned plastic ring must remain on the Filter Element.

5. Clean the inside of the Filter Housing with a damp cloth, take care to prevent any dust entering the Intake Pipe.

6. Replace the Filter Element. Use Bauer P/N N7698 only.

7. Reset Vacuum Gauge by pressing the Rubber Cap on the Gauge, indicator should change from red to green.

4.1.7 Intermediate Separators(See Figure 4-17) Intermediate Separators are mounted on the compressor block between 2nd and 3rd Stage, and between 3rd and 4th Stage. An additional Condensate Separator is provided after the 1st Stage. These Separators are designed to remove water and oil accumulating due to cooling the air down after the compression process. Separation is achieved by means of the action provided by centrifugal inserts.The Separators are maintenance-free. The condensate is drained regularly by the Automatic Condensate Drain System.

Figure 4-17 Cross Section of a Separator

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4.1.8 Oil and Water SeparatorThe compressed air leaving the final stage is cooled in the Aftercooler to approximately18 to 27 F (10 to 15 C) above ambient temperature and then enters the Oil and Water Separator (See Figure 4-17).

The maximum recommended amount of four load cycles per hour should not be exceeded. If it is possi-ble to regulate the operation of the unit to such a degree as to achieve four load cycles per hour, in our opinion this would be an optimum between usage and actual life.

Separation of the condensate produced by the recooling after the compression process is achieved by means of the action provided by a centrifugal insert. The condensate is drained regularly by the Auto-matic Condensate Drain System.

The Oil and Water Separator is maintenance-free.

^ NOTE ^

The Oil and Water Separator is subject to dynamic load. It is designed to withstand up to 360,000 load cycles for a pressure variation of approximately 7252 psi (500 bar). 1 load cycle = 1 pressurization, 1 depressurization. When the maximum number of load cycles has been reached, the Oil and Water Separa-tor must be changed.

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4.1.9 Replacement Parts List

# KIT Qty Part No. Description Notes◊ 1 072593 Crankcase1 � 1 63323 Crankcase2 � 4 N2321 Plug3 � 4 N8114 Gasket4 � 1 N22003 Circlip Ring

Figure 4-18 K28.0 Crankcase

3938

37

36

3742

4140

44

3132333435

3

3023

1

23

2 3

2324

25

27

2922

22

232628

1920

21

17

18

16

15

12

13

14

11

10

78

9

65

4

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Figure 4-18 (cont.) K28.0 Crankcase

# KIT Qty Part No. Description Notes5 � 4 N21991 Shaft Gasket Seal6 � 2 72551 Washer7 � 8 N109 Allen Screw8 � 8 N58 Washer9 � 1 72549 Cover10 � 1 N15265 O-Ring11 � 16 N15667 Hexagon Screw12 � 16 N1594 Washer13 � 1 60559 Bearing Cap14 � 1 N15268 O-Ring15 � 1 N15662 Cylindrical Roller Bearing16 � 1 61130 Spacer17 � 1 61129 Spacer18 � 1 N15663 Cylindrical Roller Bearing19 � 1 N15659 Circlip Ring20 � 1 N15664 Cylindrical Roller Bearing21 � 1 N15660 Circlip Ring22 � 3 N4261 Gasket23 � 1 N2375 Reducing Coupling24 � 1 N20230 Male Connector25 � 1 N20018 Screwed Socket26 � 1 N7436 Screw Cap27 � 1 N15833 Plug28 � 1 N20257 Stud29 � 1 N2796 Plug30 � 1 063355 Oil Filler Items 31 through 3531 � 1 N1809 Circlip Ring32 � 1 N2721 Screw Cap33 � 1 063354 Oil Dip Stick34 � 1 N18617 O-Ring35 � 1 63353 Oil Filling Pipe36 � 1 66154 Crankcase Vent37 � 2 N20018 Screwed Socket38 � 1 N370 Hexagon Nut Self-Locking39 � 2 N58 Washer40 � 1 N3769 Hose Clamp41 � 3 N2862 Washer42 � 1 N756 Hexagon Screw

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# KIT Qty Part No. Description Notes◊ 1 063040 Driving Gear1 � 1 � Crankshaft Available only with 0630402 � 1 � Balancer Weight Available only with 0630403 � 1 N15655 Feather Key4 � 4 N16095 Allen Screw5 � 1 N15656 Slotted Round Nut6 � 1 N15657 Locking Plate7 � 3 � Connecting Rod Assembly Available only with 063040

Figure 4-19 Driving Gear

7

7

1

2

3

4

56

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# KIT Qty Part No. Description Notes◊ 1 063992 1st/2nd Stage Piston and Cylinder Assembly1 � 1 63993 Stepped Cylinder Upper Part2 ..c 2 N16079 O-Ring3 � 1 63994 Stepped Cylinder Lower Part4 � 8 N2740 Hexagon Nut Self-Locking5 ..c 8 N1219 Washer6 � 8 N15648 Stud7 � 1 072670 Piston Assembly8 � 2 N16080 Circlip Ring9 � � Piston Pin Available only with 07267010 � 1 N16392 Piston Ring Set11 � 1 N16393 Piston Ring Set

Figure 4-20 K28.0 1st/2nd Stage Piston and Cylinder

4

5

1

6

4

5

3

6

2

2

7

10

8

89

11

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# KIT Qty Part No. Description Notes◊ 1 063388 3rd Stage Piston and Cylinder Assembly1 � 1 63777 Guide Cylinder2 ..c 1 N16079 O-ring3 � � Piston Available only with 0726384 � 2 N16080 Circlip Ring5 � � Piston Pin Available only with 0726386 � � Plain Compression Ring Avail. only with N181627 � � Plain Compression Ring Avail. only with N18162

Figure 4-21 K28.0 3rd Stage Piston and Cylinder

1

23 4

4

5

6

7

8

910

1112

13

1415

17

16

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Figure 4-21 (cont.) K28.0 3rd Stage Piston and Cylinder

# KIT Qty Part No. Description Notes8 ..c 1 N2858 O-Ring9 � 1 63237 Cylinder10 � 4 N15648 Stud11 � 4 N1219 Washer12 ..c 4 N2740 Hexagon Nut Self-Locking13 � 8 N15972 Stud14 � 8 N16 Washer15 ..c 8 N644 Hexagon Nut Self-Locking16 � 1 072638 Piston Cpl. Items 3 through 517 � 1 N18162 Piston Ring Set Items 6 and 7

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# KIT Qty Part No. Description Notes◊ 1 063975 4th Stage Piston and Cylinder Assembly1 � 1 N16079 O-ring2 � 4 N15648 Stud3 � 1 63777 Guide Cylinder4 � 4 N1219 Washer5 � 4 N2740 Hexagon Nut Self-Locking6 � 1 N2858 O-Ring7 � 1 63969 Cylinder8 � 8 N15972 Stud9 � 8 N16 Washer10 � 8 N644 Hexagon Nut Self-Locking11 � 4 N24763 Piston Ring Set12 � 2 N16080 Circlip Ring13 � 1 63240 Guide Piston

Figure 4-22 K28.0 4th Stage Piston and Cylinder

1 23

45

6

7

89

10

1122

23 12

13 14

12

15

16

1718 19

20

21

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Figure 4-22 (cont.) K28.0 4th Stage Piston and Cylinder

# KIT Qty Part No. Description Notes14 � � Piston Pin Available only with 07267115 � 2 N56 Stud16 � � Free Piston Available only with 06397617 � 1 61235 Press Pad18 � 4 N58 Washer19 � 4 N2765 Hexagon Nut Self-Locking20 � 1 N15419 O-Ring21 � � Sleeve Available only with 06397622 � 1 063976 Piston and Sleeve Items 11, 16 through 2123 � 1 072671 Piston Assembly Items 12 through 15

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# KIT Qty Part No. Description Notes◊ 1 063390 1st/2nd Stage Valve Head Assembly1 ..c 1 63371 Gasket2 � 1 63029 Valve Head3 a.. 4 63391 Gasket4 .b. 2 N16085 Pressure Valve5 .b. 2 N16084 Suction Valve6 � 4 63372 Hood

Figure 4-23 K28.0 1st Stage Valve Head

1

2

33

45

66

77

88

9

9

10

11

1213

14

15

1213

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Figure 4-23 (cont.) K28.0 1st/2nd Stage Valve Head

# KIT Qty Part No. Description Notes7 a.. 4 N4779 O-Ring8 � 4 62815 Pressure Flange9 � 12 N655 Washer10 � 8 N16132 Allen Screw11 .b. 2 71073 Stud12 a.. 4 N842 Gasket13 � 4 N16082 Acorn Nut14 � 4 N15644 Allen Screw15 .b. 2 71074 Stud

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# KIT Qty Part No. Description Notes◊ 1 063977 2nd Stage Valve Head Assembly1 � 2 N309 Acorn Nut2 a.. 4 N1316 Gasket3 .b. 2 71076 Headless Screw4 a.. 6 N282 Hexagon Nut Self-Locking5 � 6 N655 Washer6 � 2 60660 Pressure Flange7 a.. 2 N3165 O-Ring8 � 8 N16658 Allen Screw9 � 6 N19678 Stud10 � 2 63967 Suction and Discharge Connection11 � 2 N7063 O-Ring12 � 2 64265 Blind Flange13 � 1 N52 Plug

Figure 4-24 2nd Stage Valve Head

1 2 3

4 5

6

7

8

9

10 11

12 2

141516

17

1819

20

21

1318

1716

1011

12 2

1415

8

9

76

123

45

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Figure 4-24 (cont.) 2nd Stage Valve Head

# KIT Qty Part No. Description Notes14 � 8 N357 Hexagon Screw15 � 8 N176 Spring Washer16 � 2 N4779 O-Ring17 � 2 60659 Hood18 a.. 2 61238 Gasket19 .b. 1 N16089 Pressure Valve20 .b. 1 N16088 Suction Valve21 � 1 N20195 Straight Male Connector

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# KIT Qty Part No. Description Notes◊ 1 063831 3rd Stage Valve Head Assembly1 � 6 N15650 Allen Screw2 � 4 N19512 Hexagon Nut3 � 4 N176 Spring Washer4 � 1 61039 Valve Cover5 .b. 2 71070 Stud6 .b. 2 71071 Stud7 a.. 4 N3997 O-Ring8 � 4 56183 Valve Cap9 .b. 2 N15641 Suction Valve10 .b. 2 N15642 Pressure Valve11 a.. 4 56668 Gasket12 � 1 74780 Valve Head13 ..c 1 61040 Gasket

Figure 4-25 3rd Stage Valve Head

1 23

2 3

4

5

6

7

7

8

8

9

1011

11 12

13

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# KIT Qty Part No. Description Notes◊ 1 062637 4th Stage Valve Head Assembly1 � 1 70435 Valve Head2 � 1 064156 Suction and Discharge Valve Items 3 through 93 .b. 1 61227 Suction Valve Plate4 .b. 1 61228 Spring Plate5 .b. 1 61232 Pressure Valve Seat6 a.. 1 N7063 O-Ring7 a.. 1 N15482 Back-up Ring8 .b. 1 61241 Pressure Valve Plate9 .b. 1 64749 Pressure Spring10 � 1 70430 Valve Head11 � 1 N28168 Sealing Ring12 � 1 61240 Stroke Limiter13 � 6 N19020 Screw

Figure 4-26 4th Stage Valve Head

2

3

1

45

67

89

10

1112 13

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# KIT Qty Part No. Description Notes◊ 1 63399 Flywheel1 � 1 63219 V-Belt Rim2 � 1 N15651 Feather Key3 � 1 61576 Assembling Hub4 � 8 N2374 Allen Screw5 � 8 N16 Washer6 � 8 N644 Hexagon Nut Self-Locking

Figure 4-27 K28.0 Flywheel

1

2

3

4

56

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# KIT Qty Part No. Description Notes◊ 1 064789 Fanwheel Assembly1 � 4 N123 Allen Screw2 � 1 N7093 Hexagon Nut Self-Locking3 � 1 N1594 Washer4 � 1 59820 Fanwheel Blade Support5 � 8 N4107 Fanwheel Blade6 � 1 N3947 Grooved Wheel Bearing7 � 1 56147 Distance Sleeve8 � 1 N3948 Grooved Ball Bearing9 � 1 N17689 Circlip Ring10 � 1 59821 Excenter Shaft11 � 1 N1219 Washer12 � 1 N2740 Hexagon Nut Self-Locking13 � 4 N2581 V-Belt14 � 1 64082 Fanwheel Hub

Figure 4-28 K28.0 Fanwheel

1

2 3 4 5

67

8 910

1112

13

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# KIT Qty Part No. Description Notes◊ 1 064077 Intake Filter Assembly1 � 1 N7786 Intake Filter2 a.. 1 N7698 Filter Cartridge3 � 4 N646 Hexagon Screw4 � 6 N280 Spring Washer5 � 2 N15499 Worm Gear Clamp6 � 1 64280 Connecting Tube7 � 1 N4779 O-Ring8 � 1 N8107 Rubber Washer9 � 1 N2221 Vacuum Indicator10 � 1 N2197 Rain Cap11 � 4 N89 Hexagon Screw12 � 4 N58 Washer13 � 1 63923 Support14 � 2 N1130 Mounting Clamp15 � 4 N370 Hexagon Nut Self-Locking16 � 2 N1112 Hexagon Screw

Figure 4-29 K28.0 Intake Filter

1

2

34

4

5

5

6

7

89

10 1112

12

13

14

1516

1 2

34

598

6

10

7

This page is inserted to provide proper page sequencing

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# KIT Qty Part No. Description Notes◊ 1 072682 Lubricating System1 � 1 072687 Connecting Tube Assembly2 � 4 N20017 Straight Male Stud3 � 2 N1042 Hexagon Nut Self-Locking4 � 2 N3026 Spring Washer5 � 2 N3051 Stud6 � 1 64316 Oil Nozzle7 � 1 N4573 O-Ring8 � 1 N20054 Elbow Bulkhead Stud9 � 1 072685 Connecting Tube Assembly10 � 2 N370 Hexagon Nut Self-Locking11 � 2 N58 Washer12 � 2 N89 Hexagon Screw13 � 2 N20018 Straight Male Stud

Figure 4-30 Lubrication System

12

25

13

3 45

6 7

89

9

10

11 12

2

14

1516

17

18

192

202

2223

2425

21

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Figure 4-30 (cont.) Lubrication System

# KIT Qty Part No. Description Notes14 � 1 N1049 Screw Cap15 � 1 N16309 Plug16 � 1 N20067 Reducing Stud17 � 1 N20213 Adjustable L Stud18 � 1 N2619 Filter Head19 a.. 1 N2620 Filter Cartridge20 � 1 072683 Connecting Tube Assembly21 � 1 063878 Oil Pump Ventilator Driving System22 � 1 N22667 Reducing Stud23 � 1 N4261 Gasket24 � 1 058046 Dirt Trap25 � 1 072645 Connecting Tube Assembly

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# KIT Qty Part No. Description Notes◊ 1 063878 Oil Pump and Fanwheel Drive1 � 2 N689 Hexagon Screw2 � 1 57737 Locking Plate3 � 1 57739 Washer4 � 1 57332 V-Belt Pulley5 � 2 N15658 Circlip Ring6 � 1 N21979 O-Ring7 � 1 N1782 Feather Key8 � 1 N8980 Circlip Ring9 � 1 N21796 Shaft Seal10 � 2 72548 Disc11 � � Circlip Ring Available only with N452512 � 1 70441 Disc13 � 1 N4522 O-Ring14 � 3 N15126 Stud15 � 1 60715 Bearing Cap16 � 1 N3195 O-Ring17 � 2 N16776 Stud18 � 1 N293 Gasket19 � 1 N314 Plug20 � 4 N3497 Stud21 � 3 N370 Hexagon Nut Self-Locking22 � 3 N58 Washer23 � 1 060236 Oil Pump24 � 1 N8878 O-Ring

Figure 4-31 K28.0 Oil Pump and Fanwheel Drive

12

3

4

5 67

8 910

2112 13

14

15 16

171819 2911

30

27

2731

3233

3411

28

2625

24

23

2021

22

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Figure 4-31 (cont.) K28.0 Oil Pump and Fanwheel Drive

# KIT Qty Part No. Description Notes25 � 1 57338 Bearing Shaft26 � 1 N2507 O-Ring27 � 2 N4525 Grooved Ball Bearing28 � 1 57335 Toothed Wheel29 � 1 N7093 Hexagon Nut Self-Locking30 � 1 N1594 Washer31 � 2 N4086 Countersunk Screw32 � 1 57738 Locking Washer33 � 1 57336 Toothed Wheel34 � 1 57337 Toothed Wheel

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4.1.10 Troubleshooting

Compressor Block

Trouble Cause Remedy

No oil pressure 1. Oil Pump defective 2. Oil Pressure Regulator

clogged or dirty

1. Replace Pump.2. Clean and/or readjust Oil

Pressure Regulator.

Low oil pressure 1. Oil level in compressor too low

2. Oil Strainer in Inlet Pipe clogged

3. Lube Oil Filter clogged

1. Check oil level, top up. 2. Clean Oil Strainer. 3. Change Filter cartridge.

Compressor not building up pres-sure

1. 1st Stage Unloading Valve not receiving voltage

2. 1st Stage Unloading Valve dirty and/or blocked

3. Automatic Condensate Drain System leaking

1. Check voltage from com-pressor control.

2. Remove valve and clean or replace.

3. Refer to ACD troubleshoot-ing table.

Compressor not attaining final pressure or output insufficient

1. Condensate Drain Valve(s) and/or Fittings leaking

2. Premature opening of final Safety Valve

3. Piston Rings worn4. Valves faulty5. Pipes leaking 6. Intake Filter dirty, Vacuum

Gauge not working

1. Tighten and reseal.2. Clean final Safety Valve

and readjust 3. Replace 4. Replace5. Seal 6. Service Intake Filter.

Safety Valves between individual stages releasing pressure

1. Intermediate pressure too high

2. Valves not closing properly

Check valves. Service and clean valves.

Compressor running too hot. 1. Insufficient supply of fresh cooling air.

2. Intake or Outlet Valves not closing properly.

3. Wrong direction of rotation.

1. Check location for maxi-mum ambient temperature less than 110° F (+45°C).

2. Check and clean valves. replace as necessary.

3. See arrow on compressor and remedy accordingly

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Oil residue in delivered air 1. Improper maintenance of Filters, Filter cartridge satu-rated

2. Wrong oil type

1. Remedy Filters, change Fil-ter cartridges

2. Use right oil type and clean sooted valves

Automatic Condensate Drain


Drain Valves of 1st, 2nd, or 3rd Stage do not open (drain)

1. Solenoid Valve is not depressurizing Drain Valve

2. Solenoid Valve not receiv-ing electrical signal

3. Plunger of Drain Valve sticking

1. Check valve, replace if nec-essary

2. Check connections; check timer; replace if defective

3. Clean valve or replace

Drain Valves of 1st, 2nd, or 3rd Stage do not close

1. No control medium avail-able

2. Solenoid Valve sticking 3. Drain Valve sticking in

open position4. Drain Valve seat dirty

1. Check supply lines2. Clean or replace3. Clean or replace4. Clean or replace Valve Seat

Drain Valve of 4th Stage does not open (drain)

1. No control medium 2. Solenoid Valve inoperative,

blocking the control medium to Drain Valve

3. Solenoid Valve not receiv-ing electrical signal

4. Drain Valve Seat dirty

1. Check medium supply 2. Check valve, replace if nec-

essary3. Check connections; check

timer; replace if defective4. Clean or replace Valve Seat

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4.1.11 Repair Instructions

4.1.11.1 Preventive maintenance This usually involves replacing the valves, Gaskets and O-rings and carrying out the task in the mainte-nance schedule.

4.1.11.2 Repair workSome repair work can be carried out on the compressor unit but a certain level of training, experience and skill is necessary. It should be noted that no matter what the level of expertise is some repairs should never be attempted. These include: Safety Valves are never repaired but always replaced.

Preventive maintenance usually involves replacing the valves, Gaskets and Sealing Rings as well as carrying out the maintenance work.

Repair work can be carried out on the compressor block to a certain extent but a certain experience and skill is necessary. It should be noted, however, that

� no repair should be carried out on the crank drive nor on the bearings

� Safety Valves are not repaired but always replaced completely.

4.1.11.3 Cylinders and pistonsThe 1st/2nd Stage Piston is a double acting differential piston with Piston Rings:

The 3rd Stage Piston is also a differential piston, the lower part is the guide piston and the upper part is the compression piston with Piston Rings.

The 4th Stage Piston is a two part differential piston. The guide piston, like the 3rd Stage Piston, does not have Piston Rings and the upper compression piston works in a Cylinder Liner and has 8 chro-mium-plated Piston Rings.

The compression piston is guided by a retainer which in turn is connected to the guide piston.

Piston and Cylinder Liner must always be replaced together. The 4th Stage Piston's piston rings cannot be replaced. If the piston rings are worn, replace them as a set with the Cylinder Liner.

When carrying out maintenance work on pistons and piston rings, make sure that the piston rings are replaced in the correct order, refer to the parts list.

When locating the piston rings, make sure that the TOP mark faces upwards, but not, however, on the two lower taper faced rings of the 1st Stage. In this case, the TOP mark must face downwards.

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4.1.11.4 Piston Ring Gap

If output drops and excessive piston ring wear and high oil consumption is suspected, check the Piston Ring Gap as follows:

1. Remove the piston with piston rings.

2. Remove the piston rings from the piston.

3. Insert the piston rings in the corresponding cylinder approximately 0.4 inch (10 mm) from the top edge. Check the Piston Ring Gap with a feeler gauge.

4. Change the piston rings if permissible values are exceeded.

Figure 4-32 Checking the Piston Ring Gap

Table 4-1: Maximum Allowable Piston Ring Gap

Cylinder Gap

8.6 in (215 mm) 0.054 in (1.35 mm)

7.4 in (185 mm) 0.048 in (1.20 mm)

2 in (50 mm) 0.02 in (0.50 mm)

0.96 in (24 mm) 0.014 in (0.35 mm)

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4.2 Automatic Condensate Drain System

4.2.1 DescriptionThe automatic condensate drain system operates electropneumatically and is comprised of the follow-ing:

Four electrically controlled solenoid valves. Four electrical timersFour pneumatically operated condensate drain valves A condensate manifoldA condensate separator/silencer A condensate collector bottle

The automatic condensate drain system drains the intermediate separators 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 separators at shutdown of the compressor unit.

Figure 4-33 4 Stage Automatic Condensate Drain System

1. Condensate drain valve, 1st stage separator2. Condensate drain valve, 2nd stage separator3. Condensate drain valve, 3rd stage separator4. Condensate drain valve, oil and water separator5. Solenoid valves, 1st, 2nd, and 3rd stages6. Solenoid valve, 4th stage

7. Condensate inlet connections (tube connector)8. Manual condensate drain valves9. Condensate collector bottle connection10. Control medium connection11. Control medium feedback

1

2

3 4

56

7

89

10

11

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4.2.2 Compressor Normal OperationSee Figure 4-34

The condensate drain valves are operated pneumatically via a normally closed solenoid valve by an electrical signal from a timer. The control pressure applied to the condensate drain valves by the sole-noid valve is taken from the intermediate separator after the 2nd stage.

Before compressor start-up the separator condensate drain valves (1), (2) and (3) are open. The oil and water separator condensate drain valve (4) is closed by spring pressure.

After start-up and once the wye -delta motor has switched from wye to delta phase the solenoid valves (5) are energized and open. The solenoid valve (6) is not energized and remains closed. This results in control pressure being applied to condensate drain valves (1, 2, and 3). The servo-pistons (7) are pressed into the valve seats (8) and the condensate drain valves close. The condensate drain valve (4) is not pressurized by the control pressure. It remains closed by spring pressure and due to the pressure build of the compressor. The compressor then delivers compressed air to the connected systems.

Figure 4-34 ACD, Normal Operation

1. Condensate drain valve, 1st stage2. Condensate drain valve, 2nd stage3. Condensate drain valve, 3rd stage4. Condensate drain valve, oil and water separator

5. Solenoid valves, 1st, 2nd, and 3rd stages6. Solenoid valve, 4th stage7. Servo-piston8. Valve seat

1 2 3 4

7

8

7

8

7

8

7

8

5 5 5 6

Condensate Control Pressure

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4.2.3 Condensate DrainingSee Figure 4-35

4.2.3.1 Intermediate SeparatorsSequentially every fifteen minutes the condensate is drained from one of the intermediate separators. The appropriate solenoid valve (5) is deenergized by it�s timer and closes for approximately six sec-onds. This causes the control pressure on the top of the servo-piston (7) of the condensate drain valve (1, 2, or 3) to be vented through the relief port of the solenoid valve (5). This causes the servo-piston (7) to be raised from it�s valve seat (8) by the pressure from the intermediate separator. This opens the pas-sage which allows the condensate to drain from the intermediate separator through the condensate drain valve and into the condensate collection system. After six seconds the solenoid valve (5) is reenergized and opens. This applies control pressure to the top of the servo-piston (7) resetting it in the valve seat (8) and closing the passage to the condensate collection system.

4.2.3.2 Oil and Water SeparatorAlso every fifteen minutes and independently of the intermediate separators, the oil and water separator is drained. The solenoid valve (6) is energized for approximately three seconds by it�s timer and opens. This causes the control pressure to be applied to the top of the servo-piston (7) of the condensate drain valve (4). This moves the servo-piston (7) down and lifts the valve off the valve seat (8). The passage opens and allows condensate to drain from the oil and water separator through the condensate drain valve and into the condensate collection system. After three seconds the solenoid valve is deenergized and closes, shutting off the control pressure. The servo-piston is unloaded as the residual control pres-

Figure 4-35 ACD, Condensate Draining

1. Condensate drain valve, 1st stage2. Condensate drain valve, 2nd stage3. Condensate drain valve, 3rd stage4. Condensate drain valve, oil and water separator

5. Solenoid valves, 1st, 2nd, and 3rd stages6. Solenoid valve, 4th stage7. Servo-piston8. Valve seat

Condensate Control Pressure1 2 3 4

5 5 5 6

8

7

8

7

8

7

8

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sure is vented through the relief port of the solenoid valve. The pressure from the oil and water separa-tor causes the valve to reset and return to normal operation.

4.2.4 Start UnloadingThe unloading of the compressor during the starting phase is possible because of the lack of control air immediately after starting the unit. After the compressor has attained nominal speed, control pressure starts to flow through the open solenoid valves (5) to the condensate drain valves. The control pressure closes the condensate drain valves (1, 2, and 3). Once these valves close, the compressor delivers to the consuming device.

4.2.5 Standstill DrainageAt compressor shutdown, the solenoid valves (5) are deenergized, open and vent condensate drain valves (1, 2, and 3). The servo-pistons are raised by the residual pressure within the separators which opens the passage and drains the separators.

4.2.6 Condensate Drain PipingThe outlet opening of the condensate drain manifold is equipped with a tube connector. From here the condensation is directed into a collecting bottle by means of a tube

4.2.7 Electrical ConnectionsFor electrical connection of the automatic condensate drain, refer to any included wiring diagrams.

4.2.8 ACD MaintenanceThe 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:

5. Open all manual drain valves one after the other.

6. Observe the drainage of condensation.

7. 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.

8. Find the fault and remedy accordingly.

9. If little or no condensation emerges, the automatic system is operating properly.

10. The condensate collection bottle should be emptied regularly. Due care must be taken to ensure that any oil which is drained with the condensate is disposed of properly. Check local, state and federal regulations.

^ 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 off before the first drain cycle is completed, the timing relay 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.

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4.2.9 Replacement Parts List

Item Qty Part No. Description Notes◊ 1 081368 Automatic Condensate Drain System1 1 073256 Automatic Condensate Drain Unit See Figure 4-372 1 N4182 Solenoid Valve 115VAC 50-60Hz3 1 063925 Support4 4 N20346 Tee Fitting5 3 073286 Connecting Tube Assembly6 3 N20065 Straight Coupling7 1 N20211 Straight Coupling8 4 N102 Washer9 1 N19513 Allen Screw

Figure 4-36 ACD System

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5

56

67

8

9

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Item Qty Part No. Description Notes◊ 1 073256 Automatic Condensate Drain Unit1 2 064010 Condensate Drain Valve2 1 062523 Condensate Drain Valve3 1 064012 Condensate Drain Valve4 1 62293 Cover Plate5 1 72781 Manifold6 5 N4333 O-ring7 5 011430 Manual Condensate Drain Valve (See Figure 4-41)

Figure 4-37 Automatic Condensate Drain Unit

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Item Qty Part No. Description Notes◊ 2 064010 Condensate Drain Valve1 1 058053 Solenoid Valve2 4 N210 Allen Screw M6x203 1 N2720 O-ring4 1 N4177 Grooved Ring5 1 57628 Valve Piston6 1 N3489 O-ring7 � � Valve Body Available only with 0640108 1 N2507 O-ring9 1 56687 Valve Seat10 1 N4178 O-ring11 1 60416 Valve End12 4 N1511 Allen Screw M6x6013 2 N102 Washer14 2 N781 Allen Screw M6x35

Figure 4-38 1st and 2nd Stage Condensate Drain Valve

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8910

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Item Qty Part No. Description Notes◊ 1 062523 Condensate Drain Valve1 1 058053 Solenoid Valve2 4 N210 Allen Screw M6x203 1 N2720 O-ring4 1 N4177 Grooved Ring5 1 57629 Valve Piston6 1 N3489 O-ring7 � � Valve Body Available only with 0625238 1 N2507 O-ring9 1 56691 Valve Seat10 1 N4178 O-ring11 1 60416 Valve End12 4 N1511 Allen Screw M6x6013 2 N102 Washer14 2 N781 Allen Screw M6x35

Figure 4-39 3rd Stage Condensate Drain Valve

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Item Qty Part No. Description Notes◊ 1 060412 Condensate Drain Valve1 1 058053 Solenoid Valve2 4 N19534 Allen Screw M6x203 1 N2720 O-ring4 1 N4177 Grooved Ring5 1 60417 Valve Piston6 1 N3489 O-ring7 � � Valve Body Available only with 0604128 1 N2507 O-ring

Figure 4-40 4th Stage Condensate Drain Valve

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910

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Figure 4-40 (cont.) 4th Stage Condensate Drain Valve

Item Qty Part No. Description Notes9 1 60419 Valve Seat10 1 N4178 O-ring11 1 60418 Sealing Cone12 1 60600 Spring13 1 60415 Valve End14 4 N1511 Allen Screw M6x6015 2 N102 Washer16 2 N781 Allen Screw M6x35

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Item Qty Part No. Description Notes◊ 1 011430 Condensate Drain Tap1 1 068410 Drain Valve Body2 1 13283 Seal3 1 055888 Handle

Figure 4-41 Manual Condensate Drain Valve

1

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# KIT Qty Part No. Description Notes◊ 1 064126 Separator1 � � Filter Head Only available with 0641262 a.. 2 N4586 O-ring3 � 1 064124 Cyclone Insert4 � � Filter Housing Only available with 0641265 � � Filter Bottom Only available with 064126

Figure 4-42 4th Stage Separator

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4.2.10 Trouble shooting


Solenoid Valve does not drain. 1. Solenoid valve receives no electrical signal

2. Plunger of drain valve sticking

1. Check connections, timer. Replace if necessary.

2. Clean or replace valve.

Condensate Drain Valve does not drain.

1. Solenoid valve does not depressurize drain valve.

2. No control medium avail-able.

3. Solenoid valve sticking.4. Drain valve sticking in open

position

1. Check solenoid valve, replace if necessary

2. Check supply lines3. Clean or replace4. Clean or replace

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CHAPTER 4: CONDENSATE COLLECTING SYSTEM4.1 Description

The Condensate Collecting System serves as the central collector of the accumulated condensate and separates the condensate from the air. The Condensate Collecting Tank is equipped with a mechanical level indicator. In addition, an electrical float switch makes it possible to sound an alarm or shut off the unit. The separated air is passed through activated charcoal so that only clean and odorless air is released. When the Condensate Collecting System is full it is drained by the Condensate Drain Tap.

4.1.1 Theory of OperationSee Figure 4-43. The Condensate Collecting System is connected to the ACD System by a hose. An Electrical Connector connects the Float Switch (9) in the Condensate Tank (5) to the compressor�s PLC for alarms and warnings. The condensate enters the Condensate Collecting System at the Condensate Inlet (4) and is routed through a pipe into the Condensate Tank. The air then moves to the Filter Head (3) where it passes through two fleece Condensate Filter Mats (2), a layer of Activated Charcoal (7) and two more Condensate Filter Mats (2) before it is released to the outside air. The Condensate Tank (5) and Filter Head (3) are connected together by a Clamp (8). The Condensate Collecting System is pro-

Figure 4-43 Component Locations

1. Level Indicator2. Condensate Filter Mats3. Filter Head4. Condensate Inlet5. Condensate Tank

6. Relief Valve7. Activated Charcoal8. Clamp9. Float Switch10. Drain Tap

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tected by a Relief Valve (6) which releases the pressure in the Condensate Tank if it rises above 3 psi (0.2 bar) for any reason. The level of the condensate in the Condensate Tank is indicated by the Level Indicator (1). When the Condensate Tank becomes full it is drained by opening the Drain Tap (10). The Condensate Tank will hold approximately 42 quarts (40 liters) of condensate. Due care must be taken to ensure that any oil which is drained with the condensate is disposed of properly. Check local, state and federal regulations.

4.2 MaintenanceSee Figure 4-43.

1. Access to the Filter Mats (2) and Activated Charcoal (7) is gained by unscrewing the Level Indica-tor (1) and a hex nut from the Filter Head (2).

a. Replace the 3,700 grams of activated charcoal in the Filter Head every 1,000 operating hours.b. The fleece Filter Pads should be changed when they become dirty or saturated.

2. The Float Switch should be cleaned at regular intervals to prevent oil residue buildup causing the switch to stick.

3. Access to Float Switch is gained by opening Clamp (8) and removing the upper assembly from the Condensate Tank (5).

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4.3 Replacement Parts List

Item Qty Part No. Description Notes◊ 1 072788-342 Condensate Collecting System1 8 072347 Activated Charcoal 500 gram packets2 4 072207 Filter Mats3 1 N18341 Screwed Cable Gland4 1 072522 O-ring5 1 N21809 Plug6 1 N21810 Coupling7 1 072520 Hex Nut8 1 N15412 O-ring9 1 N18876 Ball Valve10 1 072518 Connection11 1 072519 Washer12 1 077934 Container13 1 N21806 Float Switch14 1 N18476 Relief Valve15 1 072755 Screw Cap

Figure 4-44 Condensate Collecting System

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CHAPTER 5: MAINTENANCE SCHEDULE5.1 K28.0 Compressor Block

5.1.1 Preventive Maintenance Tasks

Task

Check Oil Level

Operate Unit To Final Pressure And Check Final Pressure Switch

Check Automatic Condensate Drain

Check V-belt

Service Air Intake Filter

Check All Connections For Leakage

Test Valves

Change Oil

Replace Valves

Check Opening Pressure Of Final Safety Valve

Change Oil, If Operated For Less Than 2,000 Hours

Check Fasteners For Tightness

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5.1.2 Maintenance Intervals

^ NOTE ^

All maintenance intervals refer to normal operating conditions. Operating the compressor under conditions like high temperatures, humidity or continuous operation may shorten the intervals significantly.

Table 5-1: Maintenance Intervals Table

Calendar Periods Operating Hours

Daily

Weekly

Annually

Biennially

1000

2000

4000

Check Oil Level

Operate unit to final pressureand check final pressure switch

Check automatic condensate drain

Check V-belt

Service air intake filter

Check all connections for leakage

Test Valves

Change Oil and Oil Filter

Replace Valves

Check opening pressure of final safety valve

Replace oil and water separator, if required

Change Oil and Oil Filter, if operated for less than 2,000 hours

Check fasteners for tightness

Check Pistons and Rings

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5.1.3 Maintenance RecordsWe 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. For this purpose Maintenance Record Sheets are included in the Appendix and may be copied as required. Additionally a form for recording operating hours is included in the Appendix and may be copied as required.

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CHAPTER 6: COMPRESSOR DRIVE SYSTEM6.1 Description, Horizontal Sliding

The compressor is driven by the drive motor through the V-belts. The direction of rotation, as seen fac-ing the flywheel, is counterclockwise. Observe the arrow on the compressor block.

6.2 Maintenance of the V-belt and Sheave

6.2.1 Checking the Sheave. Before a new drive belt is installed, the condition of the sheave should be checked. A dirty or rusty sheave impairs the drive�s efficiency and abrades the cover of the belt, which results in premature fail-ure. A worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bottoms, slippage may result and the belt may burn. If the side wall is �dished out,� the bottom shoulder ruins the belt prematurely by wearing off the bottom corners.

6.2.2 Checking the V-belt Inspect the V-belt regularly for damage and wear. Replace if necessary.

6.2.3 V-belt tensionV-belt tension is adjusted by sliding the motor until pressing down on the V-belt between the sheaves results in an approximate deflection of 3/8� (10 mm). (See Figure 6-2).

Figure 6-1 Horizontal Motor Mount (typical)

1. Compressor Block2. Compressor Flywheel3. Compressor Mount

4. V-belt5. V-belt sheave6. Electric Motor

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6.3 Maintenance of the Drive Motor For maintenance of the electric motor refer to the OEM manual, if included, or see an instruction plate attached to the motor. If maintenance instructions are shown for the motor, they supersede these general instructions.

Figure 6-2 V-belt Deflection

^ WARNING ^

Always disconnect the electrical power before working on the motor

Approximate Deflection 3/8 " (10mm)

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Item Qty Part No. Description Notes1 1 MTR-0236 Electric Motor2 1 SHE-0177 V-belt Sheave3 1 BUS-0068 Sheave Bushing4 6 BET-0183 V-belt

Figure 6-3

1 2 3 4

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CHAPTER 7: ELECTRICAL PANEL ASSEMBLY 7.1 Overview

The Electrical Panel Assembly uses a micro Programmable Logic Controller, Compressor Control Panel, Soft 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 equip-ment. All necessary time delays, counters, shutdowns, sequencing and safety features are incorporated into a proprietary program permanently saved into PLC memory using EEPROM technology. The pro-gram 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. The power supply source for the unit is 440 volt, 3 phase, 60 Hz.

The basic panel components consist of a 24 I/O PLC Controller, Compressor Control Panel, Soft Starter, Control Power Transformer with fuses, 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 Disconnect Switch must be in the ON position; at this point, press the ON Button on the Operator Interface and the compressor system is ready and able to operate. If the pressure in the system drops to approximately 4500 psi, the air pressure switch will close, and the compressor will start. All other functions of the compressor are auto-matic. When the air pressure has increased, and the pressure switch opens, then the compressor will shut-down. All of these functions are accomplished through the use of a Programmable Logic Controller. When use of the equipment is complete, press the OFF Button on the Operator Interface.

7.2 AC Power RequirementsThe panel will need to be supplied with 440 VAC, 3 phase, 60 Hz power to ensure proper operation. Wir-ing and conduit selection must be in accordance with all national, state and local codes. The pre-wired panel voltage and phase is written on a label (See Figure 7-1) 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; it is written on the same label.

Figure 7-1 Electrical Panel Label

NORFOLK, VA 23502 USA757-855-6006

PANEL: ASY-0819

MAXIMUM RATING (AC3)

600 VAC Max.1 Ph 60Hz

600 VAC Max.3 Ph 60Hz

120V 230V

10HP42A

208V 230V 460V 380V

N/AN/A

N/AN/A

N/AN/A

N/AN/A

N/AN/A

MODEL:SERIAL:BLOCK:

MFG DATE:

UL File No. E109698

43857

2/2004

60/75° C COPPER WIRE ONLYTerminal Wire Range Torque

Line

Load

Ground

awg 10-3

awg 10-0

awg 14-2

45 in-lb

100 in-lb

35 in-lb

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T

7.2.1 Transformer and FusesThe transformer is fitted with three fuses. The input to the transformer has two fuses. Use two Bauer P/N FUS-0077 fuses rated at 1 amps. The secondary of the transformer is fitted with one fuse. Use one Bauer P/N FUS-0018, rated at 2 amps.

7.2.2 Soft StartThe compressor system is equipped with an Allen-Bradley SMC-3 Soft Motor Controller which is located inside the electrical enclosure. When a motor fault occurs, I0 on the PLC will illuminate and the compressor will shut down. The backlight of the LCD Display will turn red and show the alarm condition and remedies. For a more detailed description of the motor fault refer to the flashing LED located on the front of the SMC-3 Soft Start and refer to the flash code description also on the front of the SMC-3

Figure 7-2 Transformer and Fuses

1. Transformer - TRR-00622. Primary Fuses - FUS-0077

3. Secondary Fuse - FUS-0018

^ 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.

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7.3 Electric Panel Components

7.3.1 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 shut down the electric motor and all other periphery devices. Do not use the Emergency Stop Switch for securing the equipment under normal operation. Use the OFF Button on the Operator Interface.

7.3.2 Starter ResetThere 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 fault indication contact on the soft start. 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 soft start.

7.3.3 Audible AlarmThe Audible Alarm is a 110db electronic horn that sounds during alarm and warning conditions. Vari-ous warning sounds are possible by setting the DIP switches on the back of the Audible Alarm.

Figure 7-3 Soft Start Figure 7-4 Electrical Panel Assembly

1. Compressor Control Panel2. Hourmeter3. Emergency Stop Switch

4. Audible Alarm5. Starter Reset

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7.3.4 HourmeterThe panel will be 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 soft start.

7.3.5 PLC ControlThis panel is controlled with a Telemecanique 24 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.

Figure 7-5 PLC

1. Input Connections (Behind Cover)2. MMI, MNR-00283. Input LED�s4. Output LED�s

5. Status LED�s6. Output Connections (Behind Cover)7. Overrun Timer Adjustment8. PLC programming Port (In Use)

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7.3.5.1 PLC LED�sThere are three separate groups of LED�s on the PLC. See Figure 7-5.

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.

7.3.6 Compressor PLC Program VersionsThe 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

7.3.7 PLC Inputs and OutputsAll 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 vari-ous loads. Please refer to unit schematic for the as built specifications.

Table 7-1: PLC Inputs - Breathing Air Table 7-2: PLC Outputs - Breathing Air

I0 Motor Fault Contact Q0 Soft Start

I1 High Temperature Switch Q1 ACD 1

I2 Oil Pressure Switch Q2 ACD Final

I3 Final Air Pressure Switch Q3 Audible Alarm

I4 Master Panel �On� Contact Q4 ACD 2

I5 Master Panel �Run� Contact Q5 ACD 3

I6 Condensate Alarm Q6 Status Indicator

I7 N/A Q7 Light Tower, Green

I8 N/A Q8 Light Tower, Amber

I9 N/A Q9 Light Tower, Red

I10 N/A

I11 N/A

I12 N/A

I13 N/A

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7.4 Warnings

7.4.1 Final Separator WarningThe 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 pro-gram would be configured to reflect the following 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. When this is accomplished, the unit can be re-activated by making adjustments to the PLC. Please contact Bauer Product Support for detailed instructions.

7.5 Alarms

7.5.1 Compressor High TemperatureThe compressor high temperature switch is located on the high pressure breathing air compressor, on the fifth stage head. 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 LCD Display turns Red and show the Alarm condition and remedies

Table 7-3: Final Separator Warning and Shutdown Cycle Count

Maximum Compressor Pressure Warning Shutdown

5,000 psi 44,325 cycles 49,250 cycles

^ WARNING ^

Do not attempt to override this Separator Shutdown. This feature is provided to protect operating personnel from injury or death.

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7.5.2 Compressor Low Oil PressureThe compressor oil pressure switch is located on the back of the compressor block. 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, the LCD Display turns Red and show the Alarm condition and remedies.

7.5.3 Compressor Overrun TimerThe compressor has an overtime function, where if the compressor runs continuously for a set time, then the compressor will shutdown, and the LCD Display turns Red and show the Alarm condition and reme-dies. This is done to secure the equipment if it were to be started and left unattended. If the OFF Button is pressed and held in for over one second, the compressor overtime setting is shown on the LCD Display. This setting can be changed by rotating the left potentiometer located on the front of the PLC (See Figure 7-5), while pressing and holding the OFF Button. Release the OFF Button to exit the compressor over-time screen. The overtime setting can be adjusted for the following times: 5 hours and at two hour inter-vals from 6 hours to 24 hours, or it can be disabled.


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

Figure 7-6 High Temperature Switch Figure 7-7 Low Oil Pressure Switch

^ WARNING ^


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fatigue failure of this vessel, the PLC program monitors the 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 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. When this is accomplished, the unit can be re-activated by making adjustments to the PLC. Please contact Bauer Product Support for detailed instructions.

7.5.5 Condensate FaultThe compressor condensate level switch is located in the condensate collection tank beside the fanwheel exhaust. The switch is N.C., Normally Closed, 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 informa-tion. Under normal operating conditions, the switch is open and the I6 lamp on the PLC is on. When a high condensate condition occurs, the compressor will shutdown, the I6 lamp will extinguish, and the LCD Dis-play turns Red and show the Alarm condition and remedies. The operator should drain the condensate from the tank and resume operation of the equipment.

Table 7-4: Final Separator Warning and Shutdown Cycle Count

Maximum Compressor Pressure Warning Shutdown

5,000 psi 44,325 cycles 49,250 cycles

^ NOTE ^

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

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Figure 7-8 Condensate Tank Component Locations

1. Level Indicator2. Condensate Filter Mats3. Filter Head4. Condensate Inlet5. Condensate Tank

6. Relief Valve7. Activated Charcoal8. Clamp9. Float Switch10. Drain Tap

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2

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7.5.6 Motor Fault

The compressor system is equipped with an Allen-Bradley SMC-3 Soft Motor Controller which is located inside the electrical enclosure. When a motor fault occurs, I0 on the PLC will illuminate and the compressor will shut down. The backlight of the LCD Display will turn red and show the alarm condition and remedies. For a more detailed description of the motor fault refer to the flashing LED located on the front of the SMC-3 Soft Start and refer to the flash code description also on the front of the SMC-3

7.6 Installing a New ProgramThe PLC program can 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. The EEPROM would be programmed at the Bauer factory and shipped either to the customer or to a authorized distributor.

Figure 7-9 Soft Motor Start

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Figure 7-10 PLC Programing Port

1. PLC Programing Port 2. Overrun Timer Adjustment

^ CAUTION ^

When handling the cartridge, do not touch the pins. The cartridges electrical elements are sensitive to static electricity.

1

2

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7.6.1 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 Twido 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

Figure 7-11 PLC EEPROM (Typical)

EEPROM Cartridge

PLC with cartridge removed. PLC with EEPROM Installed

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7.7 Overrun Timer(See Figure 7-10). All versions of the PLC program contain an Overrun Timer that will shut the com-pressor off after a certain amount of continuous running. The length of time can be set to 5 hours (fac-tory standard) or from 6 to 24 hours in two hour increments. It can also be bypassed entirely eliminating the Overrun Timer.

7.7.1 Adjusting the Overrun Timer(See Figure 7-12). 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 while pressing and holding the OFF Button on the Compressor Control Panel. The Display will show the Overrun Timer Adjustment hours.

Figure 7-12 Overrun Timer Adjustment

FullCCW

Run5 Hours

OverrunT

imer

Bypassed

Overrun Timer Adjustment

Set Run from 6 hours to 24 hours

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7.8 Wire Harness Connections

Device Description PLC In PLC Out Wire Colors Pin

1TS Compressor High Temp. Switch I1 �Yellow 23

Violet 24

2PS Compressor Oil Pressure Switch I2 �Blue 25

Orange 26

Red 29

1PS Compressor Air Pressure Switch I3 � Black/Orange 37

Brown 30

CS Condensate High Level Switch I6 �Grey 31

Pink 32

ACD1First ACD Coil � Q1 Blue/White 4

Neutral � Orange/White 21

ACDF Final ACD Coil Q2 Yellow/Black 5

ACD 2Second ACD Coil Q4 Violet/White 6

Neutral � Grey/White 22

ACD 3 Third ACD Coil Q5 Pink/White 7

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7.9 Replacement Parts List

# KIT Qty Part No. Description Notes◊ 1 ASY-0903/75028 Electrical Panel Assembly1 � 1 MNR-0037 Compressor Control Box2 � 1 HMR-0029 Hourmeter3 � 1 SWT-0244 Switch, Emergency Stop4 � 1 IND-0038 Audible Alarm5 � 1 SWT-0284 Starter Reset Button

Figure 7-13 Electrical Panel Exterior

1

2

3

4

5

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Item Qty Part No. Description Notes1 1 RLY-0161 Relay2 2 RLY-0165 Relay3 1 SPL-0072 Power Supply, 24 VDC4 1 MNR-0028 HMI Display5 1 CNT-0056 Real Time Clock� 1 CNT-0053 PLC Controller6 1 TRR-0062 Transformer� 2 FUS-0077 Fuse, 1 amp, 600 Volts� 1 FUS-0018 Fuse, 2 amp, 250 Volts7 1 BKR-0042 Circuit Breaker8 2 SUR-0008 Protective Module9 1 SRT-0200 Isolation Contactor10 1 SRT-0225 Soft Starter

Figure 7-14 Electrical Panel, Interior

1

2

34

5

6

7

8

9

10

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7.10 Trouble Shooting Guide

7.10.1 Compressor Will Not Start

7.10.2 Compressor Is Shutdown, Alarm Code Flashing Sequence.

Possible Cause or Problem Corrective Action

Emergency Stop Switch not pulled out. Pull out Switch.

Lights on PLC not illuminated Check voltage and phases

Air Pressure not low enough to close pressure switch.

PLC input I3 should be illuminated.

7.10.2.1 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. Replace High Temperature Switch

7.10.2.2 Compressor Low Oil Pressure


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

Replace Oil Filter

Check Compressor Rotation Direction

Check Oil Pressure with Gauge, if in specified range Reset Pressure Switch

7.10.2.3 Compressor Overtime


The compressor is shut down after 5 hours of continuous operation

Turn Compressor Control Switch to OFF then back to ON.

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7.10.2.4 Securus® Alarm


Securus® Cable disconnected Reconnect Securus® Cable

Securus® Cartridge saturated or expired. Replace all purification system cartridges

7.10.2.5 Final Separator Shutdown


Final Separator has reached maximum number of Pressurization Cycles. Replace Final Separator

7.10.2.6 -Condensate Fault


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

7.10.2.7 Motor Over load Fault


Check motor starter for tripped indication Allow some time to cool, push reset button

Check motor current Compare to motor current to FLA on motor nameplate

Check setting of Overload Relay to motor FLA Adjust Overload Relay setting.

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7.11 Wiring DiagramsA Compressor Unit reference wiring diagram, ASY-0903-SO75028 is attached to the document package as a separate file or PDF document.

A Automatic Alternation Panel reference wiring diagram, SO75028-MP is attached to the document package as a separate file or PDF document.

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CHAPTER 8: DIGITAL PRESSURE SWITCH8.1 Introduction

A digital pressure switch (Bauer P/N SWT-0279) is being used for this application. To use this pressure switch it must include CON-0363 which is the electrical connector for this switch.

The switch has a three digit digital display on the face that displays the real time pressure in the line. The display can only show three digits but Bauer�s application for the switch is in the thousand psi range. The switch is set up to read pressure times 10, i.e. the display reads 384 for 3,840 psi. The switch will be programmed by our test department for the set points specified by the floor traveler. After the switch is set in test it is then locked out so that the set points can not be accidentally changed.

8.2 PROGRAMMING THE PRESSURE SWITCH.

1. Press the mode key (3) one time to enter the menu.

2. Press the up or down arrow keys (4) to scroll through the menu. (Some of the menu features are not being used for the Bauer Compressor application. Please ignore these menus.)

Figure 8-1 Digital Pressure Switch

1. CON-0363 Electrical Connector2. Display

3. Mode Switch4. UP and DOWN Switches

1

2

3

4

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3. Press the mode key (3) one time to enter that menu selection in order to adjust its values.

4. When programming is complete press and hold the mode key (3) for five seconds. The new setting is saved when u3.2 is displayed.

8.2.1 Selecting the Display Units.The switch has the capabilities of reading pressure in Bar, pounds per square inch, or Pascals. The majority of the Bauer applications use the thousand psi range.

1. Press the mode key (3) one time.

2. Press the down arrow until UNIT is displayed on the screen.

3. Press the mode key one time. Press the up or down arrow until desired units (psi, hPa, or bar) are selected.

The available units are: bar = bar, psi x = psi x 10, psi = psi, hPa = Hecto-Pascal and mbr = mbar.

4. psi x is standard for Bauer Compressors.

5. Once the units are selected, press the mode key (3) to return to the menu and go on to the next menu selection.

The unit selected is shown every 30 seconds for approximately 5 seconds.

8.2.2 Selecting the On Point for the Pressure Switch.The switch�s turn on point for when the switch comes on is selectable. The standard set point for Bauer Compressors turning on the switch�s contact is the restart pressure. This causes the switch to work as a normally closed switch. (Set lower than final pressure.)


2. Press the down arrow key until ON-1 is displayed on the screen.

3. Press the mode key (3) one time. Press the up or down keys to set the value for the first digit of the turn on pressure. (Ex. Turn on = 4680 psi, enter 4)

4. Press the mode key (3) one time. Press the up or down keys to set the value for the second digit of the turn on pressure. (Ex. Turn on = 4680 psi, enter 6)

5. Press the mode key (3) one time. Press the up or down keys to set the value for the third digit of the turn on pressure. (Ex. Turn on = 4680 psi, enter 8)

6. Press the mode key (3) one time to return to the menu and go on to the next selection.

7. For pressures less than 1000 psi return to �selecting the display units� and adjust to ps1 and start at step one to set the restart pressure point.

8.2.3 Selecting the Off Point for the Pressure Switch.The switch�s turn off point for when the switch turns off is selectable. The standard set point for Bauer Compressors turning off the switch�s contact is the final pressure. This causes the switch to work as a normally closed switch. (Set for final pressure.)


2. Press the down arrow key until OFF-1 is displayed on the screen.

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3. Press the mode key (3) one time. Press the up or down arrow keys to select the first digit of the final pressure. (Ex. Final pressure = 5240 psi, enter 5)

4. press the mode key (3) one time. Press the up or down arrow keys to select the second digit of the final pressure. (Ex. Final pressure = 5240 psi, enter 2)

5. Press the mode key (3) one time. Press the up or down arrow keys to select the third digit of the final pressure. (Ex. Final pressure = 5240 psi, enter 4)

6. Press the mode key (3) one time to return to the menu and go on to the next selection.

7. For pressures less than 1000 psi return to �selecting the display units� and adjust to PS1 and start at step one to set the final pressure point.

8.2.4 Locking and Unlocking the Switch The switch may or may not come in the lock out mode. If trying to program the switch and LOH appears the switch is locked out. Lock the switch when completing the programming so that no one can change the set points.

1. 1. Press and hold the up and down arrows for five seconds.

2. The display will show which level the switch has been set to.

3. Lu0 = lockout (no changes), Lu2 = unlock (all menu options can be changed.)

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CHAPTER 9: CONTROL SKID 9.1 Replacement Parts List

9.1.1 Regulator Control Panel

Item Qty Part No. Description Notes1 4 VAL-0402 Ball Valve 2 4 VAL-0169 Safety Valve3 4 VAL-0076 Needle Valve4 4 GAG-0012W 2.5� Gauge 0 - 5000 psi5 2 REG-0065 Dome Load Regulator6 2 REG-0003 Pressure Regulator7 2 GAG-0009W 2.5� Gauge 0 - 7500 psi8 1 SWT-0279 Digital Pressure Switch/Pressure Transducer9 2 VAL-0174 Check Valve

^ NOTE ^

The parts for Panel 1 and Panel 2 (Items 1 thru 7) are identical Part Numbers

Figure 9-1 Back of Regulator Control Panel

Panel 1

Panel 2

1 2 3 4 5 2 7 6 3 4 1

8

9

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9.1.2 Automatic Alternation Panel

Item Qty Part No. Description Notes1 6 LIT-0114 Light Green2 1 SWT-0240 Illuminated Switch 2 position3 1 MNR-0028 HMI4 1 CNT-0053 PLC5 1 CNT-0063 Analog Expansion Module6 6 RLY-0161 Control Relay

Figure 9-2 Automatic Alternation Panel

2

1 3 4 5 6

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CHAPTER 10:PNEUMATIC VALVES AND CONTROLS10.1 Nonadjustable Valves

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

10.2 Pressure Maintaining ValveThere are two pressure maintaining valves (PMV) on the Compressor Skid. The first is mounted between the 4th Stage Separator and the inlet to the ASME bottle. The second PMV is mounted between the outlet of the ASME bottle and the inlet to the Alternation Panel Skid.

The pressure maintaining valve is adjusted at the factory to the required pressure and does not normally require maintenance or readjustment.

If readjustment does become necessary proceed as follows.

1. Loosen the locking nut (1).

2. Set the adjusting screw (2) to the required pressure using an appropriate hex type wrench.

3. Turn clockwise to increase pressure, counterclockwise to decrease pressure.

4. Determine if the PMV is properly adjusted:a. Depressurize the final separator and purifier chamber by slowly opening the bleed valve.b. Close the bleed valve and start the compressor.c. Observe the final pressure gauge and note the pressure at which the valve opens (delivers). d. If the pressure is not at the specified pressure ± 100 psi, readjust the PMV.

Figure 10-1 Pressure Maintaining Valve

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10.3 Safety Valves

The safety valves are adjusted at the factory to the required pressure and do not normally require main-tenance or readjustment. In case readjustment does become necessary, have the safety valve adjusted by a BAUER qualified technician or return the valve to the factory (contact the BAUER Product Support Department for details).

10.3.1 Dome Load RegulatorThe Dome Load Valve is a reducing regulator whose shut off pressure is controlled by the pressure applied to the dome port of the valve. The Dome Load Valve will stop the flow of gas when the pres-sure in the dome port and the outlet pressure of the valve are the same. On the Regulator Control Skid the pressure in the dome port is set by the operator.

Figure 10-2 Safety Valves

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Item Qty Part No. Description Notes1 1 VAL-0022 Relief Valve2 1 VAL-0006 Drain Valve

Figure 10-3 System Relief Valve and Drain Valve

1

2

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Item Qty Part No. Description Notes1 1 SWT-0279 Digital Pressure Switch2 1 GAG-0009W Pressure Gauge3 1 VAL-0142 Pressure Maintaining Valve

Figure 10-4 Digital Pressure Switch and PMV

1

2

3

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Item Qty Part No. Description Notes1 1 GAG-0042W Pressure Gauge 0 - 100 psi2 1 GAG-0006W Pressure Gauge 0 - 200 psi3 1 GAG-0007W Pressure Gauge 0 - 600 psi4 1 GAG-0008W Pressure Gauge 0 -1500 psi5 1 GAG-0009W Pressure Gauge 0 -7500 psi

Figure 10-5

1 2 3 4 5

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CHAPTER 11:APPENDIX11.1 Safety

11.1.1 General Safety Precautions� Read the operating manual before installing or operating this compressor unit. Follow appropriate

handling, operation and maintenance procedures from the very beginning. The maintenance schedule contains measures required to keep this compressor unit in good condition. Maintenance is simple, but must be executed regularly to achieve safe operation, maximum efficiency and long service life.

� We recommend that all maintenance work be recorded in a service book, showing the date and details of the work carried out. This will help to avoid expensive repairs caused by missed maintenance work. If it is necessary to make a claim against the warranty, it will help to have proof that regular maintenance has been carried out and that the damage has not been caused by insufficient mainte-nance.

� This compressor unit must be installed, operated, maintained and repaired only by authorized, trained and qualified personnel.

� Consult and follow all OSHA, NEMA, ASME and local regulations, laws and codes covering the installation and operation of this compressor and accessories before operating the unit.

� Do not operate this unit in excess of it�s rated capacity, speed, pressure, temperature, or otherwise than in accordance with the instructions contained in this manual. Operation of this unit in excess of the conditions set forth in this manual will subject the unit to limits which it may not be designed to withstand.

� Keep safety guards in place.

� Do not modify the compressor or its systems.

� Do not wear loose clothing around machinery. Loose clothing, neckties, rings, wrists watches, brace-lets, hand rags, etc. are potential hazards.

� Provide adequate fire protection. Make sure fire extinguishers are accessible. Select alternate routes of escape and post such routes.

� Make sure you are equipped with all required safety equipment; hearing protection, safety glasses, hard hats, safety shoes and fire extinguisher.

� Visually inspect the unit before starting. Remove and /or replace any loose or broken components, tools, valves, missing equipment, etc.

� Do not tamper with, modify, or bypass safety and shutdown equipment.

� Do not tighten or adjust fitting or connections under pressure.

� The use of plastic pipe or rubber hose in place of steel tube or iron pipe, soldered joints or failure to insure system compatibility of flex joints and flexible hose can result in mechanical failure, property damage, and serious injury or death.

� The use of plastic or nonmetallic bowls on line filters without metal guards can be dangerous.

� Replace damaged fan blades promptly. Fan assemblies must remain in proper balance. An unbal-anced fan can fly apart and create an extremely dangerous condition.

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� Allow the compressor to cool before servicing. Whenever the compressor is shut down and over-heating is suspected, a minimum period of 15 minutes must elapse before opening the crankcase. Premature opening of the crankcase of an overheated unit can result in an explosion.

� Incorrect placement of the inlet and pressure valves in a compressor cylinder head can cause an extremely dangerous condition. Refer to the appropriate section of this manual before installing or replacing valves.

� Before doing any work involving maintenance or adjustment, be sure the electrical supply has been disconnected, and the complete compressor system has been vented of all internal pressure. Failure to follow these warnings may result in an accident causing personal injury and/or property damage.

� Before working on the electrical system, be sure to disconnect the electrical supply from the system at the circuit breaker or other manual disconnect. Do not rely on the ON/OFF switch to disconnect the electrical supply.

� Installer must provide an earth ground and maintain proper clearance for all electrical components.

� All electrical installation must be in accordance with recognized national, state, and local electrical codes.

� Do not use gasoline, diesel fuel or other flammable products as a cleaning solution.

� A compressor which has been used for gas service is unsuitable for air applications. Should the purchaser and/or user proceed to use the compressor for air service after it has been used for gas, the purchaser/user assumes all liability resulting therefrom without any responsibility being assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any agreement for resale of this compressor.

� The use of repair parts other than those listed in this manual or purchased from BAUER Compressors, Inc. may create unsafe conditions over which BAUER has no control. Such unsafe conditions can lead to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, BAUER Compressors, Inc. can bear no responsibility for equipment in which non-approved repair parts are installed

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

HOT SURFACES DO NOT TOUCH!

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

HIGH VOLTAGE!

Life threatening danger of electrical shock. Maintenance work on electric units or operating equipment should be carried out by a qualified electrician or by a person supervised by a qualified electrician according to electrical regulations.

AUTOMATIC COMPRESSOR CONTROLUNIT MAY START WITHOUT WARNING!

Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart.

THE INSTRUCTIONS MUST BE READ BEFORE OPERATING UNIT!

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

HEARING PROTECTION MUST BE WORN!

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

DIRECTION OF ROTATION!

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

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11.2 Unpacking, Handling and Installation

11.2.1 Unpacking and HandlingThis compressor unit is packaged according to the requirements for shipping via the requested type of carrier service. It is possible that the compressor unit could have been damaged during shipping. For this reason, we urge you to thoroughly examine the unit for possible damage and report any such dam-age to the shipping company immediately.

Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for clearance between the item being unpacked and the packaging to be removed.

Handling of the unpacked unit should be performed using only the following devices. See Figure 11-1.

The compressor unit may be furnished with one or more shipping braces for shipping and handling only. After installation and before operation, these braces must be removed entirely. Under no circum-stances should the braces remain installed during operation or the manufacturer�s warranty for the com-pressor unit will be voided. The braces are all tagged and labeled.

Figure 11-1 Lifting Devices

^ WARNING ^

Be sure the lifting devices are capable of handling the weight of the unit (see Paragraph 1.4 for the weight of the unit). Before lifting the unit, secure all loose or swinging parts to keep them from moving. Stay clear of lifted load.

Fork Lift Hand Truck

Chain Hoist

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11.2.2 Installation of the Compressor Unit

11.2.2.1 GeneralThe floor/site must be capable of supporting the weight of the unit. Secure the compressor unit to the floor using ½� lag bolts. Position the unit so that it is level. Permissible inclination of the compressor unit is listed in Paragraph 1.4.

Ensure that the compressor air intake is supplied with fresh air. The intake air must not contain any exhaust fumes or flammable vapors such as paint solvents, which may cause an internal fire. Make sure that the intake air is unobstructed and moisture in the intake air is kept to a minimum. It is important that units draw in clean air. The quality of the incoming air determines the quality of the compressed air. This is important even for industrial air, as any incoming fumes will also be compressed and will increase the toxicity to anyone working with the compressed air.

If a remote control is provided, the unit must be equipped with a clearly visible plate warning the possi-bility of the unit starting. As an additional measure, anyone starting the unit by remote control must make sure that no one is checking or operating the unit. For this purpose, a second warning plate should be provided at the remote control unit.

Observe and maintain an ambient temperature range of 43° to 113° F.

The area in which the compressor unit is installed should be well lit and easily accessible to facilitate servicing and routine maintenance.

11.2.2.2 VentilationDuring normal compression, heat is generated by the compressor and by the drive motor/engine. For air-cooled compressor units, this heat needs to be vented away by sufficient ventilation.

11.2.2.2.1Outdoor InstallationIt is recommended that all gasoline and diesel engine driven compressor units be installed outdoors. Additionally, electrically driven compressor units may be installed outdoors only if enclosed with weatherproof enclosure panels.

11.2.2.2.2Indoor InstallationThe best location to install the compressor unit indoors is against an outside wall with a suitably large air vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the opposite wall, close to the ceiling or in the ceiling.

^ CAUTION ^

The inclination values listed in Paragraph 1.4 are valid only if the oil level of the compressor is level with but does not exceed the upper mark of the oil dipstick or oil level sight glass

AUTOMATIC COMPRESSOR CONTROLUNIT MAY START WITHOUT WARNING!Before carrying out maintenance and repair work, switch off at the main switch and ensure the unit will not restart.

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As a basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room temperature from exceeding 105° F. Additional heat generating equipment or piping should be avoided or must be well insulated.

11.2.2.2.3Natural VentilationNatural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of the required intake and exhaust openings, refer to the following table: .

11.2.2.2.4Forced VentilationTo determine the required intake opening and exhaust flow refer to the following table:

Drive hp

Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)

V = 1750 ft³ h = 6.5 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft

Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²)

3 1.3 1.1 � � � �

5 3.2 2.7 1.3 1.1 � �

7.5 4.5 3.8 2.6 2.2 1.3 1.1

10 9.7 8.1 6.5 5.4 2.6 2.2

15 14.5 12.4 9.7 8.1 5.8 4.8

20 20.6 17.2 15.6 12.9 9.7 8.1

Drive hp

Dependence on Room Size (V) and Height of Exhaust Opening (h)a

a. The intake sizes given in the above table are for a cooling air velocity of 1000 ft./min. BAUER recommends that the cooling air velocity be in the range of 600 ft./min. to 2000 ft./min.

V = 1750 ft³ h = 8 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft

Intake (ft²) Exhaust cfm Intake (ft²) Exhaust cfm Intake (ft²) Exhaust cfm

25 3.3 3300 3.2 3200 3.0 3000

30 4.0 3960 3.8 3840 3.6 3600

40 5.3 5280 5.1 5120 4.8 4800

50 6.6 6600 6.4 6400 6.0 6000

60 7.9 7920 7.7 7680 7.2 7200

75 9.9 9900 9.6 9600 9.0 9000

100 13.2 13200 12.8 12800 12.0 12000

125 16.5 16500 16.0 16000 15.0 15000

150 19.8 19800 19.2 19200 18.0 18000

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11.2.2.3 Electrical Installation11.2.2.3.1Electric DriveWhen making the electrical connections to the system, the following instructions are mandatory:

� Comply with all local, state and federal regulations concerning electrical installation.

� Arrange for the electrical connections to be made by a certified electrician only.

� Ensure that the motor voltage, control unit voltage, and frequency conform with the main voltage and frequency. Do not connect the compressor unit to a voltage other than the one specified on the name-plate.

� Provide all necessary cables and main fuses and a master disconnect switch. The fusing of the compressor must be carried out in compliance with local, state and national electrical regulations.

11.2.2.3.2Electrical SupplyThe machine is factory wired according to order. If the voltage is to be changed, consult the factory for instructions and necessary parts.

For standard models the only customer wiring necessary is from the customer supplied disconnect switch to the compressor unit�s electrical enclosures All wiring should be done by a licensed electrician familiar with national, state and local electrical codes.

The use of improperly sized wire can result in sluggish operation, unnecessary tripping of overload relays and/or blowing of fuses. The following tables are provided as a guide for proper wire size.

1 PHASE

Motorhp

Full Load Amps Fuse Ampsa

a. Dual element time delay fuse amps.

Minimum Wire Sizeb

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

120V 208V 230V 120V 208V 230V 120V 208V 230V

2 24 13.2 12 30 20 17.5 10 � 14

3 34 18.7 17 50 30 25 8 10 10

5 56 30.8 28 80 50 40 4 8 8

7.5 80 44 40 100 70 60 3 8 8

10 � 55 50 � 90 60 � 6 6

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In the above tables, all values are based on 1996 NEC articles 430 and 310 (NFPA 70). These values are provided as a general guide; however, the information given on the motor nameplate supersedes the above information.

3 PHASE

Motorhp

Full Load Amps Fuse Ampsa

a. Dual element time delay fuse amps.

Minimum Wire Sizeb

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

208V 230V 460V 208V 230V 460V 208V 230V 460V

2 7.5 6.8 3.4 12 10 5.6 14 14 14

3 10.6 9.6 4.8 17.5 15 8 14 14 14

5 16.7 15.2 7.6 25 25 12 10 12 14

7.5 24.2 22 11 40 30 17.5 8 10 14

10 30.8 28 14 50 40 20 8 8 12

15 46.2 42 21 60 60 30 6 6 10

20 59.4 54 27 90 80 40 4 4 8

25 74.8 68 34 100 100 50 3 4 8

30 88 80 40 125 100 60 2 3 8

40 114 104 52 175 150 80 0 1 6

50 143 130 65 200 200 100 3/0 2/0 4

60 169 154 77 250 200 100 4/0 3/0 3

75 211.2 192 96 300 300 150 300 250 1

100 273 248 124 400 350 175 500 350 2/0

125 343.2 312 156 500 400 200 2-4/0 2-3/0 3/0

150 396 360 180 600 500 250 2-300 2-4/0 4/0

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11.3 Long Term Storage

11.3.1 GeneralIf the compressor unit will be out of service for more than six months, it should be preserved in accor-dance with the following instructions:

1. Make sure that the compressor is kept indoors in a dry, dust-free room.

2. Cover the compressor with plastic sheets only if no condensation will form under the sheet.

3. Remove the sheet from time to time and clean the outside of the unit.

4. If this procedure cannot be followed, or if the compressor will be out of service for more than 24 months, please contact Bauer Product Support for special instructions.

11.3.2 PreparationsPrior to preserving the compressor unit, it must be run until warm, i.e., up to the specified service pres-sure. Operate the unit for approximately 10 minutes, then carry out the following checks.

1. Check all pipes, filters and valves (including safety valves) for leakage.

2. Tighten all couplings, as required.

3. After 10 minutes, open the outlet valve and operate the compressor at adjusted minimum pressure using the pressure maintaining valve for approximately 5 minutes.

4. After the 5 minutes, shut the compressor unit down and completely drain all separators and filters. Close all valves.

5. Remove filter heads and lubricate the threads with petroleum jelly.

11.3.2.1 Units Equipped with a Filter System

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

2. Remove the intake filter/intake pipe completely.

11.3.3 Preserving the Compressor

1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet port while the compressor is running. Keep the shut-off valve and the condensate drain valves open.

2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before shutting the compressor unit down.

3. Close the shut-off valve and condensate drain valves.

4. Close the inlet port with a dust cap and/or tape.

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11.3.4 Preventive Maintenance During StorageOperate the compressor once every six months as follows:

1. Remove the dust cap from the inlet port and install the inlet filter.

2. Open the outlet valve and allow the system to run approximately 5 minutes until there is outflow from the valve and oil is visible in the sight glass of the oil regulating valve.

3. Shut down the compressor.

4. Open the condensate drain valves, depressurize the unit, then close the drain valves again.

5. Remove the intake filter and replace the dust cap on the inlet port.

11.3.5 Lubrication Oils for Preservation

1. After prolonged storage periods, the oil will age in the compressor crankcase. The oil must be drained at least every 24 months and replaced with fresh oil.

2. The stated period can only be attained when the crankcase is sealed during the preservation period in accordance with the preservation requirements.

3. After changing the oil, the compressor must be operated according to the instructions above.

4. Check the lubrication of the compressor during the every-six-month brief operation.

5. The oil pump is functioning properly when oil can be seen flowing through the sight glass of the oil pressure regulator or if the oil pressure gauge indicates the prescribed pressure.

11.3.6 Reactivating the Compressor Unit

1. Remove any dust cap or tape from the inlet port and install an intake filter cartridge.

2. Check the oil level of the compressor. If necessary, change the oil.

3. The motor must be thoroughly dry before applying power.

4. For units with a purification system, change all cartridges.

5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper opera-tion of the lubricating system.

6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final pressure safety valve vents. On compressor units with a compressor control system, raise the pres-sure switch setting the switch above normal limits to override the pressure switch. Be sure to reset the switch after checking.

7. Check the interstage safety valves for leakage.

8. Establish the cause of any faults and remedy.

9. Stop the unit when it is running properly. The compressor is then ready for operation.

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11.4 Reproducible Forms

11.4.1 Scheduled Maintenance Form

Daily Para. Date Signature

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Weekly or as required. Para. Date Signature

500 Operating Hours. Para. Date Signature

1,000 Operating Hours. Para. Date Signature


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Annually. Para. Date Signature

Biennially. (Every two years) Para. Date Signature

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11.4.2 Record of Operating Hours

Date Minutes Total Date Minutes Total

Subtotal: Subtotal:

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11.5 Reference Data

11.5.1 Tightening Torque Values

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

2. The indicated torque values are valid for bolts in greased condition.

3. Self locking nuts must be replaced on reassembly

4. Pipe connections (swivel nuts) should be tightened just enough so that leakage is stopped. Not more than finger tight plus up to an additional 1/2 turn.

11.5.2 Torque Sequence Diagrams

11.5.3 Conversion Formulas°F = 9/5°C + 32 °C = 5/9 x (°F-32)PSI = BAR x 14.5 BAR =PSI x 0.0689

Bolt or Screw Size Max. Torque

Hex and socket head 1/4� (M 6) 7 ft. lbs. (10 Nm)





Hex and socket head 5/8� (M 16) 141 ft.-lbs (200 Nm)

Table 11-1: Torque Values

Figure 11-2 6 Bolt and 4 Bolt Torque Sequence

12

3

4

5

6

12

4

3

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11.5.4 Approved Lubricants ChartUnless otherwise specified in text, use the lubricants in Table 2.

11.5.5 Glossary of Abbreviations and Acronyms� Available Only as Part of a Complete AssemblyAC Activated Charcoal, removes odor and tasteACD automatic condensate drainASME American Society of Mechanical EngineersCW clockwiseCCW counterclockwiseCGA Compressed Gas AssociationDIN Deutsches Institut für NormungDOT Department of TransportationE1 single phase electrical supplyE3 three phase electrical supplyHP Chemical Catalyst, converts carbon monoxide to carbon dioxideIAW In Accordance WithMS Molecular Sieve, removes moistureNEC National Electrical CodeNEMA National Electrical Manufacturers AssociationNFPA National Fire Protection AssociationOSHA Occupational Safety & Health AdministrationODP open drip-proof (motor)OEM Original Equipment ManufacturerPCB printed circuit boardPLC Programable Logic ControllerPMV pressure maintaining valveSC Securus® Moisture Sensing Device

Usage Lubricants

O-rings, rubber and plastic parts; filter housing threads, sealing rings

Parker Super �O� Lube

Bolts, nuts, studs, valve parts, copper gaskets and tube connection parts (threads, cap nut and com-pression rings)

Never-Seez® NSWT, Pipe Dope or teflon tape

Paper gaskets DOW Corning 732 or equivalent silicon compound applied on both sides before assembly,

High temperature connections DOW Corning 732 or equivalent temperature resis-tant compound,

Tube connection ferrules, Never-Seez® NSWT

Table 11-2: Lubricant Chart

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11.6 Additional Documents

11.6.1 Diagrams and DrawingsAny included drawings, wiring diagrams, pneumatic flow diagrams, etc., will be bound next to the back cover in a hardcopy manual or included as a separate file on a CD.

11.6.2 Other DocumentsOEM Manuals and other BAUER manuals may be included in the documentation shipping package.

Appendix

BAUER Compressors, Inc. Phone: (757) 855-60061328 Azalea Garden Road Fax: (757) 855-6224Norfolk, Virginia 23502-1944 www.bauercomp.com

December 22, 2006 Special Edition Rev. 0 Chg. 0 MNL- 75028

BAUERCOMPRESSORS

Industrial Air CompressorI280-100-E3 VeritasOutline Dimensional and Wiring Diagrams

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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 infor-mation and has no obligation to update these materials. This information is © 2006 Bauer Compressors, Inc., and Bauer reserves to itself all rights to this publication. Bauer�s customers have no right to repro-duce, rewrite, modify, license or permit anyone else�s use of this information, without the express writ-ten permission of Bauer Compressors, Inc.

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.

^ WARNING ^

This Outline Dimensional and Wiring Diagrams contains safety information and instructions.You must read, understand and follow all safety precautions and instructions.

Special Edition December 22, 2006

Rev Chg Date Notes Auth

0 0 12/22/2006 JD