K20V MNL-0413

BAUER
COMPRESSORS
Instruction Manual and Replacement Parts List
Open Vertical
High Pressure Breathing Air Compressor Unit
K20V-E3
June 01, 2006 1st ed. Rev. 0 Chg. 0 MNL-0413

2006 Bauer Compressors, Inc.
BAUER Compressors, Inc. Phone: (757) 855-6006
1328 Azalea Garden Road Fax: (757) 855-6224
Norfolk, Virginia 23502-1944 www.bauercomp.com
BAUER K20V
COMPRESSORS
This information is believed to be accurate by Bauer Compressors, Inc., as of its 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 informa-
tion. All information supplied is in connection with sales of Bauers products, and is thus subject to Bauers
standard terms and conditions of sale. Bauer reserves the right to change this information and has no obliga-
tion to update these materials. This information is 2005 Bauer Compressors, Inc., and Bauer reserves to
itself all rights to this publication. Bauers customers have no right to reproduce, rewrite, modify, license or
permit anyone elses use of this information, without the express written permission of Bauer Compressors,
Inc.
^ WARNING ^
This Instruction Manual and Replacement Parts List contains safety information and instructions for the
K20V High Pressure Breathing Air Compressor Unit.
You must read, understand and follow all safety precautions and instructions.
1st Edition June 01, 2006
Rev Chg Date Notes Auth

0 0 06/01/2006 Taken from MNL-0409 Chg 1 JD
Page i 1st ed. Rev. 0 Chg. 0

MNL-0413 BAUER
COMPRESSORS
TABLE OF CONTENTS
CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
1.1 How To Use This Manual...................................................................................................................................................... 1
1.1.1 Manual Safety Notices ....................................................................................................................................................... 1
1.2 How to Use the Replacement Parts List ................................................................................................................................ 2
1.3 How to Use the Appendix...................................................................................................................................................... 3
1.4 Unit Description..................................................................................................................................................................... 4
1.4.1 Economy Trim Level Standard Features............................................................................................................................ 4
1.4.2 Luxury Trim Level Standard Features ............................................................................................................................... 4
1.4.3 Economy Trim Level Factory Installed Optional Features................................................................................................ 4
1.4.4 Factory Installed Optional Features Available in Either Economy or Luxury Trim Level. .............................................. 4
1.5 K20VSpecifications ............................................................................................................................................................... 5
1.6 Compressor Block.................................................................................................................................................................. 5
1.6.1 Compressor Drive .............................................................................................................................................................. 5
1.6.2 Purification System Applicability ...................................................................................................................................... 5
CHAPTER 2: - - - - - - - - PLC CONTROLLED UNIT OPERATIONS

2.1 Pre-start Checks ..................................................................................................................................................................... 6
2.2 Start-up Procedure ................................................................................................................................................................. 6
2.3 Post Start Procedures ............................................................................................................................................................. 6
2.4 Shutdown Procedures ............................................................................................................................................................ 6
2.5 Electric Panel Components ................................................................................................................................................... 7
2.5.1 Emergency Stop Switch. .................................................................................................................................................... 7
2.5.2 Starter Reset ....................................................................................................................................................................... 7
2.5.3 Compressor Control Switch ............................................................................................................................................... 8
2.5.3.1 2-Position (Standard) ...................................................................................................................................................... 8
2.5.3.2 3-Position Compressor Control Switch (Factory Installed Option). ............................................................................. 8
2.5.3.2.1 For Breathing Air Units .................................................................................................................................................. 8
2.5.3.2.2 For Industrial Units......................................................................................................................................................... 8
2.5.4 Indicator Lamps.................................................................................................................................................................. 8
2.5.4.1 PLC Warning and Alarm Lamps .................................................................................................................................... 8
2.5.4.1.1 Warning Lamp - Amber.................................................................................................................................................. 8
2.5.4.1.2 Alarm Lamp - Red .......................................................................................................................................................... 8
2.5.5 Hourmeter........................................................................................................................................................................... 8
2.5.6 PLC Control ....................................................................................................................................................................... 8
2.5.6.1 PLC LEDs ..................................................................................................................................................................... 9
2.6 Warnings ............................................................................................................................................................................... 9
2.6.1 One Flash - Final Separator Warning................................................................................................................................. 9
2.6.2 Two Flashes - Securus Monitor ....................................................................................................................................... 10
2.7 Alarms.................................................................................................................................................................................. 10
2.7.1 One Flash - Compressor High Temperature .................................................................................................................... 10
2.7.2 Two Flashes - Compressor Low Oil Pressure.................................................................................................................. 10
2.7.3 Three Flashes - Compressor Overtime............................................................................................................................. 10
2.7.4 Four Flashes - Securus Monitor ....................................................................................................................................... 10
2.7.5 Five Flashes - Carbon Monoxide Monitor Alarm ............................................................................................................ 11
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2.7.6 Six Flashes - Final Separator Shutdown...........................................................................................................................11
2.7.7 Seven Flashes - Condensate Fault ....................................................................................................................................11
2.7.8 On Steady - Motor Starter Overload Trip.........................................................................................................................11
CHAPTER 3:- - - - - - - - - - - - - - MAINTENANCE AND PARTS

3.1 IK150 II Compressor Block .................................................................................................................................................12
3.1.1 Description .......................................................................................................................................................................12
3.1.1.1 Air Flow Diagram .........................................................................................................................................................12
3.1.1.2 Component Location.....................................................................................................................................................13
3.1.2 Lubrication System...........................................................................................................................................................14
3.1.2.1 Description....................................................................................................................................................................14
3.1.2.2 Oil Level Check ............................................................................................................................................................14
3.1.2.3 Oil Change Interval.......................................................................................................................................................15
3.1.2.4 Oil Capacity ..................................................................................................................................................................15
3.1.2.5 Oil Change ....................................................................................................................................................................15
3.1.2.6 Venting the Oil Pump ...................................................................................................................................................16
3.1.3 Intake Filter ......................................................................................................................................................................17
3.1.3.1 Service Indicator ...........................................................................................................................................................17
3.1.3.2 Replacing the Filter Element ........................................................................................................................................17
3.1.4 Intermediate Separators ....................................................................................................................................................18
3.1.4.1 Description....................................................................................................................................................................18
3.1.4.2 Maintenance..................................................................................................................................................................19
3.1.5 Compressor Valves and Valve Heads ..............................................................................................................................19
3.1.5.1 Functional Description..................................................................................................................................................19
3.1.5.2 Initial Operational Check of the Valves .......................................................................................................................19
3.1.5.3 General Instructions for Changing the Valves..............................................................................................................19
3.1.5.4 Changing the 1st Stage Valves. ...................................................................................................................................20
3.1.5.4.1 Removal Procedure.......................................................................................................................................................20
3.1.5.4.2 Installation Procedure ...................................................................................................................................................21
3.1.5.5 Changing the 2nd and 3rd Stage Valves .......................................................................................................................21
3.1.5.5.1 Removal Procedure.......................................................................................................................................................21
3.1.5.5.2 Installation Procedure ...................................................................................................................................................21
3.1.5.6 Changing the 4th Stage Valves .....................................................................................................................................22
3.1.5.6.1 Discharge Valve Removal Procedure ..........................................................................................................................23
3.1.5.6.2 Discharge Valve Installation Procedure ......................................................................................................................23
3.1.5.6.3 Inlet Valve Removal and Installation ..........................................................................................................................24
3.1.6 Repair and Troubleshooting .............................................................................................................................................24
3.1.6.1 Repair............................................................................................................................................................................24
3.1.6.2 Troubleshooting ............................................................................................................................................................25
3.1.7 Replacement Parts List .....................................................................................................................................................27
3.2 Four Stage Automatic Condensate Drain System................................................................................................................52
3.2.1 Description .......................................................................................................................................................................52
3.2.1.1 Compressor Operating ..................................................................................................................................................53
3.2.1.2 Condensate Draining.....................................................................................................................................................53
3.2.1.3 Start Unloading .............................................................................................................................................................54
3.2.1.4 Standstill Drainage........................................................................................................................................................54
3.2.1.5 Condensate Drain Piping ..............................................................................................................................................54
3.2.1.6 Condensate Drain Separator .........................................................................................................................................54
3.2.2 ACD Maintenance ............................................................................................................................................................54
3.2.3 Replacement Parts List .....................................................................................................................................................55
3.2.4 Trouble shooting...............................................................................................................................................................61
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MNL-0413 BAUER
COMPRESSORS
CHAPTER 4: - - - IK150II OR IK180II MAINTENANCE SCHEDULE

4.1 Initial start-up or after maintenance..................................................................................................................................... 62
4.2 Calendar intervals ................................................................................................................................................................ 62
4.3 Operating hours.................................................................................................................................................................... 62
4.3.1 Maintenance Records ....................................................................................................................................................... 63
CHAPTER 5: - - - - - - - - - - - - - - - - PURIFICATION SYSTEM

5.1 General................................................................................................................................................................................. 64
5.1.1 General Purification System Procedures.......................................................................................................................... 64
5.1.2 Chamber Safety Bore ....................................................................................................................................................... 64
5.1.3 Manual Condensate Drainage .......................................................................................................................................... 64
5.1.4 Model, Serial Number and Part Number Identification ................................................................................................... 65
5.1.4.1 Compressor Dataplate................................................................................................................................................... 65
5.1.4.2 Purification System Dataplate ...................................................................................................................................... 65
5.1.4.3 Cartridge Installation Dataplate.................................................................................................................................... 65
5.1.5 Breathing Air Purification System Configurations .......................................................................................................... 66
5.1.6 Cartridge Operating Life .................................................................................................................................................. 67
5.1.6.1 Calculating the Maximum Cartridge Operating Hours ................................................................................................ 67
5.1.6.2 Calculating the Adjusted Cartridge Operating Hours................................................................................................... 67
5.1.6.3 Air Purification Cartridge Operating Hours Form........................................................................................................ 69
5.2 P42 Purification System....................................................................................................................................................... 70
5.2.1 Major Components........................................................................................................................................................... 70
5.2.2 Configuration Options...................................................................................................................................................... 70
5.2.3 Component Description.................................................................................................................................................... 71
5.2.3.1 Oil and Water Separator ............................................................................................................................................ 71
5.2.3.2 Chamber........................................................................................................................................................................ 72
5.2.3.3 Cartridge Construction.................................................................................................................................................. 72
5.2.3.4 Cartridge Handling ....................................................................................................................................................... 73
5.2.3.5 Condensate Drain Valve ............................................................................................................................................... 73
5.2.3.6 Check Valves ................................................................................................................................................................ 73
5.2.3.7 Bleed Valve .................................................................................................................................................................. 73
5.2.3.8 Pressure Maintaining Valve.......................................................................................................................................... 73
5.2.3.9 Safety Valve.................................................................................................................................................................. 73
5.2.3.10 Securus Electronic Moisture Monitor System ........................................................................................................... 73
5.2.3.11 Securus Cartridge........................................................................................................................................................ 74
5.2.3.12 Securus Indicator ....................................................................................................................................................... 74
5.2.4 Maintenance ..................................................................................................................................................................... 74
5.2.4.1 Oil and Water Separator ............................................................................................................................................... 74
5.2.4.2 Cartridge Replacement ................................................................................................................................................. 75
5.2.4.3 Leaking at the Safety Bore ........................................................................................................................................... 76
5.2.5 Replacement Parts List..................................................................................................................................................... 77
CHAPTER 6: - - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

6.1 Description, Horizontal Sliding ........................................................................................................................................... 83
6.2 Maintenance of the V-belt and Sheave ................................................................................................................................ 83
6.2.1 Checking the Sheave. ....................................................................................................................................................... 83
6.2.2 Checking the V-belt ......................................................................................................................................................... 83
6.2.3 V-belt tension ................................................................................................................................................................... 83
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COMPRESSORS
6.3 Maintenance of the Drive Motor..........................................................................................................................................84
6.3.1 Lubricating the Drive Motor ............................................................................................................................................84
CHAPTER 7:- - - - - - - - - - - ELECTRICAL PANEL ASSEMBLY

7.1 Overview ..............................................................................................................................................................................85
7.2 Options .................................................................................................................................................................................86
7.3 AC Power Requirements......................................................................................................................................................86
7.3.1 Transformer and Fuses .....................................................................................................................................................88
7.4 Electric Panel Components .................................................................................................................................................88
7.4.1 Motor Starter. ...................................................................................................................................................................88
7.4.2 Overload Relay.................................................................................................................................................................88
7.4.3 Emergency Stop Switch. ..................................................................................................................................................90
7.4.4 Starter Reset......................................................................................................................................................................90
7.4.5 Compressor Control Switches ..........................................................................................................................................91
7.4.5.1 2-Position (Standard) ....................................................................................................................................................91
7.4.5.2 3-Position Compressor Control Switch (Factory Installed Option). ............................................................................91
7.4.5.2.1 For Breathing Air Units ................................................................................................................................................91
7.4.5.2.2 For Industrial Units .......................................................................................................................................................91
7.4.6 Indicator Lamps................................................................................................................................................................91
7.4.6.1 PLC Warning and Alarm Lamps ..................................................................................................................................91
7.4.6.1.1 Warning Lamp - Amber................................................................................................................................................91
7.4.6.1.2 Alarm Lamp - Red ........................................................................................................................................................91
7.4.7 Hour meter........................................................................................................................................................................91
7.4.8 PLC Control......................................................................................................................................................................91
7.4.8.1 PLC LEDs ...................................................................................................................................................................92
7.4.9 Compressor PLC Program Versions ................................................................................................................................93
7.4.10 PLC Inputs and Outputs ...................................................................................................................................................93
7.5 Warnings .............................................................................................................................................................................95
7.5.1 One Flash - Final Separator Warning...............................................................................................................................95
7.5.2 Two Flashes - Securus Monitor Warning.........................................................................................................................96
7.6 Alarms ..................................................................................................................................................................................97
7.6.1 One Flash - Compressor High Temperature.....................................................................................................................97
7.6.2 Two Flashes - Compressor Low Oil Pressure ..................................................................................................................97
7.6.3 Three Flashes - Compressor Overrun Timer ....................................................................................................................97
7.6.4 Four Flashes - Securus Monitor .......................................................................................................................................98
7.6.5 Five Flashes - Carbon Monoxide Monitor Alarm ............................................................................................................98
7.6.6 Six Flashes - Final Separator Shutdown...........................................................................................................................99
7.6.7 Seven Flashes - Condensate Fault ....................................................................................................................................99
7.6.8 On Steady - Motor Starter Overload Trip.......................................................................................................................100
7.7 Installing a New Program ..................................................................................................................................................101
7.7.1 Installing a new program using an EEPROM cartridge .................................................................................................102
7.8 Overrun Timer....................................................................................................................................................................103
7.8.1 Adjusting the Overrun Timer .........................................................................................................................................103
7.9 Wire Harness Connections ................................................................................................................................................104
7.10 Replacement Parts List.......................................................................................................................................................105
7.11 Trouble Shooting Guide.....................................................................................................................................................106
7.11.1 Compressor Will Not Start .............................................................................................................................................106
7.11.2 Compressor Is Shutdown, Alarm Code Flashing Sequence...........................................................................................106
7.11.2.1 One Flash - Compressor High Temperature ...............................................................................................................106
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COMPRESSORS
7.11.2.2 Two Flashes - Compressor Low Oil Pressure ............................................................................................................ 106
7.11.2.3 Three Flashes - Compressor Overtime ....................................................................................................................... 107
7.11.2.4 Four Flashes - Securus Alarm................................................................................................................................... 107
7.11.2.5 Five Flashes - Carbon Monoxide Monitor Alarm ...................................................................................................... 107
7.11.2.6 Six Flashes - Final Separator Shutdown..................................................................................................................... 107
7.11.2.7 Seven Flashes -Condensate Fault ............................................................................................................................... 108
7.11.2.8 On Steady - Motor Over load Trip ............................................................................................................................. 108
7.11.2.9 Eight Flashes - High Inlet Pressure (Gas Compressors Only).................................................................................... 108
7.11.2.10 Nine Flashes - Low Inlet Vacuum (Gas Compressors Only) ..................................................................................... 108
7.12 Check Compressor Rotation Direction. ............................................................................................................................. 109
7.13 PLC Standard Wiring Diagram.......................................................................................................................................... 110
7.14 PLC Industrial Compressor Wiring Diagram ................................................................................................................... 111
7.15 PLC Gas Compressor Wiring Diagram ............................................................................................................................ 112
CHAPTER 8: - - - - - - - - - - - - CARBON MONOXIDE MONITOR

8.1 Description......................................................................................................................................................................... 113
8.1.1 Component Description.................................................................................................................................................. 114
8.1.1.1 Isolation Valve............................................................................................................................................................ 114
8.1.1.2 High Pressure to Low Pressure Regulator .................................................................................................................. 114
8.1.1.3 Relief Valve ................................................................................................................................................................ 114
8.1.1.4 Solenoid Valve............................................................................................................................................................ 114
8.1.1.5 Inlet Regulator ............................................................................................................................................................ 114
8.1.1.6 CO Monitor................................................................................................................................................................. 114
8.1.1.6.1 Carbon Monoxide Sensor Cell.................................................................................................................................... 114
8.1.1.7 Test Gas Storage ......................................................................................................................................................... 114
8.2 CO Monitor Setup.............................................................................................................................................................. 114
8.3 Operation ........................................................................................................................................................................... 114
8.4 Maintenance....................................................................................................................................................................... 115
8.4.1 Calibrating Carbon Monoxide Monitor.......................................................................................................................... 115
8.4.2 Troubleshooting a Calibration Failure ........................................................................................................................... 116
8.4.3 Carbon Monoxide Sensor Cell Replacement ................................................................................................................. 116
8.4.4 Calibration Initialization ................................................................................................................................................ 117
8.4.5 CO Monitor Test Mode Buttons..................................................................................................................................... 119
8.5 Remote Display Setup ...................................................................................................................................................... 120
8.6 Replacement Parts List ...................................................................................................................................................... 122
CHAPTER 9: - - - - - - - - PNEUMATIC VALVES AND CONTROLS

9.1 Nonadjustable Valves ........................................................................................................................................................ 124
9.2 Pressure Maintaining Valve............................................................................................................................................... 124
9.3 Safety Valves ..................................................................................................................................................................... 125
CHAPTER 10: - - - - - - - - - - - - - - - - - - - - - - INDICATORS

10.1 Indicators ........................................................................................................................................................................... 126
10.1.1 Replacement Parts List................................................................................................................................................... 127
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BAUER K20V
COMPRESSORS
CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

11.1 Safety .................................................................................................................................................................................128
11.1.1 General Safety Precautions.............................................................................................................................................128
11.1.2 Safety Warning Labels ...................................................................................................................................................130
11.2 Unpacking, Handling and Installation ...............................................................................................................................131
11.2.1 Unpacking and Handling................................................................................................................................................131
11.2.2 Installation of the Compressor Unit ...............................................................................................................................132
11.2.2.1 General........................................................................................................................................................................132
11.2.2.2 Ventilation ..................................................................................................................................................................132
11.2.2.2.1 Outdoor Installation ....................................................................................................................................................132
11.2.2.2.2 Indoor Installation.......................................................................................................................................................132
11.2.2.2.3 Natural Ventilation .....................................................................................................................................................133
11.2.2.2.4 Forced Ventilation ......................................................................................................................................................133
11.2.2.3 Electrical Installation ..................................................................................................................................................134
11.2.2.3.1 Electric Drive ..............................................................................................................................................................134
11.2.2.3.2 Electrical Supply.........................................................................................................................................................134
11.3 Long Term Storage ............................................................................................................................................................136
11.3.1 General ...........................................................................................................................................................................136
11.3.2 Preparations ....................................................................................................................................................................136
11.3.2.1 Units Equipped with a Filter System ..........................................................................................................................136
11.3.3 Preserving the Compressor.............................................................................................................................................136
11.3.4 Preventive Maintenance During Storage........................................................................................................................137
11.3.5 Lubrication Oils for Preservation ...................................................................................................................................137
11.3.6 Reactivating the Compressor Unit..................................................................................................................................137
11.4 Reproducible Forms ...........................................................................................................................................................138
11.4.1 Scheduled Maintenance Form .......................................................................................................................................138
11.4.2 Record of Operating Hours ...........................................................................................................................................141
11.5 Reference Data ...................................................................................................................................................................142
11.5.1 Tightening Torque Values..............................................................................................................................................142
11.5.2 Torque Sequence Diagrams............................................................................................................................................142
11.5.3 Conversion Formulas......................................................................................................................................................142
11.5.4 Approved Lubricants Chart ............................................................................................................................................143
11.5.5 Glossary of Abbreviations and Acronyms .....................................................................................................................143
11.6 Additional Documents .......................................................................................................................................................144
11.6.1 Diagrams and Drawings .................................................................................................................................................144
11.6.2 Other Documents............................................................................................................................................................144
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MNL-0413 BAUER
COMPRESSORS
LIST OF FIGURES
CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION
There are no Figures in this Chapter
CHAPTER 2: - - - - - - - - PLC CONTROLLED UNIT OPERATIONS

Figure 2-1 Electrical Panel Front .............................................................................................................................................. 7
Figure 2-2 PLC.......................................................................................................................................................................... 9
Figure 2-3 Status LEDs ............................................................................................................................................................. 9
CHAPTER 3: - - - - - - - - - - - - - - MAINTENANCE AND PARTS

Figure 3-1 Four Stage Compressor Air Flow.......................................................................................................................... 12
Figure 3-2 IK150 II Compressor Block (Front View) ............................................................................................................ 13
Figure 3-3 Lubrication Oil System.......................................................................................................................................... 14
Figure 3-4 Oil Filler Sight Gauge ........................................................................................................................................... 15
Figure 3-5 Removing the Oil Filter Cover .............................................................................................................................. 16
Figure 3-6 Replacing the Oil Filter ......................................................................................................................................... 16
Figure 3-7 Intake Filter ........................................................................................................................................................... 17
Figure 3-8 2nd Stage Intermediate Separator.......................................................................................................................... 18
Figure 3-9 3rd Stage Intermediate Separator .......................................................................................................................... 18
Figure 3-10 Valve Function ...................................................................................................................................................... 19
Figure 3-11 1st Stage Valve and Head...................................................................................................................................... 20
Figure 3-12 2nd and 3rd Stages Valve Heads and Valves ....................................................................................................... 21
Figure 3-13 4th Stage Valve and Head ..................................................................................................................................... 22
Figure 3-14 4th Stage Discharge Valve Removal..................................................................................................................... 23
Figure 3-15 Assembly Tool....................................................................................................................................................... 24
Figure 3-16 Using Special Tool ................................................................................................................................................ 24
Figure 3-17 Crankcase Assembly ............................................................................................................................................. 27
Figure 3-18 Complete Crankshaft Assembly ............................................................................................................................ 29
Figure 3-19 K150II 1st Stage Piston and Cylinder ................................................................................................................... 30
Figure 3-20 2nd Stage Piston and Cylinder Assembly ............................................................................................................. 31
Figure 3-21 3rd Stage Piston and Cylinder ............................................................................................................................... 33
Figure 3-22 4th Stage Piston and Cylinder Assembly .............................................................................................................. 35
Figure 3-23 4th Stage Piston and Sleeve Assembly.................................................................................................................. 36
Figure 3-24 1st Stage Valve Head Assembly............................................................................................................................ 37
Figure 3-25 2nd Stage Valve Head ........................................................................................................................................... 38
Figure 3-26 3rd Stage Valve Head Assembly........................................................................................................................... 39
Figure 3-27 4th Stage Valve Head Assembly ........................................................................................................................... 40
Figure 3-28 Flywheel Drive Assembly ..................................................................................................................................... 41
Figure 3-29 Intake Filter Assembly .......................................................................................................................................... 42
Figure 3-30 2nd Stage Interfilter Assembly.............................................................................................................................. 43
Figure 3-31 3rd Stage Interfilter Assembly............................................................................................................................... 44
Figure 3-32 IK150 II and IK180 II Cooling System Assembly................................................................................................ 45
Figure 3-33 2nd Stage Intercooler............................................................................................................................................. 48
Figure 3-34 3rd Stage Intercooler ............................................................................................................................................. 49
Figure 3-35 Lubricating System Assembly............................................................................................................................... 50
Figure 3-36 Lubricating System................................................................................................................................................ 51
Figure 3-37 4 Stage Automatic Condensate Drain System....................................................................................................... 52
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COMPRESSORS
Figure 3-38 ACD Operation Diagrams .....................................................................................................................................53
Figure 3-39 4 Stage ACD System .............................................................................................................................................55
Figure 3-40 ACD Manifold and Valves ....................................................................................................................................56
Figure 3-41 3rd Stage Condensate Drain Valve........................................................................................................................57
Figure 3-42 Oil and Water Separator Condensate Drain Valve ................................................................................................59
CHAPTER 4:- - - - IK150II OR IK180II MAINTENANCE SCHEDULE

There are no Figures in this Chapter
CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

Figure 5-1 Cartridge Safety Venting .......................................................................................................................................64
Figure 5-2 Purification System Dataplate (typical).................................................................................................................65
Figure 5-3 Cartridge Installation Dataplate (typical) ..............................................................................................................65
Figure 5-4 Correction Factor for Cartridge Operating Hours .................................................................................................68
Figure 5-5 Example Record of Adjusted Operating Hours .....................................................................................................68
Figure 5-6 P42 Purification System ........................................................................................................................................70
Figure 5-7 P42S Purification System ......................................................................................................................................71
Figure 5-8 Oil and Water Separator ........................................................................................................................................72
Figure 5-9 OIl and Water Separator Labels ............................................................................................................................72
Figure 5-10 Cartridge ................................................................................................................................................................73
Figure 5-11 Oil and Water Separator ........................................................................................................................................75
Figure 5-12 Sintered Metal Filter Assembly .............................................................................................................................75
Figure 5-13 Cartridge Replacement .........................................................................................................................................76
Figure 5-14 P42 Purification System Parts List ........................................................................................................................77
Figure 5-15 Oil and Water Separator Parts List .......................................................................................................................78
Figure 5-16 Dryer Chamber Assembly Parts List ....................................................................................................................79
Figure 5-17 Purification Chamber Assembly Parts List...........................................................................................................80
Figure 5-18 Securus Moisture Monitor Parts List ..................................................................................................................81
CHAPTER 6:- - - - - - - - - - - - - COMPRESSOR DRIVE SYSTEM

Figure 6-1 Horizontal Motor Mount (typical) .........................................................................................................................83
Figure 6-2 V-belt Deflection ...................................................................................................................................................84
CHAPTER 7:- - - - - - - - - - - ELECTRICAL PANEL ASSEMBLY

Figure 7-1 Electrical Panel Assembly .....................................................................................................................................85
Figure 7-2 Electrical Panel Label ............................................................................................................................................87
Figure 7-3 Transformer and Fuses ..........................................................................................................................................87
Figure 7-4 Motor Starter and Overload Relay, SRT-0197 shown...........................................................................................88
Figure 7-5 Electrical Panel Assembly .....................................................................................................................................90
Figure 7-6 PLC CNT-0052......................................................................................................................................................92
Figure 7-7 Status Lights ..........................................................................................................................................................92
Figure 7-8 Securus System ....................................................................................................................................................96
Figure 7-9 High Temperature Switch......................................................................................................................................97
Figure 7-10 Low Oil Pressure Switch .......................................................................................................................................97
Figure 7-11 CO Monitor............................................................................................................................................................98
Figure 7-12 Condensate Level Float Switch ...........................................................................................................................100
Figure 7-13 PLC Programing Port ..........................................................................................................................................101
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Figure 7-14 PLC EEPROM..................................................................................................................................................... 102
Figure 7-15 Overrun Timer Adjustment ................................................................................................................................. 103
Figure 7-16 Electrical Panel, Interior...................................................................................................................................... 105
Figure 7-17 Checking Compressor Rotation Direction........................................................................................................... 109
CHAPTER 8: - - - - - - - - - - - - CARBON MONOXIDE MONITOR

Figure 8-1 CO Monitor, MNR-0029 ..................................................................................................................................... 113
Figure 8-2 MNR-0033........................................................................................................................................................... 113
Figure 8-3 Carbon Monoxide Monitor Flow Diagram.......................................................................................................... 114
Figure 8-4 Basic Calibration Kit ........................................................................................................................................... 116
Figure 8-5 CO Monitor Internal Components....................................................................................................................... 118
Figure 8-6 Carbon Monoxide Sensor Cell Removal............................................................................................................. 119
Figure 8-7 Mode Buttons Close-up....................................................................................................................................... 120
Figure 8-8 Remote Display ................................................................................................................................................... 121
Figure 8-9 CO Monitor Assembly - Standard....................................................................................................................... 122
Figure 8-10 CO Monitor Schematic........................................................................................................................................ 123
CHAPTER 9: - - - - - - - - PNEUMATIC VALVES AND CONTROLS

Figure 9-1 Pressure Maintaining Valve ................................................................................................................................ 124
Figure 9-2 Safety Valves....................................................................................................................................................... 125
CHAPTER 10: - - - - - - - - - - - - - - - - - - - - - - INDICATORS

Figure 10-1 Indicators ............................................................................................................................................................. 127
CHAPTER 11: - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

Figure 11-1 Lifting Devices .................................................................................................................................................... 131
Figure 11-2 6 Bolt and 4 Bolt Torque Sequence..................................................................................................................... 142
June 01, 2006 Page x

BAUER K20V
COMPRESSORS
CHAPTER 1: INTRODUCTION
1.1 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 prema-
ture 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 conse-
quences thereof.
1.1.1 Manual Safety Notices
Important instructions concerning the endangerment of personnel, technical safety or operator safety will
be specially emphasized in this manual by placing the information in the following types of safety notices.
^ DANGER ^
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury. This is limited to the most extreme situations.
^ WARNING ^
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death
or injury.
^ CAUTION ^
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices.
^ 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.
Page 1 1st ed. Rev. 0 Chg. 0

MNL-0413 BAUER
COMPRESSORS
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 compressor unit
identification plate on the compressor units 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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BAUER K20V
COMPRESSORS
1.3 How to Use the Appendix
Information contained in the Appendix to this manual includes the following.
The safety instructions applicable to this product. They must be read, understood and complied with
prior to operating the product.
The instructions for installing this product. They must be read, understood and complied with prior to
operating the product.
The instructions for long term storage (over 90 days) of this product.

MNL-0413 BAUER
COMPRESSORS
1.4 Unit Description
The BAUER K20V models have two trim levels available, Economy (E) and Luxury (L).
1.4.1 Economy Trim Level Standard Features
5,000 psig maximum pressure
BAUER Breathing Air Purification System
Air-cooled Interstage Coolers and Aftercooler
Interstage and Final Oil and Water Separators
Interstage and Final Relief Valves
Inlet Filter
P42 Purification
Electrical Enclosure, rated NEMA 4, which includes:
PLC Compressor Control System
On / Off Switch.
Emergency Stop Switch.
Hourmeter.
Final Separator Warning and Alarm.
Motor Overload Alarm.
High Temperature Alarm with shutdown.
Low Oil Pressure Alarm with shutdown.
Support of Securus Alarm and Warning, if installed.
Support of CO Monitor, if installed.
Support of Automatic Condensate System, if installed.
1.4.2 Luxury Trim Level Standard Features
The following items are added to the standard features of the Economy Trim Level.
Full Enclosure of the unit
Instrumentation Panel
P42 Purification with Securus Electronic Moisture Monitoring System
Automatic Condensate Drain
Inlet Filter Maintenance Indicator
1.4.3 Economy Trim Level Factory Installed Optional Features
The following optional items may have been added if ordered at time of manufacture.
Locally Mounted Interstage Gauges
Automatic Condensate Drain System
Audible Alarms for Safety Shutdowns
Securus Electronic Moisture Monitoring System
CO Monitoring System
1.4.4 Factory Installed Optional Features Available in Either Economy or Luxury Trim Level.
Purification Upgrades
CO Monitoring System

BAUER K20V
COMPRESSORS
1.5 K20VSpecifications
Medium air
Charging Rate 17.5 scfm1
Free Air Delivery 21.0 scfm2
Inlet pressure atmospheric
Operating pressure, max. 5,000 psig
Ambient temperature range 32 to 105 F
Weight Approximately 1,000 lb.
1.6 Compressor Block
IK150 II Mod. 10
No. of Stages 4
No. of Cylinders 4
Cylinder Bore, 1st Stage 4.72 in (120 mm)
Cylinder Bore, 2nd Stage 2.367 in (60 mm)
Cylinder Bore, 3rd Stage 1.26 in (32 mm)
Cylinder Bore, 4th Stage 0.55 in (14 mm)
Piston Stroke 1.97 in (50 mm)
Direction of Rotation, when facing flywheel Counterclockwise
Intermediate Pressure, 1st Stage 35 - 54 psi (2.4 - 3.7 bar)
Safety Valve Setting, 1st Stage 80 psi (5.5 bar)
Intermediate Pressure, 2nd Stage 203 - 247 psi (14 - 17 bar)
Safety Valve Setting, 2nd Stage 348 psi (24 bar)
Intermediate Pressure, 3rd Stage 841 - 1088 psi (58 - 75 bar)
Safety Valve Setting, 3rd Stage 1160 psi (80 bar)
Compressor Speed 1350 RPM
Maximum Inclination 20
Oil Capacity Approximately 5.28 Qts. (5 l)
Recommended Oil Bauer OIL-0024
1.6.1 Compressor Drive
Voltage Frequency Phase Power RPM Type BAUER PN

208 - 460 VAC 60Hz 3 15 Hp 3600 ODP MTR-0024
1.6.2 Purification System Applicability

The K20V-E3 is equipped with the Bauer P42 Purification System. A Securus Electronic Moisture Mon-
itoring System may be included as a factory installed option. The is equipped with the Bauer P42 Purifica-
tion System with Securus Electronic Moisture Monitoring System
1. Based on recharging an 80 cubic foot tank from 500 to 3000 PSIG
2. Referenced to standard inlet conditions of 68F and 36% humidity at 14.70 psia.

MNL-0413 BAUER
COMPRESSORS
CHAPTER 2: PLC CONTROLLED UNIT OPERATIONS
2.1 Pre-start Checks
1. Ensure that all scheduled maintenance is completed.
2. Check compressor oil level. Refer to Chapter 3.
3. On units with a gasoline or diesel engine, check engine oil level. Refer to Original Equipment Man-
ufacturers (OEM) manual.
4. Check Emergency Stop Switch is pulled out.
2.2 Start-up Procedure
(See Figure 2-1)
1. Verify that all connections downstream of the compressor are secure.
2. Open the condensate drain valves to relieve any remaining pressure.
3. Close the condensate drain valves.
4. Apply electric power to the unit.
5. Turn the Compressor Control Switch to the ON position.
2.3 Post Start Procedures
1. Allow the compressor to build up pressure. Monitor the pressure gauge.
2. Listen to the unit as it operates. If excessive knocking or vibrations are observed shut down the unit.
3. Allow the compressor to reach full pressure.
2.4 Shutdown Procedures
1. Verify all bottle valves and fill valves are closed.
2. Turn the Compressor Control Switch to the OFF position.
3. After shutting down the compressor drive, open the condensate drain valves to relieve any remain-
ing pressure and drain any moisture from the intermediate separators and the oil and water separa-
tor.
4. Close the condensate valves.
5. Leave Emergency Stop Switch pulled out for at least 8 hours every 30 days to maintain the charge
on the internal PLC battery and preserve the PLC operating memory.
6. If the compressor is to remain idle for six months or longer, refer to the Appendix titled, Long Term
Storage for preservation instructions.

BAUER K20V
COMPRESSORS
2.5 Electric Panel Components
See Figure 2-1
Figure 2-1 Electrical Panel Front
1
2
3
4
1. Compressor Control Switch 4. Hourmeter

2. Alarm Light 5. Starter Reset
3. Warning Light 6. Emergency Stop Switch
2.5.1 Emergency Stop Switch.
The Emergency Stop Switch is a switch with a mushroom head. The button must be pulled out for the
unit to operate. In an emergency, depress the push button, which will shutdown the electric motor and all
other periphery devices. Do not use the Emergency Stop Switch for securing the equipment under normal
operation, use the Compressor Control Switch. The PLC operating memory is maintained by a internal bat-
tery 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.
2.5.2 Starter Reset
The Starter Reset is a blue push button with the letter R at its center. Pushing this button will reset the
thermal overload relay on the motor starter. Should the electric motor have overloaded and tripped out during
normal operation, then depressing this button after giving the motor starter some time to cool, will reset the
overload relay portion of the motor starter.

MNL-0413 BAUER
COMPRESSORS
2.5.3 Compressor Control Switch
2.5.3.1 2-Position (Standard)
OFF Position - The Compressor Control Switch switch must be in the OFF position when securing the
compressor system.
ON Position - The Compressor Control Switch switch must be in the ON position to operate the compres-
sor system. When positioning the switch to the ON position, it will illuminate Green. The compressor will
start and stop automatically based on the status of the pressure switch.
2.5.3.2 3-Position Compressor Control Switch (Factory Installed Option).
2.5.3.2.1 For Breathing Air Units
OFF - The Compressor Control Switch must be in the OFF position when securing the compressor.
ON - The Compressor Control Switch must be in the ON position to operate the compressor system.
When positioning the switch to the ON position, it will illuminate Green. The compressor will start and stop
automatically based on the status of the pressure switch.
ACD Test - This Compressor Control Switch position will cause all condensate drains to blow down. It is
spring returned to ON Position when released.
2.5.3.2.2 For Industrial Units
OFF - The Compressor Control Switch switch must be in the OFF position when securing the compressor
system.
AUTO- The Compressor Control Switch switch must be in the ON position to operate the compressor
system. When positioning the switch to the ON position, it will illuminate Green. The compressor will start
and stop automatically based on the status of the pressure switch.
CONTINUOUS - This Compressor Control Switch position will allow the compressor to build up to final
pressure, then will activate an unloading valve. When demand is re-established, the unloading valve is de-
energized and compression will begin again.
2.5.4 Indicator Lamps
2.5.4.1 PLC Warning and Alarm Lamps
2.5.4.1.1 Warning Lamp - Amber
The lamp (Bauer P/N LIT-0128) is a LED lamp for long trouble free life. This lamp will flash a code
IAW the logic of the PLC. See Paragraph 2.6.
2.5.4.1.2 Alarm Lamp - Red
The lamp (Bauer P/N LIT-0127) is a LED lamp for long trouble free life. This lamp will flash a code
IAW the logic of the PLC. See Paragraph 2.7.
2.5.5 Hourmeter
The panel is supplied with an hourmeter. The hourmeter is not resettable and used to monitor the run
hours of the compressor. It is powered with a 120 VAC signal supplied from the auxiliary contact on the
motor starter.
2.5.6 PLC Control
This panel will be controlled with a Telemecanique 16 I/O Twido Programmable Logic Controller. This
unit will provide logical operations to the overall system that includes the high pressure compressor, purifica-
tion systems, and other accessories.

BAUER K20V
COMPRESSORS
Figure 2-2 PLC Figure 2-3 Status LEDs

Input LEDs
Inputs IN
012345678
0123456
Status
STAT
PWR
RUN
ERR
Lights
Program
Version OUT
Status LEDs Output LEDs
120 VAC Supply Outputs
2.5.6.1 PLC LEDs

There are three separate groups of LEDs on the PLC. See Figure 2-3.
1. The Input Status LEDs are in the top row.
2. The Output Status LEDs 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.
2.6 Warnings
The amber Warning Light located on the control panel flashes warning codes with a 0.5 second on, 0.5
second off sequence with a distinct pause between sequences. In addition the light will illuminate on initial
start up for a period of 5 seconds, to serve as a lamp test function. The lamp is a LED lamp for long trouble
free life.
2.6.1 One Flash - Final Separator Warning
The compressor unit is equipped with a final separator. To prevent fatigue failure of this pressure vessel,
the PLC program monitors the pressurization, de-pressurization cycles of the separator and will first issue a
Warning, and then an Alarm. The program is set up to provide the warning at 90% of the maximum recom-
mended number of cycles. The program is configured to reflect these values when it is built. When the warn-
ing is illuminated, the unit will still continue to function properly, but will prompt the operator to contact

MNL-0413 BAUER
COMPRESSORS
Bauer Compressors for making arrangements to replace the Final Separator. When the Alarm level has been
achieved, the compressor will no longer function, and will require the replacement of the Final Separator.
Once the Final Separator is replaced, the unit can be re-activated by making adjustments to the PLC. Please
contact Bauer Product Support for detailed instructions on this procedure.
^ WARNING ^
Do not attempt to override the Separator Shutdown Warning.
This feature is provided to protect personnel from injury or death.
2.6.2 Two Flashes - Securus Monitor

The compressor purification system is equipped with a Securus Electronic Moisture Monitor. This con-
sists of a control module and cable connected to the purification chamber. It functions as a capacitive sensor,
sensing the moisture in the purified air. When the chemicals in the purification cartridges have reached the
point where they retain a set level of moisture, the Securus monitor will issue a warning via the amber
Warning Light. On a Securus Warning condition, the compressor will run normally, the PLC I7 lamp will
illuminate, and the warning code will flash. This warning is meant to prompt the operator to schedule
replacement of the purification cartridge.
2.7 Alarms
The red Warning Light located on the control panel flashes warning codes with a 0.5 second on, 0.5 sec-
ond off sequence with a distinct pause between sequences.In addition the light will illuminate on initial start
up for a period of 5 seconds, to serve as a lamp test function. The lamp is a LED lamp for long trouble free
life.
2.7.1 One Flash - Compressor High Temperature
The compressor high temperature switch is located on the compressor block, third, fourth or fifth stage
head, depending on model. Under normal operating conditions, the switch is closed and the I1 lamp on the
PLC is illuminated. On a high temperature condition, the compressor will shutdown, the I1 lamp will extin-
guish, and the alarm code will flash.
2.7.2 Two Flashes - Compressor Low Oil Pressure
The compressor oil pressure switch is located on the back of the compressor block, mounted with the oil
pressure gauge. The switch is N.O., Normally Open, and is connected to the PLC on terminal I2. During star-
tup of the compressor, the oil pressure switch is bypassed for a period of 45 seconds to allow the oil pressure
to stabilize, then the switch will close. Then should the compressor lose oil pressure, the compressor will
shutdown, the I2 lamp will extinguish, and the alarm code will flash.
2.7.3 Three Flashes - Compressor Overtime
The compressor has an overtime function, where if the compressor runs continuously for 5 hours, then
the compressor will shutdown, and the alarm code will flash. This is done to secure the equipment if it were
to be started and left unattended.
2.7.4 Four Flashes - Securus Monitor
The compressor purification system is equipped with a Securus Electronic Moisture Monitor. This con-
sists of a control module and cable connected to the purification chamber. It functions as a capacitive sensor,
sensing the moisture in the purified air. When the chemicals in the purification cartridge has reached the
point where it retains a set level of moisture, the Securus monitor will issue an alarm via the red Alarm
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COMPRESSORS
Light. On a Securus ALARM condition, the compressor will shutdown, the PLC I5 lamp will be illumi-
nated, and the alarm code will flash.
2.7.5 Five Flashes - Carbon Monoxide Monitor Alarm
The compressor system is equipped with a Carbon Monoxide Monitor. This consists of an electronic
module that samples the compressed air supply. The unit will provide a continuous display of the CO level in
PPM, parts per million. If the CO level becomes excessively high, then the red alarm light on the face of the
monitor will illuminate. At the same time the alarm relay in the CO Monitor which is connected to the PLC
I4 will generate a CO ALARM condition.The compressor will shutdown, the I4 lamp will illuminate, and the
alarm code will flash.The unit should be calibrated with a test gas monthly. Refer to the chapter titled CO
Monitor for this procedure.
2.7.6 Six Flashes - Final Separator Shutdown
^ WARNING ^
Do not attempt to override the Final Separator Shutdown. This feature is provided to protect operating per-
sonnel from injury or death.
The high pressure-breathing compressor is equipped with a final separator. To prevent fatigue failure of
this vessel, the PLC program monitors the pressurization, de-pressurization cycles of the separator and will
issue a Warning, and then later an Alarm. The program is set up to provide a warning at 90% of the maxi-
mum recommended number of cycles. The program is configured to reflect these values when it is built.
When the warning is illuminated, the unit will still continue to function properly, but will prompt the operator
to contact Bauer Compressors for making arrangements to replace the separator. When the Alarm level has
been achieved, the compressor will no longer function, and will require the replacement of the separator.
Once this is accomplished, the unit can be re-activated by making adjustments to the PLC. Please contact
Bauer Product Support for detailed instructions
2.7.7 Seven Flashes - Condensate Fault
The compressor condensate level float switch is located in the condensate collection tank. Under normal
operating conditions, the switch is open and the I6 lamp on the PLC is off. On a high condensate level the
float switch will close, the compressor will shutdown, the PLC I6 lamp will illuminate, and the alarm code
will flash. The operator should drain the condensate from the tank and resume operation of the equipment.
^ NOTE ^
The compressor condensate contains some oil, and accordingly, should
be disposed of in accordance with state and local regulations.
2.7.8 On Steady - Motor Starter Overload Trip

The compressor overload relay is located in the electrical enclosure, directly beneath the motor starter.
The relay is Normally Open and is not connected to the PLC, but is connected directly to the red Alarm
Light. Under normal operating conditions, the switch is open. On an Overload Trip of the motor, the com-
pressor will shutdown, and the Alarm Light will be illuminated steady (no flash sequence).

MNL-0413 BAUER
COMPRESSORS
CHAPTER 3: MAINTENANCE AND PARTS
3.1 IK150 II Compressor Block
3.1.1 Description
The IK150 II compressor is used to compress air up to 5000 psi.
The IK150 II compressor is a four cylinder, four stage air cooled, oil lubricated reciprocating compressor.
The 4th stage cylinder is lubricated by means of the forced feed lubrication system, while the other cylinders
are splash lubricated. The cylinders are arranged 90 apart, with the 1st and 2nd stage, and the 3rd and 4th
stage opposite each other. These compressor blocks are particularly suitable for continuous operation
because of their rugged design and corrosion resistant intermediate filter and cooler assemblies.
3.1.1.1 Air Flow Diagram
Figure 3-1 Four Stage Compressor Air Flow
1
10 10
I IV
6 3 4 7
5
III II
9 9
10
11 10
12 8
9
1. Intake Manifold 7. 3rd Stage Separator
2. 1st Stage Cooler 8. Final Separator
3. 2nd Stage Cooler 9. Manual Condensate Drain Valve
4. 3rd Stage Cooler 10. Safety Valves
5. Aftercooler 11. Pressure Maintaining Valve (PMV)
6. 2nd Stage Separator 12. Compressed Air Outlet
June 01, 2006 Page 12

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COMPRESSORS
3.1.1.2 Component Location
Figure 3-2 IK150 II Compressor Block (Front View)
11
1
12
2
3 13
14
4
5 15
16
6
17
7 18
8 19
20
9 21
10
22
1. Service Indicator 12. 1st Stage Inter Cooler
2. Intake Filter 13. 4th Stage Cylinder
3. Crankcase Vent Feedback Line 14. 4th Stage After Cooler
4. 1st Stage Cylinder 15. Oil Pressure Regulating Valve
5. 2nd/3rd Inter Stage Pressure Valve 16. 3rd/4th Inter Stage Pressure Valve
6. 2nd Stage Separator 17. 3rd Stage Separator
7. 2nd Stage Cooler 18. 1st/2nd Inter Stage Pressure Valve
8. Oil Pump Housing 19. 3rd Stage Cooler
9. 3rd Stage Cylinder 20. 2nd Stage Cylinder
10. Compressed Air Outlet 21. Oil Filler with Sight Glass
11. Lifting Eyebolt 22. Condensate Outlet

MNL-0413 BAUER
COMPRESSORS
3.1.2 Lubrication System

3.1.2.1 Description.
The compressor is provided with forced-feed lubrication. The oil pressure is produced by a low revving
gear pump. The oil pressure is between 44 psi and 87 psi (3 to 6 bar).
^ CAUTION ^
This oil pump must be operated in the correct direction of rotation, other wise no oil pressure will
be built up and the compressor may be damaged.
(See Figure 3-3) The oil pump (1) is coupled to and driven by the crankshaft. It pumps oil from the crank-
case through an oil filter (2) and the oil pressure regulating valve (3) to the 4th stage cylinder. The oil is then
distributed by the guide piston of the 4th stage and lubricates all the moving parts of the compressor block.
The oil pressure sensor (5) allows mounting for an optional oil pressure gauge or electronic pressure monitor-
ing.
Figure 3-3 Lubrication Oil System
1. Oil Pump 4. Injection Line to 4th Stage

2. Oil Filter 5. Oil Pressure Sensor
3. Oil Pressure Regulating Valve
3.1.2.2 Oil Level Check
(See Figure 3-4). Check the oil level at the oil filler sight gauge on the compressor block every day before
putting the compressor into operation. Oil level must never be below the minimum mark molded into the
June 01, 2006 Page 14

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COMPRESSORS
sight gauge as this will cause severe damage due to lack of lubrication.Overfilling is prevented by the design
of the filler neck; i.e. oil should be filled right to the edge of the opening.
Figure 3-4 Oil Filler Sight Gauge
Max
Min
3.1.2.3 Oil Change Interval

The synthetic oil should be changed every 2,000 operating hours or biennially, whichever is reached first.
3.1.2.4 Oil Capacity
The oil capacity is approximately 6.5 quarts (6.0 liters). The amount of oil between the minimum and
maximum marks is approximately 1.7 quarts (1.6 liters).
3.1.2.5 Oil Change
1. Run the compressor until it is warm.
2. Remove cap from Oil Filler Sight Gauge.
3. Open the Oil Drain Plug.
^ CAUTION ^
Replace the oil filter at every oil change, otherwise when the filter becomes clogged a bypass valve
opens and the oil circulates without being filtered.
4. (See Figure 3-5) Remove two bolts (1) with a 13mm wrench. Remove cover (2).
5. (See Figure 3-6) Remove the Oil Filter (1) from the rubber gasket at the cover.
6. Mount a new filter element and replace and fasten cover.
7. Fill new oil through filler neck to the Maximum mark on the Oil Fill Sight Gauge.
8. Pour oil in slowly, wait a few minutes until the level settles then replace cap in the Oil Fill Sight
Gauge.
9. Return the unit to operation.

MNL-0413 BAUER
COMPRESSORS
Figure 3-5 Removing the Oil Filter Cover Figure 3-6 Replacing the Oil Filter
3.1.2.6 Venting the Oil Pump
^ CAUTION ^
To avoid damage after maintenance the following measures should be strictly adhered to.
(See Figure 3-6). If after the start of the compressor no oil pressure builds up, venting the oil pump may
be necessary, especially after maintenance and repair work. It may also be necessary if the unit has been
operated in the wrong direction of rotation.
1. With the unit running, open the condensate drain valves.
2. Open Oil Pump Vent Plug (2) and wait until oil comes out bubble free.
3. Replace Oil Vent Plug.
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COMPRESSORS
3.1.3 Intake Filter
Figure 3-7 Intake Filter
4 2
3
1
1. Service Indicator 3. Filter Element
2. Cover 4. Filter Housing
A dry micronic filter is used to filter intake air.
3.1.3.1 Service Indicator
The vacuum in the intake filter is monitored by the Service Indicator (1). When the preset vacuum pres-
sure is reached the indicator changes to red and the Filter Element (3) should be replaced
3.1.3.2 Replacing the Filter Element
See Figure 3-7 and proceed as follows.
1. Open clips on Filter Housing (4) and remove Cover (2).
2. Remove the Filter Element (3).
3. Clean the inside of the Filter Housing with a damp cloth. Take care to prevent any dust from enter-
ing the intake manifold.
4. Replace the Filter Element (3).
5. Mount the Cover (1) and fasten with the clips.
6. Reset the Service Indicator (1) by pressing the button.

MNL-0413 BAUER
COMPRESSORS
.
Figure 3-8 2nd Stage Intermediate Separator Figure 3-9 3rd Stage Intermediate Separator
2 4
8
4
1 5
1 2
3 3
6 7
7
^ WARNING ^
Dynamic Loading
The rapid depressurizing and repressurizing of an intermediate separator during condensate draining sub-
jects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or
death the intermediate separator must be replaced after 85,000 load cycles. A load cycle equals one depres-
surization- repressurization. The BAUER recommended frequency of condensate draining is every fifteen
minutes and is a balance between maximizing the life of the separator chamber and maintaining the quality
of the delivered air.
3.1.4 Intermediate Separators

3.1.4.1 Description
Two intermediate separators are mounted on the compressor, one after the 2nd stage and another after 3rd
stage. These separators are designed to remove oil and water which accumulates due to the cooling of the air
after the compression process. Separation is achieved by means of centrifugal action. In the 2nd stage separa-
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COMPRESSORS
tor the design of the filter head provides this action. In the 3rd stage separator the centrifugal action is pro-
vided by a vortex plate additionally a sintered metal filter is provided to remove dirt contamination.
3.1.4.2 Maintenance
The Intermediate Separators require no maintenance.
3.1.5 Compressor Valves and Valve Heads
3.1.5.1 Functional Description
The valve heads of the individual stages form the upper part of the cylinders. The inlet and pressure
valves are fitted inside the valve heads.
When the piston moves downwards, the resultant vacuum in the piston cylinder opens the inlet valve.
When the piston moves upwards, the inlet valve is closed and the pressure valve opened by the pressure cre-
ated in the compression process. See Figure 3-10.
Figure 3-10 Valve Function
Intake Pressure
3.1.5.2 Initial Operational Check of the Valves

After roughly half an hour of operation, the valves should be checked. The outlet piping should be hot if
the valves are operating properly. Note that the inlet line to the valve heads should be warm to the touch.
^ WARNING ^
Do not touch the outlet piping with bare hands, use a thermometer.
3.1.5.3 General Instructions for Changing the Valves

Please observe the following instructions for valve maintenance:
1. Always replace valves as a complete set.
2. Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and
clean with a soft brush.

MNL-0413 BAUER
COMPRESSORS
3. Check the individual components for excessive wear. If the valve seat or valve discs are dented,
replace the valves.
4. Check the valve space in the valve heads for dirt, and clean if necessary.
5. Use only satisfactory gaskets and O-rings during reassembly.
6. Observe the correct sequence when reassembling.
7. After finishing all maintenance work on the valves, turn the compressor manually using the fly-
wheel and check whether all items have been correctly installed.
8. 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature,
and retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.
9. Remove and check the valves every 1000 operating hours.
10. Replace the valves every 2000 operating hours to avoid fatigue failure.
11. Use an assembly tool (BAUER P/N: 011365) for all work on valve heads (See Figure 3-15).
3.1.5.4 Changing the 1st Stage Valves.
Figure 3-11 1st Stage Valve and Head
4 4
5
3 3
4
3
4
3
3.1.5.4.1 Removal Procedure.

1. See Figure 3-11. Unscrew and remove cap nuts (4) and washers (3).
2. Remove Valve Head Assembly (1) from studs in cylinder.
3. Remove Valve (2) and unscrew and remove center screw (6) and washer (5).
June 01, 2006 Page 20

BAUER K20V
COMPRESSORS
3.1.5.4.2 Installation Procedure
4. Fasten new Valve (2) with center screw (6) and washer (5).
5. Place assembled Valve Head (1) on studs in the cylinder.
6. Install washers (3) and cap nuts (4) and tighten to the torque value listed in the Appendix.
3.1.5.5 Changing the 2nd and 3rd Stage Valves
See Figure 3-12
Figure 3-12 2nd and 3rd Stages Valve Heads and Valves
1
2
3 3
4
4
5 8
6
9
7 7
1. Hex Nut 4. Extraction Groove 7. Valve Gaskets
2. Cap Holder 5. O-Rings 8. Valve Head
3. Valve Caps 6. Inlet Valve 9. Discharge Valve
3.1.5.5.1 Removal Procedure
1. Unscrew and remove hex nut (1).
2. Remove cap holder (2).
3. Insert two screwdrivers into the extraction grooves (4) of the valve caps (3) and lift out the valve
caps with O-Rings (5).
4. Check and replace O-Rings if required.
5. Take out valves (6 & 9).
6. Check the valve gaskets (7) and replace if required.
3.1.5.5.2 Installation Procedure

1. Fit valves(6 & 9) with gaskets (7) and replace.
2. Fit valve caps (3) with O-Rings (5) and replace.
3. Replace cap holder (2) in the proper position.

MNL-0413 BAUER
COMPRESSORS
^ CAUTION ^
The valve cap for the inlet valve protrudes 0.98 in (2.5 mm) out of the valve head more than the valve cap
for the discharge valve. The cap holder is designed accordingly.
4. Screw on hex nut (1) and tighten with a torque wrench to the torque value listed in the Appendix.
3.1.5.6 Changing the 4th Stage Valves
See Figure 3-13
^ CAUTION ^
Always change the intake and discharge valves of the 4th stage at the same time.
Figure 3-13 4th Stage Valve and Head
1
9
2
1. Acorn Nut 4. O-ring 7. Valve Head

2. Gasket 5. Discharge Valve 8. Valve Cover
3. Stud 6. Inlet Valve 9. Socket Head Screw
June 01, 2006 Page 22

BAUER K20V
COMPRESSORS
3.1.5.6.1 Discharge Valve Removal Procedure
Figure 3-14 4th Stage Discharge Valve Removal
1. Remove piping connected to the 4th Stage Valve Head.

2. Remove Acorn Nut (1) and unscrew Stud (3) three or four turns.
3. Remove the Socket Head Screws (9) and remove the Valve Cover (8).
4. Loosen the Discharge Valve (5) first by turning it with a 13mm wrench on the flat surfaces.
5. Put two screwdrivers into the groove of the Discharge Valve body. See Figure 3-14.
6. Lift out Discharge Valve together with the O-ring (4)
3.1.5.6.2 Discharge Valve Installation Procedure

1. Check condition of O-ring (4) and replace if necessary
2. Put O-ring (4) into Valve Head (7).
3. Insert Discharge Valve (5) into Valve Head (7).
4. Put on Valve Cover (8).
5. Screw in Socket Head Screws (9) and tighten with a torque wrench to the value listed in the Appen-
dix
6. Tighten Stud (3) and replace Gasket (2).
7. Tighten Acorn Nut (1) with a torque wrench to the value listed in the Appendix.

MNL-0413 BAUER
COMPRESSORS
3.1.5.6.3 Inlet Valve Removal and Installation
Figure 3-15 Assembly Tool Figure 3-16 Using Special Tool
1. If the assembly tool shown in Figure 3-15 is unavailable, place two 8mm diameter metal pins of any
length in the holes of the Valve Head (7) and secure them in a vise with the Inlet Valve (6) facing
up.
2. Unscrew the Inlet Valve (6) from the Valve Head (7) using the special tool (Bauer p/n 4555-645)
supplied with your unit. See Figure 3-16.
^ CAUTION ^
Avoid damaging the special tool or the valve when using the tool, ensure that it is pushed firmly
and properly into the sockets in the valve so that it will not tilt when it is turned.
3.1.6 Repair and Troubleshooting

3.1.6.1 Repair
Repair work can be carried out on the compressor block to a certain extent but a certain level of experi-
ence and skill is necessary. It should be noted however that no repair should be carried out on the crankshaft
nor on the bearings and safety valves are not repaired but always replaced
June 01, 2006 Page 24

BAUER K20V
COMPRESSORS
3.1.6.2 Troubleshooting
Trouble Cause Remedy
No oil pressure 1. Low oil level 1. Check oil level

2. Air trapped in oil pump. 2. Vent Oil Pump
Oil foam in crankcase 1. Last stage piston worn 1. Operate compressor with
2. Last stage pressure valve final stage valve head
defective removed. If oil flows con-
tinuously out of cylinder,
replace piston and sleeve.
2. Replace last stage valves.
Compressor output insufficient 1. Condensate drain valve(s) 1. Tighten and reseal.

or fittings leaking. 2. Clean and adjust final
2. Premature opening of final safety valve.
safety valve. 3. Replace
3. Piston rings worn 4. Replace
4. Excessive piston clearance 5. Tighten
5. Pipes leaking
Safety valves between stages 1. Intermediate pressure too 1. Service and clean valves.
releasing pressure high 2. Service and clean valves.
2. Valves not closing properly
Compressor running too hot. 1. Insufficient supply of cool- 1. Check location for adequate
ing air ventilation
2. Intake or outlet valve not 2. Check and clean valves,
closing properly replace as necessary
3. Wrong direction of rotation. 3. Check arrow on compressor
and correct accordingly.
Oil residue in delivered air 1. Improper maintenance of 1. Service filters, change puri-
filters, purifier cartridge fier cartridge.
saturated. 2. Change to proper oil and
2. Wrong oil type clean valves.
Compressor rotates in the wrong Electrical phases not connected Reverse two of the three phase
direction properly leads at the switch box. Do NOT
change the leads at the motor ter-
minal.

This page is inserted to provide proper page sequencing
8 9 1 2
6 5 7
10
3
4
BAUER K20V
COMPRESSORS
3.1.7 Replacement Parts List

Figure 3-17 Crankcase Assembly
16
1 9 17
2 3
4 10
18
11
56 12 15 20
19
7 21 22
21
8
24
23
13
14
25 34
33
26 35
27
25 36
21 26
29 28 27 37 38
23 30 39
24 31 32
# KIT Qty Part No. Description Notes

1 78577 Crankcase Assembly
1 1 N20649 Screw
2 1 68586 Cover Plate
3 1 N15093 O-ring
4 1 26281 Shaft Seal
5 1 N370 Self Locking Hex Nut
6 6 N58 Washer
7 6 78897 Bearing Cover
8 6 N3138 Stud
9 1 N18303 Roller Bearing
10 1 N3810 Circlip
12 1 N18432 Circlip
13 1 N2635 Circlip

MNL-0413 BAUER
COMPRESSORS
Figure 3-17 (cont.) Crankcase Assembly

14 1 3177 Gasket
16 1 N4467 Eye Bolt
17 1 1492 Washer
18 1 79225 Hexagonal Spacer
19 1 N4150 Stud
20 1 80197 Reducer
21 2 N293 Gasket
22 1 N314 Plug
23 12 N16 Washer
24 12 N312 Hex Head Screw
25 2 78571 Bracket
26 2 N4163 Gasket
27 2 N2796 Plug
28 1 N2447 Plug
29 1 N1316 Gasket
30 1 N4570 Plug
31 8 N102 Washer
32 8 N19496 Hex Screw
33 1 78578 Crankcase
34 1 78810 Oil Sight Gauge Assembly Items 35 - 39
35 1 N15412 O-ring
36 1 61054 Plug
37 1 78808 Gasket
38 1 78569 Oil Fill
39 1 78570 Steel Plate
June 01, 2006 Page 28

BAUER K20V
COMPRESSORS
Figure 3-18 Complete Crankshaft Assembly
5
7

1 78934 Crankshaft Assembly IK150 II Only
1 1 68587 Bushing
2 1 N4366 Dowel Screw
3 1 N108 Spring Washer
4 1 N57 Hex Nut
5 3 4220 Spacers
6 1 N18310 Circlip
7 1 N423 Circlip

MNL-0413 BAUER
COMPRESSORS
Figure 3-19 K150II 1st Stage Piston and Cylinder
4
2 7
8 6
7

1 79420 1st Stage Piston and Cylinder Assembly 120mm Dia
1 1 79017 Cylinder 120mm Dia
2 1 N2621 O-ring
3 4 N26036 Stud
4 1 79720 Piston Assembly 120 mm Dia
5 1 79719 Piston
6 1 N2930 Pin, Piston
7 2 N484 Ring, Retaining
8 1 N2963 Piston Ring Set 120mm Dia
June 01, 2006 Page 30

BAUER K20V
COMPRESSORS
Figure 3-20 2nd Stage Piston and Cylinder Assembly
9 6
10
4
5

MNL-0413 BAUER
COMPRESSORS
1 061048 2nd Stage Piston and Cylinder Assembly
1 1 60572 Cylinder
2 ..c 1 N3731 O-ring
3 4 N215 Stud, M8x25
4 4 WAS-0021 Washer, Flat, 8mm
5 ..c 4 NUT-0019 Nut, Hex, Lock M8
6 1 070010 Compressor Piston Assembly
7 1 N20907 Piston
10 1 N1461 Piston Ring Set
June 01, 2006 Page 32

BAUER K20V
COMPRESSORS
Figure 3-21 3rd Stage Piston and Cylinder
11
9 10 11
13
5
14
12
7 6 1

1 060107 Piston and Cylinder Assembly
1 1 67057 Cylinder Guide 60mm Dia
2 ..c 1 N3731 O-ring
3 1 67061 Cylinder 32mm Dia
4 ..c 1 N7063 O-ring

MNL-0413 BAUER
COMPRESSORS
Figure 3-21 (cont.) 3rd Stage Piston and Cylinder

5 4 N17462 Stud M8x80
6 4 WAS-0021 Washer, Flat 8mm
7 ..c 4 NUT-0019 Nut, Hex, Lock M8
8 1 070012 Piston, Guide Assembly 60mm Dia
9 1 60087 Piston, Guide
12 1 070013 Piston, Floating Assembly
13 1 N4378 Piston, Floating
14 1 N16313 Piston Ring Set 32mm Dia
June 01, 2006 Page 34

BAUER K20V
COMPRESSORS
Figure 3-22 4th Stage Piston and Cylinder Assembly
6 4
7 5
8
11
10

1 79180 4th Stage Cylinder Assembly
1 1 078043 Piston and Sleeve Assembly (See Figure 3-23)
2 1 76754 Cylinder
3 1 N7063 O-ring
5 4 N58 Washer
6 4 N17462 Stud
7 1 79632 Guide Cylinder
8 1 N3731 O-ring
1 070012 Piston Assembly Items 9, 10 and 11
9 1 60087 Guide Piston
10 1 N15409 Piston Pin
11 2 N1665 Circlip

MNL-0413 BAUER
COMPRESSORS
Figure 3-23 4th Stage Piston and Sleeve Assembly
3
4

1 078043 Piston and Sleeve Assembly
1 Piston Available only with 078043
2 a.. 1 N23755 O-ring
3 Piston Sleeve Available only with 078043
4 ..c 1 N2320 O-ring
5 Piston Ring Set Available only with 078043
June 01, 2006 Page 36

BAUER K20V
COMPRESSORS
Figure 3-24 1st Stage Valve Head Assembly
4 4
5
3 3
4
3
4
3

1 79680 1st Stage Valve Head Assembly
1 1st Stage Valve Head
2 1 N26029 Plate Valve
3 4 N16 Washer
5 1 N58 Washer
6 1 N150 Allen Screw M8x60

MNL-0413 BAUER
COMPRESSORS
Figure 3-25 2nd Stage Valve Head
EIN
AUS
9
3 4 5 2
10
6
11 8
7

1 070026 2nd Stage Valve Head Assembly
1 1 60583 2nd Stage Valve Head
2 6 SCR-0180 Socket Head Cap Screw M8x35
3 .b. 1 N4067 Valve, Inlet
4 .b. 1 N4068 Valve, Discharge
5 a.. 2 56668 Gasket, Valve
6 2 56183 Cap, Valve
7 .b. 2 N3997 O-ring
8 1 62924 Press Pad
9 2 N4190 Stud M10x45
11 2 NUT-0128 Nut, Hex Lock M10
June 01, 2006 Page 38

BAUER K20V
COMPRESSORS
Figure 3-26 3rd Stage Valve Head Assembly
EIN
AUS
9
3 4 5 2
10
6
11 8
7

1 068602 3rd Stage Valve Head Assembly
1 1 60583 3rd Stage Valve Head
3 .b. 1 N15273 Valve, Inlet
4 .b. 1 N15274 Valve, Discharge
5 a.. 2 56668 Gasket, Valve
6 2 56183 Cap, Valve
7 a.. 2 N3997 O-ring
8 1 62924 Press Pad
9 2 N4190 Stud M10x45

MNL-0413 BAUER
COMPRESSORS
Figure 3-27 4th Stage Valve Head Assembly
9 8
1 2

1 073629 4th Stage Valve Head Assembly
1 .b. 1 081409 Intake Valve
2 1 65191 Valve Head
3 .b. 1 N2789 O-ring
4 1 014121 Discharge Valve
5 1 14118 Valve Head Cover
6 .b. 1 71065 Stud
7 a.. 1 N3625 Gasket
8 1 N3623 Acorn Nut
9 6 N1282 Allen Screw
June 01, 2006 Page 40

BAUER K20V
COMPRESSORS
Figure 3-28 Flywheel Drive Assembly
8
7 6
5
4
2

1 79240 Flywheel Drive Assembly
1 1 68623 V-belt Pulley
2 6 55425 Fan Blade Support
3 18 79239 Blade, Fan CCW
4 12 N19495 Hex Head Screw M6x16
5 12 WAS-0029 Washer, Split Lock 6mm
6 1 68646 Washer
7 1 WAS-0002 Washer, Split Lock
8 1 N15667 Hex Head Cap Screw M12x45

MNL-0413 BAUER
COMPRESSORS
Figure 3-29 Intake Filter Assembly
2
1
3 4
5
7
6

1 079706 Intake Filter Assembly
1 1 79679 Manifold, Air Intake
2 3 N171 Socket Head Cap Screw
3 1 73036 Housing, Intake Filter
4 1 79464 Flange
6 a.. 1 N25886 Element, Intake Filter
7 1 79465 Cover, Filter Housing
8 1 N2221 Indicator, Maintenance
June 01, 2006 Page 42

BAUER K20V
COMPRESSORS
Figure 3-30 2nd Stage Interfilter Assembly
6
7

1 077387 Interfilter Assembly
1 Filter Housing Available only with 077387
2 Filter Head Available only with 077387
3 1 13937 Collar, Threaded Knurled
4 1 N3556 O-ring
5 1 76613 Tube and Baffle
6 1 N1316 Gasket, Cooper
7 1 N20215 Fitting
8 1 VAL-0169 Safety Valve

MNL-0413 BAUER
COMPRESSORS
Figure 3-31 3rd Stage Interfilter Assembly
1 5

1 081798 3rd Stage Interfilter Assembly
1 1 81148 Plate
2 1 81643 Hollow Screw
3 1 76613 Inset Assembly
4 a.. 1 N3556 O-ring
5 1 13937 Knurled Ring
6 1 N1316 Gasket
7 1 N20215 Fitting
June 01, 2006 Page 44

BAUER K20V
COMPRESSORS
Figure 3-32 IK150 II and IK180 II Cooling System Assembly
6
54 11
57
5 58
7 8 43
10 56 32 29
12 15 55
23 3 29
16 39
9 50 47
13 49 17 34
42 46 33
28 28 31
45
20 36 44
8 41 30 37
1 5 29
42 18
4 35
37 8 15 19
36 9
22 25
13 27 26 35
28
29 28
30 24
28
30 52 30
51 30 23 34
28
21 31 9 33
48 53 16 31
2 38 34
32
15
29
33
28 31
30 16 15
32

1 79626 Cooling System Assembly
1 1 79885 1st Stage Intercooler
2 1 79927 2nd Stage Intercooler
3 1 79929 3rd Stage Intercooler
4 1 79925 Aftercooler
5 4 79637 Mount
6 12 6069-M Clamp
7 12 N15414 Countersunk Screw
8 16 N58 Washer
9 14 N108 Lock Washer
11 2 75496 Bushing

MNL-0413 BAUER
COMPRESSORS
Figure 3-32 (cont.) Cooling System Assembly

13 8 N57 Hex Nut
14 2 60751 Mount
16 2 57070 Tube Clamp
17 1 76425 Connecting Tubing
24 4 55799 Spacer
26 8 N102 Washer
27 8 N3494 Stud
28 8 N293 Gasket
29 8 N1316 Gasket
30 5 N20231 Connector
31 4 N4530 Plug
32 4 N2144 Lock Washer
33 3 N3610 Cap Screw
36 2 N20312 Fitting
38 2 N20260 Elbow
40 1 N842 Gasket
45 1 N16309 Plug
46 1 N20155 Adjustable Coupling
48 1 79812 Bracket
49 1 56983 Gasket
50 1 71148 Connector
June 01, 2006 Page 46

BAUER K20V
COMPRESSORS
Figure 3-32 (cont.) Cooling System Assembly

53 1 N2003 Elbow Coupling
54 1 60709 Fan Screen
55 1 60717 Support
56 1 60716 Bracket
57 4 N542 Hex Screw

MNL-0413 BAUER
COMPRESSORS
Figure 3-33 2nd Stage Intercooler
7
4 6
5
7
6
1,
1,
2,
2,
3
3
7
6

1 079927 2nd Stage Inter-cooler Assembly
1 2 FER-0012 Ferrule
2 2 NUT-0057 Nut, Tube
3 2 N16310 Insert, Tube
4 6 60738 Clamp, Tube
June 01, 2006 Page 48

BAUER K20V
COMPRESSORS
Figure 3-34 3rd Stage Intercooler
6 1
5 2
5
4
7
3
1 4
3
2
1
4

1 79929 3rd Stage Intercooler
1 6 60738 Clamp, Tube
5 4 60694-M Clamp, Tube
6 2 N15119 Socket Fillister Head Screw M8x35
7 2 NUT-0062 Nut, Hex M8

MNL-0413 BAUER
COMPRESSORS
Figure 3-35 Lubricating System Assembly
6 5
4
2
1

1 078930 Lubricating System Assembly
1 1 080345 Lubricating System See next Figure
2 1 78421 Gasket
3 4 N503 Socket Head Screw
4 1 78928 Connecting Tube Assembly
6 1 N4501 Gasket
June 01, 2006 Page 50

BAUER K20V
COMPRESSORS
Figure 3-36 Lubricating System
3
2
4
5
1
6
7 10
9
8
18
11
9
12
9 13
17
14 15
9
14
16

1 080345 Lubricating System
1 1 N24585 Gear Pump
2 2 N58 Washer
3 2 N19506 Hex Head Screw
4 1 77885 Oil Filter Cover
5 1 N25327 O-ring
6 1 N3489 O-ring
7 1 77774 Rubber Gasket
8 1 N25326 Filter Element
9 4 N1316 Gasket
10 1 81050 Regulating Valve
11 1 N20065 Straight Male Connector
12 1 N16309 Plug
13 1 N1049 Screw Cap
14 3 N52 Plug
15 2 N2889 Gasket
16 2 N25328 Socket Head Screw
17 1 177878 Oil Pump Case
18 2 N3489 O-ring

MNL-0413 BAUER
COMPRESSORS
3.2 Four Stage Automatic Condensate Drain System
3.2.1 Description
The automatic condensate drain system operates electropneumatically and is comprised of the following:
A condensate manifold Two pneumatically operated condensate drain valves
An electrically controlled solenoid valve A condensate separator/silencer
A condensate collector bottle Electronically controlled by the PLC
The automatic condensate drain system drains the intermediate separators and the oil and water separator
every 15 minutes during operation. Additionally the automatic condensate drain system unloads the compres-
sor during the starting phase and drains these separators at shutdown of the compressor unit.
Figure 3-37 4 Stage Automatic Condensate Drain System
1
4
3 5 8
6 7
1. Solenoid valve 6. 3rd Stage intermediate separator condensate

2. Condensate drain valve 7. Oil and water separator condensate connection
3. Condensate drain manifold 8. Condensate collector bottle connection
4. Control air connection 9. Manual condensate drain valve
5. 2nd Stage intermediate separator condensate
June 01, 2006 Page 52

BAUER K20V
COMPRESSORS
Figure 3-38 ACD Operation Diagrams
2 3 6
2 3 6
4 5
1 4 5
1
Control Pressure
Control Pressure Condensate
Condensate
Normal Operation Condensate Draining
1. Solenoid Valve 4. 3rd Stage Condensate Drain Valve

2. 2nd Stage Intermediate Separator 5. Oil and Water Separator Condensate Drain Valve
3. 3rd Stage Intermediate Separator 6. Oil and Water Separator
3.2.1.1 Compressor Operating
The normally open solenoid valve (1) controls the condensate draining of the 2nd stage intermediate sep-
arator (2). The normally open 3rd stage condensate drain valve (4) controls the condensate draining of the 3rd
stage intermediate separator (3). The normally open oil and water separator condensate drain valve (5) con-
trols the condensate draining of the oil and water separator (6). The control air for the 3rd stage condensate
drain valve (4) is taken from the 2nd stage intermediate separator (2). The control air for the oil and water
separator condensate drain valve (5) comes from the 3rd stage intermediate separator (3).
As the compressor is started, the solenoid valve (1) is electrically energized and closes. This allows the
pressure to buildup in the intermediate separators (2 and 3). This pressure buildup results in control air clos-
ing both condensate drain valves (4 & 5).
3.2.1.2 Condensate Draining
Every 15 minutes the timer deenergizes the solenoid valve (1) for approximately 6 seconds. The solenoid
valve (1) opens and drains the condensation from the 2nd stage intermediate separator (2). Due to the pres-
sure loss in the 2nd stage intermediate separator the control air for the 3rd stage condensate drain valve (4) is
also removed. As the pressure of the control air is dropping, the piston of the 3rd stage condensate drain
valve (4) becomes unloaded and the remaining control air is vented through a relief port. Then the piston of
the drain valve is fully raised by pressure from the 3rd stage separator, and the condensate is drained. This in
turn causes a pressure loss in the 3rd stage intermediate separator (3) and the control air for the oil condensate
drain valve (5) is removed and the oil and water separator condensate drain valve opens and drains the oil and
water separator (6).

MNL-0413 BAUER
COMPRESSORS
3.2.1.3 Start Unloading
The unloading of the compressor during the starting phase is possible because of the lack of control air
immediately after starting the unit. As the unit is switched on the solenoid valve (1) is energized and closes.
After the compressor has attained nominal speed, pressure builds in the intermediate separators (2 and 3) and
the control air closes the condensate drain valves (4 and 5). Once these valves close, the compressor delivers
to the consuming device.
3.2.1.4 Standstill Drainage
At compressor shutdown, the solenoid valve (1) is deenergized and opens. This drains the condensate and
relieves the pressure in the 2nd stage intermediate separator (2). This action in turn removes the control air
form the condensate drain valves (4 & 5) which open and drain and relieves the pressure in the 3rd stage
intermediate separator (3) and oil and water separator (6).
3.2.1.5 Condensate Drain Piping
The 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 to the pre-separator elbow and a conden-
sate drain separator.
3.2.1.6 Condensate Drain Separator
The condensate drainage is a mixture of oil, water and air. The Condensate Drain Separator is utilized to
separate the oil and water from the air. The oil and water is then piped to the Condensate Collector Bottle
where the oil and water mixture is stored until it can be disposed of properly.
3.2.2 ACD Maintenance
The condensate drain valves are provided with manual drain valves to verify correct operation of the
automatic system.
The automatic condensate drain system must be serviced once a week as follows:
1. Open all manual drain valves one after the other.
2. Observe the drainage of condensation.
3. 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.
4. Find the fault and remedy accordingly.
5. If little or no condensation emerges, the automatic system is operating properly.
6. 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.
June 01, 2006 Page 54

BAUER K20V
COMPRESSORS
Figure 3-39 4 Stage ACD System
5
6
Item Qty Part No. Description Notes

1 063761 Automatic Condensate Drain System
1 1 MFD-0035 Manifold
2 1 N16381 Solenoid Valve
3 1 064009 Condensate Drain Valve
5 1 N1028 Gasket
6 1 RED-0058 Reducer

MNL-0413 BAUER
COMPRESSORS
Figure 3-40 ACD Manifold and Valves
7
6
3 9
8
11
2
10 4 5 1 12

3 1 MFD-0035 Manifold
4 1 064004 Valve Connection
5 1 N2320 O-ring
6 1 N3625 Gasket
8 1 N2507 O-ring
9 2 N638 O-ring
10 1 Connecting Tube
11 1 ELL-0027 Male Elbow
12 4 SCR-0133 Allen Screw
June 01, 2006 Page 56

BAUER K20V
COMPRESSORS
Figure 3-41 3rd Stage Condensate Drain Valve
15
4
5
16
15 10
11
12
14 13

1 064009 Condensate Drain Valve
1 1 064000 Top Flange
2 1 N16269 Sealing Ring
3 1 064003 Piston
4 1 N638 O-ring
5 1 N4881 O-ring
6 1 064001 Valve Body

MNL-0413 BAUER
COMPRESSORS
Figure 3-41 (cont.) 3rd Stage Condensate Drain Valve

7 1 N2507 O-ring
8 1 064005 Valve Seat
9 1 N4496 O-ring
10 1 064002 Base Flange
11 1 064498 Drain Tap Seat
12 1 065500 Drain Tap Assembly
13 1 N16334 Male Tee
14 1 N15088 Hose
16 1 067458 Tool Set for Item 12
June 01, 2006 Page 58

BAUER K20V
COMPRESSORS
Figure 3-42 Oil and Water Separator Condensate Drain Valve
16
2
5
6
17
10
16 11
12
13
15
14

1 064008 Condensate Drain Valve
1 1 64000 Top Flange
2 1 064011 Spring
3 1 N16269 Sealing Ring
4 1 064003 Piston
5 1 N638 O-ring
6 1 N4881 O-ring

MNL-0413 BAUER
COMPRESSORS
Figure 3-42 (cont.) Oil and Water Separator Condensate Drain Valve Parts List

7 1 064001 Valve Body
8 1 N2507 O-ring
9 1 064005 Valve Seat
10 1 N4496 O-ring
11 1 064002 Base Flange
12 1 064498 Drain Tap Seat
13 1 065500 Drain Tap Assembly
14 1 N16334 Male Tee
15 1 N15088 Hose
17 1 067458 Tool Set for 065500
June 01, 2006 Page 60

BAUER K20V
COMPRESSORS
3.2.4 Trouble shooting
Trouble Cause Remedy

Solenoid Valve does not drain. 1. Solenoid valve receives no 1. Check connections, timer.
electrical signal Replace if necessary.
2. Plunger of drain valve 2. Clean or replace valve.
sticking
Condensate Drain Valve does not 1. Solenoid valve does not 1. Check solenoid valve,
drain. depressurize drain valve. replace if necessary
2. No control medium avail- 2. Check supply lines
able. 3. Clean or replace
3. Solenoid valve sticking. 4. Clean or replace
4. Drain valve sticking in open
position

MNL-0413 BAUER
COMPRESSORS
CHAPTER 4: IK150II OR IK180II MAINTENANCE SCHEDULE
4.1 Initial start-up or after maintenance
Interval Task
12 hour after start up for the first time or after Manual check of valve function.
maintenance
25 operating hours after first operation or mainte- Tighten valve head bolts and pressure studs.
nance work
4.2 Calendar intervals
Interval Task
Daily before operating unit Check oil level
Weekly or as required Open manual condensate drain taps
Annually or as required Read and record hourmeter
Biennially (every two years) Synthetic oil change, if run less than 2,000 operat-
ing hours
4.3 Operating hours
Interval Task
500 operating hours Check V-belts
Service micronic intake filter
Check all connections for leakage
1000 operating hours Manual check of valve function.
2000 operating hours Synthetic oil change
Replace valves
3000 operating hours or as required Check pistons and piston rings
June 01, 2006 Page 62

BAUER K20V
COMPRESSORS
4.3.1 Maintenance Records

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 maintenance.
To assist in this process the following maintenance control sheet is provided and may be copied as
required. The shaded boxes indicate when each maintenance task is due. Enter the number of operating hours
in these blocks and date and sign it at the bottom.
Operating Hours
Biennially
Annually
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000
500
Maintenance Task
Check drive V-belts
Service intake filter
Check connections for leaks
Check valves
Oil change
Replace valves
Check pistons and rings
Check final pressure safety

valve
Check and record hourmeter

Signature
Date\

MNL-0413 BAUER
COMPRESSORS
CHAPTER 5: PURIFICATION SYSTEM
5.1 General
The purpose of all BAUER breathing air purification systems is to remove Carbon Monoxide, oil, water,
taste and odor from the compressed air stream before final delivery. For this reason BAUER purification sys-
tems are installed immediately before the compressed air delivery point
5.1.1 General Purification System Procedures
1. Keep an accurate record of operating hours to ensure exact attention to maintenance intervals
2. Change all cartridges before reactivating a compressor unit that has been out of service more than
three months. Leave cartridges in the unit as long as it is out of service.
3. While out of service keep all condensate drain valves closed. Maintain a pressure of 700 to 1,100
psi (50 to 80 bar) within the system to prevent moisture from entering the compressor and purifica-
tion system.
5.1.2 Chamber Safety Bore
The chambers in all BAUER purification systems are designed to prevent pressurization if the cartridge is
missing, not seated properly or damaged (See Figure 5-1). Without a cartridge properly in place the safety
bore is not sealed, the air escapes into the atmosphere, no pressure can be built up and thus it is ensured that
unfiltered air is not supplied to the consuming device. If air is escaping from the safety bore remove and
check cartridge. If necessary replace the cartridge or O-rings.
Figure 5-1 Cartridge Safety Venting
Safety Safety
Vent Vent
Cartridge Installed No Cartridge Installed
5.1.3 Manual Condensate Drainage

The condensate must be drained from the oil and water separator before changing any cartridge. This is
done by slowly opening the condensate drain valves. They are opened approximately 1/3 of a turn to the left
and held open until the condensate is completely drained. The condensate drain valves close by spring pres-
sure but if necessary may be tightened by hand to ensure they are completely air tight.
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COMPRESSORS
5.1.4 Model, Serial Number and Part Number Identification
5.1.4.1 Compressor Dataplate
The model number, date of manufacture and serial number can be found on the compressor unit identifi-
cation plate in the main electrical enclosure and frame.
5.1.4.2 Purification System Dataplate
Refer to the compressor unit purification system dataplate (See Figure 5-2) on the compressor front to
determine your purification system model and specifications.
Figure 5-2 Purification System Dataplate (typical)
PURIFICATION
SYSTEM
MODEL NO.
MAX. PRESSURE psig

AIR PROCESSED cu. ft.
O-RING
BACK-UP RING
LBL-
5.1.4.3 Cartridge Installation Dataplate

The function performed by each chamber in the purification system is determined by the type of cartridge
installed in that chamber. Refer to the cartridge installation dataplate on the chamber to determine the pur-
pose and part number of the cartridge installed in that chamber. (See Figure 5-3).
Figure 5-3 Cartridge Installation Dataplate (typical)
CARTRIDGE TO BE
INSTALLED
CARTRIDGE FOR
CARTRIDGE NO.
1328 Azalea Garden Road - Norfolk Virginia 23502-1944
Phone: (757) 855-6006 Fax: (757) 855-8224
LBL-

MNL-0413 BAUER
COMPRESSORS
5.1.5 Breathing Air Purification System Configurations
Number and Type of Cartridges Processing Capacity

Purification System Dryer Purification Securus cubic ft. (ft)3
P0 Combined 3,200
P1 1 15,000
P2 1 40,000
P2 with Securus 1 67,000
P4 1 1 60,000
P5 1 1 90,000
P5 with Securus 1 1 150,000
P10 2 1 140,000
P12a 1 1 420,000
P14 a 2 1 650,000
P31 Combined 11,760
P41 1 28,700
P41 with Securus 1 47,000
P42 1 1 64,000
P43 2 1 100,000
a. P12 and P14 have the Securus Electronic Moisture Monitor System as standard equipment.
June 01, 2006 Page 66

BAUER K20V
COMPRESSORS
5.1.6 Cartridge Operating Life

Every BAUER Purification System is designed to process a certain volume of air before the cartridges
require replacement. By using special test equipment that measures the quality of air at the outlet any quality
reduction may be detected. However as most compressor owners do not have this test equipment the recom-
mended method of determining cartridge operating life is to maintain a written record of the volume of air
processed by the purification system.
Each BAUER compressor block is rated to produce a standard volume of air per minute and by using this
number and the air processing capability of the purification system it is possible to calculate the maximum
operating hours before the cartridges need to be replaced. See Paragraph 5.1.6.1 for the method of determin-
ing this figure.
The ambient air temperature and its ability to cool the compressor will effect the operating life of the car-
tridge. See Paragraph 5.1.6.2 for the method of calculating this adjustment factor.
The optimum place to measure the temperature is at the inlet to the final separator as this best reflects the
temperature of the air as it enters the chambers. Experience has shown that this temperature is approximately
10 F above the ambient temperature. Therefore for the purpose of calculating cartridge operating life use the
Ambient Air Temperature plus 10 F.
A form titled Air Purification Cartridge Operating Hours is found in Paragraph 5.1.6.3 and in the Appen-
dices. It is used for recording the ambient temperature, operating time and adjustment factor. It is suggested
that it be copied, placed in a protective folder and kept with the unit to record the adjusted operating hours.
An example of how this form is used is shown in Figure 1-5.
5.1.6.1 Calculating the Maximum Cartridge Operating Hours
1. From the purification system dataplate (See Figure 5-2) on the purification chamber determine the
Air Processed (cu.ft.)
2. From the paragraph titled Compressor Specifications in the instruction manual for your compressor
unit determine the Charging Rate in SCFM of your compressor.
3. Divide the Air Processed by the Charging Rate to obtain the Maximum Operating Time in minutes
4. Divide the Maximum Operating Time in minutes by 60 to obtain the Maximum Operating Hours.
5. Record the answer on the Air Purification Cartridge Operating Hours form.
5.1.6.2 Calculating the Adjusted Cartridge Operating Hours

1. Using the Air Purification Cartridge Operating Hours form (FORM-0018) record the Date, Operat-
ing Hours and Ambient Air Temperature plus 10 F.
2. Using either the graph or the chart in Figure 1-4 determine the Correction Factor.
3. Divide the Operating Hours by the Correction Factor and record it under the column labeled Today.
4. Add the hours recorded in Today to the previous Total and record it as the current Total.
5. When the Total approaches the Maximum Operating Hours replace the Cartridges.

MNL-0413 BAUER
COMPRESSORS
Figure 5-4 Correction Factor for Cartridge Operating Hours
Temperature Correction 3.0

C
Factor o
F C r 2.5
r
32 0 3.80 e
c
41 5 2.62 t 2.0
50 10 1.85 i
o
n 1.5
59 15 1.34
68 20 1.00 F
a 1.0
77 25 0.75 c
t
o 0.5
86 30 0.57 r
104 35 0.43
122 40 0.34 0.0
41 50 59 68 77 86 104 F
5 10 15 20 25 30 40 C
Figure 5-5 Example Record of Adjusted Operating Hours
Operating Ambient Temp. Correction Adjusted Cartridge Hours

Date
Hours during Compression Factor Today Total
10/19/04 8 92F 0.48 16.66 16.66
11/01/04 4 45F 2.25 1.78 18.44
June 01, 2006 Page 68

BAUER K20V
COMPRESSORS
5.1.6.3 Air Purification Cartridge Operating Hours Form
Date Operating Ambient temp. Correction Adjusted cartridge hours

hours during compression factor
Today Total

MNL-0413 BAUER
COMPRESSORS
5.2 P42 Purification System
5.2.1 Major Components
The P42 Purification System major components are an Oil and Water Separator, and a Purification
Chamber. Figure 5-7 shows the functional interconnection of all the components.
5.2.2 Configuration Options
Some Bauer Compressors have the P42 Purification System as an option rather than a standard item,
therefore, this chapter may not apply to your unit.
The P42 Purification System is also available with the Securus Electronic Moisture Monitor System as a
factory installed upgrade. This option replaces the standard purification chamber with a Securus Purification
Chamber. A Securus Indicator and associated wiring are also added. If this option was not purchased, por-
tions of this chapter about the Securus Electronic Moisture Monitor System do not apply.
Figure 5-6 P42 Purification System
7
8 9
IN
OUT
1 2 3 4 5 4 6
1. Pressure Gauge 4. Check Valves 7. Safety Valve
2. Condensate Drain Valve 5. Bleed Valve 8. Dryer Chamber
3. Oil and Water Separator 6. Pressure Maintaining Valve 9. Purification Chamber
June 01, 2006 Page 70

BAUER K20V
COMPRESSORS
Figure 5-7 P42S Purification System
7 9
8
IN
10
OUT
1 2 3 4 5 4 6
1. Pressure Gauge 5. Bleed Valve 8. Dryer Chamber
2. Condensate Drain Valve 6. Pressure Maintaining Valve 9. Securus Chamber
3. Oil and Water Separator 7. Safety Valve 10. Securus Indicator
4. Check Valves
5.2.3 Component Description
5.2.3.1 Oil and Water Separator
^ WARNING ^
The rapid depressurizing and repressurizing of the oil and water separator during condensate draining sub-
jects it to metallurgical stresses. To prevent catastrophic failure with the possibility of damage, injury or
death the oil and water separator (P/N 079416) must be replaced after a predetermined number of cycles.
One load cycle equals one pressurization plus one depressurization.
Units operating between 3,000 and 5,000 psi = 44,000 load cycles (11,000 hours of operation)
Units operating between 5,000 and 6,000 psi = 22,000 load cycles (5,500 hours of operation)
The BAUER recommended frequency of condensate draining is every fifteen minutes and is a balance
between maximizing the life of the separator chamber and maintaining the quality of the delivered air.

MNL-0413 BAUER
COMPRESSORS
The air leaving the final stage is cooled in the aftercooler to approximately 18 - 27F (10 -15C) above
ambient temperature and then enters the oil and water separator. The oil and water separator works by means
of a sintered metal filter which separates liquid oil and water particles from the compressed air.
Figure 5-8 Oil and Water Separator
Figure 5-9 OIl and Water Separator Labels
5.2.3.2 Chamber
Each chamber is made up of an anodized aluminum housing and a filtering cartridge. There are two gen-
eral types of filtering cartridges, drying or purifying. The cartridge type is determined by the ingredients
packed in the cartridge. The chamber is named after the type of cartridge it contains, i.e. dryer chamber or
purification chamber.
5.2.3.3 Cartridge Construction
The cartridge casing, top and bottom are aluminum and are packed with one or more of the following.
1. A catalyst to convert carbon monoxide to carbon dioxide.
June 01, 2006 Page 72

BAUER K20V
COMPRESSORS
2. Activated carbon which absorbs oil vapors effecting taste and odor.
3. Molecular sieve to absorb oil and water.
Figure 5-10 Cartridge
Protective Cap
5.2.3.4 Cartridge Handling

1. Never open the protective packaging a cartridge comes in prior to its actual use. The highly sensi-
tive filter materials will absorb moisture from the atmosphere becoming saturated and useless.
2. Used cartridges must be disposed of in accordance with local regulations.
5.2.3.5 Condensate Drain Valve

A manually operated valve used for maintenance and before start-up to drain the condensed liquids from
the coalescing oil and water separator.
5.2.3.6 Check Valves
Valves allowing compressed air to flow in only one direction. One is used to maintain pressure in the
chamber when the compressor is not operating. The other check valve prevents back-flow from filled storage
cylinders or tanks.
5.2.3.7 Bleed Valve
A manually operated valve used to release the pressure in the chamber before maintenance.
5.2.3.8 Pressure Maintaining Valve
The pressure maintaining valve ensures that pressure is built up in the system from the start of delivery,
thus achieving constant optimum purification. It also assures proper working conditions for the final stage of
compression.
5.2.3.9 Safety Valve
The safety valve is located on the coalescing oil and water separator and acts as the safety valve for the
final stage of the compressor.
5.2.3.10 Securus Electronic Moisture Monitor System
The Securus Electronic Moisture Monitor System is a factory installed option which warns the operator
in advance of expiration of the life of the cartridges. The Securus Indicator receives signals concerning the
condition of the drying agent inside the Securus cartridge from the attached sensors and supplies the appro-
priate control signals whenever the preset threshold values have been reached.

MNL-0413 BAUER
COMPRESSORS
5.2.3.11 Securus Cartridge
The Securus Cartridge is packed with a catalyst which converts carbon monoxide to carbon dioxide,
activated carbon which absorbs oil vapors, molecular sieve which absorbs oil and water and the sensor com-
ponents of the Securus Electronic Moisture Monitor System.
5.2.3.12 Securus Indicator
The operating condition of the Securus Electronic Moisture Monitor System is indicated by the color
and state of four LEDs on the front of the Securus Indicator and is shown in the following table.
^ NOTE ^
After applying power it will take about second for the appropriate LED to illuminate.
During this time the status of the Securus Electronic Moisture Monitor System is tested.
Color State Indication Compressor Unit Status

Green Steady Satisfactory The unit is in operation
Yellow Flashing Cartridge Change Pre-warning The unit is in operation. The green
LED will also illuminate.
Red Flashing Cartridge Change Required The unit is shutdown and can not be
started until the cartridges are
changed.
Red Steady Cable Failure or Missing Cartridge The unit is shutdown.
No LEDs Illuminate No operating voltage or electronic failure The unit is shutdown.
5.2.4 Maintenance
5.2.4.1 Oil and Water Separator
To remove the sintered metal filter proceed as follows: (See Figure 5-11). Disconnect the power and shut
off the inlet supply line if applicable.
1. Depressurize the system by means of the bleed valve.
2. Remove the tubes connected to the side of the filter head (1).
3. Unscrew and remove the filter head.
4. Unscrew the sintered metal filter (2) from the filter head.
5. Remove the center screw (3) to remove the sintered metal filter.
6. Clean the sintered metal filter using hot soapy water. Blow dry with compressed air.
7. After cleaning the element, record the number of operating hours to ensure exact attention to the
maintenance intervals.
June 01, 2006 Page 74

BAUER K20V
COMPRESSORS
8. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter with petro-
leum jelly. Apply sparingly.
9. Dry the inside of the filter housing with a clean cloth and check for corrosion before reinstalling the
sintered metal filter.
10. In the event you discover corrosion, replace the corroded parts with new BAUER parts.
11. Reinstall the sintered metal filter assembly and filter head.
12. Replace all removed tubes, close all valves and check for leaks.
Figure 5-11 Oil and Water Separator Figure 5-12 Sintered Metal Filter Assembly
2
3
1. Filter Head 3. Center Screw

2. Sintered Metal Filter 4. O -rings
5.2.4.2 Cartridge Replacement
To change the purification cartridge, proceed as follows. (See Figure 5-13)
1. Disconnect the power and shut off the inlet supply line, if applicable.
2. Depressurize the system by means of the bleed valve.
3. Unscrew the chamber head using the special wrench supplied.
4. Pull out the cartridge using the lifting ring on top of the cartridge.
5. Dry the inside of the chamber with a clean cloth and check for corrosion.
6. Replace all corroded parts with new BAUER parts.

MNL-0413 BAUER
COMPRESSORS
Figure 5-13 Cartridge Replacement
7. Remove the shipping covering and the protective cap from the bottom of the cartridge.
8. Lubricate the O-rings with white petroleum jelly. Apply sparingly.
9. Install the new cartridge. Be sure the cartridge snaps into place.
10. Reinstall the chamber head.
11. Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable.
^ NOTE ^
If air is detected bleeding out from the bottom of the chamber, the cartridge has not been installed
properly or is missing. Follow the instructions in Paragraph 5.2.4.3.
5.2.4.3 Leaking at the Safety Bore

1. Remove the cartridge following steps 1. to 4. in Paragraph 5.2.4.2.
2. Install cartridge if missing.
3. Remove cartridge and inspect O-rings.
4. Replace O-rings if necessary.
5. Ensure protective caps and devices have all been removed.
6. Replace cartridge following steps 8. to 11. in Paragraph 5.2.4.2
June 01, 2006 Page 76

BAUER K20V
COMPRESSORS
Figure 5-14 P42 Purification System Parts List
7
8 9
IN
OUT
1 2 3 4 5 4 6

1 1 GAG-0009W Pressure Gauge
3 1 079416 Oil and Water Separator See Figure 5-15
4 2 VAL-0007 Check Valves
5 1 VAL-0377 Bleed Valve
6 1 VAL-0053 Pressure Maintaining Valve
8 1 082135 20 Dryer Chamber See Figure 5-16
9 1 082135 20 Purification Chamber See Figure 5-17
1 082136 20 Securus Purification Chamber See Figure 5-18

MNL-0413 BAUER
COMPRESSORS
Figure 5-15 Oil and Water Separator Parts List

1 079416 Oil and Water Separator Assembly
1 Separator Head Available only with 079416
2 2 N04586 O-Ring
3 1 061860 Sintered Metal Filter
4 Separator Housing Available only with 079416
5 Bottom Plug Available only with 079416
June 01, 2006 Page 78

BAUER K20V
COMPRESSORS
Figure 5-16 Dryer Chamber Assembly Parts List
1
2
3
4
5
5
4

1 082135 Chamber Assembly
1 2 012293 Tool Post Screw
4 2 N04736 Back-up Ring
5 2 N04735 O-ring
7 Filter Bottom Available only with 082135
8 1 062504 Dryer Cartridge MS

MNL-0413 BAUER
COMPRESSORS
Figure 5-17 Purification Chamber Assembly Parts List
1
2
3
4
5
5
4

1 082135 Chamber Assembly
4 2 N04736 Back-up Ring
5 2 N04735 O-ring
7 Filter Bottom Available only with 082135
8 1 067224 Purification Cartridge MS/AC/MS/HP
June 01, 2006 Page 80

BAUER K20V
COMPRESSORS
Figure 5-18 Securus Moisture Monitor Parts List
6
2 7
3 8
5 10
17
16
4
15
14
13
12
11
3
2
1 18

1 082136 Securus Chamber Assembly
1 Bottom Plug Available only with 082136
2 2 N04736 Backup Ring
3 2 N04735 O-ring
4 1 061687 Securus Cartridge
5 Filter Body Available only with 082136
6 1 ADP-0204 Adapter, Right Angle
7 1 059850 Socket, RF type
11 1 059855 Nut

MNL-0413 BAUER
COMPRESSORS
Figure 5-18 (cont.) Securus Moisture Monitor Parts List

12 1 059852 Drawback Screw
13 1 059854 Loose Pin
14 1 060062 Compression Spring
15 1 059853 Fixed Pin
16 1 059851 Bolt
17 1 002181 Compression Spring
18 1 N15095 Securus Indicator 110 - 120VAC, 50 - 60 Hz
1 N15096 Securus Indicator 12 - 24 VDC
June 01, 2006 Page 82

BAUER K20V
COMPRESSORS
CHAPTER 6: COMPRESSOR DRIVE SYSTEM
6.1 Description, Horizontal Sliding
The compressor is driven by the drive motor through a V-belt. The direction of rotation, as seen facing
the flywheel, is counterclockwise. Observe the arrow on the compressor block.
Figure 6-1 Horizontal Motor Mount (typical)
4
5
1
6 2
1. Compressor Block 4. V-belt

2. Compressor Flywheel 5. V-belt sheave
3. Compressor Mount 6. Electric Motor
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 drives efficiency and abrades the cover of the belt, which results in premature failure. A
worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bottoms, slip-
page may result and the belt may burn. If the side wall is dished out, the bottom shoulder ruins the belt pre-
maturely 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 tension
V-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).

MNL-0413 BAUER
COMPRESSORS
Figure 6-2 V-belt Deflection
Approximate Deflection
3/8 " (10mm)
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.
^ WARNING ^
Always disconnect the electrical power before working on the motor
6.3.1 Lubricating the Drive Motor

1. Stop the motor.
2. Disconnect the power and lock the system out of service.
3. Wipe all grease fittings (fill and drain) clean.
4. Remove the fill and drain plugs from the bearing hub.
5. Free the drain hole of any hard grease. Use a piece of wire if necessary.
6. Add grease using a low pressure grease gun. The amount and type of grease added is very impor-
tant. Only enough grease should be added to replace the grease used by the bearing. Too much
grease can be as harmful as insufficient grease. The grease cavity should be filled 1/3 to 1/2 full.
7. Start the motor and let it run for approximately 30 minutes.
8. Stop the motor, wipe off any drained grease and replace the filler and drain plugs.
9. The motor is ready for operation.
June 01, 2006 Page 84

BAUER K20V
COMPRESSORS
CHAPTER 7: ELECTRICAL PANEL ASSEMBLY
7.1 Overview
Figure 7-1 Electrical Panel Assembly
The Electrical Panel Assembly uses a micro Programmable Logic Controller, Motor Starter, transformer
and switches manufactured by Telemecanique. This controller model is called TWIDO. The control system
will provide logical control and safety shutdowns for the compressor equipment. All necessary time delays,
counters, shutdowns, sequencing and safety features are incorporated into a proprietary program permanently
saved into PLC memory using EEPROM technology. There are normally six PLC programs used in this
Electrical Panel Assembly, based on the pressure and use of the compressor. The program version used can
be identified by the white sticker on the face of the PLC. The panel is pre-wired and fused for the horsepower
and voltage of the compressor. The power source for the panel is selected at the time of order from the fol-
lowing options.
208 volt, 3 phase, 60 Hz supply 230 volt, 3 phase, 60 Hz supply
460 volt, 3 phase, 60 Hz supply 230 volt, 1 phase, 60 Hz supply

MNL-0413 BAUER
COMPRESSORS
^ NOTE ^
Other configurations and options are also available by special order. Some components and programs
listed may be altered by these special orders.
The basic panel components consist of a 16 I/O PLC Controller, Motor Starter with Overload Relay,
Control Power Transformer with fuses, Alarm and Warning Lights, Compressor Control Switch, Hourmeter,
Emergency Stop Switch, Starter Reset, Audible Alarm, terminal strip for wire connections and wire harness.
To run the compressor, the Emergency Stop Switch must be pulled out and the Compressor Control
Switch must be in the ON position; at this point, the switch illuminates green and the compressor system is
ready and able to operate. If the pressure in the system drops to approximately 4500 psi1, the air pressure
switch will close, and the compressor will start. All other functions of the compressor are automatic. When
the air pressure has increased, and the pressure switch opens, then the compressor will shutdown. All of these
functions are accomplished through the use of a Programmable Logic Controller. When use of the equipment
is complete, the Compressor Control Switch should be placed in the Off position.
7.2 Options
This panel will electrically support all commonly available compressor options offered by Bauer Com-
pressors. These include:
The Securus Electronic Moisture Monitoring System to monitor the air, and provide first a warning,
and later an alarm, to prompt the operator to replace the high pressure purification cartridges.
The Carbon Monoxide Monitor is used to continuously sample the air that is compressed for use in
the system. Again, the unit will alarm and shut down the compressor if unsafe levels are detected. The
Carbon Monoxide Monitor also comes with a Calibration Kit to ensure accurate readings are being
taken.
The Condensate High Level Alarm will alarm and shutdown the compressor when the condensate
level becomes too high. This Alarm is activated by a float switch in the ACD Condensate Collection
Tank. This alarm prompts the operator to drain the condensate and prevents spilled condensate.
7.3 AC Power Requirements
The panel will need to be supplied with the appropriate voltage, phase, and frequency power to ensure
proper operation. Wiring and conduit selection must be in accordance with all national, state and local codes.
The customer is responsible for providing a disconnection means and protection from instantaneous short cir-
cuit.The pre-wired panel voltage and phase is written on a label (See Figure 7-2) on the inside of the electri-
cal panel door. In this example shown, the panel is wired for 230 volt, single 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.
1. The pressure mentioned is only an example; the switch differential is approximately 10% of the set-point, and is not adjustable.
June 01, 2006 Page 86

BAUER K20V
COMPRESSORS
Figure 7-2 Electrical Panel Label
MODEL:
SERIAL: 43857
BLOCK:
NORFOLK, VA 23502 USA
757-855-6006 MFG DATE: 2/2004
PANEL: ASY-0819 UL File No. E109698

MAXIMUM RATING (AC3)
60/75 C COPPER WIRE ONLY
600 VAC Max. 600 VAC Max. Terminal Wire Range Torque
1 Ph 60Hz 3 Ph 60Hz
Line awg 10-3 45 in-lb
120V 230V 208V 230V 460V 380V
Load awg 10-0 100 in-lb
N/A 10HP N/A N/A N/A N/A
N/A 42A N/A N/A N/A N/A Ground awg 14-2 35 in-lb
This electrical panel will power up to a single 20 HP NEMA Design B motor at 208 VAC or up to a sin-
gle 50 HP NEMA Design B motor at 460 VAC. The panel is provided with a 120 VAC, 200 VA, single-
phase transformer for powering 120-volt loads. 120 VAC single-phase panel loads are as follows:
AC Power Available Light Negligible
Warning & Alarm lights Negligible
ACD coils (up to 4) 35 W each maximum, with 3 max energized
Motor Starter coil (max) 26.0 VA (sealed, max)
CO Monitor Solenoid valve 8W
CO Monitor power 0.9 W
Securus Electronic Moisture Monitor System 20.4 VA
PLC Controller 22.0 VA
Figure 7-3 Transformer and Fuses

MNL-0413 BAUER
COMPRESSORS
7.3.1 Transformer and Fuses
The transformer is fitted with three fuses. The input to the transformer has two fuses. For 208 and 230
VAC operation, use two Bauer P/N FUS-0113 fuses rated at 2 amps. For 460 VAC operation, use two Bauer
P/N FUS-0117 rated at 1 amp. The secondary of the transformer is fitted with one fuse. Use one Bauer P/N
FUS-0018, rated at 2 amps.
^ CAUTION ^
Before operating the compressor, care should be taken to ensure the voltage and phase of the power supply
are the same. A qualified electrician should make these checks.
7.4 Electric Panel Components

7.4.1 Motor Starter.
This application will require an across the line IEC starter with thermal overloads. Control voltage is 120
VAC. There are two basic sizes of motor starters. SRT-0196 will support up to 32 Amps and SRT-0197 will
support up to 65 Amps continuous. The coils of these starters can be replaced if needed, see Table 7-1 and
Table 7-2.
7.4.2 Overload Relay
The overload relay provides thermal overload protection and will be based on the voltage and motor
horsepower. The relay must be set to match the motors Full Load Amps. Refer to the motor nameplate.
Figure 7-4 Motor Starter and Overload Relay, SRT-0197 shown
1. Motor Starter 2. Overload Relay
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Table 7-1: 32 Amp Starter Part Numbers Table 7-2: 65 Amp Starter Part Numbers
Bauer P/N Description Notes Bauer P/N Description Notes
SRT-0196 Motor Starter 120 VAC Coil SRT-0197 Motor Starter 120 VAC Coil
COI-0017 Replacement Coil 120 VAC COI-0018 Replacement Coil 120 VAC
Overload Relay Selections Overload Relay Selections
RLY-0134 Overload Relay 1.6 - 2.5 Amp RLY- 0152 Overload Relay 23 - 32 Amp
RLY-0135 Overload Relay 2.5 - 4 Amp RLY- 0153 Overload Relay 17 - 25 Amp
RLY-0136 Overload Relay 4 - 6 Amp RLY- 0144 Overload Relay 30 - 40 Amp
RLY-0137 Overload Relay 5.5 - 8 Amp RLY- 0145 Overload Relay 37 - 50 Amp
RLY-0140 Overload Relay 12 - 18 Amp

MNL-0413 BAUER
COMPRESSORS
Figure 7-5 Electrical Panel Assembly
1
2
3
4
1. Compressor Control Switch 4. Hourmeter

2. Warning Light 5. Starter Reset
3. Alarm Light 6. Emergency Stop Switch
7.4.3 Emergency Stop Switch.
There is a Emergency Stop Switch on the panel. This is a 22 mm device with a 40mm mushroom head.
The button must be pulled out for the unit to operate. In an emergency, depress the push button, which will
shutdown the electric motor and all other periphery devices. Do not use the Emergency Stop Switch for
securing the equipment under normal operation. Use the Compressor Control Switch. The PLC operating
memory is maintained by a internal battery in the PLC. Removing all power from the compressor will allow
the battery to discharge over a 30 day period. Apply power to the unit by pulling out the Emergency Stop
Switch, and leave on for at least 8 hours every 30 days.
7.4.4 Starter Reset
There is a blue 22mm push button on the door of the electrical enclosure with the letter R at its center.
Pushing this button will reset the thermal overload relay on the motor starter. Should the electric motor have
overloaded and tripped out during normal operation, then depressing this button after giving some time to
cool, will reset the overload relay portion of the motor starter.
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7.4.5 Compressor Control Switches
7.4.5.1 2-Position (Standard)
OFF Position - The selector switch must be in the OFF position when securing the compressor system.
ON Position - The selector switch must be in the ON position to operate the compressor system. When
positioning the switch to the ON position, it will illuminate Green. The compressor will start and stop auto-
matically based on the status of the pressure switch.
7.4.5.2 3-Position Compressor Control Switch (Factory Installed Option).
7.4.5.2.1 For Breathing Air Units
OFF - The selector switch must be in the OFF position when securing the compressor system.
ON - The selector switch must be in the ON position to operate the compressor system. When positioning
the switch to the ON position, it will illuminate Green. The compressor will start and stop automatically
based on the status of the pressure switch.
ACD Test - This switch position will cause all condensate drains to blow down. It is spring returned to
ON Position when released.
7.4.5.2.2 For Industrial Units
OFF - The selector switch must be in the OFF position when securing the compressor system.
AUTO- The selector switch must be in the ON position to operate the compressor system. When posi-
tioning the switch to the ON position, it will illuminate Green. The compressor will start and stop automati-
cally based on the status of the pressure switch.
CONTINUOUS - This switch position, maintained, will allow the compressor to build up to final pres-
sure, then will activate an unloading valve. When demand is re-established, the unloading valve is de-ener-
gized and compression will begin again.
7.4.6 Indicator Lamps
7.4.6.1 PLC Warning and Alarm Lamps
7.4.6.1.1 Warning Lamp - Amber
The lamp (LIT-0128) has a 22 mm base and a LED lamp for long trouble free life. This lamp should flash
a code IAW, In Accordance With, the logic of the controller. See Paragraph 7.5.
7.4.6.1.2 Alarm Lamp - Red
The lamp (LIT-0127) has a 22 mm base and a LED lamp for long trouble free life. This lamp should flash
a code IAW the logic of the controller. See Paragraph 7.6.
7.4.7 Hour meter
The panel will be supplied with an hour meter (HMR-0029). The hour meter is not resettable and used to
monitor the run hours of the compressor. It is powered with a 120 VAC signal supplied from the auxiliary
contact on the motor starter.
7.4.8 PLC Control
This panel is controlled with a Telemecanique 16 I/O Twido Programmable Logic Controller. This unit
provides logical operations to the overall system that includes the high pressure compressor, purification sys-
tems, and other accessories.

MNL-0413 BAUER
COMPRESSORS
Figure 7-6 PLC CNT-0052 Figure 7-7 Status Lights
Input LEDs
Inputs
IN
012345678
Status
0123456
STAT
PWR
Lights
RUN
ERR
Program
Version
OUT
Status LEDs Output LEDs
120 VAC Supply Outputs
7.4.8.1 PLC LEDs

There are three separate groups of LEDs on the PLC. See Figure 7-7.
1. The Input Status LEDs are in the top row.
2. The Output Status LEDs are on the right hand side of the bottom row
3. The PLC Status Lights are on the left hand side of the bottom row and indicate the following.
a. PWR - The supply voltage to the PLC is correct.
b. RUN - On when the program is running. Flashes when program execution is stopped.
c. ERR - Illuminates red on application fault.
d. STAT - Indicates the status of an application variable.
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7.4.9 Compressor PLC Program Versions

The version of PLC program loaded into your compressor package is denoted with a small white sticker
in the front of the PLC. Please refer to this number when calling Bauer Compressors Product Support.
Table 7-3: PLC Program Versions
Description 5,000 psi 6,000 psi
Breathing Air Compressor without Unloader v2.45 v2.35
Industrial Compressor Unit with Unloader v2.64 v2.54
Gas Compressor Unit vG1.46 vG1.36
Unicus III with 1 ACD Solenoid vU3.4 vU1.4
Unicus III with 2 ACD Solenoids vU2.4
Industrial Unit with 4 ACD Solenoids v3.1 v3.0
7.4.10 PLC Inputs and Outputs

All PLC inputs are 24 VDC. The power supply physically exists inside the PLC. All PLC outputs are of a
relay type, and are powered through the control transformer supplying 120 VAC single phase to the various
loads. Please refer to unit schematic for the as built specifications.
Table 7-4: PLC Inputs - Breathing Air Table 7-5: PLC Outputs - Breathing Air
I0 Compressor Control Switch Q0 Motor Starter
I1 High Temperature Switch Q1 ACD 1
I2 Oil Pressure Switch Q2 ACD Final
I3 Final Air Pressure Switch Q3 Alarm Indicator
I4 CO Monitor Alarm Q4 ACD 2
I5 Securus Alarm Q5 ACD 3
I6 Condensate Alarm Q6 Warning Indicator
I7 Securus Warning
I8 ACD Test Switch (option)

MNL-0413 BAUER
COMPRESSORS
Table 7-6: PLC Inputs - UNICUS III Table 7-7: PLC Outputs - UNICUS III
I0 Motor Overload Switch Q0 Motor Starter
I4 CO Monitor Alarm Q4 ACD 2
I5 Securus Alarm Q5 ACD 3
I7 Securus Warning
I8 Air Inlet Pressure Switch
Table 7-8: PLC Inputs - Industrial Compressor Table 7-9: PLC Outputs - Industrial Compressor
I0 Compressor Control Switch (1SS) Q0 Motor Starter
I4 CO Monitor Alarm Q4 Not Used
I5 Securus Alarm Q5 Unloader Valve
I7 Securus Warning
I8 Continuous Switch (1SS)
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Table 7-10: PLC Inputs - Gas Compressor Table 7-11: PLC Outputs - Gas Compressor
I0 Compressor Control Switch (1SS) Q0 Motor Starter
I4 Not Used Q4 Not Used
I5 High Inlet Pressure Switch Q5 Inlet Solenoid Valve
I7 Low Inlet Vacuum Switch
I8 Not Used
7.5 Warnings
Warning codes are flashed with a 0.5 second on / 0.5 second off sequence with the Amber light located
on the control panel. In addition the light will illuminate on initial start up for a period of 5 seconds, to serve
as a lamp test function. The lamp has a 22 mm base and a LED lamp for long trouble free life.
7.5.1 One Flash - Final Separator Warning
The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel,
approximately 3-3/4 inch diameter, located on the purification panel, beside the compressor. To prevent
fatigue failure of this vessel, the PLC program monitors the pressurization / de-pressurization cycles of this
separator and will issue a Warning, and then later an Alarm function.
The program is set up for a 90% warning and a 100% shutdown alarm for this counter feature. The pro-
gram would be configured to reflect the following values when it is built.
Table 7-12: Final Separator Warning and Shutdown Cycle Count
Maximum Compressor Pressure Warning Shutdown
5,000 psi 39,600 cycles 44,000 cycles
When the warning is illuminated, the unit will still continue to function properly, but will prompt the
operator to contact Bauer Compressors for making arrangements to replace the separator. When the Alarm
level has been achieved, the compressor will no longer function, and will require the replacement of the sep-
arator. When this is accomplished, the unit can be re-activated by making adjustments to the PLC. Please
contact Bauer Product Support for detailed instructions.

MNL-0413 BAUER
COMPRESSORS
^ WARNING ^
Do not attempt to override this Separator Shutdown. This feature is provided to protect operating
personnel from injury or death.
7.5.2 Two Flashes - Securus Monitor Warning

The compressor purification system may be equipped with an optional Securus Electronic Moisture
Monitor System. This consists of a control module and cable connected to the purification chamber. It func-
tions as a capacitive sensor, sensing the moisture in the purified air. When the chemicals in the purification
cartridges have reacted with moisture to a point where they are beginning to sense a change in the moisture
content, then the Securus Monitor will illuminate its amber light.At the same time, the warning relay in the
Securus module which is connected to the PLC on terminal I7.
On a Securus Warning condition, the compressor will run normally, the I7 lamp will illuminate, and the
warning shows on the LCD Display. This warning is meant to prompt the operator to schedule replacement
of the purification cartridges in the near future.
Figure 7-8 Securus System
The Warning relay is wired normally open. The relay is wired into a wire harness using the Black /
Orange and Violet / Orange color wires. Refer to unit schematic for additional information. Under normal
operating conditions, the relay is open and the I7 lamp on the PLC is off.
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7.6 Alarms
Alarm codes are flashed with a 0.5 second on / 0.5 second off sequence with the Red light located on the
control panel. In addition the light will illuminate on initial start up for a period of 5 seconds, to serve as a
lamp test function. The lamp has a 22 mm base and a LED lamp for long trouble free life.
7.6.1 One Flash - Compressor High Temperature
The compressor high temperature switch is located on the high pressure breathing air compressor, on the
third, fourth or fifth stage head, depending on model. The switch is N.C., Normally Closed, and is connected
to the PLC on terminal I1. The switch is wired into a wire harness using the Yellow and Violet color wires.
Refer to unit schematic for additional information. Under normal operating conditions, the switch is closed
and the I1 lamp on the PLC is illuminated. On a high temperature condition, the compressor will shutdown,
the I1 lamp will extinguish, and the alarm code will flash.
Figure 7-9 High Temperature Switch Figure 7-10 Low Oil Pressure Switch
7.6.2 Two Flashes - Compressor Low Oil Pressure

The compressor oil pressure switch is located on the high pressure breathing air compressor, on the back
of the block, mounted with the oil pressure gauge. The switch is N.O., Normally Open, and is connected to
the PLC on terminal I2. The switch is wired into a wire harness using the Orange and Blue color wires. Refer
to unit schematic for additional information. During startup of the compressor, the oil pressure switch is
bypassed in the program for a period of 45 seconds. When the oil pressure has stabilized, the switch should
be closed. Should the compressor lose oil pressure, then the compressor will shutdown, the I2 lamp will
extinguish, and the alarm code will flash.
7.6.3 Three Flashes - Compressor Overrun Timer
The compressor has an overtime function, where if the compressor runs continuously for 5 hours, then
the compressor will shutdown, and the alarm code will flash. This is done to secure the equipment if it were
to be started and left unattended.

MNL-0413 BAUER
COMPRESSORS
7.6.4 Four Flashes - Securus Monitor
See Figure 7-8. The compressor purification system may be equipped with a Securus Electronic Mois-
ture Monitor System. This consists of a control module and cable connected to the purification chamber. It
functions as a capacitive sensor, sensing the moisture in the purified air. When the chemicals in the purifica-
tion cartridges have reacted with moisture to a point where they are no longer suitable for purifying the air,
then the Securus Module will illuminate its red light. At the same time the alarm relay in the Securus mod-
ule is connected to the PLC on terminal I5. On a Securus alarm condition, the compressor will shutdown, the
I5 lamp will be illuminated, and the alarm shows on the LCD Display. The warning relay is wired N.O., nor-
mally open. The switch is wired into a wire harness using the Black / White and Violet / Orange color wires.
Refer to unit schematic for additional information. Under normal operating conditions, the relay is open and
the I5 lamp on the PLC is off.
7.6.5 Five Flashes - Carbon Monoxide Monitor Alarm
The compressor system may be equipped with an optional Carbon Monoxide Monitor. This consists of an
electronic module that samples the compressed air supply. The unit will provide a continuous display of the
CO level in PPM, parts per million. If the CO level becomes excessively high, then the monitor will alarm
with a red light. In turn, the alarm relay in the CO Monitor is connected to the PLC on terminal I4. The unit
should be calibrated with a test gas monthly. Refer to the manual section on the CO Monitor.
The relay is wired N.O., normally open. The switch is wired into a wire harness using the White / Black
and Red / White color wires. Refer to unit schematic for additional information. Under normal operating
conditions, the relay is open and the I4 lamp on the PLC is off. On a CO ALARM condition, the compressor
will shutdown, the I4 lamp will be illuminated, and the alarm code will flash.
Figure 7-11 CO Monitor
June 01, 2006 Page 98

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7.6.6 Six Flashes - Final Separator Shutdown
^ WARNING ^
Do not attempt to override the Final Separator Shutdown. This feature is provided to protect operating per-
sonnel from injury or death.
The high pressure-breathing compressor is equipped with a final separator. This is a stainless steel vessel,
approximately 3-3/4 inch diameter, located on the purification panel, beside the compressor. To prevent
fatigue failure of this vessel, the PLC program monitors the pressurization cycles of this separator and will
issue a 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.
Table 7-13: Final Separator Warning and Shutdown Cycle Count
Maximum Compressor Pressure Warning Shutdown
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 sep-
arator. When this is accomplished, the unit can be re-activated by making adjustments to the PLC. Please
contact Bauer Product Support for detailed instructions.
7.6.7 Seven Flashes - Condensate Fault
The compressor condensate level switch is located in the condensate collection tank, below the ACD,
Automatic Condensate Drain separator. The switch is N.O., Normally Open, and is connected to the PLC on
terminal I6. The switch is wired into a wire harness using the Grey and Pink color wires. Refer to unit sche-
matic for additional information. Under normal operating conditions, the switch is open and the I6 lamp on
the PLC is off. On a high condensate condition, the compressor will shutdown, the I6 lamp will illuminate,
and the alarm code will flash. The operator should drain the condensate from the tank and resume operation
of the equipment.

MNL-0413 BAUER
COMPRESSORS
Figure 7-12 Condensate Level Float Switch
^ NOTE ^
The compressor condensate contains some oil, and accordingly, should be disposed of in accordance with
state and local regulations.
7.6.8 On Steady - Motor Starter Overload Trip

The compressor overload relay is located in the electrical enclosure, directly beneath the motor starter.
See Figure 7-4. The relay is Normally Open and is not connected to the PLC, but is connected directly to the
red alarm light. Under normal operating conditions, the switch is open. On an Overload Trip of the motor,
the compressor will shutdown, and the Alarm light will be illuminated steady (no flash sequence).
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7.7 Installing a New Program
The PLC program c an be updated in two ways. If a Bauer technician is on-site, they could connect
directly to the PLC using a notebook computer. Using a licensed version of TwidoSoft software, changes
can be made and downloaded to the PLC directly.Another method to install a new program is to use an Exter-
nal EEPROM cartridge (CNT-0051). The EEPROM would be programmed at the Bauer factory and shipped
either to the customer or to a authorized distributor.
Figure 7-13 PLC Programing Port
PLC
Programing
Port
Analog
Potentiometer
( Overrun TimerAdjustment )
^ CAUTION ^
When handling the cartridge, do not touch the pins. The cartridges electrical elements are sensitive to static
electricity.

MNL-0413 BAUER
COMPRESSORS
Figure 7-14 PLC EEPROM
PLC with cartridge removed. PLC with EEPROM Installed
EEPROM Cartridge
7.7.1 Installing a new program using an EEPROM cartridge

1. Disconnect main power to your unit
2. Open the electrical enclosure door
3. Open the bottom terminal cover on the Twido controller
4. Remove the cartridge cover
5. Push the EEPROM cartridge into the cartridge connector until it clicks.
6. Close the terminal cover.
7. Reconnect main power to the unit.
8. Pull out the Emergency Stop pushbutton.
9. At power up, the new program will automatically be downloaded to the 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
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COMPRESSORS
7.8 Overrun Timer
(See Figure 7-13). 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, 8
hours (factory standard) or bypassed entirely eliminating the Overrun Timer.
Figure 7-15 Overrun Timer Adjustment
Ov
e
n Tim rrun
Ru urs By
pa er
o ss
8H ed
Run No
5 Hours Run
Full Full
CCW CW
Overrun Timer Adjustment
7.8.1 Adjusting the Overrun Timer

(See Figure 7-15). The setting is determined by rotating the Overrun Timer Adjustment.
1. Begin by gently rotating the Overrun Timer Adjustment fully Counter-Clockwise to 9 oclock. 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 eight hours of continuous running, rotate the
Overrun Timer Adjustment 60 Clockwise to the 11 oclock position.
3. If it is desired that the compressor Overrun Timer is bypassed and does not shut the compressor off,
rotate the Overrun Timer Adjustment 120 Clockwise to the 1 oclock position.
^ NOTE ^
The compressor will not operate if the Overrun Timer Adjustment is rotated fully
Clockwise to the 3 oclock position.

MNL-0413 BAUER
COMPRESSORS
7.9 Wire Harness Connections
Device Description PLC In PLC Out Wire Colors Pin

Yellow 23
1TS Compressor High Temp. Switch I1
Violet 24
Blue 25
2PS Compressor Oil Pressure Switch I2
Orange 26
Red 29
1PS Compressor Air Pressure Switch I3
Brown 30
Grey 31
CS Condensate High Level Switch I6
Pink 32
CO Monitor Power Brown/White 1
CO Mon.
Neutral Red/Blue 14
CO SV CO Monitor Solenoid Valve Black/Yellow 2
Red/White 34
LAH CO Monitor Alarm Contact I4
White/Black 33
Securus Power Black 3
SEC
Neutral White 15
Securus Warning I7 Black/Orange 37
SEC W
Neutral Violet/Orange 36
SEC A Securus Alarm I5 Black/White 35
Black/Brown 17
3 PS Air Inlet Pressure Switch I8
Brown/Yellow 18
Automatic Condensate Drain #1 Q1 Blue/White 4
ACD1a
Neutral Orange/White 21
ACD Finalb Final ACD Coil Q2 Yellow/Black 5

Second ACD Coil Q4 Violet/White 6
ACD 2
Neutral Grey/White 22
ACD 3 Third ACD Coil Q5 Pink/White 7
a. If the unit is equipped with one ACD Solenoid, it is connected to ACD1.
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b. If the unit is equipped with two ACD Solenoids, they are connected to ACD1 and ACD Final.
7.10 Replacement Parts List

Figure 7-16 Electrical Panel, Interior
1 2 3 4 5 6
14 13 12 11 10 9

1 1 HMR-0028 Hourmeter
2 1 LIT-0127 Light Assembly Red
3 1 LIT-0128 Light Assembly Amber
4 1 SWT-0240 Control Switch 2 Position
1 SWT-0242 Control Switch 3 Position, Industrial Units
1 SWT-0259 Control Switch 3 Position, Breathing Air Units
5 1 CNT-0052 PLC Controller
6 1 SUR-0005 Surge Suppressor
7 2 FUS-0113 Fuse, 2 Amp Primary, 208 - 230VAC
2 FUS-0117 Fuse, 1 Amp Primary, 460 VAC
8 1 FUS-0018 Fuse, 2 Amp Secondary
9 1 TRR-0062 Transformer
10 1 HNS-0051 Socket
11 1 Motor Starter and Overload Relay See Table 7-1 or Table 7-2
12 1 OPR-0014 Starter Reset Button
13 1 IND-0034 Audible Alarm
14 1 SWT-0244 Emergency Stop Switch

MNL-0413 BAUER
COMPRESSORS
7.11 Trouble Shooting Guide

7.11.1 Compressor Will Not Start
Possible Cause or Problem Corrective Action
Emergency Stop Switch not pulled out. Pull out Switch.
Selector Switch not in ON position. Turn switch to ON.
Lights on PLC not illuminated Check voltage and phases
Air Pressure not low enough to close pressure PLC input I3 should be illuminated.
switch.
7.11.2 Compressor Is Shutdown, Alarm Code Flashing Sequence.
7.11.2.1 One Flash - Compressor High Temperature
Investigate or Possible Cause Corrective Action
Compressor is hot Improve compressor ventilation
Temperature switch electrical connector unplugged Reconnect plug
Temperature switch failure, check that PLC Input I1 is on. Replace High Temperature Switch
7.11.2.2 Two Flashes - 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
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7.11.2.3 Three Flashes - Compressor Overtime
The compressor is shut down after 5 hours of continuous Turn Compressor Control Switch to OFF
operation then back to ON.
7.11.2.4 Four Flashes - Securus Alarm
Securus Cable disconnected Reconnect Securus Cable
Securus Cartridge saturated or expired. Replace all purification system cartridges
7.11.2.5 Five Flashes - Carbon Monoxide Monitor Alarm
Monitor is not operating with proper pressure and flow Adjust as required.
Monitor is not properly calibrated Calibrate Monitor
If above checks are okay Replace Purifications Cartridgesa
a. A typical source of carbon monoxide is engine exhaust. Ensure compressor intake is from a fresh air source to prevent premature consumption of the purification cartridges.
7.11.2.6 Six Flashes - Final Separator Shutdown
Final Separator has reached maximum number of Pressurization Replace Final Separator
Cycles.

MNL-0413 BAUER
COMPRESSORS
7.11.2.7 Seven Flashes -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
7.11.2.8 On Steady - Motor Over load Trip
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.
7.11.2.9 Eight Flashes - High Inlet Pressure (Gas Compressors Only)
Compressor Inlet Pressure to High Adjust pressure of feed gas
Check setting of Inlet Pressure Switch
7.11.2.10Nine Flashes - Low Inlet Vacuum (Gas Compressors Only)
Inlet Pressure to compressor to low Check operation of Inlet Solenoid Valve.
Adjust feed rate of feed gas
Check setting of switch
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Figure 7-17 Checking Compressor Rotation Direction
1. Cover Screw 2. Starter Armature

7.12 Check Compressor Rotation Direction.
Turn the motor one or two revolutions to ensure proper rotation of the compressor. See Figure 7-17.
1. Remove the cover from the starter by rotating the cover screw (1) counter-clockwise.
2. Remove cover, and manually depress the blue armature of the starter (2) for a second.
3. Ensure compressor rotation is in accordance with the directional arrow on the compressor fan
shroud.
4. If rotation is incorrect, switch any two of the three power leads to reverse the rotation of the motor.
5. Replace starter cover.

MNL-0413 BAUER
COMPRESSORS
7.13 PLC Standard Wiring Diagram
&OR2EFERENCE/NLY
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BAUER K20V
COMPRESSORS
7.14 PLC Industrial Compressor Wiring Diagram
&OR2EFERENCE/NLY

MNL-0413 BAUER
COMPRESSORS
7.15 PLC Gas Compressor Wiring Diagram
&OR2EFERENCE/NLY
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CHAPTER 8: CARBON MONOXIDE MONITOR
8.1 Description
The Carbon Monoxide (CO) Monitor is a factory installed option which may not have been ordered with
your unit.
The CO Monitor, Bauer P/N; MNR-0029, is a stand alone assembly, which may be installed on a com-
pressor unit or trailer.(See Figure 8-1).
The CO Monitor, Bauer P/N; MNR-0033 (See Figure 8-2) appears outwardly identical to MNR-0029 but
is designed for use with a remote display, which can be located up to 100 feet from the compressor unit. The
Remote Display, Bauer P/N; MNR-0034, is powered by the CO Monitor, MNR-0033.
Figure 8-1 CO Monitor, MNR-0029 Figure 8-2 MNR-0033
1 2 3
5
(Right
Side)
1. LCD Display 5. Air Inlet Connection 1. CO Monitor, MNR-0033

2. Flow Indicator 6. ZERO CAL Set Switch 2. Remote Display, MNR-0034
3. Electrical Power Connection 7. Calibration Port
4. Front Cover Screw
The Carbon Monoxide (CO) Monitor is designed to provide continuous monitoring of the carbon
monoxide levels in breathing air.
The CO Monitor is enclosed in a NEMA-4X case and operates on 12 VDC or 120 VAC.
Calibration adjustment is performed automatically by the internal microprocessor.
The Carbon Monoxide Sensor Cell has a life expectancy of one and a half to three years if the calibra-
tion check is done every 30 days as recommended.

MNL-0413 BAUER
COMPRESSORS
8.1.1 Component Description
The following are the major components for the standard and trailer CO Monitor Assembly installations.
See Figure 8-3.
Figure 8-3 Carbon Monoxide Monitor Flow Diagram
8.1.1.1 Isolation Valve

Controls the input of air from the compressor to the CO Monitor.
8.1.1.2 High Pressure to Low Pressure Regulator
Typically set for 50 psi out with 5,000 psi in.
8.1.1.3 Relief Valve
A relief valve which is factory set to 165 psi to prevent over-pressurization of the CO Monitor.
8.1.1.4 Solenoid Valve
Allows air to flow to the CO Monitor when the compressor is running.
8.1.1.5 Inlet Regulator
A regulator the operator uses to set the appropriate rate of flow (0.5 to 0.8 SCFH) to the CO Monitor.
8.1.1.6 CO Monitor
The CO Monitor contains the LCD Display, Flowmeter, Microprocessor, Carbon Monoxide Sensor Cell,
Air Inlet Connection and the Calibration Port.
8.1.1.6.1 Carbon Monoxide Sensor Cell.
The Carbon Monoxide Sensor Cell is an electro-chemical element inside the CO Monitor which senses
the amount of Carbon Monoxide in the airstream and produces an analog electrical signal for the control and
display functions of the CO Monitor.
8.1.1.7 Test Gas Storage
This provides a place to keep Calibration Gas bottles so that the CO Monitor can be calibrated in all situ-
ations. Normally these are only found only in trailer installations.
8.2 CO Monitor Setup
The initial setup of the CO Monitor is done prior to shipping the unit.
8.3 Operation
1. Start the compressor unit.
2. The LCD Display will show introductory messages and a warm up countdown (WARM XX).
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3. After the warm up countdown of 120 seconds, the instrument will display CO level readings.
4. The Inlet Regulator may be adjusted at any time to set the flow level from 0.5 to 0.8 SCFH on the
Flow Indicator.
5. If the compressor is not running then a LOW FLOW indication will show on the display.
6. If carbon monoxide readings remain high or below zero calibration may be needed.
8.4 Maintenance
8.4.1 Calibrating Carbon Monoxide Monitor.
^ NOTE ^
Calibration is recommended every thirty days.
1. Before calibration, be sure that the test gas bottles in the calibration kit have an adequate amount of
gas in the them. Attach the fixed flow regulator to the gas bottle and then detach it. You should hear
a slight popping sound.
2. Turn on the compressor unit. The compressor itself does not have to run, because the test gas is
being substituted for the air supply from the compressor.
3. The compressor unit power needs to be applied to the unit for 15 minutes so the unit can stabilize.
If you attempt to calibrate before the end of this 15 minute period, TO SOON will appear on the
LCD Display.
4. Lift the cap of Inlet Regulator and turn counterclockwise until it stops. This will insure that the air
flow from the compressor unit is shut off.
5. If the gas flow from the compressor unit was not shut off, a message SUPPLY OFF will appear.If
this message appears, shut off the supply air and then begin the calibration process again.
6. Connect the Zero Gas bottle to the Fixed Flow Regulator and connect it to the Calibration Port of
the CO Monitor.
7. Turn the valve on the Fixed Flow Regulator counterclockwise until the CO Monitor Flow Indicator
shows between 0.5 and 0.8 SCFH.
8. Depress the ZERO CAL Set Switch on the front of the CO monitor with a paper clip for one to five
seconds. The Display should read ZERO CAL and will count down from 60 seconds. At the conclu-
sion, the display prompts, REMOVE ZERO GAS.
9. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the
Calibration Port.
10. Disconnect the Zero Gas bottle and connect the 20 ppm CO Test Gas 20 ppm CO to the fixed flow
regulator and connect it to the Calibration Port of the CO Monitor.
11. Turn the value on the Fixed Flow Regulator counterclockwise until the CO Monitor Flow Indicator
shows between 0.5 and 0.8 SCFH.

MNL-0413 BAUER
COMPRESSORS
12. The Display will count down from 60 seconds. At the conclusion, the display will prompt to
REMOVE CO GAS.
13. Turn the valve on the Fixed Flow Regulator clockwise until it is closed and disconnect it from the
Calibration Port and disconnect the 20 ppm CO Test Gas bottle from the fixed flow regulator.
14. Allow 10 minutes for the remaining gas in the CO Sensor Cell to dissipate after the calibration pro-
cess.
^ NOTE ^
If the compressor is started before the test gas dissipates, it could lead to incorrect CO level readings.
15. Turn the compressor on, adjust Inlet Regulator to 0.5-0.8 SCFH to restore normal operations.
8.4.2 Troubleshooting a Calibration Failure
If the unit fails to calibrate, it maybe due to low pressure in Test Gas Bottles, mixing up the Test Gas
Bottles during calibration or an aging CO Sensor Cell.
1. Ensure the Test Gas supply is adequate. See Paragraph 8.4.1 Step 1.
2. Reinitialize the CO Monitor by depressing the ZERO CAL Set Switch, for approximately 30 sec-
onds, until INITING displays in the LCD. This will allow for a greater percentage of compensation
for the gas.
3. If the Test Gas is good and the CO Monitor still refuses to calibrate, replace the CO Sensor Cell.
See Paragraph 8.4.3.
4. If it still doesnt calibrate, contact factory.
Figure 8-4 Basic Calibration Kit
1. 20 ppm CO Test Gas 2. Zero Test Gas 3. Fixed Flow Regulator

8.4.3 Carbon Monoxide Sensor Cell Replacement
(See Figure 8-6)
When CO test gas fails to show a gas response during calibration, a new CO Sensor Cell is required.
Most CO Sensor Cells will last from one and a half to three years. After installing a new CO Sensor
Cell, an initialization step permits the CO Sensor Cell to be calibrated to zero regardless of the back-
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COMPRESSORS
ground air. Caution must be taken that the inlet air is free of carbon monoxide or an Impurity Free Air
test gas is used for the initial calibration.
1. Disconnect the power from the unit.
^ CAUTION ^
Be sure the power is disconnected from the unit.
2. Remove the four corner screws and open the CO Monitor front cover.
3. Remove the screws that hold the CO Sensor Cell cover.
4. Remove the CO Sensor Cell from its socket by pulling it up from the circuit board. (See Figure 8-6)
5. Install a new CO Sensor Cell.
^ CAUTION ^
Be sure the shorting wire is removed from the new CO Sensor Cell.
6. Replace the CO Sensor Cell Cover, ensuring the longer screw is in its indicated hole.
7. Reassemble the CO Monitor and reconnect to power.
8. Let the new CO Sensor Cell warm-up for an hour before doing the initial calibration.
9. See Paragraph 8.4.1 for CO Monitor calibration procedures.
8.4.4 Calibration Initialization
The CO Monitor Calibration Initialization follows the same instructions as regular 30 day calibration
check (See Paragraph 8.4.1).
Calibration of the CO Monitor will need to be done if the 30 day calibration check is due or any mainte-
nance on the internal components of the CO Monitor and/or Remote Display was performed.

MNL-0413 BAUER
COMPRESSORS
Figure 8-5 CO Monitor Internal Components
9 8
1 2 6 5 3 4
1. Power Cord 6. Audible Alarm (not used)
2. Gas Inlet 7. Carbon Monoxide Sensor Cell
3. Carbon Monoxide Sensor Cell Cover 8. Short Screws
4. Alarm Connections 9. Long Screw
5. Remote Display Connection (only MNR-0033)
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Figure 8-6 Carbon Monoxide Sensor Cell Removal
8.4.5 CO Monitor Test Mode Buttons
^ CAUTION ^
Except for the CO Sensor Cell, all internal CO monitor parts are to be serviced only by the manufacturer.
Do not adjust factory settings with the setup menu Mode Buttons unless absolutely necessary and by a
trained technician. The only reason to access the setup information is to test the alarm relay interface of
the control system which simulates the compressor going into an alarm state. The following describes
how to access the TEST MODE.
^ CAUTION ^
Except for testing the Display LCD, adjusting the parameters set at factory incorrectly could be dangerous.
Adjustment, if necessary, must be done by a trained technician.

MNL-0413 BAUER
COMPRESSORS
Figure 8-7 Mode Buttons Close-up
1. Mode Scroll Button 2. Value Change Button

1. Unscrew the four large screws on all corners of the Front Cover (See Figure 8-3).
2. Lift the Front Cover carefully, to not harm any of the attached wires inside the CO monitor.
3. Find the two white mode buttons on the left side of the motherboard (See Figure 8-7). By briefly
depressing the top button six times it is possible to cycle through the set up parameters to access the
TEST MODE.
4. When TEST MODE is displayed simply depress the bottom Value Change Button. Depressing the
Value Change Button sends an input signal to the PLC, shutting down the compressor system and
annunciating a high CO alarm (reference the electrical section of this manual for more information).
TEST MODE also sounds the auxiliary horn (if installed) and activates the solid squares on Front
Cover LED Readout.
5. The top mode button must be depressed again to return to Normal Mode.
6. Replace Front Cover and screw in place.
8.5 Remote Display Setup
^ NOTE ^
The Remote Display must not be installed more than 100 feet from the CO Monitor.
(See Figure 8-8) To calibrate the Remote Display, adjust the internal potentiometer with the compres-
sor system control switched on, so the CO Monitor will be energized. However do not have the com-
pressor running, because the air supply from the compressor is unnecessary for the Remote Display
setup.
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1. To calibrate the Remote Display unit during normal operation of the compressor unit, make sure the
that both the compressor and CO Monitor units are on.
2. Open the Remote Display (See Figure 8-8). Find the top potentiometer and adjust it to match the
CO Monitor CO display reading. Notice that the CO Monitor rounds off to whole numbers while
the Remote Relay displays decimal places, so adjust as close as possible.
3. When the display readings match, reassemble the Remote Relay. Realign readings if necessary.
Figure 8-8 Remote Display
1. Remote Display Calibration Screw

MNL-0413 BAUER
COMPRESSORS
8.6 Replacement Parts List
Figure 8-9 CO Monitor Assembly - Standard
3 4 5

ASY-0890 Carbon Monoxide Monitor Assembly
1 1 MNR-0029 Carbon Monoxide Monitor
2 1 VAL-0076 Isolation Valve
3 1 REG-0043 High - Low Pressure Regulator
4 1 VAL-0384 Safety Valve 165 psi
5 1 VAL-0348 Solenoid Valve 115 VAC
1 VAL-0349 Solenoid Valve 12 VDC
6 1 REG-0060 Inlet Regulator
N.S. 1 SEN-0025 CO Sensor Cell
N.S. 1 CYL-0020 Zero Gas Cylinder 0 ppm
N.S. 1 CYL-0016 CO Test Gas Cylinder 20 ppm
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Figure 8-10 CO Monitor Schematic
TO CONNECTS TO
REMOTE COMPRESSOR
DISPLAY BOARD CONTROLS
A
WHT/BLK
CO Monitor
No Connection.
DP -.
DP +.
Not Used.
Not Used.
Not Used.
COM.
COM.
NC.
NC.
NO.
NO.
MNR-0029/MNR-0033
RED YELLOW
RELAY RELAY
POWER BOARD
CONNECTS TO
COMPRESSOR
CONTROLS
INCOMING
POWER
1702-113B
RED
120 VAC
RECORDER No Connection
OUTPUT
RED Jumper
1 INT. 24V OPER

1
+
No Connection.
INT PWR.
AC 1.
AC 2.
+24 VDC.
GND.
TRANSFORMER
A
EXT. 12V OPER.
No Connection.
DP -.
DP +.
GND.
12V
REMOVE JUMPER
MAX 18 AWG WIRE 12V OPERATION
+ + +
PWR SIG B/L
N/A
Remote Display Board N/A
MNR-0034 Display Adjustment Pot.

MNL-0413 BAUER
COMPRESSORS
CHAPTER 9: PNEUMATIC VALVES AND CONTROLS
9.1 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 adjust-
able or repairable and must be replaced if they malfunction.
Figure 9-1 Pressure Maintaining Valve
9.2 Pressure Maintaining Valve

The pressure maintaining valve is adjusted at the factory to the required pressure and does not normally
require maintenance or readjustment. The factory setting is 2,300 psi (159 bar) 100 psi (7 bar).
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.
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9.3 Safety Valves
Figure 9-2 Safety Valves
The safety valves are adjusted at the factory to the required pressure and do not normally require mainte-
nance 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 Depart-
ment for details).

MNL-0413 BAUER
COMPRESSORS
CHAPTER 10:INDICATORS
10.1 Indicators
The Hourmeter is used to record the number of hours the unit has been operated.
The unit may also be equipped with one or more of the following pressure indicators.
Intermediate Pressure Gauges- Indicate the pressure between compression stages.
Final Pressure Gauge - Indicates the final operating pressure of the compressor.
Inlet Pressure Gauge - Indicates the pressure applied to the inlet of the compressor.
Oil Pressure Gauge - Indicates the compressor oil pressure.
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Figure 10-1 Indicators
1 2

1 1 HMR-0021 Hourmeter
2 1 GAG-0006W 2.5 Indicator 200 psi
1 GAG-0007W 2.5 Indicator 600 psi

MNL-0413 BAUER
COMPRESSORS
CHAPTER 11:APPENDIX
11.1 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 its 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

MNL-0413 BAUER
COMPRESSORS
11.1.2 Safety Warning Labels

Notes, 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 CONTROL
UNIT 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 Handling
This 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 rea-
son, we urge you to thoroughly examine the unit for possible damage and report any such damage to the ship-
ping 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.
Figure 11-1 Lifting Devices
Chain Hoist
Fork Lift Hand Truck
^ 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.
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 circumstances
should the braces remain installed during operation or the manufacturers warranty for the compressor unit
will be voided. The braces are all tagged and labeled.

MNL-0413 BAUER
COMPRESSORS
11.2.2 Installation of the Compressor Unit

11.2.2.1 General
The floor/site must be capable of supporting the weight of the unit. Secure the compressor unit to the
floor using lag bolts. Position the unit so that it is level. Permissible inclination of the compressor unit is
listed in Paragraph 1.4.
^ 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
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 impor-
tant 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 pro-
vided at the remote control unit.
AUTOMATIC COMPRESSOR CONTROL

UNIT MAY START WITHOUT WARNING!
Before carrying out maintenance and repair work, switch off at the main switch
and ensure the unit will not restart.
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 ser-
vicing and routine maintenance.
11.2.2.2 Ventilation
During normal compression, heat is generated by the compressor and by the drive motor/engine. For air-
cooled compressor units, this heat needs to be vented away by sufficient ventilation.
11.2.2.2.1Outdoor Installation
It 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 weather-
proof enclosure panels.
11.2.2.2.2Indoor Installation
The best location to install the compressor unit indoors is against an outside wall with a suitably large air
vent in front of the cooling fan. Additionally, it is necessary to position an exhaust opening in the opposite
wall, close to the ceiling or in the ceiling.
June 01, 2006 Page 132

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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 Ventilation
Natural ventilation should only be used up to a maximum drive power of 20 hp. To determine the size of
the required intake and exhaust openings, refer to the following table: .
Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)
V = 1750 ft h = 6.5 ft V = 3500 ft h = 10 ft V = 7000 ft h = 13 ft
Drive hp Intake (ft) Exhaust (ft) Intake (ft) Exhaust (ft) Intake (ft) Exhaust (ft)
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
11.2.2.2.4Forced Ventilation
To determine the required intake opening and exhaust flow refer to the following table:
Dependence on Room Size (V) and Height of Exhaust Opening (h)a
Drive hp V = 1750 ft h = 8 ft V = 3500 ft h = 10 ft V = 7000 ft h = 13 ft

Intake (ft) Exhaust cfm Intake (ft) Exhaust cfm Intake (ft) 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
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.

MNL-0413 BAUER
COMPRESSORS
11.2.2.3 Electrical Installation
11.2.2.3.1Electric Drive
When 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 Supply
The 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 units 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
Full Load Amps Fuse Ampsa Minimum Wire Sizeb
Motor
hp 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
a. Dual element time delay fuse amps.
b. Normal copper wire with THW, THWN, or XHHW insulation.
June 01, 2006 Page 134

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COMPRESSORS
3 PHASE
Motor Full Load Amps Fuse Ampsa Minimum Wire Sizeb
hp
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
a. Dual element time delay fuse amps.
b. Normal copper wire with THW, THWN or XHHW insulation.
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.

MNL-0413 BAUER
COMPRESSORS
11.3 Long Term Storage
11.3.1 General
If 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 Preparations
Prior 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.
June 01, 2006 Page 136

BAUER K20V
COMPRESSORS
11.3.4 Preventive Maintenance During Storage

Operate 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.

MNL-0413 BAUER
COMPRESSORS
11.4 Reproducible Forms
11.4.1 Scheduled Maintenance Form
Daily Para. Date Signature
June 01, 2006 Page 138

BAUER K20V
COMPRESSORS
Weekly or as required. Para. Date Signature
500 Operating Hours. Para. Date Signature
1,000 Operating Hours. Para. Date Signature

MNL-0413 BAUER
COMPRESSORS
Annually. Para. Date Signature
Biennially. (Every two years) Para. Date Signature
June 01, 2006 Page 140

BAUER K20V
COMPRESSORS
11.4.2 Record of Operating Hours
Date Minutes Total Date Minutes Total

Subtotal: Subtotal:

MNL-0413 BAUER
COMPRESSORS
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.
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
11.5.2 Torque Sequence Diagrams
Figure 11-2 6 Bolt and 4 Bolt Torque Sequence
3
5 3
2 1 2 1
4 6
4
11.5.3 Conversion Formulas

F = 9/5C + 32 C = 5/9 x (F-32)
PSI = BAR x 14.5 BAR =PSI x 0.0689
June 01, 2006 Page 142

BAUER K20V
COMPRESSORS
11.5.4 Approved Lubricants Chart

Unless otherwise specified in text, use the lubricants in Table 2.
Usage Lubricants
O-rings, rubber and plastic parts; filter housing Parker Super O Lube
threads, sealing rings
Bolts, nuts, studs, valve parts, copper gaskets and Never-Seez NSWT, Pipe Dope or teflon tape
tube connection parts (threads, cap nut and com-
pression rings)
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
11.5.5 Glossary of Abbreviations and Acronyms

Available Only as Part of a Complete Assembly
AC Activated Charcoal, removes odor and taste
ACD automatic condensate drain
ASME American Society of Mechanical Engineers
CW clockwise
CCW counterclockwise
CGA Compressed Gas Association
DIN Deutsches Institut fr Normung
DOT Department of Transportation
E1 single phase electrical supply
E3 three phase electrical supply
HP Chemical Catalyst, converts carbon monoxide to carbon dioxide
IAW In Accordance With
MS Molecular Sieve, removes moisture
NEC National Electrical Code
NEMA National Electrical Manufacturers Association
NFPA National Fire Protection Association
OSHA Occupational Safety & Health Administration
ODP open drip-proof (motor)
OEM Original Equipment Manufacturer
PCB printed circuit board
PLC Programable Logic Controller
PMV pressure maintaining valve
SC Securus Moisture Sensing Device

MNL-0413 BAUER
COMPRESSORS
11.6 Additional Documents
11.6.1 Diagrams and Drawings
Any 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 Documents
OEM Manuals and other BAUER manuals may be included in the documentation shipping package.
June 01, 2006 Page 144

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June 01, 2006 1st ed. Rev. 0 Chg. 0 MNL-0413

1st Edition June 01, 2006

Rev Chg Date Notes Auth

Page i 1st ed. Rev. 0 Chg. 0

CHAPTER 2: - - - - - - - - PLC CONTROLLED UNIT OPERATIONS

June 01, 2006 Page ii

CHAPTER 3:- - - - - - - - - - - - - - MAINTENANCE AND PARTS

Page iii 1st ed. Rev. 0 Chg. 0

CHAPTER 4: - - - IK150II OR IK180II MAINTENANCE SCHEDULE

CHAPTER 5: - - - - - - - - - - - - - - - - PURIFICATION SYSTEM

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

June 01, 2006 Page iv

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

Page v 1st ed. Rev. 0 Chg. 0

CHAPTER 8: - - - - - - - - - - - - CARBON MONOXIDE MONITOR

CHAPTER 9: - - - - - - - - PNEUMATIC VALVES AND CONTROLS

CHAPTER 10: - - - - - - - - - - - - - - - - - - - - - - INDICATORS

June 01, 2006 Page vi

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

Page vii 1st ed. Rev. 0 Chg. 0

CHAPTER 2: - - - - - - - - PLC CONTROLLED UNIT OPERATIONS

CHAPTER 3: - - - - - - - - - - - - - - MAINTENANCE AND PARTS

June 01, 2006 Page viii

CHAPTER 4:- - - - IK150II OR IK180II MAINTENANCE SCHEDULE

CHAPTER 5:- - - - - - - - - - - - - - - - -PURIFICATION SYSTEM

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

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

Page ix 1st ed. Rev. 0 Chg. 0

CHAPTER 8: - - - - - - - - - - - - CARBON MONOXIDE MONITOR

CHAPTER 9: - - - - - - - - PNEUMATIC VALVES AND CONTROLS

CHAPTER 10: - - - - - - - - - - - - - - - - - - - - - - INDICATORS

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

June 01, 2006 Page x

Page 1 1st ed. Rev. 0 Chg. 0

June 01, 2006 Page 2

Page 3 1st ed. Rev. 0 Chg. 0

June 01, 2006 Page 4

Voltage Frequency Phase Power RPM Type BAUER PN

1.6.2 Purification System Applicability

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

Page 5 1st ed. Rev. 0 Chg. 0

June 01, 2006 Page 6

Figure 2-1 Electrical Panel Front

1. Compressor Control Switch 4. Hourmeter

Page 7 1st ed. Rev. 0 Chg. 0

June 01, 2006 Page 8

Figure 2-2 PLC Figure 2-3 Status LEDs

120 VAC Supply Outputs

2.5.6.1 PLC LEDs

Page 9 1st ed. Rev. 0 Chg. 0

2.6.2 Two Flashes - Securus Monitor

June 01, 2006 Page 10

2.7.8 On Steady - Motor Starter Overload Trip

Page 11 1st ed. Rev. 0 Chg. 0

Figure 3-1 Four Stage Compressor Air Flow

June 01, 2006 Page 12

3.1.1.2 Component Location

Figure 3-2 IK150 II Compressor Block (Front View)

Page 13 1st ed. Rev. 0 Chg. 0

3.1.2 Lubrication System

Figure 3-3 Lubrication Oil System

1. Oil Pump 4. Injection Line to 4th Stage

June 01, 2006 Page 14