Bauer Compressors Mini Verticus ImVT 120 II

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MNL-0408

June 11, 2009 Page 35

Figure 3-24 (cont.) 2nd Stage Valves and Valve Head

# KIT Qty Part No. Description Notes

13 … † – Valve Insert Available only with 012835

14 a.. 1 N3521 O-ring

15 … 1 14332 Spring Washer

16 … 1 14124 Coupling

17 .b. 1 71064 Stud

18 a.. 1 N380 Gasket

19 … 1 N84 Cap Nut

20 … 6 SCR-0180 Allen Screw

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Default Chapter3
- Table of Contents3
Chapter 1 : - - - - - - - - - - - - - - - - - - - - - Introduction11
How to Use this Manual11
- Manual Safety Notices11
How to Use the Replacement Parts List12
- Figure 1-1 Compressor Identification Plate12
How to Use the Appendix13
Compressor Unit Design14
- Compressor Unit Major Assemblies14
- Figure 1-2 Imvt 120 II (AP) Front Panel14
- Figure 1-3 Imvt 120 II (AP) Rear View15
Technical Specifications16
- Compressor Block16
- Compressor Drive Motor16
- Purification System Applicability16
Chapter 2 : - - - - - - - -Plc Controlled Unit Operations17
Pre-Start Checks17
Start-Up Procedure17
Post Start Procedures17
Normal Operations17
Shutdown Procedures17
Electric Panel Components18
- Emergency Stop Switch18
- Starter Reset18
- Figure 2-1 Electrical Panel Front18
- Compressor Control Switch19
- 2-Position (Standard)19
- Indicator Lamps19
- PLC Warning and Alarm Lamps19
- Warning Lamp - Amber19
- Alarm Lamp - Red19
- Hourmeter19
- PLC Control19
Warnings19
- One Flash - Final Separator Warning19
- Two Flashes - Securus Monitor (Optional)20
Alarms20
- One Flash - Compressor High Temperature20
- Two Flashes - Compressor Low Oil Pressure20
- Three Flashes - Compressor Overtime20
- Four Flashes - Securus Monitor20
- Five Flashes - Carbon Monoxide Monitor (Optional)21
- Six Flashes - Final Separator Shutdown21
- Seven Flashes - Condensate Fault (OPT)21
- On Steady - Motor Starter Overload Trip21
Compressor Blocks - Ik120 II22
- Description22
- Component Location22
- Figure 3-1 IK120 II Compressor Block22
- Air Flow Diagram23
- Compressor Lubrication23
- Description23
- Figure 3-2 Air Flow Diagram23
- Type of Oil24
- Figure 3-3 Lubrication Oil Circuit24
- Oil Level Check25
- Figure 3-4 Oil Sight Glass25
- Figure 3-5 Oil Filler Cap25
- Figure 3-6 Removing the Oil Filter Cover25
- Figure 3-7 Replacing the Oil Filter25
- Oil Change26
- Venting the Oil Pump26
- Intake Filter27
- Description27
- Figure 3-8 Intake Filter27
- Intermediate Separator28
- Maintenance28
- Figure 3-9 Intermediate Separator28
- Cooling29
- General29
- Valves and Heads29
- Functional Description29
- Figure 3-10 Valve Operation29
- Figure 3-11 IK120II Plate Valve29
- General Instructions for Changing the Valves30
- Changing the IK120 II 1St Stage Valves30
- Figure 3-12 IK120 II 1St Stage Valve31
- IK120 II 2Nd Stage Valves32
- Removing the Valves of the 2Nd Stage32
- Figure 3-13 IK120 II 2Nd Stage Valves32
- Reassembling the Valves of the 2Nd Stage33
- Figure 3-14 Using the Special Tool, P/N 08204833
- Figure 3-15 Securing the Intake Valve33
- IK120 II 3Rd Stage Valves34
- Removing the Valves of the 3Rd Stage34
- Figure 3-16 IK120 II 3Rd Stage Valves34
- Reassembling the Valves of the 3Rd Stage35
- Figure 3-17 Removing the 3Rd Stage Pressure Valve35
- Replacement Parts List36
- Figure 3-18 Crankcase Assembly36
- Figure 3-19 Piston and Cylinder, 1St Stage, IK120 II38
- Figure 3-20 Piston and Cylinder, 2Nd Stage39
- Figure 3-21 Piston and Cylinder, 3Rd Stage40
- Figure 3-22 Piston and Sleeve, 3Rd Stage41
- Figure 3-23 1St Stage Valve Head and Valve, IK120 II42
- Figure 3-24 2Nd Stage Valves and Valve Head44
- Figure 3-25 3Rd Stage Valves and Valve Head46
- Figure 3-26 Flywheel47
- Figure 3-27 Intermediate Separator48
- Figure 3-28 Intake Filter49
- Figure 3-29 IK120 II Cooling System50
- Figure 3-30 Lubrication System Assembly52
- Troubleshooting54
- Troubleshooting Table54
Chapter 3 :- - - - - - - - - - - - - - Maintenance and Parts22
Three Stage Automatic Condensate Drain System55
- Description55
- Figure 3-31 Automatic Condensate Drain55
- Normal Operation56
- Condensate Drain56
- Start Unloading56
- Figure 3-32 ACD Operation Diagrams56
- Standstill Drainage57
- ACD Maintenance57
- ACD Replacement Parts List58
- Figure 3-33 ACD System58
- Figure 3-34 ACD Manifold Assembly59
- Figure 3-35 Condensate Drain Valve Assembly60
Condensate Collector62
- Figure 3-36 Condensate Collector62
- Condensate Collector Replacement Parts List63
- Figure 3-37 Condensate Collector63
Chapter 4 :- - - - - - - - - - Ik120 II Maintenance Schedule64
Ik120 II Maintenance Intervals64
- Maintenance Records64
Chapter 5 :- - - - - - - - - - - - - - - Air Processing System65
General65
- General Purification System Procedures65
- Chamber Safety Bore65
- Figure 5-1 Cartridge Safety Venting65
- Manual Condensate Drainage66
- Model, Serial Number and Part Number Identification66
- Compressor Dataplate66
- Purification System Dataplate66
- Cartridge Installation Dataplate66
- Figure 5-2 Purification System Dataplates (Typical)66
- Air Processing Cartridge Operating Hours Form67
P2S Purification System Major Components68
- Figure 5-3 P2S Purification System68
Component Description69
- Oil and Water Separator69
- Figure 5-4 Oil and Water Separator69
- Chamber70
- Cartridge70
- Cartridge Construction70
- Cartridge Handling70
- Figure 5-6 Cartridge70
- Figure 5-5 Oil and Water Separator Labels70
- Condensate Drain Valve71
- Check Valves71
- Bleed Valve71
- Pressure Maintaining Valve71
- Safety Valve71
- Securus ® Electronic Moisture Monitor System71
- Securus Cartridge71
- Securus Indicator71
Maintenance72
- Oil and Water Separator72
- Cartridge Replacement73
- Figure 5-7 Oil and Water Separator73
- Figure 5-8 Sintered Metal Filter Assembly73
- Figure 5-9 Cartridge Replacement73
- Leaking at the Safety Bore74
Replacement Parts List75
- Figure 5-10 P2S Purification System75
- Figure 5-11 Oil and Water Separator76
- Figure 5-12 Securus ® Electronic Moisture Monitor System78
Chapter 6 : - - - - - - - - - - - - - - - Compressor Unit Drive80
Vertical Self Tensioning80
Maintenance of the V-Belt and Sheaves80
- Check the Flywheel and Sheave80
- Check the V-Belt80
- Figure 6-1 Vertical Motor Mount (Typical)80
Chapter 7 : - - - - - - - - - - -Electrical Panel Assembly81
Overview81
- Figure 7-1 Electrical Panel Assembly81
Options82
Ac Power Requirements82
- Figure 7-2 Electrical Panel Label83
- Figure 7-3 Transformer and Fuses83
- Transformer and Fuses84
Electric Panel Components84
- Motor Starter84
- Overload Relay84
- Figure 7-4 Motor Starter and Overload Relay84
- Emergency Stop Switch85
- Starter Reset85
- Figure 7-5 Electrical Panel Assembly85
- Compressor Control Switches86
- 2-Position (Standard)86
- 3-Position Compressor Control Switch (Factory Installed Option)86
- For Breathing Air Units86
- For Industrial Units86
- Indicator Lamps86
- PLC Warning and Alarm Lamps86
- Warning Lamp - Amber86
- Alarm Lamp - Red86
- Hour Meter86
- PLC Led's87
- Figure 7-6 PLC CNT-005287
- Figure 7-7 Status Lights87
- Compressor PLC Program Versions88
- PLC Inputs and Outputs88
Warnings89
- One Flash - Final Separator Warning89
- Two Flashes - Securus Monitor Warning90
Alarms90
- Figure 7-8 Securus ® System90
- One Flash - Compressor High Temperature91
- Two Flashes - Compressor Low Oil Pressure91
- Three Flashes - Compressor Overrun Timer91
- Four Flashes - Securus Monitor91
- Figure 7-9 High Temperature Switch91
- Figure 7-10 Low Oil Pressure Switch91
- Five Flashes - Carbon Monoxide Monitor Alarm92
- Six Flashes - Final Separator Shutdown92
- Figure 7-11 CO Monitor92
- Seven Flashes - Condensate Fault93
- Figure 7-12 Condensate Level Float Switch93
- On Steady - Motor Starter Overload Trip94
Installing a New Program94
- Figure 7-13 PLC Programming Port94
- Installing a New Program Using an EEPROM Cartridge95
- Figure 7-14 PLC EEPROM95
Overrun Timer96
- Adjusting the Overrun Timer96
- Figure 7-15 Overrun Timer Adjustment96
Wire Harness Connections97
Replacement Parts List98
- Figure 7-16 Electrical Panel98
Trouble Shooting Guide99
- Compressor will Not Start99
- Compressor Is Shutdown, Alarm Code Flashing Sequence99
- One Flash - Compressor High Temperature99
- Two Flashes - Compressor Low Oil Pressure99
- Three Flashes - Compressor Overtime99
- Four Flashes - Securus Alarm100
- Five Flashes - Carbon Monoxide Monitor Alarm100
- Six Flashes - Final Separator Shutdown100
- Seven Flashes -Condensate Fault100
- On Steady - Motor over Load Trip101
- Eight Flashes - High Inlet Pressure (Gas Compressors Only)101
- Nine Flashes - Low Inlet Vacuum (Gas Compressors Only)101
Check Compressor Rotation Direction102
- Figure 7-17 Checking Compressor Rotation Direction102
Plc Industrial Compressor Wiring Diagram103
Chapter 8 :- - - - - - - - Pneumatic Valves and Controls104
Nonadjustable Valves104
Pressure Maintaining Valve104
- Figure 8-1 Pressure Maintaining Valve104
Safety Valves105
- Figure 8-2 Safety Valve105
Digital Pressure Switch106
Programming the Pressure Switch106
- Figure 8-3 Digital Pressure Switch106
- Selecting the Display Units107
- Selecting the Unit Display107
- Selecting the on Point for the Pressure Switch107
- Selecting the off Point for the Pressure Switch108
- Locking and Unlocking the Switch108
Replacement Parts List109
- Figure 8-4 Switches and Valves109
Chapter 9110
Safety110
- General Safety Precautions110
- Safety Warning Labels112
Unpacking, Handling and Installation113
- Unpacking and Handling113
- Figure 9-1 Lifting Devices113
- Installation of the Compressor Unit114
- General114
- Ventilation114
- Outdoor Installation114
- Indoor Installation115
- Natural Ventilation115
- Forced Ventilation116
- Electrical Installation116
- Electric Drive116
- Electrical Supply116
- Figure 9-2 Incoming Power Wiring Label117
Long Term Storage119
- General119
- Preparations119
- Units Equipped with a Filter System119
- Preserving the Compressor119
- Preventive Maintenance During Storage120
- Lubrication Oils for Preservation120
- Reactivating the Compressor Unit120
Reproducible Forms121
- Scheduled Maintenance Form121
- Record of Operating Hours124
Reference Data125
- Tightening Torque Values125
- Torque Sequence Diagrams125
- Conversion Formulas125
- Figure 9-3 6 Bolt and 4 Bolt Torque Sequence125
- Approved Lubricants Chart126
- Glossary of Abbreviations and Acronyms126
Additional Documents127
- Diagrams and Drawings127
- Other Documents127

Bauer Compressors Mini Verticus ImVT 120 II - Page 45

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