Bauer Compressors Mini Verticus ImVT 120 II - Air Processing Cartridge Operating Hours Form

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MNL-0408

June 11, 2009 Page 57

5.1.4.4 Air Processing Cartridge Operating Hours Form

Date

Operating

hours

Ambient temp.

during compression

Correction

factor

Adjusted cartridge hours

Today Total

Main Page

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 - Air Processing Cartridge Operating Hours Form

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