Instruction Manual and Replacement Parts List

Portable Dive
High Pressure Breathing Air Compressor
DMT 06 DMT 08

October 23, 2012 1st Edition, Rev. 0, Chg. 4 MNL-0146

© 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
 Dive Mate

This information is believed to be accurate by Bauer Compressors, Inc., as of it’s date of publication,
but Bauer offers NO WARRANTY regarding the accuracy, or continuing accuracy, of the information
set forth herein. Bauer shall not be liable for inaccuracies in, or consequences resulting from, your use
of this information. All information supplied is in connection with sales of Bauer’s products, and is thus
subject to Bauer’s standard terms and conditions of sale. Bauer reserves the right to change this infor-
mation and has no obligation to update these materials. This information is copyrighted by Bauer Com-
pressors, Inc., and Bauer reserves to itself all rights to this publication. Bauer’s customers have no right
to reproduce, rewrite, modify, license or permit anyone else’s use of this information, without the
express written permission of Bauer Compressors, Inc.

^ WARNING
This Instruction Manual and Replacement Parts List contains safety information and instructions
for the Dive Mate High Pressure Breathing Air Compressor.
You must read, understand and follow all safety precautions and instructions.

EDITIONS, REVISIONS AND CHANGES

• An Edition is the original or a complete rewriting of the entire Manual.
• A Revision occurs whenever a complete Section or Appendix is rewritten or added.
• A Change occurs when individual pages, drawings or tables are changed.

1st Edition: February 4, 2010

Rev Chg Date Notes Auth

0 0 Feb. 4, 2010 Converted from MNL-87994 SS
0 1 Oct. 19, 2010 Added 50 Hz motor drive SS
0 2 Mar. 26, 2012 Added Dual Pressure Assembly SS
0 3 Apr. 11, 2012 Updated Compressor Block Chapter SS
0 4 Oct. 23, 2012 Added Belt Guard Part Numbers SS

Page i 1st Edition, Rev. 0, Chg. 4

MNL-0146
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 DESCRIPTION.................................................................................................................................................................... 4
1.4.1 Standard Features: .............................................................................................................................................................. 4
1.4.2 Factory Installed Optional Features: .................................................................................................................................. 4
1.4.3 Dealer Installed Options:.................................................................................................................................................... 4
1.5 SPECIFICATIONS ............................................................................................................................................................ 5
1.5.1 DMT 06 .............................................................................................................................................................................. 5
1.5.2 Compressor Block .............................................................................................................................................................. 5
1.5.3 Compressor Drive ............................................................................................................................................................. 5
1.6 PURIFICATION SYSTEM APPLICABILITY ............................................................................................................... 5
1.6.1 DMT 08 .............................................................................................................................................................................. 6
1.6.2 Compressor Block .............................................................................................................................................................. 6
1.6.3 Compressor Drive ............................................................................................................................................................. 6
1.6.4 Purification System Applicability ...................................................................................................................................... 6
1.7 COMPONENT LOCATION .............................................................................................................................................. 7

CHAPTER 2: - - - - - - - - - - OPERATIONS; ELECTRIC MODELS

2.1 PRE-START PROCEDURE ............................................................................................................................................... 8
2.2 START-UP PROCEDURE ................................................................................................................................................. 8
2.3 POST START PROCEDURES .......................................................................................................................................... 9
2.4 SHUTDOWN PROCEDURES ........................................................................................................................................... 9

CHAPTER 3: - - - - - - - - - - - - - IK120 II COMPRESSOR BLOCK

3.1 MAINTENANCE AND PARTS ....................................................................................................................................... 10
3.1.1 Description ....................................................................................................................................................................... 10
3.1.2 Component Location ........................................................................................................................................................ 10
3.1.3 Air Flow Diagram ............................................................................................................................................................ 11
3.1.4 Compressor Lubrication................................................................................................................................................... 11
3.1.4.1 Description.................................................................................................................................................................... 11
3.1.4.2 Type of Oil.................................................................................................................................................................... 12
3.1.4.3 Oil Level Check............................................................................................................................................................ 13
3.1.4.4 Oil Change .................................................................................................................................................................... 14
3.1.4.5 Venting the Oil Pump ................................................................................................................................................... 14
3.1.5 Intake Filter. ..................................................................................................................................................................... 15
3.1.5.1 Description.................................................................................................................................................................... 15
3.1.6 Intermediate Separator ..................................................................................................................................................... 16

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3.1.6.1 Maintenance..................................................................................................................................................................16
3.1.7 Cooling .............................................................................................................................................................................17
3.1.7.1 General..........................................................................................................................................................................17
3.1.8 Valves and Heads .............................................................................................................................................................17
3.1.8.1 Functional Description..................................................................................................................................................17
3.1.8.2 General Instructions for Changing the Valves..............................................................................................................18
3.1.8.3 Changing the IK120 II 1st Stage Valves ......................................................................................................................19
3.1.8.4 IK120 II 2nd Stage Valves............................................................................................................................................19
3.1.8.4.1 Removing the Valves of the 2nd Stage.........................................................................................................................19
3.1.8.4.2 Reassembling the Valves of the 2nd Stage. ..................................................................................................................21
3.1.8.5 IK120 II 3rd Stage Valves ............................................................................................................................................22
3.1.8.5.1 Removing the Valves of the 3rd Stage .........................................................................................................................22
3.1.8.5.2 Reassembling the Valves of the 3rd Stage....................................................................................................................23
3.1.9 Replacement Parts List .....................................................................................................................................................24
3.1.10 Troubleshooting................................................................................................................................................................42
3.1.10.1 Troubleshooting Table ..................................................................................................................................................42
3.2 MANUAL CONDENSATE DRAIN SYSTEM ...............................................................................................................43
3.2.1 Description .......................................................................................................................................................................43
3.2.2 Operation ..........................................................................................................................................................................43
3.2.3 Unloaded start...................................................................................................................................................................43
3.3 REPLACEMENT PARTS ................................................................................................................................................44
3.4 THREE STAGE AUTOMATIC CONDENSATE DRAIN SYSTEM...........................................................................45
3.4.1 Description .......................................................................................................................................................................45
3.4.1.1 Normal Operation .........................................................................................................................................................46
3.4.1.2 Condensate Drain..........................................................................................................................................................46
3.4.1.3 Start Unloading .............................................................................................................................................................46
3.4.1.4 Standstill Drainage........................................................................................................................................................47
3.4.2 Component Description....................................................................................................................................................47
3.4.2.1 Condensate Drain Piping ..............................................................................................................................................47
3.4.2.2 Electrical Connection....................................................................................................................................................47
3.4.2.3 Separator/Silencer .........................................................................................................................................................47
3.4.3 ACD Maintenance ............................................................................................................................................................47
3.5 CONDENSATE COLLECTOR .......................................................................................................................................48
3.5.1 ACD Replacement Parts List............................................................................................................................................49
3.5.2 Trouble shooting...............................................................................................................................................................52

CHAPTER 4:- - - - - - - DIVE MATE MAINTENANCE SCHEDULE

4.1 DIVE MATE MAINTENANCE INTERVALS...............................................................................................................53
4.1.1 Maintenance Records .......................................................................................................................................................53

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

5.1 INTRODUCTION..............................................................................................................................................................54
5.1.1 General Purification System Procedures ..........................................................................................................................54
5.1.2 Chamber Safety Bore .......................................................................................................................................................54
5.1.3 Manual Condensate Drainage...........................................................................................................................................55
5.1.4 Model, Serial Number and Part Number Identification ...................................................................................................55
5.1.4.1 Compressor Dataplate...................................................................................................................................................55

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MNL-0146
5.1.4.2 Purification System Dataplate ...................................................................................................................................... 56
5.1.4.3 Cartridge Installation Dataplate.................................................................................................................................... 56
5.1.5 Breathing Air Purification System Configurations .......................................................................................................... 56
5.1.6 Industrial Purification System Configurations................................................................................................................. 57
5.1.7 Cartridge Operating Life .................................................................................................................................................. 57
5.1.7.1 Calculating the Maximum Cartridge Operating Hours ................................................................................................ 58
5.1.7.2 Calculating the Adjusted Cartridge Operating Hours................................................................................................... 58
5.1.7.3 Air Purification Cartridge Operating Hours Form........................................................................................................ 60
5.2 P31 PURIFICATION SYSTEM....................................................................................................................................... 61
5.2.1 Major Components........................................................................................................................................................... 61
5.2.2 Configuration Options...................................................................................................................................................... 62
5.2.3 Maintenance ..................................................................................................................................................................... 62
5.2.3.1 Replacing the Cartridge ................................................................................................................................................ 62
5.2.3.2 Chamber Replacement Interval ................................................................................................................................... 63
5.2.4 Replacement Parts List..................................................................................................................................................... 64
5.3 P41 PURIFICATION SYSTEM (DIVE 07) .................................................................................................................... 67
5.3.1 Major Components........................................................................................................................................................... 67
5.3.2 Configuration Options...................................................................................................................................................... 67
5.3.3 Component Description.................................................................................................................................................... 68
5.3.3.1 Oil and Water Separator ............................................................................................................................................... 68
5.3.3.2 Chamber........................................................................................................................................................................ 69
5.3.3.3 Cartridge Construction.................................................................................................................................................. 69
5.3.3.4 Cartridge Handling ....................................................................................................................................................... 70
5.3.3.5 Condensate Drain Valve ............................................................................................................................................... 70
5.3.3.6 Check Valves ................................................................................................................................................................ 70
5.3.3.7 Bleed Valve .................................................................................................................................................................. 70
5.3.3.8 Pressure Maintaining Valve.......................................................................................................................................... 70
5.3.3.9 Safety Valve.................................................................................................................................................................. 70
5.3.3.10 Securus® Electronic Moisture Monitor System........................................................................................................... 70
5.3.3.11 Securus® Cartridge ...................................................................................................................................................... 71
5.3.3.12 Securus® Indicator ....................................................................................................................................................... 71
5.3.4 Maintenance ..................................................................................................................................................................... 71
5.3.4.1 Oil & Water (condensate) Separator............................................................................................................................. 71
5.3.4.2 Cartridge Replacement ................................................................................................................................................. 73
5.3.4.3 Leaking at the Safety Bore ........................................................................................................................................... 73
5.3.5 Replacement Parts List..................................................................................................................................................... 75

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

6.1 DESCRIPTION, HORIZONTAL SLIDING .................................................................................................................. 80
6.2 MAINTENANCE OF THE V-BELT AND SHEAVE .................................................................................................... 80
6.2.1 Checking the Sheave. ....................................................................................................................................................... 80
6.2.2 Checking the V-belt ......................................................................................................................................................... 80
6.2.3 V-belt tension ................................................................................................................................................................... 80
6.3 MAINTENANCE OF THE DRIVE MOTOR ................................................................................................................ 81
6.4 REPLACEMENT PARTS LIST ...................................................................................................................................... 82

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CHAPTER 7:- - - - - -ELECTRICAL ASSEMBLY; MOTOR DRIVEN

7.1 OVERVIEW .......................................................................................................................................................................84
7.2 COMPONENTS .................................................................................................................................................................84
7.2.1 Control Switch..................................................................................................................................................................84
7.2.2 Hour Meter .......................................................................................................................................................................84
7.2.3 Motor Reset Button ..........................................................................................................................................................84
7.2.4 Emergency Stop Button....................................................................................................................................................84
7.2.5 Temperature Switch..........................................................................................................................................................84
7.2.6 Final Pressure Switch .......................................................................................................................................................85
7.3 ELECTRICAL INSTALLATION....................................................................................................................................85
7.4 REPLACEMENT PARTS LIST ......................................................................................................................................86
7.5 PARTS LIST FOR MODELS WITH A 5 HORSEPOWER MOTOR.........................................................................88
7.6 PARTS LIST FOR MODELS WITH A 7.5 HORSEPOWER MOTOR......................................................................88

CHAPTER 8:- - - - - - - - - - - - - - - - -INDICATORS & VALVES

8.1 DESCRIPTION ..................................................................................................................................................................89
8.2 REPLACEMENT PARTS LIST ......................................................................................................................................89
8.1 NONADJUSTABLE VALVES .........................................................................................................................................91
8.2 PRESSURE MAINTAINING VALVE.............................................................................................................................91
8.3 SAFETY VALVES .............................................................................................................................................................92
8.4 DUAL PRESSURE CONTROL ASSEMBLY ................................................................................................................93
8.4.1 General .............................................................................................................................................................................93
8.4.2 Replacement Parts ............................................................................................................................................................94

CHAPTER 9:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

9.1 SAFETY ..............................................................................................................................................................................95
9.1.1 General Safety Precautions...............................................................................................................................................95
9.1.2 Safety Warning Labels .....................................................................................................................................................97
9.2 UNPACKING, HANDLING AND INSTALLATION....................................................................................................98
9.2.1 Unpacking and Handling..................................................................................................................................................98
9.2.2 Installation of the Compressor Unit .................................................................................................................................99
9.2.2.1 General..........................................................................................................................................................................99
9.2.2.2 Ventilation ..................................................................................................................................................................100
9.2.2.2.1 Outdoor Installation ....................................................................................................................................................100
9.2.2.2.2 Indoor Installation.......................................................................................................................................................100
9.2.2.2.3 Natural Ventilation .....................................................................................................................................................100
9.2.2.2.4 Forced Ventilation ......................................................................................................................................................101
9.2.3 Intake Air........................................................................................................................................................................101
9.2.3.1 Inside Air Source ........................................................................................................................................................101
9.2.3.2 Outside Air Source......................................................................................................................................................102
9.2.4 Compressor Intake Piping ..............................................................................................................................................102
9.2.5 Installation Procedures ...................................................................................................................................................103

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MNL-0146
9.2.6 Electrical Installation...................................................................................................................................................... 103
9.2.6.1 Electric Drive.............................................................................................................................................................. 103
9.2.6.2 Electrical Supply......................................................................................................................................................... 103
9.2.7 Pneumatic Leaks ............................................................................................................................................................ 105
9.3 LONG TERM STORAGE............................................................................................................................................... 106
9.3.1 General ........................................................................................................................................................................... 106
9.3.2 Preparations.................................................................................................................................................................... 106
9.3.2.1 Units Equipped with a Filter System .......................................................................................................................... 106
9.3.3 Preserving the Compressor............................................................................................................................................. 106
9.3.4 Preventive Maintenance During Storage........................................................................................................................ 107
9.3.5 Lubrication Oils for Preservation ................................................................................................................................... 107
9.3.6 Reactivating the Compressor Unit ................................................................................................................................. 107
9.4 REPRODUCIBLE FORMS ............................................................................................................................................ 108
9.4.1 Scheduled Maintenance Form ........................................................................................................................................ 108
9.4.2 Record of Operating Hours ............................................................................................................................................ 111
9.5 REFERENCE DATA....................................................................................................................................................... 112
9.5.1 Tightening Torque Values.............................................................................................................................................. 112
9.5.2 Torque Sequence Diagrams ........................................................................................................................................... 112
9.5.3 Conversion Formulas ..................................................................................................................................................... 112
9.5.4 Approved Lubricants Chart............................................................................................................................................ 113
9.5.5 Glossary of Abbreviations and Acronyms ..................................................................................................................... 113
9.6 ADDITIONAL DOCUMENTS ...................................................................................................................................... 114
9.6.1 Diagrams and Drawings ................................................................................................................................................. 114
9.6.2 Other Documents............................................................................................................................................................ 114

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List of Figures

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

Figure 1-1 Compressor Identification Label .............................................................................................................................2
Figure 1-2 Dive Mate ................................................................................................................................................................7

CHAPTER 2:- - - - - - - - - - OPERATIONS; ELECTRIC MODELS

Figure 2-1 Electrical Components.............................................................................................................................................8

CHAPTER 3:- - - - - - - - - - - - - IK120 II COMPRESSOR BLOCK

Figure 3-1 IK120 II Compressor Block...................................................................................................................................10
Figure 3-2 Air Flow Diagram..................................................................................................................................................11
Figure 3-3 Lubrication Oil Circuit ..........................................................................................................................................12
Figure 3-4 Oil Sight Glass.......................................................................................................................................................13
Figure 3-5 Oil Filler Cap .........................................................................................................................................................13
Figure 3-6 Removing the Oil Filter Cover ..............................................................................................................................13
Figure 3-7 Replacing the Oil Filter .........................................................................................................................................13
Figure 3-8 Intake Filter............................................................................................................................................................15
Figure 3-9 Intermediate Separator...........................................................................................................................................16
Figure 3-10 Valve Operation.....................................................................................................................................................17
Figure 3-11 IK120II Plate Valve...............................................................................................................................................17
Figure 3-12 IK120 II 1st Stage Valve .......................................................................................................................................18
Figure 3-13 IK120 II 2nd Stage Valves ....................................................................................................................................19
Figure 3-14 Using the Special Valve Tool ................................................................................................................................20
Figure 3-15 Securing the Intake Valve......................................................................................................................................20
Figure 3-16 IK120 II 3rd Stage Valves .....................................................................................................................................22
Figure 3-17 Removing the 3rd Stage Pressure Valve ...............................................................................................................23
Figure 3-18 Crankcase Assembly..............................................................................................................................................24
Figure 3-19 Piston and Cylinder, 1st Stage, IK120 II ...............................................................................................................26
Figure 3-20 Piston and Cylinder, 2nd Stage..............................................................................................................................27
Figure 3-21 Piston and Cylinder, 3rd Stage ..............................................................................................................................28
Figure 3-22 Piston and Sleeve, 3rd Stage..................................................................................................................................29
Figure 3-23 1st Stage Valve Head and Valve, IK120 II............................................................................................................30
Figure 3-24 2nd Stage Valves and Valve Head.........................................................................................................................32
Figure 3-25 3rd Stage Valves and Valve Head .........................................................................................................................34
Figure 3-26 Flywheel ................................................................................................................................................................35
Figure 3-27 Intermediate Separator...........................................................................................................................................36
Figure 3-28 Intake Filter............................................................................................................................................................37
Figure 3-29 IK120 II Cooling System.......................................................................................................................................38
Figure 3-30 Lubrication System Assembly...............................................................................................................................40
Figure 3-31 Manual Condensate Drains....................................................................................................................................43
Figure 3-32 Manual Drains .......................................................................................................................................................44
Figure 3-33 Automatic Condensate Drain.................................................................................................................................45
Figure 3-34 ACD Operation Diagrams .....................................................................................................................................46

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MNL-0146
Figure 3-35 Condensate Collector............................................................................................................................................. 48
Figure 3-36 3 Stage ACD System ............................................................................................................................................. 49
Figure 3-37 Condensate Drain Valve........................................................................................................................................ 50

CHAPTER 4: - - - - - - - DIVE MATE MAINTENANCE SCHEDULE

There are no Figures in this Chapter

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

Figure 5-1 Cartridge Safety Venting....................................................................................................................................... 55
Figure 5-2 P0 & P31 Safety Venting ...................................................................................................................................... 55
Figure 5-3 Purification System Dataplates (typical) ............................................................................................................... 55
Figure 5-4 Correction Factor for Cartridge Operating Hours ................................................................................................. 59
Figure 5-5 Example Record of Adjusted Operating Hours..................................................................................................... 59
Figure 5-6 P31 Purification System ........................................................................................................................................ 61
Figure 5-7 P31 Purification System Cross Section ................................................................................................................. 62
Figure 5-8 P31 Purification System Parts List ........................................................................................................................ 64
Figure 5-9 P31 Purification System Base Assembly Parts List .............................................................................................. 65
Figure 5-10 P31 Purification System Check Valve Parts List .................................................................................................. 66
Figure 5-11 P41 Purification System ........................................................................................................................................ 67
Figure 5-12 P41S Purification System ...................................................................................................................................... 68
Figure 5-13 Oil and Water Separator ........................................................................................................................................ 69
Figure 5-14 Oil and Water Separator Labels ............................................................................................................................ 69
Figure 5-15 Oil and Water Separator ........................................................................................................................................ 72
Figure 5-16 Sintered Metal Filter Assembly............................................................................................................................. 72
Figure 5-17 Cartridge Replacement .......................................................................................................................................... 73
Figure 5-18 P41 Purification System Parts List ........................................................................................................................ 75
Figure 5-19 P41 Oil and Water Separator Parts List................................................................................................................. 76
Figure 5-20 Purification Chamber Assembly Parts List ........................................................................................................... 77
Figure 5-21 Securus® Electronic Moisture Monitor System Parts List ................................................................................... 78

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

Figure 6-1 Horizontal Engine Mount (typical) ....................................................................................................................... 80
Figure 6-2 Sliding Motor Base Adjustment ............................................................................................................................ 81
Figure 6-3 V-belt Deflection ................................................................................................................................................... 81
Figure 6-4 Dive Mate Drive Parts ........................................................................................................................................... 82

CHAPTER 7: - - - - - ELECTRICAL ASSEMBLY; MOTOR DRIVEN

Figure 7-1 Electrical Components........................................................................................................................................... 84
Figure 7-2 Temperature Switch............................................................................................................................................... 85
Figure 7-3 Final Pressure Switch ............................................................................................................................................ 85
Figure 7-4 Electrical Components, Exterior ........................................................................................................................... 86
Figure 7-5 Electrical Box, Interior .......................................................................................................................................... 87

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CHAPTER 8:- - - - - - - - - - - - - - - - -INDICATORS & VALVES

Figure 8-1 Indicators ...............................................................................................................................................................89
Figure 8-1 Check Valve...........................................................................................................................................................91
Figure 8-2 Pressure Maintaining Valves (PMV).....................................................................................................................91
Figure 8-3 Safety Valves .........................................................................................................................................................92
Figure 8-4 Dual Pressure Assembly ........................................................................................................................................93
Figure 8-5 Dual Pressure Assembly ........................................................................................................................................94

CHAPTER 9:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

Figure 9-1 Lifting Devices ......................................................................................................................................................98
Figure 9-2 Leveling Feet .........................................................................................................................................................99
Figure 9-3 Example of Air Intake Piping ..............................................................................................................................103
Figure 9-4 Incoming Power Wiring Label ............................................................................................................................104
Figure 9-5 6 Bolt and 4 Bolt Torque Sequence.....................................................................................................................112

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MNL-0146

CHAPTER 1: INTRODUCTION
1.1 How To Use This Manual
This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod-
ucts 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 con-
sequences 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 seri-
ous 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 mod-
erate injury. It may also be used to alert against unsafe practices.

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

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1.2 How to Use the Replacement Parts List
• A lozenge  in the Item Number column indicates the part number for a complete assembly.
• a dagger (†) in the Qty column with or without an ellipse (…) in the Part Number column means the
part is illustrated for assembly purposes only and is not available for sale as an individual component.
This part can be obtained by ordering the complete assembly.
• AR in the Qty column means that the item is cut or manufactured to the size which the customer 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 letters in the columns labeled Kit indicate the number of operating hours when the part is to be
replaced; a = replaced every 1,000 hours, b = replaced every 2,000 hours and c= replaced every 4,000
hours.
• NS in the Item Number column indicates the part is not illustrated but is available.
When placing an order for spare parts, please provide the following information to ensure delivery of the
correct parts. The model number, date of manufacture and serial number can be found of the compressor
unit identification plate on the compressor unit frame.

Information Example
Model Number MVT 13
Serial Number 133165
Date of Manufacture 06/2012
Part Number VAL-0169
Part Description Valve
Part Quantity Required 1

Figure 1-1 Compressor Identification Label

BAUER COMPRESSORS, INC.

NORFOLK, VA 23502 U.S.A. (757) 855-6006

MODEL NO.
BLOCK NO.
SERIAL NO.
QUANTITY
MFG. DATE

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MNL-0146

^ WARNING
The use of repair parts other than those included in the Bauer Replacement Parts Lists may create unsafe
conditions over which Bauer has no control. Such unsafe conditions can lead to accidents that may be life-
threatening, cause substantial bodily injury, and/or result in damage to the equipment. Therefore, Bauer
Compressors, Inc. can bear no responsibility for equipment in which unapproved repair parts are installed.

1.3 How to Use the Appendix

Information contained in the Appendix to this manual includes the following.
• The safety instructions applicable to this product. They must be read, understood and complied with
prior to operating the product.
• The instructions for installing this product. They must be read, understood and complied with prior to
operating the product.
• The instructions for long term storage (over 90 days) of this product.
• Reproducible Forms
• Reference Data
• Torque Values
• Torque Sequence
• Conversion Formulas
• Approved Lubricants
• Glossary of Abbreviations & Acronyms
• Additional Documents

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1.4 Description
The BAUER DMT 06, & DMT 08 capacities are up to 6.0 & 8.4 scfm charging rate respectively, with
discharge pressures up to 5,000 psig.

1.4.1 Standard Features:

• BAUER Breathing Air Purification System
• Pressure Switch
• Stainless Steel Intercoolers and aftercooler
• Inlet Filter
• Vibration Isolators
• High Temperature Switch
• Motor Starter with NEMA 12/13 Enclosure
• Hour Meter

1.4.2 Factory Installed Optional Features:

The following optional items may have been added if ordered at time of manufacture.
• Interstage Gauges
• CO Indicator
• 50 Hz Electrical System
• Purification Upgrades
• ACD (Electrical and Gasoline Models)

1.4.3 Dealer Installed Options:

• B-Timer
• Lift Handles
• Crash Cart (with integral lifting handles)
• Wheels (requires either lifting handles or crash cart options)

Page 4 1st Edition, Rev. 0, Chg. 4

MNL-0146
1.5 Specifications

1.5.1 DMT 06
Medium air
Charging Rate 6 scfm (170 l/min)1
Free Air Delivery 5 scfm (141 l/min)2
Inlet pressure atmospheric
Operating pressure, max. 5,000 psig (350 bar)
Ambient temperature range 40 - 115 °F (5 - 45 °C)
Weight approx. 350 lbs. (159 kg)
1.5.2 Compressor Block
IK120 II Mod. 7
No. of stages 3
No. of cylinders 3
Cylinder bore, 1st stage 3.46 in. (88 mm)
Cylinder bore, 2nd stage 1.42 in. (36 mm)
Cylinder bore, 3rd stage 0.55 in. (14 mm)
Piston Stroke 1.57 in.(40 mm)
Intermediate pressure, 1st stage 85 - 100 psig (6 - 7 bar)
Safety valve setting, 1st stage 130 psig (9 bar)
Intermediate pressure, 2nd stage 580 - 710 psig (40 - 49 bar)
Safety valve setting, 2nd stage 870 psig (60 bar)
Direction of rotation when facing flywheel CCW
Compressor speed 1,250 RPM
Oil capacity approx. 3 qts.(2.8 liter)
Oil Pressure 60 - 85 psig (4 - 6 bar)
Recommended oil BAUER OIL-0024
Maximum Inclination 15° in all directions
1.5.3 Compressor Drive

Voltage Freq. Phase Power RPM Type BAUER PN

208 - 230 60 Hz  5 Hp 3,600 ODP MTR-0023
208 - 460 60 Hz 3 5 Hp 3,600 ODP MTR-0022

1.6 Purification System Applicability

The DMT 06 is equipped with the Bauer P0 Purification System.

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

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

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1.6.1 DMT 08
Medium air
Charging Rate 8.4 scfm (238 l/min)1
Free Air Delivery 7 scfm (198 l/min)2
Inlet pressure atmospheric
Operating pressure, max. 5,000 psig (350 bar)
Ambient temperature range 40 - 115 °F (5 - 45 °C)
Weight approx. 465 lbs. (210 kg)

1.6.2 Compressor Block

IK120 II Mod. 7
No. of stages 3
No. of cylinders 3
Cylinder bore, 1st stage 3.46 in. (88 mm)
Cylinder bore, 2nd stage 1.42 in. (36 mm)
Cylinder bore, 3rd stage 0.55 in. (14 mm)
Piston Stroke 1.57 in.(40 mm)
Intermediate pressure, 1st stage 85 - 100 psig (6 - 7 bar)
Safety valve setting, 1st stage 130 psig (9 bar)
Intermediate pressure, 2nd stage 580 - 710 psig (40 - 49 bar)
Safety valve setting, 2nd stage 870 psig (60 bar)
Direction of rotation when facing flywheel CCW
Compressor speed 1,250 RPM
Oil capacity approx. 3 qts.(2.8 liter)
Oil Pressure 60 - 85 psig (4 - 6 bar)
Recommended oil BAUER OIL-0024
Maximum Inclination 15° in all directions
1.6.3 Compressor Drive

Voltage Freq. Phase Power RPM Type BAUER PN

208 - 230 VAC 60 Hz  7.5 Hp 3,600 ODP MTR-0052
208 - 460 VAC 60 Hz  7.5 Hp 3,600 ODP MTR-0033
380 - 415 VAC 50 Hz  7.5 Hp 3,000 ODP MTR-0208

1.6.4 Purification System Applicability

The DMT 08 is equipped with the Bauer P31 Purification System.

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

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

Page 6 1st Edition, Rev. 0, Chg. 4

MNL-0146
1.7 Component Location

Figure 1-2 Dive Mate

6 7 8 9 10

2
11

3 12

5
1. Control Switch 7. Drive Motor
2. Hour Meter 8. Automatic Condensate Drain
3. Condensate Collection Tank 9. IK 120 II Compressor Block
4. Condensate Separator / Silencer 10. Final Safety Valve
5. Outlet Orifice 11. P31 Purification Assembly
6. Emergency Stop Button (E-stop) 12. Final Pressure Switch

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CHAPTER 2: OPERATIONS; ELECTRIC MODELS

2.1 Pre-Start Procedure

1. Ensure that all scheduled maintenance is completed.
2. Check compressor oil level. Refer to Chapter 3.
3. Verify that all connections downstream of the compressor are secure.
4. Open the condensate drain valves to relieve any remaining pressure.
5. Close the condensate drain valves.

2.2 Start-up Procedure

Figure 2-1 Electrical Components

4
1

1. Control Switch
2. Hour Meter
3. Starter Reset
4. Emergency Stop
1. Apply electric power to the unit.
2. Turn the Control Switch on by pressing the green button.
3. The compressor will run and shut down when it reaches final pressure.

NOTICE
The E-Stop can be pressed down in an emergency
to stop the motor and compressor.

Page 8 1st Edition, Rev. 0, Chg. 4

MNL-0146

2.3 Post Start Procedures

1. Allow the compressor to build up pressure.
2. Listen to the unit as it operates. If excessive knocking or vibrations are observed shut down the unit.
3. Monitor the automatic condensate drain valves, they should drain for 6 seconds, every 15 minutes
of operation.
2.4 Shutdown Procedures
1. Verify all valves downstream are closed.
2. Turn the Control Switch OFF by pressing the red button on the control switch.
3. After shutting down the compressor drive, open the manual condensate drain valves to relieve any
remaining pressure and drain any moisture from the intermediate separators and the purification
system.
4. Close the condensate valves.
5. If the compressor is to remain idle for six months or longer, refer to the Appendix section titled,
Long Term Storage for preservation instructions.

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CHAPTER 3: IK120 II COMPRESSOR BLOCK
3.1 Maintenance and Parts
3.1.1 Description
The IK120 II compressor is used to compress air up to 5,000 psi. The compressor is a three cylinder, three
stage air cooled, oil lubricated reciprocating compressor. The 3rd stage cylinder is lubricated by means of
the forced feed lubrication system, while the other cylinders are splash lubricated. The cylinders are
arranged in a “W” configuration, the 1st stage is in the center, 2nd stage on the right and 3rd stage on the
left looking from the filter side. This compressor block is particularly suitable for continuous operation
because of the rugged design and corrosion resistant intermediate filter and cooler assemblies.
3.1.2 Component Location

Figure 3-1 IK120 II Compressor Block

1
2 10
3
4
5 11

12
6

13
8

14

15
16
9

1. 1st Stage Cylinder 6. Oil Filter Housing 11. Aftercooler

2. Intake Filter 7. 2nd Stage Intermediate Separator 12. 2nd Stage Cylinder
3. Oil Filler Neck 8. 2nd Stage Intercooler 13. 1st Stage Intercooler
4. 3rd Stage Cylinder 9. Condensate Drain Connection 14. Oil Drain Tap
5. 2nd Stage Safety Valve 10. 1st Stage Safety Valve 15. Air Outlet Connection

Page 10 1st Edition, Rev. 0, Chg. 4

MNL-0146
3.1.3 Air Flow Diagram
Refer to Figure 3-2. The air is drawn in through intake filter (1), compressed to the final pressure in cylin-
ders (2, 3, 4,) and cooled by intercoolers (5, 6) and aftercooler (7). The safety valves (8,9, 10) protect
from overpressure in the individual stages. The compressed air is filtered by intermediate separator (11)
and oil and water separator assembly (12). The intermediate separator (11) and oil and water separator
(12) are drained by condensate valves (14). An Automatic Condensate Drain system is available as an
option. The pressure maintaining valve (13) ensures that pressure is built up in the purification system
from the start of delivery, thus achieving constant optimum purification. The parts in the shaded box are
part of the Purification System which may be a factory installed option.

Figure 3-2 Air Flow Diagram

7
1
9 2 10
13
8

4 3
5 12
Purification
11 System

14 14
6

1. Intake Manifold 6. 2nd Stage Intercooler 11. Intermediate Separator

2. 1st Stage Cylinder 7. 3rd Stage Aftercooler 12. Oil & Water (condensate) Separator
3. 2nd Stage Cylinder 8. 1st Stage Safety Valve 13. Pressure Maintaining Valve
4. 3rd Stage Cylinder 9. 2nd Stage Safety Valve 14. Manual Condensate Drain Valve
5. 1st Stage Intercooler 10. Final Pressure Safety Valve

3.1.4 Compressor Lubrication

3.1.4.1 Description
Refer to Figure 3-3. The compressor is provided with forced-feed lubrication. The oil pressure is pro-
duced by a low speed gear pump (1). The oil pressure is approximately 73 psi (5 bar).
The oil pump (1) is coupled to and driven by the crankshaft. It pumps oil through the oil line filter (2) and
a minimum pressure valve (3) to the 3rd stage cylinder. The oil is then distributed by the guide piston (4)
of the 3rd stage and lubricates all the moving parts of the compressor block.
The minimum pressure valve (3) allows for oil pressure indication at a pressure gauge and/or electronic
oil pressure monitoring.

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Figure 3-3 Lubrication Oil Circuit

5 5

1. Oil Pump 4. Guide Piston

2. Oil Filter 5. Oil Sight Glass
3. Minimum Pressure Valve

3.1.4.2 Type of Oil

For proper care and maintenance of the compressor, using the correct oil is of vital importance. Due to the
thermal load on the compressor only high quality oil should be used. You are recommended to restrict
oils to those which have been approved by us and are listed in the compressor block specifications found
in Chapter 1.

Page 12 1st Edition, Rev. 0, Chg. 4

MNL-0146

Figure 3-4 Oil Sight Glass Figure 3-5 Oil Filler Cap

Figure 3-6 Removing the Oil Filter Cover Figure 3-7 Replacing the Oil Filter

3.1.4.3 Oil Level Check

Check the oil level at the sight gauge on either side of the compressor block (See Figure 3-4) every day
before putting the compressor into operation. Oil level must be between the minimum and maximum
notches. Oil level must never be below the minimum mark as this will cause severe damage due to lack of
lubrication. Oil level must also not exceed the maximum mark as this will cause excessive lubrication of
the compressor and may result in a carbon buildup on the valves.

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3.1.4.4 Oil Change
1. Run the compressor until it is warm then shut it down.
2. (See Figure 3-5). Remove the cap (1) from the oil filler neck.
3. Drain oil while it is still warm by means of the oil drain tap.

^ CAUTION
Replace the oil filter every oil change. Failure to do so will cause the filter to clog and the bypass valve to
open resulting in unfiltered oil being circulated and possible damage to the compressor.

4. (See Figure 3-6). Remove the two bolts (1) with a 13 mm wrench. Remove the oil filter cover (2)
5. (See Figure 3-7). Remove the oil filter (1) from the rubber gasket at the cover.
6. Mount a new filter element (P/N N25326) and replace and fasten oil filter cover.
7. Slowly pour new oil through the oil filler neck until the level reaches the maximum mark on the
sight gauge.
8. Wait a few minutes and adjust the oil level if necessary before putting the unit into operation.
3.1.4.5 Venting the Oil Pump
Venting of the Oil Pump may be necessary if after maintenance work, oil pressure is low or not built up
after starting the unit, or if the unit should have been running backwards because of a wrong phase
sequence.
1. Open all the condensate drain valves to avoid building up pressure.
2. Start the compressor.
3. See Figure 3-7. Loosen the cap screw and plug (2) and wait until oil pours out free of air bubbles.
4. Tighten the cap screw and plug.
5. Stop compressor, close all condensate drain valves and check oil level.

Page 14 1st Edition, Rev. 0, Chg. 4

MNL-0146
3.1.5 Intake Filter.

Figure 3-8 Intake Filter

3
2
1
1. Knurled Nut 3. Filter Housing
2. Washer 4. Filter Element

3.1.5.1 Description
A dry, micronic filter is used to filter the intake air, see Figure 3-8
The filter cartridge must be changed at regular intervals. See the Maintenance Schedule for the recom-
mended interval.
1. Unscrew and remove Knurled Nut (1)
2. Remove Washer (2) and Filter Housing (3).
3. Discard Filter Element (4) and replace with new Filter Element Bauer Part Number N25950.
4. Reassemble in reverse order.

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3.1.6 Intermediate Separator

An intermediate separator is mounted on the compressor between the 2nd and 3rd stage. This separator is
designed to remove oil and water which accumulates due to the cooling of the medium after the compres-
sion process. Separation is achieved by means of centrifugal action provided by a vortex plate (1)

Figure 3-9 Intermediate Separator

1 5

1. Vortex Plate 4. O-ring 7. Fitting

2. Hollow Screw 5. Knurled Nut 8. Safety Valve
3. Center Insert 6. Gasket

^ WARNING
The rapid depressurizing and repressurizing of the 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
depressurization- repressurization. The Bauer recommended frequency of condensate draining is every
fifteen minutes and is a balance between maximizing the life of the oil and water separator chamber and
maintaining the quality of the delivered air.

3.1.6.1 Maintenance
The Intermediate Separator P/N 081799 requires no maintenance.

Page 16 1st Edition, Rev. 0, Chg. 4

MNL-0146

3.1.7 Cooling
3.1.7.1 General
The cylinders of the compressor, the intermediate coolers and the after cooler are air cooled. For this pur-
pose the compressor is equipped with a fanwheel which draws the cooling air through the unit. The fan-
wheel is driven by the drive motor V-belt and is also used as the compressor flywheel.
3.1.8 Valves and Heads
3.1.8.1 Functional Description
The valve heads of the individual stages form the top part of the cylinders. (See Figure 3-10). The
intake and pressure valves are fitted inside the valve heads. Note that the valves are operated by the
flow of the medium. On the intake stroke, the intake valves open and the medium flows into the cylin-
ders. At the start of the pressure stroke the intake valve closes and the medium opens the pressure valve.

Figure 3-10 Valve Operation

Intake Discharge

Figure 3-11 IK120II Plate Valve

TOP VIEW
Intake Side

Pressure Side

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3.1.8.2 General Instructions for Changing the Valves

• Always replace valves as a complete set.
• Carefully clean dirty valves. Never use a sharp tool for this purpose. Soak the valves in Varsol and
clean with a soft brush. If possible, use an ultrasonic cleaner.
• Check the individual components for excessive wear. If the valve seat or valve discs are dented,
replace the valves.
• Check the valve space in the valve heads for dirt, and clean if necessary.
• Use only satisfactory gaskets and O-rings during reassembly.
• Observe the correct sequence when reassembling.
• After finishing all maintenance work on the valves, turn the compressor manually using the flywheel
and check whether all items have been correctly installed.
• 30 minutes after restarting the compressor, stop the unit, let it cool down to ambient temperature, and
retighten valve studs and cap nuts. Otherwise the gasket set may cause a leak.
• Remove and check the valves every 1000 operating hours.
• Replace the valves every 2000 operating hours to avoid fatigue failure.

Figure 3-12 IK120 II 1st Stage Valve

5 4

6 3

7 2

1. Plate Valve 5. Hex Head Screw

2. Valve Head 6. Washer
3. Washer 7. O-ring
4. Hex Head Screw

Page 18 1st Edition, Rev. 0, Chg. 4

MNL-0146

3.1.8.3 Changing the IK120 II 1st Stage Valves

The intake and pressure valve of the IK120 II 1st stage are in a combined plate valve under the valve
head. Refer to Figure 3-12 and proceed as follows:
1. Remove all tubing connections and lines from the Valve Head (2).
2. Remove all Hex Head Screws.
3. Remove Valve Head (2).
4. Note orientation of Plate Valve (1) before removing it.
5. Reassembly is the reverse of the above steps.
3.1.8.4 IK120 II 2nd Stage Valves
3.1.8.4.1 Removing the Valves of the 2nd Stage

Figure 3-13 IK120 II 2nd Stage Valves

1
8

7
4

6
5

1. Cap Nut 5. Pressure Valve Insert

2. Stud 6. Intake Valve
3. Pressure Plug 7. 2nd Stage Valve Head
4. O-ring 8. Allen Screw

See Figure 3-13 and proceed as follows:

1. Remove the intake and pressure lines from the Valve Head (7).
2. Remove the screws (8) holding the Valve Head (7) onto the cylinder.

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3. Insert two 8 mm diameter metal pins, any length, in the holes in the valve head and secure them in a
vise with the valve head on top.
4. Using the special valve tool, remove the intake valve (6) (See Figure 3-14).
5. Turn the valve head over and replace it on the metal pins.
6. Remove the cap nut (1).
7. Unscrew the stud (2) approximately five turns.
8. Remove the pressure plug (3) and take out the valve parts.
9. Clean the intake and pressure valves and check for wear.
10. Clean and check the valve spring.
11. Clean the valve head. Check that the intake and pressure valve bores are in perfect condition.
12. Using a precision straightedge, check that the underside of the valve head is flat. If necessary use an
emery cloth to smooth out the surface.

Figure 3-14 Using the Special Valve Tool Figure 3-15 Securing the Intake Valve

^ CAUTION
In order to avoid damaging the special tool or the valve when using the tool, ensure that it is pushed prop-
erly and firmly into the valve so that it will not tilt when it is turned.

NOTICE
Valve seats and plate valves must not show any signs of wear or damage.
Replace damaged or worn parts.

Page 20 1st Edition, Rev. 0, Chg. 4

MNL-0146
3.1.8.4.2 Reassembling the Valves of the 2nd Stage.

1. Replace the intake valve (6) using the special valve tool to tighten it.

^ CAUTION
The intake valve plate and valve spring must not be jammed.

2. Check the intake valve functions correctly by blowing compressed air through the valve in the
direction of flow.
3. Secure the intake valve as follows: (See Figure 3-17) Peen the valve head aluminum over the screw-
in thread of the intake valve in two places opposite one another. Use a small drift pin, approximately
5 mm in diameter.
4. Insert the O-ring (4) and the pressure valve parts(5).
5. Check the pressure valve function and stroke by lifting the valve parts.
6. Ensure the stud (2) is unscrewed, then screw in the pressure plug (3)and tighten.
7. Screw the stud (2) in firmly, fit a new gasket and secure it with the cap nut (1).
8. Replace the valve head (7) on the cylinder and secure it with the screws (8).
9. Reconnect the intake and pressure lines.

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3.1.8.5 IK120 II 3rd Stage Valves

3.1.8.5.1 Removing the Valves of the 3rd Stage

Figure 3-16 IK120 II 3rd Stage Valves

10

8
7

5
4 1

1. Intake Valve 5. Valve Head Cover 8. Cap Nut

2. Valve Head 6. Stud 9. Allen Screw
3. O-ring 7. Gasket 10. Washer
4. Pressure Valve

1. Remove the intake and pressure lines from the valve head (2).
2. Remove the cap nut (8) and loosen stud (6) three or four turns.
3. Remove the screws (9) holding the valve head onto the cylinder and take off valve head cover (5).
4. Remove the 3rd stage pressure valve by putting two screwdrivers into the removal groove of the
pressure valve body. See Figure 3-17. It may be necessary to loosen the valve body first by turning
it with a 13 mm wrench used on the flat surfaces.
5. Insert two 8 mm diameter metal pins, any length, in the holes in the valve head and secure them in a
vise with the valve head on top of the vise. The intake valve (1) should be facing up.
6. Using the special tool (See Figure 3-14) provided with the unit, remove the intake valve (1).

Page 22 1st Edition, Rev. 0, Chg. 4

MNL-0146

Figure 3-17 Removing the 3rd Stage Pressure Valve

3.1.8.5.2 Reassembling the Valves of the 3rd Stage

1. Replace the intake valve (1) using the special tool to tighten it.
2. Check the intake valve functions correctly by blowing compressed air through the valve in the
direction of flow.
3. Secure the intake valve as follows: (See Figure 3-17) Peen the valve head aluminum over the screw-
in thread of the intake valve in two places opposite one another. Use a small drift pin, approximately
5 mm in diameter.
4. Reinstall the pressure valve (4) by putting O-ring (3) into valve head (2). Check it for abrasions.
5. Insert pressure valve through O-ring and into valve bore.
6. Put on valve head cover (5).
7. Reassemble valve head cover and valve head to cylinder. Torque screws (9) to the proper value.
8. Screw in stud (6). Put on gasket (7). Screw on cap nuts (8).

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3.1.9 Replacement Parts List

Figure 3-18 Crankcase Assembly

6
11

12
13
2
15
3
28 4 1 16

14

18
17
8
9
10

26
27 19
25
16
5 4
29 22
7
30

20
21
23 22
19 24

# KIT Qty Part No. Description Notes

 1 076743 Crankcase assembly
1 … 1 076740 Crankcase
2 … 1 083399 Crankshaft, complete
3 … 1 N2638 Roller Bearing
4 … 2 N2635 Circlip
5 … 1 66209 Bearing Cap
6 … 1 N15406 Roller Bearing
7 … 1 N15265 O-ring
8 … 1 66684 Cover
9 … 1 N170 Shaft Seal
10 … 1 N3745 O-ring
11 … 1 61054 Plug
12 … 1 N15412 O-ring
13 … 1 73830 Oil Filling Pipe
14 … 1 N4776 O-ring

Page 24 1st Edition, Rev. 0, Chg. 4

MNL-0146
Figure 3-18 (cont.) Crankcase Assembly

# KIT Qty Part No. Description Notes

15 … 2 SCR-0020 Allen Screw
16 … 8 WAS-0021 Washer
17 … 2 N4261 Gasket
18 … 2 PLU-0040 Plug
19 … 2 N25475 Oil Sight Gauge
20 … 1 N1316 Gasket
21 … 1 N4570 Plug
22 … 2 78038 Support
23 … 4 WAS-0030 Spring Washer
24 … 4 NUT-0076 Hex Nut
25 … 4 WAS-0031 Washer
26 … 4 N350 Hex Head Screw
27 … 6 SCR-0113 Hex Head Screw
28 … 3 N16126 Countersunk Screw
29 … 1 N2375 Coupling
30 … 1 N25638 Ball Valve

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Figure 3-19 Piston and Cylinder, 1st Stage, IK120 II

9 1
8

4 2
5

4
6

# KIT Qty Part No. Description Notes

 1 080826 Piston and Cylinder Assembly
1 … 1 080734 Cylinder
2 ..c 1 N4654 O-ring
 1 069975 Piston Assembly Items 3 - 6
3 … 2 N484 Circlip
4 … 1 N802 Piston Pin
5 … 1 N1787 Piston Ring Set
6 … 4 N215 Stud
7 … 4 WAS-0021 Washer
8 ..c 4 NUT-0119 Self Locking Hex Nut

Page 26 1st Edition, Rev. 0, Chg. 4

MNL-0146

Figure 3-20 Piston and Cylinder, 2nd Stage

5
6

3
7

11

10
8
9

# KIT Qty Part No. Description Notes

 1 062889 Cylinder Assembly
1 … 1 062477 Cylinder
2 ..c 1 N7063 O-ring
3 … 1 080383 Guide Cylinder
4 ..c 1 N2640 O-ring
5 … 4 NUT-0119 Self Locking Hex Nut
6 … 4 WAS-0021 Washer
7 … 4 N2790 Stud
 1 072249 Piston Assembly, Complete Items 8 - 11
8 … 1 062487 Piston
9 … 2 N484 Circlip
10 … 1 N1429 Piston Pin
11 … 1 N2647 Piston Ring Set

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Figure 3-21 Piston and Cylinder, 3rd Stage

2
3

6
7 9

10

8 11
12

13

# KIT Qty Part No. Description Notes

 1 083400 Cylinder Assembly
1 … 1 078043 Piston and Sleeve Assembly (See Figure 3-22)
2 a.. 1 N4868 O-ring
3 … 1 082480 Cylinder
4 ..c 1 N7063 O-ring
5 … 1 083404 Guide Cylinder
6 ..c 4 NUT-0119 Self Locking Hex Nut
7 … 4 WAS-0021 Washer
8 … 4 N2790 Stud
9 ..c 1 N2640 O-ring
10 … 1 072165 Guide Piston Assembly Items 11 - 13
11 … † — Guide Piston Available only with 072165
12 … † — Piston Pin Available only with 072165
13 … 2 N484 Circlip

Page 28 1st Edition, Rev. 0, Chg. 4

MNL-0146

Figure 3-22 Piston and Sleeve, 3rd Stage

3
4

# KIT Qty Part No. Description Notes

 1 078043 Piston and Sleeve Assembly
1 … † —Piston Available only with 078043
2 a.. 1 N23755 O-ring
3 … † —Piston Liner Available only with 078043
4 … 1 N25376 Piston Ring Set

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Figure 3-23 1st Stage Valve Head and Valve, IK120 II

5 4

6 3

7 2

# KIT Qty Part No. Description Notes

 1 08688 1st Stage Valve Head Assembly
1 .b. 1 N26531 Plate Valve
2 … 1 080677 Valve Head
3 … † —Washer
4 … 6 N1262 Allen Screw
5 … 1 N28108 Allen Screw
6 … 1 WAS-0021 Washer
7 … 1 N1539 O-ring

Page 30 1st Edition, Rev. 0, Chg. 4

 This page is inserted to provide proper page sequencing

8 9 1 2
6 5 7

10
3
4
 Dive Mate

Figure 3-24 2nd Stage Valves and Valve Head

19
20
18

17

16

15 8

1 14

7 13
6

5 12
2 9
4 11
10
3
7

# KIT Qty Part No. Description Notes

 1 069955 2nd Stage Valve Head Assembly
1 … 1 14123 Valve Head
2 .b. 1 012841 Intake Valve Assembly Items 3 - 7
3 … † — Intake Valve Body Available only with 012841
4 … † — Spring Available only with 012841
5 … † — Valve Plate Available only with 012841
6 … † — Valve Seat Available only with 012841
7 a.. 2 240 Gasket
8 … 1 014582 Pressure Valve Assembly Items 9, 14 - 19
9 .b. 1 012835 Pressure Valve Insert Items 7, 10 - 13
10 … † — Valve Seat Available only with 012835
11 … † — Valve Plate Available only with 012835
12 … 1 1026 Spring
13 … † — Valve Insert Available only with 012835
14 a.. 1 N3521 O-ring

Page 32 1st Edition, Rev. 0, Chg. 4

MNL-0146
Figure 3-24 (cont.) 2nd Stage Valves and Valve Head

# KIT Qty Part No. Description Notes

15 … 1 14332 Spring Washer
16 … 1 14124 Coupling
17 .b. 1 71064 Stud
18 a.. 1 N3625 Gasket
19 … 1 N84 Cap Nut
20 … 6 N503 Allen Screw

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Figure 3-25 3rd Stage Valves and Valve Head

10

8
7

5
4 1

# KIT Qty Part No. Description Notes

 1 082096 Valve Head Assembly
1 .b. 1 081409 Intake Valve
2 … 1 082087 Valve Head
3 … 1 N2789 O-ring
4 .b. 1 014121 Discharge Valve
5 … 1 082086 Valve Head Cover
6 .b. 1 N3738 Stud
7 a.. 1 N3625 Gasket
8 … 1 N3589 Acorn Nut
9 … 6 N17730 Screw
10 … 6 N58 Washer

Page 34 1st Edition, Rev. 0, Chg. 4

MNL-0146

Figure 3-26 Flywheel

8
7

5
4 3
2

# KIT Qty Part No. Description Notes

 1 082552 Flywheel Assembly
1 … 1 N1386 Feather Key
2 … 1 082553 Fanwheel Hub
3 … 1 080975 Washer
4 … 1 N176 Spring Washer
5 … 4 N26666 Screw
6 … 1 082496 Fanwheel
7 … 4 N108 Spring Washer
8 … 4 N19548 Screw

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Figure 3-27 Intermediate Separator

1 5

# KIT Qty Part No. Description Notes

 1 081799 Intermediate Separator Assembly
1 … 1 81148 Plate
2 … 1 81643 Hollow Screw
3 … 1 76613 Inset Assembly
4 … 1 N3556 O-ring
5 … 1 13937 Knurled Ring
6 … 1 N1316 Gasket
7 … 1 N20215 Fitting
8 … † —Safety Valves See Figure 3-29

Page 36 1st Edition, Rev. 0, Chg. 4

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Figure 3-28 Intake Filter

3
2
1

# KIT Qty Part No. Description Notes

 1 079577 Intake Filter Assembly
1 … 1 N4870 Knurled Nut
2 … 1 N3313 Washer
3 … 1 79574 Filter Housing, Front
4 a.. 1 N25950 Filter Element
5 … 1 79575 Filter Housing, Back
6 … 1 N19502 Hex Head Bolt
7 … 1 N3374 Clamp

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Figure 3-29 IK120 II Cooling System

29 18
17
19 16
28 12
5

13
11 12

12
20 11
3
4 31
27 32 30
26 33

25 19
12
13 12 12
24 6
7 12
11
12
13 1
14
9 15
8
21 22
2 23
10

# KIT Qty Part No. Description Notes

 1 083456 IK120II Cooling System
1 … 1 081309 Intercooler, 1st to 2nd Stage
2 … 1 078195 Intercooler, 2nd to 3rd Stage
3 … 1 070724 Aftercooler
4 … 1 078200 Fanwheel Guard
5 … 1 081802 Safety Valve, 1st Stage
6 … 1 072935 Safety Valve, 2nd Stage
7 … 8 062773 Mounting Bracket
8 … 8 WAS-0024 Washer
9 … 8 NUT-0118 Self Locking Hex Nut
10 … 8 N3494 Stud
11 … 4 N20059 Fitting
12 … 9 N1316 Gasket
13 … 3 N20195 Male Connector
14 … 1 N4530 Plug

Page 38 1st Edition, Rev. 0, Chg. 4

MNL-0146
Figure 3-29 (cont.) IK120 II Cooling System

# KIT Qty Part No. Description Notes

15 … 1 N3610 Cap
16 … 1 N20327 Tee
17 … 1 N15175 Plug
18 … 1 N7433 Cap
19 … 2 N26751 Coupling
20 … 1 N20183 Connector
21 … 2 77894 Clamp
22 … 2 N2460 Washer
23 … 2 SCR-0020 Allen Screw
24 … 1 N52 Plug
25 … 1 78197 Tubing Assembly
26 … 3 78199 Stud
27 … 3 11887 Mounting Bracket
28 … 3 WAS-0021 Washer
29 … 3 NUT-0119 Self Locking Hex Nut
30 … 1 N20310 Fitting
31 … 1 083454 Tubing Assembly
32 … 1 71148 Fitting
33 … 1 56983 Gasket

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Figure 3-30 Lubrication System Assembly

1
12

13
2

3
4

11 5

16
10 15

9 6

14
15
18

17 15
16

15 7
8
16

# KIT Qty Part No. Description Notes

 1 081075 Lubricating System Includes Items 1 - 15
1 … 1 077885 Oil Filter Cover
2 … 1 N4058 O-ring
3 … 1 N25327 O-ring
4 … 1 77774 Rubber Gasket
5 a.. 1 N25326 Filter Element
6 … 1 77878 Cover Plate
7 … 2 N25328 Allen Screw
8 … 2 N2889 Gasket
9 … 1 78421 Gasket
10 … 1 N24585 Gear Pump
11 … 2 N3489 O-ring
12 … 2 N19506 Hex Head Screw

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MNL-0146
Figure 3-30 (cont.) Lubrication System Assembly

# KIT Qty Part No. Description Notesv

13 … 2 WAS-0021 Washer
14 … 1 081050 Regulating Valve
15 … 4 N1316 Gasket
16 … 3 N52 Plug
17 … 1 076757 Connecting Tube Assembly
18 … 1 N2037 Male Connector

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3.1.10 Troubleshooting
3.1.10.1 Troubleshooting Table

Trouble Cause Remedy

No oil pressure Low oil level Check oil level

1. Last stage piston worn 1. Operate compressor with

2. Last stage pressure valve final stage valve head
Oil foam in crankcase defective removed. If oil flows con-
tinuously out of cylinder,
replace piston and sleeve.
2. Replace last stage valves.

1. Condensate drain valves or 1. Tighten and reseal.

fittings leaking. 2. Clean and adjust final
2. Premature opening of final safety valve.
Compressor output insufficient 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

1. Insufficient supply of cool- 1. Check location for adequate

ing air ventilation
Compressor running too hot. 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.

1. Improper maintenance of 1. Service filters, change puri-

Oil residue in delivered air filters, purifier cartridge fier cartridge.
saturated. 2. Change to proper oil and
2. Wrong oil type clean valves.

Reverse two of the three phase

Compressor rotates in the wrong Electrical phases not connected leads at the switch box. Do NOT
direction properly change the leads at the motor ter-
minal.

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3.2 Manual Condensate Drain System
3.2.1 Description
The purpose of the manual condensate drain system is to provide a means to drain the filters of accumu-
lated condensation.
The manual condensate drain system consists of the following items:
1. Manual condensate drain valves on the intermediate filter and the Purification Chamber.
2. Drain tubing.

The manual drains should be tubed to a condensate collection tank.

NOTICE
Condensate drained from the separators may be mixed with oil. Ensure that any oil which is drained with
the condensate is disposed of in accordance with local, state and federal regulations.

Figure 3-31 Manual Condensate Drains

3.2.2 Operation
The manual condensate drain valves must be opened and the condensate allowed to drain every 15 min-
utes while the compressor is operating.
3.2.3 Unloaded start
On shut-down, open the intermediate and final separator manual condensate drain valves to drain con-
densation and remove pressure from the block. Close the drain valves after start up.
This operation performs two functions:
1. As pressure builds, the separators are cleared of accumulated condensation.
2. There is no load on the compressor during start-up.

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3.3 Replacement Parts

Figure 3-32 Manual Drains

Item Qty Part No. Description Notes

1 2 CMP-0115 Clamp, Plastic, Double Grip
2 2 11430U Manual Drain Valve
3 30” TUB-R-0026 Tubing, Flexible, PVC cut to length needed
4 1 BRK-0664 Drain Hose Bracket

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3.4 Three Stage Automatic Condensate Drain System
3.4.1 Description
The automatic condensate drain system operates electropneumatically and is comprised of the following:
An electrically controlled solenoid valve. An electrical timer
A pneumatically operated condensate drain valve A condensate manifold
A condensate silencer-filter A condensate collector
The automatic condensate drain system drains the intermediate separator and the oil and water separator
every 15 minutes during operation. Additionally the automatic condensate drain system unloads the com-
pressor during the starting phase and drains these filters at shutdown of the compressor unit.

Figure 3-33 Automatic Condensate Drain

1
4

6
1. Silencer-Filter 4. Manual Drain Valve
2. Electric Coil 5. 2-way Solenoid Valve
3. Automatic Condensate Drain 6. Timer

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Figure 3-34 ACD Operation Diagrams

2 2 3
3
Control Air
Condensate
Control Air
Condensate

1 1

4 4

Normal Operation Condensate Draining

1. Solenoid Valve 3. Oil and Water Separator

2. Intermediate Separator 4. Condensate Drain Valve
3.4.1.1 Normal Operation
The normally open solenoid valve (1) controls the condensate draining of the intermediate separator (2).
The normally open condensate drain valve (4) controls the condensate draining of the oil and water sepa-
rator. The two valves (1 & 4) are connected together in cascade mode. This means that the operational
state (open or closed) of the solenoid valve (1) causes the same state in the condensate drain valve (4) to
occur. The control air for operating the condensate drain valve (4) is taken from the intermediate separa-
tor (2).
As the compressor is started, the solenoid valve (1) is electrically energized and closes. This allows the
pressure to buildup in the intermediate separator. This pressure buildup results in control air pressing the
piston into the valve seat, closing the condensate drain valve (4).
3.4.1.2 Condensate Drain
Every 15 minutes the Timer de-energizes the solenoid valve (1) for approximately 10 seconds. The sole-
noid valve (1) opens and drains the condensation from the intermediate separator (2). This causes a pres-
sure loss in the intermediate separator and the control air for the condensate drain valve (4). As the
pressure of the control air is dropping, the piston of the condensate drain valve (4) becomes unloaded and
the control air is momentarily vented through a relief port. Then the piston of the drain valve is fully
raised by pressure from the final separator, and the condensate is drained.
3.4.1.3 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 separator and

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MNL-0146
the control air closes the condensate drain valve (4). Once the valve closes, the compressor delivers to the
consuming device.
3.4.1.4 Standstill Drainage
At compressor shutdown, the solenoid valve (1) is de-energized and opens. This drains the condensate
and relieves the pressure in the intermediate filter (2). This action in turn removes the control air form the
condensate drain valve which opens and drains and relieves the pressure in the oil and water separator.
3.4.2 Component Description
3.4.2.1 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 filter-silencer and then on to the condensate collector via a rubber hose.
3.4.2.2 Electrical Connection
For electrical connection of the automatic condensate drain, refer to any included wiring diagrams.

^ CAUTION
The condensate drain interval is adjusted at the factory. If the regular operating time of the compressor
unit is less than the drain cycle, adjust the timing relay accordingly to ensure regular draining of the oil
and water separator. If the compressor is shut off before the first drain cycle is completed, the timing relay
would be reset each time causing the drain cycle to be started again. The condensate drain cycle would
never be completed, which could result in flooding of the separator and damage to the connected systems

3.4.2.3 Separator/Silencer
The fine construction of the filtration material with an extensive hollow volume (approximately. 90%)
results in a substantial collection of solid matter particles. The service life is accordingly high and the
pressure drop is extremely low. The operation of the separator/silencer has three steps.
1. The moisture and oily air flows through the input into a conical distribution system for a uniform
flow against the filter element and reduction of the flow velocity.
2. When flowing through the filter medium made from micro glass fibre matter, the oil particles are
formed into larger drops. This is caused by the coalescing effect of the outer foam material shell.
From there they can drop smoothly into the translucent oil collector. The obtained efficiency
amounts to more than 99.9% of all oil aerosols.
3. The cleaned compressed air can vent to the ambient pressure. The purposeful slowing down of the
flow velocity leads to the desired silencing by more than 35 dB(A). The expanding noise level of
100 psi to atmospheric can reach about 125 dB(A). The end result is clean and silent ambient air
4. The coalesced oil and water exits the collector and is tubed to a condensation collection bottle.
3.4.3 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.

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a. If the system drains more than 2 ounces of liquid per stage, either the system or the corresponding
condensate drain valve is not working properly.
b. Find the fault and remedy accordingly.
3. If little or no condensation emerges, the automatic system is operating properly.
4. The condensate collection bottle should be emptied regularly. Due care must be taken to ensure that
any oil which is drained with the condensation is disposed of properly. Check local, state and fed-
eral regulations.
5. Replace the separator/silencer element with each oil change, or more frequently if required.
3.5 Condensate Collector
During compression the water content of the air is also compressed. The resulting water is removed after
each compression stage and is collected through the automatic condensate drain system.
This water, additionally, has a small oil content. The separation of oil and water is not possible through
simple methods; therefore the condensate has to be completely removed. It is most practical to collect this
condensate in special containers and dispose of it entirely.
For these compressor units silencer - filter assembly is used. The condensate is drained from the assembly
into the condensate collector for proper disposal.

Figure 3-35 Condensate Collector

1 2

1. Condensate Collector (P/N 81672 - KD)

2. Silencer-Filter

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3.5.1 ACD Replacement Parts List

Figure 3-36 3 Stage ACD System

1
4

Item Qty Part No. Description Notes

1 1 85561 Silencer-Filter
2 1 N27288 Electric Coil 110-115 Volt, 60 bar
3 1 81005 Automatic Condensate Drain
4 1 011430 Manual Drain Tap
5 1 N27099 2-way Solenoid Valve
6 1 TMR-0025 Timer 12 VDC
or 1 TMR-0026 Timer 120 - 230 VAC

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Figure 3-37 Condensate Drain Valve

16
2

5
6

17

10

16 11
12

13
15
14

Item Qty Part No. Description Notes

 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
7 1 064001 Valve Body

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Figure 3-37 (cont.) Condensate Drain Valve

Item Qty Part No. Description Notes

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
16 8 SCR-0150 Allen Screw
17 1 067458 Tool Set for 065500

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3.5.2 Trouble shooting

Trouble Cause Remedy

1. Solenoid valve receives no 1. Check connections,

Solenoid Valve does not drain. electrical signal Timer. Replace if neces-
2. Plunger of drain valve sticking sary.
2. Clean or replace valve.

1. Solenoid valve does not 1. Check solenoid valve,

depressurize drain valve. replace if necessary
Condensate Drain Valve does 2. No control medium available. 2. Check supply lines
not drain. 3. Solenoid valve sticking. 3. Clean or replace
4. Drain valve sticking in open 4. Clean or replace
position

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MNL-0146
CHAPTER 4: DIVE MATE MAINTENANCE SCHEDULE
4.1 Dive Mate Maintenance Intervals

Interval Maintenance Work

Check Oil Level
Daily before operating unit
Operate unit to final pressure and check final pressure switch
½ hour after maintenance work Check screws and fittings for tightness
Service micronic intake filter
500 operating hours
Check all connections for leakage
1,000 operating hours Valve Check
Change Synthetic Oil and Change Oil Filter
2,000 operating hours
Replace Valves
3,000 operating hours Check pistons and piston rings
Check opening pressure of final safety valve.
Annually
Service micronic intake filter
Biennially Change Synthetic Oil, if operated for less than 2,000 hours

NOTICE
All maintenance intervals refer to normal operating conditions. Operating the compressor under extreme
conditions like high temperatures, humidity or continuous operation may shorten the intervals signifi-
cantly. If in doubt, please contact the Bauer service department.

4.1.1 Maintenance Records

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

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CHAPTER 5: PURIFICATION SYSTEM
5.1 Introduction
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.
The purpose of all Bauer industrial air purification systems is to remove oil and water from the com-
pressed air stream before final delivery.

^ WARNING
Industrial Air Purification System cartridges do not remove Carbon Monoxide
and must not be used in breathing air applications.

The quality of gas produced by the compressor is directly related to the quality and temperature of the gas
taken in by the unit. Intake gas should as close as possible to 50 °F (10 °C) and cleanest available and as
dry as possible. Bauer compressors normally add approximately 18 °F (10 °C) to the intake gas tempera-
ture. The purification cartridges perform their best at approximately 68 °F (20 °C). Adequate ventilation
enhances the quality and life of the purification cartridges.
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 - 1,100 psi
(50 to 80 bar) within the system to prevent moisture from entering the compressor and purification
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 & See Figure 5-2). 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.

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Figure 5-1 Cartridge Safety Venting Figure 5-2 P0 & P31 Safety Venting

Safety Safety
Vent Vent

Safety Safety
Vent Vent

Cartridge Installed No Cartridge Installed

correctly or Installed incorrectly Cartridge Installed No Cartridge or Installed
Correctly Incorrectly

5.1.3 Manual Condensate Drainage

The condensate must be drained from the oil and water separator before changing any cartridge, before
beginning each filling procedure and in the absence of an Automatic Condensate Drain (ACD) system,
every fifteen minutes during the filling procedure. This is done by slowly opening the condensate drain
valves. They are opened approximately 1/3 of a turn to the left and held open until the condensate is com-
pletely drained. The condensate drain valves close by spring pressure but if necessary may be tightened
by hand to ensure they are completely air tight.
5.1.4 Model, Serial Number and Part Number Identification
5.1.4.1 Compressor Dataplate
The model number, date of manufacture and serial number can be found on the compressor unit identifi-
cation plate in the main electrical enclosure and frame.

Figure 5-3 Purification System Dataplates (typical)

Purification System Cartridge Installation

PURIFICATION
CARTRIDGE TO BE
SYSTEM
INSTALLED
MODEL NO.

MAX. PRESSURE psig CARTRIDGE FOR

AIR PROCESSED cu. ft. CARTRIDGE NO.
O-RING 1328 Azalea Garden Road - Norfolk Virginia 23502-1944
BACK-UP RING Phone: (757) 855-6006 Fax: (757) 855-8224
LBL- LBL-

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5.1.4.2 Purification System Dataplate
Refer to the compressor unit purification system data plate (See Figure 5-3) on the compressor front to
determine your purification system model and specifications.
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 data plate on the chamber to determine the
purpose and part number of the cartridge installed in that chamber. (See Figure 5-3).
5.1.5 Breathing Air Purification System Configurations

Purification System Number and Type of Cartridges Processing Capacity

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
P10 with Securus® 2 … 1 230,000

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
P42 with Securus® 1 … 1 107,000
P43 2 1 … 100,000
P43 with Securus® 2 … 1 164,000
P81 1 1 124,000
P81 with Securus® 1 ... 1 198,000
a. P12 and P14 have the Securus® Electronic Moisture Monitor System as standard equipment.

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5.1.6 Industrial Purification System Configurations

Purification System Number and Type of Cartridges Processing Capacity

Dryer Purification Securus® cubic ft (ft)3
P0 Combined 3,200
P1 … 1 … 15,000
P2 … 1 … 40,000
IP2 with Securus® … … 1 67,000
P4 1 1 … 60,000
P5 1 1 … 90,000
IP5 with Securus® 1 … 1 150,000
P10 2 1 140,000
IP10 with Securus® 2 … 1 230,000
P31 Combined 11,760
IP41 with Securus® … … 1 47,000
IP42 with Securus® 1 … 1 107,000
IP43 with Securus® 2 … 1 164,000

5.1.7 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 recommended 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 maxi-
mum operating hours before the cartridges need to be replaced. See Paragraph 5.1.7.1 for the method of
determining this figure.
The ambient air temperature and its ability to cool the compressor will effect the operating life of the car-
tridge. See Paragraph 5.1.7.2 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 approxi-
mately 18 °F above the ambient temperature. Therefore for the purpose of calculating cartridge operating
life use the Ambient Air Temperature plus 18 °F.
A form titled Air Purification Cartridge Operating Hours is found in Paragraph 5.1.7.3 and in the
Appendices. It is used for recording the ambient temperature, operating time and adjustment factor. It

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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.
5.1.7.1 Calculating the Maximum Cartridge Operating Hours
1. From the purification system data plate (See Figure 5-3) 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.

5.1.7.2 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 18 °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.

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Figure 5-4 Correction Factor for Cartridge Operating Hours

3.5

3.0

2.5
Conversion Factor

2.0

1.5

1.0

0.5

0.0
0 10 20 30 40 50
Ambient Temperature in °C

°C °F Correction Factor
[(°F - 32) x 5/9] [°C x 9/5 +32]
50 122 0.21
40 104 0.34
30 86 0.58
20 68 1.00
10 50 1.81
0 32 3.44

Figure 5-5 Example Record of Adjusted Operating Hours

Operating Ambient Temp. Correction Adjusted Cartridge Hours

Date
Hours during Compression Factor Today Total
Op hrs
10/19/04 8 92°F (33 °C) 0.48 16.67 Corr. factor 16.66

11/01/04 4 45°F (7.2 °C) 2.25 1.78 Total hrs 18.44

+Today hrs

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5.1.7.3 Air Purification Cartridge Operating Hours Form

Operating Ambient temp. Correction Adjusted cartridge hours

Date
hours during compression factor Today Total

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MNL-0146
5.2 P31 Purification System
5.2.1 Major Components
The P31 purification system assembly consists of a separator and a cartridge chamber. In the separator
liquid oil and water particles are separated from the compressed air by a pipe nozzle. Residual oil and
water particles are then removed by the filter cartridge and the air leaving the filter assembly is free of oil,
taste and smell.

Figure 5-6 P31 Purification System

5
4

1. Final Safety Valve 4. System Check Valve

2. Plug 5. Bottom
3. Housing

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5.2.2 Configuration Options

On some models the P31 Purification system can be specified at the time of purchase as a factory
installed option and may not be installed on your unit.

Figure 5-7 P31 Purification System Cross Section

4 4

Cartridge Removal
5

1 8
9

1. Inlet 6. Cartridge
2. Jet Pipe 7. Bottom
3. Plug 8. Pressure Maintaining Valve
4. Final Pressure Safety Valve 9. Safety Bore
5. Housing 10. Cartridge Removal
5.2.3 Maintenance
5.2.3.1 Replacing the Cartridge
1. Depressurize system before starting any maintenance, by opening the condensate drain valve.
2. Unscrew plug (3) on top of the filter.
3. Extract old cartridge. (6) (See Figure 5-7)

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MNL-0146
4. Dry inside of the housing (5) with a clean cloth. Check for corrosion. Replace if necessary.
5. Lubricate threads, O-rings and threaded portion of replacement cartridge with petroleum jelly.
6. Insert new cartridge and secure in place with plug (3).
5.2.3.2 Chamber Replacement Interval

^ WARNING
The P31 Filter System is subject to dynamic loading. It is designed for a certain number of load cycles.
A load cycle equates to an abrupt pressure loss caused by draining the condensate.
The filter assembly must be replaced after reaching the maximum number of load cycles, otherwise the
housing may fail due to material fatigue

The maximum number of load cycles for the P31 filter assembly is 6,500 load cycles if operated at 5,000
psi (300 bar) or 20,000 load cycles if operated at 3,200 psi (225 bar).
If the number of load cycles of four per hour (i.e. the condensate is drained every fifteen minutes) is not
exceeded then the maximum number of operating hours before the filter must be replaced is 1,625 hours
at 5,000 psi (300 bar). To avoid exceeding the maximum number of load cycles the operating hours
should always be recorded.

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5.2.4 Replacement Parts List

Figure 5-8 P31 Purification System Parts List

6
4

5
4

8
7

Item Qty Part No. Description Notes

 1 082374 P31 Filter System
1 † … Plug Available only with 082374
2 1 N4784 O-ring
3 2 N4736 Backup Ring
4 2 N4735 O-ring
5 1 080100A Filter Cartridge, industrial use MS-AC
or 1 080114A Filter Cartridge, breathing air MS-AC-HP
6 † … Filter Housing Available only with 082374
7 1 80593 Filter Base Assembly See Figure 5-9
8 1 011430 Condensate Drain Tap Assembly

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Figure 5-9 P31 Purification System Base Assembly Parts List

15 7
1
6

5
4
2 3

9 8
10 16
11
12
13
14

Item Qty Part No. Description Notes

 1 80593 Filter Base Assembly
1 † … Base Available only with 082374
2 1 N24927 O-ring
3 1 N25503 O-ring
4 † … Seat Available only with 082374
5 † … Seat Spring Available only with 082374
6 1 2623 Spring
7 † … Adjusting Screw Available only with 082374
8 1 N4465 Set Screw
9 1 N3837 Hex Nut
10 1 78106 Cylindrical Pin
11 1 78688 Valve Piston
12 1 N23166 O-ring
13 1 4602 Backup Ring
14 1 91038 Valve Seat
15 † … Nozzle Available only with 082374
16 1 N24788 O-ring

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Figure 5-10 P31 Purification System Check Valve Parts List

1
2
3

5
4

Item Qty Part No. Description Notes

 1 80555 Check Valve
1 1 80716 Valve Seat
2 1 N24927 O-ring
3 1 73767 Valve Piston
4 1 80552 Valve Housing
5 4 N19539 Allen Screw

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5.3 P41 Purification System (Dive 07)
5.3.1 Major Components
The P41 Purification System major components are an Oil and Water Separator, and a Purification Cham-
ber. Figure 5-11 shows the functional interconnection of all the components.
5.3.2 Configuration Options
Some Bauer Compressors have the P41 Purification System as an option rather than a standard item,
therefore, this chapter may not apply to your unit.
The P41 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® Purifi-
cation Chamber. A Securus® Indicator and associated wiring are also added. If this option was not pur-
chased, portions of this chapter about the Securus® Electronic Moisture Monitor System do not apply.

Figure 5-11 P41 Purification System

3
10

4 9

5 7

6
1. Purification Chamber 6. Bleed Valve
2. Safety Valve 7. Check Valve
3. Check Valve 8. Pressure Maintaining Valve
4. Oil and Water Separator 9. Air Outlet
5. Condensate Drain 10. Final Pressure Switch

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Figure 5-12 P41S Purification System

8
9
7

IN

6
OUT

1 2 3 4 5
1. Pressure Gauge 6. Pressure Maintaining Valve
2. Condensate Drain Valve 7. Safety Valve
3. Oil and Water Separator 8. Securus® /Purification Chamber
4. Check Valves 9. Securus® Indicator
5. Bleed Valve
5.3.3 Component Description
5.3.3.1 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 = 130,000 load cycles (32,500 hours of operation)
Units operating between 5,000 and 6,000 psi = 55,000 load cycles (13,750 hours of operation)
The Bauer recommended frequency of condensate draining is every fifteen minutes and is a balance
between maximizing the life of the separator chamber and maintaining the quality of the delivered air.

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The air leaving the final stage is cooled in the aftercooler to approximately 18 - 27° F (10 -15° C) above
ambient temperature and then enters the oil and water separator. The oil and water separator works by
means of a sintered metal filter which separates liquid oil and water particles from the compressed air.

Figure 5-13 Oil and Water Separator

Figure 5-14 Oil and Water Separator Labels

5.3.3.2 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.
5.3.3.3 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.

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2. Activated carbon which absorbs oil vapors effecting taste and odor.
3. Molecular sieve to absorb oil and water.

5.3.3.4 Cartridge Handling

1. Never open the protective packaging a cartridge comes in prior to its Purification
actual use. The highly sensitive filter materials will absorb moisture Cartridge

from the atmosphere becoming saturated and useless.

2. Used cartridges must be disposed of in accordance with local regu-
lations.
5.3.3.5 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.
5.3.3.6 Check Valves Protective Cap
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 pre-
vents back-flow from filled storage cylinders or tanks.
5.3.3.7 Bleed Valve
A manually operated valve used to release the pressure in the chamber before maintenance.
5.3.3.8 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.
5.3.3.9 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.
5.3.3.10 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
appropriate control signals whenever the preset threshold values have been reached.

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5.3.3.11 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
components of the Securus® Electronic Moisture Monitor System.
5.3.3.12 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.

NOTICE
After applying power it will take about ½ second for the appropriate LED to illuminate.
During this time the status of the Securus® Electronic Moisture Monitor System is tested.

Color State Indication Compressor Unit Status

Green Steady Satisfactory The unit is in operation
The unit is in operation. The green
Yellow Flashing Cartridge Change Pre-warning
LED will also illuminate.
The unit is shutdown and can not be
Red Flashing Cartridge Change Required 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.

5.3.4 Maintenance
5.3.4.1 Oil & Water (condensate) Separator
To remove the sintered metal filter proceed as follows: (See Figure 5-15). Disconnect the power and shut
off the inlet supply line if applicable.
1. Depressurize the system by means of the bleed valve.
2. Remove the tubes connected to the side of the filter head (1).
3. Unscrew and remove the filter head.
4. Unscrew the sintered metal filter (2) from the filter head.
5. Remove the center screw (3) to remove the sintered metal filter.
6. Clean the sintered metal filter using hot soapy water. Blow dry with compressed air.
7. After cleaning the element, record the number of operating hours to ensure exact attention to the
maintenance intervals.
8. Lubricate the threads and O-rings as well as the threaded part of the sintered metal filter with petro-
leum jelly. Apply sparingly.

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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 5-15 Oil and Water Separator Figure 5-16 Sintered Metal Filter Assembly

2
3

1. Filter Head 3. Center Screw 1. Threaded Insert 4. Outer Filter

2. Sintered Metal Filter 4. O -rings 2. Filter Bottom 5. Filter Head
3. Inner Filter

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5.3.4.2 Cartridge Replacement

To change the purification cartridge, proceed as follows. (See Figure 5-17).

Figure 5-17 Cartridge Replacement

Pull
Up

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.
7. Remove the shipping covering and the protective cap from the bottom of the cartridge.
8. Lubricate the O-rings with white petroleum jelly. Apply sparingly.
9. Install the new cartridge. Be sure the cartridge snaps into place.
10. Reinstall the chamber head.
11. Close the bleed valve, restore the power and reconnect the inlet supply line, if applicable.

NOTICE
If air is detected bleeding out from the bottom of the chamber, the cartridge has not been installed properly
or is missing. Follow the instructions in Paragraph 5.3.4.3.

5.3.4.3 Leaking at the Safety Bore

1. Remove the cartridge following steps 1. to 4. in Paragraph 5.3.4.2.
2. Install cartridge if missing.
3. Remove cartridge and inspect O-rings.

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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 5.3.4.2

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5.3.5 Replacement Parts List

Figure 5-18 P41 Purification System Parts List

8
9
7

IN

6
OUT

1 2 3 4 5

Item Qty Part No. Description Notes

1 1 GAG-0009W Pressure Gauge
2 1 011430 Condensate Drain Valve
3 1 079416 Oil and Water Separator See Figure 5-19
4 2 VAL-0007 Check Valves
5 1 VAL-0377 Bleed Valve
6 1 VAL-0053 Pressure Maintaining Valve
7 1 VAL-0169 Safety Valve
8 1 082135 20” Purification Chamber See Figure 5-20
or 1 082136 20” Securus® Purification Chamber See Figure 5-21
9 1 … Securus® Indicator See Figure 5-21

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Figure 5-19 P41 Oil and Water Separator Parts List

a
2

b
3 c

c
4 b

f g

Item Qty Part No. Description Notes

 1 079416 Oil and Water Separator Assembly
1 † — Separator Head Available only with 079416
2 2 N04586 O-Ring
3 1 061860 Sintered Metal Filter
3a 1 N15133 O-Ring
3b 2 N04496 O-Ring, small
3c 2 N04385 O-Ring, large
3d 1 061858 Sleeve Element, large
3e 1 061859 Sleeve Element, small
3f 1 N07091 O-Ring
3g 1 061857 Screw
4 † — Separator Housing Available only with 079416
5 † — Bottom Plug Available only with 079416

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Figure 5-20 Purification Chamber Assembly Parts List

1
2
3

4
5

8
5
4

Item Qty Part No. Description Notes

 1 082135 Chamber Assembly
1 2 012293 Tool Post Screw
2 1 061237 Cover Plate
3 † — Filter Head Available only with 082135
4 2 N04736 Back-up Ring
5 2 N04735 O-ring
6 † — Filter Housing Available only with 082135
7 † — Filter Bottom Available only with 082135
8 1 067224 Purification Cartridge MS/AC/HP

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Figure 5-21 Securus® Electronic Moisture Monitor System Parts List

6
2 7

3 8

5 10

17

16

4
15
14
13
12
11
3
2

1 18

Item Qty Part No. Description Notes

 1 082136 Securus® Chamber Assembly
1 † — Bottom Plug Available only with 082135
2 2 N04736 Backup Ring
3 2 N04735 O-ring
4 1 061687 Securus® Cartridge MS/MS/AC/MS/SC/HP
5 † — Filter Body Available only with 082135
6 1 ADP-0204 Adapter, Right Angle
7 1 059850 Socket, RF type
8 2 012293 Tool Post Screw
9 1 06135 Cover Plate
10 † — Filter Head Available only with 80145
11 1 059855 Nut
12 1 059852 Drawback Screw

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Figure 5-21 (cont.) Securus® Electronic Moisture Monitor System Parts List

Item Qty Part No. Description Notes

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 - 120 VAC, 50 - 60 Hz
or 1 N15096 Securus® Indicator 12 - 24 VDC

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CHAPTER 6: COMPRESSOR DRIVE SYSTEM
6.1 Description, Horizontal Sliding
The compressor is powered by the drive motor or engine through a V-belt. The direction of rotation, as
seen facing the flywheel, is counterclockwise. Observe the arrow on the compressor block below.

Figure 6-1 Horizontal Engine Mount (typical)

6
7

1 2

1. Compressor Block 5. Electric Motor

2. V-Belt 6. Wire Mesh Guard
3. V-belt Sheave 7. Plastic Belt Guard
4. Sheave Bushing
6.2 Maintenance of the V-belt and Sheave
6.2.1 Checking the Sheave.
Before a new drive belt is installed, the condition of the sheave should be checked. A dirty or rusty
sheave impairs the drive’s efficiency and abrades the cover of the belt, which results in premature failure.
A worn sheave shortens belt life as much as 50%. If the groove is worn to the point where the belt bot-
toms, slippage may result and the belt may burn. If the side wall is “dished out,” the bottom shoulder
ruins the belt prematurely by wearing off the bottom corners.
6.2.2 Checking the V-belt
Inspect the V-belt regularly for damage and wear. Replace if necessary.
6.2.3 V-belt tension
V-belt tension is adjusted by sliding the motor or engine until pressing down on the V-belt between the
sheaves results in an approximate deflection of 3/8” (10 mm) [see pictures below]. The electric motor or
engine is secured on a sliding base. To obtain the correct belt tension, loosen the 4 motor bolts (1). There

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MNL-0146
are two bolts on the opposite side of the motor or engine, not shown in the pictures. Slide the motor or
engine away from the compressor until 3/8” belt deflection is obtained (2). Then tighten the 4 motor bolts
and recheck belt deflection.

Figure 6-2 Sliding Motor Base Adjustment

Figure 6-3 V-belt Deflection

Approximate Deflection
3 “ (10 mm)
8

6.3 Maintenance of the Drive Motor

The Only maintenance of the drive motor is occasional cleaning of the outside surfaces.

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6.4 Replacement Parts List

Figure 6-4 Dive Mate Drive Parts

6
7

1 2

Item Qty Part No. Description Notes

 DMT 06
1 1 IK 120 II Compressor Block
2 1 BET- 0013 V-belt
3 1 SHE-0220 V-belt Sheave
4 1 BUS-0026 Sheave Bushing
5 1 MTR-0023 Electric Motor 5 Hp, 1 Phase
or 1 MTR-0022 Electric Motor 5 Hp, 3 Phase
N.S. 1 BAS-0119 Sliding Motor Base
6 1 GRD-0582 Guard, Divemate, Wire
7 1 GRD-0578 Guard, Divemate, Plastic

 DMT 08
1 1 IK 120 II Compressor Block
2 1 BET- 0013 V-belt
3 1 SHE-0173 V-belt Sheave 60 Hz
or 1 SHE-0140 V-belt Sheave 50 Hz
4 1 BUS-0026 Sheave Bushing

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MNL-0146
Figure 6-4 (cont.) Dive Mate Drive Pars

Item Qty Part No. Description Notes

5 1 MTR-0052 Electric Motor 7.5 Hp, 1 Phase, 60 Hz

or 1 MTR-0033 Electric Motor 7.5 Hp, 3 Phase, 60 Hz
or 1 MTR-0208 Electric Motor 7.5 Hp, 3 Phase, 50 Hz
N.S. 1 BAS-0119 Sliding Motor Base
6 1 GRD-0582 Guard, Divemate, Wire
7 1 GRD-0578 Guard, Divemate, Plastic

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CHAPTER 7: ELECTRICAL ASSEMBLY; Motor Driven
7.1 Overview
This Dive Mate Electric model is operated by electric controls and is driven by an electric motor. Elec-
tricity supplied by the customer powers all functions of the unit.

7.2 Components
Figure 7-1 Electrical Components

4
1

1. Control Switch (Off / On)

2. Hour Meter
3. Motor Reset
4. Emergency Stop Button

7.2.1 Control Switch

The Control Switch is a 2 position switch used to turn the unit ON and OFF. When turned on it will illu-
minate to show that power is being supplied to the unit.
7.2.2 Hour Meter
The Hour Meter is a non-resettable meter used to keep track of the running time of the unit. Its a useful
tool in keeping up with the maintenance cycle of the compressor and ensuring purification filter car-
tridges are changed before they become saturated or fail due to excessive use.
7.2.3 Motor Reset Button
The Motor Reset Button is a blue push button on the front of the electrical box below the hour meter.
This button is used to reset the starter in the case of an electrical overload.
7.2.4 Emergency Stop Button
The E-Stop is a red, emergency stop button on the top of the electrical box used to shut down the unit in
the event of an emergency.
7.2.5 Temperature Switch
The Temperature Switch is located on the 3rd stage cylinder head, near the drive motor. It is provided to
prevent damage to the compressor from overheating. Once the temperature switch reaches its set point

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MNL-0146
it shuts down the drive motor and sounds the audible alarm. The compressor will not restart until the
temperature switch returns back to its operating temperature range.

Figure 7-2 Temperature Switch Figure 7-3 Final Pressure Switch

7.2.6 Final Pressure Switch

The compressor may be equipped with a final pressure switch. This switch limits the pressure the unit
can discharge. The Final Pressure Switch is a normally closed electric switch, once the pressure setting
is achieved the switch will open and shut down drive motor and compressor. The switch is adjustable
but should only be adjusted by a qualified technician.
7.3 Electrical Installation
This unit requires the customer to supply electrical power. When installing electrical supply consult the
appendix.

^ CAUTION
Only a licensed electrician should be allowed to do any electrical work on this unit

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7.4 Replacement Parts List

Figure 7-4 Electrical Components, Exterior

4
1

Item Qty Part No. Description Notes

 1 ASY-1052 Electrical Box Assembly
1 1 SWT-0309 Control Switch Green / Red
2 1 HMR-0036 Hour Meter, non-resettable
3 1 OPR-0020 Motor Reset button
4 1 SWT-0308 Emergency Stop Button

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MNL-0146

Figure 7-5 Electrical Box, Interior

4
5

6
1

Item Qty Part No. Description Notes

1 1 — Motor Starter see Table 7-1: & Table 7-2:
2 1 RLY-0184 Circuit Relay
3 1 RLY-0189 Delay Timer 5 - 100 seconds
4 1 FUS-0070 Secondary Fuse 1 Amp, 250 Volt
5 2 — Primary Fuse see Table 7-1: & Table 7-2:
6 1 TRR-0088 Transformer

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 Dive Mate

7.5 Parts List for Models with a 5 Horsepower Motor

Table 7-1: 5 HP, 60 Hz

VAC/PH Pri. Fuses Starter Relay
208/1 FUS-0077 SRT-0233 RLY-0177
208/3 FUS-0077 SRT-0233 RLY-0174
230/1 FUS-0077 SRT-0233 RLY-0177
230/3 FUS-0077 SRT-0233 RLY-0174
460/3 FUS-0075 SRT-0236 RLY-0187

7.6 Parts List for Models with a 7.5 Horsepower Motor

Table 7-2: 7.5 HP, 60 Hz
VAC/PH Pri. Fuses Starter Relay
208/1 FUS-0077 SRT-0241 RLY-0186
208/3 FUS-0077 SRT-0233 RLY-0176
230/1 FUS-0077 SRT-0241 RLY-0183
230/3 FUS-0077 SRT-0233 RLY-0175
460/3 FUS-0075 SRT-0233 RLY-0173

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MNL-0146
CHAPTER 8: INDICATORS & VALVES
8.1 Description
The Hour Meter is used to record the number of hours the unit has been operated.
The unit is also 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.
Pressure Sensors - Provide a signal to the PLC indicating air, gas, or oil pressure.
Temperature Sensors - Provides temperature readings for the PLC.

8.2 Replacement Parts List

Figure 8-1 Indicators

1 2 3 4

Item Qty Part No. Description Notes

1 1 HMR-0036 Hour Meter
2 —1 — 2.5” Pressure Indicator See Table 8-1:
3 —2 — Pressure Sensor See Table 8-2:
4 1 N30545 Temperature Sensor Optional

1.Number of pressure gauges and type vary with model

2.Number of pressure sensors and type vary with model

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Table 8-1: Pressure Gauges, 2.5” PSI & BAR

Part Number Pressure Range
GAG-0042W 0 - 100 psi (6.89 bar)
GAG-0006W 0 - 200 psi (13.79 bar)
GAG-0007W 0 - 600 psi (41.37 bar)
GAG-0008W 0 - 1,500 psi (103.42 bar)
GAG-0031W 0 - 3,000 psi (207 bar)
GAG-0009W 0 - 7,500 psi (517 bar)
GAG-0015 0 - 10,000 psi (689.5 bar)

Table 8-2: Pressure Sensors

Part Number Pressure Range Thread Color Comments
SEN-0035 0 - 8,700 psi (600 bar) 1/4 NPT Yellow
SEN-0049 0 - 8,700 psi (600 bar) 1/4 G Blue
SEN-0036 0 - 150 psi (10.34 bar) 1/4 NPT Yellow
SEN-0050 0 - 150 psi (10.34 bar) 1/4 G Yellow
SEN-0051 0 - 1,450 psi (100 bar) 1/4 NPT Green
SEN-0052 0 - 870 psi (60 bar) 1/4 NPT Grey
SEN-0053 0 - 232 psi (16 bar) 1/4 NPT Khaki
SEN-0054 0 - 14.5 psi (1 bar) 1/4 NPT Red
SEN-0055 0 - 30 psi (2 bar) 1/4 NPT Red Class I, Div 2, Groups A,B,C,D
SEN-0046 0 - 150 psi (10.34 bar) 1/4 NPT Red Class I, Div 2, Groups A,B,C,D
SEN-0047 0 - 7,500 psi (517 bar) 1/4 NPT Red Class I, Div 2, Groups A,B,C,D

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MNL-0146

8.1 Nonadjustable Valves

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

Figure 8-1 Check Valve Figure 8-2 Pressure Maintaining Valves (PMV)

2 2
1
1

8.2 Pressure Maintaining Valve

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

Figure 8-3 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).

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MNL-0146
8.4 Dual Pressure Control Assembly
8.4.1 General
The dual pressure assembly is optional and may not be on every model. This assembly must be
requested when ordering. The purpose of the dual pressure assembly is to provide two outlets with sep-
arate preset pressures. After the compressed air has been processed it travels to the high pressure outlet.
The final pressure switch and gauge are attached to the assembly also. If the lower preset pressure is
desired the lower pressure isolation valve must be opened. The compressed air then travels through the
3-port block and past the safety valve. It is then fed to the low pressure outlet. The safety valve ensures
that pressure higher than the low pressure setting is bled off.

Figure 8-4 Dual Pressure Assembly

1. Low Pressure Outlet
Safety Valve
2. Low Pressure Outlet
1 PMV
3. Low Pressure Outlet
4. Low Pressure Isolation
2 Valve
5. Final Pressure Switch
3 6. Final Pressure Gauge
7. High Pressure Outlet

4
6

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 Dive Mate
8.4.2 Replacement Parts

Figure 8-5 Dual Pressure Assembly

3
5

Item Qty Part No. Description Notes

1 1 VAL-0169 Safety Valve 1,000 - 6,500 psi
2 1 MFD-0001 3 Port Block
3 1 VAL-0076 Isolation Valve needle valve
4 1 SWT-0257 Final Pressure Switch 3,000 - 7,500 psi
5 1 GAG-0009W Final Pressure Gauge 0 - 7,500 psi

Page 94 1st Edition, Rev. 0, Chg. 4

MNL-0146
CHAPTER 9: APPENDIX
9.1 Safety
9.1.1 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 with-
stand.
• 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 fittings 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
ensure 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 unbalanced
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 and/or user assumes all liability resulting therefrom without any responsibility being
assumed by Bauer Compressors, Inc. The purchaser is urged to include the above provision in any
agreement for resale of this compressor.
• The use of repair parts other than those listed in this manual or purchased from Bauer Compressors,
Inc. may create unsafe conditions over which Bauer has no control. Such unsafe conditions can lead
to accidents that may be life-threatening, cause substantial bodily injury, and/or result in damage to
the equipment. Therefore, Bauer Compressors, Inc. can bear no responsibility for equipment in which
non-approved repair parts are installed.

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9.1.2 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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9.2 Unpacking, Handling and Installation
9.2.1 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
reason, we urge you to thoroughly examine the unit for possible damage and report any such damage to
the shipping company immediately.
Care must be taken in unpacking the compressor unit. Serious damage could result by not checking for
clearance between the item being unpacked and the packaging to be removed.
Handling of the unpacked unit should be performed using only the following devices. See Figure 9-1.

Figure 9-1 Lifting Devices

Chain Hoist

Fork Lift Hand Truck

1. Forklift 2. Chain Hoist 3. Hand Truck

^ WARNING
Be sure the lifting devices are capable of handling the weight of the unit (see Paragraph 1.4 for the
approximate 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 manufacturer’s warranty for the compressor
unit will be voided. All braces are tagged and labelled.

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9.2.2 Installation of the Compressor Unit

9.2.2.1 General
The floor site must be capable of supporting the weight of the unit. Secure the compressor unit to the
floor using ½” 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.

If equipped with machine leveling feet, ensure the unit is leveled to prevent movement when operating.
Raise the unit with a forklift or crane to raise the unit at the leveling foot. Loosen the locking nut and turn
the leveling bolt clockwise to desired height. Lock the leveling foot in place with the provided hex-nut
once the desired height is achieved. Set the unit back down on the floor and check adjusted height. If fur-
ther adjustment is needed repeat.

Figure 9-2 Leveling Feet

Before Raising After Raising

Leveling
Bolt

Locking
Leveling Nut
Foot

Ensure that the compressor air intake is supplied with fresh air. The intake air must not contain any
exhaust fumes or flammable vapors such as paint solvents, which may cause an internal fire. Make sure
that the intake air is unobstructed and moisture in the intake air is kept to a minimum. It is important that
units draw in clean air. The quality of the incoming air determines the quality of the compressed air. This
is important even for industrial air, as any incoming fumes will also be compressed and will increase the
toxicity to anyone working with the compressed air.
If a remote control is provided, the unit must be equipped with a clearly visible plate warning the possi-
bility of the unit starting. As an additional measure, anyone starting the unit by remote control must make
sure that no one is checking or operating the unit. For this purpose, a second warning plate should be pro-
vided at the remote control unit.

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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 40 - 115 °F (5 - 45 °C).

The area in which the compressor unit is installed should be well lit and easily accessible to facilitate ser-
vicing and routine maintenance.
9.2.2.2 Ventilation
During normal compression, heat is generated by the compressor and by the drive motorengine. For air-
cooled compressor units, this heat needs to be vented away by sufficient ventilation.
9.2.2.2.1 Outdoor Installation
It is recommended that all gasoline and diesel engine driven compressor units be installed outdoors. Elec-
trically driven compressor units may be installed outdoors only if enclosed with weatherproof enclosure
panels.
9.2.2.2.2 Indoor 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 oppo-
site wall, close to the ceiling or in the ceiling.
As a basic rule of thumb, the room should be ventilated sufficiently so as to prevent the ambient room
temperature from exceeding 105 °F (41 °C). Additional heat generating equipment or piping should be
avoided or must be well insulated.
9.2.2.2.3 Natural Ventilation
Natural ventilation should only be used up to a maximum drive power of 20 Hp. Units with higher pow-
ered drives should incorporate forced ventilation. To determine the size of the required intake and
exhaust openings for natural ventilation, refer to the following table:

Intake and Exhaust Openings Dependent on Room Volume (V) and Height (h)
V = 1750 ft³ h = 6.5 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft
Drive
Hp Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²) Intake (ft²) Exhaust (ft²)
3 1.3 1.1 … … … …
5 3.2 2.7 1.3 1.1 … …
7.5 4.5 3.8 2.6 2.2 1.3 1.1
10 9.7 8.1 6.5 5.4 2.6 2.2
15 14.5 12.4 9.7 8.1 5.8 4.8
20 20.6 17.2 15.6 12.9 9.7 8.1

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MNL-0146
9.2.2.2.4 Forced Ventilation
Forced ventilation should be utilized on units with drive power higher than 20 Hp. For units with lower
powered drive natural ventilation may be used. To determine the size of the required intake and exhaust
openings for forced ventilation, refer to the following table

Intake & Exhaust Openings Dependent on Room Volume (V) and Height (h)a
V = 1750 ft³ h = 8 ft V = 3500 ft³ h = 10 ft V = 7000 ft³ h = 13 ft
Drive Intake Exhaust Intake Exhaust Intake Exhaust
Hp (ft²) cfm (ft²) cfm (ft²) cfm
25 3.3 3,300 3.2 3,200 3.0 3,000
30 4.0 3,960 3.8 3,840 3.6 3,600
40 5.3 5,280 5.1 5,120 4.8 4,800
50 6.6 6,600 6.4 6,400 6.0 6,000
60 7.9 7,920 7.7 7,680 7.2 7,200
75 9.9 9,900 9.6 9,600 9.0 9,000
100 13.2 13,200 12.8 12,800 12.0 12,000
125 16.5 16,500 16.0 16,000 15.0 15,000
150 19.8 19,800 19.2 19,200 18.0 18,000
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.

9.2.3 Intake Air

The quality of air produced by the compressor unit is directly related to the quality of air that is taken in
by the compressor. Bauer compressors require clean, dry, shop air for optimal performance. The intake air
source must be free of contaminants such as fumes, engine exhaust, and solvents. If the intake source will
be piped in adhere to the following general rules:
• Use PVC or similar material that will not corrode and contaminate the incoming air.
• The entire run should be the same sized piping
• Install a moisture trap with a drain prior to the compressor inlet
• If using glue on the piping, allow sufficient time for the vapors to dissipate before using the com-
pressor
9.2.3.1 Inside Air Source
The location of the compressor and its air intake are significant to the quality of the air produced and the
performance of the purification system. Locating the air intake near other heat producing equipment must
be avoided when possible. A close proximity to water heaters, boilers, and such are potential contami-
nates to the quality of the processed air. Purification cartridge lifespans are dramatically reduced when
the processed air’s temperature is elevated. Inadequate ventilation reduces the ability of the compressor
to cool itself or the air being compressed.

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High levels of CO2 are another cause of breathing air to become contaminated. CO2 limits are 1,000 ppm.
and most fresh air already contains about 330 ppm. A number of people inside poorly ventilated rooms
can easily bring the CO2 levels up to 600 ppm or more. If high levels of CO2 are normally present at the
compressor intake, increased ventilation may alleviate the problem. Moving the intake to an outside loca-
tion is another viable solution.
9.2.3.2 Outside Air Source
Moving a compressor’s air intake to an outside location can improve the quality of the processed air and
increase the lifespan of the purification filters. Before moving a compressor’s intake to an outside loca-
tion take into account the changing conditions that may occur around where the air intake will be. Other
exhausts vents, vehicle or machinery exhausts and fumes may contaminate the air in the area you wish to
place your air intake. Air samples can be taken and submitted for laboratory analysis if there are any
doubts in the air quality.
If your air source is located outside, inspect the inlet piping regularly to ensure nothing has obstructed or
contaminated the air that is being taken in.
9.2.4 Compressor Intake Piping
It is best to keep intake piping as short and straight as possible. Minimum height should be 8 - 10 ft. The
end of the piping should point downward to avoid precipitation. Nothing should be allowed to restrict the
air flow.
Breathing air can often fail to meet CGA standards, unless procedures are taken to provide a fresh air
source for the compressor intake. The inlet source should be the cleanest ambient air available. Factors to
consider when installing compressor intake piping in a building are the length of pipe, the diameter, and
the number of 90° bends. All intake pipes must have a bug screen on the inlet end to prevent birds, bugs,
or large debris from entering the inlet system. A gooseneck end or water trap on the pipe will prevent
water from entering the compressor system. See the following table for recommended inlet pipe diameter.

Guideline for Intake Piping with Max. Four 90° bends

Pipe
Inlet Capacity Distance
Diametera
≤50 ft 2”
≤ 13 SCFM 50 - 100 ft 3”
100 - 150 ft 4”
≤50 ft 3”
13 - 30 SCFM 50 - 100 ft 4”
100 - 150 ft 5”
≤50 ft 4”
30 - 50 SCFM 50 - 100 ft 5”
100 - 150 ft 6”
a. Add 1” of pipe diameter if the number of 90° bends exceeds four

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9.2.5 Installation Procedures
1. Use PVC pipe for ease of installation.
2. Ensure pipe is attached securely to the wall.
3. Terminate the PVC pipe 3 to 5 ft from the compressor intake with a stub reducer the same size as
the compressor inlet housing pipe.

Figure 9-3 Example of Air Intake Piping

enre run
should be
same size

intake Screen must be

filter large enough not
to restrict air intake

12”
Min

compressor drain valve

9.2.6 Electrical Installation

9.2.6.1 Electric 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 fuse protection for
the compressor must be carried out in compliance with local, state and national electrical regulations.
9.2.6.2 Electrical 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 unit electrical enclosure. All wiring should be done by a licensed electrician familiar
with national, state and local electrical codes.

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The label shown in Figure 9-4 indicates where the incoming power is connected to the compressor unit
electrical enclosure. This label must be removed before using the equipment.

NOTICE
If this unit is equipped with an Air Kool system, consult the Air Kool Section for electrical installation.

Figure 9-4 Incoming Power Wiring Label

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

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MNL-0146

3 PHASE
Full Load Amps Fuse Ampsa Minimum Wire Sizeb
Motor
Hp 208 V 230 V 460V 208 V 230 V 460V 208 V 230 V 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 30 20 4
60 169 154 77 250 200 100 40 30 3
75 211.2 192 96 300 300 150 300 250 1
100 273 248 124 400 350 175 500 350 20
125 343.2 312 156 500 400 200 2-40 2-30 30
150 396 360 180 600 500 250 2-300 2-40 40
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.
9.2.7 Pneumatic Leaks
Each unit is tested prior to leaving the manufacturing facility. All loose or leaking fittings are tightened
prior to shipping. During the shipping process pneumatic connections may work loose and leaks may
develop. Ensure each unit is leak tested prior to being placed in full operational usage.

^ WARNING
Never tighten or adjust fittings or connections under pressure. Always depressurize first.

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9.3 Long Term Storage
9.3.1 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.
9.3.2 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.

9.3.2.1 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 purification inlet tubing completely.

9.3.3 Preserving the Compressor

1. Operate the compressor again and slowly spray approximately 0.35 oz. (10 cc) of oil into the inlet
port while the compressor is running. Keep the shut-off valve and the condensate drain valves open.
2. After spraying the oil into the inlet port, run the compressor unit for an additional 5 minutes before
shutting the compressor unit down.
3. Close the shut-off valve and condensate drain valves.
4. Close the inlet port with a dust cap and/or tape.

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9.3.4 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.

9.3.5 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.

9.3.6 Reactivating the Compressor Unit

1. Remove any dust cap or tape from the inlet port and install an intake filter cartridge.
2. Change the oil, ensuring proper oil level when refilled.
3. The motor must be thoroughly dry before applying power.
4. For units with a purification system, change all cartridges.
5. Run the compressor with open outlet valve for approximately 10 minutes. Check for proper opera-
tion of the lubricating system.
6. After 10 minutes, close the shut-off valve and run the system up to final pressure until the final
pressure safety valve vents. On compressor units with a compressor control system, raise the pres-
sure switch setting the switch above normal limits to override the pressure switch. Be sure to reset
the switch after checking.
7. Check the interstage safety valves for leakage.
8. Establish the cause of any faults and remedy.
9. Stop the unit when it is running properly. The compressor is then ready for operation.

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9.4 Reproducible Forms
9.4.1 Scheduled Maintenance Form

Daily Para. Date Signature

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MNL-0146

Weekly or as required. Para. Date Signature

500 Operating Hours. Para. Date Signature

1,000 Operating Hours. Para. Date Signature

2,000 Operating Hours. Para. Date Signature

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3,000 Operating Hours. Para. Date Signature

Annually. Para. Date Signature

Biennially. (Every two years) Para. Date Signature

Page 110 1st Edition, Rev. 0, Chg. 4

MNL-0146

9.4.2 Record of Operating Hours

Date Minutes Total Date Minutes Total

Subtotal: Subtotal:

October 23, 2012 Page 111

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9.5 Reference Data
9.5.1 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 half turn.

Table 9-1: Torque Values

Bolt or Screw Size Max. Torque
Hex and Socket Head 1/4 in (6 mm) 7 ft-lb. (9.5 N m)
Hex and Socket Head 5/16 in (8 mm) 18 ft-lb. (24.4 N m)
Hex and Socket Head 3/8 in (10 mm) 32 ft-lb. (43.4 N m)
Hex and Socket Head 1/2 in. (12 mm) 53 ft-lb. (71.9 N m)
Hex and Socket Head 9/16 in (14 mm) 85 ft-lb. (115.3 N m)
Hex and Socket Head 5/8 in (16 mm) 141 ft-lb. (191.2 N m)

9.5.2 Torque Sequence Diagrams

Figure 9-5 6 Bolt and 4 Bolt Torque Sequence

3
5 3

4 Bolt Torquing 6 Bolt Torquing

2 1 2 1
Sequence Sequence

4 6
4

9.5.3 Conversion Formulas

°F = 9/5 °C + 32 °C = 5/9 x (°F - 32)
psi = bar x 14.5 bar =psi x 0.0689

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MNL-0146

9.5.4 Approved Lubricants Chart

Unless otherwise specified in text, use the lubricants in Table 2.

Table 9-2: Lubricant Chart

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
tube connection parts (threads, cap nut and com- Never-Seez® NSWT, Pipe Dope or teflon tape
pression rings)
DOW Corning 732 or equivalent silicone com-
Paper gaskets
pound applied on both sides before assembly,
DOW Corning 732 or equivalent temperature resis-
High temperature connections
tant compound,
Tube connection ferrules, Never-Seez® NSWT

9.5.5 Glossary of Abbreviations and Acronyms

AC Activated Charcoal, removes odor and taste
ACD Automatic Condensate Drain
ASME American Society of Mechanical Engineers
CW Clock Wise
CCW Counter-Clockwise
CGA Compressed Gas Association
DIN Deutsches Institut für Normung
DOT Department of Transportation
E1 single phase electrical supply (Electric 1)
E3 three phase electrical supply (Electric 3)
HP Hopcalite, a chemical catalyst which 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
PLC Programmable Logic Controller
PMV Pressure Maintaining Valve
SC Securus® moisture sensing device

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9.6 Additional Documents
9.6.1 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.
9.6.2 Other Documents
OEM Manuals and other Bauer manuals may be included in the documentation shipping package.

Page 114 1st Edition, Rev. 0, Chg. 4

 CORRECTIONS & COMMENTS

In an effort towards constant improvement, the Documentation section of Bauer Compressors, Inc.
would like to give you the opportunity to suggest improvements or corrections to this manual. If you find
any inaccuracies or have suggestions feel free to E-mail us at: documentation@bauercomp.com, or fill
out the form below and mail it to us:

Submitters Contact Information: Unit Information:

Name: ______________________________ Model:

Address: _____________________________ Serial#:

(number & street)

_____________________________ Block#:
(city, state \ zip)
E-mail: ________________________ MFG Date:
(optional)

Inaccuracies: page# ________ figure# ________ paragraph# ________

Suggested Corrections:

Additional Comments:
fold here

place
postage
here

Bauer Compressors, Inc.

Attn: Documentation
1328 Azalea Garden Rd.
Norfolk, VA 23502-1944

fold here

tape or glue here