Bauer Compressors BF 100-6 Instruction Manual And Replacement Parts List
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Bauer Compressors BF 100-6 Instruction Manual And Replacement Parts List

Bottle fill panel
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Instruction Manual and Replacement Parts List
BF 100 - 6
Bottle Fill Panel
September 30, 2008
BAUER Compressors, Inc.
1328 Azalea Garden Road
Norfolk, Virginia 23502-1944
Special Edition, Rev. 0 Chg. 0
© 2008 Bauer Compressors, Inc.
BAUER
COMPRESSORS
MNL-093558
Phone: (757) 855-6006
Fax: (757) 855-6224
www.bauercomp.com

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  • Page 1 Instruction Manual and Replacement Parts List BF 100 - 6 Bottle Fill Panel September 30, 2008 Special Edition, Rev. 0 Chg. 0 MNL-093558 © 2008 Bauer Compressors, Inc. BAUER Compressors, Inc. Phone: (757) 855-6006 1328 Azalea Garden Road Fax: (757) 855-6224 Norfolk, Virginia 23502-1944...
  • Page 2 BF 100 - 6 COMPRESSORS 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.

  • Page 3: Table Of Contents

    BAUER MNL-093558 COMPRESSORS Table of Contents CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION HOW TO USE THIS MANUAL............................1 1.1.1 Manual Safety Notices ............................... 1 HOW TO USE THE REPLACEMENT PARTS LIST ....................
  • Page 4 BAUER BF 100 - 6 COMPRESSORS 4.3.2 Preparations ..................................22 4.3.2.1 Units Equipped with a Filter System ..........................22 4.3.3 Preserving the Compressor...............................22 4.3.4 Preventive Maintenance During Storage..........................23 4.3.5 Lubrication Oils for Preservation .............................23 4.3.6 Reactivating the Compressor Unit............................23 REPRODUCIBLE FORMS ..............................24 4.4.1 Scheduled Maintenance Form ............................24 4.4.2...
  • Page 5 BAUER MNL-093558 COMPRESSORS List of Figures CHAPTER 1: - - - - - - - - - - - - - - - - - - - - - INTRODUCTION Figure 1-1 Wall Mounted Fill Panel; BFP-100-6........................4 Figure 0.1-1 BFP 100 - 6 Flow ..............................

  • Page 6: Chapter 1

    INTRODUCTION 1.1 How To Use This Manual This manual contains the operating and maintenance instructions for the Bauer Compressors, Inc. prod- uct(s) listed on the front cover. All instructions in this manual should be observed and carried out as written to prevent damage or pre- mature wear to the product or the equipment served by it.

  • Page 7: How To Use The Replacement Parts List

    BAUER MNL-093558 COMPRESSORS 1.2 How to Use the Replacement Parts List • A lozenge ◊ in the Item Number column indicates the part number for a complete assembly. • A dagger (†) in the Qty column with or without an ellipsis (…) in the Part Number column means the part is illustrated for assembly purposes only and is not available for sale as an individual component.

  • Page 8: How To Use The Appendix

    BAUER BF 100 - 6 COMPRESSORS 1.3 How to Use the Appendix Information contained in the Appendix to this manual includes the following. • The safety instructions applicable to this product. They must be read, understood and complied with prior to operating the product. •...

  • Page 9: Unit Description

    BAUER MNL-093558 COMPRESSORS 1.4 Unit Description The BAUER BF 100 - 6 fill station panel is used in conjunction with an air-storage system or an air- compressor to recharge air-bottles. Figure 1-1 Wall Mounted Fill Panel; BFP-100-6 4,000 psig 300 psig 200 psig 4,500 psig 1.

  • Page 10: Pneumatic Flow

    BAUER BF 100 - 6 COMPRESSORS 1.6 Pneumatic Flow The compressed air enters through the inlet, in the back of the unit. It flows to the inlet pressure gauge, where it is channeled to 4 separate regulators. The regulators are set from left to right (facing the con- trols) 4,500 psig, 4,000 psig, 300 psig, and 200 psig.

  • Page 11: Chapter 2

    BAUER MNL-093558 COMPRESSORS BF SERIES OPERATION CHAPTER 2: 2.1 Bottle Filling Procedures See Figure 6 ^ WARNING ^ Do not attach bottles to outlets units unless the bottle is rated for appro- priate pressure. (Note pressure stamped on the tank neck) ^ WARNING ^ Never open the fill valve unless the bottle is connected to the fill hose.

  • Page 12: Attaching The Fill Yoke To The Air Storage Bottle

    BAUER BF 100 - 6 COMPRESSORS 2.1.1 Attaching the Fill Yoke to the Air Storage Bottle 1. Ensure both the fill valve and bottle valve are closed. 2. Connect the air bottle to the BFP fill hose utilizing the fill yoke. 2.1.2 Opening Sequence for Filling the Bottle 1.

  • Page 13: Parts Lists

    BAUER MNL-093558 COMPRESSORS 2.1.4 Parts Lists Figure 2-2 BFP- 100 - 6 Item Qty Part No. Description Notes GAG-0009W Pressure Gauge 7,500 psi/bar REG-0003 Regulator 6,000 psi - in — 0 - 5,000 psi - out VAL-0076 Fill Valve (needle valve) REG-0013 Regulator 6,000 psi - in —...

  • Page 14: Figure 2-3 Bfp - 100 - 6 Safety Valves

    BAUER BF 100 - 6 COMPRESSORS Figure 2-3 BFP - 100 - 6 Safety Valves Item Qty Part No. Description Notes VAL-0131 Safety Valve set to 275 psig VAL-0167 Safety Valve set to 325 psig VAL-0169 Safety Valve set to 4,400 psig VAL-0169 Safety Valve set to 5,000 psig...

  • Page 15: Pressure Gauges

    BAUER MNL-093558 COMPRESSORS MAINTENANCE CHAPTER 3: 3.1 Pressure Gauges Observe the pressure gauges daily. If the readings of any of the gauges seem to be incorrect, bleed off all system pressure. Then, remove the gauge and check for wear and tear, accuracy and proper function- ing by comparing it to a precision test gauge or a dead weight tester.

  • Page 16: Storage Bottles

    BAUER BF 100 - 6 COMPRESSORS 3.5 Storage Bottles All storage bottles should be visually inspected internally every year. Every three (3) years, D.O.T. bottles must be hydrotested. Check local and state regulations regarding testing of ASME and/or D.O.T. bottles. ^ NOTE ^ Some states require an annual visual inspection.

  • Page 17: Chapter 4

    BAUER MNL-093558 COMPRESSORS CHAPTER 4: APPENDIX 4.1 Safety 4.1.1 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.
  • Page 18 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.

  • Page 19: Safety Warning Labels

    BAUER MNL-093558 COMPRESSORS 4.1.2 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.

  • Page 20: Unpacking, Handling And Installation

    BAUER BF 100 - 6 COMPRESSORS 4.2 Unpacking, Handling and Installation 4.2.1 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 dam- age to the shipping company immediately.

  • Page 21: Installation Of The Compressor Unit

    BAUER MNL-093558 COMPRESSORS 4.2.2 Installation of the Compressor Unit 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.

  • Page 22: Indoor Installation

    BAUER BF 100 - 6 COMPRESSORS 4.2.2.2.2 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 opposite wall, close to the ceiling or in the ceiling.

  • Page 23: Cooling Air Flow Requirements

    BAUER MNL-093558 COMPRESSORS Figure 4-3 Determining the Method of Ventilation Convection Forced Ventilation Forced Ventilation Ventilation with Room Fan with Ducts 7000 ft³ (200 m³) 3500 ft³ (100 m³) 2625 ft ³ 1750 ft³ (50 m³) 3 hp 30 hp 20 hp 50 hp 150 hp...

  • Page 24: Forced Ventilation

    BAUER BF 100 - 6 COMPRESSORS 4.2.2.2.6 Forced Ventilation Forced ventilation is required for compressors with a 20 hp motor or greater. To determine the required intake opening and exhaust flow refer to the following table: Dependence on Room Size (V) and Height of Exhaust Opening (h) V = 1750 ft³...

  • Page 25: Figure 4-4 Incoming Power Wiring Label

    BAUER MNL-093558 COMPRESSORS The label shown in Figure 4-4 indicates the where the incoming power is connected to the compressor unit’s electrical enclosure. This label must be removed before using the equipment. Figure 4-4 Incoming Power Wiring Label September 30, 2008 Page 20...
  • Page 26 BAUER BF 100 - 6 COMPRESSORS 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 Amps Minimum Wire Size...

  • Page 27: Long Term Storage

    BAUER MNL-093558 COMPRESSORS 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. 4.3 Long Term Storage 4.3.1 General If the compressor unit will be out of service for more than six months, it should be preserved in accor-...

  • Page 28: Preventive Maintenance During Storage

    BAUER BF 100 - 6 COMPRESSORS 4.3.4 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.

  • Page 29: Reproducible Forms

    BAUER MNL-093558 COMPRESSORS 4.4 Reproducible Forms 4.4.1 Scheduled Maintenance Form Daily Para. Date Signature September 30, 2008 Page 24...
  • Page 30 BAUER BF 100 - 6 COMPRESSORS 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 Page 25 Special Edition, Rev. 0 Chg. 0...
  • Page 31 BAUER MNL-093558 COMPRESSORS 3,000 Operating Hours. Para. Date Signature Annually. Para. Date Signature Biennially. (Every two years) Para. Date Signature September 30, 2008 Page 26...

  • Page 32: Record Of Operating Hours

    BAUER BF 100 - 6 COMPRESSORS 4.4.2 Record of Operating Hours Date Minutes Total Date Minutes Total Subtotal: Subtotal: Page 27 Special Edition, Rev. 0 Chg. 0...

  • Page 33: Reference Data

    BAUER MNL-093558 COMPRESSORS 4.5 Reference Data 4.5.1 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.

  • Page 34: Approved Lubricants Chart

    BAUER BF 100 - 6 COMPRESSORS 4.5.4 Approved Lubricants Chart Unless otherwise specified in text, use the lubricants in Table 2. Usage Lubricants O-rings, rubber and plastic parts; filter housing Parker Super “O” Lube threads, sealing rings Bolts, nuts, studs, valve parts, copper gaskets and tube connection parts (threads, cap nut and com- Never-Seez NSWT, Pipe Dope or teflon tape...

  • Page 35: Additional Documents

    BAUER MNL-093558 COMPRESSORS 4.6 Additional Documents OEM Manuals and other BAUER manuals may be included in the documentation shipping package. September 30, 2008 Page 30...

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