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350 – 7000 PSIG4 – 206 SCFM
The Complete System
High PressureIndustrial Air Systems
Compression Pro
cessin
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istr
ibuti
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Storage
Toll Free 800.856.4046 Call 603.598.0891
BAUER COMPRESSORS, INC.Norfolk, Virginia is registered to ISO 9001:2000
HPIA111.06.08.3sp
• Medium and High Pressure Air Compressorsand Accessories for Industrial Applications
• High Pressure Compressors andAccessories for Inert Gases
• High Pressure Compressors andAccessories for Plastics Technology
• High Pressure Natural Gas Compressors andAccessories for Natural Gas Vehicle Refueling
• High Pressure Compressors andAccessories for Breathing Air
• Adsorption Dryers• Storage Systems• Distribution Panels• Training, Service, and Genuine BAUER Parts
The equipment advertised herein is not suitable for breathing air. To be suitable for breathing air a compressor must include, as a minimum, apurification system that is designed specifically to purify compressed air to meet all recognized standards for breathing air and be suitably labeledfor such use. In the absence of such a purification system and labeling, the compressor shall be considered unsuitable for breathing air. If acompressor that does not include a breathing air purification system and labeling is used by the Purchaser and/or User for breathing air, thePurchaser/User assumes all liability resulting therefrom without any responsibility or liability assumed by Bauer Compressors, Inc.
The Purchaser/User should include the above statement in their terms of sale for any resale of the compressor.
Disclaimer: Bauer Compressors, Inc. continuously reviews their products’ design and performance to better to serve our customer’s needs.Therefore, information contained herein is subject to modification without notice or obligation.
Products contained herein are subject to the standard terms and conditions of sale and warranty of Bauer Compressors, Inc.A copy of the standard terms and conditions of sale and warranty are available on request.
BAUER COMPRESSORS Inc.1328 AZALEA GARDEN ROADNORFOLK, VIRGINIA 23502-1944TELEPHONE: (757) 855-6006TELEFAX: (757) 857-1041E-MAIL: [email protected]: www.bauercomp.com
Products and Servicesfrom the Air and Gas Experts
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1
Dedication to Quality
BAUER has been manufacturing high pressure compressors for more than 60 years.From our humble beginnings in the BAUER family home in Munich, Germanyin 1946 to our current status as an industry leader, BAUER has workedhard to earn a reputation as the world’s foremost innovative designer andmanufacturer of high pressure compressors of the very highest quality.
Since then BAUER has expanded internationally with offices in Italy, Japan,Singapore, Austria, England, China, United Arab Emirates, France and theUnited States. The U.S. facility, BAUER COMPRESSORS, INC. of Norfolk,Virginia, was founded in 1976.
Since our founding, BAUER Norfolk has experienced continued growth insales and expansion of facilities. BAUER Norfolk is headquarters for branchoffices in Miami, Los Angeles, San Francisco and Detroit. We are specialistsin the markets of high pressure industrial air, plastics technology, natural gas,inert gas and breathing air.
Expertise, innovation, diversity, quality, reliability and dedication to our valued customers are reasonswhy BAUER is recognized as the leader in high pressure compressors.
BAUER compressors are field proven in a multitude of demanding applications and harsh environments.Our compressors are available with capacities from 4 – 206 SCFM with working pressures from350 – 7000 PSIG and with power requirements from 5 – 125 HP. This represents the most completeline of industrial high pressure compressors available.
We are pleased to present our products for industrial high pressure air applications. We hope youfind this catalog informative and encourage you to contact BAUER for your industrial high pressureair requirements.
BAUER COMPRESSORS, INC. Norfolk, Virginia USA
Experience for Your Benefit
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2
Dedication to You
Since the founding of our company, we have been committed to a philosophy that customer satisfactionis achieved through a strategy of continuous improvement using in-house research and development,engineering, manufacturing and support services. Our ISO 9001:2000 registered quality managementsystem is testament to our commitment to quality and customer satisfaction.
P R O J E C TM A N A G E M E N T
Our systems are expertlydesigned by experiencedengineers to meet yourrequirements. Custom
designs are our specialty.
T R A I N I N GTraining for operation and
maintenance of our products isavailable through distributors,branch offices and the factory.
On site training available.
P R O D U C T S U P P O RTTechnical assistance, spare
parts and service are availablefrom distributors, branchoffices and the factory.
We work diligently to yoursupport your needs.
Q U A L I T Y S Y S T E MThe Quality Management
System is responsible for theprocesses and procedures
required to manufactureproducts that meet and exceedour customers’ requirements.
S Y S T E M E VA L U AT I O NStart the job off right by
reviewing your requirementswith our experienced sales
staff. We can assist in selectingthe best solution tailored to
your needs.
I N S T A L L A T I O NRequest our Installation
Manual for recommendationsfor installing your BAUER air
cooled compressor toensure optimum performance
and reliability.
C U S T O M E RS A T I S F A C T I O N
Begins with expert systemevaluation and continues with
the design, installation, trainingand support services to
ensure the highest qualityand optimum performance
of the product.
Commitment to Customer Satisfaction
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Overview of the Complete BAUER
Engineered SolutionsBAUER I and B Series industrialcompressors and boosters areavailable in a variety of standardpackage configurations tosatisfy the requirements ofmost applications. For specialrequirements, BAUER can modifya standard package or designa custom package. All modelsfeature a frame for the compressorand motor that is vibration isolatedfrom the package’s main frame andinclude BAUER’s proprietary PLCcontrol system, color coded wiringharness and emergency stoppush button.
Compressors and boosters through20 HP are available in the Classic IIhorizontal design or Verticus verticaldesign. Both styles are availablewith or without enclosure. Themodern styling of the enclosurefor Classic II provides an attractivefinished look to the product. Thesound attenuated enclosure for thespace saving Verticus designmakes it perfect for installation onthe manufacturing floor in personneloccupied spaces. The smaller miniVerticus is used for all modelsthrough 7.5 HP while the slightlylarger MAXI Verticus is used for allmodels 10 through 20 HP.
Compressors 20 through 40 HPare available in horizontal or verticaldesign with or without enclosure.Compressors 50 HP and largerare standard in a horizontal designwith or without enclosure. Standardenclosures for the larger units areavailable with sound attenuatingmaterial or a custom enclosurecan be designed for special noiseor climate requirements.
See page 12 for full details
Enclosed Vertical (25 – 40 HP)
Open Horizontal (50 – 125 HP)
Enclosed Horizontal (50 – 125 HP)
3
System without Air-Kool
ClassicII
Verticus
Compression
AIR-KOOL
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It is essential that air storage issized properly for the demandsof the system and to preventshort cycling of the compressorand motor.
Storage systems for B Seriescompressors use ASME codestamped air receivers.
Storage systems for I Seriescompressors are available withDOT receivers for workingpressures to 6000 PSIG andASME receivers for workingpressures to 7000 PSIG.
Air storage systems are availablefor installation remote from thecompressor or packaged withthe compressor.
See pages 15-16 for full details
BAUER offers standard andcustom designed products forair distribution. Requirements forair distribution can range from abasic pressure regulation panelto a sophisticated distributionsystem that is controlled by aprogrammable logic controller.
Air Distribution Systems areavailable for use with or withoutstorage, with single or multipleregulators and outlets andmanual or automatic operation.
BAUER Air Distribution Systemsare well-known for theirprofessional design, reliabilityand ease of operation.
See pages 17-18 for full details
Non-RegenerativeThe BAUER IP (Industrial Processing)processing systems are the ideal solutionfor economical drying and purification.These systems do not require electricalpower for operation nor a portion of thecompressor’s flow for regeneration.
RegenerativeThe BAUER SECCANT dryers usethe pressure swing adsorption (PSA)method for automatic regeneration ofthe cartridges.
BAUER adsorption dryers offeratmospheric dewpoints to -94ºF anduse replaceable cartridges.
RefrigeratedThe BAUER AIR-KOOL refrigerated aircooler increases the efficiency of the finalseparator and extends the life of theprocessing cartridge(s) up to six times.
See pages 13-14 for full details
High Pressure Industrial Air System4
System without StorageSystem without Processing
TYPICAL STORAGE FOR B SERIES (350 – 1000 PSIG)
TYPICAL STORAGE FOR I SERIES(1000 – 7000 PSIG)
REGULATOR WITHFINAL PURIFICATION
AUTOMATIC PANEL
PRESSURE REGULATION PANEL
REGULATOR WITH FLEXIBLE HOSE
Processing Storage Distribution
IP SERIES
SECCANT
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The Heart of the System
4 – 206 SCFM 350 – 7000 PSIG5
4 STAGE7.5 - 10 HP
12.14II
3 STAGE3 - 7.5 HP
100II, 120II & 12.4II
4 & 5 STAGE10 - 20 HP
150II & 180II Range
T H E C O M P L E T E R A N G E
SCFM
SCFM
HP
B22.5B12.4II
8.5 - 10.4
7.5 - 10 60 75
58 79
7 23 - 31 46 - 60 73 98 - 113 164 206
HP5 15 - 20 30 - 40 50 60 - 75 100 125
I12.14II*
15
15
I15.11II
20
20
I18.1III25.9 I25.18
4
5
I100HII*
B23.4B25.4
B28.2B25.5*
B28.3*
I SERIES • 5000 – 7000 PSIG • 3, 4 & 5 STAGE
I SERIES • 1000 – 5000 PSIG • 3 & 4 STAGE
B SERIES • 350 – 1000 PSIG • 3 STAGE
*Models B25.5 and B28.3 have a maximum working pressure of 900 PSIG.
4 - Stage Compressor5 - Stage Compressor
3 - Stage Compressor
*Models I100HII, I12.14II and I22.42 have a maximum working pressure of 6000 PSIG.
27 - 31
25 - 30
I22.42*
11.510
I15.1II
SCFM4.7 21.5 28 - 33 35 - 48 54 - 63 86 - 117
HP5 20 25 - 30 30 - 40 50 - 60 75 - 100
I100II
I180III220
I250I230
I280
17.515
I150II
77.5
I120II
Compression
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ISO 9001:2000 Quality
T H E B A U E R A D V A N T A G E S . . .
. . . F O R Y O U R B E N E F I T
• Large Surface Area andFine Ribbing on Cylinders forEfficient Heat Dissipation
• Pressurized Lubricationwith Oil Filter for ReliableLubrication of InternalComponents
• Readily Accessible Valves – No Major DisassemblyRequired for Inspectionand Maintenance
• Extended MaintenanceIntervals Due to EfficientCooling and PressureLubrication
3 & 4 STAGE25 - 30 HP22 Range
3 & 4 STAGE30 - 50 HP23 Range
3, 4 & 5 STAGE50 - 150 HP
25 & 28 Range
• Affordable GenuineReplacement Parts forQuality Repairs
• Intake Filter for Protectionof the Internal Componentsof the Compressor
• Encapsulated Crankcase toProtect the Environment,No Oil Laden Mist
• Automatic Condensate Drainfor Automatic Drainage of theInterstage and Final Separatorsand Unloaded Starting
• Available in a Wide Rangeof Capacities to Meet YourRequirements
• Proven Air Cooled Design –Economical, Reliable,Environmentally Friendly
• Roller and Needle BearingsUsed at All Bearing Surfacesfor Reduced Friction and Heat,Improved MechanicalEfficiency and Extended Oil Life
• Heavy-Duty Roller Bearingsfor Strong Support of theCrankshaft and LongBearing Life
• Counterbalanced Crankshaftfor Smooth, PracticallyVibration-Free Operationfor Extended Life and RequiresNo Special Foundation
• Corrosion Resistant Materialsfor All Coolers and Separators
– The Compressor
6
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Integrated Design
Intake FilterClean, filtered air is essential for properoperation of the compressor. The intake to thecompressor is protected by a high performancefilter. Additional filtration or treatment of the airmay be required for dusty environments orharsh climates.
Safety ValvesA safety valve is installed after each stageof compression to ensure safe operation andto protect the compressor from overpressure.
SeparatorsSeparators remove oil and water from the compressed air. All separators are made ofcorrosion resistant materials for long life andto prevent contamination of the compressed air.
CrankcaseThe crankcase serves as a strong foundationfor the cylinders, sturdy support for the drivinggear and provides a large oil reservoir. Thecrankcase is completely sealed against dirt andmoisture for protection of internal components.BAUER uses a sturdy cast aluminum alloycrankcase on compressor frames through the23 series. A rugged cast iron crankcase is usedon the 25 and 28 series compressor frames.The crankcase is fully encapsulated to preventthe release of oil laden air to the environment.
LubricationAll BAUER compressors are pressure lubricatedfor reliable lubrication of internal components. Asight glass and replaceable oil filter are standardon all models.
3 & 4 STAGE25 - 30 HP22 Range
7
Compression Key Features of BAUER
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Drive GearAll bearing surfaces on the driving gear use longlife roller or needle bearings for reduced frictionand maximum mechanical efficiency. The drivegear is supported in the crankcase with heavyduty ball bearings. The dynamically counter-balanced crankshaft provides smooth, practicallyvibration-free operation.
ValvesThe BAUER design guarantees optimum airflow and efficiency, thus maximizing valve life.All valves are readily accessible for inspection andmaintenance. Valve maintenance is inexpensiveand easy to complete.
Automatic Condensate Drain (ACD)The ACD automates the drainage of the interstageand final separators. This device enhances theuse of the compressor for industrial applicationsby eliminating the process of having to drain theseparators manually. The ACD also unloads thecompressor automatically at restarting. Manualvalves are included to override the automaticoperation of the ACD for troubleshooting.
CoolingThe BAUER air cooled design is based on morethan 60 years experience. All coolers are locatedin the direct blast of the cooling fan(s) for effectiveremoval of the heat of compression. All cylindersand cylinder heads have large surfaces and fineribbing for maximum heat dissipation. All coolersare made of corrosion resistant material for longlife and non-contaminating service.
The BAUER design provides discharge airtemperatures of only 20ºF – 40ºF above ambienttemperature depending upon the model.
Quality and Performance
Compressor Technology
8
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9
Innovation for Your Benefit
Details of BAUER
InstrumentationAll compressor packages includeinstrumentation and monitoringdevices for supervising thecompressor’s performance.Standard features include:
• Gauge Panel(optional on some models)
• Hourmeter• Operator Keypad• Emergency Stop Pushbutton• Back-lit LCD Display for
Operational, Maintenance &Troubleshooting Messages
All instrumentation and control devicesare mounted for maximum visibilityand easy accessibility for the operator.Each device is identified with a label.
Air ProcessingClean compressed air isessential for the properoperation of a highpressure compressed airsystem. BAUER uses a coalescing separator toremove condensed oiland water from the cooledcompressed air leavingthe aftercooler. The oil andwater emulsion collects
in the bottom of the separatorand is drained by the automaticcondensate drain. For applicationsthat require additional processing, arefrigerated air cooler can be installedupstream of the final separator or aBAUER high pressure processingsystem can be installed downstreamof the final separator.See pages 13-14 for full details
EnclosureA standard or customdesigned enclosure addsan attractive finishedlook to your industrialcompressor andimproves the coolingof the compressor byallowing only cool airinto the enclosure whileexpelling the hot air outof and away from theenclosure.
Enclosures aredesigned to permit fullaccessibility to internalcomponents for inspectionand maintenance. Soundattenuation material and specialsound attenuating designs are available.
MAXI VerticusStandard with enclosure
Open VerticalMAXI Verticus without enclosureShown with IP5 Air Processing System with Securus
Compression
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Adaptable for Your Needs
System Technology
10
Compressor Controls
All compressor packages include afactory installed, UL approved, PLC-basedelectrical control system that includes allof the components and features required tosafely operate a high pressure compressor.The electrical enclosure is NEMA 4 rated.
Standard Features:• Back-lit LCD Display for
Operational, Maintenance &Troubleshooting Messages
• Full Voltage Motor Starter
• Overload Relay with Manual Reset
• Fused Transformer
• Automatic Condensate Drain (ACD)control with Test Pushbutton
• Condensate Collector with Alarmfor High Condensate Level
• Pressure Switch for LowOil Pressure Protection
• Solid State Pressure Switch forAutomatic Start-Stop Control
• Temperature Switch forHigh Temperature Protection
• Adjustable Excessive Run Timer
• Load Cycle Counter
• Emergency Stop Pushbutton
• Operator Keypad
• Warning and Alarm Indication
• Color-coded Wiring Harness
• Battery Back-Up
Available Features:• Soft Start
• Disconnect
• SECURUS®
• TEFC Motor
• Audible Alarm
• Constant Speed Unloader
• Explosion Proof Motor and Controls
• Gas Detectors for a Variety of Industrial Gases
Proprietary Compressor Controller
Wiring HarnessConnectorbottom view
Standard BAUER CompressorControl System
Display is back-lit green for normal conditions,orange for warning conditions and red for alarmconditions, warning and alarm conditions includetext messages for troubleshooting assistance.Display includes Operator Keypad for Off/Oncontrol and alarm reset.
Solid State PressureSwitch with Built-inPressure Readout andAdjustable Deadband
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The Complete Range
Technical Data forBare Compressors
I SERIES • 5000 – 7000 PSIG • 3, 4 & 5 STAGE
I SERIES • 1000 – 5000 PSIG • 3 & 4 STAGE
B SERIES • 350 – 1000 PSIG • 3 STAGE
I100II 4.7 8 4.1 3 1315 2.8 70 1.57 40 121 55
I120II 7 11.9 6.4 4.8 1310 3.5 88 1.57 40 121 55
I15.1II 11.5 19.5 9.9 7.4 1010 4.33 110 1.97 50 205 93
I150II 17.5 29.7 15 11.2 1280 4.7 120 1.97 50 205 93
I180II 21.5 36.5 18.5 13.8 1345 5.1 130 1.97 50 215 98
I220 28-33 47.6-56 24-28.3 17.9-21.1 1125-1325 5.1 130 3.15 80 660 300
I230 35-48 59.5-81.6 29.9-41.7 22.3-31.1 925-1290 6.3 160 3.15 80 970 440
I250 54-63 91.8-107 46.4-54.3 34.6-40.5 955-1120 7.3 185 3.54 90 1985 900
I280 86-117 146.2-198.9 74.1-87.4 55.3-65.2 815-1100 8.5 215 4.92 125 2050 930
B12.4II 7 11.9 4.5 3.4 1275 3.5 88 1.6 40 121 55
B22.5 23-31 39-52.7 14.3-19.5 10.7-14.6 915-1245 5.1 130 3.1 80 490 220
B23.4 46-60 78.1-102 28.9-37.8 21.6-28.2 925-1210 5.1 130 3.1 80 1010 460
B25.4 73 124 45.8 34.2 955 8.5 215 3.5 90 1960 890
B28.2 98-113 166.6-192 61-70.6 45.5-52.7 915-1060 8.5 215 4.9 125 2020 920
B25.54 164 278.8 99.9 74.6 1060 8.5 215 3.5 90 2000 910
B28.34 206 350 120 90 1000 8.5 215 4.9 125 2070 940
1. Capacity is referenced to standard inlet conditions and to 80% of the compressors’ maximum working pressure and are valid to altitudesof 3,300 feet (1,000 meters). Brake horsepower ratings are valid for the compressors’ maximum working pressure. Contact BAUER for deratingsfor capacity and power at altitudes above 3,300 feet. Tolerance for capacity ratings is +/- 5%.
2. Compressor speeds are nominal and are based on standard sheave sizes.3. Dry weight for bare compressor. All weights are nominal.4. Models B25.5 and B28.3 have a maximum working pressure of 900 PSIG.
11
4 - Stage Compressor5 - Stage Compressor
3 - Stage Compressor
BARE CAPACITY BRAKE COMPRESSOR DIAMETERSTROKE
WEIGHT OFCOMPRESSOR FAD1 HORSEPOWER1 SPEED2 FIRST STAGE COMPRESSOR3
MODEL SCFM / M3/hr HP / kW RPM INCHES / MM INCHES / MM LBS / KG
*Models I100HII, I12.14II and I22.42 have a maximum working pressure of 6000 PSIG.
I100HII* 3.7 6.3 3.5 2.6 1075 2.8 70 1.57 40 121 55
I12.14II* 8.5-10.4 14.4-17.7 7.5-9.2 5.6-6.9 1070-1315 4.1 105 1.57 40 130 59
I15.11II 15 25.5 13.5 10 1335 4.3 110 1.97 50 205 93
I18.1II 20 34 18.2 13.6 1295 5.1 130 1.97 50 230 105
I22.42* 27-31 45.9-52.7 23.7-27 17.7-20.1 1085-1245 5.1 130 3.15 80 660 300
I25.9 58 98.6 52.6 39.3 1060 7.3 185 3.54 90 3170 1440
I25.18 79 134.3 71.1 53 1060 8.5 215 3.54 90 3215 1460
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The Complete Package
Dimensional Data forStandard Packages
12
I100II / I120II / I12.14II 36 x 56 x 38 500 - 700B12.4 II / BK12.2 II 914 x 1422 x 965 227 - 318
I15.1II / I150II / I180II 36 x 61 x 40 700 - 950I15.11II / I18.1II / BK15.3II 914 x 1549 x 1016 318 - 432
DIMENSIONSCOMPRESSOR L x W x H WEIGHT
MODEL INCHES LBMM KG
Dimensions and weights are approximate and for standard models.Custom designs available.Classic II LS open design available
I100II / I120II 46 x 29 x 58 880 - 950B12.4 II / BK12.2 II 1168 x 737 x 1473 399 - 431
I12.14II - I18.1II 64 x 34 x 66 700 - 1175BK15.3II 1626 x 864 x 1676 318 - 534
Enclosed Vertical (through 20 HP) open design available
I220 / I22.4265 x 44 x 72 1200
1651 x 1118 x 1829 545
I23081 x 50 x 72 2900
2057 x 1270 x 1829 1315
Enclosed Vertical (25 – 40 HP) open and horizontal designs available
B23.490 x 44 x 60 2700
2286 x 1118 x 1524 1225
B25.4 / B25.5 / B28.2 / B28.3 114 x 84 x 66 4500 - 5100I25.9 / I25.18 / I250 / I280 2896 x 2134 x 1676 2040 - 2315
Open Frame Horizontal
B12.4II56 x 36 x 38 750
1422 x 914 x 965 340
B22.581 x 38 x 49 1400
2057 x 965 x 1245 635
B23.492 x 50 x 60 3000
2337 x 1270 x 1524 1360
B25.4 / B25.5 / B28.2 / B28.3 114 x 89 x 72 4800 - 5400I25.9 / I25.18 / I250 / I280 2896 x 2261 x 1829 2175 - 2450
Enclosed Horizontal
H
WL
B12.4II55 x 24 x 38 700
1397 x 610 x 965 320
B22.580 x 35 x 48 1350
2032 x 889 x 1219 615
MAX
I VT
min
i VT
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Drying and Purifying
For the I Series Compressors
IP Processing SystemsThe BAUER IP non-regenerative processing systemsare the ideal solution for economical processing of highpressure compressed air. The IP Systems do not requireelectrical power for operation and there are no systemlosses for regeneration. The IP Systems are designedfor working pressures from 2000 – 6000 PSIG and flowrates to 125 SCFM.
SECCANT Regenerative DryersBAUER SECCANT heatless regenerative dryers are theideal solution for cost effective drying of high pressurecompressed air for continuous applications. These dryersrequire a partial stream of the dried air (5% maximum)for regeneration. The SECCANT dryers are standard withan on-board controller which requires 115V electricalpower for operation and connection to the compressor’scontrol circuit for cycle control. The SECCANT dryers aredesigned for working pressures from 2000 – 6000 PSIGand flow rate to 125 SCFM.
SECCANT Dryer shownwith optional purification
13
AIR NUMBERMODEL PROCESSING OF FILTER
CAPACITY* HOUSINGS
NON-REGENERATIVE SYSTEMS WITH 20" CARTRIDGE(S)
SECCANT III2Drying Only 3.5 to 53
SECCANT III / A SCFM3Drying and Purifying
SECCANT IV2Drying Only 53 to 125
SCFMSECCANT IV / A 3Drying and Purifying
IP41 SECURUS 47,000 1IP42 SECURUS 107,000 2IP43 SECURUS 164,000 3
IP2 SECURUS 67,000 1IP5 SECURUS 150,000 2IP10 SECURUS 230,000 3IP12 SECURUS 420,000 2IP14 SECURUS 650,000 3
Air processing is essential for trouble-freeoperation of a high pressure compressed airsystem. The primary objective of processingcompressed air is to remove or reduce waterand oil to a permissible level. BAUER is aninternational leader in the field of highpressure air processing systems. Wemanufacture high pressure non-regenerativeand heatless regenerative dryers for ourI Series compressors (1000 – 6000 PSIG).BAUER’s air processing systems are easyto use, inexpensive to operate and have areputation for reliable service.The IP and SECCANT dryers offeratmospheric dewpoints to -94˚F. Both typesof dryers use replaceable cartridges.Contact BAUER for your high pressure airprocessing requirements.
REGENERATIVE SYSTEMS
NON-REGENERATIVE SYSTEMS WITH 27" CARTRIDGE(S)
*Air processing capacity in standard cubic feet per minute and referencedto 4350 PSIG and 70ºF inlet temperature to the purification system.
Processing
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Accessories for Processing Systems
AIR-KOOLThe Refrigerated Air Cooler
AIR-KOOL is the ideal solution for reducingthe operating costs of your compressorand air processing system. AIR-KOOL is arefrigerated, counterflow heat exchangerthat further cools the compressed air fromthe compressor’s air cooled aftercooler to36˚F – 46˚F. This additional cooling causesmore water and oil to condense out of thecompressed air for removal by the finalseparator. AIR-KOOL increases the efficiencyof the final separator and extends the life ofthe processing cartridge(s) up to six times.
AIR-KOOL is designed for working pressuresto 7000 PSIG and flow rates to 21 SCFM.
AIR-KOOL is available as an option on newBAUER units or as an aftermarket additionto existing BAUER units. AIR-KOOL requires115V electrical power for operation and isfor indoor use only.
SECURUS®
The Patented Moisture Monitoring System
SECURUS® ensures 100% utilization ofthe air processing cartridges because themoisture sensor is embedded directly in themolecular sieve. The SECURUS cartridge, withits moisture sensor, is the last cartridge in theair processing system. SECURUS requires115V electrical power for operation andconnection to the compressor’s control panelor to the SECCANT controller for automaticwarning and shutdown when the SECURUScartridge becomes saturated. The SECURUSstatus display can be locally mounted to theSECURUS cartridge chamber or to thecompressor’s instrument panel. SECURUSis available for working pressures from2000 – 6000 PSIG and flow rates to 125 SCFM.SECURUS is suitable for outdoor use.
® U.S. Patent Number 4,828,589
from aftercooler
11.. Condenser2. Collecting Tank3. Cooling Compressor4. Temperature Indicator5. Counterflow Heat Exchanger
to oil and water separator
Dimensions: 26" x 15" x 14" (660 mm x 380 mm x 360 mm)Weight: 105 lbs. (46 kg)
14
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Working Pressure ΔP(PSIG) (PSID)
500 125
1000 150
5000 750
6000 900
High Pressure AirStorage Systems
For Cost Effective Operation
The chart below summarizes the deadband of thecompressor’s final pressure switch for the variouspressure ranges covered by BAUER IndustrialCompressors.
Air receivers for storage are available to meetthe code requirements of either the AmericanSociety of Mechanical Engineers (A.S.M.E.) orthe Department of Transportation (D.O.T.)
Consult BAUER for storage with multiple banks.
15
Should an application require the use ofstorage, a properly sized air storage systemoffers many benefits to a high pressurecompressed air system. Each high pressurecompressed air application must be reviewedcarefully to determine the best type and sizeof storage. By engineering the compressorand storage as a complete system, the costof equipment and the operational and maintenance costs can be reduced.The main purpose of a storage system is toserve as an air reservoir to handle constant,sudden or unusually high demands for airwhich can exceed the compressor’s capacity.Storage protects the compressor from thedirect demands of the system and preventsshort cycling of the compressor and motor.Thus, the compressor works consistently
within a certain pressure range provided thecompressor and storage system have beensized correctly for the application. Storagewill also dampen or eliminate pressurepulsations from the compressor’s dischargeline and from the system, thus protecting thecompressor and the system from potentialdamage. Storage can precipitate some ofthe moisture from the compressed air thatmay be carried over from the compressor’saftercooler or a defective separator or dryer.The size of the storage system required fora particular application will depend upon:
A. Air consumption of the systemB. Capacity of the compressorC. Deadband of the compressor’s
final pressure switch
BAUER recommends that the compressor doesnot start more than 4 times per hour. Thus thecompressor can operate long enough duringeach load cycle to allow it to attain normalworking temperature. If the compressor is allowedto short cycle, moisture can precipitate out of thecompressed air inside of the compressor andemulsify the oil.
Buffer storage can be sized by the following formula:
VR = 58 x (QC / ΔP)where:• VR = Volume of storage in cubic feet water volume
• QC = Capacity of compressor in standard cubicfeet per minute (scfm)
• ΔP = Deadband of final pressure switch in poundsper square inch (psid)
Multiple receivers can be used for applications thatrequire a large volume of storage.
All values are approximate.
Storage
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16
500 9.8 73 345 18 - 72 450
500 17.4 130 610 24 - 72 650
500 32.1 240 1130 30 - 84 1250
500 53.5 400 1880 36 - 98 1975
500 86.9 650 3060 42 - 120 3750
1000 9.8 73 680 18 - 72 750
1000 32.1 240 2240 30 - 84 2380
WORKING WATER WATER CAPACITY @ DIMENSIONS WEIGHTPRESSURE VOLUME VOLUME MAX. PRESSURE DIAMETER - LENGTH LBSPSIG SCF GALLONS SCF INCH
The chart below lists recommended water volumes for buffer storage with respect to compressor capacity,working pressure and the deadband of the final pressure switch.
Dimensions are for bare receiver only, excludes legs or skirt and saddle.
All values are approximate and subject to change.Weight is for empty receiver.
This chart is for reference only. Intermittent periods of high system demand may require additional storage volume.Consult BAUER to confirm your storage volume requirements.
Dimension includes shutoff valve.
WORKING PRESSURE (PSIG )
125150
750900
5000 1.47 11 436 9 9/16 - 54 400
6000 1.47 11 491 9 9/16 - 54 400
7000 1.47 11 537 9 9/16 - 54 400
4500 1.59 11.9 444 9 5/16 - 55 145
5000 1.59 11.9 472 9 3/8 - 56 160
6000 1.53 11.4 509 9 9/32 - 55 190
DOT Receivers
ASME Receivers
Technical Data for Typical Air Receivers
ASME Receivers
FINAL PRESSURE SWITCH DEADBAND
5001000
50006000
COMPRESSOR CAPACITY – SCFM
STORAGE WATER VOLUME – SCF10 20 30 40 50 60 70 80 90 100 150 200 250
Calculated Volume
Calculated Volume
Calculated Volume
Calculated Volume
4.6 9.3 13.9 18.6 23.2 27.8 32.5 37.1 41.8 46.4 69.6 92.8 116.0
3.9 7.7 11.6 15.5 19.3 23.2 27.1 30.9 34.8 38.7 58.0 77.3 97.0
0.8 1.5 2.3 3.1 3.9 4.6 5.4 6.2 7.0 7.7 –– –– ––
0.6 1.3 1.9 2.6 3.2 3.9 4.5 5.2 5.8 6.4 –– –– ––
Dimensions are for bare receiver only.
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17
High pressure air is used in a multitudeof industrial applications. The design ofa safe and efficient distribution systemis critical to the successful use ofcompressed air. BAUER has over 50 yearsexperience in the design and manufactureof distribution systems for high pressurecompressed air. We have a reputation forproviding safe, reliable and user friendly
air distribution panels and systems. Wecan supply everything from individualcomponents to basic pressure regulationpanels to systems controlled by aProgrammable Logic Controller (PLC) forautomatic control from the outlet of thecompressor to storage, and fromstorage to the point of use.
ComponentsBAUER uses only quality components that aredesigned specifically for high pressure applications.We maintain a complete inventory of high pressuretubing, tube fittings, instrument pipe fittings,full-turn and quarter-turn ball valves, gauges,regulators, manifolds, hose, couplings, reducers,adapters, relief valves and other miscellaneouscomponents. Our design staff carefully reviews eachapplication to provide a distribution system with thefewest possible components. BAUER pays particularattention to safety, so every distribution systemdesigned by BAUER includes a safety relief valve.
Regulator with Flexible HoseSome applications require only a simple regulatorand a flexible hose to connect to the point of use.BAUER high pressure hose assemblies are completewith a pressure gauge, manual shut off valve andmanual vent valve to facilitate venting the hose whennot in use. These systems are ideal for cylinderfilling applications where cylinders are rotated fromthe point of use to the refilling area. For example,cylinders for paintball guns can be filled directly fromthe compressor or from storage.
High Pressure AirDistribution Systems
Hose and TubingBAUER recommends the use of stainless steeltubing for all permanent high pressure connections.For temporary installations or where flexibility isrequired, high pressure hose can be used withsuitable end connections. The use of hose shouldbe limited to clean, noncorrosive environments andwhere it is possible to inspect the hose regularlyfor deterioration. BAUER recommends replacingall high pressure hoses annually or as recommendedby the hose manufacturer. Hoses must be replacedimmediately if wear or deterioration is evident orsuspected.
Safe and Reliable Distribution
Standard Components for High Pressure
Distribution
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Basic Regulation Panel – Front View
Regulation Panel with Multiple Outlets
Pressure Regulation PanelsBAUER can design simple regulation panels ormore elaborate regulation panels for use withsingle or multiple cylinders or banks of storagecylinders. All regulation panels include, as aminimum, pressure gauges for inlet and outletpressure readings at the regulator, a safety reliefvalve for the regulated pressure and a manualshut off valve on the outlet to the point of use.Custom panels can include multiple regulators,e.g. a high pressure regulator and a low pressureregulator, with single or multiple outlets for eachregulator. Each outlet is supplied with a manualshut off valve. A pressure gauge can be includedfor each outlet to indicate outlet pressure. Panelsare fabricated of steel, aluminum or stainlesssteel depending upon the application or userpreference. Panels are suitable for wall mountingor can be designed to fit a specific mountingrequirement.
Automatic PanelsBAUER offers standard and custom designedautomatic panels with simple pneumatic devicesor PLC controlled systems to automate thedistribution, regulation and dispensing of highpressure compressed air. These systems can beused for cylinder filling applications where thecylinder must be completely filled from storageor automatically topped off from the compressorif storage pressure is insufficient to provide acomplete fill. PLC controlled systems offer moreeffective storage management by controlling thedistribution of the compressed air from thecompressor to the storage system and from thestorage system to the point of use by monitoringthe status of analog devices for pressure,temperature and flow and, if required, time. Bothtypes of panels have built-in safety features toprevent accidental overpressurization of thesystem. Automatic panels greatly simplify theprocess of controlling high pressure compressedair and offer increased safety by eliminating thepotential for operator error.
• User Friendly• Versatile Design
• Quality Craftsmanship• Built-in Safety• Minimum Use
of Components
• Designed and Built toBAUER’s Standards of Quality
• Standard and Custom Designs
• All Panel Mounted DevicesIdentified with Engraved Labels
• Clear, Precise OperatingInstructions
• Standard Fitting Sizes for EasyInstallation and Compatibility
Regulation Panel for Multiple Banks of Storage – Rear View
Basic Regulation Panel – Rear View of Alternate Design
of High Pressure Air18
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Boosters
19
Model ImnBK-E3 - mini Verticuswith BK 12.2II
Model IMXBK-E3 - Maxi Verticuswith BK15.3II
BK15.3II
• Rated to 2000 - 5000 PSIG
• Air Cooled
• Pressure Lubricated
• Inlet Pressure Range, 100 to 145 PSIG
• Horsepower Range, 7.5 to 15
• Capacity Range, 14 to 27 SCFM
• Continuous-Duty Rated
• Instrument Panel Standard
• Automatic Condensate Drain Standard
• PLC Control for UnattendedAutomatic Operation
• Open or EnclosedPackage Designs Available
• Available Oil Removal Filtration
BK12.2II
• Rated to 2000 - 5000 PSIG
• Air Cooled
• Pressure Lubricated
• Inlet Pressure Range, 72 to 160 PSIG
• Horsepower Range, 5 to 7.5
• Capacity Range, 3 to 16 SCFM
• Continuous-Duty Rated
• Instrument Panel Standard
• Automatic Condensate Drain Standard
• PLC Control for UnattendedAutomatic Operation
• Open or EnclosedPackage Designs Available
• Available Oil Removal Filtration
BK SERIES2-Stage Boosters for Air and Nitrogen
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20
Compressors in Operation Worldwide
Component Testingand Calibration• Pressure Gauges
• Relief Valves
• Valves
• Tubing
• Pipe
• Valve Actuators
• Transducers
• Hose
Cylinder Refilling• Storage
• Air Rifle
• Paintball
Research• Industry
• Educational
• Aviation
Model IE100 - Classic DesignOpen Version
Model IL100II – Classic DesignEnclosed Version
Applications
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21
Applications
Engineered Systems from the
Model B23.4 – Horizontal DesignOpen Version
MAXI VerticusOpen Version
MAXI VerticusEnclosed Version
Automotive Industry• Test Sleds
• Wind Tunnel
Offshore Platforms• Rig Stabilization
Shipboard• Cable Compensation
• Air Guns forSeismographic Exploration
Plant Air
Food Processing
Chemical Industry• Compressors with
Explosion Proof Controls
Applications
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22
High Pressure Specialists
Model I220 – Vertical DesignOpen Version
Aviation• Engine Starting
• Aircraft Maintenance
Oil and Gas• Pipeline Pressure Testing
Shipyard• Dockside Air Supply
Model I25.18in Sound Attenuated Enclosure
ElectricPower Plants• Turbine Starting
• Circuit Breaking
Hydraulics• Air-Oil Accumulators
Pneumatic Control
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