Installation Manual - Jordair Compressors · Installation Manual Page i 2nd Edition, Rev. 0 Chg. 7...

Installation Manual

BAUER Compressors, Inc. Phone: (757) 855-60061328 Azalea Garden Road Fax: (757) 855-6224Norfolk, Virginia 23502-1944 www.bauercomp.com

June 19, 2014 2nd Edition, Rev. 0 Chg. 7 MNL-0131© Bauer Compressors, Inc.

Installation Requirementsfor Air & Water Cooled Medium and High Pressure Air Compressor Units

Installation Manual

Page i 2nd Edition, Rev. 0 Chg. 7

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.

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.

! WARNING

This Installation Manual contains safety information and instructions for installingMedium and High Pressure Air Compressor Units.You must read, understand and follow all safety precautions and instructions.

2nd Edition: August 29, 2005

Rev. Chng. Date Notes Auth.

0 0 Aug. 29, 2005 JD

0 1 July 11, 2006 Updates and Changes after Review JD

0 2 Feb. 11, 2008 Updates after Executive Review CLA

0 3 June 16, 2009 Update Warnings SS

0 4 Aug. 6, 2009 Corrected Temperatures available SS

0 5 Oct. 18, 2011 Corrected Formula at para. 2.5.1 SS

0 6 June 21, 2012 Added Intake Air Chapter SS

0 7 June 19, 2014Added Water Cooling Chapter, Changed Large Condensate Collector Assembly SS

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June 19, 2014 Page ii

Table of Contents

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

1.1 PREFACE............................................................................................................................................................................. 1

1.2 MANUAL SAFETY NOTICES.......................................................................................................................................... 1

1.3 PRELIMINARY NOTE ...................................................................................................................................................... 21.3.1 Environment ....................................................................................................................................................................... 21.3.2 Floor Area .......................................................................................................................................................................... 21.3.3 Foundations ........................................................................................................................................................................ 21.3.4 Extreme Environments....................................................................................................................................................... 31.3.4.1 Dusty and Sandy Environments...................................................................................................................................... 31.3.4.2 Solvent Vapors................................................................................................................................................................ 31.3.4.3 Corrosive Cleaning Agents............................................................................................................................................. 31.3.4.4 Tropical Installation Environments ................................................................................................................................ 3

CHAPTER 2: - - - - - - - - - - - - - - - - - - - - - - - INTAKE AIR

2.1 INSIDE AIR SOURCE ........................................................................................................................................................ 4

2.2 OUTSIDE AIR SOURCE.................................................................................................................................................... 4

2.3 COMPRESSOR INTAKE PIPING.................................................................................................................................... 4

2.4 INSTALLATION PROCEDURES .................................................................................................................................... 5

CHAPTER 3: - - - - - - - - - - - - VENTILATION REQUIREMENTS

3.1 INSTALLATION PREREQUISITES................................................................................................................................ 63.1.1 Compressor Room/Building............................................................................................................................................... 63.1.2 Space Requirement............................................................................................................................................................. 63.1.3 Foundation.......................................................................................................................................................................... 73.1.4 Floor Load .......................................................................................................................................................................... 73.1.5 Extreme Temperature Conditions ...................................................................................................................................... 7

3.2 HEAT FLOW - CHOICE OF PROPER VENTILATION .............................................................................................. 73.2.1 Cooling Air Flow Requirements ........................................................................................................................................ 8

3.3 VENTILATION BY CONVECTION ................................................................................................................................ 83.3.1 Size of the Required Intake and Exhaust Openings for Convection .................................................................................. 93.3.1.1 Example .......................................................................................................................................................................... 93.3.1.2 Example ........................................................................................................................................................................ 103.3.2 Installation Examples for Ventilation by Convection ...................................................................................................... 11

3.4 FORCED VENTILATION................................................................................................................................................ 133.4.1 Types of Forced Ventilation............................................................................................................................................. 133.4.2 Forced Ventilation Using a Room Fan............................................................................................................................. 133.4.3 Forced Ventilation by Using Ducts .................................................................................................................................. 153.4.4 Forced Ventilation Using Ducts and a Baffle .................................................................................................................. 153.4.5 Forced Ventilation Using Ducts with the Exhaust Used as Heating Air ......................................................................... 16

3.5 PLANNING ASSISTANCE FOR FORCED VENTILATION...................................................................................... 173.5.1 Calculation of the Duct Area; in Feet & Horsepower...................................................................................................... 173.5.2 Calculation of the Duct Area; in Meters & Kilowatts...................................................................................................... 173.5.3 Duct Backpressure............................................................................................................................................................ 18

3.6 CONNECTION VENTILATION FRAMES................................................................................................................... 18

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3.6.1 Air Intake Opening ...........................................................................................................................................................18

3.7 MULTIPLE UNIT INSTALLATIONS ...........................................................................................................................18

CHAPTER 4:- - - - - - - - - - - - - - - - - - - - WATER COOLING

4.1 COOLING FLUID .............................................................................................................................................................194.1.1 Frost and Corrosion Protection.........................................................................................................................................194.1.2 Coolant Volume................................................................................................................................................................19

4.2 COOLING WATER CIRCUIT ........................................................................................................................................20

4.3 INSTALLATION ...............................................................................................................................................................224.3.1 General Notes ...................................................................................................................................................................224.3.2 Cooling Water Circuit with Water/Air Cooler .................................................................................................................234.3.2.1 Structure........................................................................................................................................................................234.3.2.2 Installation ....................................................................................................................................................................234.3.3 Plate Heat Exchanger Set .................................................................................................................................................244.3.3.1 Requirements for Cooling Water Circuit......................................................................................................................244.3.3.2 Structure........................................................................................................................................................................244.3.3.3 Installation ....................................................................................................................................................................24

4.4 FILLING THE WATER CIRCUIT .................................................................................................................................254.4.1 Prepare the Coolant Mixture ............................................................................................................................................254.4.2 Filling the Coolant Circuit................................................................................................................................................254.4.3 Venting the Water Circuit ................................................................................................................................................26

CHAPTER 5:- - - ELECTRICAL AND CONDENSATE COLLECTION

5.1 ELECTRICAL DATA .......................................................................................................................................................28

5.2 CONDENSATE REMOVAL ............................................................................................................................................305.2.1 Compressor Units up to 20 Hp (15kW)............................................................................................................................305.2.2 Compressor Units Greater than 20 Hp (15 kW)...............................................................................................................315.2.3 Condensate Collection for Multiple Installations.............................................................................................................31

CHAPTER 6:- - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

6.1 REQUIRED INTAKE AND EXHAUST OPENINGS FOR CONVECTION..............................................................32

6.2 COOLING AIR FLOW REQUIRED FOR CONVECTION COOLING ....................................................................33

6.3 COOLING AIR FLOW REQUIRED FOR FORCED VENTILATION ......................................................................36

6.4 REQUIRED AIR INTAKE OPENING FOR FORCED VENTILATION ...................................................................39

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June 19, 2014 Page iv

List of Figures

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

There are no Figures in this Chapter

CHAPTER 2: - - - - - - - - - - - - - - - - - - - - - - - INTAKE AIR

Figure 2-1 Example of Air Intake Piping.................................................................................................................................. 5

CHAPTER 3: - - - - - - - - - - - - VENTILATION REQUIREMENTS

Figure 3-1 Temperature Limits ................................................................................................................................................. 6

Figure 3-2 Determining the Method of Ventilation .................................................................................................................. 7

Figure 3-3 Convection Ventilation............................................................................................................................................ 8

Figure 3-4 Convection Ventilation Examples, up to 20 Hp.................................................................................................... 11

Figure 3-5 Convection Ventilation Examples, continued ....................................................................................................... 12

Figure 3-6 Forced Ventilation Using a Room Fan.................................................................................................................. 13

Figure 3-7 Examples of Forced Ventilation Using a Room Fan............................................................................................. 14

Figure 3-8 Forced Ventilation by Using Ducts ....................................................................................................................... 15

Figure 3-9 Forced Ventilation Using Ducts and a Baffle........................................................................................................ 16

Figure 3-10 Forced Ventilation Using Ducts with the Exhaust Used as Heating Air............................................................... 16

Figure 3-11 Duct Backpressure................................................................................................................................................. 18

Figure 3-12 Air Intake Opening ................................................................................................................................................ 18

CHAPTER 4: - - - - - - - - - - - - - - - - - - - - WATER COOLING

Figure 4-1 Connection Examples............................................................................................................................................ 21

Figure 4-2 Hose Height & Length........................................................................................................................................... 22

Figure 4-3 Cooling Water Circuit ........................................................................................................................................... 23

Figure 4-4 Venting Valve Location ........................................................................................................................................ 25

Figure 4-5 Filling the Coolant Circuit..................................................................................................................................... 26

CHAPTER 5: - - -ELECTRICAL AND CONDENSATE COLLECTION

Figure 5-1 Condensate Collector for Small Units................................................................................................................... 30

Figure 5-2 Condensate Collection for Large Units ................................................................................................................. 31

CHAPTER 6: - - - - - - - - - - - - - - - - - - - - - - - - APPENDIX

There are no Figures in this Chapter

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List of Tables

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

There are no Tables in this Chapter

CHAPTER 2: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - INTAKE AIR


CHAPTER 3: - - - - - - - - - - - - - - - - -VENTILATION REQUIREMENTS

Table 3-1: Required Intake &Exhaust Opening Sizes for Ventilation by Convection; Standard.....................9Table 3-2: Required Intake & Exhaust Opening Sizes for Ventilation by Convection; Metric .....................10

CHAPTER 4: - - - - - - - - - - - - - - - - - - - - - - - - - - - - WATER COOLING


CHAPTER 5: - - - -ELECTRICAL AND CONDENSATE COLLECTION

Table 5-1: Single Phase Motor Data ...............................................................................................................28Table 5-2: Three Phase Motor Data ................................................................................................................29

CHAPTER 6: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -APPENDIX

Table 6-1: Convection Cooling Intake & Exhaust Openings..........................................................................32Table 6-2: Cooling Air Flow Required for Convection Cooling ....................................................................33Table 6-3: Cooling Air Flow Required for Forced Ventilation ......................................................................36Table 6-4: Required Air Intake Opening for Forced Ventilation....................................................................39

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June 19, 2014 Page 1

CHAPTER 1: INTRODUCTION

1.1 PrefaceCorrect installation influences, to a large extent, the reliability and efficiency of a compressor unit. Spe-cial consideration should be given to proper ventilation in order to ensure sufficient dissipation of heat.

This manual provides suggestions and directions for the installation of Bauer air and water cooled high and medium pressure compressor units. These suggestions and directions cover two stage through five stage compressor units with outputs in the range of 3.5 to 250 scfm (6 to 420 Nm³/hr) and pressures of 370 to 7,500 psi (25 to 500 bar).

All EPA, NEC and OSHA installation codes must be followed.

The enclosed installation instructions are specifically for the Bauer air cooled reciprocating compressor units. The explanation and much of the technical data are of a general nature and can be applied to all Bauer high and medium pressure compressors. For specific applications, corresponding data is included in a table as part of the appendix which can be applied to special proposal drawings.

The best possible installation will in the end be dependent on the operating conditions

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 consequences thereof.

1.2 Manual Safety NoticesImportant 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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Page 2 2nd Edition, Rev. 0 Chg. 7

1.3 Preliminary NoteThis handbook contains important information concerning the installation of Bauer compressors. Read this handbook carefully and follow the instructions precisely. Non-observance of the installation instructions can lead to damage and injuries. Damage caused by unsuitable and improper installation by the customer or third parties or the use of unsuitable operating materials may void the warranty.

The erection and installation of your unit is decisive for its reliability and efficiency. Before installation particular attention should be paid to heat dissipation and ventilation. This manual contains instructions and provides notes for the installation of high and medium-pressure compressors.

1.3.1 EnvironmentThe installation of compressors in specially designed machinery rooms is recommended. The optimum situation is to have a separate compressor room. If no separate room is available, the following should be taken into account:

• The compressor’s environment should be relatively clean, dust-free, dry, and as cool as possible.

• Avoid direct sunlight if possible.

• Additional equipment or piping systems which produce heat should be avoided or adequately insu-lated.

• The temperature of the environment must be kept between 40 - 115 °F (5 - 45 °C).

• Seasonal temperature fluctuations must be accounted for.

• Good lighting is essential for maintenance purposes.

1.3.2 Floor AreaRequired floor area for your compressor installation can be taken from an assembly drawing. For gen-eral maintenance purposes a distance of approximately 30 -36” (0.8 - 1 m) around the unit is advisable. Units with swinging access doors may require more room.

1.3.3 FoundationsEvery Bauer compressor is designed optimally balanced and well insulated from vibrations. Special foundations are not necessary. The ground must be solid and able to support the weight of the compres-sor unit.

Larger compressor installations, where feet are equipped with lug holes, need to be fastened down onto the foundation with suitable bolts.

NOTICE

The most suitable installation is ultimately dependent on the operational conditions. Each unit and its environment are unique.

! CAUTION

Remove any shipping braces before putting the unit into operation.

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1.3.4 Extreme EnvironmentsExtreme conditions such as temperature ranges or sandy environments can be accounted for by the engineering design team and should be mentioned at the time of ordering.

1.3.4.1 Dusty and Sandy EnvironmentsDusty or sandy environments may require additional inlet side filters to prevent penetration of damag-ing and abrasive particles.

1.3.4.2 Solvent Vapors Contamination of fresh air being drawn into the compressor with solvent vapors must be avoided. If this is not possible the quality of the air entering the compressor must be modified using special air preparation measures. This should be clarified at the quotation and ordering stage.

1.3.4.3 Corrosive Cleaning AgentsIn rooms where corrosive cleaning agents are used, the metal parts that come into contact with the cleaning agent can suffer corrosion. To prevent this, it is beneficial to place the compressor unit either on a hard rubber plates or in a stainless steel tank.

1.3.4.4 Tropical Installation EnvironmentsWhen installing in tropical environments, ensure that the quoted temperatures are not exceeded. In addition clarify whether the unit needs to be termite-resistant. These clarifications should be made at the quotation phase.

Installation Manual


CHAPTER 2: 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

2.1 Inside Air SourceThe 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.

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.

2.2 Outside Air SourceMoving 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.

2.3 Compressor Intake PipingIt 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 goose-neck end or water trap on the pipe will prevent water from entering the compressor system. See the following table for recommended inlet pipe diameter.

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2.4 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.

Guideline for Intake Piping with Max. Four 90° bends

Inlet Capacity DistancePipe

Diametera

a. Add 1” of pipe diameter if the number of 90° bends exceeds four

≤ 13 SCFM≤50 ft 2”

50 - 100 ft 3”

100 - 150 ft 4”

13 - 30 SCFM≤50 ft 3”

50 - 100 ft 4”

100 - 150 ft 5”

30 - 50 SCFM≤50 ft 4”

50 - 100 ft 5”

100 - 150 ft 6”

Figure 2-1 Example of Air Intake Piping

intakefilter

compressor drain valve

12”Min

Screen must belarge enough notto restrict air intake

en�re runshould besame size

Installation Manual


CHAPTER 3: VENTILATION REQUIREMENTS

Both the compression process as well as the motor or engine which drives the compressor create extreme heat. This heat must be dissipated in order to stay below the max operating temperature of the compressor.

3.1 Installation Prerequisites

3.1.1 Compressor Room/BuildingThe following should be observed, even if there is no special room available.

• The room should be clean, free of dust, dry and cool.

• Direct sunlight should be avoided, possibly by picking the north side of the building.

• Additional heat generating equipment or piping should be avoided or must be well insulated.

• The room temperature must not fall below 40 °F due to the danger of frost or corrosion damage resulting from condensate accumulation.

• To prevent overheating of the compressor, the room temperature should not exceed 115 °F under any circumstances.

• Seasonal temperature changes should be evened out if possible.

• For different set-up temperatures, please ask for a special quotation. Temperatures down to 35 °F (1.6 °C) or up to 125 °F (52 °C) may well be possible with modifications.

• Good access and lighting should be provided for service and maintenance.

• For the larger compressor sizes, it is recommended to have accessibility to the compressor unit by a forklift or a crane for easier service and maintenance.

3.1.2 Space Requirement

1. If a special set-up is required, reference special set-up drawings for necessary spacing of the com-pressor unit.

2. Otherwise, a space of 30 - 40 inches (75 - 100 cm) should be maintained on all sides, for mainte-nance on the compressor.

Figure 3-1 Temperature Limits

Maximum+ 115 °F (+45 °C)

Minimum+ 40 °F (+5 °C)

Room Temperature Limits

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3. The applicable NEC and local government regulations for switch box access should be followed.

4. Check the width of any necessary doorways to ensure that the compressor can be brought into the room and/or building.

3.1.3 FoundationEach Bauer compressor unit is optimally balanced and is, additionally, vibration isolated through the use of vibration mounts. A special foundation or connection is therefore not necessary, however, the floor should be solid and level.

3.1.4 Floor LoadThe floor should be able to support the compressor weight. If uncertain about the weight of the com-pressor unit, refer to the compressor unit manual or confer with our Product Support Department.

3.1.5 Extreme Temperature ConditionsIf the compressor unit is to be installed in extreme temperature conditions, the compressor unit can be adapted for correct operation. Temperatures down to -35 °F (-37 °C) or up to 125 °F (52 °C) may well be possible with modifications. The necessary technical modifications should be defined during the proposal stage, please ask for a special quotation.

3.2 Heat Flow - Choice of Proper VentilationSufficient heat dissipation must be provided by proper ventilation as part of correct installation. It is necessary to dissipate this heat by ventilation. The heat generated in the compressor increases with more compression. Approximately 70% of the heat generated during compression is in the compressor, the additional heat is generated by the compressor drive.The necessary ventilation may be attained by natural or artificial means. The graph in Figure 3-2 illustrates how the room volume and drive power determine the necessity for natural or forced ventilation. An example of 2,625 ft³ room with a 10 Hp compressor is indicated in green.

Figure 3-2 Determining the Method of Ventilation

7,000 ft³(200 m³)

1,750 ft³(50 m³)

3,500 ft³(100 m³)

3 hp 2.2 kW

20 hp 15 kW

30 hp 23 kW

50 hp 37 kW

150 hp 113 kW

2,625 ft ³

10 hp

ConvectionVentilation

Forced Ventilationwith Room Fan

Forced Ventilationwith Ducts

Installation Manual


In determining the necessary type of ventilation the following factors should also be considered:

• Ambient temperature of the set-up room • Size of the intake and exhaust openings• Length of a possible ventilation ducts • Additional heat sources in the set-up room• Back pressure of the ventilation ducts

3.2.1 Cooling Air Flow RequirementsThe minimum amount of cooling air required may be approximated by the following formulas.

Cooling Air Flow (cfm) = 132 x Drive Power (Hp)

A table has been included in the appendix for more precise requirements.

3.3 Ventilation by ConvectionVentilation by convection is the simplest type of ventilation. In operation, the compressor draws in cool air and exhausts warm air. Warm air rises and is automatically circulated with no additional require-ments, such as fans.

To maximize the effect of convection, the following should be considered:

• The compressor drive should be 20 Hp (15 kW) or less.

• The compressor unit must be set up such that the air current between room air intake and room air exhaust flows through the compressor.

• The cooling air intake should be as close as possible to the ground.

• The compressor should be placed close to the air intake.

• Cooling air suction should occur directly from the air intake

• The heat exhaust should be placed as high in the room as possible.

• An intake baffle to prevent overcooling is used when the intake air temperature is below 40 °F (5 °C).

• Recirculation, the intake of warm exhaust air back into the compressor should be avoided.

Figure 3-3 Convection Ventilation

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3.3.1 Size of the Required Intake and Exhaust Openings for ConvectionThe intake opening for cooling air should be approximately 20% larger than the exhaust opening to compensate for the effect of dirty louvers or gratings. These openings may be of the same size only if they both use the larger area.

The required approximate sizes are tabulated below.

• V is the volume of the room

• h is the height difference between the air intake and exhaust openings

The values above define the necessary size of air intake and exhaust openings in ft² should these values not be possible, because of construction reasons, forced ventilation will be necessary.

3.3.1.1 ExampleThe drive power is 10 Hp, the room size is approximately V = 1750 ft³, the height difference between air intake and exhaust is h = 6.5 ft:

by using Table 3-1:

Exhaust opening is approximately 2.7 ft²

Intake opening is approximately 3.2 ft²

Table 3-1: Required Intake &Exhaust Opening Sizes for Ventilation by Convection; Standard

V 1,750 ft³ 3,500 ft³ 7,000 ft³

h 6.5 ft 10 ft 13 ft

Power, Hp Inlet, ft² Outlet, ft² Inlet, ft² Outlet, ft² Inlet, ft² Outlet, ft²

5.0 1.3 1.1 1.6 1.3 — —

7.5 2.2 1.8 2.4 2.0 — —

10 3.2 2.7 3.2 2.7 2.1 1.7

15 4.3 3.6 4.8 4.0 3.1 2.6

20 6.5 5.4 6.5 5.4 4.1 3.4

Installation Manual


The values above define the necessary size of air intake and exhaust openings in ft² should these values not be possible, because of construction reasons, forced ventilation will be necessary.

3.3.1.2 ExampleThe drive power is 7.5 kW, the room size is approximately V = 40 ft³, the height difference between air intake and exhaust is h = 2 m:

by using Table 3-2:

Exhaust opening is approximately 0.75 m²

Intake opening is approximately 0.9 m²

Table 3-2: Required Intake & Exhaust Opening Sizes for Ventilation by Convection; Metric

V 50 m³ 100 m³ 200 m³

h 2 m 3 m 4 m

Power, kW Inlet, m² Outlet, m² Inlet, m² Outlet, m² Inlet, m² Outlet, m²

2.2 0.12 0.10 — — — —

3.0 0.24 0.20 0.12 0.10 — —

4.0 0.30 0.25 0.12 0.10 — —

5.5 0.42 0.35 0.24 0.20 0.12 0.10

7.5 0.90 0.75 0.60 0.50 0.24 0.20

11.0 1.38 1.15 0.90 0.75 0.54 0.45

15.0 1.92 1.60 1.45 1.20 0.90 0.75

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3.3.2 Installation Examples for Ventilation by Convection

Figure 3-4 Convection Ventilation Examples, up to 20 Hp

Correct Air intake is near the ground;

Cooling Air flows through the unit.

Incorrect Air Intake to high:

Air rushes through the room without cooling the compressor.

Correct Channeled air intake includes a baffle;

for temperatures below 40 °F the baffle closes the opening to the outside.

IncorrectAir Intake is channeled; however

there is no baffle to shutting off outside airbelow 40 °F.

Installation Manual


Figure 3-5 Convection Ventilation Examples, continued

Warm air is channelled upward; a cooling air loop is not possible

Warm air is not channelled; the cooling air circulates in a loop

The cooling air is channelled directly into the unit;

proper cooling is assured

The cooling air is not channelled into the unit;

proper cooling is not assured

Correct Incorrect

Correct Incorrect

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3.4 Forced VentilationForced ventilation is a requirement for compressors with a 20 hp or greater drive. Compressors with a drive power less than 20 hp natural ventilation may not be sufficient under the following unfavorable conditions.

• The compressor room is very small.

• The ventilation openings cannot be adequately sized.

• There are additional heat sources in the room, including multiple compressor installations.

• When other unfavorable conditions make forced ventilation necessary.

3.4.1 Types of Forced Ventilation• Exhaust with a room fan

• Ventilation through ducts without an additional fan

• Ventilation through ducts with an additional fan

• Ventilation through ducts with baffle and an additional fan

• Ventilation through ducts with use of exhaust as source of auxiliary heat.

3.4.2 Forced Ventilation Using a Room FanThis is the simplest type of forced ventilation. It functions principally in the same manner as natural ventilation, except that the warm exhaust is blown out through an room exhaust fan. Ducts for the intake and exhaust are not required.

• The room fan should be mounted near the compressor exhaust and mounted as high as possible.

• The air intake should be installed so that the compressor suction is not impeded.

• The room fan must be sized appropriately. See the Appendix for required air flow.

Figure 3-6 Forced Ventilation Using a Room Fan

Installation Manual


Figure 3-7 Examples of Forced Ventilation Using a Room Fan

CORRECT INCORRECT

CORRECT INCORRECT

Air intake is near the ground;Cooling air flows through the unit.

Air intake too high:Cooling air rushes through the room.

The cooling air is channeled directly into the unit;

Proper cooling is assured

The cooling air is not channeled directly into the unit;

Proper cooling is not assured.

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June 19, 2014 Page 15

3.4.3 Forced Ventilation by Using DuctsA ventilation duct can be directly attached to the exhaust of the compressor unit. For longer ducts, an exhaust fan mounted in the duct will become necessary. This type of ventilation is recommended for greater drive power and in unfavorable set-up conditions. The heat dissipation is optimized.

3.4.4 Forced Ventilation Using Ducts and a Baffle(See Figure 3-9) This type of ventilation for the most part is similar to the simple duct ventilation, with the exception of an installed baffle. This is absolutely necessary if the outside temperature falls below 40°F. The cool air from outside is mixed with the warm exhaust by means of the baffle, producing the necessary cooling air temperature. The baffle can be controlled either manually or by thermostat. This provides optimal ventilation; therefore, we recommend this type of ventilation for all Bauer compres-sors operating under the following conditions:

• Drive power exceeding 50 hp

• Extended run time

• Outside temperature at times below 40°F

• Multiple installations.

Figure 3-8 Forced Ventilation by Using Ducts

NOTICE

The duct area and length cannot be chosen at random, but must be adapted to the conditions.

Installation Manual


3.4.5 Forced Ventilation Using Ducts with the Exhaust Used as Heating Air(See Figure 3-10) This version is also an extension of the previous version, therefore the same operat-ing condition requirements apply. The use of the warm compressor exhaust for room heating (i.e. store-room) is possible; however, it is seldom used because of the noise level produced and the relatively short run times of the compressor unit.

Figure 3-9 Forced Ventilation Using Ducts and a Baffle

Figure 3-10 Forced Ventilation Using Ducts with the Exhaust Used as Heating Air

Outside Temperature above 40 °F (5 °C) Outside Temperature below 40 °F (5 °C)

Open to HeatBoth Rooms

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June 19, 2014 Page 17

3.5 Planning Assistance for Forced Ventilation

3.5.1 Calculation of the Duct Area; in Feet & HorsepowerThe recommended cooling air velocity within the duct is 600 to 1000 ft/min. The maximum velocity is 1,575 ft/min.

The necessary cooling air flow can be approximated by means of the following formula or can be found more accurately from the tables in the Appendix.

Required Cooling Air Flow (cfm) = 132 x Drive Power (Hp)

The required duct area can be calculated based on the velocity and the required flow of the cooling air using the following formulas.

Example:

• Compressor Model: B25.4 - 50• Drive Power: 50 Hp• Cooling Air Flow: 132 x 50 = 6,600 cfm • Velocity: 600 ft/min

3.5.2 Calculation of the Duct Area; in Meters & KilowattsThe recommended cooling air velocity within the duct is 3 meters/sec. to 5 meters/sec. The maximum velocity is 7- 8 meters/sec.

The necessary cooling air flow can be approximated by means of the following formula or can chosen more accurately from the tables in the Appendix.

Required Cooling Air Flow (m³/h) = 300 x Drive Power (kW)

The required duct area can be calculated based on the velocity and the required flow of the cooling air using the following formulas.

Example:

• Compressor Model: B25.4 - 50 Hp• Drive Power: 50 Hp = 37 kW (approx.)• Cooling Air Flow: 300 x 37 = 11,100 m³/h • Velocity: 5 m/s

DuctArea ft2 CoolingAirFlow ft

3min

Velocity ft min -----------------------------------------------------------------=

DuctArea 6 600 ft3

min 600 ft min

--------------------------------------- 11ft2

= =

DuctArea m2 CoolingAirFlow m

3h

Velocity[m /s ] x 3,600 [s/h]--------------------------------------------------------------------=

DuctArea 11 100 m3

h 5 m s x3 600 s h --------------------------------------------------- 0.62m

2= =

Installation Manual


3.5.3 Duct Backpressure(See Figure 3-11) The maximum static pressure created by the cooling fans on Bauer compressors is 0.31” water. The inlet and outlet openings on the enclosure are sized for a maximum back pressure of 0.20” water, measured at 40” from the start of the duct. Should the back pressure exceed this limit, an additional fan must be mounted in the ventilation duct.

As a rule of thumb, the back pressure is as follows:

1 ft. duct 0.01” water or 1 m duct = 0.1 mbar

one 90o Bend 0.16” water or one 90° bend = 0.4 mbar

This means that the maximum value allowed of 0.20” water (5 mmWs) is attained with a duct length of 4 ft. (1 m) and with one 90° bend. Should the duct length be greater or include multiple bends, an addi-tional fan must be installed.

3.6 Connection ventilation framesUpon request, certain models of Bauer compressors can be delivered with a connection frame. To avoid the transfer of vibration, any connection between the compressor and the ventilation duct should be flexible.

3.6.1 Air Intake Opening(See Figure 3-12) A built in screened louver is recommended with the screen preventing entry of con-taminates and the louvers preventing entry by precipitation. Some form of cold weather protection should also be installed, i.e. baffles which can be closed if necessary. This louver in the air intake open-ing should be inspected for cleanliness on a regular basis and should be cleaned if necessary.

3.7 Multiple Unit InstallationsIf multiple compressor units are located in the same vicinity ventilation is even more important than singular unit installation. The units are often running continuously and simultaneously, so high heat dis-sipation is required. Each unit needs to be provided adequate cooling air. A separate inlet and outlet opening must be provided for each unit. The above installation rules apply to each unit.

Figure 3-11 Duct Backpressure Figure 3-12 Air Intake Opening

max. 40 inches(1 meter)

max.0.40 inch

H2O(0.5 mbar)

Airflow

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June 19, 2014 Page 19

CHAPTER 4: WATER COOLING

Water cooling of a compressor carries out approximately 85% of the total heat dissipation, the remain-ing heat must be dissipated through air cooling. With water cooling the heat is dissipated by circulation of cooling water in a cooling circuit. In order to ensure perfect circulation, the composition of the cool-ing fluid is decisive. The cooling water circuit must be structured in such a way that the quality of the cooling fluid is guaranteed at all times.

4.1 Cooling FluidThe quality of the cooling water represents an important factor with regard to cooling efficiency and service life of the installation. In order to minimize organic deposits (scale and salt) and the formation of coatings by microbic growth, the cooling water must meet the following minimum requirements or be at least drinking water quality. Have a water analysis carried out, if necessary.

4.1.1 Frost and Corrosion ProtectionFrost and corrosion protection must be added to the cooling water. Anti-freeze with corrosion inhibitors are recommended. The minimum proportion of antifreeze in the cooling water is 20%. This should rep-resent frost safety down to approximately 15 °F(-10 °C).

4.1.2 Coolant VolumeThe cooling fluid volume required depends on the configuration of the installation. The volume required is estimated by adding the following values:

• V(b): Compressor block fill volume. (see specifications page for block)

• V(s): Coolant volume in the connecting hoses (inner diameter x length)

• V(r): Coolant in the cooler.

Component Volume

Ph Value (@ 77 °F or 25 °C) 7 - 8

Total Hardness 268 ppm (< 15 °dH)

Chloride (CL) <130 mg/l (ppm)

Sulphates (SO42-) <150 mg/l (ppm)

NOTICE

For purposes of this text, 1 mg/l = 1 ppm

Compressor Block

Coolant inWater/Air

Cooler

Coolant inWater/Water

Cooler

K 23.0 22 qts (21 l) 8.5 qts (8 l)

K 24.0 43 qts (41 l) 8.5 qts (8 l)

K 26.0 54 qts (51 l) 8.5 qts (8 l)

Installation Manual


Example: V(b) = G 23.0 Compressor Block = 15.3 qts

V(s) = Coolant hoses 1.5” width x 3 yards = 63.6 in³ = 1 qt

V(r) = Water / Water cooler = 8.5 qts

V(b) + V(s) + V(r) = Coolant volume required or 15.3 + 1 + 8.5 = 24.8 qts = 6 gal. & 0.8 qt.

4.2 Cooling Water CircuitDepending on the equipment, the Bauer water-cooled compressor installations can be connected to an open or closed cooling water circuit. The scope of the cooling water circuit depends on the order.

Bauer Compressors, Inc. offers two different closed cooling water circuits for cooling the compressors:

• Water / Air cooling set: Closed cooling water circuit with water / air cooler

• Plate heat exchanger set: Closed cooling water circuit with water / water cooler (plate heat exchanger)

The selection of cooling water circuit depends on the local conditions. If there is no cooling water cir-cuit available in the building, we recommend installing a a closed cooling water circuit with a water / air cooler.

When connecting the installation to an existing cooling water circuit you must always ensure the water quality requirements are met. If the existing cooling water circuit cannot meet these quality require-ments, a closed intermediate cooling circuit with a plate heat exchanger will need to be installed.

NOTICE

Running the unit with open circuits, or with untreated water is not recommended.

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June 19, 2014 Page 21

Figure 4-1 Connection Examples

Bauer Scopeof Supply

A B C D

E F

Water / Air Cooling Set:closed circuit for connec�on to a

closed circuitfor connec�on to a

cooling tower

Plate Heat Exchanger Setsfor connec�on to an

opened cooling circuit

Compressor Directly connected to Cooling Tower Compressor Directly Connected to Open Cooling Water Circuit

WatchWater Quality!

Installation Manual


4.3 Installation

4.3.1 General Notes• Ensure adequate ventilation. Water-cooling the compressor dissipates approximately 85% of the

generated heat; the remaining heat must be dissipated by convection (air cooling). For this reason, always observe the installation instructions in the air cooling sections when installing the compressor.

• Room temperature should always be monitored. If necessary, installation should be updated.

• Use only hoses to connect the cooler with the compressor to prevent transmitting vibrations.

• Use only anti-freeze resistant hoses.

• Our cooling water circuits are designed with maximum height difference of 5.5 yds (5 m) between the cooler connection and the compressor connection. Also our circuits are designed with a maximum length 11 yds (10 m) of connecting hoses. (See Figure 3-2)

• Do not kink or loop the hoses. The gradient must run continuously and without interruptions.

• Connect the water pump and cooler in accordance with circuit diagrams provided and check for func-tion. On three-phase AC motors, check that the direction of rotation is correct. If not, switch off the power supply and swap two of the incoming main wires.

• Provide a suitable collection vessel under the rupture disc to prevent any cooling fluid from contami-nating the environment.

NOTICE

Compressor Operating Temperature Range is 40 - 115 °F (5 - 45 °C)

Figure 4-2 Hose Height & Length

Max.5.5 yds

Max.5.5 yds

max. 115 °F

min. 40 °F

L = max. 11 yrds

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June 19, 2014 Page 23

4.3.2 Cooling Water Circuit with Water/Air Cooler

4.3.2.1 StructureThe colling water circuit with water/air cooler consists of the following components:

• Water/air cooler for cooling the heated coolant (1)

• Venting valve for removing air from the circuit (2)

• Temperature sensor for PLC monitoring (3)

• Water pump for conveying the coolant (4)

• Rupture disc for protection from excess pressure (5)

• Safety valve to prevent slight overpressure (6)

• Pressure gauge to monitor the pressure (7)

• Expansion tank to contain thermal expansion of coolant (8)

4.3.2.2 InstallationYou must always observe the following when installing the cooling water circuit:

• The components need to be connected in the sequence shown in Figure 4-3

• Erect the cooler outside. Ideally above the compressor room. The substrate must be suitable for the plant. Affix the cooler down to the floor.

• Leave at least 38 inches (1m) free space around the cooler. Also leave exhaust from the cooler free of obstruction.

Figure 4-3 Cooling Water Circuit

1. Cooler2. Vent Valve3. Temperature Sensor4. Water Pump5. Rupture Disc6. Safety Valve7. Pressure Gauge8. Expansion Tank9. Compressor Cooling Outlet 10. Compressor Cooling Inlet

12

34

56

7

8

910

Installation Manual


• Erect the expansion vessel with safety valve, pressure gauge and isolation cock in the compressor room.

4.3.3 Plate Heat Exchanger SetThe plate heat exchanger set facilitates the connection of a compressor installation to an existing cool-ing water circuit. In doing so, the cooling water circuit minimum requirements must always be met.

4.3.3.1 Requirements for Cooling Water CircuitThe customer’s cooling water circuit must be equipped with temperature and flow monitoring systems to protect the compressor installation. Connect the sensors to the compressor control system so the compressor installation switches off when a fault occurs. In addition the cooling water circuit must ful-fill the following minimum requirements:

4.3.3.2 StructureThe plate heat exchanger set consist of

• Plate Heat Exchanger for cooling the heated coolant

• Water Pump for conveying the coolant

• Venting Valve to remove air from the circuit

• Temperature Sensor for temperature monitoring by the PLC

• Rupture Disc to protect from excess pressure

• Safety valve to prevent slight overpressure

• Pressure Gauge to monitor the pressure

• Expansion Tank to accommodate volume variations

4.3.3.3 Installation You must always observe the following when installing the heat exchanger assembly:

• Erect the plate heat exchanger set in the compressor room

Table 1: Cooling Water Circuit Minimum Requirements

Plate Heat Exchanger set for K 23.0 K 24.0 K 26.0

Medium (customer side) Water

Operating Pressure (building side) Max. 145 psi (10 bar)

Coolant Inlet Temperature < 104 °F (40 °C)

Coolant Outlet Temperature < 86 °F (30 °C)

Temperature Difference (outlet - inlet) approx. 18 °F (10 °C)

Max. Pressure Loss [psi (bar)] 5.8 (0.4) 5.8 (0.4) 6.09 (0.42)

Min. Cooling Water Flow [gpm (m³/hr)] 55.75 (12.66) 55.75 (12.66) 80 (18.09)

Coolant Connection R1 1/2” (DN 40)

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June 19, 2014 Page 25

• The automatic venting valve must always be at the highest point of the cooling circuit. If the plate heat exchanger set is installed no higher than the compressor, the quick acting venting unit must be mounted as shown: (See Figure 4-4).

4.4 Filling the Water CircuitThe following fundamental activities for (re)filling the cooling circuits must be carried out:

• Prepare the coolant mixture

• Filling by an external fluid pump

• Check/switch on circulation pump and vent the system

4.4.1 Prepare the Coolant MixtureBefore filling the coolant mixture consisting of 3 parts tap water and at least 1 part Antifrogen-N or it’s equivalent. Mix the 2 components in a separate container so that adequate corrosion protection is ensured. The mixture corresponds to a concentration of 25% and frost protection down to 10.4 °F (-12 °C). For stronger frost protection See Paragraph 4.1.1. For colling fluid volume See Paragraph 4.1.2. Prepare slightly more coolant than calculated volume in order to be able to top up after venting.

4.4.2 Filling the Coolant CircuitFor the initial filling of the coolant circuit, the water pump (P/N N27749) and associated initial filling assembly (P/N 84320), is recommended. Filling is by means of a fluid pump that produces a pressure of more than 45 psi (3 bar). Proceed as follows to fill the installation. See Figure 4-5

Figure 4-4 Venting Valve Location

Ven�ngValve

Installation Manual


• Fit a hose (1) to the blow off fitting on the safety valve and have the other end empty into a collection tank (2).

• Ensure that ball valves (5&6) on the compressor are open.

• Fit suction and pressure hoses (8 & 9) to the pump (11).

• Immerse the suction hose (8) on the pump into the mixing tank (7) and connect the pressure hose (9) to the drain ball valve (10) on the compressor. If there is no ball valve, fit the ball valve (R1/2” connection) from the initial filling set to one of the heat exchangers on the compressor.

• Fill the pump (11) with coolant through the screw plug fitting on the pump housing.

• Open the filling valve (10), switch the pump on and continuously increase the system pressure. Observe the pressure increase on the pressure gauge (4) {it can take up to 4 minutes after turning the pump on before coolant is delivered}.

• Switch the pump off as soon as the safety valve (3) opens.

• Close the filling valve (10) and unscrew the filling hose (9).

4.4.3 Venting the Water CircuitThe cooling system must be bled as well as possible in order to prevent overheating of the compressor during operations. On the cooler or at the highest point of the cooling circuit there is an automatic quick venting valve.

• Switch on the system and you must immediately check the direction of rotation of the pump (if neces-sary using a rotating field measuring unit) (direction of rotation arrow on the casing).

Figure 4-5 Filling the Coolant Circuit

56

1

2

3 4

7

8

9

11

3/4”1/2”

1”

10

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June 19, 2014 Page 27

• To bleed, release the cap on the quick venting valve slightly to allow the air to escape from the cooling circuit.

• Briefly open the venting valve on the pump housing.

• The safety valve should be opened briefly for this purpose by turning the red cap to vent the line to the expansion tank.

• Allow the pump to run for at least 30 minutes. Observe the water pressure and temperature in order to detect correct venting and thus avoid possible overheating of the compressor. Venting has been successful if the water pressure and water temperature are stable and within the permissible limits:

Water Pressure: 20 - 45 psi (1.5 - 3 bar)Water Temperature:...................................... < 105 °F (<40 °C)

• Carry out a leak test when running

It may be necessary to top up with coolant and then vent again. After filling and bleeding the system, the circulation pump should be allowed to run for approximately 1 hour before commissioning the com-pressor, in order to detect proper bleeding and to prevent possible overheating of the compressor during the subsequent commissioning.

! WARNING

If the direction of rotation is wrong, the system must be switched off immediately at the main switch on the power cabinet! Switch off the power supply and swap two of the incoming main lines.

Installation Manual


CHAPTER 5:ELECTRICAL AND CONDENSATE COLLECTION

5.1 Electrical Data In the below tables, all values are based on 2011 NEC. These values are provided as a general guide; however, the information given on the motor nameplate supersedes the above information.

• Wiring should be done by a certified electrician who is familiar with national, state and local codes.

• Check that the motor voltage and frequency agree with the main power supply.

• The applicable NEC regulations for switch box access should be followed.

Table 5-1: Single Phase Motor Data

1 PHASE

MotorHp

Full Load Amps Fuse Ampsa

a. dual element time delay fuse amps

Minimum Wire Sizeb

b. normal copper wire with THW, THWN or XHHW insulation

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

5 56 31 28 80 50 40 4 8 8

7.5 80 44 40 125 70 60 3 8 8

10 --- 55 50 --- 90 80 --- 6 6

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Table 5-2: Three Phase Motor Data

3 PHASE

MotorHp

Full Load Amps Fuse Ampsa

a. dual element time delay fuse amps

Minimum Wire Sizeb

b. normal copper wire with THW, THWN or XHHW insulation

208V 230V 460V 208V 230V 460V 208V 230V 460V

5 16.7 15.2 7.6 25 25 12 12 14 14

7.5 24.2 22 11 40 30 20 10 10 14

10 30.4 28 14 50 40 20 8 10 14

15 46.2 42 21 60 60 30 6 6 10

20 59.4 54 27 90 80 40 4 4 10

25 74.8 68 34 100 100 50 3 4 8

30 88.0 80 40 125 100 60 2 3 8

40 114 104 52 175 150 80 1/0 1 6

50 143 130 65 200 200 100 3/0 2/0 4

60 169 154 77 250 200 100 4/0 3/0 3

75 211 192 96 300 300 150 300 mcm 250 1

100 273 248 124 400 350 175 500 mcm 350 2/0

125 343 312 156 500 400 200 2 @ 4/0 2 @ 3/0 3/0

150 396 360 180 600 500 250 2 @ 300 mcm 2 @ 4/0 3/0

Installation Manual


5.2 Condensate RemovalDuring 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. This water, addi-tionally, 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.

5.2.1 Compressor Units up to 20 Hp (15kW)For these compressor units a housing and tank assembly is used. A float level switch is also included. The discharged air is passed through an activated carbon filter to free the air of oil particles. The con-densate is drained from the tank assembly by the manual drain valve into a separate container for proper disposal.

Figure 5-1 Condensate Collector for Small Units

1. Cover2. Gasket3. Fine Filter Elements4. Coarse Filter Elements5. Separator Tank Inner6. Separator Tank Outer

7. Float Switch8. Collection Tank9. Reducer10. Drain Valve11. Plug12. ACD Manifold

12

3

4

67

8

9

11

12

5

10

2

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June 19, 2014 Page 31

5.2.2 Compressor Units Greater than 20 Hp (15 kW)There is a specially developed condensate container for these units. This container is equipped with a level indicator to prevent overflows. This container is especially environmentally friendly as it is sound insulated. This assembly is supplied with two mesh screens which can be periodically cleaned of resi-due.

5.2.3 Condensate Collection for Multiple InstallationsFor multiple installations several condensate drains can be concentrated together, however, it is crucial that one pays close attention that the diameter of the collection pipe is of sufficient size. Otherwise, there is the possibility of condensate stagnation in the pipe.

Figure 5-2 Condensate Collection for Large Units

1. Level Indicator2. Condensate Tank3. Drain Tap4. Thumb Screws5. Filter Head6. Mesh Screen

7. Gasket8. Inner Separation Tank9. Outer Separation Tank10. Gasket11. Intake Manifold12. Gasket

1

2

3

4

5

678

91011

12

Installation Manual


CHAPTER 6: APPENDIX

6.1 Required Intake and Exhaust Openings for Convection

Table 6-1: Convection Cooling Intake & Exhaust Openings

Convection Cooling Intake and Exhaust Openings; in Feet² and Horsepower

Va =

a.V = volume of the room

1,750 ft³ 3,500 ft³ 7,000 ft³

hb =

b.Dh = the height difference between the air intake and the exhaust openings

6.5 ft 10 ft 13 ft

Power Hp Inlet, ft² Outlet, ft² Inlet, ft² Outlet, ft² Inlet, ft² Outlet, ft²

5 1.3 1.1 1.6 1.3 — —

7.5 2.2 1.8 2.4 2.0 — —

10 3.2 2.7 3.2 2.7 2.1 1.7

15 4.3 3.6 4.8 4.0 3.1 2.6

20 6.5 5.4 6.5 5.4 4.1 3.4

Convection Cooling Intake and Exhaust Openings; in Meters² and Kilowatts

Va

a.V = volume of the room

50 m³ 100 m³ 200 m³

hb

b.Dh = the height difference between the air intake and the exhaust openings

2 m 3 m 4 m

Power kW Inlet, m² Outlet, m² Inlet, m² Outlet, m² Inlet, m² Outlet, m²

2.2 0.12 0.10 — — — —

3.0 0.24 0..20 0.12 0.10 — —

4.0 0.30 0.25 0.12 0.10 — —

5.5 0.42 0.35 0.24 0.20 0.12 0.10

7.5 0.90 0.75 0.60 0.50 0.24 0.20

11.0 1.38 1.15 0.90 0.75 0.54 0.45

15.0 1.92 1.60 1.45 1.20 0.90 0.75

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6.2 Cooling Air Flow Required for Convection Cooling

Table 6-2: Cooling Air Flow Required for Convection Cooling

Cooling Air Flow Required for Convection Cooling; in Feet³ and Horespower

Wall Material

Room VolumeCeiling Height

Motor Hp

Concrete Brick Cinder Block

cfm cfm cfm

V = 900 ft³h = 8 ft

5 37 110 183

7.5 55 165 274

10 73 219 365

15 110 329 548

20 146 439 731

V = 1750 ft³h = 8 ft

5 156 259 359

7.5 239 389 538

10 117 468 702

15 176 702 1,053

20 234 936 1,404

V = 3500 ft³h = 10 ft

5 59 234 351

7.5 88 351 526

10 117 468 702

15 176 702 1,053

20 234 936 1,404

V = 5,300 ft³h = 11.5 ft

5 80 249 351

7.5 120 374 526

10 160 499 702

15 239 748 1,053

20 319 997 1,404

Installation Manual


Cooling Air Flow Required for Convection Cooling; in Meters³ and Kilowatts

Wall Material


Motor kW


m³/hr m³/hr m³/hr

V = 25 m³h = 2.5 m

5 5 — —

7.5 7.5 120 220

10 10 410 510

15 15 650 770

20 20 1,060 1,180

25 25 1,590 1,770

30 30 1,940 2,120

V = 50 m³h = 2.5 m

3 50 150 250

4 200 370 400

5.5 700 870 1,000

7.5 1,100 1,300 1,500

11 1,800 2,000 2,200

15 2,700 3,000 3,100

18.5 3,300 3,600 3,700

22 4,000 4,200 4,300

V = 100 m³h = 3 m

3 — 25 200

4 — 180 350

5.5 400 650 900

7.5 800 1,100 1,350

11 1,400 1,800 2,100

15 2,400 2,700 3,000

18.5 3,000 3,300 3,600

22 3,700 4,000 4,250

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V = 150 m³h = 3.5 m

3 — — —

4 — — 170

5.5 — 50 600

7.5 — 500 1,000

11 400 1,250 1,800

15 1,800 2,100 2,600

18.5 1,900 2,700 3,200

22 2,600 3,400 3,900

V = 200 m³h = 4 m

3 — — —

4 — — 50

5.5 — — 400

7.5 — 200 900

11 — 1,000 1,600

15 900 1,800 2,500

18.5 1,500 2,500 3,100

22 2,200 3,200 3,800

Cooling Air Flow Required for Convection Cooling; in Meters³ and Kilowatts

Wall Material


Motor kW



Installation Manual


6.3 Cooling Air Flow Required for Forced Ventilation

Table 6-3: Cooling Air Flow Required for Forced Ventilation

Cooling Air Flow Required for Forced Ventilation; in Feet³ and Horsepower

Wall Material


Motor Hp


cfm cfm cfm

V= 1,750 ft³h = 8 ft

25 3,144 3,290 3,363

30 3,772 3,948 4,036

40 5,030 5,264 5,381

60 7,545 7,896 8,071

100 12,575 13,159 13,452

3,500 ft³h =10 ft

25 2,924 3,144 3,290

30 3,509 3,772 3,948

40 4,679 5,030 5,264

60 7,018 7,545 7,896

100 11,697 12,575 13,159

7,000 ft³h =13 ft

25 2,632 2,961 3,217

30 3,158 3,553 3,860

40 4,211 4,737 5,147

60 6,317 7,106 7,720

100 10,528 11,844 12,667

17,700 ft³h =16.5 ft

25 1,791 2,449 2,924

30 2,149 2,939 3,509

40 2,866 3,919 46,79

60 4,299 5,878 7,018

100 7,165 9,797 11,697

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June 19, 2014 Page 37

Cooling Air Flow Required for Forced Ventilation, in Meters³ and Kilowatts

Wall Material


MotorkW



V= 50 m³h = 2.5m

18 5000 5300 5600

22 6100 6400 6700

30 8600 9000 9200

37 10800 11200 11400

45 13400 13700 14000

55 16500 16900 17100

75 22800 23200 23400

90 27600 28000 28200

110 33900 34300 34500

V = 100 m³h =2 m

18 4400 5000 5400

22 5500 6100 6500

30 8000 8600 9000

37 10300 10800 11200

45 12800 13400 13800

55 15900 16500 16900

75 22300 22850 23200

90 27000 27600 28000

110 33300 34000 34300

V = 200 m³h =4 m

18 3600 4500 5100

22 4600 5600 6200

30 7200 8100 8800

37 9400 10300 11000

45 12000 12900 13500

55 15100 16000 16700

75 21400 22300 23000

90 26200 27100 27700

110 32500 33500 374100

Installation Manual


V = 500 m³h = 5m

18 1,300 3,100 4,300

22 2,400 4,200 5,500

30 4,900 6,700 8,000

37 7,100 8,900 10,200

45 9,600 11,500 12,800

55 12,800 14,600 15,900

75 19,900 20,900 22,200

90 23,900 25,600 27,000

110 30,200 32,000 33,300

Cooling Air Flow Required for Forced Ventilation, in Meters³ and Kilowatts

Wall Material


MotorkW



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June 19, 2014 Page 39

6.4 Required Air Intake Opening for Forced Ventilation

Table 6-4: Required Air Intake Opening for Forced Ventilation

Intake Opening Area, in Feet²

Cooling Air Flow 590 ft/min 985 ft/min

cfm ft² ft²

2,942.5 5.4 3.2

5,885.0 9.7 6.5

8,827.5 15.1 9.7

11,770.0 20.5 11.8

14,712.5 24.8 15.1

17,655.0 30.1 18.3

20,597.5 34.4 21.5

23,540.0 39.8 23.7

26,482.5 45.2 26.9

29,425.0 49.5 30.1

Intake Opening Area, in Meters²

Cooling Air Flow 3 m/s 5 m/s

m³ m² m²

5,000 0.5 0.3

10,000 0.9 0.6

15,000 1.4 0.9

20,000 1.9 1.1

25,000 2.3 1.4

30,000 2.8 1.7

35,000 3.2 2.0

40,000 3.7 2.2

45,000 4.2 2.5

50,000 4.6 2.8

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: [email protected], or fill out the form below and mail it to us:

Submitters Contact Information: Unit Information:

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Address: _____________________________ Serial#:

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E-mail: ________________________ MFG Date:

Inaccuracies: page# ________ figure# ________ paragraph# ________

Suggested Corrections:

Additional Comments:

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Bauer Compressors, Inc.Attn: Documentation1328 Azalea Garden Rd.Norfolk, VA 23502-1944

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